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Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom.All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

Digital Re-print - March | April 2011 HTST and the Feed Expander

www.gfmt.co.uk

Choosing the correct pre-treatment for your compound can be crucial for your feed output. The Feed

Expander is in many ways capable of bringing your feed pellets to a higher quality level as well as improving your production process and flow.

The Feed Expander is capable of greater throughput with lower energy cost, giving the advantages a feed pro-ducer is looking for.

The interest for opti-misation of the pelleting process by improving the pre-treatment of the compound and by fully computerized systems started back in the 1980s.

Government regu-lation in terms of spe-cific thermal processing requirements for elimina-tion of risk for salmonella and related bac-teria, and the increased demand for a higher durability of feed generated a need for HTST conditioning.

The Feed Expander is a result of the increasing need for High Temperature Short Time conditioning and is able to produce feed in an economically way meeting the increasing demand from the feed customers for durable feed as well as government regulations.

The expander processThe expander process is referred to as

a high temperature and short time process (HTST). A process primarily used for pre-treatment and conditioning of animal feed.

A traditional cascade mixer is used to raise the feed temperature to 80-90°C by means of steam. The feed is then further

conditioned in the Feed Expander by a kneading process under high pressure result-ing in an increase in the temperature of the feed.

The following are some of the advantages which can be achieved:• Better physical pellet quality, fewer fines • Elimination of bacteria, mould etc • Better activation of natural binders

inherent in raw materials

• Possibility of adding larger amounts of liquid additives, that is, fat or molasses - pellet coating may become unnecessary

• Improved digestibility of the feed • Reduction of growth inhabitants

The high temperature - up to 150°C - in the Feed Expander is obtained by the heat from friction (electrical energy transferred into thermal energy) and by steam injection directly into the screw.

With such high temperatures starch cooking is improved resulting in increased

HTST and the Feed Expander by anne Mette lorenzen, andritz Feed & Biofuels a/S, Denmark

Temperature °C

Temperature °C

Temperature

Pressure

Steam

120 °C

100 °C

85 °C

20 - 80 bar

Loss-in-weight system

Feeder screw

Conditioner

By-pass

By-pass

Feed Expander

Wing crumbler

Pellet mill

Pellets outlet

Grain&feed millinG technoloGy18 | march - april 2011

FEATURE

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Grain&feed millinG technoloGy march - april 2011 | 19

MADE IN HOLLAND

AL30O

Almex b.v., Verlengde Ooyerhoekseweg 29, 7207 BJ Zutphen, The Netherlands, tel. +31 (0)575 572666, e-mail info@almex.nl, www.almex.nl

High capacity extruders and expanders.

AD System

MADE IN HOLLAND

Since 1883

HIGH PERFORMANCES LOW COST MAINTENANCE MAXIMUM SAFETY LONG LIFETIME WWW.CPMEUROPE.NL

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• Long term conditioners,

Hygieniser

• Remote roll

adjustment, Lineator

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The best value package with the lowest cost per tonne

CPM is again setting the standard for the future with the recently developed 7936-12 pellet mill equipped with 355 kW drive motor

Quick diechangeclamp

355 kw

Roll speed

Measurement

More than 125 years world 's leader in produc tivity

GFMT11.02.indd 19 30/03/2011 15:53

Expander. In the Feed Expander screw the material is further kneaded, compressed and heat-treated in a continuously control-led HTST (high temperature, short time) process.

By a process of pressure, kneading and friction the feed temperature is increased to for example 105°C in the Feed Expander. This temperature can even be increased to 130°C by addition of steam directly into the barrel of the expander.

The process is another alternative to double (2-stage) pelleting. Recipes can con-tain higher fat contents and in some cases downstream fat coating of pellets can be eliminated.

Rule of thumb regarding the effect of the feed expander: One tonne of mixed feed increases the temperature by 2°C at a power consumption of 1kWh.

The process pressure and the motor load are controlled by means of hydraulical adjust-ment of the screw’s variable nozzle (see Figure 1) closed, (see Figure 2) open. This con-struction ensures maximum mechanical stability and easy/quick access to the nozzle and the screw. The pressure and the temperature in the nozzle as well as the degree of open-ing are continuously registered and monitored in the process control.

Heating of the product in the Feed Expander screw is obtained by heat of fric-tion (electrical energy), and by steam injection directly into the screw. The process pressure, temperature, and distribution of steam and friction energy are chosen depending on

which product improve-ment is required.

The product is dis-charged from the expander directly to the pellet mill die or to the cooler if pelleting is not required.

The Feed Expander offers several benefits such as animal performance improvements, lower feed moisture, more flexible feed formulation, improved feed hygiene, increased pellet mill throughput, manipulation of feed bulk density and particle size, ability to crumble without pelleting and longer pellet die life.

The Feed Expander is a great alternative to the traditional conditioning technology.

a larger capacity of the pellet mill and fewer blockages and longer lifetime on pelletmill wear parts due to smoother flow with expanded compound. Higher feed temperatures giving an extra safe-guard against Salmonella and a noticeable improvement in physical pellet quality are just some of the advantages obtained from the process.

Functional principle The Feed Expander can be compared

with a simple extruder screw where the die plate has been exchanged with a hydraulically operated nozzle. By regu-lating the nozzle gap, the temperature

and pressure to which the feed is subjected in the screw section can be controlled.

The feed mixture is preheated in a cas-cade mixer to 80°C as used in traditional pelletizing and thereafter fed to the Feed

gelatinisation making it possible for the par-ticles/mixture to absorb more liquid (steam, fat/oil, molasses) and to improve the binding properties. This makes it possible to com-pose feed formulas without considering the binding properties of the raw material thus the natural binders in the raw material are activated on a higher level.

At the outlet of the expander the mixture expands once in atmospherical conditions due to the high pressure (10-80 bars) in the Feed Expander, causing evaporation of moisture to a level just enough for an optimal pelleting process and at the same time resulting in feed pellets with a lower moisture content meeting the demand for pellets with longer durability.

Benefits are not only met in the physical improvement, elimination of bacteria and improved digestibility of compound feed, but also process-wise.

Expansion of compound also results in fewer fines, meaning less recirculation,

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Grain&feed millinG technoloGy20 | march - april 2011

Figure 1 Figure 2

FEATURE

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Grain&feed millinG technoloGy march - april 2011 | 21

Process technology, machinery, and complete plants for the animal feed industry

ANDRITZ FEED & BIOFUELEurope, Asia, and South America: andritz-fb@andritz.comUSA and Canada: andritz-fb.us@andritz.com www.andritz.com

Lifland, Iceland. A complete pro­cess ing line for animal feed pro-duction. With this greenfield plant (capacity 50,000 t/a), Lifland will cover nearly 60% of total animal feed production in Iceland. The turnkey feed plant star ted pro-ducing in October 2010.

Together, we make it work!

■ New process lines and plants ■ Process equipment upgrades and replacements ■ Spare and wear parts ■ Service and maintenance programs ■ Optimization and support■ Leading technologies ■ Global presence ■ Local service

Save money and improve quality

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DA 7300 On-Line

VICTAM 2011

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The road to profitabilityhas never been clearerOur well proven bench top DA 7200 and the DA 7300 On-Line NIR analyzers improve quality and profitability of your feed.

• Save on ingredients & reduce waste • Optimize moisture content • Improve feed quality and consistency

Learn more about our NIR feed analysis systems, visit www.perten.com

BPRV (Barrel Pressure Release Valve)(PATENT REGISTERED MACHINE)

Features• No watse factory space by installing on 2nd barrel from fi nal.• Convenient and easy control of DENSITY OF FEED by valve control.• Maintenance Free from Machine (Very Lower cost)• Saving power energy by circulation heat energy to Conditioner from

barrel and down main motor torque 10~20%.• BPRV can be installing on Existing Extruder.

Usage: For improvement to make sinkable feed (adjust slow/fast sinking) and help consistent feed production very easily!Also, enhance digesting of fi sh feed by enough cooking and show fast growing rate of fi sh.

YONG BOK CHO / PRESIDENT

Tel: +82 104112 8833 +82 53 3512323

Email: maruexport@yahoo.co.kr

We can supply also these items:Twin/single extruder, barrel, sleeve & screw, die plate, etc

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GFMT11.02.indd 21 30/03/2011 15:53

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WorldOfDiffSEB_HD_Oct2010 10/25/10 11:40 AM Page 1

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Innovations for a better world.

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DFZP_210x297_Granulex.indd 1 03.02.2011 07:41:43GFMT11.02.indd 62 30/03/2011 15:56

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