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Manufacturing process for shrimp feed


IDAH’s contribution to shrimp feeds
In early 1970s, when IDAH introduces a pelleting system it was the only system from Asia engineered for aqua feeds production. IDAH understands making a good shrimp feeds is not just about how a single machine performs but having a perfect systems is something that really matters and being very different from making animal feeds. Owning the right philosophy and perseverance to achieve perfection which were rooted in company’s core values, IDAH delivers a proprietary process sequences to make shrimp feeds and this sequence comprises key equipments of pulverizer, pellet mills with stages of pre-conditioner, and post-conditioner.  
  
IDAH’s contribution to shrimp feeds
In early 1970s, when IDAH introduces a pelleting system it was the only system from Asia engineered for aqua feeds production. IDAH understands making a good shrimp feeds is not just about how a single machine performs but having a perfect systems is something that really matters and being very different from making animal feeds. Owning the right philosophy and perseverance to achieve perfection which were rooted in company’s core values, IDAH delivers a proprietary process sequences to make shrimp feeds and this sequence comprises key equipments of pulverizer, pellet mills with stages of pre-conditioner, and post-conditioner. 
 

 

  • Pellet mill system that is engineered with dual stages pre-conditioners: a differential diameter conditioner (DDC) followed by a two set single shaft conditioners.
  • A pulverizer that uses swing hammers was introduced. Certainly without a pulverizer, shrimp feeds cannot be made with good quality (smooth surface) and it will run into a quality stability problem when mash is only grinded with hammer mills. ( fibers from the plant protein source need to be further reduced in size )
  • Concept of post-conditioner was proposed by IDAH in 1980s. A process which cuts down the formulation need for binders and strikingly improves water stability.

 
Because of the demands for smaller shrimp feed in diameter, IDAH invests the first gun drill facility in Asia from Germany in 1989. IDAH looks closer into the die designs and its connection with feed quality. With all the relentless efforts and thanks to all of our customers’ feedbacks, PM-53 pellet mill, a 4TPH system, is developed and become the most proven and acclaimed pellet mills in the world for shrimp feed pelleting.
 
Features and Benefits of IDAH process design and equipment
Formulation
Formulation is important to two perspectives: culturing performances and efficiency of the machinery. For example, choose the right starch source (types of flour) is important. Inappropriate starch sources will prevent the level of steam to be added and causes jams at the pellet mills. Fat and moisture content play big roles in the hammer mill and pulverizer throughput. High fiber mixes will increase wear of all machineries in the process thus reducing the life cycle of the parts especially for the hammers, screens and dies. In addition, water stability relates to fiber content level.
Mixing
We offer a range of mixers, depending on customer needs and preferences. Our mixers are all of very rugged design and we continue to develop new features such as geared shaft drives on our twin shaft mixers, which reduce noise, energy costs and maintenance costs.
Two stage Grinding and Pulverizing
We are firm believers in evenly reducing the particle size of the dry ingredients
down to a very fine powder, our typical target being more than 95% passing through a 60 mesh screen. It is impossible to make products efficiently with good quality at or below 2mm in size without this fine grind, and even for larger products process efficiencies and product quality are improved when using finely ground material, not to mention that it is possible to use less expensive starch ingredients when the grind is fine. It is also extremely difficult to make small pellets from high fiber ingredient mixes unless the ingredients have been finely ground through a pulverizer. We do recognize the potential extra energy costs incurred when using a pulverizer, which is why we have created a revolutionary design that runs at much lower energy costs. The small extra energy requirement still used by the pulverizer is more than compensated for by the ability to use cheaper ingredients and downstream energy cost savings. Pellet surface will be smooth, shiny and attain good water stability when pulverized raw material is used.
Pre-Hydration
We always recommend the use of pre-hydration in mixers designed to do this. The addition of even a small amount of water to dry ingredients at this early stage in the process dramatically improves throughput, energy costs and product quality. To ensure that the potentially more cohesive pre-hydrated mix can be evenly fed to the pellet mill we also supply our activated hopper system, with slowly rotating paddles in a semi-cylindrical hopper.
Pre-Conditioning
Our twin shaft pre-conditioners have an independent drive on each shaft, which improves power consumption and noise, and also allows the machine to be completely emptied by slowing and reversing the paddles. The addition of misting steam and water injectors further improves conditioner performance, followed by the use of steam jacketed mixer conveyors after the conditioner which creates an homogenous mix with little to no free water. Inappropriate pre-conditioning will cause cracks on pellet surface and creating more fines.
Pellet Milling Shrimp Feed
IDAH are in many regions the market leaders in this area. We pioneered the special design features that allowed us to be the first to make small water stable shrimp feed pellets. We have continued to improve design of our pellet mills with the recent launch of automation systems. IDAH makes its own dies and rollers for its pellet mills to ensure the most update arrangement of the compression ratio and holes patterns for change of formulation.
Post conditioning
IDAH is the first company which proposes the post-conditioning solutions in producing shrimp feeds. Direct results are pellets are stronger bounded with fewer fines and higher water stability. Cost of formulation is saved because less binder needs to be added and this tremendously helps digest ability of shrimps.
Drying
It is recommended to use a dryer after post-conditioner when 2% or more moisture is required to be removed. We offer a range of dryers, both horizontal belt/conveyor dryers and vertical cross-counterflow designs. Wherever possible we prefer to offer the cross-counterflow model to save energy costs. IDAH VC2R dryer has an especially small footprint and height compared to typical vertical counterflow dryers and also uses a lot less electrical power than most other designs, cutting down on capital costs, energy costs, maintenance costs and noise. A round shaped VCR dryer generates a very homogeneous air flow stream inside the dryer which allows an extremely uniform treatment of the product. This process air flow leads simply to the fact that over drying of the product is not given. Constant tumbling (up to seven times) of the product to be dried leads to best results in uniform water evaporation.
Cooling
Batch and semi batch counterflow cooling is the most efficient way to operate, so we offer this equipment whenever possible. Note that we like to stack dryers, coaters and coolers above one another whenever possible, allowing gravity to do the work, saving yet again on energy costs, capital costs and maintenance costs.
Crumbling
Dual stage crumbling (double roll) enhances the size homogeneity of the crumbled feeds and dramatically reduces the fines to increase yield rate.

 

 
 
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