benefits of using extruders to process aquatic feed

8/14/2019 Benefits of using Extruders to process aquatic feed

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Digital re-print - March | April 2009Feature: Extruders

Feature title: Benefts o using Extruders to process aquatic eed

International Aquafeed is published five times a year by Perendale Publishers Ltd of the United Kingdom.All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies,

the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis ofinformation published.Copyright 2009 Perendale Publishers L td. All rights reserved. No par t of this publication may be reproduced in any formor by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1464-0058

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There are wide varieties ofmethods that can be used

to process aquatic feeds.

For examples, in early days

the most common method to feed the

fish was hand feeding of mixed, home-

blended diets and trash fish. Then fish

farmers started using cold forming

of moist diets. Pelleting presses then

became popular and a majority of the

fish feed were processed using pellet

mill technology.

Today extrusion technology is the

method of choice to process aqua feed

because of the benefits it offersto fish farmers.

Each method had its advan-

tages and disadvantages.

The initial days of aquacul-

ture were very simple which

involved hand feeding of trash

fish or home-blended diets. These diets

were simulated natural diets and were

very palatable but the availability was not

consistent and providing fresh feed every

day was difficult.

Storage of the fresh fish was a problem.

Farmers need to store these fish in cold

storage or use only fresh. At the same time

disease and virus transmission was very

common in fresh trash fish. Feeding the

fresh trash fish in large ponds was very

labor intensive and water pollution was a

huge issue in the ponds.

Pelleted aqua feedThe next phase in aquatic feed process-

Benefits of using

Extrudersto process aquatic feedTable 1:Effect of Extrusion on Microbial Populations

Mic robe Raw Rec ipe AfterExtrusion

TPC (CFU/g) 240,000 9,300

Coliform 22,600


3/6

control of the density of the products and

thus buoyancy properties are managed.

Picture 2 shows a quick test for floating

and sinking while making feed with extruder.

The use of wet materialin the pellet

Extrusion allows raw aquaculture

wastes and undercooked waste to be used

in final feed without any problem.

A reclamation system to recover wet,

under-processed product that cannot be

recycled through the dryer as dry re-

work are available to be used in extrusionprocessing.

These are closed loop systems designed

for recycling wet product with extruders.

These systems allow us to use wet

slurries at levels ranging from 22 to 42

percent (as a percentage of the dry recipe)

depending upon the moisture contents of

the slurries in single screw extruders.

In a twin-screw extruder, addition of

wet slurries can be as high as 60 percent

depending upon the final moisture contents

of the wet slurry. Picture 3 shows a closed

looped system that can be used for wet

material addition during extrusion

in preconditioner. Picture 4 shows

addition of wet slurry (more than

40 percent) in the extruder barrel.

High fat pelletsThe main purpose of lipids

(fats and oils) in feeds are as an

energy source; to increase palat-

ability; provide essential fatty acids;

carrier for fat soluble vitamins;

modified texture; density control

and dust reduction.

Fat level in fish diets can vary

depending upon the species of

the fish.

Some fish, like salmon, need

feed with up to 40 percent fat in

640g/l bulk density for sea water at 20C

(three percent salinity) and > 600g/l for

fresh water at 20C.

To make slow sinking pellet it requires

580-600g/l for sea water and 540-560g/l

for fresh water. At neutral buoyancy pellets

should have 520-540g/l for sea water and

480-520g/l for fresh water.

Extrusion cooking provides ultimate

take pellet and some are column feeders

(taking the feed as it slowly sinks through

the water).

For examples

catfish, carp and

tilapia like float-

ing feed where as

shrimp and river

crab require sink-

ing feed.

On the other

hand salmon, trout,

sea bass/sea bream,

and cod like to eatthe pellet when it

is slowly sinking.

Picture 1 shows

different species

requirements for

floating and sinking.

E x t r u s i o n

allows buoyancy control to make floating,

sinking or slow sinking feed by controlling

the processing parameters on one extruder.

To make the pellet float in fresh or sea

water requires

Picture 7: Pellet soaked in water and then pressed

Picture 6: Micro aquatic feed made using twin screwextruder

Size of the fish and pellet

BEFORE - AFTER

20 | InternatIonalAquAFeed | Mch-api 09

Extruders

- i

Dry with 20-50% less energy

Geelen Counterflow/T +31-475-592315

Geelen Counterflow USA Inc. /T +1-772-559-4338

Geelen Counterflow Amrica Latina /T +54-9-2362-418899

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Extrusion processing allows us to make

pellets which are very stable in water for a

long duration. Picture 7 shows pellet soaked

in the water and then pressed with spatula

to see if it will break or not. If it breaks that

means it will not be water stable.

Water absorption of pelletsExtrusion moisture content during

processing can be controlled over a wide

range, which helps to increase the water

stability of the final feed.

These pellets absorb more water,

retains shapes for longer time and results

in reduced losses of nutrients. Water

Absorption and integrity after hydra-

tion is very important. It benefits pellet

technical qualities and fish health. Picture

8 shows pellets disintegrate in the water

after some time.

Mechanical resistanceof pellets

Feed made using extrusion technology is

more resistant to mechanical durability and

produces fewer fines in the finished feed

during transportation.

Extruded feed has an internal matrix

system which tends to increase resist-

ance to mechanical handling of feed.Extruded feed produces approx one-

to-two percent fines in the finished

products during bulk handling, where as

pelleted feed normally generates five-

to-eight percent fines during handling in

bulk or bag form.

Extrusion reduces 75 percent of the

amount of fines which normally enters the

water and ends up decaying on the bottom

of the pond.

In other words, fewer fines means:

increased water stability; clearer

ponds; lower fatality rates; less unde-

sirable bacteria growth; increased

is not going to eat 10mm pellet since the

size of the pellet is bigger than the mouth.

Picture 5 (behind the headline) shows dif-

ferent sizes of the feed made with extrud-

ers at Texas A&M University extrusion pilot

plant. Picture 6 shows micro aquatic feed

made using twin-screw extruder.

Manufacturing softaquatic pellets

Some species like blue fin tuna prefer

very soft pellet.

Extrusion processing allows us to make

a very soft pellet (moisture content up to

30 percent in finished feed), which is not

possible by pelleting or other methods.

This is accomplished using a preserva-

tion system in aquatic feeds (final prod-

uct moisture of 16-28 percent) during

extrusion processing. Lower Aw, (water

activity) below 0.70 can be controlled

with humectants at 10-12 percent levels

and by reducing pH to 4.0-4.5 with acids

at 1-2 percent levels or with fish silage/

solubles.

Mould inhibitors are also added at 0.2-

0.5 percent level in the formulation.

Recent developments indicate that soft,

gel-like aquatic pellets can be processed

by coupling alkaline extrusion with a post-extrusion acid bath to adjust ph and s et or

firm up the texture and pellet integrity.

Water stable pelletPellets that break down quickly in water

will lose nutrients.

Some farmers hydrate feed in water

and nutrient solution prior to feeding and

require rapid and excellent water stability

for handling and feeding purposes. Pellets

that breakdown quickly in the stomach of

fish loses nutrients (during regurgitation)

and may contribute to GDAS (Gastric

dilation and air sacculitis) in certain species.

the pellet. Extrusion processes allow feed

manufacturers to produce high fat feed.

With twin screw extruder a 20 percent fat

can be added during extrusion of feed. Where

as in single screw it is limited to around 12

percent fat addition during extrusion.

Additional fat is added to the pellet

using different coating systems (vacuum or

atmospheric). Extruded feed can absorb

more fat externally in the coating steps

as compared to pelleted feed. Nowadays

aquatic feed is processed to contain

almost 50 percent fat which is only pos-

sible by using extrusion technology.

Different Sizes of the PelletsDifferent shapes and sizes of aquatic

feed can be produced using extrusion

technology.

Depending upon the size of the fish the

pellet size can range from 0.6mm to 60mm.

The size of the pellet is important for the

fish from juvenile to adult. A very small fish

Picture 9: Pellet made with extruderwith very little or no fines

Picture 8: Pellet disintegrate inthe water after soaking

"Different shapes & sizes of aquatic

feed can be produced using extrusion

technology. Depending upon the size

of the fish the pellet size can range

from 0.6mm to 60mm"

22 | InternatIonalAquAFeed | Mch-api 09 - i

Extrudersis a continu-

ing demand for

extrusion lines

- approximately

50-60 - to meet

future demand.

MoreinforMation:

Dr Mian N Riaz,

Head Extrusion

Technology Program

Food Protein R&D

Center

Texas A&M University

College Station

Texas 77843, USA,

Email: mnriaz@tamu.

edu

conversion rates (10 - 20 percent);

higher production yields; improved

digestibility and reduced feed cost.

Picture 9 shows pellet made with

extruder with very little or no fines.

World demandsextruded feeds

According to experts, the global

aquatic feed market is expected togrow by over six percent per year.

This estimate is based on feed sales of

21,000,000 tonnes/year in 2005. The

global aquatic feed market is expected

to be 28,000,000 tonnes by 2010. Based

on the assumption that an extruder

would run an average 5000h/year, there

www.andr i tzsprout .com

[email protected]

GLOBAL PRESENCE

Denmark Netherlands Germany France UK USA

Venezuela Brazil Chile Mexico Australia P.R. China

Andritz Sprout

extruders provide the

newest technology for

production of the most

demanding extrudates

within aquatic feed and

pet food industries.

Extrusion

Superior performance,quality and controllability

Extrusion features:

Starchcookcontrol

Bulkdensitycontrol

Rawmat erialexibility

Nutrientadvantages

Optimalproductuniformity

Uniquevisualappearance

Extruder 1250 with Flextex and ECS

MADE IN HOLLAND

Almex b.v., Verlengde Ooyerhoekseweg 29, 7207 BJ Zutphen

The Netherlands, tel. +31 (0)575 572666, fax +31 (0)575 572727

E-mail [email protected], www.almex.nl

High capacity extruders and expanders.

AL30O

www.extruder.nl

Related companies:

Wenger Manufacturing Inc | Contact: Doug Baldwin

Tel no: +1 816 8919272 | Website: www.wenger.com

Buhler AG | Contact: Christopher Rubin

Tel no: +41 71 9551317| Website: www.buhlergroup.com/extrusion

- i Mch-api 09 | InternatIonalAquAFeed | 23 NEXT PAGEPREVIOUS PAGE
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5/6

The solution behind the solution.

Bhler AG, Feed & Biomass, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 28 96

[email protected], www.buhlergroup.com

Its the mix that makes the dierence. Feed manuacturers desire high

durability, reliability and sanitation. Quality eed with minimum operating costs is

a must. Your needs are Buhlers frst priorit y. That is why we commit our-

selves to delivering seamless solutions meeting your highest requirements. Get

in touch with one o our specialists worldwide and we will deliver a complete

process design package, equipment, automation and customer service. You and

Buhler the perect mix.

NEXT PAGEPREVIOUS PAGE
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ExtrudersBenefitsof using Extrudersto

processaquatic feed

IAF090 .indd 1 1 /03/ 009 10:01

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The solution behind the solution.

BhlerAG,Feed &Biomass, CH-9240 Uzwil,Switzerland,T +41 71 955 11 11,F+41 71 955 28 96

u.buz@buhlergro up.com,www.buhlerg roup.com

Its the mix that makes the dierence. Feed manuacturers desire high

durability, reliability and sanitation. Quality eed with minimum operating costs is

a must. Your needs are Buhlers frst priority. That is why we commit our-

selves to delivering seamless solutions meeting your highest requirements. Get

in touch with one o our specialists world wide and we will deliver a complete

process design package, equipment, automation and customer service. You and

Buhler the perect mix.

Aqua_Feed-09.indd 1 03.0 . 009 15:51:05IAF090.indd 4 1 /03/ 009 10:04

is a co ntinu-

ing demand for

extrus io n l ines

- approximately

50-60 - to meet

future demand.

r e i f r t i :

r i an iaz ,

Head Extrusion

Technology rogram

Food rotein &

Center

Te x as& U n i ve rs i ty

CollegeStation

Texas77843,US ,

Email:mnriaz tamu.

edu

co nvers io n rates (10 - 20 percent);

higher pro ductio n yie lds ; impro ved

diges tib i l ity and reduced f eed co s t.

Picture 9 sho ws pe lle t made with

extruder with very l ittle o r no f ines .

rl ntru f

cco rding to experts ,the glo bal

aquatic feed market is expected to

grow by over six percent per year.

This estimate is based on feed sales of

21,000,000 tonnes/year in 2005. The

global aquatic feed market is expected

to be 28,000,000 tonnes by 2010.Based

on the assumption that an extruder

would run an average 5000h/year,there

. n r i t r u t .c m

n r i t r u t n r i t . c m

L L E E CE

n m r k t h r l n r m n Fr n c UK U SV n u l r i l Ch il x ic u t r li . . Ch in

n r i t r u t

t ru r r v i t h

n t t chn l y f r

r u ct i n f t h m t

m n i n t ru t

i t hi n u t i c f n

t f i n u tr i .

E trusi n f a tur s:

tarchcookcontrol

ulkdensitycontrol

a materialexibility

utrientadvantages

ptimalproductuniformity


E t r e r 1 5 w i t h F le t e a n E C

MADE IN HOLLAND

Almex b.v., Verlengde Ooyerhoekseweg 29, 7207 BJ Zutphen

The Netherlands, tel. +31 (0)575 572666, fax +31 (0)575 572727

E-mail [email protected], www.almex.nl


AL30O

www.extruder.nl

l t c ni :

enger anu facturing Inc | Contact: oug Baldwin

Tel no:+1 816 8919272 | ebsite: www.wenger.com

u h le r G | Contact:ChristopherRubin

Telno:+1 719551317| ebsite:www.buhlergroup.com/extrusion

c h -p i 09 | InterntIn l uF e e | 23

IAF090 .indd 3 1 /03/ 009 10:0

2 0 | I n t e r n t I n l u F e e | ch-pi09

Dry with 20-50% less energy

Geelen Counterflow /T +31-475-592315

Geelen Counterflow USA Inc. /T +1-772-559-4338

Geelen Counterflow Amrica Latina /T +54-9-2362-418899

E [email protected] /I www.geelencounterflow.com

adv10x97 fc08.indd 1 13-05- 008 10:34:57IAF0902.indd 21 12/03/2009 10:02

Picture3: closedloopsstem u sed to ad d etslurr inpreconditioner

ing was useof pelletmills.Pelleted aquatic

feed offered several advantages overthe

hand fed natural diets.

For example,pelle ted feed was

denser and lower in moisture than the

natural feed,so the long-term storage

was better.Pelleting also reduced the

segregation of the ingredients which

was a very common problem in home-

made diets.

Sincefeed was pelleted therewas less

wasteof feed in thewaterand thatresulted

in someimprovements in waterpollution

and quality.s a result,pelleting offered low

processing costand a higherprocessing

rateto theaquaticfeed industry.

perationofapellet mill

wa sno t a c o m pl exproc -

ess. n t heo t herha ndi t

wasverydifficultto make

floatingfishfeed withthe

pelletmill.Thismeansthere

wasno controloverbuoyancy.

tthe sametimemicroaquatic feed

(lessthan2.00mm)wasnotpossiblewiththe

pelletmill.Thecookingtemperaturein the

pelletingprocesswastoolowtobeadequate

fordestruction ofanti-nutritionalfactors,

pathogenicorganismsandviruses

inthefeed.

F l t i n n i n i nCurrentaquaticfeed manufac-

turing practices seemto fitinto

two simplecategories;floating and

sinking.

Today100 percentfloating feed

is extruded and nearly60 percent

sinking feed is extruded. hereas,

t herest o f t he0 perc ent si nk-

ing feed is still pelleted.This is

just simply because extrusion

cooking offers several benefits

to theaquaticfeed manufactures.

Following is thebrief description

of theadvantages of theextruded

feed.

H i n ic u l it ftru fIngredients arecooked athigh tempera-

tures and pressures.

Therefore,extrusion cooking provides

hygienicprocessing of feed destroying the

pathogens and mostviruses and reducing

thetoxin levels in thefeed ingredients.

In extrusion cooking avian influenza

virus is destroyed during theprocessing

(greaterthan 70C).

lso, ewcastlediseasevirus

is inactivated bytheextrusion and drying

process wheretemperatures exceed 75C

foroneminute.Growth inhibitor,allergens

and otheranti-nutritional factors largely

inactivated during extrusion cooking.

Table1 shows theeffectof extrusion on

microorganismand theirsurvival.

t i n f r u ci nf l t i n r i n i n f

Therearemanyaquaticspecies thatare

cultured today.

Someof thempreferto eatthepelleton

thebottomof thepound whereas some

of species liketo comeon thesurfaceto

Picture2: uicktestfor floatingandsinkingfeedduringe trusion

P ic ture4:d d it io n o fetslu rr in th eetru d erb arrel

KAHLExtruder OEEfor Fish Feed

KAHLExtruder OEEfor Fish Feed

Flexibleproduction Hydraulicallyadjustabledie

Production offloating,slowly

sinking,and water stablepellets Fat content up to30 % Pellet diameter 2 -12 mm

Flexibleproduction

Hydraulicallyadjustabledie Production offloating,slowly

sinking,and water stablepellets Fat content up to30 %

Pellet diameter 2 -12 mm

AMANDUSKAHLGmbH& Co.KG, Dieselstrasse5-9,D-21465 Reinbek/Hamburg,Phone:+49 40 727 71 0,Fax:+49 40 727 71 100

[email protected],www.akahl.de

I 03-EEishf d 10.12.2008 10:5 Uhr Sit 1

18| I nt ernt I n l uFee | ch-pi09 ch - p i 09| I nt ernt I n l uFee | 19

IAF090 .indd 19 1 /03/ 009 10:0

is a continu-ing demand forextrusion lines- approximately50-60 - to meetfuture demand.

r e i f r t i :

rian iaz,Head ExtrusionTechnology rogramFood rotein &CenterT exas & Un iversityCollegeStat ionTexas77843,US,Email:mnriaz tamu.

edu

conversion rates (10 - 20 percent);higher production yields;improveddigestibility and reduced feed cost.Picture 9 shows pellet made withextruder with very little or no f ines.

orlddemandsetrudedfeeds

ccording to experts,the globalaquatic feed market is expected togrow by over six percent per year.This estimate is based on feed sales of21,000,000 tonnes/year in 2005.Theglobal aquatic feed market is expectedto be 28,000,000 tonnes by 2010.Basedon the assumption that an extruderwould run an average 5000h/year,there

www.andritzsprout.com

[email protected]

GLOBAL PRESENCE

DenmarkNetherlandsGermanyFranceUKUSAVenezuelaBrazilChileMexicoAustraliaP.R.China

Andritz Sprout

extruders provide the

newest technology for

production of the most

demanding extrudates

within aquatic feed and

pet food industries.

ExtrusionSuperior performance,quality and controllability

Extrusion features:

Starchcookcontrol

Bulkdensitycontrol

Rawmaterialexibility

Nutrientadvantages

Optimalproductuniformity


Extruder1250withFlextexandECS

E I H L L

l m e . v ., Verlengde oyerhoekseeg 29, 7207 J utphen

The etherlands, tel. +31 (0)575 572666, fax +31 (0)575 5727 27E-mail infoalmex.nl, .almex.nl


www.extruder.nl

Relatedcompanies:

enger anufacturing Inc | Contact:oug BaldwinTel no:+1 816 8919272 | ebsite:www.wenger.com

u h le rG | Contact:ChristopherRubinTelno:+1719551317|ebsite:www.buhlergroup.com/extrusion

22| InterntInl uFee | ch- pi 09 ch- pi 09 | Intern tI nl uFee | 23

IAF090 .indd 3 1 /03/ 009 10:0

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benefits of using extruders to process aquatic feed

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