There are two different models of mixers: the vertical grits mixer and the horizontal ribbon mixer. The most common and easiest to use is the vertical grits mixer. Raw materials are fed from floor level and an Archimedes screw brings the raw materials into the mixer. Water is added (auto control) and the mix is prepared. Together with the screw feeder (transport to extruder) and extruder hopper, it forms one big buffer of raw materials.
The more universal mixer is a ribbon mixer, which can also mix a wider range of raw materials. A double action ribbon mixes the raw materials while water is gently added. The mixer has weight sensors and auto water feeding. The cleaning of a ribbon mixer is easy and for accessibility, it is recommended to have a locally built platform.
Lalesse offers various types as well as capacities when it comes to extrusion. These are, however, always single screw, short screw and high shear. The capacities range from 80 to 300 kg per hour. The actual capacity is a result of raw materials used, shape to produce, desired bite and density. Testing is key, hence we encourage all producers to test before we can guarantee a result.
What is important is that we offer as many controls/settings as possible to run the extrusion process. All extruders run variable speed, feed control, full water cooled process and different pressure settings. Also all extruders have a hollow main shaft. After ending the extrusion process, either a planned or a sudden stop, the process screw can be pushed out within minutes.
Lalesse Extrusion offers the direct drive system on the extruders: a drive system without a V-belt; the most modern drive system and considered the strongest in this market segment. We also offer a split sleeve system. This means a separate front and a separate back sleeve for more cost-efficiency. Most shapes are made via die inserts rather than a die plate. The insert needs a holder, the die plate, this can hold the different inserts. As the insert is a smaller part, this means cost advantage.
For the smaller capacity lines, we advise using an infrared heated drum dryer, a very user-friendly model. Infrared elements are placed in a hood inside the drum resulting in a great output. The heat quantity can be controlled as well as the rotation speed and the slope of the drum.
A more sophisticated dryer model is the belt dryer: drying with hot air. In a heat exchanger, on top of the dryer, hot air is made with a gas or fuel burner, by electricity or by steam. Where applicable, heating is always indirect (no fumes to reach the snacks). Hot air is forced through the bed of snacks and returned to the burner. Depending on the moisture level, a percentage of hot air is re-used. The rest is replaced by fresh air. The dryer is single pass; over the belt the pressure chamber is mounted to force the air through the belt (and through the snacks) . This results in a very uniform drying, benefiting the end product.
The IR drum dryer runs a capacity of approximately 200 kg per hour output. The belt dryer starts at 300 kg and can dry up to 2000kg per hour output.
Snacks need a coating to become more appealing. This process comes after drying and is done in a coating drum. The drum comes in various diameter sizes and has on the inside a self-cleaning profile. To ensure uniform residence time, strips are mounted in the drum. The rotation speed and the slope of the drum are variable.
The coating is done by a slurry. This is a mix of oil and flavour powder. For this purpose, Lalesse Extrusion invented the slurry on-demand system. Rather than having huge melting tanks full of slurry, we create a consistent flow of oil and flavour powder. This is mixed in a buffer silo of 15 liters and pumped from here. This way the exact desired amount of slurry is sprayed onto the snacks. The amount of slurry will no longer dictate the process runs. The slurry on-demand system can be stopped at any time. Please note that during production, quantities of oil and flavour can be adjusted as also for the ration oil and flavour. It could not be more simple!
Lalesse developed this smart solution to cope with the huge volume flow coming from the extrusion line. It is not recommended to stop (or reduce) the extruder capacity. The most effective and efficient way is to leave the equipment running, produce the required snacks and collect them in a buffer silo, just before packaging. We use the vertical buffer silo with a vibration feeder at the exit. You can also opt for belt bunkers and other types of buffers. It is vital here that the system is closed to limit snack exposure to outside air and humidity.