What is Extrusion and why Extruding?

What is Extrusion?Screws & Choke Plates

What is Extrusion and why Extruding?  A question I am sure many would ask.  Several definitions for extrusion exist – from the traditional “forcing material through a die or hole” to definitions focussing on other aspects of extrusion as well.

Extrusion, as it is applied in the animal feed industry, could not be discussed without focussing on extrusion as a Thermal Process.  By extruding feed ingredients and formulations, we involve heat energy as part of the extrusion process.

Therefore, a more descriptive definition in terms of animal feed manufacturing could be :

  1. Extrusion is a Thermal Process,
  2. where we knead and cook starchy and / or protein-based ingredients under specific moisture conditions,
  3. into a plastic-like dough of viscosity we can control during the process.
  4. We achieve primary “thermal cooking” through friction between feedstock (the formulation or ingredients we are extruding) and the internal extruder barrel components.
  5. We can also apply additional heat externally via
    • Barrel Jackets or Heater Bands, or
    • Direct injection of steam into the barrel at appropriate positions.
  6. Apart from creating a thermal effect as discussed above, we also apply shear forces to the dough creating very specific extrusion end results that could be controlled during operation.
  7. The mix of operating conditions as discussed above leads to gelatinisation of starch; denaturing of protein; minimising of anti-nutritional factors and neutralisation of microbial counts in feed ingredients and by-products used in animal feed manufacturing.

A more in-depth discussion of how temperature is generated is discussed in the Extrusion defined page of this website.

A complete Extruder is composed of various parts or zones in order to make it functional as the following diagram shows:What is Extrusion and Why Extruding?

  1. Mass Flow Surge Bin – making feedstock available for extrusion without flow-interruption.
  2. Volumetric Feeder – extracts feedstock from Surge Bin in “first-in-first-out” manner
  3. Preconditioner – conditions feedstock with steam and / or water or other liquids.  Some Thermal Processing starts taking place in the Preconditioner.
  4. Extruder – extrusion cooking of feedstock.  Primary point of Thermal Processing.
  5. Restriction Head – used for processing Oilseeds or in some cases wet products such as By-Products
  6. Cutter Head – used to produce shaped feeds such as Aquatic Feeds, Petfoods or other shaped animal feeds.

Why should we extrude?

Extrusion, just like any other feed milling process, has to be justified before money is invested into an extrusion line.  At least the following boxes should be ticked before we can justify an investment in extrusion:

  1. To minimise the effect of any “anti-nutritional” factors present in the Feed Ingredients we are using to make feeds with.  Soybeans is a classic example as it contains Anti-Nutritional Factors that prevents farmed animals to utilise the full nutritional value thereof.  Fortunately the majority of anti-nutritional factors are heat sensitive – extrusion is one of the most effective Thermal Processes available.
  2. To fulfil specific Process Requirements.  Do we need to shape final products for application as Petfood or Aquatic Feed?; do we have to sterilise a By-Product? do we have to control product density (as for floating aquatic feeds)?; etc.  Our page Effect of Extrusion outlines such potential process requirements.
  3. To maximise nutritional value of feed.  The main purpose of making animal feeds is to provide nutrition and to ensure safe feeds for farmed animal.  Extrusion processing maximises the digestibility of
    • Protein
    • Fat
    • Fiber

and therefore helps to produce edible meat, milk and eggs at the lowest cost per kilogram.

Remember : the ultimate goal is to maximise cash inflow into and minimise cash outflow from the business.  There is more than one way through which Extrusion can help achieving this goal.  The application opportunities for extrusion is only limited by our imagination and understanding of the opportunities around us.

Contact us today to discuss the extrusion solution that will fit your specific requirements or that will help to make use of locally available ingredients or by-products.

ALMEX joined the Triott Group

Triott Group Logo

ALMEX joined the Triott Group of Companies.  ALMEX is renowned for their innovation in the Expansion and Extrusion Industries.

The Triott Group of Companies is the Parent Company of Ottevanger Milling Engineers, Wynveen International, Inteqnion, TSC, PTN and now also ALMEX.

The daily business of ALMEX will still be driven by Jaap and Robbert Veenendaal, the previous sole owners of ALMEX.  The new structuring of ALMEX within the Triott Group, will lead to new opportunities in serving the animal feed industries with expertise and experience and will further widen the Triott Group’s capabilities as a truly Single-Source-of Supply.  It will also help ALMEX expanding their market focus and further developing their capabilities.

Triott Group of Companies

The Extrusion Wait is History!

We are happy to announce that The Extrusion Wait is History!  Our non-compete agreement with an American Extruder Manufacturer is history.  But the 2 year “quiet time” came in handy as we could attend to issues we know are important to our customers.  The challenge of supplying Extrusion Solutions to a modern-day Food and Feed Extrusion Industry, kept our hearts passionate and our minds working throughout this period. Extruded Products 1

 Our Extrusion Background

  1. During the past 25 years we travelled to and worked in more than 50 countries around the world.  We learned to work across the borders of countries and cultures and in the process learned a lot about what people need and what people want.  A complete Capability Profile is available on our website.
  2. We worked with companies small and large; Research Institutes and Universities; The American Soybean Association and Human Food Relief Programmes.
  3. Our passion has always been understanding the science behind extrusion on the one hand, and the commercial requirements for extruded products on the other hand.  This was the driving force behind our Research and Development work, improving and designing Extruders and Extrusion Process Plants.
  4. Our strengths in Project Management played a key role in helping many customers establishing Extrusion Plants successfully around the world.
  5. We have 25 years experience training Extruder Operators and Commissioning Extrusion Plants around the world.
  6. We assisted numerous customers Trouble Shooting their Extrusion Operations and finding solutions that could fast track their commercial success.
  7. We designed a great number of complete Extrusion Plants for various extrusion applications.
  8. We supplied extrusion equipment carefully to suit application and customer budgets.
  9. During our 25 year involvement, we served the following Extrusion Industry Sectors:
    1. Oilseed Processing
      • “Full Fat” Extruded oilseed meal as well as extruded / mechanically expelled oilseed meal
      • Vegetable oil refining
      • Biodiesel manufacturing
    2. Extruded Petfood Manufacturing
    3. Extruded Aquatic Feed Manufacturing
    4. Extruded By-Product Processing
    5. Extruded Human Foods such as:
      • RTE (Ready-to-Eat) Breakfast Cereals
      • TVP (Textured Vegetable Protein) including TSP (Textured Soy Protein)
      • Corn-Soy Blends and other foods of value to Human Food Relief Programs

The Difference We Can Make

There are thousands of Food and Feed Manufacturers around the world using High Shear Extruders (also referred to as “Dry” Extruders or “Low Cost Extruders”) making a range of feed and food products.  We are well aware of your challenges using High Shear Extruders.  We now offer solutions to many of these challenges that will…..

  1. lower Wear / Spare Part Cost
  2. give you more flexibility in terms of the Raw Materials you can use and the Extruded Products you can make.

These solutions have a big effect on lowering Operating Cost while increasing Marketing Opportunities (especially Shaped Products) and include:

  1. Replaceable Barrel Liners – greatly reduces Wear Part Cost and Shipping Cost as you do not have to replace the Barrel Housing or Compression Chamber anymore.
  2. Split Barrels – we offer Split Barrel options for Compression Chambers / Barrel Housings that greatly assists in disassembling an extruder barrel.  This minimises the cost of down-time during unwanted blockages.
  3. Complete Medium Shear Barrel Kits – these fit onto your existing High Shear / Dry / Low Cost Extruder (Millbank / MILTENZ / JSC / Insta-Pro) and converts it into a Medium Shear Extruder.  Medium Shear is the required technology should you want to make shaped products successfully (Petfood / Aquatic Feed / some Human Foods).  It will also allow you to make use of a wider range of raw materials (making “least cost formulation” more achievable) thereby cutting raw material costs substantially.

Visit the hp dezign website today to learn more about Wear Parts and Medium Shear Barrel Kits we have on offer.

Please contact us to discuss challenges with you current operation or your requirements for a new operation.

Ottevanger & hp dezign at Australasian Milling Conference 2014

The Australasian Milling Conference 2014 (AMC 2014) is staged in the Gold Coast Convention & Exhibition Centre on the 25th to the 27th of May 2014.  It is the first year Ottevanger Milling Engineers are taking part as an Exhibitor at this event.  Paul Eijmberts (Ottevanger Asia Pacific Sales Manager) and Hennie Pieterse from hp dezign (Authorised Ottevanger Representative for Australia & New Zealand) will be there to meet you and discuss your Feedmilling aspirations and needs with you.  Paul will also present a paper on Containerised Feed Mills on Tuesday the 27th.  Don’t miss this event!  You are invited to come and see us and learn how we can help you realise your Feed Milling plans……..

Australasian Milling Conference 2014

Invitation AMC 2014

Ottevanger & hp dezign at VICTAM Asia 2014

hp dezign will be on the Ottevanger Milling Engineers Stand during the upcoming VICTAM Asia 2014 Trade Fair in Bangkok, Thailand.  We invite all our Customers to visit our Stand and learn more about the capabilities and support Ottevanger and hp dezign can provide.  The Ottevanger Stand number is A099 and the Trade Fair runs from 8 – 10 April 2014.  We look forward to seeing you in Bangkok!

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Containerised Feed Plant Options in ASEAN Region

Hennie Pieterse, hp dezign

Ottevanger, Inteqnion and the other Sister Companies of the TRIOTT Group (Wynveen, PTN & TSC Silo) are determined to establish a strong presence in Asia-Pacific.  The company has relationships with several Representatives in the Asia Pacific Region of which hp dezign (Australia & New Zealand) is one. Ottevanger built several Feed Plants around the Asia Pacific Region and demand is on the increase.  A News Release in the Sep – Oct 2013 issue of Grain & Feed Milling Technology features a Case Study of Ottevanger in the ASEAN Region.  In the article a discussion follows focussing on Containersied Feed Plants.

Please also see our latest Blog “Does a Containerised Feed Plant make sense for what you have in mind?” for a discussion on Containerised Feed Plants. A Containerised Feed Plant might be the ideal solution for the New Plant or Plant Expansion you are planning.  hp dezign and Ottevanger are ready to help you decide whether a Containerised Feed Plant is the right solution for the application you have in mind.  Contact us today to discuss.

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