Surimi

High moisture extrusion :
optimisation of texturisation
through control of rheological
and textural parameters
D. Bounie, E. Van Hecke

USTL (Université des Sciences et Technologies de Lille)
IAAL (Institut Agricole et Alimentaire)
Bâtiment C6
59655 Villeneuve d’Ascq Cedex - France
Tel : +33 (0)3 20.43.49.21, Fax : +33 (0)3 20.43.44.86
E-Mail : Bounie@univ-lille1.fr, vanhecke@univ-lille1.fr
Smart Extrusion Workshop, Sydney,

2 december 1997
D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97 (p1)
PLAN
High moisture extrusion
 Usual extrusion conditions (50 - 80 % water, 15 - 30 % proteins, fats <8 %,

q > 130 °C) and consequences (reduction of : shear, viscous dissipation of
energy and expansion at die outlet, especially with long cooling dies)
 Raw materials
 Main applications
 Typical extrusion line
• specific feeding device
• special screw profiles (+ break plates)
• long cooling-dies
• temperature control
Fundamentals of high moisture texturization during extrusion-cooking
 Main steps
• protein melting (plasticising) : within the extruder
• material texturization (fibration) : along the die
Flow in extruder and die during texturization
Control of texturization through control of rheological behaviour
• (shear) viscosity
• elasticity
• visoelasticity
• elongational viscosity
Correlation between on-line and off-line assessment of rheological and
textural parameters
Perspectives
PLAN

 Raw materials
 Main steps
• elasticity
• visoelasticity
textural parameters
Perspectives
D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97

HIGH MOISTURE EXTRUSION : APPLICATIONS
Moisture Wet extrusion Wet extrusion : usual raw materials

content % vs. dry extrusion (Roussel, 1996)
(Roussel, 1996)
80 % Fruits and vegetables Animal raw materials
 red and white meat minces
 meat trimmings
Cheese analogs
 fish meats (surimi)
60 % Enzyme reactors
 filleting co-products
 minced from shell fish or
cephalopoda
40 % TVP
Petfood-moist  egg or milk proteins
Pasta
Vegetable raw materials
20 % Breakfast cereals  protein-rich meals
Dry petfoods
Snacks - Flat breads  protein concentrates or isolates
(soya, wheat, peas, brans,...) after
Confectionery adequate rehydratation
0%
APPLICATIONS (Cheftel and al., 1992)
Sterilization
 preparation of sterile vegetables purées, meat-vegetables mixes
Chemical reaction (enzymic or acid hydrolysis)
 starch or proteins modification for preparation of glucose syrups,
fermentation substrates, flavor preparations
Texturization
Gelation/fibration
 gelation and fiber formation using vegetable proteins (soya, gluten)
 restructuration of mince, surimi, mechnically deboned meats (with
binders)
 texturization and fiber formation with fish muscle proteins
Emulsification/gelation : « microcoagulation » of dairy proteins
 processed cheeses
 cheese analogs
 fat substitutes
 casein coagulation
D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97 (p3a)
MACRO AND MICRO STRUCTURES
OF FIBROUS EXTRUDED PRODUCTS
A commercial extruded crab analog Scanning electron micrographs

from Nippon Suisan of an extruded
(Cheftel and al, 1992) surimi/soya concentrate mix
(Thiebaud,1995)
D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97 (p3b)
TYPICAL EXTRUSION LINE
FOR PRODUCT FIBRATION
Feeding device
Twin screw extruder with

accurate temperature control
Gear pump
Extra long cooling die

(Nippon Suisan patent)
D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97 (p3c)
PLAN

 Raw materials
 Main steps
• elasticity
• visoelasticity
textural parameters
Perspectives

TEXTURIZATION : MELTING + FIBRATION
Flow in extruder and cooled die
Metering zone Transition zone Die
Biopolymer phases separate Domains orientate as a Products sets to fibrous

into different domains result of flow through die structure on cooling
in extruder
Structure formation as a result of phase separation in biopolymer

mixtures followed by subsequent orientation in flow through die
(Tolstoguzov, 1986 ; Mitchell et al., 1994)
PLAN

 Raw materials
 Main steps
• elasticity
• visoelasticity
textural parameters
Perspectives

COOLING DIES FOR TEXTURATION
Rectangular die
Circular die
Annular die
FLOW PATTERN IN EXTRUDER AND DIE
(Bhattacharya and Padmanabhan, 1992)
Intermediary
region
(relaxation)
Metering zone Entrance Viscometric flow Exit
region region region
Shear flow Extensional flow Shear flow
P
DPentry
DPshear flow
DPexit
die axis
DPtotal = DPentry + Dpshear flow + DPexit
FLOW PROFILES THROUGH DIES
Effect of cooling
Flow through insulated die
Flow through supercooled die
Liquid Liquid / solid Solid
EFFECT OF OPERATING CONDITIONS ON FLOW,
TROUBLESHOOTING
Effect of implementing Effect of viscosity

a non-newtonian fluid
m=1
m<1
m << 1
Troubleshooting
«Shark-skin» : periodic rupture of fluid bed (no slip at die wall)
«Two-phases wavy flow» : insufficient cooling rate (die too short or

too thick) ; inner layers of flow are still melted at die outlet
PLAN

 Raw materials
 Main steps
• elasticity
• visoelasticity
textural parameters
Perspectives

STRESS TENSOR
s2,2
s2,1
s1,2
s2,3
s3,2
s1,1
s1,3
2 s3,1
s3,3
1
3
Shear stress (if no rotation, i.e. no torque)
s3,1 = s1,3 N1 = s1,1 - s2,2 (first normal stress difference)

.
s3,2 = s2,3 = he e = k g 2 (e : elongational strain rate)
s2,1 = s1,2
N2 = s2,2 - s3,3 (second normal stress difference)
N2 < 0, N2 << N1
Normal stress
s1,1
s2,2
s3,3
sT
SHEAR VISCOSITY
F dl
S dx
v
sT Bingham plastic
F
sT = shear stress (N.m-2 = Pa)
S
hs
dl
v= shear velocity (m.s-1) s T,o Newtonian
dt Dilatent
Yield (shear thickening)
.
g=
dv
shear rate (s-1) stress
dx
sT Pseudoplastic
hs = . shear viscosity (Pa.s)
g (shear thinning)
.
g
VISCOSITY : LAWS OF BEHAVIOUR
Newtonian h = constant
Power law (Ostwald’s law)

.
Non Newtonian h = K g m-1 (K : index of consistency,
m :flow behaviour index
Effect of Effect of thermo-

temperature T mechanical history W (SME)
(Harper and al., 1971) (Della Valle and Vergnes, 1994)
. .
h  (K g m-1) e -a T h  (K g m-1 ) e -e W
Effect of Effect of chemical reaction (DE, R)

moisture content MC (Remsen and Clark, 1978)
(Harper and al., 1971)
-DE
.
h (K g m-1 ) e -b MC
- k e
RTa(t)
dt
.
h (K g m-1)e
Example : corn starch at low MC

(Della Valle and Vergnes, 1994)
DE
( - a MC - b W) . m’-1
h = Ko e RTa g
with : m’ = c1 T + c2 MC + c3 MC.T
IN-LINE MEASUREMENT OF VISCOSITY
Qv
DL
P (Mac Master and al., 1987)
DP
Apparent Real
Shear stress at wall shear rate at wall shear rate at wall Viscosity
. .
sw gw, a gw, r h
4 Qv 4 Qv 3m + 1 sw
R DP .
R 2 DL p R3 p R3 4m gw, r
W
h DP 1 6 Qv 6 Qv 2m + 1 sw
.
h 2 DL h W h2 W h2 3m gw, r
1+
W
Log sw for different Qv
Log K
.
Log gw, a
IN-LINE RHEOMETERS
WITH CONTROLLED FEEDRATE
By pass or side stream rheometers (Goettfoert system for plastics)
Gear pump
« Rheopac » slit die rheometer (Vergnes et al., 1990 and 1993)
Piston keys
Rheometer
Derivation
DISPLAY OF ELASTICITY :
Weissenberg effect, Barus effect
Weissenberg effect sN
increase with
.
increasing g
sT
Barus effect : swelling at die outlet
fdie fextrudate
sN
(sN)
sT
IN-LINE MEASUREMENT OF ELASTICITY :
EXIT PRESSURE METHOD
(Padmanabhan and Bhattacharya, 1991)
related to extensional
viscosity
DPentrance proportional to
P elasticity
DPexit
IN-LINE MEASUREMENT OF ELASTICITY
HOLE PRESSURE METHOD
( Baird, 1976 ; Padmanabhan and Bhattacharya, 1992 ; Bhattacharya M. and
Padmanabhan M., 1992, Malkus and al., 1992 ; Bouvier and Gelus, 1994)
sN
flush-mounted
transducers
P1 P2 P3
Qv
transducer at the
bottom of the hole
P4
P
P1
DP1,3 (shear viscosity)
P2
P3
Dphole (elasticity)
P4
L
N1 = s1,1 - s2,2 = he e
DYNAMIC DETERMINATION
OF VISCOELASTICITY (1)
(Ross-Murphy, 1988)
Accelerometer Force transducer
Imposed
oscillatory Measured stress s = f(t)
strain g = f(t)
Viscous fluid Elastic fluid

Strain Stress Strain Stress
g s g s
t t
p d=0
d=
2
g(t) = g0 cos (wt)

Viscoelastic fluid
Strain Stress
s(t) = s0 cos (wt + d) g s
t
p
0<d<
2
DYNAMIC DETERMINATION
OF VISCOELASTICITY (2)
Ideal viscous liquid Viscoelastic fluid Ideal elastic solid
Newton’s law Hooke’s law

.
sT = h g sN = E g
Viscosity Viscoelasticity Elasticity
Loss modulus Storage modulus
s0 s0
G’’ G’ = cos d
G’’ = sin d = tg d g0
g0 G’
log scale
G’ G’’ or tg d
Temperature
Transition
ELONGATIONAL VISCOSITY
he (Trouton
hs modulus)
Type of extensional flow
Newtonian Non-newtonian
fluid fluid
Uniaxial extension
3 >> 3
ex : spinning of fibers
Planar extension
4 >> 4
ex : foil stretching, central disk injection
Biaxial extension
6 >> 6
ex : blowing extrusion, plug extrusion
ELONGATIONAL vs. SHEAR VISCOSITY
Newtonian Non-newtonian
h h fluid
fluid
he
he
hs
hs
. .
g
g
he he
= constante  constante
hs hs .
[= f(g)]
 In-line determination of extensional viscosity :

Entrance pressure drop method
(White and al., 1987 ; Bhattacharya and al., 1994)
PLAN

 Raw materials
 Main steps
• elasticity
• visoelasticity
textural parameters
Perspectives

PERSPECTIVES : NEW DIES ?
Breaker plates
BIBLIOGRAPHY
• Baird D.G., 1976. Fluid elasticity measurements from hole pressure error data. J. Appl. Polym. Sci, 20, pp 3155-
3173.
• Bhattacharya M. and Padmanabhan M., 1992. Extrusion processing : texture and rheology. In : Encyclopedia
of Food and Science Technology, Hui Y.H. Ed., Willey Interscience, New York, pp 800-814.
• Bhattacharya M., Padmanabhan M. and Seethamraju K., 1994. Uniaxial extensional viscosity during
extrusion cooking from entrance pressure drop method. J. Food Sci., 59(1), pp 221-226, 230
• Bouvier J.M. and Gelus M., 1994. Apport des mesures en ligne à l’analyse du procédé de cuisson-extrusion. In
: La Cuisson-Extrusion, Colonna P. and Della Valle G. Eds., Tec & Doc Lavoisier, Paris, pp 323-355.
• Cheftel J.C., Kitagawa M. and Quéguiner C., 1992. New protein texturization processes by extrusion cooking
at high moisture levels. Food Rev. Int., 8(2), pp 235-275.
• Cheftel J.C., Kitagawa M. and Quéguiner C., 1994. Nouveaux procédés de texturation protéique par cuisson-
extrusion à teneur élevée en eau. In : La Cuisson-Extrusion, Colonna P. and Della Valle G. Eds., Tec & Doc
Lavoisier, Paris, pp 45-84.
• Cheftel J.C. and Dumay E., 1993. Microcoagulation of proteins for development of "creaminess". Food Rev.
Int., 9(4), pp 473-502.
• Della Valle G. and Vergnes B., 1994. Propriétés thermophysiques et rhéologiques des substrats utilisés en
cuisson-extrusion. In : La Cuisson-Extrusion, Colonna P. and Della Valle G. Eds., Tec & Doc Lavoisier, Paris, pp
439-467.
• Harper J.M., Rhodes T.P. and Wanninger L.A., 1971. Viscosity model for cooked cereal doughs. A.I.Ch.E.
Symposium Series, 676(108), pp 40-43.
• Malkus D.S., Pritchard W.G. and Yao M., 1992. The hole-pressure effect and viscosimetry. Rheol. Acta, 31,
pp 521-534.
• Mc Master T.J., Senouci A. and Smith A.C., 1987. Measurements of rheological and ultrasonic properties of
food and synthetic polymer melts. Rheol. Acta, 26, pp 308-315.
• Mitchell J.R., Areas J.A.G. and Rasul S., 1994. Modifications chimiques et texturation des protéines à faible
teneur en eau.. In : La Cuisson-Extrusion, Colonna P. and Della Valle G. Eds., Tec & Doc Lavoisier, Paris, pp 85-
104.
• Padmanabhan M. and Bhattacharya M., 1991. Flow behavior and exit pressures of corn meal under high-
shear-high-temperature extrusion conditions using a slit die. J. Rheol., 35(3), pp 315-343.
• Padmanabhan M. and Bhattacharya M., 1992. Rheological measurement of fluid elasticity during extrusion-
cooking. Trends in Food Science and Technology, 6, 149-151.
• Quéguiner C., Dumay E., Cavalier-Salou and Cheftel J.C., 1991. Application of extrusion cooking to dairy
products : preparation of fat analogues by microcoagulation of whey proteins. In : Applied Food Extrusion
Science, Kokini J. and al. Eds., Dekker, New York, pp 363-376.
• Quéguiner C., Dumay E., Cavalier-Salou and Cheftel J.C., 1992. Microcoagulation of a whey protein isolate
by extrusion cooking at acid pH. J. Food Sci., 57, pp 610-616.
• Remsen C.H. and Clark J.P., 1978. A viscosity model for a cooking dough. J. Food Process Eng., 2, pp 39-64.
• Ross-Murphy S.B., 1988. Small deformation measurements. In : Food Structure : its Creation and Evaluation,
Blanshard J.M. and Mitchell Eds., Butterworth, London, pp 387-400.
• Roussel L., 1996. Making meat products using extrusion technology. Extrusion Communiqué, nov-dec, pp 16-
18.
• Thiebaud M., 1995. Texturation par cuisson-extrusion de mélanges protéiques hydratés à base de surimi de
poisson. Influence des paramètres opératoires et de la formulation sur les caractéristiques biochimiques et
physicochimiques des extrudats. PhD. Thesis, University of Montpellier.
• Tolstoguzov V.B., 1986. Functional properties of protein-polysaccharides mixtures. In : Functional Properties
of Food Macromolecules, Mitchell J.R. and Ledward D.A. Eds., Elesevier Applied Science Pub., London, pp 385-
415.
• Vergnes B., Della Valle G. and Tayeb J., 1990. Rheopac : a new on-line rheometer with controlled feed rate to
determine the viscosity of starchy products. In : Proceedings of ACoFoP2, 13-14 nov. 1990, Bimbenet J.J. and
Trystram G. Eds., Paris.
• Vergnes B., Della Valle G. and Tayeb J., 1993. Rheopac : a specificin-line rheometer for extruded starchy
products. Design, validation and application to maize starch. Rheol. Acta, 32, pp 465-476.
• White S.A, Gotsis A.D. and Baird D.G., 1987. Review of the entry flow problem : experimental and numerical.
J. Non-Newtonian Fluid Mech., 24, pp 121-160.

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High moisture extrusion :

D. Bounie, E. Van Hecke

Smart Extrusion Workshop, Sydney,

High moisture extrusion

 Usual extrusion conditions (50 - 80 % water, 15 - 30 % proteins, fats <8 %,

Fundamentals of high moisture texturization during extrusion-cooking

High moisture extrusion

 Usual extrusion conditions (50 - 80 % water, 15 - 30 % proteins, fats <8 %,

Fundamentals of high moisture texturization during extrusion-cooking

D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97

Moisture Wet extrusion Wet extrusion : usual raw materials

APPLICATIONS (Cheftel and al., 1992)

A commercial extruded crab analog Scanning electron micrographs

Twin screw extruder with

Extra long cooling die

High moisture extrusion

 Usual extrusion conditions (50 - 80 % water, 15 - 30 % proteins, fats <8 %,

Fundamentals of high moisture texturization during extrusion-cooking

D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97

Flow in extruder and cooled die

Metering zone Transition zone Die

Biopolymer phases separate Domains orientate as a Products sets to fibrous

Structure formation as a result of phase separation in biopolymer

High moisture extrusion

 Usual extrusion conditions (50 - 80 % water, 15 - 30 % proteins, fats <8 %,

Fundamentals of high moisture texturization during extrusion-cooking

D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97

Shear flow Extensional flow Shear flow

DPtotal = DPentry + Dpshear flow + DPexit

Flow through insulated die

Flow through supercooled die

Liquid Liquid / solid Solid

Effect of implementing Effect of viscosity

«Shark-skin» : periodic rupture of fluid bed (no slip at die wall)

«Two-phases wavy flow» : insufficient cooling rate (die too short or

High moisture extrusion

 Usual extrusion conditions (50 - 80 % water, 15 - 30 % proteins, fats <8 %,

Fundamentals of high moisture texturization during extrusion-cooking

D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97

Shear stress (if no rotation, i.e. no torque)

s3,1 = s1,3 N1 = s1,1 - s2,2 (first normal stress difference)

Power law (Ostwald’s law)

Effect of Effect of thermo-

Effect of Effect of chemical reaction (DE, R)

Example : corn starch at low MC

Log sw for different Qv

By pass or side stream rheometers (Goettfoert system for plastics)

« Rheopac » slit die rheometer (Vergnes et al., 1990 and 1993)

Barus effect : swelling at die outlet

Accelerometer Force transducer

Viscous fluid Elastic fluid

g(t) = g0 cos (wt)

Ideal viscous liquid Viscoelastic fluid Ideal elastic solid

Newton’s law Hooke’s law

Viscosity Viscoelasticity Elasticity

Loss modulus Storage modulus

ex : foil stretching, central disk injection

ex : blowing extrusion, plug extrusion

 In-line determination of extensional viscosity :

High moisture extrusion

 Usual extrusion conditions (50 - 80 % water, 15 - 30 % proteins, fats <8 %,

Fundamentals of high moisture texturization during extrusion-cooking

D. Bounie, E. Van Hecke : High moisture extrusion - Sydney, dec. 2nd 97