Efficiency Justification for Modernizing a Grain Screw Extruder to Produce Feed Additives from Crop Residues
Received: 1 July 2025 | Revised: 20 July 2025 | Accepted: 2 August 2025 | Online: 6 October 2025
Corresponding author: Alina Kim
Abstract
This study presents a scientific and experimental justification for improving the design of a grain screw extruder for processing crop and forestry residues. The screw assembly is the core and most sensitive part of any extruder. To transform the initial feed mixture into the finished product at the extruder output, the material passes through a series of technological processes along the screw length. The accomplishment of these processes over a shorter screw length—without compromising the product quality—reduces the processing time, construction costs, and energy consumption, while it increases productivity. This research evaluates the potential for performance improvement through modifications to the screw assembly. The justification for modernization began with theoretical investigations. Both existing and newly derived analytical equations were used to assess the screw design and its impact on the performance and efficiency when processing crop residues and ground Siberian fir needles. The study also validates the structural integrity, functionality, and technological feasibility of the modernized extruder system. The upgraded extruder was tested on a feed mixture of crushed sunflower stalks and heads, as well as fir needles, which are rich in minerals and vitamins. The tests showed that the extruder’s operation is virtually independent of the feedstock composition. The machine can be adjusted to process any type of crushed plant residue, significantly simplifying the raw material preparation for extrusion.
Keywords:
extruder, extruder screw, double-entry screw, compression rings, inter-turn spacing, screw pitch, die plateDownloads
References
K. E. Mironov et al., " Development and Study of the Grain Crushing Working Process of Shocking and Reflective Crusher," Vestnik of Kazan State Agrarian University, vol. 14, no. 1, pp. 100–106, Mar. 2019.
X. Mu, H. Li, Z. Wang, Q. Wang, D. Geng, and J. Zhu, "Comparison of Crushing Effect of Differently Shaped Crushing Rollers on Whole-Plant Silage Maize," Agriculture, vol. 13, no. 7, June 2023, Art. no. 1276.
Penza State Technological University et al., "Justification of a Promising Functional Scheme of a Grain Crusher," Bulletin Samara State Agricultural Academy, vol. 9, no. 2, pp. 34–43, May 2024.
S. Y. Bulatov, "Modeling of Work Process of Grain Crusher Ejector," Traktory i sel hozmashiny, vol. 82, no. 5, pp. 25–27, May 2015.
O. F. Kraugerud and B. Svihus, "Effects of Online Pretreatment of Plant Ingredients on Processing Responses and Physical Properties in Extruded Fish Feed," Animal Feed Science and Technology, vol. 168, no. 3–4, pp. 250–256, Sept. 2011.
V. Kushnir, N. Gavrilov, and T. Shkotova, "Improvement of the Extruder Construction," in Proceedings of the 4th International Conference on Industrial Engineering, A. A. Radionov, O. A. Kravchenko, V. I. Guzeev, and Y. V. Rozhdestvenskiy, Eds., Springer International Publishing, 2019, pp. 2133–2142.
H. Li, Z. Xiong, and X. Li, "Optimization of the Extrusion Process for the Development of Extruded Snacks Using Peanut, Buckwheat, and Rice Blend," Journal of Food Processing and Preservation, vol. 43, no. 12, Dec. 2019.
A. Kabdusheva, A. Kurmanov, M. Amantayev, Y. Khasenov, and V. Sapa, "The Effect of Parameters on the Performance Efficacy of a Single Screw Feed Extruder Using a Design Experiments and Response Surface Methodology," Bulgarian Journal of Agricultural Science, vol. 26, no. 2, pp. 492–497, 2020.
Q. Liu, Y. X. He, W. W. Sun, T. T. Ji, and S. Zhuang, "Effect of Enzyme Supplementation and Extruding Process on the Digestibility of Nutrients and Phenolic Acids of Defatted Rice Bran Based Diets in Ileal-cannulated Growing Pigs," Livestock Science, vol. 240, Oct. 2020, Art. no. 104138.
J. Amft, J. L. Bauer, J. Rostek, S. Spielvogel, and K. Schwarz, "Effect of Water Addition on the Microstructure, Lipid Incorporation, and Lipid Oxidation of Corn Extrudates," European Journal of Lipid Science and Technology, vol. 121, no. 9, Sept. 2019, Art. no. 1800433.
V. Y. Frolov, E. A. Kotelevskaya, and M. I. Tumanova, "Theoretical Aspects of the Working Process of a Press Extruder with a Variable Step Auger for Preparation of Concentrated Feed," IOP Conference Series: Earth and Environmental Science, vol. 548, no. 5, Aug. 2020, Art. no. 052003.
A. Likunov, "New Technology of the Steel Fiber Manufacturing from Technogenic Waste," International Journal of Mechanical and Production Engineering Research and Development, vol. 10, no. 3, pp. 611–622, 2020.
L. A. Adache, T. S. Mogaji, M. O. Olayinka, and Z. A. Olagoke, "Design and Finite Element Analysis of an Extractor Machine for Castor Oil Biodiesel Production," Journal of Applied Research in Technology & Engineering, vol. 6, no. 1, pp. 34–50, Jan. 2025.
S. Yadav, A. K. Jha, and H. B. Darlami, "Design and Improvement of Dewatering System Implemented for Biogas Slurry," International Journal for Multidisciplinary Research, vol. 5, no. 6, Dec. 2023, Art. no. 9184.
S. A. Karrab and M. A. Ballem, "Failure Analysis and Repair of a Broken Extruder Shaft," European Journal of Engineering Research and Science, vol. 5, no. 1, pp. 107–111, Jan. 2020.
O. Lyashuk et al., "Fracture Cause Analysis of the Extruder’s Shaft and Geometry Optimization of the Spline," Journal of Mechanical Engineering and Sciences, vol. 13, no. 1, pp. 4449–4460, Mar. 2019.
M. Doudkin, A. Kim, M. Młyńczak, G. Kustarev, and V. Kim, "Development and Parameter Justification of Vibroscreen Feed Elements," in Mining Machines and Earth-Moving Equipment, M. Sokolski, Ed. Springer International Publishing, 2020, pp. 203–226.
S. L. Li and J. Lu, "Finite Element Analysis of Worm Auger in Meat Grinder," Advanced Materials Research, vol. 945–949, pp. 162–165, June 2014.
P. Pareek and K. Madloi, " Ansys Analysis on Screw Conveyor Employing Diverse Coating Materials," International Journal of Emerging Technologies and Innovative Research, vol. 9, no. 6, pp. d36–d48, June 2022.
O. Lyashuk, M. Sokil, V. Klendiy, O. Skyba, and V. Dmytrenko, "Study on Nonlinear Model of Dynamics of a System ‘Extruder Elastic Auger Working Body,’" Acta Technologica Agriculturae, vol. 19, no. 4, pp. 101–106, Dec. 2016.
B. Hu, F. Cao, and Z. Xing, "Numerical Study on Rotor Deformation of Multiphase Twin-screw Pumps Under High Gas Volume Fraction Conditions," in the International Compressor Engineering Conference, Purdue, West Lafayette, IN, USA, Jul. 2012, Art. no. 2143.
W. E. Abdel-Ghany, S. J. Ebeid, and I. Fikry, "Mechanical Design Aspects of Single Screw Extruders Using Finite Element Analysis," International Journal of Engineering and Technical Research, vol. 3, no. 7, pp. 47–52, July 2015.
V. I. Pakhomov et al., "Results of experimental studies of the process of joint extrusion of forage grain and green mass of alfalfa," Processes and Machines of Agro-Engineering Systems, no. 9, pp. 45–48, 2017.
Z. Y. Tian et al., "Optimization and Characteristic Analysis of Screw Rotor of a Twin-screw Pump," Journal of Vibroengineering, vol. 25, no. 1, pp. 171–188, Feb. 2023.
A. M. Bizhanov, "Mathematical Modeling of Extrusion Agglomeration," Metallurgist, vol. 67, no. 9–10, pp. 1362–1372, Jan. 2024.
K. Kombayev, A. Kim, D. Yelemanov, and G. Sypainova, "Strengthening of Low-Carbon Alloy Steel by Electrolytic-Plasma Hardening," International Review of Mechanical Engineering, vol. 16, no. 2, Feb. 2022, Art. no. 84.
A. Kim, G. Guryanov, A. Vavilov, A. Bugayev, and Y. Doudkina, "Development of Mounted Impact-Rotor Working Equipment for Destruction of Snow-Ice Formations," International Review of Mechanical Engineering, vol. 15, no. 5, May 2021, Art. no. 258.
A. T. Nguyen et al., "Determination of Best Input Parameters for Internal Grinding SKD11 Tool Steel using MCDM," Engineering, Technology & Applied Science Research, vol. 15, no. 1, pp. 20190–20196, Feb. 20252023.
Downloads
How to Cite
License
Copyright (c) 2025 Mikhail Doudkin, Alina Kim, Andrey Vavilov, Georgy Guryanov, Vladimir Yakovlev, Yevgeniy Varavin
This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors who publish with this journal agree to the following terms:
- Authors retain the copyright and grant the journal the right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after its publication in ETASR with an acknowledgement of its initial publication in this journal.
