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EXTRUDER TO NIXTAMALIZE MAIZE FRACTIONS

20220087303 · 2022-03-24

    Inventors

    Cpc classification

    International classification

    Abstract

    The present utility model “Extruder to nixtamalize maize fractions” aims to provide and extruder to nixtamalize maize fractions previously conditioned with water and food grade lime, eliminating the production of nejayote in the production of nixtamalized maize flour, as well as the reduction of clogging of the extruded material. In addition to the aforementioned, it's easy to assemble for cleaning.

    Claims

    1. The extruder to nixtamalize maize fractions, characterized in that it comprises: a barrel (1) that has four sections: coupling (2), feeding (3), transition (4), and die (5), from the coupling section to the transition, the cannon has an elongated perforation (6) in the middle of the bases of the barrel in the shape of an eight, inside the perforation two twin screws (7) are found, the screws are moved by a transmission (8) that moves a motor (9).

    2. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the barrel (1) has a length of 125 cm to 170 cm and the diameter is of 14 cm to 18 cm.

    3. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the coupling (2) section has a length of 8 cm to 12 cm not including the thickness of the flanges and has two flanges at the extremes with a diameter of 23 cm to 30 cm while the thickness of the flanges is 3 cm to 4 cm.

    4. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the coupling (2) section has to circular perforations, one on the top and the other at the bottom with a diameter of 7.5 cm to 10 cm, which are aligned.

    5. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the coupling (2) section is joined to the feeding section by flanges.

    6. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the feeding section has a length of 35 cm to 45 cm not including the thickness of the flanges and has two flanges with a diameter of 23 cm to 30 cm, while the thickness of the flanges is 3 cm to 4 cm.

    7. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the feeding (3) section has a circular orifice at the top with a diameter of 10 cm to 14 cm located from 4 cm to 6 cm after the flange.

    8. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the feeding (3) section can be coupled with a dispenser that can be volumetric or gravimetric.

    9. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the feeding (3) section must be fed at least 80% of the capacity of the extruder, measured in terms of amperage of the motor of the transmission and velocity of the screws.

    10. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that in the feeding (3) section 4.5 kg to 6 kg per minute can be processed.

    11. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the feeding (3) section is joined to the transition (4) section by flanges.

    12. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the transition (4) section has a length of 35 cm to 45 cm not including the thickness of the flanges and has two flanges with a diameter of 23 cm to 30 cm and a thickness of 3 cm to 4 cm.

    13. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the transition (4) section can add heat by means of band type electrical resistors that surround this section.

    14. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the transition (4) section is joined to the die (5) section by a flange that has a thickness of 3 cm to 4 cm and a diameter of 23 cm to 30 cm.

    15. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the die (5) section has a cylindrical shape and two sprocket hubs of different heights protrude from it, one on each side.

    16. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the die (5) section has two sprocket hubs, one of input and another for output.

    17. The extruder to nixtamalize maize fractions in conformity with claim 16 characterized in that the input sprocket hub is joined to the transition (4) section of the barrel.

    18. The extruder to nixtamalize maize fractions in conformity with claim 16 characterized in that the input sprocket hub has a length of 5 mm to 10 mm.

    19. The extruder to nixtamalize maize fractions in conformity with claim 16 characterized in that the input sprocket hub has an external diameter of 14 cm to 23 cm, while the internal diameter is 5 cm to 13 cm.

    20. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the input sprocket hub has a conical shaped orifice that reaches up to 60% of the length of the die, afterwards orifice has a cylindrical shape until coming out through the output sprocket hub.

    21. The extruder to nixtamalize maize fractions in conformity with claim 16 characterized in that the output sprocket hub has a cylindrical shape and a height of 25 mm to 50 mm.

    22. The extruder to nixtamalize maize fractions in conformity with claim 16 characterized in that the output sprocket hub has an external diameter of 12 cm to 20 cm, while the internal diameter is 5 cm to 11 cm.

    23. The extruder to nixtamalize maize fractions in conformity with claim 16 characterized in that the output sprocket hub has and obstruction (10) in its internal diameter that had the shape of a ring, the ring has a thickness of 3 mm to 5 mm with a depth of 6 mm to 10 mm and an internal diameter of 4 cm to 10 cm.

    24. The extruder to nixtamalize maize fractions in conformity with claim 16 characterized in that the output sprocket hub has an internal diameter bigger than the obstruction.

    25. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the die (5) section has a circular orifice that has an area equivalent to 40% to 50% of the elongated perforation (6) area in the shape of an eight.

    26. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that after the die (5) section the pressure is 1 kg/cm.sup.2 to 1.3 kg/cm.sup.2 while the temperature is at 55° C. to 70° C.

    27. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that at the die (5) section a cutter may be coupled. The cutter has 2 to 4 blades that pass through the face of the die.

    28. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the perforation (6) at the bases of the barrel (1) that goes from the coupling (2) section to the transition (4) section has a constant transversal section.

    29. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the perforation (6), the diameters of the circles that make up the eight are 5 cm to 8 cm.

    30. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that in the perforation (6) the distance from the center of the circles that make up the eight is 5 cm to 8 cm.

    31. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the screws have a diameter of 2 cm to 6 cm and a length of 80 cm to 120 cm.

    32. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the screws have a helical thread along the screw, the thickness of the thread is 3 mm to 9 mm and its depth is 7 mm to 12 mm.

    33. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the two screws are place interspersed along the entire length of the screws and rotate axially in opposite directions.

    34. The extruder to nixtamalize maize fractions in conformity with claim 1 characterized in that the screws are divided in four sections.

    35. The extruder to nixtamalize maize fractions in conformity with claim 34 characterized in that the length of the first section (11) is 15 cm to 20 cm, while the spacing between the threads is 50 mm to 70 mm and the angle of the thread is 106 degrees to 109 degrees.

    36. The extruder to nixtamalize maize fractions in conformity with claim 34 characterized in that the length of the second section (12) is 18 cm to 23 cm, while the spacing between the threads is 40 mm to 60 mm and the angle of the thread is 102 degrees to 105 degrees.

    37. The extruder to nixtamalize maize fractions in conformity with claim 34 characterized in that the length of the third section (13) is 12 cm to 16 cm, while the spacing between the threads is 35 mm to 40 mm and the angle of the thread is 98 degrees to 102 degrees.

    38. The extruder to nixtamalize maize fractions in conformity with claim 34 characterized in that the length of the fourth section (14) is 30 cm to 35 cm, while the spacing between the threads is 23 mm to 28 mm and the angle of the thread is 90 degrees to 100 degrees.

    39. The extruder to nixtamalize maize fractions in conformity with claim 34 characterized in that in the fourth section (14), three heating stages are reached: one of 40° C. to 50° C., another of 50° C. to 60° C., and another of 60° C. to 70° C.

    Description

    BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

    [0019] FIG. 1 shows the lateral view of the extruder to nixtamalize maize fractions.

    [0020] FIG. 2 shows the internal section of the extruder die to nixtamalize maize fractions.

    [0021] FIG. 3 shows the top view of the coupling and feeding section of the extruder to nixtamalize maize fractions.

    [0022] FIG. 4 shows the frontal view of the cannon perforation in the transition section of the extruder to nixtamalize maize fractions.

    [0023] FIG. 5 shows the screw of the extruder to nixtamalize maize fractions.

    DETAILED DESCRIPTION OF THE INVENTION

    [0024] The utility model refers to an extruder to nixtamalize maize fractions, where the extruder comprises a barrel (1) that has four sections: coupling (2), feeding (3) and die (5). The advantage of selecting the barrel is that the parts can be quickly shown, this brings a decrease in the time used for cleaning and maintaining the equipment. When selecting the barrel, the sections are joined by flanges. The barrel has an elongated perforation (6) in the shape of an eight that extends from the coupling to the transition section. In the perforation, two twin screws (7) are found, the screws are moved by a transmission (8) that moves a motor (9). The barrel has a length from 125 cm to 170 cm and from 14 cm to 18 cm of diameter. The coupling section (2) has a length of 8 cm to 12 cm not including the thickness of the flanges and has two flanges at the ends with a diameter of 23 cm to 30 cm, while the thickness of the flanges is of 3 cm to 4 cm. Two circular perforations are found in the coupling section, one at the top and another at the bottom, with a diameter of 7.5 cm to 10 cm, which are aligned and allow the mechanical coupling of the screws. The coupling section is joined by the flanges to the feeding section. The feeding section has a length of 35 cm to 45 cm not including the thickness of the flanges and has two flanges with 35 cm to 45 cm of diameter, while the thickness of the flanges is between 3 cm to 4 cm. The feeding section has a circular orifice at the top, with a diameter of 10 cm to 14 cm located between 4 cm to 6 cm after the flange. This orifice serves for feeding the material to be extruded. The extruder to nixtamalize maize fractions can process from 4.5 kg to 6 kg per minute. It's important to mention that the feeding rate must be lower that 80% of the capacity of the extruder measured in terms of amperage of the transmission motor and velocity of the screws, at a constant flow. To facilitate the feeding to the extruder to nixtamalize maize fractions, a dispenser can be coupled to feed the quantity of material to be extruded in the feeding section. The types of dispenser that can be coupled are volumetric or gravimetric. The feeding section joins the transition section by flanges. The transition section has a length of 35 cm to 45 cm not including the thickness of the flanges and has two flanges with a diameter of 23 cm to 30 cm and a thickness of 3 cm to 4 cm. In the transition section heat can be added by band-type electric resistors that surround this section with the objective of compensating for the temperature at the final section of the barrel. The transition section is joined to the die (5) section by flanges. The die section is coupled to the transition section by a flange that has a thickness of 3 cm to 4 cm and a diameter of 23 cm to 30 cm. The die has a cylindrical shape, and two sprocket hubs of different heights protrude from it, one on each side. The input sprocket hub is the lowest and it's found in the input of the die, has a cylindrical shape and a length of 5 to 10 mm. The input sprocket hub has an exterior diameter of 14 cm to 23 cm, which the interior diameter is of 5 cm to 13 cm. The input sprocket hub has an orifice with conic shape that reaches up to 60% of the die longitude, afterwards the orifice has a cylindrical shape up until coming out through the output sprocket hub. The output sprocket hub is the highest, and it's found in the discharge of the die (also known as output), it has a cylindrical shape and a height of 25 cm to 50 cm. The exterior diameter of the output sprocket hub is of 12 to 20 cm, while the interior diameter is of 5 cm to 11 cm. The output sprocket hub has an obstruction (10) in its interior diameter that has the shape of a ring, the ring has a thickness of 3 mm to 5 mm with a depth of 6 mm to 10 mm and an internal diameter of 4 dm to 10 cm. The internal diameter of the obstruction is smaller than the internal diameter of the output sprocket hub. When the extruded material is forced through the die, pressure is released causing a loss in humidity and a drop in the temperature of the extrudate. The die serves primarily as a resistance to flow. In this case, as the die of the extruder to nixtamalize maize fractions has a big diameter, the change in pressure causes a change in temperature of around 5° C. The circular orifice of the die is equivalent to 40% to 50% of the perforation area (6) elongated in the shape of an eight (also known as the discharge of the barrel). The pressure at the back of the die is of 1 kg/cm.sup.2 to 1.3 kg/cm.sup.2, while the output temperature is between 55° C. to 70° C. As mentioned, the die features a big output diameter which causes the extruded material to loss humidity and a decrease in temperature when passing through the die. Additionally, it causes better organoleptic properties and the decrease of clogging in the barrel, this feature brings with it a novelty. A cutter can be couples to the output of the die with the objective of cutting the extruded material in small granules to particles with a maximum length of 7 mm. The cutter is mounted outside the die, which has 2 to 4 blades that pass through the face of the die. For a good cut, the blades must be held rigidly close to the die. Regarding the perforation at the base of the cannon, it has a constant area of transversal section. This perforation come from the coupling section to the transition. The diameter of the circles that make up the eight in the perforation are of 5 cm to 8 cm and the distance between the center of the circles that make up the eight is from 5 cm to 8 cm. With respect to the screws, they are from 2 cm to 6 cm in diameter and their length is from 80 cm to 120 cm. The screws feature a helical thread that goes along the length of the screw, the thickness of the thread is of 3 mm to 9 mm and its depth is of 7 mm to 12 mm. The thickness and depth of the thread is constant along the screw. The threads of the screws are placed interspersed along the entire length of the screws, adding to this the two screws rotate axially in opposite directions. The screws have the function of transporting the product forward, mixing, generating, and transferring heat, in addition to generating texture, pressure, and homogenization. The screw is divided in four sections, the first two sections are fore transport of the material, the third for mixing, and the fourth for compression of the material. The pumping efficiency (transport of the material along the cannon) is affected by the geometry of the screw (pitch, thread angle, depth, etc.). Next, the geometries of the sections are described. The first section (11) of the screw has a longitude of 15 cm to 20 cm, while the spacing between the threads is of 50 mm to 70 mm and the angle of the thread is of 106 degrees to 109 degrees. In the second section (12) the length is of 18 cm to 23 cm, while the spacing between the threads is of 40 mm to 60 mm and the angle is of 102 degrees to 105 degrees. In the third section (13) the length is of 12 cm to 16 cm, while the spacing between the threads is of 35 mm to 40 mm and the angle of the thread is of 98 degrees to 102 degrees. In the fourth section the cutting phenomenon is created, which makes the product stretch, accelerates gelatinization of the starches and other reactions, aligns long chain molecules, and can depolymerize them (causing dextrinization). In this section, three temperature stages are reached, one being of 40° C. to 50° C., another of 50° C. to 60° C. and one of 60° C. to 70° C. The main novelty is the configuration of the screws and die. The two screws have threads uniform in thickness and depth, but the spacing between the threads and the angle varies along the screw. The aforementioned characteristics cause four sections to be generated along the screw. The first two sections are for transport, the third for mixing, and the fourth for compression. Another novelty is that the die features a circular orifice that has an area equivalent to 40% to 50% of the elongated perforation (6) in the shape of an eight. Together, screws and die, help the material flow in a short amount of time, reducing the cutting force (friction) and the pressure at the back of the die, maintaining a low temperature at the output of the extruder without expanding the material.

    Use Cases:

    [0025] The extruder to nixtamalize maize fractions was employed in the following manner, first a mixture of degermed maize grain fractions was conditioned, previously conditioned with hot water at 80° C. to 95° C. and calcium hydroxide of 0.1% to 0.15% for a two-hour to three-hour period of rest. The mixture of degermed maize grain fractions has the following proportions: the endosperm represents from 65% to 75% of mass; while the dark flours, from 10% to 15%; and the milled germ and pericarp, from to 10% to 15%. The humidity of the mixture does from 25% to 35% and its temperature after the rest goes from 35° C. to 50° C. This mixture was processed in the extruder to nixtamalize maize fractions. Next, the components of the extruder to nixtamalize maize fractions are described, the barrel of the extruder had four sections: coupling, feeding, transition and die. In the center of the bases of the barrel a perforation in the shape of an eight is located, it extends from the coupling section to the transition. The screws are moved by a transmission that moves the motor. The length of the barrel was 128 cm while its diameter was 15 cm. In this case, the coupling section was of 9.6 cm, while the thickness of the flanges was 3 cm, and the diameter was 27 cm. The diameter in the perforations of the coupling section was 7.95 cm. The coupling section was joined to the feeding section by a flange. The feeding section had a length of 40.43 cm, while the thickness of the flanges was 3.55 cm, with respect to the diameter of the flanges, it was 27 cm. The diameter of the circular orifice of the feeding section was 10.8 cm and it was position in the top part 4.5 cm away from the flange. The feeding section was joined to the transition section by a flange. The transition section had a length of 40 cm, while the thickness of the flanges was 3.5 cm, and the diameter of the flanges was 27 cm. The transition section is connected to the die section by a flange of 3.5 cm of thickness while its diameter was 27 cm. The die had a cylindrical shape and two sprocket hubs of different height protruded from it, one on each side. The input sprocket hub was the lowest and had a cylindrical shape and a length of 8 mm. The input sprocket hub was joined to the transition section of the barrel. The external diameter of the input sprocket hub was 15 cm, while the internal diameter was 6.8 cm. The input sprocket hub had a conic shaped orifice that reached up to 60% the length of the die, to then come out in a cylindrical shape until coming out through the output sprocket hub. The output sprocket hub had a cylindrical shape and a height of 40 mm. The output sprocket hub had an exterior diameter of 13 cm while the interior diameter was 6.8 cm. The output sprocket hub had an obstruction in its internal diameter that had the shape of a ring, the ring had a thickness of 4 mm with a depth of 9 mm. The internal diameter of the ring was 6 cm. The circular orifice that the die had was equivalent to 40% of the elongated perforation in the shape of an eight. In the perforation at the bases of the barrel, the diameter of the circles that make up the eight in the perforation was 6.5 cm. The diameter of the screws war 4.44 cm and its length was 81 cm. The helical thread had a thickness of 6.35 mm and a depth of 9.52 mm. The threads were interspersed along the screw. The screw was divided in four sections, the first had a length of 18.09 cm and the spacing between the threads was 60 mm with an angle of 107.6 degrees of the thread. The second section of the screw had a length of 19.05 cm and the spacing between the threads was 48 mm with an angle of 10.4 degrees. The third section had a length of 14.28 cm, with spacing between the threads of 36 mm and an angle of 100.7 degrees. Finally, the fourth section had a length of 33.57 cm, with spacing between the threads of 24 mm and an angle of 97 degrees. In the fourth section, three heating stages are reached, 40° C., 50° C., and 60° C. Once the material passes through the die it reaches a pressure of 1 kg/cm.sup.2 to 1.3 kg/cm.sup.2 at a temperature of 55° C. to 70° C. Once the material passed through the extruder, the extrudate was then cut in small pieces at a maximum of 7 mm, with a cutter of four blades. After the extrudate was cut, it was cooled to temperatures below 60° C. The cooling took place through a pneumatic process. The humidity of the extrudate was in a range between 25% and 30%. The extrudate was milled with a BCH roller mill (micropulverizer). Afterwards, it was instantly dehydrated with a flow of hot air in a range of 200° C. to 400° C. This hot air was transported through a pipe in which the diameter was reduced, decreasing its pressure, and increasing its speed (Venturi effect) until the milled and dehydrated extrudate reached a temperature between 30° C. to 35° C., by means of a pneumatic transport using room temperature air. Afterwards, the mixture passed to the sifting process, were the flour had the following granulometric characteristics: with a sieve of 0.60 mm (US #30) it retained no particles, with a sieve of 0.425 mm (US #40) it retained a maximum of 15%, with a sieve of 0.250 mm (US #60) it retained a maximum of 6%, with a sieve of 0.150 mm (US #100) it retained a maximum of 90%. The flour that did not comply with the granulometry was remilled and integrated to the sifting. The color characteristics of the produced flour were the following: dry color of 84% reflectance and humid color of 40% reflectance, while the humidity was at 7%, and 6.3 pH. The efficiency of flour to produced dough when adding water to a kilogram of flour was 2.3 kilograms of dough.