Direct extrusion is the process in which grits (for example corn) are forced through a die plate into the final snack-shape, and flavourings are added to produce a tasty snack.
MIXER: In the mixer the raw materials are mixed and brought to the desired moisture level. The mix is then transferred to the extruder hopper by means of a screw feeder. A level indicator ensures that the extruder does not run empty.
EXTRUDER: In the extruder the raw materials are pressed through a die plate using high pressure build-up by the screw and high temperature created by shear between sleeve and screw. The pressure drop at the die plate causes the snack to expand and the face cutters set the desired snack length and mass. Unique to Lalesse Extrusion is the fully water-cooled extrusion process.
DRYING + COATING: After extrusion the snacks are dried for extra crispness and for shelf-life, next they are coated with slurry; a mixture of oil and flavour powder. Coating takes place in the rotating coating drum and the slurry is made on demand (continuously) in the Lalesse Extrusion flavour equipment.
BUFFER SILO: Now the snacks are ready to be packed. This is best done immediately. It is recommended that a buffer silo is installed between packing equipment and processing line, mainly to overcome the differences in operational speed.