Extrusion Processing Aquatic Feed

Transcription

1 II Congresso sobre Tecnologia da Produção de Alimentos para Animais Extrusion Processing Aquatic Feed Sajid Alavi, Ph.D. Professor Dept. of Grain Science & Industry Kansas State University U.S.A. September 3, 2013 CBNA, Brazil

2 Applications - Aquatic Feed Assortment of aquatic feed products

3 Aquatic Feeds Floating Catfish Carp Slow Sinking Salmon Trout Fast Sinking Shrimp Product Properties: Piece density Nutritional quality Water stability Wenger Mfg., Inc.

4 Extrusion System for Aquatic Feed Raw Materials Extruder Mixer The extruder is considered the heart of the system. Coater Dryer/ Cooler Finished Product to Packaging

5 Raw Materials for Aquatic Food

6 Raw Material Selection Criteria nutrition processability economic viability uniformity inclusion of high levels of fat water stability floating versus sinking feed

7 Aquatic Feed Ingredients - Starch/ Cereal Grain Type of Aquatic Feed Floating Sinking Minimum Starch Starch is structure forming provides binding, expansion Also caloric source Source: wheat, wheat byproducts, corn, barley, rice, brewer s rice, tuber starches, etc.

8 0.75 Role of starch in binding and expansion % floating 0.25 Bulk density requirements (pre-dryer, moisture 25-27%): Floating: g/l Sinking: g/l 15.5% 25.5%

9 Aquatic Feed Ingredients - Proteins Balanced amino acid profile required for proper growth and body maintenance Proteinaceous ingredients up to 70% of formulation Protein sources: animal vs. plant

10 Protein - animal sources Example, fish meal, poultry meal, etc Good amino acid profile Drawbacks: -high cost -usually low PDI and binding characteristics -do not contribute structurally because they do not expand or combine with other ingredients in the same manner as plant proteins - mineral deposits in screw and die; phosphorous and calcium from fish meal with extra salt

11 Protein - plant sources Examples, soybean meal, other legumes, corn gluten meal, etc High protein dispersibility index (PDI) - degree of water solubility, compatibility with other ingredients Good binding; can contribute to structure Higher oil absorption levels possible in coating operations Low cost Drawback: limited amino acid profile

12 Effect of Vegetable Protein Levels On Extrusion Moisture* Extrusion Moisture (%) Vegetable Proteins in Recipe (%) * Maintaining same density and binding characteristics

13 Pumping fresh meat slurries into preconditioner and extruder barrel

14 Pumping fresh meat slurries into preconditioner and extruder barrel

15 Aquatic Feed Ingredients Lipids Caloric density - more energy than starch Increased palatability, attracts fish Deliver essential free fatty acids and fat-soluble vitamins Drawback: lubrication Usually < 15% in extruded formulations; additional lipids added post-extrusion Sources: fish oil, soybean oil, etc.

16 Effects of Internal Fat Level on Expansion % ADDED BULK DENSITY FAT g/l Lb/ft (Wenger Mfg.)

17 To Maximize Lipid Inclusion Levels Use lipids indigenous to other ingredients Heat lipids to C prior to inclusion Add late in process Maintain starch/functional protein levels Maximize mixing with extruder screw configuration

18 Vacuum Fat Inclusion Product From Dryer Surge Hopper Weigh Hopper Liquid Liquid Addition System To Atmosphere Vacuum Pump Water Separator Vacuum Mixer Vessel Counterflow Cooler Finished Product

19 Aquatic Feed Ingredients Fiber Bulking agent Wheat midds or bran Drawback poor structure and binding

20 Aquatic Feed Ingredients Micronutrient Premixes Fat soluble vitamins (A, D and E) are fairly stable, only 15 to 20% losses Water soluble vitamins (B and C) are not heat stable, higher overages are recommended

21 Wenger Mfg., Inc.

22 Aquatic Feed Ingredients Particle Size U.S. Standard Sieve Pan Openings in Microns Percent on Sieve Typical particle size for pet food and aquatic feed; 1.5 mm screen Geometric Mean Diameter: 327 Microns Geometric Standard Deviation: 1.58

23 Benefits of Proper Particle Size Smooth product surface Reduced incidence of die orifice plugging Ease of cooking, binding, expansion, floatability Reduced product breakage and fines Increased water stability Improved retention of liquid coatings due to small cell structure

24 Guidelines for Grind of Recipe Maximum particle size = 1/3 of die opening Not to exceed 1.5mm grind 800 micron 1.5 mm

25 Generic Formulation for Floating Aquatic Feed Soybean meal 10 Wheat flour 28 Wheat midds 5 Fish meal 53 Premixes 2 Fat/ oil 2 Total 100% External fat 20%

26 Processing of Starter Feed/ Micro Aquatic Feed

27 Micro Aquatic Feeds (Starter feed, ornamental aquatic feed; mm) 0.3 mm 1.2 mm

28 Challenges with processing of microsized aquatic feeds High pressure development Throughput Particle size of ingredients P Q R 4 P = pressure, Q = throughput, R = die radius

29 Processing Methods for Micro Aquatic Feeds Large pellet extrusion followed by crumbling Direct extrusion Spheronization

30 Micro Aquatic Feeds Crumbling Process Mixing Sifting Drying / Cooling Crumbling Sizing Cooking Extrusion Recycle or waste Packaging

31 Micro Aquatic Feeds - Crumbling Advantages High rates Easy recipe preparation Low cost No special equipment Disadvantages Low Yields Final product sifting Unattractive appearance Sinking only Poor water stability Non-homogeneous

32 Micro Aquatic Feeds - Direct Extrusion Mixing Pulverizing Drying / Cooling Sifting Cooking Extrusion Recycle or waste Sizing Packaging

33 Twin-Screw Extrusion better flow and operational stability better flow and operational stability allows intricate shapes and small product sizes diversity of products and formulations - high fat and moisture formulations - broader range of raw materials - high levels of fresh meat - ease in cleaning (self-wiping)

34 Raw Material Preparation Hammer Mill Limited to 2/64 (0.8mm) grind Size Not suitable for micro aquatic feed (<1.2 mm size) Air Swept Pulverizer 40 mesh (420 microns) 80 mesh (177 microns) Note: Ground Materials must be sifted prior to extrusion!!!

35 Processing Notes for Direct Extrusion Production rates lower for smaller size feed 100% sinking product can be guaranteed 100% floating product can not be guaranteed for products less than 2mm Single screw extruder is not recommended for product less than 1.2 mm Even a twin screw extruder might not be adequate for product less than 0.8 mm

36 Micro Aquatic Feeds - Direct Extrusion Advantages Pasteurized Excellent appearance Good water stability Partial floating possible Good durability Homogeneous product Disadvantages Low rates Requires dedicated line (twin screw extrusion) High cost / unit of throughput

37 Recommendations for direct-extruded micro-aquatic feeds Pulverizer (100% through 250 microns) Sifter (300 micron screen) Extruder (with oil, steam, and water injection streams screened through 250 microns) Pneumatic conveying system Dryer (screen size < 250 microns) Sifter for sizing final product

38 Extruded / Flaked Aquarium Feed Extruded pellets are flaked before drying and coating

39 Filled Pellets Antibiotics Vitamins Probiotics Heat Sensitive Ingredients

40 Co-extrusion or Filling Die Filling Extrudate from Extruder

41 Filled-Extruded Aquatic Feed Process involves one extruder plus filling pump(s) Post-extrusion cutting/shaping Prefer twin, but single can be used Filling typically 15-20% of weight Rates of 2 ton/hr or less Applications for heat-sensitive fillings System can also be used to produce micro-pellets

42 Micro Aquatic Feeds - Spheronization Process Spheronizer Marumerizer Sphere-izer Agglomeration System (SAS)

43 Spheronization Process Hatched grooves - most efficient for speherical shapes Radial grooves - gentler process Disc speeds: rpm Processing time: 3-8 min

44 Process Flow for Spheronization Mixing Pulverizing Drying / Cooling Sphere-izer Sifting Forming Extrusion Recycle or waste Sizing Packaging

45 Product Capacities for SAS System Product Size (mm) System Rate (kg/h) Note: Any single or twin screw extrusion system can be configured for this process as long as it can deliver the above rates.

46 Micro Aquatic Feed - Spheronization Process Advantages Low temp process Moderate Investment Homogeneous Product Disadvantages No pasteurization Final product sifting Low production rate Low product durability Dedicated line Sinking feeds only

47 Bioprocessing and Industrial Value-Added Program (BIVAP) Facility

48 KSU Extrusion Lab

49 KSU Extrusion Lab

50 Pilot-scale twin-screw extruder (TX-52 Wenger Manufacturing, Sabetha, KS) KSU Extrusion Lab

51 Pilot-scale singlepilotsingle-screw extruder (X(X-20, Wenger Manufacturing, Sabetha, KS) KSU Extrusion Lab

52 Pilot-scale double-pass dryer/cooler (4800 Series, Wenger Manufacturing, Sabetha, KS) KSU Extrusion Lab

53 Lab-scale American Leistritz Micro-18 twin screw extruder KSU Extrusion Lab

54 KSU Extrusion Lab

55 KSU Extrusion Lab

56 KSU Extrusion Lab

57 Michael Gibson, M.S. student Dry expanded pet food A comparative study of extrusion and baking processes Michael Joseph, Ph.D. student Novel delivery mechanisms for food assistance and nutrition via grain sorghum and other commodities processed using extrusion

58 Anubha Garg, M.S. student Stochastic modeling of process dynamics and structure formation in extruded cellular products Ryan Roberts, M.S. student Texturized vegetable proteins understanding of processing and chemical interactions Impact of rework on dry expanded pet food processed using extrusion

59 Pavan Harshit Manepalli, M.S. Student Heat and mass transfer modeling of the extrusion process. Natarajan Padmanabhan, M.S. student Sorghum-based micronutrient fortified blended foods using extrusion

60 Dr. Lijia Zhu Post-doctoral research associate Digestibility of starch and protein and micronutrient retention in extruded products, Dr. Bode Adedeji Post-doctoral research associate Value-added utilization of sorghum and sorghum by-products using extrusion; Sorghum distillers dried grain in aquatic feed

61 Eric Maichel Operations manager and M.S. student Pet food processing via extrusion and impact of different hydration regimens

62 KSU Extrusion Processing Technology and Commercialization Short Course 10 th edition; August 2014

63 Thanks!