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Maker - Product Challenge

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Changemakers

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

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

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 process is used to produce a large number of commercial products which include plastic tubing, plastic sheets, and many food types.


<h2>Kneading, mixing and extruding in one continuous process</h2>
The Extrud-O-Mix from Hosokawa Micron is an efficient extruder that kneads, mixes, and extrudes in one continuous process; as a standalone unit or in combination with other process equipment. Perfect for mixing solids and liquids into very viscous and homogeneous pastes as well as plastic masses, and moreover it has better particle dispersion in comparison to higher pressure systems, is also less expensive to buy and less expensive to operate. The high shear mixer can be used for a variety of applications like mixing base powders with liquids to form uniform pastes, homogenizing filter cakes, blending wet material with powders or liquids, homogenizing powders with liquids into a plastic mass followed by extrusion and pre-feeding of caked masses.
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Continuous extruder for mixing solids and liquids

Products can be extruded with a variety of shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of substrates as they are propelled through a screw style mixing machine. Precise control of pressure at the point of extrusion is essential to predictable, desirable results.


<h2>Small scale, precisely controlled extrusion of animal feed</h2>
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. The stop is moved towards and away from the tube creating an adjustable sized gap through which material leaves the tube. Controlling the size of this gap relative to the material throughput determines the pressure under which the material is extruded and influences many of the product’s final characteristics.

These units can be provided with heating or cooling jackets and provisions for monitoring temperature and pressure. Precisely controlled product extrusion is thus achieved by applying Amandus Kahl’s patented gap control technology from the annular gap expanders to this simpler machine.

Laboratory extruder

Products can be extruded with various shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of substrates as they are propelled through a screw-style mixing machine. Precise control of pressure at the point of extrusion is essential to predictable, desirable results.


<h2>Product shaping with easy start-up and less waste</h2>
Amandus Kahl’s Extruder OE series is an extruder line that works on the same principle as the successful annular gap expander design. A conical stop restricts the flow out of a tube as materials are driven through it by a rotating shaft. The stop is moved towards and away from the tube, creating an adjustable-sized gap through which material leaves the line. Controlling the size of this gap relative to the material throughput determines the pressure under which the material is extruded and influences many of the product’s final characteristics.

Heating or cooling jackets can be added to these units for monitoring temperature and pressure. Precisely controlled product extrusion is thus achieved by applying Amandus Kahl’s patented gap control technology from the annular gap expanders to this more straightforward machine.

Extruder with annular gap expander

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

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

Extruded aquafeed

Ventilex is an expert in drying technologies. More than 800 fluid bed dryers, belt dryers &amp; air dehumidifiers are already installed worldwide.

<a href="https://making.com/products/aquafeed">Aquatic feed production</a> has been on the rise in recent years due to the increasing demand for proteins. However, feed manufacturers are faced with multiple challenges, such as sourcing raw materials (e.g. <a href="https://making.com/soybean-meal">soybean</a> and <a href="https://making.com/fishmeal-powder">fishmeal</a>) and preserving nutrients, especially for farmed fish diet. Aquafeed as a high-quality source of protein for fish production is therefore crucial to fish farms to improve fish quality.


<h2>Challenges of aquafeed production</h2>
Aquafeed manufacturers are seeking sustainable and secured raw materials as well as alternative feed ingredients, which need to be processed properly. Protein content, feed quality, shelf life, and homogeneity are the main factors to consider when it comes to processing aquafeed. However, many drying technologies only allow for a limited range of product types, reducing feed variety and volume produced in one feed production facility.
<h2>Optimal drying of fish feed</h2>
<a href="https://making.com/equipment/continuous-fluid-bed-dryer">Fluid bed drying</a> is one of the proven solutions to thermal drying of fish feed. It combines upward-moving flow of gas with mechanical movement to make products in solid form into fluid and makes sure high heat transfer. It thus guarantees a gentle and uniform drying process that helps to preserve nutrients and increase shelf life of fish feed products. In addition, fish feed of a wide range (e.g. particle size, density and moisture content) can be produced on the same drying unit, achieving a high production volume. Click <a href="https://www.ventilex.com/ventilex-news/aquafeed-high-quality-for-low-cost-per-ton/">here</a> to learn more about fish feed drying.

Improve the quality of fish feed products

Feed

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!

Find production technology for Sinking pellets extrusion, and connect directly with leading machine manufacturers worldwide

Sinking pellets extrusion

Which sinking pellets extrusion equipment do you need?

Continuous extruder for mixing solids and liquids

Laboratory extruder

Extruder with annular gap expander

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