FENACAM’14 Programação Técnica -VIII Simpósio Internacional de Aquicultura 11 –13 DE NOVEMBRO DE 2014 Extrusion Offers Flexibility in Production for Various Feed Designs Joseph P. Kearns Wenger Manufacturing, Inc Sabetha, Kansas, USA jkearns@wenger.com
Extrusion History 1929 Joe and Louis Wenger start building mixers
1948 Wenger builds its first extruder
Current Designs 1954 Wenger fills its first export order a pellet mill to Venezuela
1958 Wenger patents the first commercial extruder for Pet Food
Variations of Extruded Products
Final Product Bulk Density Correlation with Float/Sink Properties Pellet Characteristic
In sea water @ 20째C (3% salinity)
In fresh water @ 20째C
Fast sinking
> 640 g/l
> 600 g/l
Slow sinking
580-600 g/l
540-560 g/l
Neutral buoyancy
520-540 g/l
480-520 g/l
Floating
< 480 g/l
< 440 g/l
Floating: Catfish, Carp, Tilapia
Coated and Uncoated Salmon and Trout Feeds
Big Fish Feeds
Small Diameters
Shrimp Feeds
Large Semi Moist Feeds
High Intensity Preconditioner
High Intensity Preconditioner 1)
2) 3) 4) 5)
Mixing intensity controlled by speed and rotational direction of each shaft Increased radial and distributive mixing Up to 2 times more beater contacts than original DDC Instant display of retention time Retention time can be varied
HIP Performance Process Performance: 1) Cook levels* 2) â&#x2020;&#x2018; Mixing = â&#x2020;&#x201C; particle size 3) Use MI to control product density 4) Smaller particles off preconditioner improve food safety efforts because of more uniform hydration and temperature
*DDC average cook 30-35% with occasional 40% cook:
HIP average cook levels 35-40% with occasional 70% cook
DDC
HIP
Comparison of Particle Size Off Preconditioner at 70% Meat Addition
High Mixing Intensity
Low Mixing Intensity
Coefficient of Variation for Moisture Content of Various Preconditioner Designs
Preconditioner Design HIP DDC DC (Double Cylinder) SC (Single Cylinder)
CV (%) 2.65 4.96 6.66 9.36
Water
Fresh Meat
Steam
Fat
Meat / Slurry Injection
• Low Speed
• Large Paddles • Build up on Paddles • Non-uniform Discharge
• High Speed • Small Paddles • Low Build up on Paddles
• Uniform Discharge
Comparison of Preconditioner Designs Conditioner
Specifications
SC
• 30 seconds retention time1 • Up to 4% fat2 • Very limited levels of fresh meat2
DC
• 1-1.5 minutes retention time1 • Up to 8% fat2 • Up to 15% fresh meat2
DDC
• 1.5 – 3 minutes retention time1 • Up to 20% fat2 • Up to 40% fresh meat2
HIP
• • •
1.0 – 2.5 minutes (variable) retention time Up to 40% fat2 Up to 90% fresh meat2 1.
Retention times assume comparable total free volumes
2.
Fat / fresh meat is calculated as a proportion of the dry recipe.
Thermal Twin For Marine Feeds
Special mechanical designs permit up to 12% steam injection into extruder
Process Parameters from Thermal Twin Extrusion of Aquatic Feed HIP temperature HIP moisture
71째 C 29.2%
HIP retention time BPV opening
2.75 minutes 35%
Extrusion SME Extrusion STE
7.9 kWhr/t 86.9 kWhr/t
Ratio of STE/SME*
11/1 *Normal ratio is 1/1 or 2/1
Finely Ground Dry Raw Material
Wet Ingredient Ground Fish at 50% of Total Formula
Additional Liquids Added
Computer Control and L-I-W Dry Feed
Back Pressure Valve to Control Cook
Dryer Used as Cooler
Final Pellets Approx. 30 x 60mm
Advancements in Extrusion for a Wide Variety of Species C²TX for Shrimp Feed & Micro Feeds
Small TX For Micro Feeds
Big Single for Bulk Production of Floating Feeds
Thermal Twin for Marine Fish Feeds
Aquatic Feeds on Single Screw Extruders • Usually higher Marine Protein Diets or vegetable ingredients • Normally better functional ingredients, high water solubility. • Sinking Rate is required • Larger Pellet Diameters (+1.5mm) • Higher Oil Contents • Higher energy inputs
Standard Twin or Conical TX for Micro Feeds
Patented High Capacity Extrusion Process for Shrimp and Micro-Aquatic Feed
Large TX-3000 for High Capacity Small Diameter
Thanks