-The following work discusses the main features of feed extrusion process explaining the expected effects on the final product according to the raw material used as starch, protein, fat and fiber. The selection of processing equipments as feeder, preconditioner and extruder is discussed considering the involved costs and the probability of future expansion. Dryers are also essential in the extrusion process as it reduces the level of moisture in an extrusion cooked product. High moisture levels increase the water activity which favors the bacterial and mold growth so an overview of different kinds of dryers is considered. Guidelines for an economic prediction are shown to determine the potential for profit considering the input of raw material cost, energy cost and capital equipment cost as related to the extrusion module.Key Words: extruder, extrusion process, feed extrusion, livestock feed, pet food Descrição do processo de extrusão do alimento RESUMO -Este trabalho aborda as principais características do processo de extrusão de alimentos, explicando os efeitos esperados no produto final, em função do tipo de componente utilizado na receita, como amido, proteínas, gorduras e fibras. O dimensionamento dos equipamentos da linha de extrusão, como silo, pré-condicionador e extrusor, é tratado considerando-se os custos envolvidos e a possibilidade de expansões futuras. Secadores também são essenciais no processo de extrusão, pois reduzem o nível de umidade do produto final. Altos níveis de umidade aumentam a atividade de água, favorecendo a proliferação de bactérias e mofo, portanto, uma visão geral de diferentes tipos de secadores é considerada. Orientações para uma previsão econômica são apresentadas para se determinar o potencial de lucro, considerando-se os custos com a matéria-prima, a energia utilizada no processo de fabricação e os equipamentos relacionados ao módulo de extrusão.Palavras-chave: alimentos para animais de compania, extrusão do alimento, extrusor, processo de extrusão, ração animal

Multiple outbreaks of salmonellosis have been associated with the consumption of low-moisture products, including extruded products. Therefore, there is a need for a nonpathogenic, surrogate microorganism that can be used to validate extrusion processes for Salmonella. The objective of this research was to determine if Enterococcus faecium NRRL B-2354 is an adequate surrogate organism for Salmonella during extrusion. Extrusions at different temperatures were done in material contaminated with both organisms. Results indicated that the minimum temperature needed to achieve a 5-log reduction of E. faecium was 73.7°C. Above 80.3°C, the enumeration of E. faecium showed counts below the detectable levels (<10 CFU g(- 1)). Salmonella was reduced by 5 log at 60.6°C, and above 68.0°C the levels of this organism in the product were below the detection limit of the method. The data show that E. faecium is inactivated at higher temperatures than Salmonella, indicating that its use as a surrogate would provide an appropriate margin of error in extrusion processes designed to eliminate this pathogen. Attempting to minimize risk, the industry could validate different formulations, in combination with thermal treatments, using E. faecium as a safer alternative for those validation studies.

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Outbreaks of salmonellosis and recalls of low-moisture foods including extruded products highlight the need for the food and feed industries to validate their extrusion processes to ensure the destruction of pathogenic microorganisms. Response surface methodology was employed to study the effect of moisture and temperature on inactivation by extrusion of Enterococcus faecium NRRL B-2354 in a carbohydrate-protein mix. A balanced carbohydrate-protein mix was formulated to different combinations of moisture contents, ranging from 24.9 to 31.1%, and each was inoculated with a pure culture of E. faecium to a final level of 5 log CFU/g. Each mix of various moistures was then extruded in a pilot scale extruder at different temperatures (ranging from 67.5 to 85°C). After the extruder was allowed to equilibrate for 10 min, samples were collected in sterile bags, cooled in dry ice, and stored at 4°C prior to analysis. E. faecium was enumerated with tryptic soy agar and membrane Enterococcus media, followed by incubation at 35°C for 48 h. Each extrusion was repeated twice, with the central point of the design being repeated four times. From each extrusion, three subsamples were collected for microbial counts and moisture determination. Based on the results, the response surface model was y = 185.04 - 3.11X(1) - 4.23X(2) + 0.02X(1)(2) - 0.004X(1)X(2) + 0.08X(2)(2), with a good fit (R(2) = 0.92), which demonstrated the effects of moisture and temperature on the inactivation of E. faecium during extrusion. According to the response surface analysis, the greatest reduction of E. faecium for the inoculation levels studied here (about 5 log) in a carbohydrate-protein meal would occur at the temperature of 81.1°C and moisture content of 28.1%. Other temperature and moisture combinations needed to achieve specific log reductions were plotted in a three-dimensional response surface graph.