News Solution for extrusion aquafeed production Muyang Group

April 2011,Vol.4,No.2
View
Integrated Solution Provider
Solution for extrusion
aquafeed production
Muyang Group:Continually
improving products and
services
Energy efficiency improving &
pellet uniformity control in the
extrusion of aquafeed

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7
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News
Solution for extrusion
aquafeed production
Muyang Group:
Continually improving
products and services
Energy efficiency
improving & pellet
uniformity control in the
extrusion of aquafeed
Events
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NEWS
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Muyang in
VIV Asia
Trade shows review:
Muyang in a new developed stand
In the first season of 2011, from IPE (International Poultry Expo) 2011 in Atlanta to “Complete
Feed” in Moscow and VIV Asia in Bangkok, Muyang has been activated in most of international
events in the industry.
With the novel designed booth, the well-made products and latest technologies that displayed,
and most of all, the complete solution team made up of professional sale managers and technicians
from feed machinery, grain handling and storage, steel structure building, project engineering sectors,
Muyang was clearly visible in the trade shows, and impressed a lot o f visitors and local customers.
In a new developed stand, Muyang will participate in the upcoming events with a more active
attitude, and hope for more global customers who can enjoy our complete and quality solutions.

Cooperation between
Sunwind and Muyang
Muyang enters farm machinery distribution business
On Jan. 19, 2011, Muyang held a grand opening
celebration for its first farm machinery distribution store
in Gaoyou City, Yangzhou prefecture, China. Through its
subsidiary, Mufeng Farm Machinery Ltd, Muyang has
diversified and expanded its business into a new field.
Covering over 2,000m 2 , the Gaoyou-based farm
machinery distribution store, will be the first 4S farm
machinery distribution store which integrates sale, spare
part, service and survey of farm machines such as tractors,
harvesters, rice transplanters and other relative equipment
for farmers in Yangzhou region.
Shaanxi Province to add a state-of-the-art sustainable
feed mill complex
Sunwind, the Sichuan-based feed manufacturing giant in China and an integration
of feed manufacturing, food processing, animal farming as well as additives and animal
health care products, had announced
to build its 12 th feed mill in Shaanxi
Province at the end of 2010.
With an annual capacity of
360,000 tons, the feed mill complex
will be able to produce concentrate
feed, poultry & livestock pellet
feed and extrusion aquafeed in a
sustainable manner. Once built,
it will greatly increase Sunwind’s
market share in the Northwest
region of China.
Muyang had been contracted to
deliver the turnkey project with the
most modern technology and energy
efficiency solution as well as CSR
consideration.
The competitive edges of the feed mill will be the MUZL610TW pellet mill
(specialized for poultry & livestock feed), the MY120*2I twin-screw extruder (upgraded
for energy efficiency in aquafeed production), the latest generation of Muyang
hammermill and pulverizer (with grinding efficiency increased by 20%) and the MYCOS
automation system. With the optimal integrated solution provided by Muyang, the
power consumption per ton of feed will be decreased by 10-20%.
Mufeng Farm
Machinery
Gaoyou Store
With the strong financial support, solid R&D technology, advanced
sale and management system as well as quality service character of
Muyang Group, Mufeng Farm Machinery Ltd is aim to develop rapidly
by expanding the distribution store chain national wide to meet the
ever changing needs of farmers in China and grow to be the “Wal-Mart”
in the field of farm machinery distribution.
Signing ceremony of
JV agreement between
Muyang and WEM
Muyang and WEM create a JV
It is reported that Muyang Group had signed an
agreement with the Wisconsin-based WEM Automation
International, LLC. on March, 2011, to create a joint
venture --- Muyang-WEM Automation Co., Ltd.
According to the Agreement, Muyang holds 51
percent of the shares in the joint venture and shall take the charge of operating the new company. The
joint venture will be located in the Hanjiang Economic Zone, Yangzhou, China. The completion of the
transaction is expected to occur in approximately the next 6 months following the execution of final
agreements. Both companies are highly satisfied and looking forward to achieve the envisioned global
growth targets together.
Product scope
The JV will be devoted to developing, manufacturing, marketing and selling computer automatic
control system and electric equipment for the machinery and engineering in the fields of feed, grain, food
processing and storage.
About the partners
Muyang Group is a global leading integrated solution provider in the fields of feed manufacturing,
grain milling, environment protection, food processing, bulk solids handling and storage, steel structure
building as well as industrial automation. Headquartered in Yangzhou, China, the Group is active in over
80 countries and regions and has 2,500 employees worldwide.
WEM, since its founding in 1995, is recognized around the world as the leading supplier of control
systems for feed and grain, ethanol, aggregate, concrete, asphalt, food, pet food, wood processing and
other industries.
EU to allow feed imports with 0.1% GM material
NFU Scotland has welcomed new EU measures which will allow EU Member States to accept shipments of
animal feed materials which include traces of not yet EU-approved GM material up to 0.1%.
The measures agreed upon by the EU’s Standing Committee on the Food Chain and Animal Health are
intended stop shipments of feed material imported from third countries into the EU market from being turned
back because of minute quantities of not-yet-approved GM grain. Previously, a zero-tolerance policy was in place.
“Until now, Europe’s zero-tolerance approach had restricted feed imports from countries where new GM crops
are widely grown, most notably in Argentina, Brazil and the United States,” said Peter Loggie, NFU Scotland’s
pigs and poultry policy manager. “Even with thorough cleaning of the boats used for transporting materials, it
is almost impossible to avoid trace contamination. Given that the EU needs to import almost 80% of its protein
requirements for livestock from those countries, it is no wonder that UK farming unions have
campaigned for years to introduce a low level of tolerance.”
Still, the NFUS said it remains to be seen whether the new measure will make a difference in
import costs. “The percentage is a step in the right direction, but could still prove too low as the
rocketing cost of shipping feed material from these countries and the bureaucratic hassle that
entails when shipments are rejected has meant that third countries have begun developing markets
elsewhere, largely in Asia, where livestock production is growing and where the process of gaining
approval for new GM varieties is more rapid than the EU system,” said Loggie.
World Feed Panorama:
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NEWS

Alaska Commercial Salmon Harvest Forecast
The Alaska Department of Fish and Game announces that the statewide commercial salmon
harvest for 2011 is forecast to total 203 million salmon of all species.
This would be the fifth largest total harvest, and fourth
highest pink salmon harvest, since Alaska became a state and
took over the management of its fisheries in 1960. All major
pink salmon producing areas are expected to produce abundant
harvests. Statewide sockeye and chum salmon are also expected to generate
excellent harvests, with chum salmon predicted to provide the fifth largest harvest since 1960.
The 2011 harvest forecasts for the other four salmon species are 45.1 million sockeye
salmon, 4.7 million coho salmon, 133.7 million pink salmon, and 19.2 million chum salmon.
VIV Asia meeting highlights alternative feed ingredients
With grain prices soaring, the potential for using alternative ingredients to manage feed costs was
discussed at an important meeting during the VIV Asia show in Bangkok, Thailand.
A theme of future trends in animal feeds had been chosen for the Feedtech-Croptech Asia 2011
Conference held 9 March, by VNU in association with WATT.
Within that theme, the presentations by guest speakers Dr. Budi
Tangendjaja (U.S. Grains Council) and Dr. Chinnadurai Sugumar
(Kemin Industries) focused firmly on whether agricultural co-products
or other crop products might be used instead of conventional energy
and protein sources in Asian feeds for poultry and pig.
Alternative ingredients offer more options and therefore more control over the future when supplies
of the main grains or proteins may be limited, these presenters pointed out.
Japan Earthquake Could Impact Grain
Trade
The US Grains Council received initial reports that
the earthquake and subsequent tsunami may have caused
significant damage to many of Japan’s agricultural facilities
and production areas. While the extent of the damage is not yet
known, it will likely impact grain trade.
“Some ports in northern Japan, Kushiro, Hachinohe,
Ishinomaki and Kashima, were hit by the tsunami. We’ve
heard some feed mills and livestock operations have also been
damaged by the tsunami. Those facilities were not severely
damaged by the earthquake itself but were affected by the
tsunami,” said Tommy Hamamoto, USGC director in Japan.
“It is too early to tell what effect this will have on Japan’s
agricultural sector, but it could be of significance.”
Driven by the increasing
consumption of fish meat
due to world population
boom and the limitation of wild
catch, volume growth rate of global
aquaculture has been sustained at
about 8% over the last 10 years,
and must continuously undergo a
tremendous development in order
to fill the huge gap between supply
and demand for the premier protein
sources. This represents a divine
opportunity and a promising future for
the aquafeed industry.
The unique physiology of
aquatic animal is asking for
special requirements in aquafeed
manufacturing technology. This article
will discuss the complete solution for
aquafeed manufacturing based on
Muyang’s years of experience as an
aquafeed mill supplier and builder in
such aquaculture regions as Asia, Latin
America, etc.
PROJECT
Solution for
extrusion aquafeed
production
1. Requirements of
aquafeed
1) Grinding fineness: Proper
particle size of ground materials
can contribute to lower energy
consumption of a feed mill, facilitate
the subsequent conditioning process,
increase the water stability of aquafeed
pellets, and eventually obtain
nutritional aquafeed that benefits the
digestibility of aquatic animals.
2) Size of feed pellet: It is
depending on the size of aquatic animal
to be fed and its feeding habits.
3) Water stability: 45~90 min for
shrimp feed and 5~30 min for common
fish feed.
4) Floating / Sinking ability:
Different aquatic animal species live
in different depths of water (shallow
water, middle water and deep water)
and different habitats. Therefore,
the feed for different aquatic animals
should be sustainable in corresponding
By Zheng Zhenhua
(Project design center of Muyang I.B.D)
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depths.
5) Palatability: Most of aquatic
animals favor feed of special color,
scent and flavor.
2. Aquafeed processing
technology and
equipment
Both pelleting process and
extrusion process are adaptable
to aquafeed production. As the
development of aquaculture, however,
feed extrusion technology i s
more and more popular in
the aquafeed production
because of its wellbalanced

Fig 1 Process flow
of aquafeed feed
production
nutrition, the excellent water stability,
and most of all, the environment
friendliness. Usually, the common
(pre-grinding) aquafeed extrusion
process flow is as Fig 1.
2.1 Raw material receiving
and cleaning
The designed capacity for raw
material intake in an aquafeed mill
shall be 2~3 times of its production
capacity. For materials of different
properties, special cleaning operation
should be carried out where it is
received. For instance, granular
materials can be cleaned with a
Muyang Drum Precleaner and the
powdery materials with a Muyang
Conical Precleaner, under the assistant
of an aspiration system.
2.2 Primary grinding
As the pretreatment of finegrinding
or ultra-fine grinding in
aquafeed production, primary grinding
(or coarse grinding) is designed to
diminish the difference in and the
variation of material particle size, to
improve the working performance and
working efficiency of the pulverizer
thereof, and to ensure constant quality
of finished products.
2.3 Primary proportioning
and batch mixing
In such processing section, the
major ingredients, i.e. the ingredients
of larger proportion in aquafeed
formulation, are batched by an
electronically controlled proportioning
system, and then sent to the mixer for
primary mixing. Primary proportioning
and batch mixing are designed to
limit the variation of material particle
size before ultra-fine grinding, so as
to further ensure constant quality of
finished product. The proportioning
bins in this process section should be
designed to have a storage capacity to
sustain the 4~6 hours’ uninterrupted
production of subsequent process.
2.4 Secondary grinding
Eating little, short digestive tract as
well as bad digestibility of the aquatic
animals require finely ground feed
particles. See Table 1, Standard of
grinding fineness for different aquafeed
in China.
Table 1 Grinding fineness standard for different aquafeed in China
No. Aquafeed variety Grinding fineness standard
1 Adult carp 30-50 mesh
2 Young carp 50-80 mesh
Eel About 90-95% of ingredients for eel feed is required to be finely ground.
3
White eel larva With at less 98% ground particles passing through the 100 mesh screen
Black eel larva With at less 98% ground particles passing through the 80 mesh screen
Adult eel With at less 98% ground particles passing through the 60 mesh screen
Turtle
Receiving
Primary
grinding
Primary proportionaing
& batch mixing
Turtle starter With at less 95% ground particles passing through the 120 mesh screen
4
Yong turtle With at less 95% ground particles passing through the 100 mesh screen
Adult or parent
turtle
With at less 95% ground particles passing through the 80 mesh screen
5 Prawn With at less 90% ground particles passing through the 60 mesh screen
Secondary
grinding
Secondary grinding usually is
executed by a specialized pulverizer
(ultra-fine grinding) or a fine-grinding
hammermill in Muyang solutions.
2.5 Secondary
proportioning and batch
mixing
The finely ground ingredients are
fed into the other mixer for secondary
batch mixing after proportioning.
Usually, a manual feeding inlet is
provided for adding micro ingredients
into the secondary mixing mixer. And
also two liquid application devices
are furnished for adding water and oil
respectively.
2.6 Extrusion and drying
1) Conditioning
Preconditioning is used to properly
condition the material before the
follow-up extruder cooking stage so
as to supplies the extruder with a
uniformly mixed and hydrated material
by mechanical stirring and adding
saturated steam. Under the turning
and blending efforts of conditioner
paddles, the moisture content of mash
is uniform and the temperature is
steady eventually.
Conditioning brings such
advantages for extrusion as follows
(see Table 2).
2) Extrusion
Extrusion process is mainly
executed by an extruder that is
basically composed of a stationary
barrel housing in which such elements
as segmented screws and shearlocks
rotates, fulfilling extrusion operation
together with a disc and knife assembly.
There are two kinds of extruders that
might be used in aquafeed production:
Secondary
grinding
Table 2 Advantages of conditioning process
shelled turtle and young fish. For other
special aquafeed production like the
Precooking feed mash
Precooked feed mash benefits to decrease extruding
intensity of extruder screw, which preventing amino acid production of micro aquafeed (pellet
and protein of fish meal from damage.
size: Φ0.8~1.5mm), oil-rich aquafeed
Reduced wear of extruding
Since the moisture content of preconditioned feed mash is
uniform, its abrasion effect on screw and liner of extruder
and the aquafeeds with changeable
formulas, the twin screw extruder is of
parts and increased production is eased. And the precooked feed mash also contributes
capacity
to lighten extrusion action, thus reaching the target of
improving production capacity and saving spear parts cost.
genuine differentiation.
Refer to Table 3 for the differences
Widened extrusion
applicability
Conditioning treatment enables the extrusion technology
adapt to a large variety of feed formulations.
between single-screw extruder and
twin-screw extruder (co-rotation
Treated under the atmospheric pressure inside the longtime–high-temperature
conditioner, the odor of feed mash screws) with the same capacity.
Improved palatability is volatilized, and the gelatinized grain starch gives the
product a distinctive scent, which contribute to improved
feed palatability.
3) Drying
Once the product leaves the
extrusion system, a drying step is
the single-screw extruder and the twin- of its low equipment cost and high required to remove the excess water
screw extruder.
production efficiency.
and return the product back to a
shelf-stable moisture condition. It is
Single-screw extruder: As its Twin-screw extruder: The twin- recommended to apply a crossflow
name implies, a single-screw extruder screw extruder is characterized by its dryer for drying wet extrudates, in
has only one extruding screw and wide adaptability, sliding conveying in which moisture and heat of product
is of simple structure, so its price is the barrel and self-cleaning function, is exchanged with a perpendicular
relatively lower. Since it has been etc. However, it is relatively expensive airflow.
applied in aquafeed manufacturing due to the high primary investment
for over 40 years, the single-screw and operation and maintenance costs. 2.7 Coating and cooling
extruding technology becomes Therefore, the twin-screw extruder is If necessary, liquid fats, flavors,
mature, and the working performance usually applied in the production of and vitamins can be added externally
is relative stable and reliable. petfood and feed for high value-added to extruded feeds after drying. Post
Traditionally, single-screw extruders
are widely used for producing
aquatic animals such as eels, soft- liquid application by coating will not
the feeds for low protein adult
fishes such as tilapia, catfish
fish, grass carp, etc. Besides, Item
Table 3 Single-screw extruder VS. Twin-screw extruder (co-rotation)
Twin-screw extruder (Co-
Single-screw extruder
rotation)
for the cultivation of different
fish species in lake, the
grinding fineness of feed only
Conveying manner
Self-cleaning function
Feed mash is conveyed forward by
friction
Unavailable
Feed mash is forced to slid
forward
Excellent self-cleaning
performance
requires that 95% of ground Running Stable and occasional blockage Stable and reliable
particles should pass through
the screen of 30~50 mesh,
which can be achieved by a
Heat distribution of
feed mash
Ingredient
adaptability
Non-uniform
Common
Uniform
Wider (incl. ingredient rich of
moisture and fat)
common grinding process
without ultra-fine grinding.
Moisture content of
ingredient
10%~30% 5~95%
In such case, the advantages
Product variety Limited Various
of a single-screw extruder are
Machine price Relatively cheap Expensive
obvious and superb, because Capacity Common Relatively high
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Extrusion
& Dying
Coating
& Cooling
Bagging
PROJECT

Solution Reference
Muyang extrusion aquafeed
milling solution for CITICO
Feed
only avoid the risk of damaging heat sensitive ingredients, but also improve the
palatability and reduce powder generation generation of the finished product. product. After coating,
extruded aquafeed is is cooled as required.
2.8 Bagging
When bagging aquafeed, the amount of air entrained in the bag or that
penetrating into the bag should be controlled to a minimum, so as to prevent
feed from oxidation and deterioration. Therefore, Therefore, it is is recommended to close the
bag through sewing plus heat sealing (plastic film lining), which can prolong the
shelf life of finished product by 50~100%.
3. Conclusion
Aquafeed production solutions are different from case to case. They should be tailor-made on
the basis of a good understanding of the customers’ needs, the local market’s requirements and
the aquatic animals to be cultivated. The equipment and process applied for an aquafeed mill
shall be optimized by considering the long-term sustainable profitability.
Following are the solution details of a
classical floating fish feed production line that
Muyang provided to CITICO Feed in Sichuan
Province, China. As a full-line aquafeed mill,
the plant also includes three pelleting lines (one
preserved for further expansion). The feed mill
is a turnkey project delivered by Muyang Group.
Flow diagram for a full line aquafeed mill
Technical requirements of the
extrusion line:
1. Floating fish feed, 4t/h
2. Proportioning accuracy: static 0.1%FS,
dynamic 0.3% FS
3. Mixing homogeneity: CV≤7%
4. Dust concentration: ≤10 mg/m 3
5. Noise level of central control room: ≤75dB(A)
6. Plant automation system: computer control
system
Ⅰ Process Equipment / Mechanical
1. Intake/Cleaning
Bag intake (warehouse, 2500m 2 ), conveyor
(2×32m 3 /h), elevator(2×35m 3 /h), cleaner (20t/h for
granular material and 15t/h for powdery material),
aspiration dusting(2×2160~4320m 3 /h+1×675~1350
m 3 /h)
2. Primary grinding
Muyang SFSP112×30 Hammermill, 1 set, 75kW,
Φ2.0mm, 30-40 mesh, 10-15t/h
Muyang SFSP132×36 Hammermill, 1 set, 75kW,
Φ2.0mm, 30-40 mesh, 10-15t/h
3. Primary proportioning / mixing
Muyang LCS Proportioning System, 1000kg+500kg,
1t/batch, 15 batches/h, static accuracy: 0.1%FS,
dynamic accuracy: 0.3% FS
Muyang SLHSJ2.0A Twin-shaft Paddle Mixer, 1 set,
1t/batch, 15 batches/h, CV≤5%
4. Secondary grinding
Muyang SWFP66X80A Fine-grinding Hammermill, 1
set, 90kW, Φ1.2mm, 40-60 mesh, 7t/h
Muyang SWFL110B Ultra-fine Pulverizer, 1set,
110kW, without screen,80 mesh, 3t/h
5. Secondary proportioning / mixing
Muyang LCS Proportioning System, 1000kg, 1t/
batch, 15 batches/h, static accuracy: 0.1%FS, dynamic
accuracy: 0.3% FS
Muyang SLHSJ2.0A Twin-shaft Paddle Mixer, 1 set,
1t/batch, 15 batches/h, CV≤5%
6. Extrusion
Muyang MY165E Single-screw Extruder, 1set, 160kW,
4t/h, starch gelatinization:98%, expansion ratio:1.5-1.8
7. Dryer
Muyang SKGD2000-4ZP Crossflow Dryer, 1 set, 4t/h,
H2O%:11%
8. Coating
Muyang SYPL15A Continuous Liquid Coater, 1set,
4.5t/h, coating rate: 0.5~0.6%, H2O%:11%
9. Cooling
Muyang SLNF19×19A Counterflow Cooler, 1 set, 10t/
h, H2O%:10%, floating rate:100%
10. Bagging
Muyang LCS-50-BZ Automatic Bagging Machine, 1set,
300-400 bags/h, static accuracy: 0.1%FS
11. Plant automation system
Plant control software MYCos + PLC + Control center
12. Mechanical
Incl. spouting elements, aspiration ducting,
miscellaneous, installation material, bins storage,
accessories
Ⅱ Facilities
Steel structure buildings (warehouse + workshop
tower)+ storage silo (not required for this project, but
available)
Ⅲ Services
PROJECT
Project engineering, mechanical and electrical
installation, commissioning, supervision, customer
training, etc.
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FEATURES
in the areas of Asia and South America, the
The first reason is our idea to “create value
for customers and make our staff dreams
come true”. Taking this as a guide, we have
set up many agencies, offices, liaison offices
and service centers in tens of countries over
the past few years, so that we can get nearer
to our customers, and offer better and faster
feed processing industry is developing rapidly,
especially the Chinese, Indian and Brazilian
markets, which means that the integrated
enterprises in those markets are showing
more concerns to advanced feed processing
equipment. Despite a relatively developed feed
processing industry, the Western Europe and
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Muyang Group:
Continually
improving
products
and services
LIU Guangdao
the president
of Muyang
International
Business Division
As the most famous feed mechanical equipment and project
supplier in China, Muyang Group will start to construct its Sci-Tech
Industrial Park in 2011. This project is designed to be a state-of–
the–art production and experimental complex for feed machinery,
biomass equipment, agricultural machinery and food machinery.
Mr. Liu Guangdao, the president of Muyang International
Business Division, recently spoke with International Animal
Husbandry China about this project and the future direction for
Muyang Group’s development.
IAHC (short for International Animal
Husbandry China): As we know, Muyang
Group is going to start the construction
of the Sci-Tech Industrial Park this year,
what is your main purpose for this largescale
investment?
LIU: We hope that we can use this project
to offer better and faster service to more
global customers. We are using a lot of new
technologies, new process and new materials
in the construction of this Sci-Tech Industrial
park, hopefully these new technologies can
help us to improve our production process,
upgrade production equipment, and make us
more professional at every single point of the
production process. Thus, we can fulfill the goal
to offer a full range of products to our customers
and, in turn, we can meet all the requirements
of customers all around the world.
IAHC: Once this project is completed,
what will it signify for Muyang Group?
LIU: This Sci-Tech Industrial Park will
greatly upgrade our technological innovative
capabilities, which is precisely the strongest
drive for Muyang’s sustainable development.
Besides, once this park is built, it will become
the most modern production base for feed, grain
and food machines in the world. This will help
in making our products more competitive in the
global market.
IAHC: Your products have been sold
to many countries in the world, and the
company’s development has been quite
rapid. What do you think have been the
main factors for this rapid development
in your process of globalization?
LIU: Yes, we have had a rapid development
in the global market. Since we first entered
the global market in 1998, we have sold our
products in over 80 countries around the world.
I think there are several reasons for this.
services to them. Meanwhile, we provide many
opportunities for the development of our staff,
who can really make their dreams come true.
Our staff’s hard work greatly promotes the
globalization process of Muyang Group.
Secondly, Muyang Group pays a lot of
attention to technical innovation. We invest
significant amounts of capital in the research
and development of new products and process,
and continue to import advanced processing and
quality control devices to upgrade our industrial
structure. On this basis, we have been raising
the production and innovation efficiency, and
we are able to keep offering our customers with
efficient and quality equipments and projects.
The last reason is that we did a lot to
develop multi-services and offer our customers
integrated solutions, which includes the
designing, production, installation and afterservice
of processing/storage equipment. This is
also known as our“One-Stop” service, and it has
attracted a lot of global customers for us.
IAHC: Regarding the market and
customers, which areas in the world do
you think are of a growth potential for
the feed industry?
LIU:To see from the trend of population
growth, economy development and the
growth of meat
consumption per
capita, the regions
of Asia, Africa and
South America will
be promising. On
the other hand, for
feed processing
equipment, people
already pay more
attention to particular criteria such as the safety,
environment-friendliness, automation and
user-friendliness, this will in turn bring more
advanced equipment to the market. Meanwhile,
FEATURES
We want to use
this project to offer
better and faster
service to global
customers.

US market are saturated.
IAHC:What do you think will be
the factors to influence the future
development of feed processing industry?
Under the impact of these factors, which
direction will the industry take in the
future?
LIU: First of all, with the development of
the global economy, people are more and more
concerned with healthy food and green feed, and
this, in turn, sets even higher demands on feed
processing equipment and technology. Secondly,
just as I mentioned before, with higher labor
costs, people will begin to pay more attention
to safety, automation and user-friendliness of
equipment. Thirdly, environmental and resource
problem calls for low-energy consumption
equipment. Finally, a growing population needs
We can be competitive in
the global market only by
considering the position
of the customer and
developing equipment
to meet all their
requirements.
greater quantities of meat products, so largescale
equipment will be needed in the future.
IAHC: As you said, the future
direction of the industry will be largescale,
automation, low-energy costs,
safety and environmental friendliness.
What new requirements will they
translate into for global feed processing
equipment suppliers?
LIU: All these new trends require us to
make an all-around programme to be customeroriented,
and to understand their demands. We
can be competitive in the global market only
by considering the position of the customer
and developing equipment to meet all their
requirements.
IAHC: What has Muyang prepared for
all those challenges and requirements?
LIU:We have made a number of
preparations:
First and foremost, we have set up sales
and service centers in the places nearest to our
customers, to try to know and satisfy their needs
in the shortest time, and to offer prompt and
quality service in line with their requirements.
Second, we continue to bring in global
professional talent and high-end processing
equipment so that we can offer our customers
high-efficiency and stable products which can
fully meet their demands.
Thirdly, with our professional and
experienced engineers and after-service staff,
we are able to offer the “one-stop” service to
customers. The service includes storage, steel
structure, automation control, a consultation
service for technology and on-site operation
training, ensuring our quality integrated
solutions.
Finally, we do believe in the idea of
sustainable development. No matter whether in
our production and operation or in our product
and project design or offering customers, we
always persevere with this concept. Corporate-
Social-Responsibility (CSR) is very important for
Muyang to be responsible to the environment
and to reduce energy-cost and emissions.
IAHC:The 2011 Victam show will be
held in May. What expectations do you
have as one of the exhibitors? What goals
do you have?
LIU: We’d like to show some new products
and our comprehensive strength to all global
customers through this great show, and also
we hope to communicate with friends from all
over the world. I’m sure we will meet some old
friends during the show and, of course, we’d
like to make more new friends. We would be
very pleased to introduce them to the products
and projects we can offer, and we hope for more
global customers who can enjoy our prompt and
quality service.
--Roy SUN
Roy SUN is a journalist with International Animal
Hubandry China Edition, in Shanghai, China.
Technology
Energy efficiency
improving & pellet
uniformity control in the
extrusion of aquafeed
To substantially improve
extruder performance in
aquafeed production, in recent
years Muyang Group made research
efforts in five aspects and gained some
achievements : to increase energy
efficiency of extruder, to enhance pellet
uniformity, to lengthen service life of
wear parts, to increase production rate
of sinking aquafeed as well as that of
micro-aquafeed, among which, the
energy efficiency improving technology
and its application as well as the
development on pellet uniformity
control will be introduced in the
present article.
1. How did Muyang
increase energy
efficiency of the
extruder system
By Ma Liang, Zhang Guiyang, Mi Changyu, Zhang Wenliang
(Muyang R&D Center)
With the development of extrusion technology, one of the development trends
in aquafeed milling is that extruder is taking the place of pellet mill and becomes
the most popular and most efficient milling machine because of its flexible
production adaptability, high product quality and high sanitation assurance.
However, the obstacle impeding extruder popularization is energy input, which
must be decreased.
As we all know, sufficient energy is required
to put into the extrusion system to sustain
the whole extrusion process, from material
conditioning to kneading, shearing, cooking,
extruding, forming and finally obtaining
qualified aquafeed. Essentially, the input energy
is normally defined into two forms: the specific
mechanical energy (SME) and the specific
thermal energy (STE).
Analyzing from the energy inputs
that required for cooking the raw recipe
components, there are three possible ways to
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improve energy efficiency of an extrusion system, i.e. to
increase production capacity while decrease the power
consumption:
(1) Improve the utilization efficiency of SME;
(2) Improve the utilization efficiency of STE;
(3) Try to input and utilize most STE from the
relatively cheaper source -- steam to substitute some SME
input.
1.1 Method to maximize SME utilization
First of all, the approach was studied to match the
SEM input with that required for material ripening. If
lower than that required, the input SME could not ripen
the material sufficiently even though it would result in higher
production capacity, vice versa. Therefore, only proper SME input
can guarantee high quality extruded aquafeed while maximizing
production capacity.
By quantifying the abilities of each screw segment (including
conveying, shearing and mixing abilities) and testing the effects
of different screw combinations, Muyang extruder research team
found out the optimal screw configuration that can achieve proper
SEM input for a given auquafeed production task.
Based on above mentioned studies and a perceptual as well as
rational knowledge of extrusion technology, Muyang extrusion team
worked out a new concept — “stabilized shearing”.
Usually, the whole extrusion process that
material undergoes, from being fed into the
extruding chamber up to being extruded out of the
die plate, is a “hasty shearing” process accompanied
by high pressure, high power consumption and high
wearing of working parts, and also
unconstant discharge of extrudates.
The stabilized shearing technology
brought by Muyang Group can largely
stabilize the shearing efficiency in the
whole extrusion process (see Fig.1).
The optimal screw configuration can
not only impart extrusion process
proper SME inputs but also ensure the
product gelatinization not less than
that of the “hasty shearing technology”.
It has been proven that, when
shearing efficiency
hasty shearing
stabilized shearing
Feeding Discharging
Fig.1 Stabilized shearing VS. hasty shearing
producing aquafeed with the stabilized shearing
technology, an extruder can increase the capacity
by 15% with an energy savage of 12% per ton of
feed.
1.2 Method to maximize STE
utilization
Aquafeed mash needs to be pre-cooked in the
conditioner by hot steam before entering into the
extruder chamber for extrusion. How to maximize
the utilization of thermal energy from a given
amount of steam to improve the gelatinization of
aquafeed mash in the conditioner has been the
focus of Muyang’s research efforts for years.
The moisture and heat of steam is hard to
penetrate into the core of feed mash particles and
“cook” them just by the simple physical mixing
function of a conventional conditioner, especially
for the oil-rich aquafeed mash. That means more
steam and longer conditioning time has to be given
in order to achieve high mash gelatinization.
Targeting the goal of improving steam
utilization and enhancing feed gelatinization,
Muyang has invented the “reinforced conditioning technology”,
which can improve the mass and heat transfer efficiency and
uniformity of steam effectively. In addition, Muyang has
innovated the SPTZ series Complex Conditioner by combining
the reinforced conditioning technology with a Muyang SCTZ
DDC Conditioner, which achieves excellent conditioning performance. See
Table 1 and Fig.2.
Table 1 SPTZ Complex Conditioner VS. SCTZ DDC Conditioner
SPTZ series Complex
Conditioner
SCTZ series DDC
Conditioner
Filling degree 55~60% 30~35%
Conditioning time (s) 180~200 40~45
Gelatinization 50~55% 35~40%
Remarks With the same effective volume and capacity
Gelatinizition(%)
Conditioning Time(sec.)
Fig.2 SPTZ Complex Conditioner VS. SCTZ DDC Conditioner
Besides, the production capacity of an extrusion system equipped
with a SPTZ Complex Conditioner is able to increase by 10-15%
compared to that with a common DDC conditioner, because of
the thorough pre-cooking function in the conditioning process.
Furthermore, the enhanced pre-cooking could bring in more
stable running of the machine and less wear of the working parts
such as the segmented screws and extruding chamber liner, which
alternatively is saving maintenance cost.
TECHNOLOGY
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SPTZ
SCTZ
0 30 60 90 120 150 180 210 240
1.3 Substitute SME with steam thermal energy
As we all know, the same energy in steam thermal form is far cheaper than that
in electric power form. And the SME input to a running extruder always comes
from electric power supply. What if some part of the required electric power is
substituted with steam thermal energy, the production cost of aquafeed will be
decreased significantly.
During cooking, the amount of steam thermal energy utilized by feed mash is
determined by conditioner pressure. For instance, conditioned by saturated steam,
the highest conditioning temperature that feed mash can achieve is 100 o C under
0.1MPa while can reach 164.19 o C under 0.6MPa. Therefore, on one hand to make
full use of steam thermal energy under ambient condition, on the other hand to
optimize the conditioning pressure and maximize the steam energy utilization.
The more the steam energy being utilized by feed
mash, the less the SME required for extrusion.
The “substituting SME with steam thermal
energy” technology is widely used in the Muyang
extruders and has been proven to be an effective
and economic way.
2. How did Muyang control
pellet uniformity in aquafeed
extrusion
Good pellet uniformity and pleasing
appearance are the important and attractive
characters for high quality aquafeed. However,
the relationship between good pellet uniformity
and high production capacity is hard to balance,
just like you can’t have your cake and eat it
too, especially for the single-screw extruder.
As the production capacity increases, the
pellet uniformity declines. Usually, good pellet
uniformity can be gained when the extruder is
running at 70~80% of its rated load.
Essentially, the nonuniform
extruded pellets are generated by
materials lacking homogeneity in
the whole feed milling process. From
grinding to mixing, conditioning,
extruding and forming, material’s lack
of proper homogeneity in any of these
processes will finally cause nonuniform
extruded pellets. Fortunately, material
homogeneity in the grinding, mixing
and conditioning processes is easy to
be controlled with available techniques.
The most challenge is to control feed
mash homogeneity during extruding.

Nonuniform
shearing force
What are the causes of nonuniform feed mash during
extruding? See Fig.3
Different
flow rate
Nonuniform
ripeness
Different
ripening
time
Nonuniform
gelatinization
(1) Nonuniform shearing force. The more difference
of shearing force brought by extruding screw stressing on
feed mash, the more nonuniform gelatinization and the more
nonuniform pellet finally achieved.
(2) Different flow rate. Flow rate of feed mash during
extruding could be different in two zones: the screw zone and
the non-screw zone (between the end of screw and the die
plate). The different flow rate of feed mash in the extruder will
cause different ripening time, and different gelatinization as
well as different pellets quality accordingly.
For a normal extruder, the difference of shearing force and
that of flow rate are related to production capacity. The larger
the actual capacity that is close to the rated value, the bigger
the difference of shearing force and that of flow rate.
In view of above impacting factors, Muyang has developed
the so called “turbulent flow extruding technology” to control
pellet uniformity in aquafeed extrusion (See Fig.4). It is
applied to well distribute the shearing force in the screw zone
and to unify the flow rate in both the screw zone
and the non-screw zone (between end of
Nonuniform
gelatinization
Nonuniform
expansion
character
Fig.6 MY120×2 I Twinscrew
Extruder
Nonuniform
expansion
character
Nonuniform
extruded
pellets
Nonuniform flow rate
Flow pass width
Uniform flow rate
Flow
Flow
pass
pass
width
width
Fig.3 The causes
of nonuniform
feed mash during
extruding
Nonuniform
extruded
pellets
Fig.4 Non-uniform flow rate VS. uniform flow rate
screw and die plate) in an extruder chamber. The turbulent flow extruding
technology can help extruder (especially the single-screw extruder)
perform outstandingly in aquafeed production.
3. Application of Muyang innovations
By integrating the stabilized shearing technology and the reinforced
conditioning technology as well as the turbulent flow extruding technology
in one extruder, Muyang rolled out the MY120×2 I Twin-screw Extruder
in Nov. 2009. With many sets’ reliably running in customers’ feed mills for
more than one year, the MY120×2 I Twin-screw Extruder has been proven
to perform well in energy efficiency improving and pellet uniformity
control.
Table 2 Test result of MY120×2 I twin-screw extruder
TECHNOLOGY
Fig.5 Uniform extruded aquafeed pellets
No. Feed Die hole (mm) Main motor power (kW) Load factor (%) Capacity (t/h) Floating / Sinking rate (%)
1 Floating fish feed 5.0 200 68 7.689 100
2 Floating fish feed 1.0 200 65.55 3.479 100
3 Sinking fish feed 3.0 200 31.28 3.714 99.65
Note: The capacity was calculated on the basis of that the aquafeed pellets were dried to a moisture content of 10%.
VISIT MUYANG GROUP
AT THESE UPCOMING EVENTS
May 3-5 Victam International Cologne,Germany
May 17-19 Avesui Florianópolis,Brazil
May 17-19 VIV Russia Moscow,Russia
Jun5-8 Iran Food + Bev Iran
Jun10-12 AGRITEX Syria
Jun 9-11 VIV Turkey Istanbul,Turkey
Jun 15-17 Indo Livestock 2011 Surabaya,Indonesia
July 2-4 AGRENA 2011 Cairo,Egypt
Coming in Next Issue:
It will focus on
integrated
solutions for
poultry feed
production.
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Add.:No.1 Muyang Road,Yangzhou, Jiangsu, China 225127
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