Improved extruders and methods for the extrusion cooking of comestible
products such as human foods or animal feeds are provided wherein the
products may be produced with very low specific mechanical energy (SME)
inputs as compared with conventional processing. The methods preferably
involve introduction of very high levels of steam into the extruder
barrel (12) during processing, which concomitantly reduces necessary SME
inputs required to achieve desired cook and expansion levels in the
products. In accordance with the invention, fully-cooked pet foods can be
fabricated with SME inputs of up to about 18 kWhr/T, whereas aquatic
feeds can be fabricated with SME inputs of up to about 16 kWhr/T. In
preferred forms, the extruder (10) includes specially configured,
intermeshed extrusion screws (18, 20) and a plurality of obliquely
oriented steam inlets (48, 50), and an upstream, dual-shaft
preconditioner (90) is used having individual variable frequency drives
(98, 100) which allow infinite variablility in the speed and rotational
direction of the preconditioner shafts (94, 96).