our process
our modular production process
DFE processes a wide range of raw materials, from proteins to starch, from fava beans to wheat. To operate flexibly and provide guarantees (including the absence of allergens), DFE has an extensive machine park. Each process step is (modularly) set up in a completely separate compartment. Here are some of our capabilities:
Extruder
The heart of our processes is, of course, the extruder itself. This is where the product gets its shape and texture. DFE has multiple Cooperion twin-screw extruders. These extruders are known for their high reliability and are equipped with precise gravimetric and liquid feeders, ensuring a consistent end product.
Dryer
During extrusion, moisture is added to enable the process. When the extrudate exits the extruder, it generally contains too high a percentage of moisture to guarantee good shelf life. In the next step, the product is further dried. DFE uses "Fluidized Bed" dryers, which have cooling and drying sections and air circulation systems. These dryers are suitable for various shapes and sizes of extrudates, such as granules, flakes, and crumbs, and are highly adjustable, even down to a moisture content of less than 4%.
The dryer is designed for quick (intermediate) cleaning to ensure compliance with allergen separation objectives.
Internal transport
Extrudates can be fragile. Therefore, DFE opts for belt conveyors and spiral conveyors for (intermediate) transport between various processes, rather than suction or blow pipelines. This guarantees gentle handling of the products and prevents damage, breakage, and dust formation.
tumbler
Extrudates can be coated, also known as seasoning. For this purpose, a tumbler is used in the process. Using techniques like oil spraying, a (flavor) coating can be applied. DFE has an extensive portfolio of these seasonings through one of its sister companies.
Crushing and sieving
After the drying process, the product can be reduced in size if desired. DFE uses a crusher for this purpose. This innovative process-step results in optimal cutting geometry and achieves a uniform structural size without heating.
During the reduction process, simultaneous sieving can be performed in up to maximum four fractions. DFE has an extensive range of sieve decks to separate virtually every fraction.
packaging
DFE's parent company has its roots in mixing and packaging, allowing it to offer almost any packaging form. Standard in the extrusion process is the big bag, but 10kg (plastic) bags and consumer packaging (pouch/pillow/bucket) are also possible.
Ask about our extensive possibilities.
we stand for quality, customization, and short lead times
In a controlled environment, our team is ready for you.
Contact us and inquire about our customized solutions.