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Coperion K-Tron (Schweiz) GmbH
Lenzhardweg 43/45,
5702
Niederlenz
Switzerland
Switzerland
Location
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Andreas Weissenberger
Regional Sales Manager Food / Pharna - Coperion & Coperion K-Tron
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Our range of products
Product categories
- 01 Packaging machines and devices
- 01.01 Preparing and feeding
- 01.01.07 Dosing and portioning machines
- 01.01.07.03 Gravimetric dosing
Gravimetric dosing
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 01 Packaging machines and devices
- 01.01 Preparing and feeding
- 01.01.07 Dosing and portioning machines
- 01.01.07.05 Volumetric dosing
Volumetric dosing
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 01 Packaging machines and devices
- 01.05 Inspection and control
- 01.05.01 Checkweighers
Checkweighers
- Good Vibrations - Coperion K-Tron Announces the Next Generation of High Accuracy Vibratory Feeding Technology
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 03 Machines and equipment for the production of confectionery (Chocolate confectionery, sugar confectionery, gum)
- 03.02 Single machines / equipment for the production of confectionery (Chocolate confectionery, sugar confectionery, gum)
- 03.02.27 Single machines /equipment for the production of confectionery / Dosing and mixing equipment
Single machines /equipment for the production of confectionery / Dosing and mixing equipment
- 03 Machines and equipment for the production of confectionery (Chocolate confectionery, sugar confectionery, gum)
- 03.03 Operating and auxiliary equipment for the production of confectionery (Chocolate confectionery, sugar confectionery, gum)
- 03.03.03 Operating and auxiliary equipment for the production of confectionery / Containers for charging / discharging machines
Operating and auxiliary equipment for the production of confectionery / Containers for charging / discharging machines
- 03 Machines and equipment for the production of confectionery (Chocolate confectionery, sugar confectionery, gum)
- 03.03 Operating and auxiliary equipment for the production of confectionery (Chocolate confectionery, sugar confectionery, gum)
- 03.03.05 Operating and auxiliary equipment for the production of confectionery / Laboratory equipment
Operating and auxiliary equipment for the production of confectionery / Laboratory equipment
- 03 Machines and equipment for the production of confectionery (Chocolate confectionery, sugar confectionery, gum)
- 03.04 Storage, logistics and transport equipment (Chocolate confectionery, sugar confectionery, gum)
- 03.04.01 Storage, logistics and transport equipment / Conveying and storage systems
Storage, logistics and transport equipment / Conveying and storage systems
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 03 Machines and equipment for the production of confectionery (Chocolate confectionery, sugar confectionery, gum)
- 03.04 Storage, logistics and transport equipment (Chocolate confectionery, sugar confectionery, gum)
- 03.04.02 Storage, logistics and transport equipment / Feeding systems
Storage, logistics and transport equipment / Feeding systems
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 03 Machines and equipment for the production of confectionery (Chocolate confectionery, sugar confectionery, gum)
- 03.04 Storage, logistics and transport equipment (Chocolate confectionery, sugar confectionery, gum)
- 03.04.10 Storage, logistics and transport equipment / Transport and handling systems
Storage, logistics and transport equipment / Transport and handling systems
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 04 Machines and equipment for the production of bakery products, snacks and cereals (including biscuits, waffles, etc.)
- 04.02 Single machines / equipment for the production of bakery products, snacks and cerials (including biscuits, waffles, etc.)
- 04.02.12 Single machines / equipment for the production of bakery products, snacks and cerials / Dosing and mixing equipment
Single machines / equipment for the production of bakery products, snacks and cerials / Dosing and mixing equipment
- 04 Machines and equipment for the production of bakery products, snacks and cereals (including biscuits, waffles, etc.)
- 04.03 Operating and auxiliary equipment for the production of bakery products, snacks and cerials (including biscuits, waffles, etc.)
- 04.03.03 Operating and auxiliary equipment for the production of bakery products, snacks and cerials / Containers for charging / discharging machines
Operating and auxiliary equipment for the production of bakery products, snacks and cerials / Containers for charging / discharging machines
- 04 Machines and equipment for the production of bakery products, snacks and cereals (including biscuits, waffles, etc.)
- 04.04 Storage, logistics and transport equipment for the production of baked goods, snacks and cerials (including biscuits, waffles, etc.)
- 04.04.01 Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Conveying and storage systems
Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Conveying and storage systems
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 04 Machines and equipment for the production of bakery products, snacks and cereals (including biscuits, waffles, etc.)
- 04.04 Storage, logistics and transport equipment for the production of baked goods, snacks and cerials (including biscuits, waffles, etc.)
- 04.04.02 Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Feeding systems
Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Feeding systems
- 04 Machines and equipment for the production of bakery products, snacks and cereals (including biscuits, waffles, etc.)
- 04.04 Storage, logistics and transport equipment for the production of baked goods, snacks and cerials (including biscuits, waffles, etc.)
- 04.04.07 Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Transport and handling systems
Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Transport and handling systems
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 05 Machines and equipment for the processing of other food products (e.g. coffee processing, production of ice cream, etc.)
- 05.03 Operating and auxiliary equipment for the processing of other food products (no confectionery and bakery machines)
Operating and auxiliary equipment for the processing of other food products (no confectionery and bakery machines)
- 06 Machines and equipment for the production of pharmaceuticals and cosmetics
- 06.03 Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics
- 06.03.05 Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics / Containers for charging / discharging machines
Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics / Containers for charging / discharging machines
- 06 Machines and equipment for the production of pharmaceuticals and cosmetics
- 06.03 Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics
- 06.03.07 Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics / Feeding systems
Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics / Feeding systems
- 06 Machines and equipment for the production of pharmaceuticals and cosmetics
- 06.03 Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics
- 06.03.13 Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics / Laboratory facilities
Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics / Laboratory facilities
- 06 Machines and equipment for the production of pharmaceuticals and cosmetics
- 06.04 Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products
- 06.04.01 Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Conveying, storage and transportation systems
Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Conveying, storage and transportation systems
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 06 Machines and equipment for the production of pharmaceuticals and cosmetics
- 06.04 Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products
- 06.04.02 Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Feeding systems
Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Feeding systems
- Good Vibrations - Coperion K-Tron Announces the Next Generation of High Accuracy Vibratory Feeding Technology
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 06 Machines and equipment for the production of pharmaceuticals and cosmetics
- 06.04 Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products
- 06.04.03 Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Product and material handling
Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Product and material handling
- Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
- Coperion Equipment - Food Trends & Requirements
- Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
- Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
- 07 Services
- 07.01 Business support
- 07.01.01 Assembly, maintenance and repair services
Assembly, maintenance and repair services
Our products
Product category: Checkweighers, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Feeding systems
Good Vibrations - Coperion K-Tron Announces the Next Generation of High Accuracy Vibratory Feeding Technology
Coperion K-Tron is proud to announce a completely new K3 line of vibratory feeders for dry bulk solids.
The innovative new feeder design features a unique, patent-pending drive system combined with an advanced control package. The new K3 vibratory feeder is able to achieve accuracies averaging 35% better over traditional vibratory technologies. This revolutionary new generation of Coperion K-Tron loss-in-weight vibratory feeders offers gentle handling of the bulk material, higher accuracy and faster product changeover, resulting in less product waste, less downtime and better end product quality as well as improved sustainability.
New technology brings significant advantages
These advantages are possible thanks to groundbreaking new technology. The key to achieving high accuracy is the ability to deliver a continuous, even product discharge with minimal pulsations. The new K3 vibratory drive is able to do this thanks to a completely new shock absorber design. Conventional vibratory feeders use rubber or spring shock absorbers, which allow movement of the drive in all directions, resulting in rotational motion. In contrast to these conventional shock absorbers, the new K3 line uses a unique flexible pendulum technology which provides shock absorption only parallel to the desired direction of motion, eliminating rotational movement. This parallel motion ensures an even material flow of the product along the entire length of the tray.
The innovative new feeder design features a unique, patent-pending drive system combined with an advanced control package. The new K3 vibratory feeder is able to achieve accuracies averaging 35% better over traditional vibratory technologies. This revolutionary new generation of Coperion K-Tron loss-in-weight vibratory feeders offers gentle handling of the bulk material, higher accuracy and faster product changeover, resulting in less product waste, less downtime and better end product quality as well as improved sustainability.
New technology brings significant advantages
These advantages are possible thanks to groundbreaking new technology. The key to achieving high accuracy is the ability to deliver a continuous, even product discharge with minimal pulsations. The new K3 vibratory drive is able to do this thanks to a completely new shock absorber design. Conventional vibratory feeders use rubber or spring shock absorbers, which allow movement of the drive in all directions, resulting in rotational motion. In contrast to these conventional shock absorbers, the new K3 line uses a unique flexible pendulum technology which provides shock absorption only parallel to the desired direction of motion, eliminating rotational movement. This parallel motion ensures an even material flow of the product along the entire length of the tray.
Product category: Storage, logistics and transport equipment / Conveying and storage systems, Storage, logistics and transport equipment / Feeding systems, Storage, logistics and transport equipment / Transport and handling systems, Gravimetric dosing, Volumetric dosing, Checkweighers, Single machines /equipment for the production of confectionery / Dosing and mixing equipment, Single machines / equipment for the production of bakery products, snacks and cerials / Dosing and mixing equipment, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Conveying and storage systems, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Feeding systems, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Transport and handling systems, Operating and auxiliary equipment for the processing of other food products (no confectionery and bakery machines), Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics / Feeding systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Conveying, storage and transportation systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Feeding systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Product and material handling
Coperion Food Processing Systems & Equipment - Hygienic Quick Change Design
Watch our YouTube Video about Coperion Food Processing Systems & Equipment in Hygienic Quick Change Design and lean more about the system and technology.
Product category: Gravimetric dosing, Volumetric dosing, Checkweighers, Single machines /equipment for the production of confectionery / Dosing and mixing equipment, Storage, logistics and transport equipment / Conveying and storage systems, Storage, logistics and transport equipment / Feeding systems, Storage, logistics and transport equipment / Transport and handling systems, Operating and auxiliary equipment for the production of bakery products, snacks and cerials / Containers for charging / discharging machines, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Conveying and storage systems, Single machines / equipment for the production of bakery products, snacks and cerials / Dosing and mixing equipment, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Transport and handling systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Conveying, storage and transportation systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Product and material handling, Assembly, maintenance and repair services
Coperion Equipment - Food Trends & Requirements
Watch our YouTube Video Coperion Equipment - Food Trends & Requirements and learn more about the various Coperion equipment.
Product category: Gravimetric dosing, Volumetric dosing, Checkweighers, Operating and auxiliary equipment for the production of confectionery / Containers for charging / discharging machines, Operating and auxiliary equipment for the production of confectionery / Laboratory equipment, Storage, logistics and transport equipment / Conveying and storage systems, Storage, logistics and transport equipment / Feeding systems, Storage, logistics and transport equipment / Transport and handling systems, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Conveying and storage systems, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Feeding systems, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Transport and handling systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Conveying, storage and transportation systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Feeding systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Product and material handling, Assembly, maintenance and repair services
Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry
Watch our YouTube Video on Coperion Food Safety Designs - Innovative Equipment & Systems for the Food Industry and learn about these innovations.
Product category: Gravimetric dosing, Volumetric dosing, Checkweighers, Single machines /equipment for the production of confectionery / Dosing and mixing equipment, Storage, logistics and transport equipment / Conveying and storage systems, Storage, logistics and transport equipment / Feeding systems, Storage, logistics and transport equipment / Transport and handling systems, Single machines / equipment for the production of bakery products, snacks and cerials / Dosing and mixing equipment, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Conveying and storage systems, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Feeding systems, Storage, logistics and transport equipment for the production of baked goods, snacks and cerials / Transport and handling systems, Operating and auxiliary equipment for the processing of other food products (no confectionery and bakery machines), Operating and auxiliary equipment for the production of pharmaceuticals and cosmetics / Feeding systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Conveying, storage and transportation systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Feeding systems, Storage, logistics and transport equipment for the production of pharmaceutical and cosmetic products / Product and material handling, Assembly, maintenance and repair services
Production of meat analogues (HMMA - High Moisture Meat Analogues) with the Coperion Extruder
A growing world population coupled with the search for alternatives to animal protein has led to an increased interest in plant-based ingredients and consumption of vegetable derived proteins. Texturized vegetable protein (TVP) – also known as textured soy protein or soy meat – and high moisture meat analogues (HMMA) produced by high moisture extrusion cooking (HMEC) are examples of these alternative protein sources. These alternatives are not only less expensive but also environmentally friendly. Other advantages of TVP and HMMA include longer shelf life and low fat content.
Coperion, Stuttgart, Germany, has had a long working relationship with the German Institute of Food Technologies (DIL) in Quakenbrueck, Germany. One focus of the cooperation is the research and further development of TVP extrusion technology and the HMEC of textured protein concentrate into a vegetable meat substitute.
The customized Coperion twin screw extrusion systems which include Coperion's high quality ZSK food extruders, Coperion K-Tron’s line of high accuracy loss in weight feeders, Coperion and Coperion K-Tron’s material handling equipment for ingredient delivery, and very specialized cooling die technology, are designed to provide the highest quality TVP and HMMA products.
Typical ingredients are vegetable proteins like soy protein (defatted soy flour and concentrate), gluten, lupine and pea protein for texturized vegetable protein (TVP), high moisture meat analogues (HMMA), meat substitutes, meat extenders and soy meat.
Coperion, Stuttgart, Germany, has had a long working relationship with the German Institute of Food Technologies (DIL) in Quakenbrueck, Germany. One focus of the cooperation is the research and further development of TVP extrusion technology and the HMEC of textured protein concentrate into a vegetable meat substitute.
The customized Coperion twin screw extrusion systems which include Coperion's high quality ZSK food extruders, Coperion K-Tron’s line of high accuracy loss in weight feeders, Coperion and Coperion K-Tron’s material handling equipment for ingredient delivery, and very specialized cooling die technology, are designed to provide the highest quality TVP and HMMA products.
Typical ingredients are vegetable proteins like soy protein (defatted soy flour and concentrate), gluten, lupine and pea protein for texturized vegetable protein (TVP), high moisture meat analogues (HMMA), meat substitutes, meat extenders and soy meat.
Company news
Date
Topic
01 Apr 2020
Coperion ZSK Food Extruder for Plant Based Proteins Now in Hybrid Design
For its ZSK Food Extruder, Coperion has developed a hybrid solution for manufacturing meat substitute products. With only a minimum of retrofitting effort, both texturized vegetable protein (TVP) and high moisture meat analogues (HMMA) can be produced on this ZSK Food Extruder, providing manufacturers of meat substitutes maximum flexibility to be able to profitably react to changing market demands, even on short notice.
Coperion’s co-rotating ZSK twin screw extruders are used in the manufacture of both TVP and HMMA. Previously, the food extrusion system’s configuration differed for each application: While the ZGF centric food pelletizer is attached to the process section for manufacturing TVP in order to cut the product directly at the nozzle plate, HMMA is discharged using a specialized cooling die which produces a product strand exhibiting a texture closely resembling that of genuine meat.
Using a newly developed adapter solution from Coperion, the ZSK Food Extruder’s discharge can now be changed over from a ZGF to a cooling die in record time. The machine’s operator personnel can perform the changeover; no electrician is needed. The ZGF is first opened and moved to the side. Next, after the nozzle plate is opened by loosening a few screws; the nozzle is switched using the adapter, and the cooling die is flanged. The same principle functions just as quickly in reverse when performing product changeovers from an HMMA process to TVP.
The Food Extruder’s design, with feeding and process section, remains largely unchanged in most cases. In combination with the self-cleaning profile of the extruder’s twin screws, product conversion is completed in a few minutes.
TVP Extrusion
TVP is used both as a meat substitute and as a supplement to meat products. It can be produced in various sizes and forms, as smaller pellets or larger chunks, broken down or ground. TVP is a dry, expanded product with a long shelf life under normal ambient conditions. TVP requires rehydration in water/liquid before use.
When manufacturing TVP, the extruder’s main inlet is continually fed with bulk raw protein material using Coperion K-Tron’s high accuracy loss in weight feeders and material handling refill systems. Immediately thereafter, water is injected using Coperion K-Tron liquid feeders. In certain cases, direct steam injection is applied into the process section as well. Within the process section, materials are mixed, kneaded, and cooked. The product then moves out of the extruder via a nozzle plate where it is processed such that it achieves a porous, foamy structure with oriented fibers. The attached ZGF pelletizer’s knife rotor then immediately cuts the product. The TVP granules are then dried to ensure long-term product stability.
HMMA Manufacturing
HMMA is primarily used as a high-quality meat-analogue product in ready-to-eat meals. By adjusting recipe and process parameters, structures of different meat types can be replicated with striking similarity to the original. HMMA’s moisture content lies between approximately 50-80% and must therefore be refrigerated.
Protein sources used to manufacture high-quality HMMA are primarily legumes such as soy, lupine or pea. In certain cases, i.e., when manufacturing meat product extenders, lesser quantities of genuine meat or fish products are added.
The bulk raw protein material is fed into the extruder inlet. Water is then added. Within the ZSK Food Extruder’s process section, this mass is then fully mixed and kneaded. Discharge takes place using a cooling die that generates a meat-like texture which is “frozen in”. The result is a solid strand with fiber structure similar to meat; the strand is then conveyed to the next process step.
Stefan Gebhardt, General Manager of Business Unit Food & Pharma at Coperion, is convinced of the new ZSK Food Extruder hybrid design: “The high demand for this hybrid technology shows us that it corresponds exactly to the current market trend. The need for meat substitute products is growing steadily and at the same time undergoing major changes. With this hybrid machine concept that allows production of TVP and HMMA on one and the same extruder, we’re providing meat analogue manufacturers with a solution that gives them a high degree of flexibility to be optimally prepared for rapidly changing market conditions.”
Coperion’s co-rotating ZSK twin screw extruders are used in the manufacture of both TVP and HMMA. Previously, the food extrusion system’s configuration differed for each application: While the ZGF centric food pelletizer is attached to the process section for manufacturing TVP in order to cut the product directly at the nozzle plate, HMMA is discharged using a specialized cooling die which produces a product strand exhibiting a texture closely resembling that of genuine meat.
Using a newly developed adapter solution from Coperion, the ZSK Food Extruder’s discharge can now be changed over from a ZGF to a cooling die in record time. The machine’s operator personnel can perform the changeover; no electrician is needed. The ZGF is first opened and moved to the side. Next, after the nozzle plate is opened by loosening a few screws; the nozzle is switched using the adapter, and the cooling die is flanged. The same principle functions just as quickly in reverse when performing product changeovers from an HMMA process to TVP.
The Food Extruder’s design, with feeding and process section, remains largely unchanged in most cases. In combination with the self-cleaning profile of the extruder’s twin screws, product conversion is completed in a few minutes.
TVP Extrusion
TVP is used both as a meat substitute and as a supplement to meat products. It can be produced in various sizes and forms, as smaller pellets or larger chunks, broken down or ground. TVP is a dry, expanded product with a long shelf life under normal ambient conditions. TVP requires rehydration in water/liquid before use.
When manufacturing TVP, the extruder’s main inlet is continually fed with bulk raw protein material using Coperion K-Tron’s high accuracy loss in weight feeders and material handling refill systems. Immediately thereafter, water is injected using Coperion K-Tron liquid feeders. In certain cases, direct steam injection is applied into the process section as well. Within the process section, materials are mixed, kneaded, and cooked. The product then moves out of the extruder via a nozzle plate where it is processed such that it achieves a porous, foamy structure with oriented fibers. The attached ZGF pelletizer’s knife rotor then immediately cuts the product. The TVP granules are then dried to ensure long-term product stability.
HMMA Manufacturing
HMMA is primarily used as a high-quality meat-analogue product in ready-to-eat meals. By adjusting recipe and process parameters, structures of different meat types can be replicated with striking similarity to the original. HMMA’s moisture content lies between approximately 50-80% and must therefore be refrigerated.
Protein sources used to manufacture high-quality HMMA are primarily legumes such as soy, lupine or pea. In certain cases, i.e., when manufacturing meat product extenders, lesser quantities of genuine meat or fish products are added.
The bulk raw protein material is fed into the extruder inlet. Water is then added. Within the ZSK Food Extruder’s process section, this mass is then fully mixed and kneaded. Discharge takes place using a cooling die that generates a meat-like texture which is “frozen in”. The result is a solid strand with fiber structure similar to meat; the strand is then conveyed to the next process step.
Stefan Gebhardt, General Manager of Business Unit Food & Pharma at Coperion, is convinced of the new ZSK Food Extruder hybrid design: “The high demand for this hybrid technology shows us that it corresponds exactly to the current market trend. The need for meat substitute products is growing steadily and at the same time undergoing major changes. With this hybrid machine concept that allows production of TVP and HMMA on one and the same extruder, we’re providing meat analogue manufacturers with a solution that gives them a high degree of flexibility to be optimally prepared for rapidly changing market conditions.”
01 Apr 2020
Sustainable Compounding: Blown film manufacturer switches to biodegradable products with help from Coperion
Coperion has enabled Benin-based blown film manufacturer Asahel Benin Sarl. to produce sustainable, bio-based plastic films in the future by delivering a complete compounding system and sharing the corresponding process engineering expertise.
The system includes a ZSK 26 Mc18 twin screw extruder, four highly accurate feeders from Coperion K-Tron, as well as a water bath, an air wipe and a strand pelletizer from Coperion Pelletizing Technology. Before plastic bags and packaging were banned in Benin in July of 2018, this west African manufacturer had made its plastic films using polyethylene (PE). The new law forced the company to completely convert its production. Following a successful test and training phase at Coperion’s Stuttgart test lab, Asahel Benin Sarl. will produce biodegradable compounds in its home country with the aid of the ZSK twin screw extruder, and will then further process these on its existing blown film machinery into biodegradable bags and packaging materials. Importation, production, sale, and possession of petroleum-based plastic bags and packaging has been forbidden in Benin since 2018. Until then, Asahel Benin Sarl. had used both new PE compounds as well as recyclate for manufacturing its films that were then used predominantly in household products and in shopping bags for supermarkets.
The system includes a ZSK 26 Mc18 twin screw extruder, four highly accurate feeders from Coperion K-Tron, as well as a water bath, an air wipe and a strand pelletizer from Coperion Pelletizing Technology. Before plastic bags and packaging were banned in Benin in July of 2018, this west African manufacturer had made its plastic films using polyethylene (PE). The new law forced the company to completely convert its production. Following a successful test and training phase at Coperion’s Stuttgart test lab, Asahel Benin Sarl. will produce biodegradable compounds in its home country with the aid of the ZSK twin screw extruder, and will then further process these on its existing blown film machinery into biodegradable bags and packaging materials. Importation, production, sale, and possession of petroleum-based plastic bags and packaging has been forbidden in Benin since 2018. Until then, Asahel Benin Sarl. had used both new PE compounds as well as recyclate for manufacturing its films that were then used predominantly in household products and in shopping bags for supermarkets.
About us
Company portrait
Coperion is the international market and technology leader in compounding systems, feeding technology, bulk materials handling systems and services. Coperion designs, develops, manufactures and maintains systems, machines and components for the plastics, chemicals, pharmaceuticals, food and minerals industries. Within its four divisions – Compounding & Extrusion, Equipment & Systems, Materials Handling and Service – Coperion has 2,500 employees and nearly 30 sales and service companies worldwide. Coperion K-Tron is a brand of Coperion.
Company data
Target groups
- Food
- Confectionery products
- Industrial goods
- Pharmaceuticals