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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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8/14/2019 Benefits of using Extruders to process aquatic feed
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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
-
8/14/2019 Benefits of using Extruders to process aquatic feed
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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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8/14/2019 Benefits of using Extruders to process aquatic feed
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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
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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8/14/2019 Benefits of using Extruders to process aquatic feed
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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
Uniquevisualappearance
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
High capacity extruders and expanders.
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
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
Uniquevisualappearance
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
High capacity extruders and expanders.
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
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