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Feature title: Aquafeed twin-screw extrusion processing - Versatile and ideal for aquafeed
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Versatile and ideal for aquafeed mechanical energy requirements. and screw
speed are not
AL30O
Twin-screw Extruder / Thermo- interdependent;
By Mr Daniel Durand, Senior Extrusion Expert at Clextral mechanical cooking for a given High capacity extruders and expanders.
The preconditioned feed mix is submit- formulated feed
T
ted to the controlled thermo-mechanical mix, the mul-
he aquafeed manufactur- combination of ingredients with the proper Mixing cooking which is the main stage in extrud- tiple operating
ing industry is widely levels of essential nutriments required for Mixing accuracy depends on the proper- ing aquafeeds. points combine
www.extruder.nl
recognised as one of the the animal species. The formulation is also ties of the components, which should be Thermo-mechanical cooking of the feed with a high con-
fastest expanding food based on cost, availability and chemical similar in density and particle size. Additives mix in an extruder requires two energy trol efficiency Almex b.v., Verlengde Ooyerhoekseweg 29, 7207 BJ Zutphen
industries in the world. Fishmeal is composition of the raw materials. Ingredient or micro ingredients are added at this step. inputs: of the barrel The Netherlands, tel. +31 (0)575 572666, fax +31 (0)575 572727
the main protein source in aquafeed, selection has a direct impact on final prod- The required mixing time depends on the - mechanical energy input defined temperature E-mail info@almex.nl, www.almex.nl
but supply is limited, which means uct characteristics. type of mixer technology used, as well as
that alternative sources must be According to their functions, these dry ingredient mixing time before liquids
used. ingredients can be divided in three groups: are added.
- Nutriments: to meet the require-
From a processing point of view, extru- ments of fish Extrusion cooking The twin screw extrusion expert
sion is the most efficient way of turning - Functional product: binders, expan- This step of the aquafeed processing line
plant protein into fish feed. Twin-screw sion, hardness can be divided into three stages: precondi-
extruders offer a definite advantage in this. - Palatants and attractants tioning, thermo-mechanical cooking and die
The goal for production of aquatic feed texturization-shaping
Pre- grinding / grinding
HIGH QUALITY
is to manufacture a nutritionally complete
product that achieves the desired product It is essential to decrease the particle Preconditioning
characteristics. While all aspects of the size to a powder state before mixing the The primary objective of precondi-
process are important, a number of the unit ingredients. Post grinding achieves the best tioning in an extrusion cooking process Aquatic Feed
operations of the manufacturing process final performance. is to initiate the hydration and the
are critical to achieve this goal. In addition, particle size is dependent cooking of the feed mix. The dry feed
These operations are organized along on the final size of the pellets. For die mix and the liquid parts (slurry, oil From 300kg/h to 30 000kg/h
the process as follows: openings up to 3mm, the largest particle …) are separately introduced into the
size should not be larger than 1/3 of the preconditioner where they are continu-
Selecting raw materials die opening. Smaller particles improve pel- ously mixed, heated and moisturised by
The first step of the aquafeed process let durability, water stability and decrease the injection of water and steam. The
line is feed mix preparation–selecting a pellet friability. intense mixing created by the rotat-
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F: Extrusion F: Extrusion
The drying parameters must be applied must be lowered to approximately • reduction of anti-nutriments
to remove the moisture while maintaining 50°C otherwise, the water in the • flavouring improvement
pellet quality. (that is, limiting fine gen- pellets will start boiling because of • protein/lipid complexes
eration, maintaining palability and pigment the vacuum applied (0.2 bar absolute • increase digestibility
ingredients, minimum energy losses and pressure). • texturization, shaping
moisture variance) The vacuum coating process allows the • expansion, density
Floating and sinking product characteris- oil to be drawn into the pellets by capillary • hygienic, salmonella-free pellets
tics can be influenced by the drying condi- forces ensuring perfect control of the pellet
tions. Elevated temperatures can lower oil absorption and the addition of more Challenges ahead
residual moisture and improve floatability. oil into the product while ensuring a dry The major challenge is to expand sus-
Sinking aquatic feeds are preferably dried surface and limiting the oil discharge in the tainable aquaculture to achieve enhanced
at moderate temperatures until the storage natural environment. food security and economic development
stability of the pellets is obtained. With this technology it is possible to for the global population as a whole. In the
In aquafeed processing lines, extruded achieve more than 40 percent total product context of substitution of fish meal with
pellets are generally dried on one of the fat content. plant-derived feedstuffs, extrusion technol-
following dryer designs:
• under vacuum pressure: this consists Thanks to twin-screw extrusion, high Clextral
1 Rue du Colonel Riez
of a closed system with a mixing quality aquafeed pellets are achieved:
Final pellet total fat % >35 15 - 35 15 - 25 5 - 15 5 - 10 5 - 10 <5 Firminy, F-42700 France
shaft or screw and spray system in • denaturing of proteins Website: www.clextral.com
Texture bulk density Slow sinking Slow sinking Slow sinking Floating Floating Floating Fast sinking the top. The product temperature • gelatinization of starch
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LINKS
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