Increasing Aquatic Feed Production Through Plant Audits “Aquafeed Horizons”
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Increasing Aquatic Feed Production Through Plant Audits “Aquafeed Horizons”
Transcript of Increasing Aquatic Feed Production Through Plant Audits “Aquafeed Horizons”
Increasing Aquatic Feed Production Through Plant Audits
“Aquafeed Horizons”
What is the Global Seafood Market?
1) Estimated at more than US$ 100 billion per year (130 million ton)
2) 30% of seafood production is from aquaculture
3) World demand is expected to increase by up to 3% per year
4) Fresh water aquaculture accounts for 58% of output
5) Marine aquaculture accounts for 42% of output
Where is Aquaculture Conducted?
Global Region Seafood Production (million tons)
Asia 37.0
Europe 2.0
Americas 1.2
Africa 0.3
Extruder barrel
DDC Preconditioner
Live bin
Feeder system
Extruder Cut-A-Way
Factors That Potentially Limit Capacity of Extruders
1) Preconditioning capacity
2) Available power to the extruder
3) Volumetric capacity of extruder
4) Open area in die
5) Down time and Usable Product
6) Upstream/down stream processing
Extrusion Line Audit
STARCH GELATINIZATION
DURING PRECONDITIONING
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24681012141618200
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Sta
rch
Gel
atin
izat
ion
(%)
Retention Time (sec)
Steam Flow Rate (% of Total)
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0 20 40 60 80 100 120 140 160 180 200 220 240 260
Retention Time (seconds)
Sta
rch
Gel
atin
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tion
(%
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20 % Moisture
25% Moisture
Influence of Time and Moisture on Starch Gelatinization in DDC Preconditioners
Comparison of Methods for Determination of Starch Gelatinization
1) DSC uses a 20mg sample versus 500mg in enzyme method
2) DSC requires pure starch source and a raw sample for accurate sample analysis
3) DSC method gives inflated values compared to enzymatic method used by most cereal chemists
4) DSC method has poor correlation to digestibility
Method of determining %
cook
Starch Gelatinization
(%)
DSC method 57.8
Enzyme Susceptibility method used by Wenger
40.0
To Increase Preconditioning Capacity1) Increase preconditioner size
2) Increase existing preconditioner fill by adjusting beater configuration
3) Add Retention Time Control System (RTC)
4) Increase energy inputs in extruder
Extrusion Line Audit
Adjust beater configuration to increase preconditioner fill
Benefits of RTC(Retention Time Control)Preconditioning
1) Instant display and control of retention time to produce desired product quality
2) Constant rate discharge of feed upon shut down to increase usable product
3) Reduce waste and off-spec product during startup
4) Significant potential reduction in steam usage to produce equivalent product
5) Time/temperature documentation
6) Increase retention time of existing preconditioner
1500 liter DDC Preconditioner Retention Time Control Performance Specification
20% Fill Factor
187 kg
80% Fill Factor
748 kg
40% Fill Factor
374 kg
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Capacity (kg/h)
Ret
enti
on
Tim
e (m
in)
EXTRUSION SYSTEM ENERGY
INPUTS
Factors That Potentially Limit Capacity of Extruders
1) Preconditioning capacity
2) Available power to the extruder
3) Volumetric capacity of extruder
4) Open area in die
5) Down time and usable product
6) Upstream/down stream processing
Extrusion Line Audit
1) Install larger motor (more available kW)2) Check with extruder manufacturer on design limitations3) Factor in effects of improved preconditioning and other process improvements
Increasing Power to Drive Extruder
Extrusion Line Audit
Factors That Potentially Limit Capacity of Extruders
1) Preconditioning capacity
2) Available power to the extruder
3) Volumetric capacity of extruder
4) Open area in die
5) Down time and usable product
6) Upstream/down stream processing
Extrusion Line Audit
Increase Volumetric Capacity of Extruders
1) Larger extruder screw diameter
2) Increase extruder shaft speed
3) New inlet screw designs with more conveying volume
4) Grooved barrel liners
5) Control of extruder barrel temperatures
Factors That Potentially Limit Capacity of Extruders
1) Preconditioning capacity
2) Available power to the extruder
3) Volumetric capacity of extruder
4) Open area in die
5) Down time and usable product
6) Upstream/down stream processing
Extrusion Line Audit
Increasing open area of die orifices
1) Use wear plate assemblies
2) Flare-out to larger die plates
Move to die designs that permit more die orifices on a given surface area
Insert die holder Wear plates assembly
Factors That Potentially Limit Capacity of Extruders
1) Preconditioning capacity
2) Available power to the extruder
3) Volumetric capacity of extruder
4) Open area in die
5) Down time and usable product
6) Upstream/down stream processing
Extrusion Line Audit
Down-Time
1) Plants that believe they operate 24/7 may still have 20% down time annually
2) Example: 10 ton/hr system down for 30 minutes is 5 ton of lost production
3) Increase average capacity especially with short production runs
To Reduce Down-Time
1) Scheduling2) Hardware tools for “quick-change”3) Control or software systems that compress
shutdown and startup times4) Operator training and experience5) Preventative maintenance6) New hardware design technologies (that allow easy access for maintenance and
sanitation)
Increase Usable Product (decrease off-spec material)
1) Automated Retention Time Control in DDC preconditioner
2) Screw element and liner designs to give positive conveyance
3) High extruder speeds and variable-speed drives4) Automated control systems (SME, fat, etc.)5) Warm-restart control systems compress startup
time to less than 1 minute 6) Operator experience and training7) Gentle product handling8) Systems to recycle under-processed material
Factors That Potentially Limit Capacity of Extruders
1) Preconditioning capacity
2) Available power to the extruder
3) Volumetric capacity of extruder
4) Open area in die
5) Down time and usable product
6) Upstream/down stream processing
Extrusion Line Audit
Grinding, sifting, storage, conveying, drying, cooling, coating, and packaging are all unit operations that must
be sized properly to avoid a flow bottleneck!
Eliminating the bottlenecks can result in a 50% increase in annual throughputs for a given line!
1) Preconditioning capacity
2) Available power to the extruder
3) Volumetric capacity of extruder
4) Open area in die
5) Down time and usable product
6) Upstream/down stream processing
Extrusion Line Audit
“Aquafeed Horizons” WORKSHOP
