Animal feed extrusion: what machinery is needed?

In previous articles, we have discussed the advantages of extruded products in animal feed. Here’s a reminder:

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• High stability in water and lower environmental pollution
• Improved food digestibility
• High efficiency and high conversion rate
• Selection of food buoyancy

Today we will outline the machinery and processes needed to produce top-quality extruded feed.

In the diagram above, the main steps in the manufacturing process of extruded feed are shown. Below, we will describe the main equipment involved and its importance.

Grinding

The raw materials for feed arrive at the factories in various formats and grain sizes, such as cereals, flours, and grain legumes. These elements must be ground to the proper particle size for subsequent mixing and 'cooking' during the extrusion process.

Hammer mills are commonly used for this task. Typically, two mills are used in series for pre-grinding and grinding. With the right size achieved, the materials are fed into the mixer.

Mixing

This step involves combining the ground materials to create the right mixture, following recipes developed by animal nutrition experts. Paddle rotor mixers are usually used to homogenize the mixture, ensuring uniformity before extrusion.

Extrusion

Conditioner

Intensive pre-conditioning is a crucial stage in the extrusion process. To prevent the pellets from expanding outside of the extruder, ingredients must be kept at a specific temperature.

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Extruder

Extrusion is the most critical phase. It is a high-temperature, short-duration process that minimizes nutrient degradation while improving the digestibility of starches and proteins. Extrusion compacts and 'cooks' the feed, requiring high humidity, temperature, and pressure to achieve the desired expansion. Single or twin-screw extruders compress the mixed materials to meet these conditions. The extruder continuously feeds the mixture of ingredients, which is then cut into cylinders of the desired thickness and length.

Drying

The extruded food contains excess moisture due to water added during pre-conditioning and extrusion. Drying is compulsory to maintain moisture stability in the finished feed. Large drying hoppers with hot, dry air eliminate moisture. The feed can move horizontally on a vibrating belt or pass vertically from one chamber to another.

Fat Coating

The fat coating process adds liquids, mainly oils, to the extruded products to increase their nutritional and energy value. A fat coating machine or vacuum mixer allows for higher oil incorporation by extracting air from the extruded pellet.

Cooling

Finally, the extruded product must be thermally stabilized. It is placed in a vertical cooler where room-temperature air circulates counterflow to reduce its temperature.

From this point, the feed is ready for packaging in various formats depending on the product and target market. These processes and associated machinery are supervised by experts. The quality of our products hinges on both raw materials and the recipes prepared by our animal nutrition experts.

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