Malik Engineers

Vasai East, Mumbai, Maharashtra

    Food Extruders are used for converting large variety of food cereals for extruding various shapes which are pellets, RTE Snacks, Breakfast cereals, Precooked flours and starches, Expanded products such as Soy Nuggets, Aqua feed, and various Pasta products viz. macaroni, vermicelli, spaghetti, etc. Extruders have also been employed to produce Soy Dal Analague product (SDAP) which taste very much like natural Tur Dal but with added proteins and nourishment than possible with natural Tur dal alone. Further applications of Extruders have been to produce Pet/Acquatic feeds or pellets for Race Horse, Dog food and for other pet animals. The extruded pet food not only aids in easy digestability by the animal, but could be made with added minerals, vitamins or flavours thus providing useful ingredients and taste to the animal promoting it’s all round growth. More Recently, Extruder has been developed for producing Fortified/Reconstituted Rice which can produce natural Rice fortified with added minerals or vitamins which is very healthy for the consumer Thus Food Extruders have very wide applications.  Following categories of Extruders are used for producing the above products:  HTST High Temperature Short Residence Time) Cooker or Gelatanizer  High Shear Adiabatic Extruders.  Low Shear Extruders (Formers).  Collette Extruders.  Medium Shear Extruders which employ more wet Raw materials for Extrusion. Pellets are half-cooked products or “third generation” Snacks, and need to be fried or heated in hot oil or air for complete expansion and consumption. Raw pellets are produced using HTST and Former or Product Densification Unit (PDU)- Raw-materials (Wheat, Rice, Potato, etc.) being first cooked, followed by cooling and densification in the Former. The Former is fitted with various die inserts for forming the shape of pellet, e.g. Wheels, Tubes, Stars, Etc. In addition to conventional 2-D shapes mentioned, 3-D or hollow pellets are formed using special tubular die units to extrude a cooked sheet first with two layers. The two layers after collapsing and pre-drying could be punched with suitable dies to get 3D pellet which are further dried before final packing.  Direct Expanded Snack products are produced using High Shear Adiabatic Extruders, using various Food Cereals which are fully expanded immediately as they emerge from the die attached to the Extruder. They are used for producing RTE Snacks, Baked Corn Curls or Collette, Soy Nuggets, Aqua Feed (floating), etc. For producing sinking aquatic feeds, combination of Cooker (Gelatiniser) and PDU is employed.  Low Shear Extruders or Formers are used for producing various Pasta products like Macaroni, Spaghetti, Vermicelli, etc.  Medium Shear Extruders are employed to get partially expanded snacks, Pet foods, Snack Pellet, SDAP, Fortified Rice and such other products needing high moisture content upto 40% approx. while processing in the Extruder.  In all the above Extrusion processes, product has excess moisture and the same is removed by passing in Dryers before the product cools down for safe packing. The Drying Equipment should include a Pre-Dryer to remove some moisture before final Drying in the Main Dryer to permit safe handling without sticking of products. Continuous Belt Driers with Conveying Belts arranged in multiple decks are usually employed to operate continuously.  The Fry type Collette Extruder is a specialized Extruder designed for producing Fried Corn Curls/Collette. The working principle is entirely different from normal Screw Extruder, as the raw-material (corn meal or grits) gets cooked between two circular bronze discs (one is fixed and other is rotating, there is no die) and randomly cut by stationery knife on periphery. A short, feed screw feeds the de-germinated corn meal or grits between the 2 bronze discs where the material gets cooked due to high shearing forces and is cut into suitable lengths as it emerges out of the gap between the discs, by the knives. The product is fried in hot oil and applied with seasonings in a coating drum.  For Range of Food Extruder being manufactured by us, download our brochure following “Download” link.

HOT FEED EXTRUDER in screw sizes of 50, 65, 75, 100, 150, 200mm suitable for processing warm rubber to produce hoses, tubing, profiles & sections, tire treads, cables, etc. MALIK'S manufacture Single Screw Hot Feed Extruder for warm rubber strips. The screw configuration is specially designed with multi start threads and is hollow bored to control the temperature. The screw is manufactured from special steel and hardened for long life. The cylinder is press fitted with hardened liner and is jacketed for temperature control. All the flow channels including the die have smooth finish for easier cleaning and the controlled shear minimizes the risk of "scorching" of rubber.For extruding Silicon rubber, the machine is equipped with modified screw suitable for processing heat/shear sensitive silicone.  Cold Feed Extruders which employ raw rubber materials are more adapted for producing precision rubber goods, since they have ability to provide increased shear on the raw rubber thus providing uniform and adequeate mixing of the raw materials before extruding out through the die opening. Hot feed Extruders rarely employed L/D Ratio greater than 5/1 (4.5/1 being common) whereas cold feed extruders commonly employ L/D of typical 16/1- the longer screw permitting better mixing with the aide of TCU (Temperature Control Unit) provided for the Barrel through fluid heating/cooling medium.  DISPERSION KNEADER in 10, 35, 55 liters capacities, suitable for producing RUBBER COMPOUNDS.  The Rotors are counter rotating and rotate at differential speed and have special helical blades with hardened edges for long life. Both the mixing chamber and rotors are temperature controlled. Dumping is by automatic tilting of the chamber by suitable motorized gear unit.

 Layflat film from PE, PP, HM-HDPE, LLDPE, PET, PVC, etc.  Thick sheet from ABS, PE, PP, PVC, HIPS, PS, PET, etc.  EPE Foam sheet, pipe, rod & netting from PE.  UPVC conduits, pipe & profiles.  SPVC, LDPE, HDPE, PP pipe & profiles, Nylon tubing, etc.  PE, PP, Nylon, PBT fibres (monofilament).  PE, PP Box strapping.  PVC Compounding & alloying of polymers.  FRP polymer granules.  Recycled granules from PE, PP, PS, ABS, Nylon, Delrin, PC, etc.  Masterbatches.  Solid sections (Rods & square) from Nylon, Delrin, PP, PP, ABS, PEEK, etc.  PVC cables & wires.  Co-extrusion systems for 2, 3, 5 layer packaging film for LDPE, HDPE, LLDPE, HM-HDPE, etc.  Co-extrusion systems for braided hose pipe from SPVC.   MALIK'S Single screw Extruders feature:    Stellited/carbide coated/nitrided screw & hardened barrel for long life. Helical gear box with hardened and ground gears, with integral high capacity thrust bearing.  High L/D ratio with powerful drive for increased throughputs.  Fully solid-state, electronic control panel for smooth control of the screw speed.  Temperature control panel fitted with most accurate digital PID temperature controllers for accurate control of process temperature.  Transducers with digital instrumentation for monitoring/controlling the extrusion pressure with open loop/closed loop control.