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Grinding more value out of raw materials
A Muyang story in the PhilippinesSNA feed mill in Sidi El Heni:
Goals achieved
Integrated Solution ProviderView
July 2011, Vol.4, No.3
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©copyright 2011 Muyang Group.All rights reserved.
News
Grinding more value out ofraw materials
A Muyang story in the Philippines
SNA feed mill in Sidi El Heni: Goals achieved
Efficient production of alternative aquafeed
Events
Muyang global presence
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CONTENTS
Subscribe:http://www.guojixumu.com/en/nyindex.html
Ms. Riva Ganguly Das, the consul-general of India in Shanghai, made a special visit
to the headquarter of Muyang Group during her recent official trip in Yangzhou
City for widening the bilateral cooperation.
Accompanied by Muyang leaders, the consul-general was shown all aspects of the Group
and was given an overview of Muyang’s activities in India. Muyang has been active in the
Indian feed industry for years. Today, Muyang has many very good references of turn-key
projects with leading-edge technology in India, and lots of Muyang machines are running
wonderfully to produce high quality feed for Indian market, especially in the radically
evolving aquafeed sector there. The Muyang Indian Office opened last year has reduced the
distance between India and Muyang, which will definitely enable Muyang to better serve the
local customers. And additionally many business promotion plans are in the pipeline.
With her visit, Ms. Riva Ganguly Das spoke highly of Muyang’s specific technology support
to India, noting that with the second largest population in the world, India is of tremendous
developing potential. Muyang is welcomed and encouraged to widen its investment and to
extend its business in the fields of grain storage and processing in India.
NEWS
Indian Consul-General in Shanghai visited Muyang
Customers’ needs are the
priority, and we will adapt
according to their needs.
Cover photo: SNA feed mill, provided by Leon Liang
Liu Guangdao
Muyang International Division
“
”
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The global animal feed additives market will
reach $18.7 billion in 2016, according to estimates
in the latest MarketsandMarkets report.
According to "Global Animal Feed Additives by
Type, Livestock, Geography, Regulations Trends
& Forecasts (2009-2016)" , the Asian market, a
driving sales force, will hold 28.5% of the global
market share in 2016. Increasing demand for
meat products in the region and rising domestic
meat production are both expected to contribute
to the area's growth.
Europe is currently the leading market for feed
additives, with a 35% share in 2011 resulting
from regulatory concerns and increasing per-
capita meat consumption. North America is the
second largest market as of 2011, with a share of
The winners of “Muyang Cup” CAD
Drawing Competition were finally
announced in the Science Lecture Hall of
Wuhan Polytechnic University on April
28, 2011.
The Competition lasted for a month.
Over 300 compet i tors f rom such
departments as Food Science and
E n g i n e e r i n g , A n i m a l S c i e n c e ,
Mechanical Engineering and Civil
Engineering of the University took part
in the competition to show their talents
and skills.
Muyang Cup CAD Drawing Competition: foster talents with college
Global animal feed additives market to hit $18.7 billion in 2016
In order to maintain a high level productivity to support its fast
development worldwide, Muyang has been adopting the mode of
college-enterprise cooperation to substantially foster its workforce.
On the other hand, the talented college students the enterprise needs
could make clearer career planning for themselves.
Contact information:
Frank K. Adelholm, Sales General Manager of Muyang Europe Branch.
Address: Venusvaenget 101 DK-6710 Esbjerg V
Mob: +45 21597038
Office: +45 36964538
E-mail: [email protected]
INDUSTRY NEWS
Muyang Group is strengthening its business in Europe with the opening
of its European Office in Esbjerg, Denmark and the appointment of Mr.
Frank K. Adelholm, effective June 8, 2011.
Frank K. Adelholm, who is experienced in feed mill operation and
management as well as the sales of feed machine and equipment in
Europe, will manage the office and also serves as sales general manager
of Muyang Europe Branch. He believed that as a “real” turn-key supplier
and an environmentally responsible organization, Muyang will blow fresh
air to European feed industry, and Muyang’s high quality machineries,
equipment and services can have a positive value creating effect to the
customers there.
Wheat and bajra, also known as pearl millet, are being used as substitutes for corn in
chicken feed as corn prices in India continue to rise.
Wheat is currently selling for Rs 7.50 (US$0.17) per kilogram, while bajra and
broken rice are selling for Rs 11,000 (US$242.89) per metric ton. Corn stands at Rs
10 (US$0.22) per kilogram, kept higher due to high moisture content in the current
harvest and an increase in exports, according to farmers. The Compound Livestock
Feed Manufacturers’ Association of India is calling for a stop to corn exports to
ensure stable prices. “If corn exports are discontinued, prices will fall by 5% to 10%,”
said B Soundararajan, managing director of chicken producer Suguna Group.
Muyang opens new office in Europe
India poultry farmers using wheat, bajra as chicken feed alternatives
The price of corn in India remains high due to a high moisture
content in the current harvest and an increase in exports.
Farmers have begun substituting out corn in chicken feed for
other lower-priced grains.
From May 18 to 31, top Chinese legislator Wu Bangguo visited Namibia, Angola, South Africa and
Maldives to promote the mutual cooperation in a wide range of fields.
Muyang Group, as an integrated technology supplier for the feed-to-food chain, was represented by its
Chairman Mr. Li Minyue in Wu’s trading promotion delegation to Africa. Made up of over 40 top figures
of the Chinese famous enterprises covering bank, construction, information, energy, manufacturing,
agriculture, etc. the delegation also visited Kenya and other SADC countries for business communication
and survey, which will surely do Muyang lots of good in African market promotion.
Muyang joined the delegation led by state leader to Africa
An ongoing drought in Northern Ireland will affect the country’s animal feed industry if conditions
persist, according to reports.
The information comes on the heels of reports that the UK barley harvest is set to be the worst in 40 years
due to lack of rainfall. “This is going to have an impact in terms of the feed for our livestock, the lack of
forage, the lack of hay, will have repercussions next winter for which we will all start to pay a heavy price,”
said Dr. Therese Coffey, Conservative MP for the Suffolk Coastal district.
Ireland drought to affect animal feed industry
28%; the U.S. is the largest market with a share of
more than 80%, according to the report.
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PRODUCT UPDATE
The current difficulty of grain sourcing and price hike makes it very important for millers to process
the valuable and expensive raw materials more efficiently and effectively.
Having adapted to the changing needs of customers, Muyang is developing raw material processing
solutions designed to further increase output and promote the efficient use of available raw materials. On
May of 2011, Muyang announced the adding of three grinding products to its portfolio.
The hammer mill is designed for high capacity fine-grinding in various
industries. It is mainly applied in the primary- or secondary-grinding process
in feed milling industry. It is also used for sized reduction of grain and oilseed
meal in the food and oil milling industries.
SWFP66×125C Hammer Mill, high capacity fine-grinding
*Depending on formulation and required granulation.
Redesigned pulverizing structure
and aspiration system, smooth
grinding and reduced power
consumption.
New materials and technology
for wear parts production, long
serve life.
Aspiration conveying, low
temperature without nutrient
degradation.
No sieve furnished, avoiding
over-grinding and less
maintenance.
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*The capacity depends on raw material composition and required granulation.
Model
Speed of main shaft
Rotor dia.
Screen area
Number of hammers
Motor
Hammer tip speed
SWFP66×125C
2970 r/min
660 mm
2.25m2
160
200 kW (available of 220/250 kW)
up to 102 m/s
≥16 t/h
≤14 kW·h/t
≥22 t/h
≤10 kW·h/t
Capacity
Power consumption
Capacity
Power consumption
φ1.0 mm
screen hole
φ1.5 mm
screen hole
High capacity with maximum efficiency,
power consumption less than 10 kW•h/t
with φ1.5 mm screen.
High tip speed up to 102m/s, for superior
fine grinding quality.
Widened screen area of 2.25m2, facilitates
throughput and prolongs service life of hammer
and screen.
Bearing vibration minimized to 1.1mm/s,
stable running and reliable performance resulted.
One-step screen hold-down device
and fully-open sliding doors, labor and
maintenance saving.
SWFP66×100XM Hammer Mill, specialized for alternative ingredients
F a c i n g r a w m a t e r i a l s h o r t a g e
a n d h i g h p r i c e p r e s s u r e , f e e d
manufacturers would turn to the
alternative ingredients rather than
keep the formulation unchanged.
Today, substituting corn with the
more available and much cheaper
wheat is more acceptable in the feed
industry. However, tough and small,
wheat grain is hard to be ground,
thus raising different requirements to
the grinding machine and technology.
The size reduction of raw materials
usually counts for over 1/3 of the total
power consumption of a feed mill, so it
is essential to improve energy efficiency
of grinding machines for both interests
o f customers and environment ,
especially when it comes to the ultra-
fine pulverizer.
Muyang has devoted great research
efforts to the continuously improving
of product quality, the output as well as
energy efficiency of Muyang pulverizers
for years, and rolled out the SWFL
130E Pulverizer recently.
SWFL130E Pulverizer, energy-efficient ultra-fine grinding
Specialized for wheat grinding and
with the point of departure to get
more value out of wheat without
c h a n g i n g t h e o r i g i n a l g r i n d i n g
process, Muyang SWFP66×100XM
h a m m e r m i l l i s d e v e l o p e d . T h e
h a m m e r m i l l i s d e s i g n e d t o b e
more compatible to the original
process, and most of its spare parts
are interchangeable with those of
the other Muyang hammer mills.
On the other hand, like the other
Muyang SWFP hammer mills, this
wheat gr inding machine i s a lso
characterized by its high energy
efficiency, stable performance and
less maintenance.
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Rotor speed (r/min)
Product granulation
Require air volume (m3/h)
Capacity (t/h)*
Power consumption (kW·h/t)*
SWFL130E
132/160
11
1.5
Service life (t)*
Hammer knife
Gear ring
Wear plate
Grinding disc
1200~1600
4000~6500
1200~1600
6000~8000
Model
Power (kW)
Main drive
Grading motor
Feeding motor
(secondary grinding, 95% through 80 meshes)
1570
60~200 meshes
8400
4.0~6.5
22~24
Model
Speed of main shaft (r/min)
Rotor dia. (mm)
Screen area (m2)
Number of hammers
Hammer tip speed (m/s)
Ideal run vibration (mm/s)
Motor (kW)
Screen hole size (mm)
Capacity (t/h)
Power consumption (kW·h/t)
Recommend application
SWFP66×100XM
2970
660
1.96
108
up to 102
1.1~1.8
132 160
φ2.0
12~16
9~10.5
φ2.0
15~19
9~10.5
φ2.5
16~20
7~8.5
φ2.5
20~24
7~8.5
φ3.0
18~22
6~7.5
φ3.0
23~27
6~7.5
Grinding wheat for livestock & poultry feed with φ2.5 screen; Primary grinding wheat for aquafeed with φ2.0 screen.
Grinding More Value out of Raw Materials
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A Muyang StoryA Muyang Story in
the Philippines
As one of the important members in China Pavilion, Muyang Group became one of the focuses on the 2011 VIV Asia show successfully held in Bangkok, Thailand from March 9th to 11th, 2011. During the show, the reporter from International Animal Husbandry
China met Mr. Enrique A. Repalda from BELMONT, the exclusive agent for Muyang in the Philippines, and had a conversation with him. From the talk, you can get a general view of the development of Muyang Group in the Philippine market.
IAHC: Thank you so much for your time
to our interview, could you please firstly
introduce your company to us?
R: Well, Belmont is a Filipino corporation
representing major manufacturers from the
US and around the world for agricultural and
industrial equipment over the past 40 years. It
is the industry leader who serves the poultry
and livestock, bulk grain storage and handling,
and feed milling industries. All the major
poultry integrators, large-scale piggeries, and
feed millers in the Philippines are Belmont’s
customers.
I A H C : W h e n d i d y o u s e t u p s u c h
relationship with Muyang Group? And
why did you choose Muyang?
R: Our business relationship with Muyang
started in 2006. We chose Muyang to be our
partner because of their excellent equipment,
very strong technical support, and great
innovative ability and R&D force. Muyang staff
is very votive, efficient and always gives fast
and friendly supports to Belmont and to the
customers.
IAHC: What was the market like when
Muyang was at the outset to Philippine
market?
R: Before Muyang’s equipment exposure to
the Philippines, the feed milling industry was
dominated by European and US companies.
Muyang had to work very hard to convince
people of their fine quality equipment and
multi-disciplined services. Muyang brought
customers to China so they could see with their
own eyes the excellent Muyang facilities and
how big Muyang’s market was in China, for
seeing is believing.
IAHC: And now what is the situation for
Muyang in the local market there?
R: Well, that is the thing I feel proud of most.
From the year of 2008, Muyang became more
and more aggressive in marketing in the
Philippines. For now, I believe that Muyang has
a strong position with a large market share and
prestige locally. It is really incredible that we
have made all these become true just in such a
few years.
IAHC: Facing stiff competitions, how has
Muyang Group successfully developed in
the Philippine market so quickly?
R: I think we should attr ibute i t to the
competitive products and good services that
Muyang offers.
Muyang equipment is of natural advantages
and good price. You have to know, in the
Philippine market, similar products of European
or US brands are much more expensive than
Muyang’s, but for the quality and performance,
the difference is not so obvious. It is such a
natural thing that the customers prefer those
products which are more cost effective.
On the other hand, Muyang manufactures
complete l ine of equipment, which is a
distinguished advantage over the other suppliers.
If the customer goes to buy one machine from
one European brand, he may need to get other
kind of machines from another company. But
if he chooses Muyang, he can get everything he
needs just from one single competent source.
Besides the complete production line Muyang
also fabricates other things or elements needed
by its turnkey project, including steel silos,
steel structures, etc. This makes it all the more
important for the customers to rely on Muyang
to provide the perfect coordination of the
individual steps of project development from
planning right up to commissioning of the
turnkey plants. Additionally, Muyang can offer
all kinds of after-sales services at the same time,
which also helps our customers to save time and
cost due to the deals with different companies.
INTERVIEWINTERVIEW
Being a good listener, Muyang can always define and turn those improvement advices
or specific requirements from customers into actual
products or solutions.
——talking with Mr. Enrique A. Repalda By Roy
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PROJECT
SNA Feed Mill in Sidi El Heni: Goals Achieved There is no reason for
a company who pays attention to such tiny details not to have its own place in the market.
Backing to the price issue, as an agent company
with so many years’ experience, we know, it goes
without saying, that if one company or product
takes the advantage only in price, it is no way
for them to take enough shares from the market,
that’s why I just emphasized the good services
Muyang offers. Muyang’s services are something
strong and comprehensive rather than single
ones, which you can see it clearly from the
so called “one-stop” service and customized
services. Being a good listener, Muyang can
always define and turn those improvement
advices or specific requirements from customers
into actual products or solutions, thus meeting
customers’ demands to the greatest extent. And
the “one-stop” service makes our customers
feel so convenient, and then wins great market
shares for Muyang Group.
Muyang always puts customers’ demands
in the first place, and takes the initiative in
fulfilling them. I think that’s essential to the
success. I can give you two examples. The first,
Muyang has already considered the cost-saving
performance when it provides solutions to
customers. The product itself is designed to be
cost-saving, which can produce more feed with
less power. And the equipment installation or
the project implementation also takes shorter
time, which saves the time cost, and makes
the return on investment much higher. The
second example shows more concerns to the
details from Muyang. Just like other companies,
Muyang offers extra accessories to customers,
but the difference is that, considering some
of the customers may have equipment from
other suppliers, Muyang not only offers the
accessories of its own but also those of other
brands. In my opinion, there is no reason for a
company who pays attention to such tiny details
not to have its own place in the market.
IAHC: Are there any important movements
of Muyang in Philippines now?
R: I think one of the most important things is
that Muyang has helped several feed companies
to set up their own plants. Muyang made the
whole project for them according to their needs,
from planning, manufacturing, construction
up to equipment commissioning and operation
training, especially the quality management
all down the line. I do believe that the opening
ribbon-cutting of these plants have shown
that our “turn-key” projects have won the
satisfaction and trust from our customers.
IAHC: How do you think these plants
can help those companies, and the whole
feed industry in the Philippines?
R: The superior equipment and power saving
technology Muyang provided at a lower price
have made the feed companies more efficient
(less feed cost) and competitive locally and
globally. Feed cost contributes 65% cost per
kilo animal meat, thus less feed cost will mean a
better future for the animal industry.
IAHC: How can these plants build up
brand image for Muyang in the local
market?
R: It is really helpful for Muyang to have
stunning showcase projects locally. Customers
can now see how Muyang’s project run and
how Muyang’s equipment actual work in
the Philippines. It is more convenient and
convincing. The industry now recognizes the
market-front-runner position and quality of
Muyang.
IAHC: Will there be any more plants
build by Muyang in the future?
R: There is a continuing demand for quality
equipment and complete technology support
in the Philippine feed industry. I believe that
Muyang will get a good share of the business,
and build more competitive feed mills for the
customers. Our company will strengthen the
cooperation with Muyang in this area, try
our best to make more customers know and
trust Muyang, and we are quite upbeat about
the brighter future for all of us—Muyang,
BELMONT, and the Philippine feed industry.
SNA has been an important part of animal feed market as early as in 1976. It is the trademark property
of the Poulina Group Holding (PGH), a leading Tunisian Group that engages in strategic integration
of all activities in its agriculture business ranging from breeding to the distribution of food.
With its ambition and values, SNA targets at building a modern company to honor Tunis and create wealth,
quality and health to all its concerned domains (customers, employees, society, environment, etc).
The feed mill-related top priorities lie in the establishment of essential automation for easy operation,
the increase of energy-efficiency for sustainable development, and the compliance with rigorous sanitary
standards for animal welfare and human health. In addition, SNA will exert the greatest effort to pursue other
goals to fully realize its intrinsic values.
With all these respects, when SNA was considering how to increase productivity and how to build the fourth animal
feed production site in Sidi El Heni in 2008, they turned to Muyang for a project as a result of the
pleasant cooperation between the two parties in 2004.
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Cutting-edge automation
In the new facility, all levels of production cycle,
from storage of raw materials to delivery, the
manufacture of feed is managed by an advanced
process control system, which is characterized
by its advanced traceability and the elimination
of cross contamination and easy accessibility.
From every single equipment to the whole plant,
Muyang has concerned every detail to create
a precise and reliable fully automatic control
system. For instance, the solutions selected to
stop elevators from running back or sliding,
sensors for material level detecting and that
speed measuring of drag conveyors, the feeding
proportion control of pellet mill and steam
application system, etc.
Rigorous safety and sanitary
S N A h a s c o m m i t t e d i t s e l f t o t h e s t r i c t
implementation of HACCP and ISO standards.
Catering to SNA’s needs, Muyang bears in
mind the feed quality as well as the safety of
operators and machines when designing every
installation accessories of the Sidi El Heni Feed
Mill.
Muyang U-shaped drag conveyor is selected for
finished product handling in this feed mill, which
because of its excellent residue-eliminating
performance, has been recommended for
the other SNA feed mills. In order to prevent
ingredients from bridging in the bins, a specially
designed stepped surge hopper with an eccentric
outlet was fabricated. As to dust control in this
facility, at where dust is mainly produced such
as dumping pit, elevator, conveyor, hammermill,
The feed mill construction was commenced
in March 2009 and was completed on schedule
and on the proposed budget in December 2009.
After putting into production, Sidi El Heni Feed
Mill and the other three production sites of
Borj Cédria, Mateur and Sfax, SNA will see a
40 % of annual increase in Tunisia’s animal
feed production.
23,000 tons of corn storage in seven
(4×5,000 tons +3×1,000 tons) steel silos
representing approximately two months
consumption.
A steel structure workhouse
accommodating three 15T/H pelleting
lines and a reserved thermal treatment
line for powdery feed.
A precise 50TPH proportioning system
with 35 ingredient bins.
All processing equipments ranging from
raw material receiving to finished product
bagging.
1,000 tons of finished product storage in
18 bulk load-out bins with two 20TPH
bagging lines available.
Computer-controlled operation and
management within the entire plant.
Lighting system, communication system
and monitoring system.
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Scope of the project
With a nominal output of 45 tons per hour, the
facility mainly produces φ3.5mm poultry feed.
It is also flexibly designed to produce pellet
feed for cattle or sheep. The scope of the project
mainly includes:
For more information on the SNA Sidi El Heni Feed Mill project,
Please contact: Leon Liang Sales Manager
Muyang I.B.D. North Africa [email protected]
From every single equipment to the whole plant, Muyang has concerned every detail
to create a precise and reliable fully automatic
control system.
etc. spot dust collectors are adopted to diminish
dust emission. The many spot dust collectors,
together with the central dust collecting systems,
can gain the feed mill good housekeeping and
added profit by reducing shrinkage and lowering
the chance of dust explosion.
In addition, the plant automation system is
applied to secure the safety of processing and
eliminate cross contamination.
Goals achieved
With the idea of “Create value for customers”,
Muyang always considers the cost-effective
performance from all aspects of its integrated
solutions. After it was put into production in
December 2009, the new poultry feed plant
of SNA has been running into cost efficient
operation in the country.
The latest Muyang machines and technologies,
which are upgraded for energy-efficiency
and stable running, are applied in this mill.
Besides, based on its vast technical resources
and expertise, Muyang designs many products
and solutions that meet every paticular need
of SNA. The customized double-deck cooler ,
for instance, could reduce the waiting time for
formulation change.
On the other hand, as a global integrated
solution provider in feed industry, Muyang is
specializing in the so called “One-stop” service.
And its numerous resources are focused on the
design, production, installation, commissioning,
training, consultation and after service of grain
storage silos, plant steel structure facilities,
processing machines and plant automation,
bringing more convenience, flexibility and
simplicity for SNA.
In 2010, Muyang was awarded another 45TPH
poultry feed mill project from SNA in Libya. The
continuous cooperation between the two parties
confirms that Muyang is able to guarantee
the satisfaction of customers with its own
technology and service.
PROJECT
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TECHNOLOGY
TECHNOLOGY
Efficient Production of New Alternative Aquafeeds
——By Hongyuan Cheng1, Liang Ma2
1-Assistant Professor, Technical University of Denmark, National Food Institute;2-Senior Engineer, Muyang Group R&D Center.
New challenges in extrusion processing alternative aquafeeds
With rapid development in
aquaculture, the industry
has realized that the use of
capture fish and fish processing by-products
(so called fish meal) in aquafeed threatens
aquaculture’s sustainability. Sooner or
later, not enough fish meal can be used for
aquafeed manufacture. Meanwhile, the
aquaculture product increasingly plays a
more important role in global food supply
with the increase in world population,
because agriculture productivity is limited
by the amount of cultured land. As the
aquaculture will play an important role
in global food supply, the development of
alternative materials to replace fish meal
becomes one crucial aspect to allow the
industry to expand in a sustainable manner.
Many efforts have been made to use plant-
based ingredients in alternative aquafeed production. The potential plant-
based alternatives already in use include soybeans, barley, rice, peas and
other crops, along with canola, lupine, wheat gluten, corn gluten, various
plant proteins and algae. With these potential ingredients, a many new
aquafeed recipes can be formed for processing in the product development
stage. To process all these new recipes in the extrusion process is a very
expensive task in terms of time and raw material cost and can become a
bottleneck sometimes. Although extrusion processing has been widely
applied in aquafeed production, the understanding of the process is still
very limited. In most cases, the search of suitable extrusion processing
parameters depends on trial-and-error experiments and experience. To
face the new challenges, new methods should be adapted to improve the
efficiency in extrusion processing new aquafeed recipes.
Improvement of extrusion processing method for aquafeed production
Extrusion cooking technology is a very efficient processing method in feed
production. Nowadays, nearly all auqafeed is produced using extrusion.
Within extrusion processing, several processes may occur, including fluid
flow, heat transfer, mixing, shearing, particle size reduction and melting,
where feed materials are exposed to high temperatures for a very short
time. This gives a distinct advantage over conventional pressure cooking,
in which the exposure could last several minutes at high temperatures. In
the extrusion of food and feed, pellet
expansion (or bulk density) is one
important property in product quality
control and measurement during pellet
manufacture, which is different from paste
and spaghetti production.
Different strategies have been proposed
to improve extrusion process technology.
In industrial practice, two strategies
are typically employed to control and
determine suitable extrusion parameters
to obtain the correct expansion pellet. One
method is to set up extrusion parameters
from experience and experimentation and to
analyse processing results through response
surface methodology or other methods.
The other way is to modify the mechanical
segments in the extrusion line, such as screw
configuration and die structure and to change
raw material particle size and precondition
parameters. In industrial practice, however,
the optimal combination of these methods is a
very difficult job when initial trials cannot give
the correct pellet expansion for one or several
new recipes. In such a case, industrial practice
experiences play a crucial role. At the same
time, engineers and researchers have also made
efforts to search for new methods to improve
the extrusion efficiency in terms of time and
raw material cost for new product development.
Recently, engineers have worked on
using a new mathematical modelling
m e t h o d t o a n a l y s e e x t r u s i o n
processing aquafeed to improve the
procedure that determines extrusion
parameters.
Application of modelling method to improve the procedure that determines extrusion parameters
Various modelling techniques have
been established to describe and
analyse extrusion process operations,
such as response surface methodology,
principle component analysis, neural
network method, genetic algorithm
and numerical simulation. In the
application of response surface methodology, principle component
analysis and other multivariate data analysis methods, the extrusion
process is treated as a black box. All possible factors are analysed
through a statistic algorithm for identification of impact on pellet
properties, e.g. pellet bulk density. The neural network method and
genetic algorithm can be treated as a grey-box model for the extrusion
process, in which the model can automatically update its equation
behaviours in a few cases; learning from real extrusion process operation
data. The numerical simulation method is built from a basic physical
principle to describe an extrusion process. However, the construction of
the numerical simulation method involves several equations to describe
the extrusion process so that it has to be simplified for a real process and
to yield a numerical solution.
Engineers have started to explore a grey-box model to correlate the
relationship between pellet bulk density and extrusion parameters
based on the work of Cheng and Friis (Cheng, H. and Friis, A. Food and
Figure 1 composition changes of four recipes
Muyang Group have worked on using a new mathematical modelling method to analyse
extrusion processing new aquafeed process in order to
improve extrusion parameter determination procedure.
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Bioproducts Processing, 2010, 88:188-194). In the
model, the pellet bulk density is correlated with
important extrusion process parameters, e.g. die
temperature, moisture content, screw speed and
specific mechanic energy. The formulation of the
model is simple and can be solved using common
mathematical tools, such as Microsoft Excel. The
application of the model shows it doescorrelate
pellet bulk density with extrusion parameters. An
application is shown in following section.
Application of the model
In the development of alternative aquafeed,
the extrusion engineer often has to process a
batch of different recipe feeds in a pilot plant
extrusion process. Even the production is not in
a large amount; the production cost may be high in terms of time
and materials. In practice, a typical method is to conduct initial
trials in an existing extrusion line from experience to obtain the
correct feed pellet. An experienced engineer may reach the correct
feed pellet in a few runs. If the test run fails for one or several new
recipes, the engineer must investigate all possible reasons, such
as more extrusion parameter combinations, particle size, screw
configuration, etc. The feed pellet extrusion processing may become
a bottleneck in the alternative recipe development.
To improve the current procedure for processing a group of new recipes,
we introduce the modelling method of Cheng and Friis to analyse the
trial results. For a group of new recipes, we first use a composite design
method to arrange the initial trial sequence. Using the trial results, the
pellet bulk density can be correlated to extrusion process parameters
using the modelling method. By the correlation results, we analyse the
TECHNOLOGY
Figure 2 water content (XH2O)=15%, fish meal (Xf)=48-84%, wheat+bean (Xp)=16-52%.
Figure 3 water content(XH2O)=20%, fish meal(Xf)=48-84%, wheat+bean(Xp)=16-52%
Figure 4 water content(XH2O)=25%, fish meal (Xf)=48-84%, wheat+bean(Xp)=16-52%
Sep.
Oct.
effects of adjusting extrusion parameters on pellet
bulk density. From the analysis, we can obtain an
optimal direction with which to adjust the extrusion
process for a specific recipe.
For example, there are four new recipes for
processing, which is shown in Figure 1. In these
recipes, the fish meal content (Xf) decreases with
increasing wheat+bean/pea content (Xp). A small
composite design method is used to arrange the
extrusion process parameter adjustment table,
which includes temperature, moisture content
and screw speed. Between eight and 11 runs are
arranged for each recipe. From these runs, a set
of experimental data can be obtained. Based on
the experimental data, we use the mentioned
modelling method to take into account the effects
of extrusion parameters on pellet bulk density. The
modelling results are represented in Figures 2-4.
In Figures 2-4, the z axis represents the pellet
bulk density (g/l), the x and y axes represent,
respectively, die temperature Td (◦C) divided by
25◦C and parameter group Pd/SME, where Pd
is the die pressure (bar) and SME is the specific
mechanic energy, SME=τ·Ns/FT (τ: torque,
Nm, Ns: screw speed, rpm, FT: total flowrate in
extruder, kg/hr).
In Figures 2-4, the modelling results are given in
three moisture content conditions for four recipe
composition variations. As shown in Figures 2-4,
four surfaces represent pellet bulk density behaviours along the extrusion
parameters for four recipes. On each surface, the pellet bulk density can be
read through given die temperature, Td and SME (calculated from screw
speed). An operation window or range can be outlined from the surface.
The analysis can help the engineer determine an optimal parameter
adjustment direction to improve pellet bulk density. For example, Figures
2-4 show that Td/25=4.0-4.5 and Pd/SME=0.1-0.2 will give lower pellet
bulk density or good expansion for processing all four recipes.
To take advantage of extrusion process modelling work
As shown in the application, the modelling work
provides a quantitative tool with which to aid
the engineer in analyzing the effects of extrusion
parameters on pellet bulk density. The modelling
results can give a guide to avoid the blind trial-
and-error procedure when a recipe processing
cannot give the correct pellet bulk density. From
the modelling work, we do not need to examine
every possible extrusion parameter combination
and, therefore, can reduce the amount of
experimental tests. The modelling result can
quantitatively determine the relationship
between pellet bulk density and extrusion
operational parameters and, thus, can predict
the pellet bulk density that has not been reached
in experimental trials. Therefore, the time and
raw material cost can be reduced in processing a
group of new recipes in the product development
stage. From our experience in application of
the model for different extruders, the model is
suitable for both twin-screw and single-screw
extruders and can also be applied for laboratory,
pilot and industrial-scale equipment.
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Muyang Global Presence
Localized sale, technology and service, creating more value for customers. As its presence
extended to over 80 countries, Muyang executes its go-to-market strategy by strengthening its
international sale & service network to commit itself to delivering customers the latest technology,
prompt service and complete solution. As of Jun. 30, 2011, there had already 26 overseas offices been built
in countries such as Russia, Brazil, India and so on. Over 200 professional salesmen and service personal
are fostered and sent out with qualification, professional skills as well as social and linguistical knowledge,
and the numbers will grow larger. It is believed with through a solid international sales & service network
and plus about 40 overseas agencies, the customers can find Muyang wherever they are and be served
whenever they need.
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