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Extruded whole flours from blends of cereals and pulses have great potential to be key ingredients in the development of more innovative gluten-free products, both from a technological and nutritional perspective. The objective of this work was to obtain pre-cooked flours from four formulations based on blends of whole cereals (PR: parboiled brown rice; PM: pearl millet) and pulses (CP: chickpea; CB: common bean). CB was fixed at 10%, and the other components (PR-PM-CP) were set at 60-15-15 (F1), 15-60-15 (F2), 15-15-60 (F3), and 30-30-30 (F4), which were extruded at two combined conditions of feed moisture and screw speed: mild E1 (30% and 300 rpm) and severe E2 (18% and 600 rpm). The temperature profile was kept constant from 25 to 130 °C (from feed to output). The protein, dietary fiber, and ash contents in the raw formulations varied from 11.2 to 17.4%, 9.8 to 15.0%, and 2.2 to 3.3%, respectively, according to the low or high pulse content in the blend. As more mechanical energy was delivered to the raw formulations (W·h/kg, 63.7 for E1 and 179.4 for E2), the extruded particles had increased water absorption (g/g) from 1.7 to 4.5 (E1) or 3.8 (E2), increased water solubility due to E2 from 10.9 to 20.9%, and decreased oil absorption (g/g) from 1.5 to 0.9 (E1 and E2). The peak viscosity (PV, cP) was noticeable only in the raw formulation F2 (355), which decreased 10.3% due to E1. In the other formulations, PV appeared due to E1 in F1 (528), F3 (420), and F4 (371), while it disappeared due to E2 in all formulations. However, at the E2 condition, they did show cold viscosity in the initial stage (222 to 394 cP). The final viscosity (FV, cP) decreased from 795 to 390 (E1) or 123 (E2). In F2, the contents of phenolic compounds (285 µg GAE/g) and ABTS+ (13.2 μmol TE/g) were more than twice that in the other formulations, and their respective degradations were low due to E1 (4.2 and 12%) and high due to E2 (16 and 17%). Extrusion cooking did not cause significant changes in the luminosity (81) and redness (0.9) of particles, while yellowness increased from 15.7 to 18.2 (E1) or 18.7 (E2). Based on these findings, it is concluded that both extrusion conditions improved the technological and functional properties. Regarding the formulations, F2 stood out for being rich in antioxidant capacity, which poorly degraded under the conditions studied. Further work is needed to contribute to understanding the optimization of formulas and processes that would improve the nutritional, sensorial, and functional properties while still preserving the bioactive value of the final products.

This study takes the power battery pack of a pure electric vehicle as the research object, focusing on safety—a core concern widely emphasized in the automotive industry. In practical application scenarios, evaluating the safety of the power battery pack through a single operating condition fails to fully reflect its comprehensive safety performance throughout the vehicle’s entire life cycle. To overcome this limitation, a systematic analysis process was established. First, Catia geometric modeling software was used to simplify the battery pack structure, and HyperMesh was then employed for mesh generation. Second, three core analyses were conducted: static analysis, modal analysis, and extrusion condition analysis. A multi-condition safety evaluation system for electric vehicle battery packs during computer simulation analysis was proposed, which evaluates the battery pack from three dimensions: “dynamic stiffness-static strength-extrusion safety”. Results show that: modal analysis reveals the battery pack’s low-order natural frequencies exceed the vehicle’s excitation frequency (excitation point on the case cover); static analysis confirms it meets operational requirements; extrusion verification proves its safety complies with new national standards. The coupling effect of this multi-dimensional analysis breaks through the limitations of safety performance evaluation under a single operating condition, more realistically reflecting the battery pack’s comprehensive safety over its life cycle and providing a more systematic basis for power battery pack optimization.

Distillers dried grains with solubles (DDGS), a feed coproduct from the fuel ethanol industry, has been shown to be a viable potential alternative protein source for aquaculture feeds. To investigate this, three isocaloric (3.5kcal/g) ingredient blends containing 20, 30, and 40% DDGS, with a net protein adjusted to 28% (wet basis, wb), were prepared for use as Nile tilapia feed. Extrusion processing was then conducted using three DDGS contents (20, 30, and 40%, wb), three moisture contents (15, 20, and 25%, wb), three barrel temperature gradients (90-100-100°C, 90-130-130°C, and 90-160-160°C), and five screw speeds (80, 100, 120, 140, and 160rpm) using a single screw laboratory extruder. Several processing parameters, including mass flow rate, net torque required, specific mechanical energy consumption, apparent viscosity, and temperature and pressure of the dough inside the barrel and die, were measured to quantify the extrusion behavior of the DDGS-based blends. For all blends, as the temperature profile increased, mass flow rate exhibited a slight decrease, die pressure decreased, and apparent viscosity exhibited a slight decrease as well. Likewise, the net torque requirement, specific mechanical energy consumption, and apparent viscosity decreased as screw speed increased, but mass flow rate increased. Additionally, as moisture content increased, die pressure decreased. At higher temperatures in the barrel and die, the viscosity of the dough was lower, leading to lower torque and specific mechanical energy requirements. Increasing the DDGS content, on the other hand, resulted in a higher mass flow rate and decreased pressure inside the die. As demonstrated in this study, the selection of suitable temperature and moisture content levels are critical for processing DDGS-based ingredient blends.

Although the extrusion process has found numerous applications in developing ready-to-eat cereals, confectionary products, and sweet and salty snacks, interest has grown in understanding how extrusion influences the nutritional components in cereals and legumes. Extrusion offers the opportunity to manipulate the rate and extent of starch digestibility and nondigestible carbohydrate fermentation by gut bacteria, both of which have implications on human health. Proteins are generally modified in a positive way by increasing their digestibility and solubility, although some exceptions exist and losses in available lysine can occur. Extrusion can be used to deliver high-value oils that are rich in ω-3 fatty acids using novel strategies such as encapsulation. Vitamin stability can be an issue in extruded products, although mineral element bioavailability can increase with extrusion. Overall, extrusion has the potential to produce highly nutritious ready-to-eat products from cereals and legumes.

This chapter contains sections titled: Introduction Quality by Design Utilizing QbD for HME Process Understanding References

Extrusion-based 3D printing holds great potential for manufacturing solid propellants. Among the various methods, screw- and plunger-based extrusion are the most frequently reported techniques for propellant 3D printing, each employing different extrusion mechanisms. This paper compares the flow characteristics of these two methods through a combination of simulations and experiments. Simulation results reveal that propellant slurry in a plunger extrusion device exhibits relatively stable flow characteristics, especially near the nozzle outlet, with high flow velocity, high shear rate, and low-pressure distribution. Compared to the screw-based device, the plunger extrusion achieves a more uniform outlet velocity. In contrast, the screw extrusion device produces more complex rheological behavior, with backflow observed in the gap between the screw and the extrusion channel wall. However, the average pressure in the flow channel for screw extrusion (3885.11 Pa) is notably lower than that of plunger extrusion (7292.92 Pa). Experimental results indicate that the printing quality of plunger extrusion is comparable to that of screw extrusion. These findings provide valuable insights into advancing extrusion-based 3D-printing processes for solid propellants.

Surface cracking is one of the common problems in the extrusion process of Al–Li alloys, which seriously affects the surface quality and performance of the profile. In this study, the extrusion experiments of 2195 Al–Li alloy profiles were carried out under different temperatures and speeds to reveal the influence of extrusion parameters on the profile cracking and clarify the cracking mechanism. It was found that the extrusion cracking is closely related to the profile temperature at the die outlet and the plastic work accumulation after the material flows through the die bearing. Cracking occurs when the surface temperature of the profile is too high and the tensile plastic work accumulation exceeds the critical value. Based on the cracking mechanism, a prediction criterion for the extrusion cracking was established by taking into account the influences of deformation temperature and strain rate. The extrusion cracking of the spray-deposited 2195 Al–Li alloy profile was predicted by finite element simulation coupled with the established criteria. The predicted cracking position and degree were in good agreement with the experimental results. Finally, the boundary conditions for safe extrusion without cracking were investigated, and the extrusion limit diagram of the 2195 Al–Li alloy was constructed, which can be conveniently used to guide the selection of extrusion parameters in actual production.

Thermoplastic extrusion, a widely used method for processing thermoplastic materials, requires precise temperature control to ensure product quality. However, existing computer-aided engineering tools often oversimplify the temperature distribution calculations, leading to additional discrepancies between simulations and the actual processes. This study introduces a novel multi-region modeling approach to address this issue. By employing realistic temperature control conditions, the methodology overcomes the limitations of current numerical modeling tools. The key contributions include the development of a transient, incompressible, non-isothermal solver integrated into the OpenFOAM computational library and the implementation of a specialized boundary condition that emulates Proportional-Integral-Derivative (PID) control using real-time thermocouple measurements. The findings highlight temperature deviations at the flow channel walls and total pressure drop while demonstrating a smaller impact on velocity and flow uniformity at the outlet under steady-state conditions. This research substantially advances the understanding of thermal dynamics in extrusion processes, offering crucial insights for enhancing temperature control and laying the groundwork for more effective and precise operational strategies.

The development of plant-based meat analogs is currently hindered by the beany flavor generated by raw soybean protein and extrusion processing. Wide concern has led to extensive research on the generation and control of this unwanted flavor, as an understanding of its formation in raw protein and extrusion processing and methods through which to control its retention and release are of great significance for obtaining ideal flavor and maximizing food quality. This study examines the formation of beany flavor during extrusion processing as well as the influence of interaction between soybean protein and beany flavor compounds on the retention and release of the undesirable flavor. This paper discusses ways to maximize control over the formation of beany flavor during the drying and storage of raw materials and methods to reduce beany flavor in products by adjusting extrusion parameters. The degree of interaction between soybean protein and beany compounds was found to be dependent on conditions such as heat treatment and ultrasonic treatment. Finally, future research directions are proposed and prospected. This paper thus provides a reference for the control of beany flavor during the processing, storage, and extrusion of soybean raw materials used in the fast-growing plant-based meat analog industry.

Abstract In the process of internal thread cold extrusion, the extrusion tap is an indispensable tool. Therefore, it is important to improve the service life of the extrusion tap and reduce the tool wear. In this paper, using Central Composite Design response surface test, the influence of the parameters (including the guide cone angle, backhoe capacity, guide cone length and working cone length) of the extrusion tap on the forming quality of internal cold extrusion are investigated, so as to obtain the minimum extrusion torque and the minimum extrusion temperature. A polynomial regression response model of the minimum extrusion torque and minimum extrusion temperature is obtained. Using the regression model, the objective function is optimized, and a group of optimal parameters is obtained (guide cone angle: 10°, backhoe capacity: 0.32, guide cone length: 4 mm, and working cone length: 13 mm). Numerical simulation of the optimal parameters is also carried out. The results show that the measured extrusion torque and extrusion temperature are close to the predicted values with errors of 2 and 2.55%, respectively, which are well fitted by the model.