SUPERCRITICAL FLUID EXTRUSION (SCFX)

PRAGATI SINGHAMRoll No.- 10703Ph.D 1st year

CONTENTS

CASE STUDIES

CONCLUSION

FUTURE THRUSTS

INTRODUCTION

INTRODUCTION

High temperature

High shear

Steam puffing

Extrusion Technology Disadvantag

es

High solubilizing capacity

High Diffusivity

Low temperature process

Supercritical Fluid CO2

Advantages

Supercritical Fluid Extrusion

SUPERCRITICAL FLUID EXTRUSION

(SCFX)

Versatile

High production Rate

Low temperature

Low shear

High expansion

SUPERCRITICAL FLUID EXTRUSION PROCESS

(SCFX)•

Development of gas

holding rheological properties

Injection of CO2

Nucleation of Cells Expansion

OBJECTIVE

To develop novel extrusion protocols to directly incorporating fruit/dairy by-products into shelf-stable, puffed, extruded products

and evaluate changes in their quality due to processing.

MATERIALS AND METHODS

MaterialsPre-gelatinized starch 76%Apple pomace powder (22% & 28%)

Lecithin 1% Distilled monoglycerides, 1%

At 7.58 MPa

RESULTSExternal

Internal

Nutrient Retention

Direct utilization of apple pomace into nutrient-enriched, shelf stable puffed extruded products

Retention of 84% of the Total Phenolic Content (TPC) and 74% of the total antioxidants

Low density extrudates 0.21-0.35 g/cm3 were obtained

INFERENCES

OBJECTIVE

To produce soy based expanded crisps fortified with micronutrients and protein by using SCFX

MATERIAL AND METHODS

Lecithin (1.5g/100g), Distilled monoglycerides (1g/100g), Table Salt (1.5g/100g) Micronutrient premix 325mg/100g

Flour % Soy protein Conc.

(RS SPC-25)

% Soy protein Conc. (RS SPC-

40)

% Soy flour

(RS SF-25)

% Soy flour

(RS SF-40)

Waxy rice flour (WRF)

(g/100g)

71.5 56.5 71.5 56.5

Rice-Soy Concentrate Crisps (A) 25% (B) 40% Rice-Soy Flour Crisps (A) 25% (B) 40%

RSC-SPC 25

RSC-SF 25 RSC-SPC 40

RSC-SF 40 RSC-SPC 25

RSC-SPC 40

RSC-SPC 40

RSC-SF 40

Piece Density (g/cm3) Bulk Density (g/cm3)

0

0.1

0.2

0.3

RSC-SPC 25 RSC-SF 25 RSC-SPC 40 RSC-SF 40Expansion Ratio (%)

0

1

2

3

4

5

Density

Expansion Ratio

RESULTS

RSC-SPC 25 RSC-SF 25 RSC-SPC 40 RSC-SF 40a value

-0.6

-0.4

-0.2

0

0.2

0.4

0.6

0.8

RSC-SPC 25 RSC-SF 25 RSC-SPC 40 RSC-SF 40L value

59

60

61

62

63

64

RSC-SPC 25 RSC-SF 25 RSC-SPC 40 RSC-SF 40b value

0

4

8

12

16

COLOR

RSC-SPC 25 RSC-SF 25 RSC-SPC 40 RSC-SF 40Vitamin A (IU/100g)

0

2000

4000

6000

8000

10000

12000

Before ExtrusionAfter Extrusion

RSC-SPC 25 RSC-SF 25 RSC-SPC 40 RSC-SF 40Vitamin C (mg/100g)

0

20

40

60

80

100

120

140

160

Before ExtrusionAfter Extrusion

MICRONUTRIENTS

RSC-SPC 25 was found to be best among the samples

Improved amino acid balance due to incorporation of soy protein to rice flour

No undesirable quality attributes on fortification of vitamin A, C and minerals.

Effective process based nutrient fortification approach to reduce malnutrition.

INFERENCES

OBJECTIVE

To quantify the effects of die temperature, different levels of alkalized cocoa powder and CO2 gas injection on cellular

structure and physical properties of extruded meal

MATERIAL AND METHODS

Corn meal

Variables Temperature 95˚C, 110 ˚C and 120˚CAlkalized cocoa powder (6% and 12%)

RESULTSSe

ctio

nal E

xpan

sion

Ind

ex (

SEI)

Effect of die temperature, ACP content and C02 gas injection

EXPANSION INDEX PIECE DENSITY

0%

6%

12%

ACP 95˚C 110˚C 120˚C 95˚C 110˚C 120˚CDIE TEMPERTURE

CELL STRUCTURE

Without CO2 injection With CO2 injection

Die temperature, Alkalized Cocoa powder (ACP) content and CO2 injection significantly affected the physical properties of the extrudates

Addition of ACP imparted rigidity to the extruded structure and reduced shrinkage

Uniform microcellular structure with reduced breaking strength in ACP added CO2 injection process

INFERENCES

OBJECTIVE

To develop SCFX leavened dough and breads with density comparable to the density of conventionally yeast-leavened

breads and commercial bread products

MATERIAL AND METHODS

Dough FormulaePercentage Flour Weight

Ingredients Formula 1 Formula 2 Formula 3Guar Gum 0.5 0.15 Nil

Egg powder 1 0.5 NilAscorbic acid 0.01 0.2 0.2

Conventional baking 180˚C for 30 min

Combined Vacuum and Conventional 188 ˚C with 50.8kPa vacuum for 30 min followed by 180 ˚C for 10 min.39 rpm

RESULTSEXTERNAL MORPHOLOGY

C V+C C V+C C V+CFormula 1 Formula 2 Formula 3

0

0.1

0.2

0.3

0.4

0.5 Bread Density (g/cm3)

C V+C C V+C C V+CFormula 1 Formula 2 Formula 3

0

10

20

30

40Crumb Moisture (%)

PHYSICO-CHEMICAL PROPERTIES

FORMULA 2 STALING TEST

Conventional Baking

Combined Conventional and

vacuum baking

Formula 2 yeast-free bread produced by combined conventional vacuum baking using SCFX leavened dough was found to be the best

Density and crumb hardness obtained in SCFX leavened bread was comparable to yeast leavened breads

Bread quality was controllable as compared to conventional yeast-leavened bread

Consistent ready-to-bake dough can be produced in shorter time (approx. 0.36 to 0.41 h ) without ethanol emmission

INFERENCES

OBJECTIVE

To study the cross-linking of native/pre-gelatinized starch blends and to create cross-linked microcellular starch foams by

reaction SCFX with STMP

MATERIAL AND METHODSSamples:

Pre-gelatized wheat starch Control mixture of native starch (40% w/w)and pre-gelatinized starch (60% w/w)

Food-grade Sodium Trimetaphosphate (STMP): 9%NaOH (0.1 M, 0.2 M) SC-CO2: 0%, 1% and 1.5%

DENSITY and EXPANSION RATIO

RESULTS

EXTERNAL MORPHOLOGY

Yellowish

Bright white

Bright white

0% 1% 1.50%SC-CO2 (% DRY FEED)

0

5

10

15

20

25

30

9% STMP 0.1 M NaOH at 60˚C9% STMP , 0.1 M NaOH at 90˚C

0% 1% 1.50%SC-CO2 (% DRY FEED)

0

2

4

6

8

10

12

9% STMP 0.2 M NaOH at 60˚C9% STMP , 0.2 M NaOH at 90˚C

WATER SOLUBILITY

Cross-linking, modified and integrated the structure of extrudates

High pH, low temperature favoured restricted mobility which leads to decrease in water solubility

pH played a key role in reactive supercritical fluid extrusion

Reactive Supercritical fluid extrusion can be successfully used for production of starch-based biodegradable films.

INFERENCES

• Production of yeast-free continuous baked products can be done using SCFX

• Fortification of heat labile micronutrient into extrudates

• Utilization of agro-food industry wastes into nutritionally attractive by-products

• Biodegradable material can be produced using SCFX

CONCLUSION

• Development of dairy based extrudates using SCFX

• Development of several biodegradable material using SCFX

• Development of meat extrudates using SCFX

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FUTURE THRUSTS