Extrusion Technology
R&D Center, Muyang Group
2009
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Main Contents
1. Aquafeed Extrusion Technology
1.1 Typical process of fish feed line in China 1.2 Muyang new techniques about aquafeed extrusion 1.3 Common problems in aquafeed extrusion & analysis
2. Full-fat Soybean Extrusion Technology
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Aquafeed Extrusion Technology
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Aquafeed Extrusion Technology
1. Typical process of fish feed line in China
2. Muyang new techniques about aquafeed extrusion
3. Common problems in aquafeed extrusion & analysis
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1) Fish feed production process flow
INTAKE 1 INTAKE 2
COARS GRINDING
RAW MATERIAL BINS
DOSING
MIXING
COARS GRINDING
FINE GRINDING
ULTRA-FINE G.
CLEANING
DOSING & MIXING
DOSING & MIXING
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1) Fish feed production process flow
WATER
EXTRUSION
STEAM
DRYING
STEAM
SIFTING
FAT COATING
FISH OIL
COOLING
SIFTING
BAGGING/dispach
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2) Key points of the extrusion process
Mission:
To increase the capacity To improve the quality To reduce the power consumption To enhance the lifespan of the parts
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a. Functions of extrusion
Agglomeration Degassing Dehydration Gelatinization Grinding Homogenization Mixing Pasteurization and sterilization Protein denaturization Shaping and sizing Shearing Texture alteration Thermal cooking
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b. General technical parameters
Steam injection water: 1923% Temperature: 9095 Water filling Water filling
Steam injection
water: 2224% temperature:110140 pressure: 30 40 bar gelatinization: 98%
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c. Bulk density correlation with float-sink properties for aqua-feed
Feed characteristics Fast-sinking Slow-sinking Neutral buoyancy floating
Sea water - 20 (3% salinity) 640 g/l 580-600 g/l 520-540 g/l 480 g/l
Fresh water - 20 600 g/l 540-560 g/l 480-500 g/l 440 g/l
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d. Process parameters for aqua feed production
Parameters Temperature prior to die discharging Moisture prior to die discharging Moisture of extruded product Pressure of discharging barrel
Floating fish feed 125-135 22-26% 21-24% 34-37 atmos
Sinking fish feed 110-125 25-32% 24-27% 20-29 atmos
Slow sinking 115-130 24-28% 22-26% 30-35 atmos
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e. Methods for controlling the density of extruded aquafeed
Regulating the starch content in feed formula: floating aquafeed, 20% for pellet 1.0 mm 12% for pellet above 3.0 mm sinking aquafeed 10% Adjusting the open area of discharging die plate: floating aquafeed: 200250 mm2/t/h sinking aquafeed: 550600 mm2/t/h Increasing oil added When the oil addition is between 12%22%, the feed density will be increased proportionally with the increasing of oil addition. Properly reducing screw rotating speed.
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f. Conditioning time and temperature required
Category Floating feed Sinking feed Shrimp feed
Pre Conditioning time 90-120 S 90-120 S 150-180 S
Pre Conditioning Temperature 95-105 85-95 93-95
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Aquafeed Extrusion Technology
1. Typical process of fish feed line in China
2. Muyang new techniques about aquafeed extrusion
3. Common problems in aquafeed extrusion & analysis
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III. Muyang Single Screw Extruder
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IV. Muyang Twin Screw Extruder
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Improvement of Muyang single screw extruder 1). Preconditioner
a. b. c. d. Single paddle conditioner 2-pass paddle conditioner Double shaft different speed conditioner Complex conditioner
2). Extrusion elements improvement 3). Sinking feed process method 4). Muyang single screw extruder category
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1) Preconditioner
Hot moist circumstance
1. The objective of preconditioning is to completely moisten raw material particles, eliminating the dry core 2. High temperature to pregelatinize the raw material 3. Complete mixing of steam and raw material to keep stable quality
Dry core
Moistened surrounding
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a) Single-cylinder conditioner
low rotating speed
too high rotating speed
correct rotating speed
So the right linear speed of the conditioner paddle should be 220-250 rpm (say MUTZ 600 conditioner for fresh water fish feed production)
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b) Two-pass single-cylinder conditioner
high speed mixing
Low speed heat preservation
Contradictories for heat conservation in the second pass: To increase fill rate, rotating speed must be reduced; To improve mixing homogeneity, rotating speed must be increased.
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c) Double-shaft Differential Conditioner (DDC)
Mixing can be well done by a DDC.
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d) SPTZ The conditioning result of SPTZ series tri-shaft series Complex conditioner
conditioner is superior than that of the forementioned 3 types of conditioner.
Intensified mixing function of the single-cylinder conditioner for water, steam and mash; Through adjusting the paddles, fill rate of the DDC increased, conditioning time extended, meanwhile mixing function is also performed.
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e) Comparison of DDC and Tri-Shaft conditioners
Water intake Feeding inlet
Positions of material in a DDC
Material outlet Steam intake
Increased fill rateprolonged conditioning timeimproved material gelatinization increased production rate of extruder Can we further increase the fill rate through adjusting paddles on the present conditions?
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Existing DDC The existing DDC can not be more filled, otherwise the mixing of mash material with water and steam will become worse!
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Complex conditioner
Upper passsingle cylinder conditioner (addition of water and steam)
Steam water
Fill rate of the material in a single cylinder conditioner:40-45% The fill rate over 40-45% shall impact the penetration effect of water and steam.
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Complex conditioner The lower trough of SPTZ series conditioner can be further filled with more material.
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Filling level comparison
material in the lower trough of new-type conditioner
Material in the lower trough of existing DDC
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Mainly put in water and steam on upper pass Water
Steam
Steam
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Comparison of gelatinization
gelatinization
60
Gelatinization can be around 15% higher
50 40 30 20 10 0 0 30
Complex
DDC
60
90
120
150
180
210
240
conditioning time (sec.)
Note: fresh water fish formulation, conditioner temperature 98 , conditioning water 24%.
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f) Determination of conditioning time
Accurate determination method:
In which: t = conditioning time, s A = the amount of material filled in the conditioner, kg S = material flow rate, kg/h
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g) Conditioning time with different conditioner
Category 2 pass single MUTZ-600x2J DDC SCTZ33 Complex conditioner SPTZ33
Conditioning time (s) 82
Temperature () 98
Moistrue (s) 24
Gelatinization (%) 38.1
125
98
24
47.2
175
98
24
54.5
* Same capacity as for 6 t/h floating fish feed
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Full-fat Soybean Extrusion Technology
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Producing expanded soybean with a raw material extruder
Machine type TPH200 Throughput 3.03.5 T/h Urase UA0.2
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Producing expanded soybean with a raw material extruder
Machine typeTPH260 Throughput6.07.0 T/h UraseUA0.2
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FQAs that expanded soybean manufacturers always concern about
1.1 Extruding soybean with steam or without steam 1.2 How to control the urase activity of the extruded soybean 1.3 How to detect the urase in expanded soybean quickly 1.4 Are there any other issues we must be pay attention to when extruding soybean
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1.1 Extruding soybean
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With Steam Extrusion
First pre-ripen the materials with steam in the conditioner then further ripen the materials by extruding them in the extruder. The extruding in the extruder is a gentle one. Energy that make material ripenessspecific thermal energy (STE), specific mechanical energy SME
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Without steam extrusion
The materials are directly ripened in the extruder without preripening with steam in the conditioner Material ripened mostly by the Specific Mechanical Energy (SME during extruding.
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Comparison of Without steam Extrusion and With steam Extrusion
No. Methods Without steam extrusion Throughput Max. temperature 150160 Color Smell Protein solubility
Slightly Lower
Super good
Super good
Low
With steam extrusion
Slightly Higher
130145
Good
Good
High
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Evaluation standard for expanded soybean
Is it ripe ? Is it overripe ?
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Two indexes must be considered when extruding soybean
Urase activitythe index used for evaluating soybean ripeness Standard 10.1 < UA < 0.2 Standard 20.04 < UA < 0.1 Protein solubilitythe index for evaluating soybean overripe status Low standardC 60% High standardC 75%
ra e a t ty ea ur ng et o G urase activity in soybean products rote n o u ty ea ur ng et o ota
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Method for the determination of u y ro e ou ty Met o
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The conditioner with good conditioning efficiency can help in increasing the expanded soybean protein solubility
Conditioner volume Urase activity Protein solubility
1.5V
2.4V
2.8V
0.1~0.15 60~65% 65~70% 73~75% 78~82%
Measurement for urase activityGB/T 8622 Method for the determination of urase activity in soybean products Measurement for protein solubilitypotassium hydroxide solubility method Laboratory machine: TPH200 extruder Conditioner: MUTZ350, MUTZ350J, MUTZ420, MUTZ420JC Conditioning temperature: 90
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Summary
Extruding soybean with steam is the best choice Only wet-extrusion can guarantee no nutritional ingredients burned during extruding. Conditioning with steam can not only increase the output per unit time but also the strength in destroying anti-nutritional factors, which will further enhance the nutritive value of soybean mash; The soybean protein solubility can only be improved just by maximizing the conditioning efficiency.
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1.2 How to control soybean urase activity?
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How to control soybean urase activity
1.2.1 To control urase activity by adjusting SME 1.2.2 To control urase activity by adjusting technical parameters during production 1.2.3 To control urase activity by installing and using the steam pipeline correctly 1.2.4 How to improve the soybean unrase activity effectively at the beginning of starting up an extrusion 1.2.5 A new method of improving production capacity while reducing the urase activity.
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1.2.1 To control urase activity by adjusting SME
Change the numbers of double-screw
Change the shear lock
Adjust the discharging die holes
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Change the discharging die
The old discharging die
The new discharging die Muyang patent
The new discharging die which the die holes are adjustable during production is more convenient in controlling urase activity can eliminate machine blockage problem caused by error operating.
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Change the shear lock with different diameter so as to adjust SME
Mash flow
Shear lock Steam Lock
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1.2.2
To control urase activity by adjusting technical parameters during production
Controllable parameters Feeding rate of soybean mash Steam adding rate under the max. conditioning temperature Steam pressure-relief valveupstream pressure, downstream pressure Observable parameters Temperature of each barrel sectionwhich is related to the configured screws and shear locks of the extruder Discharging temperature.
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1.2.3
To control urase activity by installing and using the steam pipeline correctly
Good pipeline design can remove the un-wanted moisture in the steam pipeline so as to improve conditioning efficiency Steam pressure Upstream stream pressure0.6MPa ( 6bar ) Steam pressure for conditioning0.150.25MPa ( 1.5 2.5bar )
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Recommended steam pipeline
Steam flow direction
1 steam-water separator 2 cut-off valve 4 pressure gauge 5 pressure-relief valve 7 steam trap
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3 filter 6 safety valve
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Use of a steam water separator
Which can effectively reduce water contained in steam flow and provide high quality steam for steam using equipments
Flow direction
Steam water separator
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1.2.4
How to improve the soybean unrase activity effectively at the beginning of starting up an extrusion?
Pre-heat the principal machinepreheating temperature and preheating time Steamapplied only after draining out water, and please note the temperature difference between the start-up and stabilized running of the machine After the extrudates begin to be discharged out of the barrelgradually increase the feeding rate, adjust the die holes to a small diameter and then increase the pressure of the extruding chamber.
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1.2.5
A new method of improving production capacity while reducing the urase activity
Heat preservation
Appropriate time
Extruder
Discharging temperature: 8085
Cooling
Keep the materials stating in the heat preservation equipment for five minutes to finish final ripeness; The materials in the heat preservation equipment should be keep in the order of FIFO Throughput can be increased by 3050%
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1.3 Fast methods for detecting urase during production
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Conventional methods for detecting urase activity
pH value-added method The measured pH value of the soybean urase activity defined by the China Feed Standard is0.2 The old standard is:0.4 Phenol red method Examine the urase activity by qualitative detection. Can make an initial determination about whether the urase activity qualified or not in a short time.
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Relationship between phenol red method qualitativ detection) and pH value-added method quantitative detection
Sample 1 2 3 4 5 6
Phenol red method min
10
15
20
30
40
pH value-added method
0.4
0.10.15
0.080.12
0.060.1
0.030.05
0.010.02
Adopt phenol red method for qualitative detection quantitative detection
and pH value-added method for
Qualitative detection in the above table indicates the time that 10~15% expanded soybean mash take to turn red by adopting phenol red method to detect soybean urase; Quantitative detection in the above table indicates adopting pH value-added method to detect urase activity Test sampleexpanded soybean that have been discharged out barrel within one hour.
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Determine expanded soybean urase activity base on experience
0.2 > UA >0.1
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1.4
Other relevant matters that should be concerned when producing expanded soybean
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The soybean mash to be extruded should have an appropriate granularity
Too coarse soybean mash
Too coarse soybean mash will result in insufficient conditioning which will cause hard friction when the soybean mash go into the extruder chamber, and then the temperature will rise up rapidly, the protein solubility will be reduced thereby.
Too fine soybean mash
Too fine soybean mash is apt to slide in the extruder chamber, so that the shear effect generated by the screw to shear materials will be minimized, which will result in further decrease in the urase activity. And also it is easy to result in regurgitation problem and make the machine to be stopped. When extruding fine soybean mash with a worn screw and worn shear locks, it will be easy to result in regurgitation and blockage problems.
Generally, expanded soybean is ground by a hammer mill with a 2.53.0 mm screen. However, there are also some feed mills that produce expanded soybean with a 1.5mm screen.
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Post treatment for the expanded soybean
After extruding the temperature of expanded soybean mash is usually 8085 Cooling is needed. If the expanded soybean have not be cooled down for a long time, it will be browned and part of the expanded soybean will be overripe, and the protein deteriorated which will influence the availability as well as the palatability of the product After extruding with steam, the product is of high moisture content, which in the cooling process will be taken off, then the product will finally obtain a safety moisture content for storage.
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THANKS FOR YOUR TIME
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