4-5T/H Aquafeed Packaging Scale in Turkey

From the DCS series, the DCS-50P (belt feed) was selected. Why this model?

• Belt feed: Moves sticky pellets gently without bridging – the belt keeps material moving
• Belt scraper: Wipes oil residue off the belt after each cycle – prevents buildup
• Easy cleaning: Smooth belt surface and removable components
• Speed: 6-8 bags per minute – enough for his 4-5 ton/hour output
• Accuracy: ±0.2% dynamic – critical for high-value aquafeed

Mehmet chose the DCS-50P with mixed sealing (heat seal + sew) – aquafeed bags need moisture protection, and the heat seal also contains the oily smell.

What He's Packaging – Turkish Seabass and Seabream Feed

Turkey is one of Europe's largest aquaculture producers. Mehmet's mill produces:

• Seabass feed (extruded pellets, 2-8mm depending on fish size): 60% of production – 20kg and 25kg bags
• Seabream feed (extruded pellets, 2-6mm): 40% of production – 20kg and 25kg bags

The feed composition is specialized:

• Fish meal (high-quality, imported from Peru or Iceland): 35-45%
• Fish oil (18-22%): This is the problem – the oil makes pellets sticky
• Soy protein concentrate: 15-20%
• Wheat flour (binder): 10-15%
• Vitamins and minerals: 2-3%

The pellets are extruded (not pelleted), which makes them more porous and absorbent. They are coated with fish oil after extrusion. The final product has an oil film on the surface. It's sticky, slightly soft, and has a strong smell.

Packaging: 20kg and 25kg bags, both with plastic liner (heat-sealed).

Installation – Focus on Oil Management

The DCS-50P arrived at the Port of Izmir – Turkey's third-largest port, located on the Aegean coast.

Shipping time from Qingdao to Izmir is about 30-35 days (through the Suez Canal and across the Mediterranean). The machine was packed in a 20-foot container with:

• DCS-50P main unit (belt feeder, scale, heat sealer)
• Belt scraper kit (15 blades – he would need them)
• Spare belts (two – one smooth, one textured)
• Spare bag clamp rubbers (four sets)
• Spare heat sealer elements (three sets)
• Installation manual and electrical diagram in Turkish

Customs clearance in Izmir took about 5 days. Total landed cost was about 22% higher than the FOB price.

Installation took two days. The old gravity-fed scale was removed. The DCS-50P was positioned on a stainless steel platform (Mehmet had it custom-built to resist oil and salt corrosion from the nearby sea).

The belt scraper was the most important feature. Mehmet installed it immediately – it wipes oil residue off the belt after each cycle, preventing buildup. Without it, the belt would become slippery within an hour.

The electrical hookup was straightforward (380V, 50Hz three-phase – Turkish standard). The pneumatic system required clean, dry air at 0.5MPa. Mehmet added an oil filter to the air line – oil mist in the compressed air could contaminate the aquafeed.

The heat sealer required adjustment for oily bags. Standard temperature (180°C) wasn't enough – the oil on the bag surface insulated the plastic liner. After testing, they settled on 195°C for the 20kg bags and 200°C for the 25kg bags.

Performance – Cleaning Time Reduced by 90%

After six months of operation, Mehmet documented the following results:

Old gravity-fed scale (before):

• Speed: 3-4 bags per minute
• Cleaning frequency: Every 45 minutes (the hopper would clog with oil buildup)
• Cleaning time per event: 15-20 minutes
• Total cleaning time per 8-hour shift: 2.5-3 hours (lost production)
• Accuracy: ±50-100 grams (0.2-0.4% error)
• Giveaway: Approximately 0.3% of production = 75 tons/year at €1,300/ton = €97,500

DCS-50P belt-fed scale (after):

• Speed: 6-7 bags per minute
• Cleaning frequency: Once per day (end of shift – belt scraper handles buildup during operation)
• Cleaning time per event: 15 minutes
• Total cleaning time per 8-hour shift: 15 minutes (2.5 hours saved per shift)
• Accuracy: ±15-25 grams (0.06-0.1% error)
• Giveaway: Approximately 0.08% of production = 20 tons/year = €26,000

Cleaning time savings: 2.5 hours per shift × 2 shifts × 250 days = 1,250 hours per year. At €25/hour labor + overhead = €31,250 per year.

Giveaway reduction: From €97,500 to €26,000 = €71,500 saved per year.

Total annual savings: Approximately €102,750

The machine cost delivered approximately €12,500. Payback period was about 1.5 months.

Customer Feedback – Mehmet's Experience

Here's what Mehmet said after six months (paraphrased from a conversation, translated from Turkish):

"The old machine was a cleaning nightmare. Every hour, we had to stop production, scrape oil off the hopper walls, and restart. My workers hated it. I hated it. We were losing 2-3 hours of production every day.

The DCS-50P changed everything. The belt feeder moves the pellets gently. The scraper wipes the belt clean after every cycle. We clean the machine once at the end of each shift. That's it.

The belt feeder is the only solution for oily aquafeed. Gravity doesn't work – the pellets stick to the hopper. Augers crush the pellets. The belt is gentle and the scraper keeps it clean.

The accuracy is also much better. Aquafeed is expensive – over €1,000 per ton. Giving away 50 grams per bag adds up fast. Now we're within 20 grams every time.

A few specific observations: The belt scraper blades wear out every 2-3 months – the oil and abrasive fish meal wear them down. We buy them in packs of 20. The heat sealer needs to run hotter for oily bags – 195-200°C instead of 180°C. The bag clamp rubbers also wear faster – the oil degrades the rubber. We change them every 10,000 bags.

Would I recommend this machine? Yes. For any aquafeed mill, belt feed with a scraper is not optional – it's essential."

Why Belt Feed for Aquafeed

Aquafeed is different from any other animal feed. Here's why belt feed is the only sensible choice:

Oil content comparison:

• Poultry feed: 3-5% fat
• Pig feed: 3-5% fat
• Cattle feed: 2-4% fat
• Aquafeed (seabass/seabream): 18-22% fat

The high oil content makes aquafeed sticky and prone to buildup.

Gravity feed (DCS-50W, DCS-50K):

• Pellets stick to hopper walls
• Bridging occurs within 30-45 minutes
• Requires frequent cleaning
• Not suitable for aquafeed

Auger feed (DCS-50F, DCS-50FB):

• Auger crushes soft extruded pellets
• Oil smears on auger flights
• Clogs within hours
• Not suitable for aquafeed

Belt feed (DCS-50P, DCS-50P*2):

• Belt moves pellets gently, no crushing
• Belt scraper wipes oil off after each cycle
• Minimal buildup
• The only suitable choice for aquafeed

The Belt Scraper – Essential for Aquafeed

The DCS-50P includes a belt scraper – a spring-loaded blade that wipes the belt clean after each cycle. For aquafeed, this is essential. Without it, oil builds up on the belt within 30-60 minutes. The belt becomes slippery. Pellets don't move consistently. Accuracy suffers.

Mehmet's scraper blade wears out every 2-3 months. He keeps a box of 20 blades on the shelf. Each blade costs about €15. Cheap insurance against downtime.

The scraper also needs adjustment. If it's too tight, it wears the belt. If it's too loose, it doesn't clean effectively. Mehmet checks the scraper tension weekly.

The Sealing Method – Mixed (Heat + Sew) for Aquafeed

Mehmet uses mixed sealing (heat seal + sew) for all aquafeed bags. Why?

• Heat seal: The plastic liner prevents oil from seeping through the paper bag. Without a heat seal, oil stains appear on the outside of the bag within days. Customers reject stained bags.
• Sewn seam: Provides mechanical strength for stacking. Aquafeed bags are heavy (25kg) and are often stacked 10-15 high in warehouse storage.

The heat sealer requires a higher temperature for oily bags – 195-200°C instead of 180°C. The oil on the bag surface insulates the plastic liner, so more heat is needed to melt it properly. Mehmet figured this out through testing. He now has a temperature chart on the wall next to the machine.

The workflow:

1. Operator puts empty bag on clamp
2. Machine fills via belt (6-8 seconds for 20kg, 8-10 seconds for 25kg)
3. Heat sealer seals the top (2 seconds)
4. Operator removes bag, places on conveyor
5. Second operator sews the bag (15 seconds)
6. Second operator stacks on pallet

Two operators, 6-7 bags per minute.

Shipping – Qingdao to Izmir

The DCS-50P shipped from Qingdao to Port of Izmir, Turkey – the country's third-largest port, located on the Aegean coast.

Shipping time from Qingdao to Izmir is about 30-35 days. The route goes through the South China Sea, past Singapore, across the Indian Ocean, through the Suez Canal, and across the Mediterranean.

The machine was packed in a 20-foot container. Customs clearance in Izmir took about 5 days. Total landed cost was about 22% higher than the FOB price.

The truck transport from Izmir to the mill was short – about 50km, roughly 1 hour.

What Mehmet Learned – Lessons for Other Aquafeed Producers

After six months of running the DCS-50P, Mehmet shared several observations:

Lesson 1: Belt feed is not optional for aquafeed. Gravity and auger systems fail. The oil buildup is too severe. Belt feed with a scraper is the only solution that works reliably.

Lesson 2: Keep spare scraper blades. The blades wear out every 2-3 months. Mehmet buys them in packs of 20. When the blade wears down, the belt doesn't clean properly. He changes the blade at the first sign of residue buildup.

Lesson 3: Adjust heat sealer temperature for oily bags. Standard temperatures don't work. The oil insulates the plastic liner. Mehmet runs at 195-200°C instead of 180°C. He checks seal integrity weekly.

Lesson 4: Clean the belt scraper area daily. Oil residue collects around the scraper. Mehmet's team wipes it down at the end of each shift. Takes 5 minutes. Prevents oil from dripping onto the floor.

Lesson 5: Monitor belt tension weekly. The belt stretches over time. If it's too loose, it slips and feed rate becomes inconsistent. Mehmet checks tension every Monday morning.

What RICHI Provided Beyond the Machine

RICHI provided several services that helped Mehmet get the DCS-50P operational:

• Turkish documentation: The manual and electrical diagram were provided in Turkish, not just English.
• Material testing: Mehmet sent a 5kg sample of his seabass feed (20% oil content) to the RICHI factory. They tested it on a DCS-50P and sent a video showing the belt scraper in action.
• Scraper blade recommendation: Based on the oil content, RICHI recommended a harder scraper blade material. Mehmet ordered the upgraded blades.
• Heat sealer temperature guidance: RICHI provided a temperature guide for different oil contents. Mehmet used it as a starting point and fine-tuned from there.

Is an Aquafeed Packaging Scale Right for Your Operation?

For an aquafeed mill producing high-oil feeds (seabass, seabream, salmon, trout, shrimp), the belt-fed DCS-50P is the recommended choice.

Consider the DCS-50P if:

• Your feed contains more than 15% oil or fat
• Your pellets are sticky and cause buildup on equipment
• You need accurate bag weights for high-value product
• Your current packing scale requires frequent cleaning

Consider the DCS-50P*2 (twin-belt) if:

• Your volume exceeds 50,000 tons per year
• You need more than 8 tons per hour bagging capacity

For Mehmet's seabass/seabream feed mill, the DCS-50P was the right investment. It reduced cleaning time by 90%, improved accuracy, and paid for itself in less than two months.

Final Thoughts

If you're an aquafeed producer struggling with sticky, oily pellets that clog your packing equipment, don't waste time with gravity or auger systems. They weren't designed for high-oil feeds.

The DCS-50P belt-fed packaging scale is specifically designed for sticky materials. The belt feeder moves pellets gently without crushing. The belt scraper wipes oil residue off after every cycle. The result is consistent operation with minimal cleaning.

For high-volume operations, the twin-belt DCS-50P*2 offers even higher speed with the same belt feed technology.

RICHI offers material testing, documentation in Turkish, spare parts kits, and remote support. Contact RICHI Machinery through the website with your aquafeed type (seabass, seabream, salmon, trout, shrimp), oil content percentage, bag sizes, and daily throughput for a recommendation. Tell them about your oil content – this determines whether belt feed with a scraper is required.