INNOVATION AND FISH FEED EXTRUSION Cliquez pour modifier le style de sous titre 36th Fish Feed and Nutrition workshop si nécessaire Hadrien DELEMAZURE September 14, 2017
EXTRUSION and INNOVATIONS for Aquatic feed Introduction Part I: Generic Extrusion Technology Part II: Fish feed extrusion Part III: Generated innovations Conclusion 2
INTRODUCTION
CLEXTRAL IN SHORT Sales 2016 61M 80% export Workforce 280 employees Locations 3 test centers 12 subsidiaries and offices
INTERNATIONAL NETWORK
CLEXTRAL APPLICATIONS Since 1956, we have continually expanded the range of applications served by our core technology, twin-screw extrusion and we serve numerous markets throughout the world : Extruded cereals, snacks, Ingredients,, baby food, novel protein products Short pasta, Couscous Pet Food, Fish feed Plastics & recycling, Chemical applications, Cellulose pulp, Biomass, Porous powders with improved functionalities for the food processing or chemical and pharmaceutical industries Dosing pumps for oil and gas nuclear industry extrusion
CLEXTRAL A worldwide presence and network Specialist in Twin Screw Extrusion processing Certified Iso 9001 & 14001 40 years experience in aquafeed extrusion processing Process expertise ; 3 pilot plants (France, USA, Australia) Cooperation with Research Institutes (FR, CL, AU, PT,..) 7
EXTRUSION PROCESSING TECHNOLOGY: definitions Extrusion-cooking is a Thermomechanical process consisting in forcing a product through a small size hole, under pressure and temperatures get thanks to Archimède s screws. Single Screw Extruder - SSE Twin Screw Extruder - TSE Expansion is due to the water flash off caused by the pressure difference out of the die. Functions of an extruder: feeding, conveying, mixing, compressing, cooking, shaping
BASICS OF SSE TECHNOLOGY Raw mix Screw design = single piece (constant pitch, decreasing channel depth) or a splined shaft that holds screw sections of varying configuration (pitch). PRECONDITIONER P SSE P Transport Compression Cooking Shaping Parameters dependant, Very low mixing effect Axial distance, z
Activ part -> 2 identical intermeshing co-rotating screws Screws rotate inside a fix body -> barrel Screw elements of modular conception are mounted on a splined shaft TSE EXTRUDER - OVERVIEW In intermeshing co-rotating twin screw extruder-reactors, very intense mixing is observed in the intermeshing zone of the screws Co-rotating TSEs show much better mixing capability than SSEs Intermeshing zone FLOW DIRECTION
BASICS OF COROTATING TSE TECHNOLOGY Different unit-operations Raw mix PRECONDITIONER Parameters independent Positive displacement pump Venting P TSE Transport Compression Melting Cooking Degassing Shaping P Axial distance, z
TWIN SCREW EXTRUSION TECHNOLOGY DETERMINANT PROCESS ADVANTAGES Extensive choice of RAW MATERIALS & FORMULATIONS High tolerance to LIPIDS in raw materials & formulations Large flexibility in THERMOMECHANICAL COOKING: - ratio of mechanical/thermal energy inputs - efficient barrel cooling - large choice of product profiles (texture/structure, density) Product quality => CONSISTENCY
Alain BRISSET AQUAFEED PROCESSING
AQUACULTURE & EXTRUSION-PROCESS Fishing Processing fishmeal Oil + Fish farming Fish Food Extrusion Wastes Plants Pn Cereals Premix Slurries Binders Hydrolysates...
FISH FEED EXTRUSION PROCESSING Ingredients storage Grinding/ sifting Mixing Feeding Extrusion Cooking Préconditioning Forming/Cutting Drying Fat Coating Packaging Cooling
AQUACULTURE & EXTRUSION-PROCESS Floating feed Sinking feed Shrimp feed Ornemental fish-feed Micro & Macro feed 0,5 to 30 mm product diameter; 350 to 700 gr/l product bulk density
RECIPE: COST BREAKDOWN 4% 3% 1% 25% Recipe Coating 67% Personal & Energies Depreciation Maintenance COST BREAKDOWN FOR A SALMON FOOD RECIPE (TON) WITH TSE
TSE EXTRUDED FISH FEED From Micro to Macro aquatic feeds Floating & sinking Feed characteristics Bulk density (g/l) Fast sinking Slow sinking Neutral floating Floating > 640 540-600 480-540 < 450
AQUACULTURE : SOME FACTS AND CHALLENGES
WORLD FISHERIES AND AQUACULTURE PRODUCTION 180 160 167,2 Mt 140 120 100 93,4 Mt 80 60 40 20 0 2005 2006 2007 2008 2009 2010 2011 2012 2014 73,8 Mt* World Production Capture fisheries Aquaculture + 5,4 % Source: FAO- 2016 * does not include aquatic algae (27,3 Mt)
WORLD AQUACULTURE 2014 Estimation of the world population in 2014: 7,3 billion World fish production: 167,2Mt 146,3 Mt: human consumption (87%) > 20,0 kg/capita/year 20.9 Mt: non food use Aquaculture 2014: 73,8 Mt (86% in Asia, and 62% just for China) 2025: 102 MT => + 38% Aquaculture 50 % of the human consumption; contributes to 17,0% global animal protein intake; Aquaculture = US$ 160,2 billion 19 million people directly engaged in fish farming Source: FAO 2014
AQUACULTURE CHALLENGES RAW MATERIAL avalaibility: Fish meal Fish oil, long chain ω3 DHA, EPA CLIMATE: high T weather POLLUTION dumping at sea chemicals, pesticides, breeding pratices POPULATION + 2 billion people in 2050
AQUACULTURE CHALLENGES RAW MATERIAL Fish meal: fish trimmings, animal by-products, protein-rich vegetables, Fish oil, DHA, EPA: algae, yeast, fungis, vegetable oils (salmon conversion) research: improve FCR (nutritonaly adapted), functional feeds (sinking/floating ability, water stability,..), immune response feed, GMO raw materials,?? CLIMATE Temperature: new species, plankton, increased growing rates, GMO fishes?? storms, waves: cage techniques: submerged, in land farming, POLLUTION - state policy, legislation, water treatment, controls, - lower use of chemicals, eco-responsible behaviour, environmentaly friendly - good breeding practices, high quality feed (texture, size, oil retention,..) POPULATION access to balanced food: logistic, conservation, cost, fish species, processing
REDUCTION IN FISHMEAL INCLUSION IN COMPOUND AQUAFEED OF DIFFERENT SPECIES GROUPS Species/species group Fishmeal inclusion in compound aquafeed (%) 1995 2008 2020* Tilapias 10 5 1 Catfishes 5 7 2 Milkfishes 15 5 2 Salmons 45 25 12 Trouts 40 25 12 Marine fishes 50 29 12 Marineshrimps 28 20 8 Freshwater crustaceans 25 18 8 Source:Chutima Tantikitti, Feed palatability and the alternative protein sources in shrimp feed SJST, 36(1), 51-55, Jan-Feb.2014 * projected
EVOLUTION OF SALMON FEED COMPOSITION Source: fishfarming Xpert, Aug. 2012, «Future Feed» p 31 «present and future raw material in salmon feed»
EVOLUTION OF SALMON FEED COMPOSITION
TSE = PROCESS INTENSIFICATION TOOL = do More with Less Throughput Quality Reliability Food Safety ROI INTENSIFICATION Waste Energy, water Time to market Space Investment
GENERATED INNOVATIONS Preconditionning Hygiene Intelligence Throughput Venting Shearing Die design
PRECONDITIONER MAIN FUNCTIONS Mixing homogeneously powders & liquids Heating & moistering raw materials Swelling of flour particles Starch pre-gelatinization Protein pre-denaturation Extruder mechanical energy Thermal energy Product quality Extruder capacity Extruder screw wear
TWIN SCREW EXTRUDER BASIC DESCRIPTION TEMPERATURE CONTROL SYSTEM POWDER FEEDER BARREL ASSEMBLY GEARBOX MOTOR OPERATOR INTERFACE DIE-FACE CUTTER OPENING DEVICE FRAME
HYGIENE: BARREL OPENING
ENERGY CONTROL & EFFICIENCY S.M.E THERMAL ENERGY Automatic Start up Optimized Start up times Reduced wastes Option : Vent stuffer For high density pellets
FEATURES OF EVOLUM + RANGE
EXTRUDER CONTROL Main Machine Interface (Intouch & touch screen) Complete interface Easy integration into a process line Interactive Synoptic Automatic startup and shutdown Recipe management, parameters trends
EXTRUDER CONTROL
VERY HIGH CAPACITY MACHINES: 25-34 T/H * Twin-screw extruder type BC 160 Screw diameter = 200 mm * Coated salmon feed pellets
GENERATED INNOVATIONS Preconditionning Hygiene Intelligence Throughput Venting Shearing Die design
TSE PROCESS - VENT STUFFING TECHNOLOGY B. Density (gr/l) 750 B. Density vs Vacuum Pellets Diameter (mm) 6,00 Pellets diameter vs Vacuum 700 5,50 650 5,00 600 4,50 550 4,00 500 1,00 0,90 0,80 0,70 0,60 0,50 0,40 Vacuum Level (bar) 0,30 0,20 1,00 0,90 0,80 0,70 0,60 0,50 Vacuum Level (bar) 0,40 0,30 0,20
GENERATED INNOVATIONS Preconditionning Hygiene Intelligence Throughput Venting Shearing Die design
SCREW ELEMENT C2-1F Definition : Twin flight feeding screw Fonction : higher feeding volume Nominal diameter Pitch Length
SCREW ELEMENT C1F Definition : Conjugated screw 1 flight Fonction : Transport and compression Nominal diameter Pitch Length
SCREW ELEMENT C2F Definition : conjugated twin-flight element Fonction : Alimentation / Transport / Compression / Degassing Nominal diameter Pitch Length
SCREW ELEMENT CF1C Definition : Conjugated reverse screw element with helicoidal slots Fonction : Shearing/Mixing Nominal diameter Pitch Length
GENERATED INNOVATIONS Preconditionning Hygiene Intelligence Throughput Venting Shearing Die design
EXTRUDER DIE ASSEMBLY LL D Die holder with inserts or Die drilled with holes shaping Distribution die plate = Male and female diffusing cones distributes the single stream to the die Central Feed Die Plate allows the flow from each screw to converge into a single stream
EXTRUDER DIE ASSEMBLY Micro fish feed Ø 0.6 2 mm Macro fish feed Ø 20 mm and more Medium fish feed Ø 4 12 mm
MICRO AQUATIC FEEDS Grinding / Micronising Sifter Twin Screw Extruder + adapted Die and Cutter design Pneumatic Conveying System Fluid bed or Rotante Dryer Coating Drum Packaging
EXTRUDER DIE FACE CUTTING 49
AQUACULTURE & EXTRUSION-PROCESS
CONCLUSION: WHY INNOVATION? Often to take up some challenges: - population - raw material availability - economy / cost - climate - food security - logistic But also generated by ideas, luck, The market validates the innovation through a buying/use action.
THANK YOU FOR YOUR ATTENTION Find us on : www.clextral.com Alain BRISSET