10T/H Fish Shrimp Aqua Feed Mill in Brazil

This is a comprehensive feed mill project and also an aqua feed mill expansion project in Brazil.

The 10 t/h aqua feed mill in Brazil project was originally a manufacturer that processes livestock and poultry feed, concentrated feed, premix, and extruded feed. Based on the prospects of aquatic feed and biological fermentation feed, the client company finally decided to invest US$3 million to expand the aqua feed factory.

The 10 t/h aquatic feed mill in Brazil project covers a total area of 33367.96m2. The expansion project relies on the existing workshop and builds a new 5-story aquatic products workshop with a total construction area of 3674.35m2 in the existing factory area.

The 10 t/h aqua feed mill in Brazil project builds 1 puffed fish feed production line, 1 shrimp feed production line, 1 fermented raw material production line and 1 fermented feed production line, with a production capacity of 70,000 tons (Fish feed processing 8t/h, shrimp feed processing 2.5-3t/h, fermented feed processing 1.5t/h, fermented raw material processing 300kg/h), supporting environmental protection projects, etc.

After the aqua feed factory expansion project is completed, the entire plant will have an annual output of 135,000 tons of various Plant aquatic products, livestock and poultry feed and feed additives.

Note:

• For pig feed pellets: Among them, 2,000 tons are used as raw materials for the fermented feed production line of this expansion project.
• For shrimp feed pellets: Among them, 4,000 tons are used as raw materials for the fermented feed production line of this expansion project.
• For extruded fish feed pellets: Among them, 0.1 million tons are used as raw materials for the fermented feed production line of this 10 t/h aqua feed mill in Brazil expansion project.
• For Fermentation raw materials: Used as raw material for feed production in the 10 t/h aqua feed mill.
• Fermented feed production: Raw materials are the finished pellet feed from shrimp feed production line, pig feed production line and puffed fish feed production line.

Labor quota and work system

• Labor capacity: The 10 t/h aqua feed mill in Brazil project will add 30 employees, all of whom will have room and board in the aqua shrimp fish feed mill factory.
• Working system: two shifts a day, 8 hours each, specific working hours 7:30-12:00, 13:00-16:30, 16:30-23:30, 300 days of work per year.

The main engineering contents of the 10 t/h aqua feed mill plant in Brazil project are detailed in the table below.

• New aquatic feed production workshop:
  covering an area of about 517.9m2, with 1 puffed fish feed production line and 1 shrimp feed production line. The main aqua feed machine includes cylindrical primary cleaning screen, wide micro pulverizer, ultrafine pulverizer, aquatic feed extruder, and vacuum spraying machine, impeller cooler, packaging scale;
• New fermentation raw material workshop:
  covering an area of about 1227.93m2, 1 fermentation raw material production line, the main equipment includes bucket elevator, mixing mixer, fermentation tank, counter flow cooler, automatic packaging platform; (relying on the original fermentation feed raw material workshop)
• Fermented feed production workshop:
  covering an area of about 150m2, with 1 fermented feed production line. The main feed equipment includes a strain batching and metering system, a bacteria liquid adding system, a pellet feed batching and mixing system, and a packaging and metering system. (Relying on the original feed workshop)

• Raw material storage area:
  The raw materials for the extruded fish feed and shrimp feed production lines are located in the northeast of the new aquatic products workshop (relying on the new aquatic products workshop), and the fermented raw materials and fermented feed production line raw materials are located in the northeast of the original raw material workshop;
• Finished product storage area:
  The finished products of the puffed fish feed and shrimp feed production line are located in the finished product warehouse, and the finished products of the fermented raw material production line are located in the fermented raw material workshop;
• Fermented feed workshop:
  The finished products of the fermented feed production line are located in the original raw material workshop;
• Boiler room:
  Located in the north of the production workshop, there is a 15t/h biomass-fired steam boiler and an 8t/h biomass pellet-fired boiler. The 8t/h biomass pellet-fired boiler is on standby. (Relying on existing projects)
• Comprehensive building:
  used for the office life of 10 t/h aqua feed mill in Brazil project employees, located on the southeast side of the production workshop. (Relying on existing projects)
• Canteen:
  first floor of the complex building. (Relying on existing projects)

The main raw and auxiliary materials of this 10 t/h aqua feed mill in Brazil project are detailed in the table below:

After the expansion and operation of this 10 t/h aqua feed mill in Brazil project, the main energy consumed will be water, electricity, and boiler steam. The construction relies on the company's existing public and auxiliary projects.

• ① Power supply:
  provided by local Power Supply Bureau. The company’s existing power supply facilities can guarantee the electricity demand for 10 t/h aqua feed production line in Brazil project construction and commissioning.
• ② Water supply:
  The water for the expansion project is supplied by the local water pipe network, mainly domestic water. The total water consumption is approximately 1080 m3/a.
• ③ Drainage:
  The drainage in the factory area adopts a rainwater and sewage diversion system. The wastewater discharged is mainly domestic sewage. Rainwater pipes installed on grade highways.
• ④ Boiler steam:
  The boiler steam required for the expansion project will be provided by the existing 15t/h biomass-fired steam boiler in the factory area.
  The gas supply volume of the existing boilers in the plant can meet the needs of the entire fish shrimp feed plant after the expansion Brazil aqua feed mill project is put into operation.Boiler steam supply requirements.
  Based on similar production experience, the steam requirements for various products in the project are shown in the table below:

• The expanded aquatic feed workshop is adjacent to the west side of the existing aquatic products workshop, making it easy to rely on the odor treatment facilities of the existing aquatic products workshop and the raw material storage area and finished product storage area of the existing aquatic feed processing line.
• Each production workshop arranges process equipment that are closely related to each other in production into zones according to their usage functions. The production links in the workshop are tightly connected, which is conducive to energy saving and consumption reduction, and the loss of construction materials, which is conducive to clean production and can meet the feed production process requirements.
• The main noise-generating production equipment is arranged on the side of the factory building away from surrounding enterprises and sensitive points, which is conducive to reducing noise at the factory boundary and reducing the impact on the external acoustic environment.

The biological feed of this 10 t/h aqua feed mill in Brazil project uses soybean meal, corn DDGS, flour, chicken meal, etc. as the main raw materials, and is combined with trace ingredients such as vitamins, amino acids, and minerals to make granular feed. The project adopts the process of first crushing and then batching.

The raw and auxiliary materials that need to be crushed (soybean meal, corn DDGS, rice bran) are crushed by the crusher respectively, enter the batching bin, and are mixed with other raw and auxiliary materials that do not need to be crushed (fish meal, flour, etc.) The machine performs mixing, puffing and granulation processes to produce feed products.

The production process of the puffed fish feed production line and the shrimp feed production line of this 10 t/h aquatic feed plant in Brazil project are basically the same. Except that the feed of the puffed fish feed line needs to be puffed and sprayed with grease, only the ratio of raw and auxiliary materials is different.

The main processes are briefly described as follows:

01

Raw material receiving, cleaning and crushing section

The auxiliary materials required for production are directly sent to the raw material workshop for storage after being weighed, weighed and inspected by a truck scale.

If the moisture content of the material is too high, the amount of steam added during pelleting will be reduced, which will affect the increase of the poultry feed making machine pelleting temperature, thereby affecting the yield and quality of pelleted feed.

The raw materials that need to be crushed enter the production workshop through conveying equipment, and then enter the warehouse to be crushed after being passed through a preliminary cleaning screen to remove impurities and a permanent magnet cylinder to remove ferrous impurities.

After the raw materials in the crushing bin are crushed to qualified particle size requirements by the crusher, they are distributed to the raw material bin for storage through the conveying equipment.

The raw materials that do not need to be crushed enter the production workshop through the conveying equipment. After the initial cleaning screen removes impurities and the permanent magnetic cylinder removes ferrous impurities, they are sent to different raw material bins for storage by the distributor.

02

Batching and mixing section

According to the requirements of the formula, various raw materials participating in the batching are entered into the mixer in sequence through the computer-controlled batching scale. Two batching scales, one large and one small, are used in the batching process to ensure the accuracy of batching and shorten the batching time.

Some additives, vitamins and other raw materials with small amounts are manually weighed and put into the mixer manually. Various raw materials are mixed in the mixer. The mixed powder enters the puffing section to make puffed feed, and the feed that does not require puffing enters the pelleting section.

03

Granulation and screening

The 10 t/h aqua feed mill in Brazil project adopts thermal granulation method for granulation. The granulation process uses steam modulation. The aqua feed production line project uses a 15t/h biomass boiler to provide the steam required for granulation.

The materials from the mixing section are conditioned through a conditioner, and then indirectly heated to 85C with high-temperature steam to gelatinize, before entering the shrimp feed pelletizer for granulation.

The main pollution during the granulation process is mechanical noise and granulation dust when the shrimp feed pellet machine is running. The finished feed enters the impeller cooler for exhaust cooling. Cooling is a physical process that reduces the moisture inside and outside the feed to a qualified moisture range.

The cooled pellet feed enters the plane rotary classifying screen through the elevator. The overly fine particles or powder re-enter the granulation process, and the overly coarse particles enter the granulation process after being crushed.

04

Puffing, drying and spraying

The prepared, mixed and finely powdered materials first enter the expansion bin to be processed. When working, the feeder evenly and continuously feeds the materials to be expanded into the dual-shaft differential conditioner for conditioning.

When the material enters the conditioner, the material is added to the conditioner evenly, continuously and measured. steam, water and other liquid additives.

After a certain conditioning time in the conditioner, the material enters the feeding section of the extrusion assembly to start the extrusion operation. The material is input from the feeding section. The main function of the feeding section is to transport the material to the kneading area. and preliminary compression of the material.

In the kneading section, the material undergoes intense stirring, mixing, shearing, etc., and the material gradually matures or melts; entering the final curing section, the pressure and temperature further increase, the material is further matured, and the starch is further Gelatinization, fat and protein denaturation, tissue homogenization and formation of amorphous texture, the final material is extruded and cut into shape through the discharging assembly.

The expanded molding materials enter the dryer through the air transport system, and the steam-heated air is used as the drying medium to remove excess moisture in the materials so that they can meet the moisture requirements required for the finished product. Finally, the surface of the pellet feed is sprayed with liquids such as grease, vitamins, antioxidants, amino acids, etc. in batches through a spraying machine.

05

Measuring and packaging of finished products

Packaging of finished products is the last step in feed processing. There is a packaging scale installed under the finished product warehouse. The packaging scale automatically quantifies packaging according to the quantity set during debugging, and then the bag mouth is sewn by a sewing machine to complete the processing.

The production process of the fermentation raw material production line is as follows:

01

Soybean meal feeding system

The soybean meal and stone powder (ratio 100:2.23) purchased outside the 10 t/h livestock poultry aqua feed mill in Brazil project were manually broken into bags and put into the pit-type feeding port near the ground, and then entered the raw material warehouse through a bucket elevator and screw conveyor.

02

Bacteria inoculation mixing and batching system

The materials are transported into the mixer through the screw conveyor, and bacteria and water are added at the same time to mix and inoculate the materials. The starter culture mainly includes yeast, lactic acid bacteria, Bacillus, etc.

After purchase, it is temporarily stored in the bacterial culture tank in the factory. The solid starter culture is in a dormant state before it comes into contact with the materials and can be activated after inoculation.

According to the requirements, the bacteria are added at a ratio of 4kg bacteria/t soybean meal; the fermentation water consumption is controlled between 35~40%. The entire mixing process is completed in a closed system.

03

Raw material fermentation system

Load the evenly mixed materials into the hopper of a forklift and transport them to the fermentation tank for fermentation of the materials. The project builds 3 fermentation tanks. Each fermentation tank can accommodate 100t of soybean meal. Deep fermentation is used.

The fermentation stacking height is greater than 2.0m. It is left to stand for the whole process without turning. Each fermentation tank is fermented in batches and each batch can accommodate 300t. Soybean meal is fermented, the fermentation time for each batch is 72 hours, and there are 100 batches of fermentation per year.

During the fermentation process, the temperature is controlled at about 28~40°C, the moisture content of the material is maintained at about 40%, and the pH is controlled between 4.5 and 7 according to different stages.

The fermentation process is a fermentation method that combines aerobic fermentation and anaerobic fermentation. At the beginning, the fermentation process is aerobic and the starting pH is natural (around 6.5). Aerobic fermentation promotes the reproduction and growth of aerobic microorganisms such as Bacillus and yeast. At the same time, Bacillus and yeast powder produce a large number of enzymes, vitamins and other active products to promote the growth of lactic acid bacteria.

In the later stage of fermentation, there is anaerobic fermentation, lactic acid bacteria multiply in large numbers, and the pH decreases accordingly. Microorganisms are forced to autolyse under anaerobic conditions, and intracellular mold and other biologically active components in the cells are secreted.

During anaerobic fermentation, proteases undergo enzymatic hydrolysis reactions. It also produces fermentation waste gas (mainly ethanol), which is unorganized emissions, and workshop ventilation should be strengthened.

The soybean meal fermentation process of the 10 t/h livestock poultry aqua feed mill in Brazil project is divided into two stages, the aerobic fermentation at the beginning and the anaerobic fermentation stage at the end.

04

Drying and cooling system

Drying: After the fermentation is completed, the materials are transported to the tube bundle dryer by forklift. The drying source relies on a 15t/h coal-fired boiler to indirectly heat the materials. The moisture content of the materials discharged through the discharge port is between 10% and 15%. between.

Cooling: The dried materials are transported to the counterflow cooler via the elevator, and air cooling is used for cooling.

05

Finished product packaging system

The cooled materials are bagged and packaged and used as feed processing raw materials for existing projects.

The 10 t/h livestock poultry aqua feed mill in Brazil project uses mixing, fermentation, drying, cooling and other processes to produce fermented soybean meal. The production process is not a high-pollution, high-energy-consuming, high-water-consuming process and meets the requirements of clean production level.

Brief analysis of process flow:

The semi-finished product raw materials are put into the raw material warehouse. The bacteria and water are automatically weighed and entered into the water distribution scale and mixed evenly. The raw materials enter the vacuum tank for mixing.

The bacteria liquid is automatically entered into the vacuum tank from the water distribution scale for mixing. After the mixing is completed, the materials are sent to the finished product warehouse by the conveyor belt. The finished product is packed on a scale and fermented in a cool place for three days.

It is worth highlighting the enviable resilience of Brazilian feed companies in face of dwindling increase in labour productivity, low economic growth, contraction of supply due to the scarcity of inputs and concerning exchange rate. They overcome these obstacles and continue to manage high costs and supply producers.

The production of feed for fish and shrimp totalled 1.4 million tonnes in Brazil last year. An atypical colder climate also reduced Brazilian consumption for those products during the months between September and October. Even so, a moderate recovery should take place in the last months of the year and allow feed demand to increase around 8% in the whole year.

Brazilian aquaculture production could reach 10 million tons annually, given the country’s favourable climate, availability of fresh water, the extent of the coastline and its millions of hectares of lakes and reservoirs.

As one of the countries with the fastest growing aquatic feed processing scale in South America, Brazil is developing aquaculture and aquatic feed processing at a very impressive growth rate.