{"id":23460,"date":"2025-11-26T06:00:41","date_gmt":"2025-11-26T12:00:41","guid":{"rendered":"https:\/\/www.insta-pro.com\/?p=23460"},"modified":"2025-11-11T13:30:30","modified_gmt":"2025-11-11T19:30:30","slug":"additional-ingredient-processing-via-high-shear-dry-extrusion-and-express-technology","status":"publish","type":"post","link":"https:\/\/instapro.spinuhost.com\/en\/blog\/engineeringandextrusionprocess\/additional-ingredient-processing-via-high-shear-dry-extrusion-and-express-technology\/","title":{"rendered":"Additional Ingredient Processing via High-Shear Dry Extrusion and ExPress\u00ae Technology"},"content":{"rendered":"<p>Rising input costs and record-low commodity prices have created economic challenges and an unprecedented new reality for farming. A <a href=\"https:\/\/www.uaex.uada.edu\/media-resources\/news\/2025\/october\/10-8-2025-ark-farm-losses.aspx\">recent economic analysis<\/a> from the University of Arkansas showed U.S. farm losses of $240\/acre for corn, $144\/acre for soybeans, and $380\/acre for rice, with significant losses for cotton, which was not shared. Now, more than ever, farmers need to pivot and focus on how to add value to their business. On-farm ingredient processing allows farmers an opportunity to make their own ingredients while avoiding losses from selling their crops and buying those processed ingredients \u2013 typically at higher prices for a loss \u2013 back to feed their animals.<\/p>\n<p>High-shear dry extrusion developed by Insta-Pro was built on the foundation of on-farm processing to produce high-quality nutritional ingredients. The nutritional benefits of high-shear dry extruded ingredients include:<\/p>\n<ul>\n<li>Improved digestibility<\/li>\n<li>Longer shelf-life<\/li>\n<li>Increased dry matter<\/li>\n<\/ul>\n<p>While this technology was invented to process soybeans, Insta-Pro has continued to adapt and conduct <a href=\"https:\/\/www.insta-pro.com\/en\/blog\/nutritionandtechnologies\/what-oilseeds-can-you-mechanically-process\/\">research<\/a> on alternative ingredients to traditional soybeans. Today, I will highlight some of the alternative ingredients that can be processed via high-shear dry extrusion and the ExPress\u00ae process.<\/p>\n<p>Whole grains (i.e. corn, wheat, etc.), blended ingredients (i.e. corn-soy blend, flax-corn\/wheat blends, canola\/pea etc.), and stabilized ingredients (i.e. rice bran, full-fat cottonseed meal, tomato pomace, etc.) can all be processed with high-shear dry extrusion. For example, <a href=\"https:\/\/insta-pro.com\/en\/blog\/engineeringandextrusionprocess\/stabilizing-rice-bran-extracting-oil-with-insta-pro-mechanical-processing\/\">stabilized rice bran<\/a> processed immediately following the bran separation at the rice facility has a shelf-life of at least 8 months, as measured by free-fatty acid levels remaining below 5% in the extruded rice bran.<\/p>\n<p><a href=\"https:\/\/www.insta-pro.com\/en\/blog\/success-story\/other-oilseed-processing-at-natural-selection-farms\/\">Other oilseeds<\/a> can also be processed via the ExPress\u00ae process \u2013 a pairing of the high-shear dry extruder with a single (crude fat &lt; 35%) or double (crude fat &gt; 40%) \u00a0mechanical oil press(es) which will yield both a partially-defatted cake and crude oil. Most common ExPress\u00ae oilseeds applications include: cottonseed, canola\/rapeseed, sunflower, and flaxseed\/linseed. \u00a0<a href=\"https:\/\/www.sciencedirect.com\/science\/article\/pii\/S0032579119448591\">A research trial<\/a> conducted at the University of Manitoba concluded that ExPress\u00ae canola meal had greater standardized ileal digestible amino acids and AME (i.e. metabolizable energy) compared with solvent-extracted canola meal. This data suggests that ExPress\u00ae processed canola can provide broilers with more protein and energy for productive purposes.<\/p>\n<p>The table below shows the typical analysis of canola and other oilseeds determined by continuous research and development.<\/p>\n<table style=\"width: 98.526%;\" width=\"630\">\n<tbody>\n<tr>\n<td style=\"width: 18.4252%;\" width=\"120\"><strong>Oilseed<sup>**<\/sup><\/strong><\/td>\n<td style=\"width: 14.8031%;\" width=\"96\"><strong>raw, Starting crude Oil Content, %<\/strong><\/td>\n<td style=\"width: 14.8031%;\" width=\"96\"><strong>raw, Starting CRUDE Protein Content, %<\/strong><\/td>\n<td style=\"width: 16.063%;\" width=\"102\"><strong>Oil Extraction Efficiency, %<\/strong><\/td>\n<td style=\"width: 15.1181%;\" width=\"96\"><strong>Finished, ExPress\u00ae Meal Oil Content, %<\/strong><\/td>\n<td style=\"width: 109.862%;\" width=\"120\"><strong>Finished, ExPress\u00ae Meal Protein Content, %<\/strong><\/td>\n<\/tr>\n<tr>\n<td style=\"width: 18.4252%;\" width=\"120\"><strong>Soybean<sup>1<\/sup><\/strong><\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">18 \u2013 22<\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">36 \u2013 40<\/td>\n<td style=\"width: 16.063%;\" width=\"102\">65 \u2013 72<\/td>\n<td style=\"width: 15.1181%;\" width=\"96\">6 \u2013 8<\/td>\n<td style=\"width: 109.862%;\" width=\"120\">42 \u2013 50<\/td>\n<\/tr>\n<tr>\n<td style=\"width: 18.4252%;\" width=\"120\"><strong>Cotton<sup>1*<\/sup><\/strong><\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">20 \u2013 22<\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">20 \u2013 22<\/td>\n<td style=\"width: 16.063%;\" width=\"102\">65 \u2013 70<\/td>\n<td style=\"width: 15.1181%;\" width=\"96\">6 \u2013 8<\/td>\n<td style=\"width: 109.862%;\" width=\"120\">26 \u2013 30<\/td>\n<\/tr>\n<tr>\n<td style=\"width: 18.4252%;\" width=\"120\"><strong>canola<sup>2<\/sup><\/strong><\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">35 \u2013 40<\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">22 \u2013 26<\/td>\n<td style=\"width: 16.063%;\" width=\"102\">72 \u2013 75<\/td>\n<td style=\"width: 15.1181%;\" width=\"96\">8 \u2013 11<\/td>\n<td style=\"width: 109.862%;\" width=\"120\">32 \u2013 37<\/td>\n<\/tr>\n<tr>\n<td style=\"width: 18.4252%;\" width=\"120\"><strong>sunflower<sup>3<\/sup><\/strong><\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">35 \u2013 45<\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">16 \u2013 22<\/td>\n<td style=\"width: 16.063%;\" width=\"102\">62 \u2013 75<\/td>\n<td style=\"width: 15.1181%;\" width=\"96\">10 \u2013 16<\/td>\n<td style=\"width: 109.862%;\" width=\"120\">22 \u2013 27<\/td>\n<\/tr>\n<tr>\n<td style=\"width: 18.4252%;\" width=\"120\"><strong>flax<sup>2<\/sup><\/strong><\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">36 \u2013 40<\/td>\n<td style=\"width: 14.8031%;\" width=\"96\">21 \u2013 25<\/td>\n<td style=\"width: 16.063%;\" width=\"102\">75 \u2013 78<\/td>\n<td style=\"width: 15.1181%;\" width=\"96\">8 \u2013 10<\/td>\n<td style=\"width: 109.862%;\" width=\"120\">36 \u2013 40<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><sup>1<\/sup> ExPress\u00ae &#8211; single press<br \/>\n<sup>2<\/sup> ExPress\u00ae-Press double press<br \/>\n<sup>3<\/sup> Press-ExPress\u00ae double press \u2013 initial cold press<br \/>\n<sup>*<\/sup>Whole, fuzzy cottonseed<br \/>\n<sup>**<\/sup>All values used for oil and protein content are expressed in average ranges. Actual content will vary due to differences in the varieties and growing conditions. Operator management and material handling also influence the quality of the product.<\/p>\n<p>&nbsp;<\/p>\n<p>In these tough economic times, it is important to invest in strategies to help re-cooperate losses or even generate new revenue streams. ExPress\u00ae processing is an adaptable and flexible technology that gives farmers the tools needed to address these challenges.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Rising input costs and record-low commodity prices have created economic challenges and an unprecedented new reality for farming. A recent economic analysis from the University of Arkansas showed U.S. farm losses of $240\/acre for corn, $144\/acre for soybeans, and $380\/acre for rice, with significant losses for cotton, which was not shared. Now, more than ever, [&hellip;]<\/p>\n","protected":false},"author":31,"featured_media":15662,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[51,7180],"tags":[6045,155,8982,179,147,6052,288,6046],"class_list":["post-23460","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-engineeringandextrusionprocess","category-nutritionandtechnologies","tag-canola","tag-cottonseed-processing","tag-express-soy","tag-extruded-products","tag-extrusion-cooking","tag-grains","tag-oilseed-processing","tag-sunflower"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.2 (Yoast SEO v27.3) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Additional Ingredient Processing via High-Shear Dry Extrusion and ExPress\u00ae Technology - Insta-Pro<\/title>\n<meta name=\"description\" content=\"While 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