Grinding more value out of raw materials

A Muyang story in the PhilippinesSNA feed mill in Sidi El Heni:

Goals achieved

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July 2011, Vol.4, No.3

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News

Grinding more value out ofraw materials

A Muyang story in the Philippines

SNA feed mill in Sidi El Heni: Goals achieved

Efficient production of alternative aquafeed

Events

Muyang global presence

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CONTENTS

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Ms. Riva Ganguly Das, the consul-general of India in Shanghai, made a special visit

to the headquarter of Muyang Group during her recent official trip in Yangzhou

City for widening the bilateral cooperation.

Accompanied by Muyang leaders, the consul-general was shown all aspects of the Group

and was given an overview of Muyang’s activities in India. Muyang has been active in the

Indian feed industry for years. Today, Muyang has many very good references of turn-key

projects with leading-edge technology in India, and lots of Muyang machines are running

wonderfully to produce high quality feed for Indian market, especially in the radically

evolving aquafeed sector there. The Muyang Indian Office opened last year has reduced the

distance between India and Muyang, which will definitely enable Muyang to better serve the

local customers. And additionally many business promotion plans are in the pipeline.

With her visit, Ms. Riva Ganguly Das spoke highly of Muyang’s specific technology support

to India, noting that with the second largest population in the world, India is of tremendous

developing potential. Muyang is welcomed and encouraged to widen its investment and to

extend its business in the fields of grain storage and processing in India.

NEWS

Indian Consul-General in Shanghai visited Muyang

Customers’ needs are the

priority, and we will adapt

according to their needs.

Cover photo: SNA feed mill, provided by Leon Liang

Liu Guangdao

Muyang International Division

“

”

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The global animal feed additives market will

reach $18.7 billion in 2016, according to estimates

in the latest MarketsandMarkets report.

According to "Global Animal Feed Additives by

Type, Livestock, Geography, Regulations Trends

& Forecasts (2009-2016)" , the Asian market, a

driving sales force, will hold 28.5% of the global

market share in 2016. Increasing demand for

meat products in the region and rising domestic

meat production are both expected to contribute

to the area's growth.

Europe is currently the leading market for feed

additives, with a 35% share in 2011 resulting

from regulatory concerns and increasing per-

capita meat consumption. North America is the

second largest market as of 2011, with a share of

The winners of “Muyang Cup” CAD

Drawing Competition were finally

announced in the Science Lecture Hall of

Wuhan Polytechnic University on April

28, 2011.

The Competition lasted for a month.

Over 300 compet i tors f rom such

departments as Food Science and

E n g i n e e r i n g , A n i m a l S c i e n c e ,

Mechanical Engineering and Civil

Engineering of the University took part

in the competition to show their talents

and skills.

Muyang Cup CAD Drawing Competition: foster talents with college

Global animal feed additives market to hit $18.7 billion in 2016

In order to maintain a high level productivity to support its fast

development worldwide, Muyang has been adopting the mode of

college-enterprise cooperation to substantially foster its workforce.

On the other hand, the talented college students the enterprise needs

could make clearer career planning for themselves.

Contact information:

Frank K. Adelholm, Sales General Manager of Muyang Europe Branch.

Address: Venusvaenget 101 DK-6710 Esbjerg V

Mob: +45 21597038

Office: +45 36964538

E-mail: frank.adelholm@muyang.com

INDUSTRY NEWS

Muyang Group is strengthening its business in Europe with the opening

of its European Office in Esbjerg, Denmark and the appointment of Mr.

Frank K. Adelholm, effective June 8, 2011.

Frank K. Adelholm, who is experienced in feed mill operation and

management as well as the sales of feed machine and equipment in

Europe, will manage the office and also serves as sales general manager

of Muyang Europe Branch. He believed that as a “real” turn-key supplier

and an environmentally responsible organization, Muyang will blow fresh

air to European feed industry, and Muyang’s high quality machineries,

equipment and services can have a positive value creating effect to the

customers there.

Wheat and bajra, also known as pearl millet, are being used as substitutes for corn in

chicken feed as corn prices in India continue to rise.

Wheat is currently selling for Rs 7.50 (US$0.17) per kilogram, while bajra and

broken rice are selling for Rs 11,000 (US$242.89) per metric ton. Corn stands at Rs

10 (US$0.22) per kilogram, kept higher due to high moisture content in the current

harvest and an increase in exports, according to farmers. The Compound Livestock

Feed Manufacturers’ Association of India is calling for a stop to corn exports to

ensure stable prices. “If corn exports are discontinued, prices will fall by 5% to 10%,”

said B Soundararajan, managing director of chicken producer Suguna Group.

Muyang opens new office in Europe

India poultry farmers using wheat, bajra as chicken feed alternatives

The price of corn in India remains high due to a high moisture

content in the current harvest and an increase in exports.

Farmers have begun substituting out corn in chicken feed for

other lower-priced grains.

From May 18 to 31, top Chinese legislator Wu Bangguo visited Namibia, Angola, South Africa and

Maldives to promote the mutual cooperation in a wide range of fields.

Muyang Group, as an integrated technology supplier for the feed-to-food chain, was represented by its

Chairman Mr. Li Minyue in Wu’s trading promotion delegation to Africa. Made up of over 40 top figures

of the Chinese famous enterprises covering bank, construction, information, energy, manufacturing,

agriculture, etc. the delegation also visited Kenya and other SADC countries for business communication

and survey, which will surely do Muyang lots of good in African market promotion.

Muyang joined the delegation led by state leader to Africa

An ongoing drought in Northern Ireland will affect the country’s animal feed industry if conditions

persist, according to reports.

The information comes on the heels of reports that the UK barley harvest is set to be the worst in 40 years

due to lack of rainfall. “This is going to have an impact in terms of the feed for our livestock, the lack of

forage, the lack of hay, will have repercussions next winter for which we will all start to pay a heavy price,”

said Dr. Therese Coffey, Conservative MP for the Suffolk Coastal district.

Ireland drought to affect animal feed industry

28%; the U.S. is the largest market with a share of

more than 80%, according to the report.

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PRODUCT UPDATE

The current difficulty of grain sourcing and price hike makes it very important for millers to process

the valuable and expensive raw materials more efficiently and effectively.

Having adapted to the changing needs of customers, Muyang is developing raw material processing

solutions designed to further increase output and promote the efficient use of available raw materials. On

May of 2011, Muyang announced the adding of three grinding products to its portfolio.

The hammer mill is designed for high capacity fine-grinding in various

industries. It is mainly applied in the primary- or secondary-grinding process

in feed milling industry. It is also used for sized reduction of grain and oilseed

meal in the food and oil milling industries.

SWFP66×125C Hammer Mill, high capacity fine-grinding

*Depending on formulation and required granulation.

Redesigned pulverizing structure

and aspiration system, smooth

grinding and reduced power

consumption.

New materials and technology

for wear parts production, long

serve life.

Aspiration conveying, low

temperature without nutrient

degradation.

No sieve furnished, avoiding

over-grinding and less

maintenance.

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*The capacity depends on raw material composition and required granulation.

Model

Speed of main shaft

Rotor dia.

Screen area

Number of hammers

Motor

Hammer tip speed

SWFP66×125C

2970 r/min

660 mm

2.25m2

160

200 kW (available of 220/250 kW)

up to 102 m/s

≥16 t/h

≤14 kW·h/t

≥22 t/h

≤10 kW·h/t

Capacity

Power consumption

Capacity

Power consumption

φ1.0 mm

screen hole

φ1.5 mm

screen hole

High capacity with maximum efficiency,

power consumption less than 10 kW•h/t

with φ1.5 mm screen.

High tip speed up to 102m/s, for superior

fine grinding quality.

Widened screen area of 2.25m2, facilitates

throughput and prolongs service life of hammer

and screen.

Bearing vibration minimized to 1.1mm/s,

stable running and reliable performance resulted.

One-step screen hold-down device

and fully-open sliding doors, labor and

maintenance saving.

SWFP66×100XM Hammer Mill, specialized for alternative ingredients

F a c i n g r a w m a t e r i a l s h o r t a g e

a n d h i g h p r i c e p r e s s u r e , f e e d

manufacturers would turn to the

alternative ingredients rather than

keep the formulation unchanged.

Today, substituting corn with the

more available and much cheaper

wheat is more acceptable in the feed

industry. However, tough and small,

wheat grain is hard to be ground,

thus raising different requirements to

the grinding machine and technology.

The size reduction of raw materials

usually counts for over 1/3 of the total

power consumption of a feed mill, so it

is essential to improve energy efficiency

of grinding machines for both interests

o f customers and environment ,

especially when it comes to the ultra-

fine pulverizer.

Muyang has devoted great research

efforts to the continuously improving

of product quality, the output as well as

energy efficiency of Muyang pulverizers

for years, and rolled out the SWFL

130E Pulverizer recently.

SWFL130E Pulverizer, energy-efficient ultra-fine grinding

Specialized for wheat grinding and

with the point of departure to get

more value out of wheat without

c h a n g i n g t h e o r i g i n a l g r i n d i n g

process, Muyang SWFP66×100XM

h a m m e r m i l l i s d e v e l o p e d . T h e

h a m m e r m i l l i s d e s i g n e d t o b e

more compatible to the original

process, and most of its spare parts

are interchangeable with those of

the other Muyang hammer mills.

On the other hand, like the other

Muyang SWFP hammer mills, this

wheat gr inding machine i s a lso

characterized by its high energy

efficiency, stable performance and

less maintenance.

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Rotor speed (r/min)

Product granulation

Require air volume (m3/h)

Capacity (t/h)*

Power consumption (kW·h/t)*

SWFL130E

132/160

11

1.5

Service life (t)*

Hammer knife

Gear ring

Wear plate

Grinding disc

1200~1600

4000~6500

1200~1600

6000~8000

Model

Power (kW)

Main drive

Grading motor

Feeding motor

(secondary grinding, 95% through 80 meshes)

1570

60~200 meshes

8400

4.0~6.5

22~24

Model

Speed of main shaft (r/min)

Rotor dia. (mm)

Screen area (m2)

Number of hammers

Hammer tip speed (m/s)

Ideal run vibration (mm/s)

Motor (kW)

Screen hole size (mm)

Capacity (t/h)

Power consumption (kW·h/t)

Recommend application

SWFP66×100XM

2970

660

1.96

108

up to 102

1.1~1.8

132 160

φ2.0

12~16

9~10.5

φ2.0

15~19

9~10.5

φ2.5

16~20

7~8.5

φ2.5

20~24

7~8.5

φ3.0

18~22

6~7.5

φ3.0

23~27

6~7.5

Grinding wheat for livestock & poultry feed with φ2.5 screen; Primary grinding wheat for aquafeed with φ2.0 screen.

Grinding More Value out of Raw Materials

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A Muyang StoryA Muyang Story in

the Philippines

As one of the important members in China Pavilion, Muyang Group became one of the focuses on the 2011 VIV Asia show successfully held in Bangkok, Thailand from March 9th to 11th, 2011. During the show, the reporter from International Animal Husbandry

China met Mr. Enrique A. Repalda from BELMONT, the exclusive agent for Muyang in the Philippines, and had a conversation with him. From the talk, you can get a general view of the development of Muyang Group in the Philippine market.

IAHC: Thank you so much for your time

to our interview, could you please firstly

introduce your company to us?

R: Well, Belmont is a Filipino corporation

representing major manufacturers from the

US and around the world for agricultural and

industrial equipment over the past 40 years. It

is the industry leader who serves the poultry

and livestock, bulk grain storage and handling,

and feed milling industries. All the major

poultry integrators, large-scale piggeries, and

feed millers in the Philippines are Belmont’s

customers.

I A H C : W h e n d i d y o u s e t u p s u c h

relationship with Muyang Group? And

why did you choose Muyang?

R: Our business relationship with Muyang

started in 2006. We chose Muyang to be our

partner because of their excellent equipment,

very strong technical support, and great

innovative ability and R&D force. Muyang staff

is very votive, efficient and always gives fast

and friendly supports to Belmont and to the

customers.

IAHC: What was the market like when

Muyang was at the outset to Philippine

market?

R: Before Muyang’s equipment exposure to

the Philippines, the feed milling industry was

dominated by European and US companies.

Muyang had to work very hard to convince

people of their fine quality equipment and

multi-disciplined services. Muyang brought

customers to China so they could see with their

own eyes the excellent Muyang facilities and

how big Muyang’s market was in China, for

seeing is believing.

IAHC: And now what is the situation for

Muyang in the local market there?

R: Well, that is the thing I feel proud of most.

From the year of 2008, Muyang became more

and more aggressive in marketing in the

Philippines. For now, I believe that Muyang has

a strong position with a large market share and

prestige locally. It is really incredible that we

have made all these become true just in such a

few years.

IAHC: Facing stiff competitions, how has

Muyang Group successfully developed in

the Philippine market so quickly?

R: I think we should attr ibute i t to the

competitive products and good services that

Muyang offers.

Muyang equipment is of natural advantages

and good price. You have to know, in the

Philippine market, similar products of European

or US brands are much more expensive than

Muyang’s, but for the quality and performance,

the difference is not so obvious. It is such a

natural thing that the customers prefer those

products which are more cost effective.

On the other hand, Muyang manufactures

complete l ine of equipment, which is a

distinguished advantage over the other suppliers.

If the customer goes to buy one machine from

one European brand, he may need to get other

kind of machines from another company. But

if he chooses Muyang, he can get everything he

needs just from one single competent source.

Besides the complete production line Muyang

also fabricates other things or elements needed

by its turnkey project, including steel silos,

steel structures, etc. This makes it all the more

important for the customers to rely on Muyang

to provide the perfect coordination of the

individual steps of project development from

planning right up to commissioning of the

turnkey plants. Additionally, Muyang can offer

all kinds of after-sales services at the same time,

which also helps our customers to save time and

cost due to the deals with different companies.

INTERVIEWINTERVIEW

Being a good listener, Muyang can always define and turn those improvement advices

or specific requirements from customers into actual

products or solutions.

——talking with Mr. Enrique A. Repalda By Roy

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PROJECT

SNA Feed Mill in Sidi El Heni: Goals Achieved There is no reason for

a company who pays attention to such tiny details not to have its own place in the market.

Backing to the price issue, as an agent company

with so many years’ experience, we know, it goes

without saying, that if one company or product

takes the advantage only in price, it is no way

for them to take enough shares from the market,

that’s why I just emphasized the good services

Muyang offers. Muyang’s services are something

strong and comprehensive rather than single

ones, which you can see it clearly from the

so called “one-stop” service and customized

services. Being a good listener, Muyang can

always define and turn those improvement

advices or specific requirements from customers

into actual products or solutions, thus meeting

customers’ demands to the greatest extent. And

the “one-stop” service makes our customers

feel so convenient, and then wins great market

shares for Muyang Group.

Muyang always puts customers’ demands

in the first place, and takes the initiative in

fulfilling them. I think that’s essential to the

success. I can give you two examples. The first,

Muyang has already considered the cost-saving

performance when it provides solutions to

customers. The product itself is designed to be

cost-saving, which can produce more feed with

less power. And the equipment installation or

the project implementation also takes shorter

time, which saves the time cost, and makes

the return on investment much higher. The

second example shows more concerns to the

details from Muyang. Just like other companies,

Muyang offers extra accessories to customers,

but the difference is that, considering some

of the customers may have equipment from

other suppliers, Muyang not only offers the

accessories of its own but also those of other

brands. In my opinion, there is no reason for a

company who pays attention to such tiny details

not to have its own place in the market.

IAHC: Are there any important movements

of Muyang in Philippines now?

R: I think one of the most important things is

that Muyang has helped several feed companies

to set up their own plants. Muyang made the

whole project for them according to their needs,

from planning, manufacturing, construction

up to equipment commissioning and operation

training, especially the quality management

all down the line. I do believe that the opening

ribbon-cutting of these plants have shown

that our “turn-key” projects have won the

satisfaction and trust from our customers.

IAHC: How do you think these plants

can help those companies, and the whole

feed industry in the Philippines?

R: The superior equipment and power saving

technology Muyang provided at a lower price

have made the feed companies more efficient

(less feed cost) and competitive locally and

globally. Feed cost contributes 65% cost per

kilo animal meat, thus less feed cost will mean a

better future for the animal industry.

IAHC: How can these plants build up

brand image for Muyang in the local

market?

R: It is really helpful for Muyang to have

stunning showcase projects locally. Customers

can now see how Muyang’s project run and

how Muyang’s equipment actual work in

the Philippines. It is more convenient and

convincing. The industry now recognizes the

market-front-runner position and quality of

Muyang.

IAHC: Will there be any more plants

build by Muyang in the future?

R: There is a continuing demand for quality

equipment and complete technology support

in the Philippine feed industry. I believe that

Muyang will get a good share of the business,

and build more competitive feed mills for the

customers. Our company will strengthen the

cooperation with Muyang in this area, try

our best to make more customers know and

trust Muyang, and we are quite upbeat about

the brighter future for all of us—Muyang,

BELMONT, and the Philippine feed industry.

SNA has been an important part of animal feed market as early as in 1976. It is the trademark property

of the Poulina Group Holding (PGH), a leading Tunisian Group that engages in strategic integration

of all activities in its agriculture business ranging from breeding to the distribution of food.

With its ambition and values, SNA targets at building a modern company to honor Tunis and create wealth,

quality and health to all its concerned domains (customers, employees, society, environment, etc).

The feed mill-related top priorities lie in the establishment of essential automation for easy operation,

the increase of energy-efficiency for sustainable development, and the compliance with rigorous sanitary

standards for animal welfare and human health. In addition, SNA will exert the greatest effort to pursue other

goals to fully realize its intrinsic values.

With all these respects, when SNA was considering how to increase productivity and how to build the fourth animal

feed production site in Sidi El Heni in 2008, they turned to Muyang for a project as a result of the

pleasant cooperation between the two parties in 2004.

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Cutting-edge automation

In the new facility, all levels of production cycle,

from storage of raw materials to delivery, the

manufacture of feed is managed by an advanced

process control system, which is characterized

by its advanced traceability and the elimination

of cross contamination and easy accessibility.

From every single equipment to the whole plant,

Muyang has concerned every detail to create

a precise and reliable fully automatic control

system. For instance, the solutions selected to

stop elevators from running back or sliding,

sensors for material level detecting and that

speed measuring of drag conveyors, the feeding

proportion control of pellet mill and steam

application system, etc.

Rigorous safety and sanitary

S N A h a s c o m m i t t e d i t s e l f t o t h e s t r i c t

implementation of HACCP and ISO standards.

Catering to SNA’s needs, Muyang bears in

mind the feed quality as well as the safety of

operators and machines when designing every

installation accessories of the Sidi El Heni Feed

Mill.

Muyang U-shaped drag conveyor is selected for

finished product handling in this feed mill, which

because of its excellent residue-eliminating

performance, has been recommended for

the other SNA feed mills. In order to prevent

ingredients from bridging in the bins, a specially

designed stepped surge hopper with an eccentric

outlet was fabricated. As to dust control in this

facility, at where dust is mainly produced such

as dumping pit, elevator, conveyor, hammermill,

The feed mill construction was commenced

in March 2009 and was completed on schedule

and on the proposed budget in December 2009.

After putting into production, Sidi El Heni Feed

Mill and the other three production sites of

Borj Cédria, Mateur and Sfax, SNA will see a

40 % of annual increase in Tunisia’s animal

feed production.

23,000 tons of corn storage in seven

(4×5,000 tons +3×1,000 tons) steel silos

representing approximately two months

consumption.

A steel structure workhouse

accommodating three 15T/H pelleting

lines and a reserved thermal treatment

line for powdery feed.

A precise 50TPH proportioning system

with 35 ingredient bins.

All processing equipments ranging from

raw material receiving to finished product

bagging.

1,000 tons of finished product storage in

18 bulk load-out bins with two 20TPH

bagging lines available.

Computer-controlled operation and

management within the entire plant.

Lighting system, communication system

and monitoring system.

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Scope of the project

With a nominal output of 45 tons per hour, the

facility mainly produces φ3.5mm poultry feed.

It is also flexibly designed to produce pellet

feed for cattle or sheep. The scope of the project

mainly includes:

For more information on the SNA Sidi El Heni Feed Mill project,

Please contact: Leon Liang Sales Manager

Muyang I.B.D. North Africa leonliang@muyang.com

From every single equipment to the whole plant, Muyang has concerned every detail

to create a precise and reliable fully automatic

control system.

etc. spot dust collectors are adopted to diminish

dust emission. The many spot dust collectors,

together with the central dust collecting systems,

can gain the feed mill good housekeeping and

added profit by reducing shrinkage and lowering

the chance of dust explosion.

In addition, the plant automation system is

applied to secure the safety of processing and

eliminate cross contamination.

Goals achieved

With the idea of “Create value for customers”,

Muyang always considers the cost-effective

performance from all aspects of its integrated

solutions. After it was put into production in

December 2009, the new poultry feed plant

of SNA has been running into cost efficient

operation in the country.

The latest Muyang machines and technologies,

which are upgraded for energy-efficiency

and stable running, are applied in this mill.

Besides, based on its vast technical resources

and expertise, Muyang designs many products

and solutions that meet every paticular need

of SNA. The customized double-deck cooler ,

for instance, could reduce the waiting time for

formulation change.

On the other hand, as a global integrated

solution provider in feed industry, Muyang is

specializing in the so called “One-stop” service.

And its numerous resources are focused on the

design, production, installation, commissioning,

training, consultation and after service of grain

storage silos, plant steel structure facilities,

processing machines and plant automation,

bringing more convenience, flexibility and

simplicity for SNA.

In 2010, Muyang was awarded another 45TPH

poultry feed mill project from SNA in Libya. The

continuous cooperation between the two parties

confirms that Muyang is able to guarantee

the satisfaction of customers with its own

technology and service.

PROJECT

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TECHNOLOGY

TECHNOLOGY

Efficient Production of New Alternative Aquafeeds

——By Hongyuan Cheng1, Liang Ma2

1-Assistant Professor, Technical University of Denmark, National Food Institute;2-Senior Engineer, Muyang Group R&D Center.

New challenges in extrusion processing alternative aquafeeds

With rapid development in

aquaculture, the industry

has realized that the use of

capture fish and fish processing by-products

(so called fish meal) in aquafeed threatens

aquaculture’s sustainability. Sooner or

later, not enough fish meal can be used for

aquafeed manufacture. Meanwhile, the

aquaculture product increasingly plays a

more important role in global food supply

with the increase in world population,

because agriculture productivity is limited

by the amount of cultured land. As the

aquaculture will play an important role

in global food supply, the development of

alternative materials to replace fish meal

becomes one crucial aspect to allow the

industry to expand in a sustainable manner.

Many efforts have been made to use plant-

based ingredients in alternative aquafeed production. The potential plant-

based alternatives already in use include soybeans, barley, rice, peas and

other crops, along with canola, lupine, wheat gluten, corn gluten, various

plant proteins and algae. With these potential ingredients, a many new

aquafeed recipes can be formed for processing in the product development

stage. To process all these new recipes in the extrusion process is a very

expensive task in terms of time and raw material cost and can become a

bottleneck sometimes. Although extrusion processing has been widely

applied in aquafeed production, the understanding of the process is still

very limited. In most cases, the search of suitable extrusion processing

parameters depends on trial-and-error experiments and experience. To

face the new challenges, new methods should be adapted to improve the

efficiency in extrusion processing new aquafeed recipes.

Improvement of extrusion processing method for aquafeed production

Extrusion cooking technology is a very efficient processing method in feed

production. Nowadays, nearly all auqafeed is produced using extrusion.

Within extrusion processing, several processes may occur, including fluid

flow, heat transfer, mixing, shearing, particle size reduction and melting,

where feed materials are exposed to high temperatures for a very short

time. This gives a distinct advantage over conventional pressure cooking,

in which the exposure could last several minutes at high temperatures. In

the extrusion of food and feed, pellet

expansion (or bulk density) is one

important property in product quality

control and measurement during pellet

manufacture, which is different from paste

and spaghetti production.

Different strategies have been proposed

to improve extrusion process technology.

In industrial practice, two strategies

are typically employed to control and

determine suitable extrusion parameters

to obtain the correct expansion pellet. One

method is to set up extrusion parameters

from experience and experimentation and to

analyse processing results through response

surface methodology or other methods.

The other way is to modify the mechanical

segments in the extrusion line, such as screw

configuration and die structure and to change

raw material particle size and precondition

parameters. In industrial practice, however,

the optimal combination of these methods is a

very difficult job when initial trials cannot give

the correct pellet expansion for one or several

new recipes. In such a case, industrial practice

experiences play a crucial role. At the same

time, engineers and researchers have also made

efforts to search for new methods to improve

the extrusion efficiency in terms of time and

raw material cost for new product development.

Recently, engineers have worked on

using a new mathematical modelling

m e t h o d t o a n a l y s e e x t r u s i o n

processing aquafeed to improve the

procedure that determines extrusion

parameters.

Application of modelling method to improve the procedure that determines extrusion parameters

Various modelling techniques have

been established to describe and

analyse extrusion process operations,

such as response surface methodology,

principle component analysis, neural

network method, genetic algorithm

and numerical simulation. In the

application of response surface methodology, principle component

analysis and other multivariate data analysis methods, the extrusion

process is treated as a black box. All possible factors are analysed

through a statistic algorithm for identification of impact on pellet

properties, e.g. pellet bulk density. The neural network method and

genetic algorithm can be treated as a grey-box model for the extrusion

process, in which the model can automatically update its equation

behaviours in a few cases; learning from real extrusion process operation

data. The numerical simulation method is built from a basic physical

principle to describe an extrusion process. However, the construction of

the numerical simulation method involves several equations to describe

the extrusion process so that it has to be simplified for a real process and

to yield a numerical solution.

Engineers have started to explore a grey-box model to correlate the

relationship between pellet bulk density and extrusion parameters

based on the work of Cheng and Friis (Cheng, H. and Friis, A. Food and

Figure 1 composition changes of four recipes

Muyang Group have worked on using a new mathematical modelling method to analyse

extrusion processing new aquafeed process in order to

improve extrusion parameter determination procedure.

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Bioproducts Processing, 2010, 88:188-194). In the

model, the pellet bulk density is correlated with

important extrusion process parameters, e.g. die

temperature, moisture content, screw speed and

specific mechanic energy. The formulation of the

model is simple and can be solved using common

mathematical tools, such as Microsoft Excel. The

application of the model shows it doescorrelate

pellet bulk density with extrusion parameters. An

application is shown in following section.

Application of the model

In the development of alternative aquafeed,

the extrusion engineer often has to process a

batch of different recipe feeds in a pilot plant

extrusion process. Even the production is not in

a large amount; the production cost may be high in terms of time

and materials. In practice, a typical method is to conduct initial

trials in an existing extrusion line from experience to obtain the

correct feed pellet. An experienced engineer may reach the correct

feed pellet in a few runs. If the test run fails for one or several new

recipes, the engineer must investigate all possible reasons, such

as more extrusion parameter combinations, particle size, screw

configuration, etc. The feed pellet extrusion processing may become

a bottleneck in the alternative recipe development.

To improve the current procedure for processing a group of new recipes,

we introduce the modelling method of Cheng and Friis to analyse the

trial results. For a group of new recipes, we first use a composite design

method to arrange the initial trial sequence. Using the trial results, the

pellet bulk density can be correlated to extrusion process parameters

using the modelling method. By the correlation results, we analyse the

TECHNOLOGY

Figure 2 water content (XH2O)=15%, fish meal (Xf)=48-84%, wheat+bean (Xp)=16-52%.

Figure 3 water content(XH2O)=20%, fish meal(Xf)=48-84%, wheat+bean(Xp)=16-52%

Figure 4 water content(XH2O)=25%, fish meal (Xf)=48-84%, wheat+bean(Xp)=16-52%

Sep.

Oct.

effects of adjusting extrusion parameters on pellet

bulk density. From the analysis, we can obtain an

optimal direction with which to adjust the extrusion

process for a specific recipe.

For example, there are four new recipes for

processing, which is shown in Figure 1. In these

recipes, the fish meal content (Xf) decreases with

increasing wheat+bean/pea content (Xp). A small

composite design method is used to arrange the

extrusion process parameter adjustment table,

which includes temperature, moisture content

and screw speed. Between eight and 11 runs are

arranged for each recipe. From these runs, a set

of experimental data can be obtained. Based on

the experimental data, we use the mentioned

modelling method to take into account the effects

of extrusion parameters on pellet bulk density. The

modelling results are represented in Figures 2-4.

In Figures 2-4, the z axis represents the pellet

bulk density (g/l), the x and y axes represent,

respectively, die temperature Td (◦C) divided by

25◦C and parameter group Pd/SME, where Pd

is the die pressure (bar) and SME is the specific

mechanic energy, SME=τ·Ns/FT (τ: torque,

Nm, Ns: screw speed, rpm, FT: total flowrate in

extruder, kg/hr).

In Figures 2-4, the modelling results are given in

three moisture content conditions for four recipe

composition variations. As shown in Figures 2-4,

four surfaces represent pellet bulk density behaviours along the extrusion

parameters for four recipes. On each surface, the pellet bulk density can be

read through given die temperature, Td and SME (calculated from screw

speed). An operation window or range can be outlined from the surface.

The analysis can help the engineer determine an optimal parameter

adjustment direction to improve pellet bulk density. For example, Figures

2-4 show that Td/25=4.0-4.5 and Pd/SME=0.1-0.2 will give lower pellet

bulk density or good expansion for processing all four recipes.

To take advantage of extrusion process modelling work

As shown in the application, the modelling work

provides a quantitative tool with which to aid

the engineer in analyzing the effects of extrusion

parameters on pellet bulk density. The modelling

results can give a guide to avoid the blind trial-

and-error procedure when a recipe processing

cannot give the correct pellet bulk density. From

the modelling work, we do not need to examine

every possible extrusion parameter combination

and, therefore, can reduce the amount of

experimental tests. The modelling result can

quantitatively determine the relationship

between pellet bulk density and extrusion

operational parameters and, thus, can predict

the pellet bulk density that has not been reached

in experimental trials. Therefore, the time and

raw material cost can be reduced in processing a

group of new recipes in the product development

stage. From our experience in application of

the model for different extruders, the model is

suitable for both twin-screw and single-screw

extruders and can also be applied for laboratory,

pilot and industrial-scale equipment.

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Muyang Global Presence

Localized sale, technology and service, creating more value for customers. As its presence

extended to over 80 countries, Muyang executes its go-to-market strategy by strengthening its

international sale & service network to commit itself to delivering customers the latest technology,

prompt service and complete solution. As of Jun. 30, 2011, there had already 26 overseas offices been built

in countries such as Russia, Brazil, India and so on. Over 200 professional salesmen and service personal

are fostered and sent out with qualification, professional skills as well as social and linguistical knowledge,

and the numbers will grow larger. It is believed with through a solid international sales & service network

and plus about 40 overseas agencies, the customers can find Muyang wherever they are and be served

whenever they need.

RussiaMr. Ou Yongouyong@muyang.comscouyong@gmail.com

CISMr. James Xiexcy@muyang.commuyangxcy@gmail.com

EuropeMr. Tempe Liangliangtongbin@muyang.comliangtongbin@gmail.com

Africa(North & West)Mr. Sam Yinsamyin@muyang.comsamyzsa@gmail.com

Africa(South & East)Mr. Kevin Zhongkevinzhong@muyang.comzds1212@gmail.com

President of I.B.D.Mr. Liu Guangdaoliuguangdao@muyang.comliuguangdao@gmail.com

Asia PacificMr. Mani Qianmaniqian@muyang.comqsf1977@gmail.com

South AsiaMr. Bob chenbobchen@muyang.com bobchent@gmail.com

ThailandMr. Xia Guoxinxgx@muyang.commybjxgx@gmail.com

Middle EastMr. Arron Liuarronliu@muyang.commyliugang@gmail.com

North AmericaMr. Justin Huangjustinhuang@muyang.comhuajustin@gmail.com

South AmericaMr. Tim Xutimxu@muyang.comtimoncf2003@gmail.com

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