Extrusion extrusion die PolyCool series

pilot-scale

Overview
Combine the cooling die PolyCool with a Bühler extruder to produce wet textured proteins from soy, pulses, oilseeds and other raw materials. The PolyCool family covers R&D to industrial-scale throughput options up to and above 1000 kg/h.

Key benefits

• Scalable throughput: models from research (PolyCool 50) to industrial (>1000 kg/h, PolyCool 1000).
• Versatile raw material handling: suitable for soy, pulses, oilseeds, microalgae, insect-based ingredients and other protein sources to produce meat- or fish-like textures.
• Hygienic design: electro-polished product-contact surfaces and excellent accessibility for fast, effective cleaning and maintenance.

Range of cooling dies

• PolyCool 1000: Patented high-throughput cooling die; individual cooling circuits with independent control; withstands up to 50 bar; cools extrudate from ~150 °C to below boiling point; electro-polished hygienic design.
• PolyCool 500: Medium industrial-scale die delivering ~500 kg/h; hygienic wing door for accessibility and easy maintenance.
• PolyCool 350: Modular round cooling die (standard three segments) for up to 350 kg/h; scalable configuration for larger capacities.
• PolyCool 200: Modular flat-channel die with two or more segments producing up to 200 kg/h; segments on trolleys for handling and cleaning; slot 150 mm x 15 mm for thicker end products.
• PolyCool 50: Small R&D die with ~50 kg/h throughput for recipe and process testing.

Protein aeration technology
Gas injection into the extruder creates a microporous structure and expansion at the cooling die outlet, producing brighter colour, improved mouthfeel, increased volume and adjustable textures that can resemble meat, fish or seafood.

Breaker plates
Patented breaker plates inside the cooling dies modify flow patterns of the protein melt, generating fibre formation or flaky structures to improve mouthfeel and bite.

Solution provider and process support
Bühler offers integrated solutions across the protein value chain, including extrusion, cooling and downstream handling. Application centres and labs are available for trials, scale-up and process optimisation.

Applications

• Wet textured proteins and meat/fish analogues from plant-based and novel raw materials.
• R&D and small-scale trials (PolyCool 50), medium production (200–500), and large industrial runs (PolyCool 1000).

Technical specifications

• Models and typical throughputs: PolyCool 50 (~50 kg/h), PolyCool 200 (up to 200 kg/h), PolyCool 350 (up to 350 kg/h), PolyCool 500 (~500 kg/h), PolyCool 1000 (>1000 kg/h).
• Maximum pressure resistance: up to 50 bar (PolyCool 1000).
• Cooling capability: cools extrudate from around 150 °C to below boiling point or to stabilise near ambient + ~10 °C depending on configuration.
• Design: electro-polished product-contact surfaces; modular segmented designs; easy-access doors for cleaning and maintenance.
• Technologies: protein aeration (gas injection), patented breaker plates, independent cooling circuits (selected models).