Shrimp Feed
Shrimp feed can be produced by two methods, pelleting or extrusion,
depending on the dietary of the shrimp species. For the majority of
the markets in Asia, pelleting solutions are still highly recommended.
This page will give a comprehensive description of the pellet mill
system. If you are interested to know more about the extrusion
process, you can find more in
fish feed solution.
Raw Material
The raw material for shrimp feed consists of coarse and powdery
material
15 Dec(你看不見,這個理論上可以不要加)
Pre-grinding
Optional step for coarse material.
Pre-grinding will lower the
energy needed for ultra-fine grinding.
Daily Tank Storage
In general, the shrimp feed line will utilize 12 raw material bins.
Every bin will be filled with around 5-6 batches of material.
Dosing and Weighing
The material will be dosed based on the formula.
In the shrimp
feed line, usually material will be processed by batch.
Post-grinding
Post-grinding is the final size reduction in the system.
It is common to use a pulverizer for producing ultra-fine powder.
Wet mixing
Water, oil, and other liquid material will be added.
This will help to hydrate the material before the cooking
process.
Pelleting
Pelleting starts with pre-conditioning, adding steam to further
hydrate, and cooking the material before entering the pelleting
chamber to be formed into pellets.
Post-conditioning
Post-conditioning utilizes pellet inner heat added with the heat (by
steam or electrical) to prolong cooking and avoid condensation
inside the chamber.
Drying
In "High Moisture Pelleting", this is a very crucial step to lower
the moisture on the pellets.
Cooling
Cooling utilizes ambient air to cool down the hot pellet from the
post-conditioner (or dryer).
Thorough cooling is needed to prevent condensation inside the
packaging.
Pelleted Feed
Crumbling
Crumbling is needed to reduce pellets' size into smaller particles.
This crumbled feed is needed for the shrimp post-larvae period
Packing
Packing gives protection to the pellets and also give easiness to
handle and transport to customer's hand
Pelleting process description for aquatic feeds
Raw material intake system consisting of tip hopper, mechanical conveyors, and elevators into
storage bins. Raw material such as soybean meal, corn, fish meal, and
other grain or powder is sieved to remove any impurity and metals.
Pre-grind systems are a size
reduction process for raw materials that contain large particulates or
grains by hammer mills. Pre-ground material is conveyed to storage bins.
Storage bins are used for
the temporary storage of raw materials.
Formula batch dosing system weighing hoppers to proportionally weigh dry ingredients by batches
based on every formulation.
The first mixing system is used for dry material mixing to stabilize the following process.
Pulverizer grinding is the
second grinding process that grinds the formulation into finer powder
with fineness up to 80 mesh 95% pass.
Second mixing system
Other sources like pre-mix, liquid, oil, and fat are now added and mixed
with raw material by batches. This is the step where the mixed recipe is
ready.
Pelleting with Pre-conditioning
The mixer feeds down through a feed hopper into the feed screws which
continuously feed the ingredients into the following pre-conditioner
system. The configuration of the pre-conditioner will depend on the type
of ingredient that we produce. A specially designed pellet die and
roller shell with the right compression ratio is set to produce the
compact and tough pellet with higher PDI shrimp feed.
Post-conditioning and drying
This process is designed to prolong pellet cooking by providing a hot
temperature to avoid condensation. Depending on the moisture of the
pelleted feed, a dryer can be incorporated into the production system to
lower the moisture of the pellet to a shelf-stable moisture level.
Cooling
Cooler lowers the temperature of the hot pellets to + 3°C of room
temperature by utilizing the ambient air.
Impurity and dust sieve
All pellets will go through a vibration sieve to remove any irregular
pellets or dust.
Bagging and sealing system
Finished pellets will be placed in bags or other transportation vessels
to the reseller or customer site.
Pellet crumbling system
Pellets are conveyed into storage bins before either being packaged or
being turned into crumble in the crumbling machine. Pellets can be
processed by crumblers to produce smaller pellets as No.1, No.2, and
No.3 products. (Sizes between 20 to 60 mesh) Fines will be recycled to
the pellet mill section for re-use and undesired bigger pellets that
pass through the sieve will be re-crumbled again.
Features and Benefits of IDAH Process Design and Equipment
IDAH firmly believes in a strategy of design fit for purpose. We
recognize the constraints our customers face with rising ingredient
costs, energy costs, and overheads costs, yet in the face of these
challenges, it is still expected that high-quality products be supplied
into a very competitive market. Our design philosophy is to work
continuously to refine and improve processes and equipment to maximize
the success of our customers. The following describes some of the
features and benefits resulting from this philosophy.
Rugged 24/7 Design
We design our equipment for continuous operations and fulfill the
expectation for minimal downtime. Our mission is to see our equipment
still working years after installation, with only maintenance required
being routine maintenance caused by normal fair wear and tear.
Formulation
Two perspectives are influencing the formulation: culturing performances
and efficiency of the machinery. For example, choosing the right starch
source (types of flour) is essential. Inappropriate starch sources will
lower the steam incorporation level and causes jams at the pellet mills.
Fat and moisture content play inseparable roles in the hammer mill and
pulverizer throughput. Formulation with high fiber content not only
increases the risk of broken pellets, lowering the water stability of
the pellets. High fiber content also increases the wear of all machinery
in the process. Reducing the use-life of the parts such as the hammers,
screens, and dies.
Two-Stage Grinding and Pulverizing
We firmly believe in the benefit of even particle reduction to
ultra-fine powder. The typical target is to reach more than 95% passing
through a 60 mesh screen. It is impossible to efficiently produce
small-size products with size 2.0 mm and below without this ultra-fine
grind process. Ultra-fine grinding will increase production efficiency
and end product quality during the production of larger-size products.
It will also open the possibility to utilize less expensive starchy
ingredients. IDAH understands that many production practitioners might
worry about the extra energy cost of utilizing a pulverizer, which is
why we designed a revolutionary pulverizer that runs at much lower
energy costs. The ability to substitute with cheaper ingredients cost
will compensate for the small extra energy requirement of the
pulverizer. The ultra-fine raw material will produce smooth, shiny, and
water-stable products.
Pre-hydration
We always recommend the pre-hydration in pre-pelleting mixers. The
hydration of dry ingredients at this production stage improves the
throughput, lowers energy costs, and increases product quality. To
evenly feed the pre-hydrated mix to the pellet mill, we supply an
activated semi-cylindrical hopper system, with slowly rotating paddles.
Pre-conditioning
The independent drive on each shaft of the IDAH twin shaft lowers power
consumption and noise. The paddles' reverse rotation allows completely
emptying the chamber. The misting steam and water injectors further
improve conditioner performance. The following conditioner system used
steam jacketed (or heat jacketed) to create a homogenous mix with little
to no free water. Insufficient pre-conditioning will cause cracks on the
pellet surface and create dust fines.
Pellet Milling Shrimp Feed
IDAH pellet mills are born from years of experience and continuous
improvements to ensure high production efficiency at the lowest cost.
IDAH has standardized the pellet die and the roller shell for aqua feed
production. The compression ratio of our pellet die is specially
designed to ensure compact and tough pellets with higher PDI. The roller
shells are designed individually for each different hole size. IDAH has
been producing machinery for aqua feed since 1974. IDAH pellet mill is
well-known because we consider the design of conditioning. The “High The
moisture Pelleting” method can be achieved through our advanced
pre-conditioning technology. Careful control in the incorporation of
heat, moisture, and time provides sufficient cooking for the production
of premium quality feeds with good water stability to the market. In
addition to altering the product quality, sufficient pre-conditioning
also reduces wear out of the parts.
Post-conditioning
IDAH Post-conditioner was proposed and invented by IDAH in the 1970s and
has since become a standard in pellet mill systems in Asia.
Post-conditioning is the most effective and economic method to achieve
high-quality pellets. The quality of the pellets is determined by how
well the water stability and the nutrient retention when pellets are fed
to the water.
Drying
The latest design of the post-conditioner system is composed of a
KB-series conditioning cooker and a T-series dryer. In the
post-conditioning system, the hot pellets enter the steam- or
electrical-heated retention chamber to keep material in a
high-temperature environment and prevent condensation inside the
post-conditioner. This step ensures optimum starch cooking on a
considerable proportion of starch contained in the shrimp feed for
improving pellet quality (hardness and durability) and water stability.
The next step is the drying process where products tumble through
multiple decks at thin bed depth. Air circulation and rotating screens
inside the T-series dryer are exclusively designed based on shrimp feed
properties which ensure pellets are made without cracks, with fewer
fines, high water stability, and smoother surface.
Cooling
The counterflow cooler is used for cooling pellet and extrudate. Warm
(hot) pellets get into the cooling chamber, the suction fan will
transport out the air inside the chamber, and fresh ambient air will
enter the chamber from the bottom, promoting pellet cooling action. When
pellets are accumulated and touch the high-level limit sensor, a
pneumatic discharge swivel valve will operate immediately to discharge
the products. Counterflow air heat exchange ensures to achieve high
cooling efficiency.
Crumbling
IDAH crumbler series is designed for high capacity and highly efficient
particle reduction. Three types are available for every industry
application. Every crumbler is equipped with the feeder on the top, to
control the throughput of the product. The roll gap is easily adjustable
to achieve the required granulation.
Specification of Pellet Mills (for Shrimp feed)
Model |
PM-42SA |
PM-51SA |
PM-53SA |
PM-53F |
PM-635D |
Main Motor (HP) |
100 |
150 |
200 |
215 |
300 |
Operation Capacity1 (t/h) |
1.3-1.5 |
2.3-25 |
3.0-3.5 |
3.5-4.0 |
4.5-5.0 |
Operation Capacity2 (t/h) |
3.0-4.0 |
4.0-5.0 |
5.0-6.0 |
6.0-8.0 |
9.0-10.0 |
Note:
1) Shrimp Feed, pellet die hole size Ø 2.0 mm
2) Sinking Fish Feed, pellet die hole
size Ø 3.0 mm