WENGER THERMAL TWIN

EXTRUSION SYSTEMS
This changes everything.
twin screw extruders
have had their limitations like the fact that thermal to
mechanical energy ratios are typically in the range of 1 to 1.
Unfortunately, as energy costs increase, so do your expenses.
Similarly, fresh meat levels in pet food formulas have typically
been limited to 40 percent, which limits your choice of raw
materials and market options.
Then theres the fact that products high in corn and rice
with low levels of shear are typically sticky due to mechanical
energy inputs.
Well, we thought it was time to change the limits! With the
introduction of new Wenger TT760 and TT3630 Thermal Twin
Extruders and a new High Intensity Preconditioner, weve literally
shattered the limits and changed everything.
DIFFERENT IN EVERY WAY
Unlike previous twin screw extruders, which utilize vertical
injectors, the Wenger TT760 and TT3630 Thermal Twin extruders
use angled steam injector ports oriented in the direction of
material flow. This allows for four times more steam injection into
the extrusion zones. In addition, the steam is injected over
kneading and folding zones designed into the unique screw
profile, allowing
the steam to be
mixed into the
product.
The result is up
to 12 percent
steam injection
evenly
distributed over
the length of the
barrel. That translates into thermal to mechanical energy ratios
as high as 14 to 1, which means lower energy costs, less wear
and a lower environmental impact.
An adjustable mid-barrel valve allows the addition of
mechanical energy for meeting certain specifications.
Tight-pitch, self-wiping extrusion screws act as a steam lock
to seal the inlet against high-pressure, high-volume steam
blowout.
Thermal Twin options include back pressure valves, a wide
assortment of dies and all the flexibility that is available in
other Wenger extrusion systems.
GREATER ENERGY SAVINGS
As energy demands continue to grow at a time when even
more environmental constraints are placed on power generation
companies one thing is certain. Energy costs are not going to
go down anytime soon. Fortunately, the ability to shift your
process to a more favorable energy source is one of the greatest
attributes of the Thermal Twin extrusion system.
While typical twin screw costs are 1.5 to 2 times that of a single
screw extruder, the Thermal Twin has exhibited operating costs
that are nearly equal to that of single screw technology. Yet,
drying costs are the same for identical products, since moisture
content is the same in both cases. With Thermal Twin
technology, steam simply replaces process water.
GREATER PRODUCT FLEXIBILITY
We also know that the mechanical/thermal ratio of extruded
products influences product characteristics and that it takes a
certain level of energy to create a given product via extrusion.
Translation? The new Thermal Twin technology permits unique
applications that have never before been possible.
Higher Levels of Fresh Meat
In addition to standard dog food and cat food formulas with
moisture levels of 22 to 24 percent and 23 to 25 percent
respectively, the Thermal Twin TT760 and TT3630 have the
potential to produce high and ultra-high fresh meat pet foods
with up to 90 percent fresh meat (as a percent of the dry recipe)
and up to 40 percent moisture all without changing the
extruder configuration. Products containing more than 50
percent fresh meat do, however, require a pre-dryer between
the extruder and dryer.
Until now...
TT 760 TT3630
Capacity range (kg/hr) 1,000-4,000 3,000-12,000
Main Drive Motor (kW) 110 188
EASIER PROCESSING OF HIGH STARCH FORMULAS
Youre undoubtedly
aware of the way
recipes that are high
in corn and rice can
become sticky when
processed with
mechanical energy
inputs due to low levels
of shear. However, thats
not the case with the
Thermal Twin extruder. Even as gelatinized starch levels
approach 100%, products with high rice levels remained non-
sticky when processed with the Thermal Twin and its higher use
of thermal energy.
Even in applications that have failed with conventional extrusion,
the Thermal Twin process is able to extrude products where the
starch granules are gelatinized without any significant starch or
protein degradation.
New, Non-Conventional Products
Due to its natural cooking process, compared to high-shear
cook, Thermal Twin technology promises the ability to produce
non-conventional products that have not yet appeared on the
market. For starters, the Thermal Twin permits high levels of
barrel steam, which has much higher pressure and energy than
preconditioner steam.
Secondly, testing of Thermal Twin technology has consistently
yielded products with over 90 percent cook when the same
products extruded on conventional extruders had cook values in
the 80s. Yet, there has been no change in product density or
palatability.
New Wenger High Intensity Preconditioner
THE PERFECT COMPLEMENT TO
THERMAL TWIN TECHNOLOGY
Referred to at Wenger as the most significant precondition-
ing development for extrusion cooking in the last 20 years,
the new Wenger High Intensity Preconditioner (HIP) truly
provides a new level of mixing intensity.
Thanks to two independently driven shafts,
which offer both speed and rotational
direction control, the Wenger
HIP allows a wide range
of capacities, mixing
intensities and
retention times.
The benefits include:
Increased addition of meat slurries and other liquids
in the recipe.
Smaller particles for more uniform hydration and heating
of the recipe.
The potential for increased levels of process steam
added to the preconditioner.
An increase in starch gelatinization (cook).
Greater retention of heat-sensitive nutrients.
Reduction in under-processed material during start-up
and shutdown.
Increased levels of hygiene and food safety.
THREE MODELS, THREE SPEEDS
With new levels of adaptability, the Wenger High Intensity
Preconditioner promises to meet virtually every application. It
starts with a choice of three models, with capacities to 24,000
kg/hr. to match extrusion capacities.
Model 450 HIP 1,000 5,000 kg/hr.
Model 1500 HIP 5,000 12,000 kg/hr.
Model 3000 HIP 12,000 24,000 kg/hr.
In addition, all three models offer a choice of three
mixing intensity settings for control by process personnel.
Low* Dry expanded standard pet foods and floating
aquatic feed.
Medium Moderate levels of fresh meat and other liquids;
semi-moist; sinking feeds, and high-fiber
floating feeds.
High Ultra-high levels of fresh meat (>40%) or oil (>12%) and
other liquids.
* Similar to original DDC
TWO CONTROL OPTIONS
The Wenger High Intensity Preconditioner can be controlled via
two different control options.
Manual The selector switch is simply set to low, medium
or high for the desired mixing level.
Automated Mixing Intensity Control (MIC) Load cells under
the preconditioner, the slide gate and the necessary controls
for temperature, moisture and shaft speed take control of the
process, including start-up, shutdown and cleanout modes.
The automated MIC option not only ensures that product
temperature becomes a critical control point in the process,
but helps reduce waste at both start-up and shutdown.
C E R T I F I E D
ISO 9001:2000
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Inventing the new original since 1935.
Improved Hygiene By Design
Theres no question that food safety has become one of the most important issues in the pet food and aquatic feed industry.
Consequently, hygiene and food safety have become a primary design criteria in every new Wenger product. The new Thermal
Twin screw extruders and High Intensity Preconditioner are certainly no exception.
The new extruders start with stainless steel hygienic frames. Constructed with
minimal seams, theyre not only easier to clean, but they have less horizontal surface
area for product accumulation.
The High Intensity
Preconditioner (HIP) is
available with welded and
balanced stainless steel
beaters that eliminate the
need for threaded shafts
and points that can collect
material. Plus, the slide gate,
which is an integral part of the sanitation process, reduces discharge
of under-processed material.
CLEANER INSPECTION AND DISCHARGE
Among the other hygienic innovations from Wenger is a sealed, dust-tight downspout that
reduces fugitive dust at the transition point between the preconditioner and the extruder. A
standard feature on the new High Intensity Preconditioner, the downspout can be retrofitted to
most existing preconditioners.
Another innovation is a new Hygienic Pneumatic Hood, designed for attachment to most
Wenger extrusion systems. Among its features are electric actuators for raising the hood
segment, and quick disconnect clamps for quick access to the die or knife. The hood is also
equipped with a sampling port for taking density and quality samples, as well as a sight glass
for no-touch monitoring.
New Wenger
stainless steel
hygienic frame.
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New Wenger slide gate
and hygienic downspout.
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Interior of the new Wenger
High Intensity Preconditioner.
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