Post on 14-Dec-2015
transcript
Raw Materials and Their Impact on the Extrusion of Aqua Feeds
Presented by:
Brian Plattner, PEWenger Manufacturing, Inc.
Recipe Hardware Software Product Specifications
Fundamentals of Extrusion Processing
Raw Materials
Raw materials and their characteristics are always the
most important extrusion variable.
Particle Size Analysis of Typical Aquatic Feeds
20
30
40
50
60
80
Pan
850
600
425
300
250
180
0
1.00
3.00
28.0
29.0
21.0
14.0
4.0
U.S. Standard Sieve
Openings in Microns
Percent on Sieve
Geometric Mean Diameter: 327 Microns
Geometric Standard Deviation: 1.58
Benefits of Proper Particle Size
• Improved product appearance• Reduced incidence of die orifices plugging• Ease of cooking• Reduced product breakage and fines• Increased water stability• Improved retention of liquid coatings due to
small cell structure
Guidelines for Grind of Recipe
• Maximum particle size = 1/3 of die opening• Not to exceed 1.5mm grind
800 micron 1.5 mm
US Sieve Opening (microns)
1.5 mm grind (%)*
425 micron grind (%)**
20 840 0.50
30 590 3.51
40 420 37.75
50 297 40.16 36.75
60 250 10.44 34.31
70 210 5.12 13.60
80 177 3.15
100 149 3.55
140 105 4.37
Pan 2.51 4.26
Particle Size Analysis of Two Grinding Processes of Extruded Feed
*Mean Diameter = 316µm, 66,768 particles/g
**Mean Diameter = 224µm, 519,365 particles/g
Grind Bulk Density (g/l) at Given
Rate
SME (kWh/t) at Given Rate and
Bulk Density
Rate (kg/h) at Given
Bulk Density
1.5 mm 316 46.8 357
425 microns 232 42.3 513
Effect of Grind Size on Extruded Feed Processing on X85 System
Effect of Grind on Floating Aquatic Feed
0
200
400
600
800
1000
1200
1400
1600
1800
2000
0 200 400 600 800 1000 1200
Time (Seconds)
Vis
cosi
ty (
cP)
0
20
40
60
80
100
120
Tem
per
atu
re (
C)
3.5 g solids25 ml water
Temperature
3/64" Grind
2/64" Grind
40 Mesh Grind
Recipe Preparation
1) Grind ingredients to proper particle size2) Weigh individual ingredients3) Particle size and density of each ingredient should be
similar4) Premix by hand the micro-ingredients (anything less than
1% of total recipe) and add a carrier (part of a major ingredient) if necessary to bring premix size up to 3% of total recipe
5) Add major ingredients, then premix (from #4) to mixer and mix 3-5 minutes. Add any liquids slowly and then mix another 3-5 minutes
6) Final grind, if required7) Use sifter and/or magnet to detect and remove foreign
material
PROTEIN
Plant Sources Soy, Legumes, Wheat/corn glutens, cereal grains
• Good functional properties• Lower cost• Amino acid profile may require supplementation
Animal or Marine Sources Meat, Fish, Poultry, Blood, Gelatin
• Poor functional properties unless fresh or spray dried• Higher costs• Good amino acid profile
Vegetable Proteins in Salmon, Trout, and Shrimp Diets
Vegetable ProteinMaximum Substitution for
Fish Meal (%)Disadvantages
Maize Gluten Meal 40Yellow
pigmentation of flesh
Wheat Gluten 25 High Cost
Soybean Meal 50Palatability and
Growth Inhibitors
Soy Concentrate 75 High Cost
Canola Meal 67Low Protein
Content
Hardy (January 1999) Feed Management Magazine
Benefits of Vegetable Proteins in Aquatic Diets
• More expansion potential for floating diets• More binding potential for improved durability• Reduced ingredient costs• Lower incidence of white mineral deposits in screw and die
area• Higher oil absorption levels possible in coating operations• Reduce dependence on fish meal
Effect of Vegetable Protein Levels On Extrusion Moisture
15
17
19
21
23
25
27
29
31
10 15 20 25 30 35 40
Vegetable Proteins in Recipe (%)
Ext
rusi
on
Mo
istu
re (
%)
Soybean Meal Nutrient Level Comparison
Crude Protein (%)
Crude Fiber (%)
Oil (%)
Dehulled
Solvent Extracted
49.0
3.3
1.2
Non-dehulled
Solvent Extracted
44.0
7.0
1.2
Full Fat Soy
37.5
7.4
17.4
Addition of Slurries to Extrusion System
• Maximum particle size not to exceed 1.5 mm• Fish ensilage slurries pumped into DDC • Fat/oil slurries heated to 60°C• Moisture is limiting factor for most slurry
additions• Enzyme treatments reduce viscosity
Wet slurries pumped into DDC preconditioner
and extruder barrel (head #2)
Positive Displacement Wet Slurry Pump System slaved to Dry Recipe Rate
Maximum Wet Slurry Addition to Single Screw Extrusion Systems*
% moisture in wet slurry
Maximum slurry addition
(% of total)
Maximum slurry addition
(% of dry)
% slurry in final dried product
66.7 25.0 33.3 10.9
40.0 41.8 71.8 32.4
50.0 33.4 50.0 21.8
60.0 27.8 38.5 14.6
70.0 23.9 31.4 9.5
80.0 20.9 26.4 5.6
* Maximum moisture addition to Single Screw Systems is 16.7%
Maximum Meat Addition to Twin Screw Extrusion Systems*
% moisture in wet slurry
Maximum slurry addition
(% of total)
Maximum slurry addition
(% of dry)
% slurry in final dried product
66.7 30.0 43.0 13.7
40.0 50.0 100.0 40.0
50.0 40.0 66.7 26.3
60.0 33.3 50.0 18.1
70.0 28.6 40.1 11.8
80.0 25.0 33.3 6.9
* Maximum moisture addition to Twin Screw Systems is 20.0%
• Protein denatures at 60 - 700C• As protein denatures, it becomes insoluble
(non-functional)
• Starch gelatinizes at 55 - 750C• As starch gelatinizes it becomes soluble
STARCH
• Carbohydrate - energy source• Assists expansion• Improves binding and pellet
durability• Found in two forms
Amylose Amylopectin
• 10 - 60 % levels in aquatic food Raw potato starch magnified 450 X
Effect of Extrusion on Starch
• Gelatinizes starch• Improves digestibility in most species• Forms starch-lipid complexes• Increases binding characteristics• Increases susceptibility to enzyme hydrolysis
Recommended Starch Levels in Aquatic Feeds
Type
Floating
Sinking
Minimum Starch (%)
20
10
Starch Content of Common Cereal Grains
Cereal Grain
CornWinter WheatSorghumBarleyOatsUnpolished Rice
% Starch (Dry Basis)
736571604575
Heat of Gelatinization for Various Starches
Starch Source
Heat of Gelatinization (cal / gram)
Amylose Content (%)
Size (microns)
High Amylose Corn
Potato
Tapioca
Wheat
Waxy Corn
7.6
6.6
5.5
4.7
4.7
55
20
22
28
0
5-25
15-121
5-35
1-35
5-25
Minimum Moisture Levels Necessary to Initiate Starch Gelatinization
Wheat
Corn
Waxy Corn
High Amylose Corn
31
31
28
34
Starch Source % Moisture
Lower moistures during extrusion require higher extrusion temperatures to achieve same level of cook.
Rice as a Starch Source
1) Small, tightly packed starch granules that hydrate slowly
2) Becomes sticky when it gelatinizes3) Choose long grain varieties over medium
and short grain varieties as they are much less sticky when cooked
4) Rice is very digestible even when cook values are low
5) Rice bran may contain up to 40% starch
Corn as a Starch Source
1) Good expansion
2) Excellent binding
3) Sticky at high levels (>40%)
Wheat as a Starch Source
1) Good binding
2) Good expansion
3) Can be sticky if overcooked
4) Contains gluten (good binder)
5) Most widely available starch source
6) Often utilized as wheat flour which has most of the bran removed
Tubers as a Starch Source(Potato & Cassava)
1) Excellent binding (at 5% levels)
2) Requires less total starch in diet
3) Good expansion
4) Often precooked
5) Smooth pellet surface
6) Increased cost
Effect of Extrusion on Starch
Process
Raw Recipe
Preconditioner
Extruder
Dryer
% Cook
15.5
31.6
92.8
96.7
Purposes of Fat in Feeds
• Energy Source• Increases Palatability• Provides Essential fatty acids• Carrier for Fat Soluble Vitamins
Fat Sources
• Animal Fat• Poultry Fat• Marine Oils• Blended Animal and Vegetable Fats• Feed Grade Vegetable Fats
Must use FAH (fat acid hydrolysis) method for determining fat levels in extruded products.
Effect of Fat Levels on Product Quality (Single Screw Systems)
<7%
7-12%
12-17%
Above 17%
Little or no effect
For each 1% of Fat Above 7%, the final bulk density will increase 16 g/l
Product will have little or no expansion, but will retain some durability
Final product durability may be poor
Level of Fat in Extruded Mix Effect on Product Quality
Add 5% to above figures for twin screw systems
Effect of Internal Levels of Fat on Expansion of Extruded Feeds
0
5
10
15
% Added
Fat
Bulk Density
(g / l)
256
309
408
533
Internal Fat vs. Pellet Durability
30
35
40
45
50
55
60
65
70
75
6 8 10 12 14 16 18 20 22 24 26 28 30
Internal Fat (%)
Max
imu
m C
om
pre
ssi
ve
Str
ess
(g
/ m
m2
)
To Maximize Fat Inclusion Levels
• Formulate with ingredients high in indigenous fats (example: flax meal)
• Heat fats to 40 - 600C prior to inclusion• Add late in the process• Maintain starch / function protein levels• Increase thermal and/or mechanical energy
inputs• Increase moisture levels during extrusion
Ingredient Moisture
(%)
Protein
(%)
Fat
(%)
Starch
(%)
Fish meal, Menhaden 8.0 62.0 9.8 0.0
Corn gluten meal 8.0 60.0 2.3 0.1
Soy Bean Meal 9.5 49.0 1.2 0.0
Broken rice 10.5 7.1 0.4 68.0
Wheat flour 11.5 12.0 3.0 65.0
Potato Starch 7.5 7.8 4.3 60.0
Fish Silage 75.5 20.6 2.6 0.0
Vitamin & Pigment Retention
Vitamin/Pigment Retention Depends On: Raw material formulation Temperature Moistures Retention times
An average of 10 to 15 percent of vitamins and pigments are lost during extrusion. Compensation is made by overages. Heat stable forms are preferred.
Preservation System Required for Soft Moist Aquatic Feeds
(Final product moisture of 16-28%)
• Lower Aw (water activity) below 0.70 with humectants at 10-12% levels
• Reduce pH to 4.0 - 4.5 with acids at 1-2% levels or with fish silage/solubles
• Add mold inhibitors at 0.2-0.5% levels
Effect of Extrusion on Microbial Populations
Microbe
240,00
22,600
54,540
16,000
positive
negative
9,300
<10
<10
<10
negative
negative
TPC (CFU/g)
Coli form
Mold count
Clostridium
Listeria
Salmonella
Raw Recipe After Extrusion
1
10
100
1000
10000
130 150 170
Tim
e (S
eco
nd
s)
Thermal Plastic SporesE. ColiSalmonellaListeria
70 90 110
Temperature (C)
30 50
Thermal Destruction Studies for Pathogenic Organisms
Effect of Extrusion Temperature on Fumonisin Toxin Levels(Katta, Jackson, Sumner, Hanna, Bullerman, Cereal Chem. 76(1):16-20, 1999)
20
25
30
35
40
45
50
55
60
65
70
140 150 160 170 180 190 200
Extrusion Temperature (C)
Fu
mo
nis
in B
1 R
eco
vere
d (
%)
Effects of Heat Processing on Insect Survival
>62
50-60
45-50
30-35
25-32
Death in less than 1 minute
Death in less than 1 hour
Death in less than 1 day
Max temperature for reproduction
Optimum for development
Feed Management, January 2001, Vol. 52, No. 1, pg 27
Temperature (°C) Effect
After Ripening Factor
Biochemical changes occurring after harvest are influenced by storage time.
By-Products
• Starch / Filler Sources Wheat Bran Wheat Midds (Pollards) Rice Bran
• Protein Sources Co-Products such as DDGS
By-Product Moisture
(%)
Protein
(%)
Fat
(%)
Fiber
(%)
Sorghum DDG 9.5 30.3 12.5 10.7
Dried Brewers Grains
(Barley)9.5 24.0 5.0 15.5
Wheat DDG 7.5 38.5 8.2 6.2
Corn DDG 8.5 32.0 11.0 6.0
By-Products
Effects of Adding Rework to Recipe (5 to 10 percent levels)
• Darker color• Less expansion, higher bulk density• Higher levels of cook• More defined shape
+ Starch
+ Oil (Internal)
+ Fiber
+ Functional Protein
+ Non-Functional Protein
+ Rework
-
+
?
-
+
+
Bulk DensityRECIPE
Product Hardness
Smooth Skin
More Uniform
Better Shape
Definition
+
-
-
+
-
-
+
+
(1)
(2)
+
+
?
+
?
?
?
+
?
+
+
?
+
+
(1) Function of grind and particle size
(2) Large cell structure