COLLIN ZK 20 P Food-Grade Twin-Screw Extruder

Overview

The COLLIN ZK 20 P is a compact, food-grade twin-screw extruder engineered for R&D laboratories, pilot-scale formulation development, and small-batch production in the food industry. It operates on co-rotating, intermeshing twin-screw principle—providing precise control over residence time distribution, shear history, thermal input, and mixing intensity. Unlike single-screw systems, its modular screw configuration enables tailored conveying, melting, mixing, devolatilization, and shaping functions within a single continuous process. The ZK 20 P is specifically configured for applications demanding high hygiene standards and rapid changeover, including extruded breakfast cereals, textured vegetable protein (TVP), pet food kibbles, fish feed pellets, filled snack bars, pasta analogs, and starch-based confectionery matrices.

Key Features

• Horizontal split barrel (“clamshell”) design: Enables full 180° opening of the barrel assembly without disassembling drive components—allowing immediate visual inspection of screw elements, barrel wear, and material flow behavior during or immediately after operation.
• Modular screw system: Composed of interchangeable conveying, kneading, reverse, and mixing elements; permits rapid reconfiguration for different rheological profiles and product requirements without requiring specialized tools.
• Five-zone temperature control: Each zone independently regulated via combined electric heating cartridges and water-cooling channels, supporting precise thermal profiling from feed throat (ambient or cooled) to die (up to 200 °C), critical for heat-sensitive ingredients like proteins and probiotics.
• Real-time process monitoring: Integrated pressure transducers (at multiple barrel locations) and PT100 temperature sensors feed live data to the central HMI, enabling closed-loop adjustment and traceable batch records compliant with GLP/GMP frameworks.
• Sanitary architecture: Fully enclosed stainless-steel guarding with IP54-rated enclosures; smooth internal surfaces, minimal crevices, and sloped drain paths conform to EHEDG Doc. 8 hygienic design criteria for food contact equipment.
• Multi-point feeding capability: Five top-mounted gravimetric feeders and two side-feeding ports support sequential ingredient introduction—including liquid additives, slurries, or pre-gelatinized starches—enabling controlled co-extrusion and layered product structures.

Sample Compatibility & Compliance

The ZK 20 P accommodates a broad spectrum of food-grade raw materials: wheat, corn, rice, and potato starches; soy, pea, and fava bean proteins; cereal flours; dietary fibers (inulin, resistant starch); hydrocolloids (xanthan, guar); and lipid phases (vegetable oils, emulsifiers). All wetted parts are constructed from AISI 316L stainless steel with Ra ≤ 0.8 µm surface finish. The system complies with CE marking under the EU Machinery Directive 2006/42/EC and meets mechanical safety requirements per EN ISO 12100. Optional validation packages support IQ/OQ documentation for laboratory accreditation (ISO/IEC 17025) and regulatory submissions (EFSA, FDA GRAS dossiers). Data integrity features—including user-level access control, electronic signatures, and audit-trail-enabled event logging—align with FDA 21 CFR Part 11 expectations for electronic records.

Software & Data Management

The extruder is operated via a dedicated 10.1″ industrial touchscreen HMI running COLLIN’s proprietary EXTRU-CONTROL software. This platform provides synchronized control of screw speed, barrel zone temperatures, feeder rates, vacuum level (if equipped), and die backpressure. Process recipes can be saved, versioned, and recalled with timestamped metadata. Export options include CSV-formatted time-series datasets (pressure, temperature, torque, throughput) compatible with MATLAB, JMP, or LIMS integration. Optional OPC UA server interface allows seamless connection to enterprise MES or SCADA environments for centralized production analytics and SPC charting.

Applications

• Development and optimization of high-moisture extrusion (HME) processes for meat analogs and fibrous plant-protein textures
• Rheological characterization of dough-like and paste-like formulations under shear and thermal stress
• Pilot-scale production of expanded snacks, puffed cereals, and multi-layered confectionery cores
• Starch gelatinization kinetics studies and retrogradation behavior analysis post-extrusion
• Encapsulation trials using molten carbohydrate matrices (e.g., maltodextrin, gum arabic)
• Validation of novel ingredient interactions—e.g., enzyme stability under extrusion conditions or vitamin retention during thermal processing

FAQ

Is the ZK 20 P certified for direct food contact?
Yes—wetted components meet FDA 21 CFR 177.2400 and EU Regulation (EC) No. 1935/2004 requirements for food-contact plastics and metals. Full material declarations and surface finish certifications are available upon request.
Can the system be integrated with upstream/downstream units?
Yes—standardized electrical and pneumatic interfaces support integration with gravimetric feeders, cooling conveyors, rotary cutters, and inline NIR moisture analyzers. Mechanical coupling dimensions follow DIN 3320 standards.
What validation support does COLLIN provide?
IQ/OQ protocols, calibration certificates for all sensors, and FAT/SAT documentation packages are offered as optional services. GAMP 5-aligned software qualification support is available for regulated environments.
Is remote diagnostics supported?
The control system includes embedded Ethernet connectivity and optional VPN-enabled remote maintenance access—subject to customer network security policies and prior authorization.
Are spare parts and technical service available globally?
COLLIN maintains regional service hubs in Europe, North America, and Asia-Pacific. Critical spares—including screw elements, barrel segments, and heating cartridges—are stocked and shipped within 72 hours under standard terms.