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Maker - Product Challenge

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Aquafeed Extrusion

Black Soldier fly larvae (BSF or BSFL), also known by its scientific name, <em>Hermentia Illucens</em>, offer great nutritional values, making them an excellent alternative protein source for animal feed and pet food. Black soldier fly technologies have evolved sufficiently to turn the insect into a viable food ingredient. But there is no official authorization for human consumption yet and you are unlikely to find them at a restaurant anytime soon.

Black soldier fly protein

Cotton has been used for about five millennia in ancient civilizations in America, Africa, and Asia. But up until the nineteenth century, cottonseed was not considered a product of value. The first cottonseed oil production started in 1833, consequently forming the cottonseed cake. Nowadays, we know cottonseed meal is a useful by-product for the feed industry and the fertilizer sector.

Cottonseed meal

Crickets are better known for their nighttime serenades than for their nutritional notes, but their serious protein content as well as vitamin B12 content and iron, moves them into the category of superfoods. With a light brown color and a nutty taste, cricket protein powder is a versatile dietary ingredient that makes it difficult to go off-tune with your recipes.

Cricket protein

Extruded aquafeed

The fishmeal powder market forecast shows that its global market value will reach USD 10.3 billion by 2025. Expanding since 2019, at an annual growth rate of 6.5%. Fishmeal powder production has strong business potential with the increase of applications in animal feed, pet food, and fortified foods.

Fishmeal powder

There are two misconceptions about floating pellets. The first one is that they are made with a pellet mill, when the proper floating pellets-making machines are extruders. The second misconception is that floating feed is only used for fish. However, many other species consume feed on the water, such as crocodiles and birds.

Floating pellets

Mealworms are a classic angling bait, but their high protein content makes them more than just a snack for fish. The fresh larvae of the insect have long been consumed in Southeast Asia and, in 2021, the European Commission approved dried yellow mealworm as an edible product.

Mealworm protein

In aquafeed, you can find three types of pellets: floating pellets, sinking pellets, and slow-sinking pellets, because not all aquatic species eat at the same height of the water column. In the case of bottom feeders such as shrimp, river crab, sea bass, and some species of catfish, they eat sinking pellets. Contrary to tilapia and carp that feeds from the surface with floating pellets. Sinking pellets production must control water stability to preserve the quality and form of the pellets, avoiding nutrients' dissolution in the water.

Sinking pellets

When it comes to aquafeed, you can find three types of pellets: floating pellets, sinking pellets, and slow-sinking pellets. Not all aquatic species eat at the same height of the water column. For example, tilapia and carp eat at the surface (floating pellets) while shrimp and sea bass eat at the bottom (sinking pellets). Slow-sinking pellets are ideal for species that eat along the water column such as salmon and cod.  To get the pellets to sink at the right rate, slow sinking pellets production must control water stability in the products.

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Slow sinking pellets

Only about 6% of the soy produced globally is directly consumed by humans, typically as edamame beans, tofu, or soy milk.  More than three-fourths of global soy production goes to animal feed. The rest is processed by soybean meal technology into oils or used for biofuels and other industrial processes.

Soybean meal

oil-and-feed-technology-brochure-pdf

Oil-and-Feed-Technology-Brochure.pdf

horizontal-agriculture-soybean-processing-plant-pdf

Horizontal-agriculture-soybean-processing-plant.pdf

Vegan meat alternatives and plant-based foods have rapidly grown in popularity over the last decade. Many people are switching to meat substitute food products. Your body does not discriminate between proteins and calories coming from meats and those coming from plants. From a nutritional point of view, they all have the same value. But chewing on a portion of veggie pumpkin protein does not feel the same as a cut of meat - the texture is completely different.

Textured Vegetable Protein

With consumerism comes great responsibility. More and more are switching their diet towards vegan and vegetarian alternatives, varying from dairy to meat. As more plant-based meat technologies are being invented, the production is rising in popularity. Ever wondered which challenges come with that?

Plant-based meat

Feed premix delivers a quality blend of macro and micronutrients to meet the overall growth and health needs of animals. Although they constitute a small portion of the feed, they provide enormous benefits by adding a balanced, nutrient-rich feed that supports the animal health. Feed premix making equipment ensures a proper combination of important ingredients to generate a perfect blend.

Feed premixes

Pellet snacks, or snack pellets, are intermediate products which you can further process and develop into snack products for consumption. Pellet snacks production involves mixing, extrusion, frying, and packing. Since these are intermediate products, final product customization on the production line will depend on your customer’s desired product and flavor profile.

Pellet snacks

Poultry feed

In Ancient Egypt, starch production was used mainly for coating and gluing the papyrus sheets. Today, the paper industry still uses the same technique even if starch processing equipment has changed immensely. But besides shiny reams, starch has a fundamental place in the food and beverages industry.

Starch

Pelleted feed

In the feed sector, it's common to talk about feed as balanced, compound, or concentrate. Many people use one of these terms to refer to any feed mill product. However, the processing of feed concentrates, only requires grinding and mixing. The further transformation into pellets adds is an added value for the market.

Feed concentrates

Can process from 80 to 170 tons per day

Ability to withstand strong abrasive forces during operation

  Easy exchange of wearable parts

Biomass

Feed

Extrusion equipment

The extruder was first developed to make lead pipes in the late 18th century. But the extrusion process technique quickly spread to other manufacturing sectors, including food, feed, and biomass products. An extruder machine presses a fluid or solid material through a die. Depending on your use case, extruders adopt single- or twin-screw systems to push the premixed feed material through a barrel. Thermal pressure applied in this step can chemically modify the mixture, so the screw system must be precisely calibrated to achieve the desired result. Finally, a knife head cuts the extruded material into your designed dimensions. Extrusion machinery produces items of a uniform size, shape, and consistency.

Extrusion

Connect directly with world leading manufacturers of extrusion equipment and find technology to build or improve your production line.

Extrusion &ndash; Making.com

Extrusion Equipment and Machines - Making.com

Aquaculture feed is used when rearing marine livestock such as fish, shellfish, and algae. Quality nutrition is needed for healthy growth and reproduction and feed usually consists of fats, carbohydrates, protein, vitamins, and minerals. Extruded aquaculture feed floats on the water surface and pressure-pelleted feed will sink to the bottom.

Aquafeed

We continuously talk to suppliers of feed processing technologies that have important know-how on how to create the smarter, better, and greener feed products we need to kickstart a better tomorrow. Are you into making animal feed or pet food and looking for ways to improve your production process? Let’s navigate the world of feed production technologies together!

Protein

Process

Continuous

Pelleting equipment transforms powdered, mashed, or grounded material into a denser cylindrical shape. Pellet processing compresses the fine material against a perforated die, where it will be shaped and cut. Although granulating and extrusion also produce pellet-like products, manufacturing pellets is a distinct process.

Pelleting

solid

Soybeans are an essential ingredient in the creation of protein-rich animal feed. To achieve high-quality feed production, extrusion technology is used to

Organic soybean feed extruder &ndash; Making.com

We open production technology to everyone

Making.com

brochure_hmbv_mixing-pdf

Brochure_HMBV_Mixing.pdf

Stock cubes, also known as bouillon cubes or broth cubes, have been used in cooking for centuries. Think that, the first written version of a stock cube comes from Anne Blencowe’s recipe book from 1694. Made of dehydrated vegetables or meat stock, the bouillon cube production line consists of mixers, homogenizers, cube forming machines and packaging machines.

Stock cubes

Cheese is the most demanding food in the entire dairy family to emulate using non-animal and dairy free ingredients. The complex physical and taste profiles of animal-derived milk products make plant-based cheese manufacturing challenging to pull off. But the growing appetite for lactose-free and non dairy products is serving alternative platters of cheese.

Plant-based cheese

Nougat is a delicious confection that contains lots of nuts and dried fruits. The word “nougat” itself derives from an old Latin word for nuts. In addition to nuts, the white variety of nougat contains egg whites, honey, and sugar. Similar ingredients make brown nougat variations, except caramelized sugar replaces egg whites as the base ingredient. Depending on your intended scale of production, there are quite a few nougat making equipment you should consider getting.

Nougat

Continuous, intensive mixing of viscous materials

Compact design

Mixing, kneading and extrusion in one unit

Homogeneous mixing of very viscous pastes and plastic masses

A variety of extrusion plates with different shapes and sizes (diameters up to 5 - 6 mm)

Chemical

Food

Pharmaceutical

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

Blending

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

The Extrud-O-Mix from Hosokawa is an efficient extruder that kneads, mixes and extrudes in one continuous process.

An extrusion machine pushes or pulls material through a shaped die to form a continuous length of product with a preset cross-section. The extrusion

Continuous extruder for mixing solids and liquids &ndash; Making.com

amandus-kahl-extruder-brochure-pdf

Amandus-Kahl-extruder-brochure.pdf

amandus-kahl-extruder-for-petfood-brochure-pdf

Amandus-Kahl-extruder-for-petfood-brochure.pdf

Children love them, and adults love them too. Extruded cereal is a typical ready-to-eat cereal with different flavors and shapes. You pour cold milk into a bowl of extruded cereal and eat them for breakfast or sometimes as a dessert. These shapes of cereals are refined by thermo-mechanical cereal extruder machines. Typically, extruded cereal can be categorized into three kinds: direct expanded cereal, co-extruded cereal, and extruded flakes. Depending on which kind of extruded cereal you are making among these three kinds, your choice of processing line will differ.

Extruded cereal

Fodder

The ubiquitous plastic shopping bag was first designed as a reusable carrier. Its inventor, Sten Gustaf Thulin, will have been appalled to see his creation turn into a single-use object. But this disposable tendency is common to all plastic materials, from screw taps to milk carton lining. With plastic recycling equipment, however, plastic waste can be reprocessed and given a second lease of life.

Recycled plastic

Proven design form an industry leader

Production capacity from 200 Kg/h to 8 Ton/h

Less sensitive process and less wasted product than traditional extruders

Does not require liquid additions at start up and can be started with an “open die” configuration

Cereals are also defined as breakfast food made from roasted grain and typically eaten with milk or yogurt. Cereal grain is a small, hard, and dry seed, which mainly harvests for human or animal consumption, like wheat, maize, or rye. Processed from the edible components of the grains, breakfast cereals contain rich nutrients and usually serve as the main course during breakfast meals. Different cereal manufacturing equipment allow various options to appear on the market, ranging from cereals, granola, and muesli. Granola and muesli can be converted into cereal bars. The healthy, on-the-go snack bar shows a growing trend due to its nutrient content and convenience.

Breakfast cereal

Pet food is a specialty food mostly based on formulated ingredients for various nutritional and dietary requirements. Pet food formulas are becoming more diverse and complex, considering the special health conditions and needs of young and aging pets that live in cities. The production of pet food is similar to processing food in general when it comes to fresh feedstock and flesh products.

Pet food

A snack is a small portion of food ready to eat and simple and fast to prepare. People usually consume snacks during the day between traditional meals such as breakfast, lunch, or dinner. Snack foods include simple products such as nuts, dried fruits, peanuts as well as packaged and processed foods. Puffed corn products made by extrusion or flavored potato chips are examples of processed foods.

Snacks

liquid

Products can be extruded with various shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of

Extruder with annular gap expander &ndash; Making.com

amandus-kahl-oee-laboratory-extruder-brochure-pdf

Amandus-Kahl-OEE-laboratory-extruder-brochure.pdf

What does a $300,000 burger taste like? Meat. The first lab-grown burger took two years and 20,000 strands of muscle tissue to produce. But with rapid advances in cultivated meat processing technology, non-animal meat alternative products can now take a lot shorter to prepare. And cost much less.

Cultivated meat

Up to 200 Kg / h production capacity for OEE 8

Does not require liquid additions at start up

Can be started with an “open die” configuration

R&amp;D

Batch

Amandus Kahl’s Extruder OE 8 is a small batch or laboratory extruder that works on the same principal as the successful Annular gap expander design where a conical stop is used to restrict flow out of a tube as materials are driven through it by a rotating shaft.

Products can be extruded with a variety of shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of

Laboratory extruder &ndash; Making.com

Apart from floating and sinking feed, pellet size and protein content are key parameters. Pellets should be large enough to be quickly found and still swallowed easily. Different species require different diets representing the plant-based or carnivorous diets in the wild. The <a href="http://www.fao.org/3/AB412E/ab412e10.htm">required protein level</a> in aquafeed differs per species, fish size and age, and breeding environment.

Aquafeed still relies very much on fish meal and fish oil made out of the by-catch of fisheries, which due to the growing worldwide protein shortage actually enhances overfishing. Insects, plant-based ingredients, and aquaculture by-products are therefore seen as promising more sustainable sources to help create the <a href="https://www.sciencedirect.com/science/article/pii/S2590332219301320">37.7 million tons of aquafeed</a> required by 2025.

Commercial fish feed manufacturers process dry ingredients for long-term storage and transport. Farms that manufacture feed themselves can more easily make wet feed and use local raw materials. Often feed is supplemented with certain additives such as mold inhibitors, pellet binders, grain conditioners, anti-stress agents, or for example immunostimulants as an alternative to antibiotics.

Protein shortage and overfishing 

<h2>Technology for packing and processing aquafeed</h2>
As for every production plant, the technology used to make aqua feed will differ greatly depending on available resources and raw materials as well as the end product and quantity.

Generally speaking, the process is as follows: If required wet materials such as fish scraps are cut into smaller pieces and course dry materials like grains need to be milled first before blending. This premix or dough can then be shaped into the desired form by for example a pellet press or extrusion cooker and will be dried afterward. Starches and proteins are key in the formulation because they form a large part of the diet and alter properties when exposed to heat influencing for example solubility and digestibility.

Pasteurization or heat is essential for longer shelf life and is preferably stored in a cool and dry place. Silos systems should be easy to clean and provide easy accurate dosing into desired bagging systems or bulk containers for further use.

Making Aquafeed

Find production technology for making aquafeed and connect directly with leading machine and equipment manufacturers wordlwide

Aquafeed &ndash; Making.com

Aquafeed production technology &ndash; Making.com

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In a Fluid Bed, a product or solid is made fluid by an upward moving flow of gas. The mechanical movement of the Fluid Bed strengthens this effect. Thus, the gas and product are intensively mixed so that high heat transfer and an optimum physical reaction speed are achieved.


<h2>Continuous fluid bed dryer for an energy-efficient drying</h2>
Ventilex Continuous fluid bed dryers apply world-leading fluid bed technology to high-throughput bulk processes. By choosing a good combination of gas speed and mechanical movement, you will be able to process granular products with a wide range of grain sizes while forming a minimum amount of dust.

A whole range of products can be processed in the fluid bed for long residence times, up to two hours per machine are possible. Ventilex Fluid bed dryer can function at temperatures from–15ºC to +600ºC. The gas speed can vary from 0.2 to 3m/sec.

Continuous fluid bed dryer

Aquatic feed production has been on the rise in recent years due to the increasing demand for proteins. However, feed manufacturers are faced with

Improve the quality of fish feed products &ndash; Making.com

Improve the quality of fish feed products

We are happy to share our knowledge on making animal feed and how to make good use of what grows on the land. Send us a message and we will help you solve your production challenge.

Find production technology for Aquafeed Extrusion, and connect directly with leading machine manufacturers worldwide.

Aquafeed Extrusion

Which aquafeed extrusion equipment do you need?

Organic soybean feed extruder

Continuous extruder for mixing solids and liquids

Extruder with annular gap expander

Laboratory extruder

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