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Innovation on ContraTwin
                                                                                                                         Last update: Oct. 04, 2016

DEBUNKING THE MYTHS OF TWIN SCREW EXTRUSION FOR
AQUATIC FEEDS AND PET FOOD
   
Background of Extrusion

The beauty behind extrusion is that it not only simplifies tedious manufacturing steps into a single one-stage process, but also allows for wider characteristics of extruded feed and food products to be produced. Owners of extruders could save significant amount of money by avoiding traditional processes which often are composed of multiple equipments and significant operation costs.
Ever since the extruder was introduced to the market, there have been tremendous improvements to the machine to make it more functionally versatile and stronger built. After nearly a century of academic studies and feasibility in the commercial runs, two categories of extruders can be bought in the market categorized by its mechanical forms: single screw extruder and co-rotating twin screw extruder.   

Background of Innovation

Still in its infancy stage in Southeast Asia, the petfood and aquafeed industry (especially for floating fish feeds made by extrusion) has been experiencing high organic growth by volume of feeds produced every year. In order to fulfill this growing demand, more lines of extrusion equipments are invested. Several challenges have emerged from this unprecedented expansion: lack of qualified operators, production problems due to formulation changes (increasing the concentration of plant protein versus animal protein), loss of startup wastes, unseasoned equipment operational and maintenance skills, higher standards for feed quality, and costs of energy per ton of feeds produced. 
Manufacturers of petfood and aquatic feeds have seen significant increases in the cost of their raw materials and energy costs. Profit margins have been difficult to maintain and the future promises no change in this situation. IDAH have always recognized these issues and it is built into our core philosophy to supply solutions that maximize opportunities for our customers.

ContraTwin: answer to all challenges 

To meet these new challenges, a revolutionary extrusion system designed to fit the local markets was required. With a 40-year history in Aquafeeds Production, IDAH developed its answer: ContraTwin. It is designed with twin screw extrusion features but with reengineered screw designs and rotation direction to accommodate future aquafeed formulation. Developed to convey very sticky and puffy material (such as high fiber materials like plant protein), ContraTwin uses a very positive pump that does not waste mechanical energy or shear. For tougher materials, operators can perform cooking in the mid-barrel system: this is where the actual work is done. The result of this strong pump and cooking significantly increases efficiency and utilizes low Specific Mechanical Energy (SME) when compared with other single or co-rotating twin screw extrusion.
The ContraTwin is designed with an innovative 3-part transmission system. A motor drives a splitter gear box and a relatively large bearing base is aligned and interconnected: this delivers a 24/7 rugged operation machine.
The ContraTwin extruder is very easy to use and offers a unique operation experience. It is designed for beginner operators, easing most customer fears of finding skillful extruder operators. Simply put, the ContraTwin extruder is designed to be operated by “farmers”. Sharing the benefits of extruders with twin screws, ContraTwin has low start up waste and wide product characteristics compared to single screw extruders. More than 30 products, ranging from 0.8mm floating fish feeds to 27 mm sinking fish feeds have been successful tested. Remarkable energy saving per ton (up to 20% energy saving) have been observed at customer sites. Another method that ContraTwin saves energy is by using more direct steam thermal energy instead of mechanical energy or shear. Due to the significant reduction in energy consumption, feed millers are able to produce less carbon foot prints: directly giving them sustainable feed products.

Features and Benefits of ContraTwin:

  • Unique drive train to minimize capital costs, energy costs and maintenance costs – We engineer for rugged 24/7 operations
  • ContraTwinscrews don’t waste energy shearing product. They convey even the most difficult fibrous ingredient mixes to the point in the extruder where we choose to do the work
  • ContraTwinmid-barrel die with shaft support system is the place we choose to do the work for most products. This short intensive work zone minimizes the wasted energy resulting from traditional extrusion systems, with minimum back-flow (pressure flow) giving minimized length of the work zone, reducing torque.
  • The very positive action of the ContraTwinscrews forms highly uniform pellets even when fibre content is high or viscosity is low.
  • All this creates a machine that has specific mechanical energy (SME) costs and wear costs only typically previously seen in single screw systems, with capital costs that also match.




IDAH has experienced a breakthrough in becoming the first Asian extrusion company that has its own extrusion technology. We believe that the development of ContraTwin will accelerate the extrusion technology. 
  
IMPROVING YOUR BOTTOM LINE IS OUR MISSION
 

 
 
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