The FKD-2100 flat cooling die is designed for use in combination with a twin-screw extruder (e.g. ZSK 43 Mv Plus, Coperion GmbH) for the production of protein-based, wet-extruded (HME) extrudates. Protein powder and water are thermomechanically stressed inside the extruder and cooled in the downstream flat cooling die unit, where fibrous, meat-like structures are formed.
The flat cooling die FKD-2100 may only be used in combination with a twin screw extruder. The flat cooling die consists of two transition elements, four flat cooling die segments and associated contact guards. The extruder can be operated with up to four flat cooling die segments attached to each other. The number of flat cooling die segments depends on the product properties and the desired throughput. The cooling of the flat cooling die must be ensured by an external cooling unit with a cooling capacity of at least 25 kW in order to cool the hot product flow from the extruder.
Suitable raw materials are any flowable, fine-grained protein-powder-water mixtures which are heated and transported from the upstream product channel of the twin screw extruder into the cooling die. First the product enters the transfer segment 1C (Item No.1), which is connected to the extruder end plate. Then the product passes the transfer segment 2C (Item No.2) and enters the flat cooling die unit consisting of up to four cooling die segments (Item No.3). The product is successively cooled down to the desired temperature. A coolant (water or glycol/water mixture) is pumped through the double jacket of the cooling nozzle segments by an external cooling unit. Finally, the textured product leaves the flat cooling die and can be further processed, such as cutting, chopping, freezing.
A contact protection around the flat cooling die unit offers protection against burning.
The throughput of the flat cooling die unit is between 100 and 250 kg/h. This depends mainly on the settings of the extruder, the product formulation, the material properties, the desired product structure and the temperature of the protein-water mixture. Typically, the inlet temperature into the flat cooling die unit should be around 110 °C to 130 °C. The product temperature at the outlet of the flat cooling die unit can be between 60 °C and 90 °C. Temperatures above 100 °C lead to expanded products and may be undesirable. Typical protein to water ratios range from 1:2 to 1:1.
|4x coolant connection||internal thread ¾”|
|Product channel||800 x 150 x 15 (mm)|
|Fastening of the cooling die segments to each other via quick release fasteners (with additional screw connection)|
|segment length||800 mm|
|Center height (distance floor-product-channel-center)||1.100 mm|
|Segments with hinged cover and quick clamping connection (12x)|
|Surfaces in contact with the product are electropolished|
|Frames with height adjustable swivel castors||+/- 40 mm (4x)|
|Removable protective hood (protection against accidental contact)|