the invention is described in detail below with reference to several embodiments and numerous examples . such discussion is for purposes of illustration only . modifications to particular examples within the spirit and scope of the present invention , set forth in the appended claims , will be readily apparent to one of skill in the art . terminology used herein is given its ordinary meaning consistent with the exemplary definitions set forth immediately below . as referred to herein , the term “ high sugar concentrate ” may refer to monosaccharides such as glucose or fructose , disaccharides such as sucrose ( from sources such as beet or cane ) or maltose , and oligosaccharides such as raffinose and cyclodextrins ( for example , alpha or beta cyclodextrins may be used as encapsulation aids and modifiers ), and sugar alcohols , also referred to herein as polyol sugars , such as maltitol , isomalt , mannitol , and sorbitol , as well as liquid and semiliquid materials comprising such saccharides , such as molasses , corn syrup , corn steep , honey , agave nectar , and juices such as apple or pear juice . the process and apparatus of the invention may also suitably be used for other additives , such as carbohydrates including polysaccharides such as maltodextrin ( from sources such as rice , potato , or corn ), starches , cellulose and cellulosic polymers , and the like , or additives silica ( from sources such as quartz ), urea , amino acids , acetylated amino acids , ethyl alcohol , proteins such as yeasts , dairy products , soya , legumes , or seed meals , and complex minerals and chelates and the like . in the context of the present specification , wetting components are those that come in contact with the high sugar concentrate . the density of the high sugar concentrate may be expressed in brix or specific gravity . brix ( or ° bx ) is a measure of total dissolved solids and varies based on the extraction method , for example of sucrose from beets , used . one degree brix corresponds to 1 gram of sucrose in 100 grams of aqueous solution , and thus approximates a percent by weight . brix values also vary depending upon the source of sugar ( for example , beet , cane , or citrus ), as the sugar remaining in the molasses after sucrose extraction is dependent upon the source , and this results in higher or lower brix values . the high sugar concentrate preferably is provided with as high a brix level as possible . for example , molasses is commercially available with a range of brix of about 76 to about 86 . very high brix levels can result in a material that is difficult to handle . as another example , sugar beet molasses is a by - product of the manufacture of sucrose from based and may be at least 79 . 5 ° brix . this corresponds to a specific gravity of 1 . 41 . in the present invention , for example , for a high sugar concentrate material of molasses , the density may increase due to the preheating , cooking and cooling steps from about 78 brix to about 85 brix . a system 10 for producing a high sugar concentrate - based animal feed supplement is disclosed in fig1 . the system 10 is provided with a heating chamber 100 , a cooling region 200 , a dry - ingredient mixer 300 , and a vacuum pump 400 for removing spent gases from the heating chamber and moisture from the cooling units . the high sugar concentrate raw material is stored in an optionally - heated tank 20 provided with a heater 30 and tank heating tubes 32 and may be routed through a product conditioner 40 before it is provided to the heating chamber 100 . flowrate through the system 10 is controlled by pump 50 . the heating chamber 100 is provided with a plurality of burners 110 , a series of preheat tubes 120 and at least one cooking unit 130 . each cooking unit comprises a heat - exchanger wall 132 and a cooking auger 140 , shown in fig2 . the cooling region 200 is provided with at least one cooling unit 210 . each cooling unit 210 is provided with a wall 212 and a cooling auger 220 , shown in fig4 . the dry - ingredient mixer 300 is provided with a dry ingredient storage tank 310 , a wall and auger ( not shown ), a metering belt 320 for receiving mixed product , and a scale 330 suitable for supporting product tubs 332 . high sugar concentrate is pumped from tank 20 through product conditioner 40 into preheat tubes 120 which raise the temperature of the high sugar concentrate close to a predetermined cooking temperature . the high sugar concentrate is transferred from preheat tubes 120 into a first cooking unit 130 , two of which are shown in fig1 . preheat tubes 120 and cooking units 130 are heated by burners 110 . the high sugar concentrate is transferred from the first cooking unit to a second cooking unit 130 via transition 134 . in the cooking units 130 , the high sugar concentrate is agitated as the temperature increases . exhaust gases produced in the heating chamber 100 are removed via line 410 by vacuum pump 400 . the cooked high sugar concentrate exits the second cooking unit 130 via transition 136 and enters a first cooling unit 210 , two of which are shown . high sugar concentrate is moved from the first cooling unit to a second cooling unit 210 via transition 214 . as the high sugar concentrate moves through the at least one cooling unit 210 , the concentrate is agitated and releases moisture and heat . the moisture is removed from the cooling unit ( s ) 210 via line 420 by vacuum pump 400 . the cooled high sugar concentrate exits the second cooling unit via transition 216 and enters mixer 300 , which is typically a ribbon mixer . the mixer 300 agitates the cooled high sugar concentrate and blends in dry ingredients , such as protein , vitamins and minerals , metered from dry ingredient tank 310 , resulting in a product wherein the high sugar concentrate serves to suspend the dry ingredients . blended product , having a consistency similar to taffy or cookie dough , is deposited onto metering belt 320 via transition 316 . metering belt 320 delivers predetermined amounts of blended product into tubs 332 by weight , as monitored using scale 330 . fig2 and cross - section fig3 illustrate the features of the inventive cooking auger 140 . auger flights 144 are supported on a central core 142 . orifices 146 are provided at regular intervals along the flights 144 , and provide passages through which the high - sugar concentrate passes during the cooking cycle . non - stick paddles 150 are positioned at regular intervals along the circumference of the flights 144 on angled supports 148 . as the auger 140 rotates , the paddles 150 scrape the surface of the wall ( not shown in fig2 ), preventing build - up of highly viscous high sugar concentrate and preventing charring . fig4 and cross - section fig5 illustrate the features of the inventive cooling auger 220 . auger flights 224 are supported on a central core 222 . orifices 226 are provided at regular intervals along the flights 224 . gaps 228 are located regularly along the circumference of the flights 224 , and alternate with protrusions 230 . the protrusions 230 serve to collect viscous high sugar concentrate as it cools and the gaps 228 and orifices 226 allow the passage of the high sugar concentrate , thoroughly agitating and moving the cooling high sugar concentrate progressively forward through the cooling unit . while not being bound by theory , applicants believe that the agitation provided by the augers by breaking surface tension increases the surface area at which water in the molasses can become water vapor and increases the vapor pressure of water . the amount of water vapor liberated is dependent upon the water content of the molasses . as the cooking process progresses , the water content of the molasses decreases , thus slowing liberation of water vapor . the agitation provided by the inventive apparatus increases the availability of the water remaining in the molasses . as the water content is reduced , caramelization of the sugars occurs wherein sugar molecules bond together , making longer or branched chains of sugar . while not being bound by theory , applicants believe that the present invention exposes molasses to higher temperatures , encouraging an increase in such reaction . a direct heat source , or direct fire heat source , is used in the present invention , and is controlled by regulating fuel flow . gas flow may suitably be regulated at a control panel mounted to the apparatus , which may be , for example , an oven . the fuel may suitably be natural gas or propane . the fuel is suitably combusted , for example , in stainless steel burners having a length approximately the same as the cooking units . the direct heat source may reach a temperature of up to about 800 ° f . this is significantly higher than heat sources used in conventional operations . the higher temperatures achievable by the direct fire heat source allow the elevated cooking temperatures of the high sugar concentrate to be reached more efficiently than conventional systems . higher temperatures can be used on this unit because of an innovative cooking unit having a novel auger that improves heat distribution . these higher temperatures allow for an improved reduction of water content of the final product . exhaust may be drawn off using a fan . molasses , or another high sugar concentrate , is generally preheated slowly to bring the raw material to a cooking temperature of about 240 - 310 ° f . without impairing the raw material , before cooking to remove moisture and crystallize sugars . this also reduces the viscosity of the molasses . preheating is generally conducted in about 400 to about 500 ft of preheat tubes that run back and forth through the top of a heating chamber . the rate of molasses moved through the preheat tubes is regulated by a pressure valve , and must be maintained at a level that will prevent charring of the molasses . the pressure is generally in the range of around 150 to 200 pounds gauge . after preheating , the high sugar concentrate is transferred to a cooking unit , in which the temperature of the high sugar concentrate is further increased . the cooking unit comprises a heat exchanger , similar to a conventional scraped - surface heat exchanger , containing a novel heating auger . the heat exchanger is generally cylindrical in shape . the auger , similar to a modified screw conveyor , scrapes the inside of the heat exchanger wall . paddles , affixed to the flights of the auger , spread molasses over the inside surface of the surrounding cylinder . the auger flights are orificed , having holes spaced regularly across the flights of the auger . the holes decrease surface area to prevent char buildup , as well as provide an alternative route for molasses flow so that the flow is not solely forward through the system . this indirect lateral movement gives the unit more time to break surface tension , in turn giving more time for moisture to be released . moisture content and crystallization of sugars is generally controlled by temperature and time of operation . a high sugar concentrate , such as molasses , is moved through the first heating chamber . as the inventive auger rotates , it picks up the molasses and evenly distributes it throughout the inside of the chamber . it also moves the molasses through the system . as the paddles move , the molasses achieves a homogenous temperature by the end of the chamber , and thus a more uniform crystallization of its sugars . the temperature can be regulated from about 200 to about 310 ° f . the novel auger distributes heat . the auger may be approximately 12 feet long and approximately 14 ″ in diameter . commerically - available augers generally provide spacing between flights equal to the diameter of the auger , although different spacing is available . to increase processing speed , the diameter may be increased . the inventive auger may be stainless steel or any other suitable material , particularly tempered metals , such as ferrous metals and alloys including carbon steels and chrome - molybdenum , and non - ferrous metals such as aluminum , copper , and tin , although this list is not intended to be limiting . molybdenum , cadmium , zinc , tungsten , titanium , nickel , beryllium , carbon , zirconium , magnesium , iron , calcium , aluminum , and copper may be used to harden other metals , such as cobalt - tungsten alloys ; any suitable alloys may also be used . the auger may optionally be fluted to allow heat to disperse outward from the core of the auger , thus prolonging the longevity of the equipment . the paddles may be positioned along the circumference of the flights approximately every 72 degrees , providing 5 paddles for a 360 degree revolution . the number of paddles may optionally be increased to 7 paddles per 360 degree revolution , provided that the number of paddles remains odd rather than even to prevent binding or vibration . a standard auger may suitably be modified consistent with the invention by first attaching angle iron in five places around the circumference . these angle iron pieces traverse the entire length of the auger . the angle iron is then prepared for paddle attachment . the paddles may be attached to the angle iron at each auger flight and angle iron intersection using , for example , stainless steel fasteners . the auger is further modified to reduce the flight surface area by cutting holes through the flights . reduction of flight surface area helps in uniform heating of the molasses , because rather than allowing for the molasses to collect on the auger , the molasses drips back to the walls of the heat exchanger to continue uniform heating . three inch diameter holes in the flights are a suitable size . the holes , or perforations , allow backflow as well as advancing cooked material . in contrast , a conventional screw conveyor would advance the high sugar concentrate through the cooking unit too quickly to achieve the benefits of the present invention , whereas a conventional ribbon auger would advance the high sugar concentrate too slowly . the auger rotates at a suitable speed , which may be from about 12 rotations per minute up to about 100 rotations per minute or more . the paddles may be made of any suitable material , such as teflon ®, a polytetrafluoroethylene material , or dicronite ®, a proprietarily modified form of tungsten disulfide . the paddles serve three major functions : ( 1 ) the paddles break surface tension of the high sugar concentrate , e . g ., molasses , which aids in water vapor removal ; ( 2 ) the paddles mix the high sugar concentrate to prevent charring by maintaining uniform heat distribution ; and ( 3 ) the paddles move the high sugar concentrate along the length of the auger axis . there may be about 45 paddles , ensuring that no area on the inner surface of the cooking tube is untouched . preferably , the paddles overlap . the paddle arrangement allows for the high sugar concentrate to be scraped from the cooking unit wall . in addition , the paddle arrangement moves the high sugar concentrate around the circumference of the cooking unit as well as laterally throughout the length of the cooking unit . the arrangement also allows for high sugar concentrate conveyance to the next unit . paddle dimensions , configuration and arrangement also affect the product “ rate of passage ”, or the speed with which the high sugar concentrate is moved through the apparatus . a staggered configuration is especially conducive to conveying the high sugar concentrate through the heat exchanger . the paddle size and arrangement have been found to break the surface tension of the high sugar concentrate . breaks in the surface tension of the high sugar concentrate aid in removal of water vapor . preferably , the paddles are reversible . unlike conventional units that transfer heat indirectly via a heat transfer medium such as steam , the cooking unit of the present invention uses a direct heat source which provides a temperature in excess of 400 ° f . to the outside wall of the heat exchanger . the modified auger and paddles of the present invention allow such a heat source to be applied without charring the high sugar concentrate . a conventional unit is generally unable to apply direct heat without charring the high sugar concentrate , rendering the product useless . in a preferred embodiment , two cooking units may be used in series configuration . in this embodiment , high sugar concentrate enters the first heat exchanger one end of the cylinder and exits at the opposite end . then the high sugar concentrate enters the other cooking unit for additional heating . the present invention provides for significantly shorter heat exchanger length in comparison to a conventional cooking unit . as the surface of the wall is scraped , denser material is forced to run out the area of the paddle , and less dense material containing a higher concentration of water is allowed to return to the wall surface . without this circulatory movement , the high sugar concentrate would be charred and rendered unusable . therefore , this arrangement improves on the previous art by allowing direct fire heating and significantly reducing heat exchanger length . for example , the improved auger configuration may reduce the heat exchanger length by about 66 % or more . the innovative design of the heating auger contributes to the compact nature of the heat exchanger . it is believed that this unique design prevents the high sugar concentrate from becoming charred and unusable . the inventive cooking apparatus comprises compact heat exchangers that allow a nutrient tub producer to have the advantage of a transportable facility . using the present invention , applicants have surprisingly been able to produce nutrient tubs in a much smaller manufacturing space , allowing smaller , more efficient facilities to be cost - effectively located more closely to the product destination . the cooking apparatus may measure less than 10 feet wide and less than 20 feet in length , and may be anchored to a steel frame that allows the unit to be easily moved . in addition , the physically shorter production process now allows the flexibility of short production time requirements . this gives the unit more flexibility to provide specific customer requirements without the losses in a large production format . the innovative production process also improves the previous art by removing water vapor from the product with superior efficiency . further , the present invention allows easier control of the density of the final product ; i . e ., how hard or soft the product is . after exiting the cooking units , the high sugar concentrate then enters a series of cooling units , for example two units in series . the cooling units utilize a novel cooling auger . the auger combines features of a “ cut and fold ” auger and a “ ribbon ” auger or mixer . the combination of these features in the inventive auger allows for high sugar concentrate surface tension to be broken more often than in conventional equipment . in particular , holes are designed in the flights similar to a ribbon auger , and notches are provided at the circumference of the flights similar to a cut and fold auger . the cooling auger may also be manufactured of any suitable material , such as those identified above in relation to the cooking auger . these features provide a bead of molasses around the inner surface of the cooling unit wall and then subsequently scrape the molasses back as the auger rotates . as with the cooking units , the flow in the cooling units is not solely in a forward direction . the cooling units cool the molasses to about 150 ° to about 175 ° f . moisture is drawn off from the cooling units by modest vacuum , for example , using a fan . the use of conventional equipment for the cooling portion of the apparatus would increase the size of the facility significantly . the cooling unit augers may rotate at a speed ranging from about 10 to about 50 rotations per minute ( rpm ), preferably 20 to 40 rpm , most preferably approximately 25 rpm . the inventive cooling augers improve the ability to regulate and control the temperature of the molasses . this is important for achieving the desired concentration and crystallization of the high sugar concentrate . a cooling unit auger according to the invention may be attained by starting with a standard auger and removing flight material at various locations . then , small lengths of angle iron may be welded to the flights at the largest diameter on the auger . small circumferential lengths of the flight may be removed at each “ cut and fold ” location . after cooling and adequate water removal , the high sugar concentrate is conveyed to a suitable mixer , such as a heavy ribbon mixer . desired dry ingredients , such as protein , vitamins and minerals , are mixed into the partially cooled molasses , over a period ranging from about 1 minute to about 5 minutes , resulting in a product having a consistency similar to cookie dough at a temperature of about 120 to 160 ° f ., preferably about 130 to about 150 ° f . once the mixture cools , it hardens much like corn syrup in peanut brittle . then the high sugar concentrate with the dry ingredients is conveyed to a product container , such as a tub . the product is weighed and moved to a storage facility . nutrients added are generally in a form of a premix . the premix can be customized for the needs of the customer and have a variety of nutrients to add to the cooked molasses . suitable nutrients added to the cooked molasses may include , but are not limited to , microorganisms , such as yeast , enzymes , vitamins , such as a , b , d , and e , minerals , such as zinc , calcium , magnesium , phosphorus , manganese , copper , and protein sources such as grain or feather meal . a more extensive listing of feed ingredients may be found in chapter 7 of the feed inspector &# 39 ; s manual , second edition , published may 1 , 2000 by the association of american feed control officials inspection and sampling committee . tubs may be from about 5 lbs . to about 1250 lbs . finished , cooled tubs may be relatively hard or relatively soft depending upon the desired properties of the product . the hardness of the product regulates consumption to the rate desired by a customer for a particular application . the hardness is determined by the maximum temperature to which the molasses is cooked ; the higher the temperature , the harder the tub . the temperature may be controlled by the rate of flow of the molasses through the cooking units . for example , the flow rate may range from about 1 gallon per minute ( gpm ) to about 5 gpm . table 1 , below , provides a general relationship between the ambient temperature at the point of consumption , the rate of molasses required , and the molasses temperature achieved in the heating chamber . a conventional facility would require three times as much length in the heating chamber , and three times as much length in the cooling chamber . therefore , an apparatus according to the invention achieves a reduction in length of approximately 66 %. conventional cooling units frequently are equipped with a water jacket to aid in heat removal . however , applicants have discovered that a water jacket is inadvisable for cooling because it encourages condensation in the molasses . crystallization in molasses is a function of temperature , as is moisture removal . wetted components of the inventive apparatus are manufactured of suitable materials , particularly tempered metals , such as stainless steel , other ferrous metals and alloys including carbon steels and chrome - molybdenum , and non - ferrous metals such as aluminum , copper , and tin , although this list is not intended to be limiting . molybdenum , cadmium , zinc , tungsten , titanium , nickel , beryllium , carbon , zirconium , magnesium , iron , calcium , aluminum , and copper may be used to harden other metals , such as cobalt - tungsten alloys ; any suitable alloys may also be used . stainless steel is a preferred material for corrosion resistance and availability . molasses is stored in a 9000 gallon tank in ambient conditions . heat tubes in the tank ensure a viscosity suitable for pumping . the apparatus , comprising pre - heat tubes , cooking chambers , and cooling chambers , is flushed with water for about 1 hour while the burners heat up . the water is drained as molasses flow begins . a very small portion of product , generally less than 1 wt %, is discarded at start up and shut down . the rate of molasses flow is set to 1 . 85 gallons / minute to achieve the maximum cooking temperature of 300 ° f ., thus achieving the desired hardness of the finished product . molasses is brought up to a standardized temperature of 80 ° f . prior to entering pre - heat tubes . in the pre - heat tubes , the molasses is heated to 280 ° f . before entering the cooking chambers . the temperature of the heating chamber is constant . the molasses enters a first cooking chamber and proceeds to a second cooking chamber where it is heated to a temperature of 300 ° f . as the molasses exits the second cooking chamber , it enters the first of two cooling chambers . the cooking and cooling augers run at constant speeds . an exhaust system draws moisture off the molasses in the cooling chambers in a 5 - 15 % shrink and removes exhaust gases from the heating unit surrounding the cooking chambers . as the molasses leaves the second cooling chamber , the molasses is mixed in a ribbon mixer with predetermined amounts of dry ingredients consisting of a protein source , vitamins , and minerals , provided in amounts such that the dry ingredients , provided as premix , comprise about 49 . 2 % of the total weight of the product . the speed of the ribbon mixer auger is controlled to achieve desired dry premix ratios . the resulting taffy - like mixture is immediately conveyed into plastic tubs in 200 lb . increments where it cools and hardens for 24 hours . the final product is a 30 % protein tub with a guaranteed vitamin - mineral analysis . the speed at which the product is pumped through the unit and the speed at which the units rotate may be adjusted to accommodate another high sugar concentrate . the plant is operated continuously for a maximum of 20 hours per day . at the end of the operation period , the molasses flow is stopped and an aqueous cleaning solution is circulated throughout the apparatus for a period of at least 4 hours . while the invention has been described in detail , modifications within the spirit and scope of the invention will be readily apparent to those of skill in the art . in view of the foregoing discussion , relevant knowledge in the art and references discussed above in connection with the background and detailed description , the disclosures of which are all incorporated herein by reference , further description is deemed unnecessary . in addition , it should be understood that aspects of the invention and portions of various embodiments may be combined or interchanged either in whole or in part . furthermore , those of ordinary skill in the art will appreciate that the foregoing description is by way of example only , and is not intended to limit the invention .
a process of , and apparatus for , accelerated water vapor removal from molasses is provided . raw molasses is preheated ; continuously agitated while advancing at a flowrate of at least about 1 . 5 gpm through a cooking apparatus in the presence of a temperature greater than 310 ° f . ; continuously agitated while advancing through a cooling apparatus at a reduced temperature , and while removing separated water vapor water from the cooked molasses to form a cooled molasses having a homogenous temperature profile . the molasses may be admixed with supplements . the product is then packaged . an orificed helical conveyor having a plurality of protrusions from the outer perimeter agitates the cooking molasses . an orificed helical conveyor having gaps in the perimeter of the conveyor alternating with protrusions along the perimeter of the conveyor agitates the cooling molasses .