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10T/H Fish Shrimp Aqua Feed Mill 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.

10T/H Fish Shrimp Aqua Feed Mill in Brazil

OVERVIEW

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.

  • Name:

    Floating fish and shrimp feed plant

  • Country:

    Brazil

  • Date:

    December 2021

  • Capacity:

    10 Tons Per Hour

  • Feed Pellet Size:

    1-4 mm

  • The install period:

    1.5 Years

  • Control Mode:

    Automatic

  • Guiding Price:

    US$3 million

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.

Product plan of 10 t/h aqua feed mill in Brazil

Name Annual output (t/a) (before expansion) Annual output (t/a) (after expansion)
Poultry feed 10000 10000
Feed for pig 18000 18000
Extruded livestock and poultry feed 1800 1800
Concentrated feed 6000 6000
Premix 6000 6000
Shrimp feed 3200 13200
Extruded fish feed 40000 80000
Fermentation raw materials / 1300
Fermented feed / 7000

Note:

Labor quota and work system

Construction content and scale

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

Main engineering

Auxiliary engineering

Main equipment for 10 t/h aqua feed mill in Brazil

Aquatic feed production line equipment

Raw material receiving system
Feeding port and fence 1
Pulse dust collector 1
Silencer 1
Fan 1
Scraper conveyor 1
Self-cleaning bucket elevator 1
Cylindrical primary cleaning screen 1
Scraper conveyor 1
Permanent magnet cylinder 1
Pulse dust collector 1
Rotary distributor 1
Permanent magnet cylinder 1
Rotary distributor 1
First coarse crushing system
Crushing bin 4
Buffer bucket 1
Feeder 1
Wide micro grinder 1
Pulse dust collector 1
Fan 1
Silencer 1
Settling chamber 1
Material sealing auger 1
Self-cleaning bucket elevator 1
Fan 1
Pulse dust collector 1
Rotary distributor 1
Ingredients warehouse 1
Ingredients auger 1
Ingredients scale 1
Feeding port and fence 1
Mixer 1
Screw conveyor 1
Self-cleaning bucket elevator 1
First batching system
Ingredients warehouse 32
Ingredients auger 10
Arch breaking and unloading machine 2
Air cannon arch breaking device 2
Broken arch ingredient auger 2
Ingredients scale 3
Pulse dust collector 1
Fan 1
Feeding port 1
Twin-shaft paddle mixer 1
Mixing buffer bucket 1
Scraper conveyor 1
Self-cleaning bucket elevator 1
Pulse dust collector 1
Fan 1
Permanent magnet cylinder 1
Scraper conveyor 1
Crushing bin 2
Buffer bucket 1
Feeder 1
Wide micro grinder 1
Pulse dust collector 1
Fan 1
Silencer 1
Settling chamber 1
Material sealing auger 1
Permanent magnet cylinder 1
Pulse dust collector 1
Fan 1
Permanent magnet cylinder 1
Ultrafine grinding system
Ultra-fine crushing bin (12 cubic meters/unit) 3
Air cannon arch breaking device 3
Ultrafine grinder 4
Paddle type unloader 4
Pulse dust collector 4
High pressure blower 4
Silencer 4
High square sieve 4
Conveying auger 4
Second batching mixing system
The second batching warehouse (12m³/piece) 5
Air cannon arch breaking device 5
Ingredients auger 5
Ingredients scale (1000KG/P) 2
Pulse dust collector 2
Fan 2
Feeding port 2
Twin-shaft paddle mixer (1000KG/P) 2
Mixing buffer bucket 2
Scraper conveyor 2
Unpowered pulse dust collector 2
Self-cleaning bucket elevator 2
Pulse dust collector 2
Fan 2
Permanent magnet cylinder 2
Buffer bucket (4m3/piece) 1
Conveying auger 1
High square sieve 1
Conveying auger 1
Fish feed puffing and drying system
Warehouse to be puffed (15m3/piece) 2
Air cannon arch breaking device 2
Out of warehouse auger 2
Vertical feeder 1
Dual-shaft differential conditioner 1
Conditioner 1
Floating fish feed machine 1
Density controller 1
Extruder water adding system 1
Extruder steam system 1
Settling tank and pipe (1 cubic meter) 1
Dehumidification air network system 1
Fan 1
Cyclone dust collector (900) 1
Drying box 1
Wind network system 1
Silencer 1
Cyclone Dust Collector (1800) 1
Self-cleaning bucket elevator 1
Flat rotary grading screen 1
Puffed fish feed spraying and cooling system
Cooler (28X28) 1
Wind network system 1
Silencer 1
Fan 1
Cyclone dust collector (50-Φ1800) 1
Warehouse to be sprayed 1
Vacuum spraying machine 1
Vacuum spraying machine refueling system 1
Self-cleaning bucket elevator 1
Puffed fish feed packaging system
Finished product warehouse 1
Distributor 1
Finished product drawer sieve 1
Buffer bucket 2
Packing scale 1
Belt sewing conveyor 1
Fan 1
Pulse dust collector 1
Shrimp feed pelleting cooling system
Silo to be granulated 1
Air cannon arch breaking device 1
Broken arch feeding tube 1
Frequency conversion stainless steel feeder 1
Dual-shaft differential conditioner 1
Preserver 1
Conditioner 2
Shrimp feed pellet machine 1
Post-aging machine 1
Wind network system 1
Cyclone 1
Fan 1
Silencer 1
Cooler 1
Self-cleaning bucket elevator 1
Flat rotary grading screen 1
Granular shrimp feed packaging section
Finished product warehouse 2
Distributor 2
Drawer sieve 1
Pulse dust collector 1
Fan 1
buffer bin 1
Packing scale 1
Belt sewing conveyor 1
Shrimp feed crumbling and packaging system
Permanent magnet cylinder 2
Buffer bin 1
Distributor 1
Crusher (special for shrimp feed) 2
Self-cleaning bucket elevator 1
Rotary distributor 1
High square sieve 3
Finished product warehouse 3
Pulse dust collector 1
Fan 1
Buffer bucket 2
Fully automatic packaging scale 2
Belt sewing conveyor 2
Powder recycling section
Return to the powder bin (3 cubic meters) 3
Conveying auger 1
Return material feeding port 1
Self-cleaning bucket elevator 1
Scraper conveyor 1
Garbage dump 1
Auxiliary section
Fish slurry adding liquid storage tank machine feeding scale device 1
Fish slurry weighing device 1
Fish oil adding liquid storage tank machine feeding scale device 1
Soybean oil adding liquid storage tank machine feeding scale device 1
Phospholipid oil adding liquid storage tank machine feeding scale device 1
Secondary mixed grease weighing device 1
Water adding liquid storage tank machine feeding scale device 1
Scale water addition system 1
Air compressor 2
Gas tank filter 2
Three stage filter 4
Air dryer 2

Fermentation raw material production line equipment

Device name QTY
Feeding port (1.2×1.5) 1
Dust removal system (pulse bag dust collector) 1
Fan (3500m3/h) 1
Bucket elevator 1
Screw conveyor 1
Material level indicator 4
Raw material warehouse (6m3/warehouse, 4m3/warehouse) 4
Ingredients screw conveyor (TLSS·20/TLSS·12) 4
Stirring mixer (SLHJ3.0) 1
Hopper (3m3) 2
Bacteria storage tank 1
Fermentation tank (20×3.5×2.5m) 3
Forklift 3
Stainless steel feed hopper 1
Dryer 1
Counter flow cooler 1
Fan (4000m3/h) 1
Spray tower 1
Finished product warehouse (6m3/warehouse) 1
Automatic packaging platform 1
Bag sewing machine 1

Fermented feed production line

Device name QTY
Bacteria batching and metering system (5.5KW) 1
Bacteria liquid adding system 1
Pellets batching and mixing system 1
Packaging measurement system 1
Electrical control system 1

Consumption of main raw materials and auxiliary materials

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

Name Consumption (t) (before expansion) Consumption (t) (after expansion) Specification
Soybean meal 35088 55728 25kg, bagged
Corn 17850 28350 25kg, bagged
Flour 12920 20520 25kg, bagged
Chicken powder 510 810 25kg, bagged
Fishmeal 340 540 25kg, bagged
Other additives (mainly salt, lime powder, flavors, amino acids, vitamins, etc.) 5100 8386 25kg, bagged
Grease 2210 3510 20-30 tons, oil canned
Bran 5950 10360 25kg, bagged
Rice bran 4760 7560 25kg, bagged
Miscellaneous meal / 910 bagged
Strain / 92 20KG/bag

public Utilities of 10 t/h aqua feed mill in Brazil

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.

Production line name Product name Annual output (t) Steam consumption(kg/t) Maximum daily steam consumption (t)
2 livestock feed production lines chicken and duck feed 10000 50~80 2.7
Pig pellets 18000 50~80 4.8
1 concentrated feed production line Concentrated feed 6000 50~80 1.6
1 premix production line premix 6000 50~80 1.6
Shrimp feed production line 1 shrimp feed 3200 200~250 2.7
1 expanded aquatic feed production line Puffed fish feed 40000 500~600 80
1 extruded livestock feed production line Puffed livestock and poultry feed 1800 500~600 3.6
1 shrimp feed production line shrimp feed 10000 200~250 8.3
1 expanded aquatic feed production line Puffed fish feed 40000 500~600 80
1 fermentation raw material production line Fermentation raw materials 13000 40~50 2.2

As can be seen from the table above, after the 10 t/h shrimp fish aqua feed mill in Brazil project is implemented, the maximum daily steam volume will be 187.4t, and the maximum hourly steam volume will be 11.7t.

The existing 15t/h biomass-fired steam boiler gas supply capacity in the plant can satisfy the entire plant after the expansion project is put into operation. Boiler steam supply requirements.

General layout of 10 t/h aqua feed mill in Brazil

The connection between equipment layout and 10 t/h Brazil aqua feed mill process flow is basically reasonable, the building structure is basically complete, and can meet the production process requirements.

All processes in the production workshop are reasonably arranged and sufficient space is reserved to ensure smooth transportation of feed.

Process design of 10 t/h aqua feed mill in Brazil

The production process flow of the extruded floating fish feed production line and shrimp feed production line

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:

  1. 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.
  2. 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.
  3. 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.
  4. 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.
  5. 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.

Production process design of fermentation raw material production line

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

  1. 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.
  2. 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.
  3. 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.
  4. 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.
  5. 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.

The production process of the fermented feed production line

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.

Prospects for the development of aquafeed processing in Brazil

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.

If you want to start livestock feed production, poultry feed production or aqua feed mill in Brazil, feel free to contact Richi Machinery for design and quotations.

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