Digital re-print - March | April 2009

Feature: Extruders
Feature title: Benefits of using Extruders to process aquatic feed

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THE INTERNATIONAL MAGAZINE FOR THE AQUACULTURE FEED INDUSTRY

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Benefits of using
Extruders
to process aquatic feed
by Dr Mian N Riaz, Head
Extrusion Technology Program,
Texas A&M University, USA
T
here are wide varieties of
methods that can be used
to process aquatic feeds.
For examples, in early days
the most common method to feed the
fish was hand feeding of mixed, home-
blended diets and trash fish. Then fish
farmers started using cold forming
of moist diets. Pelleting presses then
became popular and a majority of the
fish feed were processed using pellet
mill technology.
Today extrusion technology is the
method of choice to process aqua feed
Picture 1: Floating and sinking requirements of different species
18 | InternatIonal AquAFeed | March-april 09
Table 1: Effect of Extrusion on Microbial Populations
TPC (CFU/g)
because of the benefits it offers
to fish farmers.
Each method had its advan-
tages and disadvantages.
The initial days of aquacul-
ture were very simple which
involved hand feeding of ‘trash
fish’ or home-blended diets. These diets
were simulated natural diets and were
very palatable but the availability was not
consistent and providing fresh feed every
day was difficult.
Storage of the fresh fish was a problem.
Farmers need to store these fish in cold
storage or use only fresh. At the same time
Picture 3: A closed loop
system used to add wet
slurry in preconditioner
Extruders
Operation of a pellet mill
was not a complex proc-
ess. On the other hand it
was very difficult to make
floating fish feed with the
pellet mill. This means there
was no control over buoyancy.
At the same time micro aquatic feed
(less than 2.00mm) was not possible with the Also, Newcastle disease virus
pellet mill. The cooking temperature in the is inactivated by the extrusion and drying
pelleting process was too low to be adequate process where temperatures exceed 75ºC
for destruction of anti-nutritional factors, for one minute. Growth inhibitor, allergens
pathogenic organisms and viruses
in the feed.
Floating and sinking
Current aquatic feed manufac-
turing practices seem to fit into
two simple categories; floating and
sinking.
Today 100 percent floating feed
is extruded and nearly 60 percent
After sinking feed is extruded. Whereas,
Microbe Raw Recipe
Extrusion the rest of the 40 percent sink-
Picture 2: Quick test for floating ing feed is still pelleted. This is
240,000 9,300 and sinking feed during extrusion just simply because extrusion
Coliform 22,600 <10 cooking offers several benefits
Picture 4: Addition of wet slurry in the
to the aquatic feed manufactures.
Mold count 54,540 <10 ing was use of pellet mills. Pelleted aquatic extruder barrel
Following is the brief description
Clostridium 16,000 <10 feed offered several advantages over the
of the advantages of the extruded
Listeria positive negative
hand fed natural diets.
feed.
For example, pelleted feed was
Salmonella negative negative and other anti-nutritional factors largely
denser and lower in moisture than the
natural feed, so the long-term storage Hygienic quality of inactivated during extrusion cooking.
Table 1 shows the effect of extrusion on
disease and virus transmission was very was better. Pelleting also reduced the extruded feed
microorganism and their survival.
common in fresh trash fish. Feeding the segregation of the ingredients which Ingredients are cooked at high tempera-
fresh trash fish in large ponds was very was a very common problem in home- tures and pressures.
labor intensive and water pollution was a made diets. Therefore, extrusion cooking provides Option of producing
huge issue in the ponds. Since feed was pelleted there was less hygienic processing of feed destroying the floating or sinking feed
waste of feed in the water and that resulted pathogens and most viruses and reducing There are many aquatic species that are
Pelleted aqua feed in some improvements in water pollution the toxin levels in the feed ingredients. cultured today.
The next phase in aquatic feed process- and quality. As a result,
IAF03-OEEFishfeed pelleting offered
10.12.2008 10:54low
Uhr In extrusion
Seite 1 cooking avian influenza Some of them prefer to eat the pellet on
processing cost and a higher processing virus is destroyed during the processing the bottom of the pound where as some
rate to the aquatic feed industry. (greater than 70ºC). of species like to come on the surface to
KAHL Extruder OEE
for Fish Feed
● Flexible
● Flexible production
production
● Hydraulically
● Hydraulically adjustable
adjustable die die
● Production
● Production of
of floating,
floating, slowly
slowly
sinking,
sinking, and
and water
water stable
stable pellets
pellets
● Fat
● Fat content
content up
up to
to 30
30 %%
● Pellet
● Pellet diameter
diameter 2 2 -- 12
12 mm
mm
AMANDUS KAHL GmbH & Co. KG, Dieselstrasse 5-9, D-21465 Reinbek / Hamburg, Phone: +49 40 727 71 0, Fax: +49 40 727 71 100
info@amandus-kahl-group.de, www.akahl.de
PREVIOUS PAGE NEXT PAGE
March-april 09 | InternatIonal AquAFeed | 19
Extruders
Size of the fish and pellet

take pellet and some are column feeders 640g/l bulk density for sea water at 20C control of the density of the products and
(taking the feed as it slowly sinks through (three percent salinity) and > 600g/l for thus buoyancy properties are managed.
the water). fresh water at 20C. Picture 2 shows a quick test for floating
For examples and sinking while making feed with extruder.
catfish, carp and
tilapia like float- The use of wet material
ing feed where as in the pellet
shrimp and river Extrusion allows raw aquaculture
crab require sink- wastes and undercooked waste to be used
ing feed. in final feed without any problem.
On the other A reclamation system to recover wet,
hand salmon, trout, under-processed product that cannot be
sea bass/sea bream, recycled through the dryer as dry re-
and cod like to eat work are available to be used in extrusion
the pellet when it processing.
is slowly sinking. These are closed loop systems designed
Picture 1 shows for recycling wet product with extruders.
different species These systems allow us to use wet
Picture 6: Micro aquatic feed made using twin screw
requirements for extruder slurries at levels ranging from 22 to 42
floating and sinking. percent (as a percentage of the dry recipe)
Extrusion depending upon the moisture contents of
allows buoyancy control to make floating, To make slow sinking pellet it requires the slurries in single screw extruders.
sinking or slow sinking feed by controlling 580-600g/l for sea water and 540-560g/l In a twin-screw extruder, addition of
the processing parameters on one extruder. for fresh water. At neutral buoyancy pellets wet slurries can be as high as 60 percent
To make the pellet float in fresh or sea should have 520-540g/l for sea water and depending upon the final moisture contents
water requires <480g/l bulk density. In 480-520g/l for fresh water. of the wet slurry. Picture 3 shows a closed
order to make pellet sink fast requires > Extrusion cooking provides ultimate looped system that can be used for wet
material addition during extrusion
in preconditioner. Picture 4 shows
addition of wet slurry (more than
40 percent) in the extruder barrel.

High fat pellets

The main purpose of lipids
(fats and oils) in feeds are as an
Dry with 20-50% less energy
energy source; to increase palat-
ability; provide essential fatty acids;
carrier for fat soluble vitamins;
modified texture; density control
and dust reduction.
Fat level in fish diets can vary
depending upon the species of
BEFORE - AFTER
the fish.
Some fish, like salmon, need Geelen Counterflow / T +31-475-592315
Picture 7: Pellet soaked in water and then pressed Geelen Counterflow USA Inc. / T +1-772-559-4338
feed with up to 40 percent fat in
Geelen Counterflow América Latina / T +54-9-2362-418899
20 | InternatIonal AquAFeed | March-april 09 PREVIOUS PAGE NEXT PAGE
E info@geelencounterflow.com / I www.geelencounterflow.com

Extruders
the pellet. Extrusion processes allow feed
manufacturers to produce high fat feed.
With twin screw extruder a 20 percent fat
can be added during extrusion of feed.Where
as in single screw it is limited to around 12
percent fat addition during extrusion.
Additional fat is added to the pellet
using different coating systems (vacuum or
atmospheric). Extruded feed can absorb
more fat externally in the coating steps
as compared to pelleted feed. Nowadays
aquatic feed is processed to contain
almost 50 percent fat which is only pos-
sible by using extrusion technology.
Different Sizes of the Pellets
Different shapes and sizes of aquatic
feed can be produced using extrusion
technology.
Depending upon the size of the fish the
pellet size can range from 0.6mm to 60mm.
The size of the pellet is important for the
fish from juvenile to adult. A very small fish
Picture 8: Pellet disintegrate in
the water after soaking
22 | InternatIonal AquAFeed | March-april 09
"Different shapes & sizes of aquatic
feed can be produced using extrusion
technology. Depending upon the size
of the fish the pellet size can range
from 0.6mm to 60mm"
Picture 9: Pellet made with extruder
with very little or no fines
is not going to eat 10mm pellet since the
size of the pellet is bigger than the mouth.
Picture 5 (behind the headline) shows dif-
ferent sizes of the feed made with extrud-
ers at Texas A&M University extrusion pilot
plant. Picture 6 shows micro aquatic feed
made using twin-screw extruder.
Manufacturing soft
aquatic pellets
Some species like blue fin tuna prefer
very soft pellet.
Extrusion processing allows us to make
a very soft pellet (moisture content up to
30 percent in finished feed), which is not
possible by pelleting or other methods.
This is accomplished using a preserva-
tion system in aquatic feeds (final prod-
uct moisture of 16-28 percent) during
extrusion processing. Lower Aw, (water
activity) below 0.70 can be controlled
with humectants at 10-12 percent levels
and by reducing pH to 4.0-4.5 with acids
at 1-2 percent levels or with fish silage/
solubles.
Mould inhibitors are also added at 0.2-
0.5 percent level in the formulation.
Recent developments indicate that soft,
gel-like aquatic pellets can be processed
by coupling alkaline extrusion with a post-
extrusion acid bath to adjust ph and set or
‘firm up’ the texture and pellet integrity.
Water stable pellet
Pellets that break down quickly in water
will lose nutrients.
Some farmers hydrate feed in water
and nutrient solution prior to feeding and
require rapid and excellent water stability
for handling and feeding purposes. Pellets
that breakdown quickly in the stomach of
fish loses nutrients (during regurgitation)
and may contribute to GDAS (Gastric
dilation and air sacculitis) in certain species.
conversion rates (10 - 20 percent); is a continu-
higher production yields; improved ing demand for
digestibility and reduced feed cost. extrusion lines
Picture 9 shows pellet made with - approximately
extruder with very little or no fines. 50-60 - to meet
Extrusion
future demand.
World demands
extruded feeds More inforMation:
According to experts, the global
aquatic feed market is expected to
Dr Mian N Riaz, Superior performance,
quality and controllability
Head Extrusion
grow by over six percent per year. Technology Program
This estimate is based on feed sales of Food Protein R&D
Center
21,000,000 tonnes/year in 2005. The
global aquatic feed market is expected Texas A&M University
College Station
to be 28,000,000 tonnes by 2010. Based
Texas 77843, USA,
Extrusion processing allows us to make on the assumption that an extruder Email: mnriaz@tamu.
pellets which are very stable in water for a would run an average 5000h/year, there edu
long duration. Picture 7 shows pellet soaked
in the water and then pressed with spatula
to see if it will break or not. If it breaks that Related companies:
means it will not be water stable.
Wenger Manufacturing Inc | Contact: Doug Baldwin
Water absorption of pellets Tel no: +1 816 8919272 | Website: www.wenger.com
Extrusion moisture content during Buhler AG | Contact: Christopher Rubin
processing can be controlled over a wide Tel no: +41 71 9551317| Website: www.buhlergroup.com/extrusion
range, which helps to increase the water
stability of the final feed.
These pellets absorb more water,
retains shapes for longer time and results
in reduced losses of nutrients. Water
Absorption and integrity after hydra-
MADE IN HOLLAND
tion is very important. It benefits pellet
technical qualities and fish health. Picture
8 shows pellets disintegrate in the water
after some time.
Mechanical resistance
of pellets
Feed made using extrusion technology is
more resistant to mechanical durability and Extruder 1250 with Flextex and ECS
produces fewer fines in the finished feed
during transportation.
Extruded feed has an internal matrix Andritz Sprout Extrusion features:
system which tends to increase resist- extruders provide the • Starch cook control
ance to mechanical handling of feed.
newest technology for • Bulk density control
Extruded feed produces approx one-
to-two percent fines in the finished production of the most • Raw material flexibility
products during bulk handling, where as AL30O demanding extrudates • Nutrient advantages
pelleted feed normally generates five-
within aquatic feed and • Optimal product uniformity
to-eight percent fines during handling in
bulk or bag form.
High capacity extruders and expanders. pet food industries. • Unique visual appearance
Extrusion reduces 75 percent of the
amount of fines which normally enters the www.andritzsprout.com
water and ends up decaying on the bottom www.extruder.nl andritzsprout@andritz.com
of the pond.
In other words, fewer fines means:
Almex b.v., Verlengde Ooyerhoekseweg 29, 7207 BJ Zutphen GLOBAL PRESENCE
increased water stability; clearer
The Netherlands, tel. +31 (0)575 572666, fax +31 (0)575 572727 Denmark · Netherlands · Germany · France · UK · USA
ponds; lower fatality rates; less unde-
E-mail info@almex.nl, www.almex.nl Venezuela · Brazil · Chile · Mexico · Australia · P.R. China
sirable bacteria growth; increased
PREVIOUS PAGE NEXT PAGE
March-april 09 | InternatIonal AquAFeed | 23
It‘s the mix that makes the difference. Feed manufacturers desire high
durability, reliability and sanitation. Quality feed with minimum operating costs is
a must. Your needs are Buhler‘s first priority. That is why we commit our-
selves to delivering seamless solutions meeting your highest requirements. Get
in touch with one of our specialists worldwide and we will deliver a complete
process design package, equipment, automation and customer service. You and
Buhler – the perfect mix.

Bühler AG, Feed & Biomass, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 28 96
fu.buz@buhlergroup.com, www.buhlergroup.com

The solution behind the solution.

PREVIOUS PAGE NEXT PAGE
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IAF0902.indd 1 12/03/2009 10:01

To purchase a paper copy of the magazine, or to subscribe to the paper edition please contact
our Circulation and Subscriptions Manager on the link above. Picture 3: A closed loop
system used to add wet
slurry in preconditioner
Extruders
conversion rates (10 - 20 percent); is a continu-
Operation of a pellet mill
higher production yields; improved ing demand for was not a complex proc-
digestibility and reduced feed cost. extrusion lines ess. On the other hand it
Picture 9 shows pellet made with - approximately was very difficult to make
extruder with ver y little or no fines. 50-60 - to meet floating fish feed with the
pellet mill. This means there

Extrusion
future demand.
was no control over buoyancy.
World demands At the same time micro aquatic feed
extruded feeds More inforMation: (less than 2.00mm) was not possible with the Also, Newcastle disease virus
According to experts, the global
Superior performance,
pellet mill. The cooking temperature in the is inactivated by the extrusion and drying
Dr Mian N Riaz, pelleting process was too low to be adequate process where temperatures exceed 75ºC
aquatic feed market is expected to
quality and controllability
Head Extrusion for destruction of anti-nutritional factors, for one minute. Growth inhibitor, allergens
grow by over six percent per year. Technology Program pathogenic organisms and viruses
This estimate is based on feed sales of Food Protein R&D in the feed.
21,000,000 tonnes/year in 2005. The Center
global aquatic feed market is expected Texas A&M University Floating and sinking
College Station Current aquatic feed manufac-
to be 28,000,000 tonnes by 2010. Based
Texas 77843, USA, turing practices seem to fit into
on the assumption that an extruder Email: mnriaz@tamu.

ADVERTISERS LINKS INFORMATION FOR ADVERTISERS - CLICK HERE

would run an average 5000h/year, there
Related companies:
Wenger Manufacturing Inc | Contact: Doug Baldwin
Tel no: +1 816 8919272 | Website: www.wenger.com
Buhler AG | Contact: Christopher Rubin
Tel no: +41 71 9551317| Website: www.buhlergroup.com/extrusion
edu
Picture 2: Quick test for floating
and sinking feed during extrusion
ing was use of pellet mills. Pelleted aquatic
feed offered several advantages over the
hand fed natural diets.
For example, pelleted feed was
denser and lower in moisture than the
It‘s the mix that makes the difference. Feed manufacturers desire high natural feed, so the long-term storage
durability, reliability and sanitation. Quality feed with minimum operating costs is was better. Pelleting also reduced the
a must. Your needs are Buhler‘s first priority. That is why we commit our- segregation of the ingredients which
selves to delivering seamless solutions meeting your highest requirements. Get was a very common problem in home-
two simple categories; floating and
sinking.
Today 100 percent floating feed
is extruded and nearly 60 percent
sinking feed is extruded. Whereas,
the rest of the 40 percent sink-
ing feed is still pelleted. This is
just simply because extrusion
cooking offers several benefits
to the aquatic feed manufactures. Picture 4: Addition of wet slurry in the
Following is the brief description extruder barrel
of the advantages of the extruded
feed.
and other anti-nutritional factors largely
Hygienic quality of inactivated during extrusion cooking.
Table 1 shows the effect of extrusion on
extruded feed
microorganism and their survival. conversion rates (10 - 20 percent); is a continu-
Ingredients are cooked at high tempera- higher production yields; improved ing demand for
tures and pressures. digestibility and reduced feed cost. extrusion lines

made diets. Therefore, extrusion cooking provides Option of producing Picture 9 shows pellet made with - approximately

MADE IN HOLLAND
in touch with one of our specialists worldwide and we will deliver a complete extruder with ver y little or no fines. 50-60 - to meet
Since feed was pelleted there was less hygienic processing of feed destroying the floating or sinking feed
Extrusion
future demand.
process design package, equipment, automation and customer service. You and World demands
waste of feed in the water and that resulted pathogens and most viruses and reducing There are many aquatic species that are extruded feeds
Buhler – the perfect mix. More inforMation:
in some improvements in water pollution the toxin levels in the feed ingredients. cultured today. According to experts, the global
aquatic feed market is expected to
Dr Mian N Riaz, Superior performance,
Some of them prefer to eat the pellet on
and quality. As a result, pelleting offered low In extrusion cooking avian influenza quality and controllability
IAF03-OEEFishfeed 10.12.2008 10:54 Uhr Seite 1 Head Extrusion
grow by over six percent per year. Technology Program
processing cost and a higher processing virus is destroyed during the processing the bottom of the pound where as some This estimate is based on feed sales of Food Protein R&D
21,000,000 tonnes/year in 2005. The Center
rate to the aquatic feed industry. (greater than 70ºC). of species like to come on the surface to global aquatic feed market is expected Texas A&M University
College Station
Bühler AG, Feed & Biomass, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 28 96
to be 28,000,000 tonnes by 2010. Based
Texas 77843, USA,
fu.buz@buhlergroup.com, www.buhlergroup.com on the assumption that an extruder Email: mnriaz@tamu.
would run an average 5000h/year, there edu

KAHL Extruder OEE Related companies:

Extruder 1250 with Flextex and ECS
for Fish Feed Wenger Manufacturing Inc | Contact: Doug Baldwin
Tel no: +1 816 8919272 | Website: www.wenger.com
Buhler AG | Contact: Christopher Rubin
● Flexible
● Flexible production
production
Andritz Sprout Extrusion features: Tel no: +41 71 9551317| Website: www.buhlergroup.com/extrusion
● Hydraulically
● Hydraulically adjustable
adjustable die die
● Production
● Production of
of floating,
floating, slowly
slowly
extruders provide the • Starch cook control sinking,
sinking, and
and water
water stable
stable pellets
pellets
newest technology for ● Fat
● Fat content
content up
up to
to 30
30 %%
• Bulk density control
● Pellet
● Pellet diameter
diameter 2 2 -- 12
12 mm
mm
production of the most • Raw material flexibility MADE IN HOLLAND
AL30O demanding extrudates • Nutrient advantages AMANDUS KAHL GmbH & Co. KG, Dieselstrasse 5-9, D-21465 Reinbek / Hamburg, Phone: +49 40 727 71 0, Fax: +49 40 727 71 100
info@amandus-kahl-group.de, www.akahl.de

within aquatic feed and • Optimal product uniformity

High capacity extruders and expanders. pet food industries. • Unique visual appearance 18 | InternatIonal AquAFeed | March-april 09 March-april 09 | InternatIonal AquAFeed | 19
Extruder 1250 with Flextex and ECS

Dry with 20-50% less energy

Andritz Sprout Extrusion features:
extruders provide the
www.andritzsprout.com IAF0902.indd 19 12/03/2009 10:02 newest technology for
• Starch cook control
• Bulk density control

www.extruder.nl andritzsprout@andritz.com
AL30O
production of the most
demanding extrudates
• Raw material flexibility
• Nutrient advantages
within aquatic feed and • Optimal product uniformity
High capacity extruders and expanders.
Almex b.v., Verlengde Ooyerhoekseweg 29, 7207 BJ Zutphen GLOBAL PRESENCE pet food industries. • Unique visual appearance

The Netherlands, tel. +31 (0)575 572666, fax +31 (0)575 572727 Denmark · Netherlands · Germany · France · UK · USA www.andritzsprout.com Geelen Counterflow / T +31-475-592315
www.extruder.nl andritzsprout@andritz.com Geelen Counterflow USA Inc. / T +1-772-559-4338
E-mail info@almex.nl, www.almex.nl Venezuela · Brazil · Chile · Mexico · Australia · P.R. China The solution behind the solution. Geelen Counterflow América Latina / T +54-9-2362-418899
E info@geelencounterflow.com / I www.geelencounterflow.com
Almex b.v., Verlengde Ooyerhoekseweg 29, 7207 BJ Zutphen GLOBAL PRESENCE 20 | InternatIonal AquAFeed | March-april 09

The Netherlands, tel. +31 (0)575 572666, fax +31 (0)575 572727 Denmark · Netherlands · Germany · France · UK · USA
E-mail info@almex.nl, www.almex.nl Venezuela · Brazil · Chile · Mexico · Australia · P.R. China IAF0902.indd 21 12/03/2009 10:02
adv 210x297 fc 08.indd 1 13-05-2008 10:34:57
March-april 09 | InternatIonal AquAFeed | 23 IAF0902.indd 4
Aqua_Feed-09.indd 1
12/03/2009 10:04
03.02.2009 15:51:05
22 | InternatIonal AquAFeed | March-april 09 March-april 09 | InternatIonal AquAFeed | 23

IAF0902.indd 23 12/03/2009 10:02

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