1.5-2T/H Floating Catfish Feed Extruder in Malaysia

Malaysia is Southeast Asia's third-largest producer of catfish, with farms concentrated in Perak, Pahang, and Johor.

Most Malaysian catfish farmers use sinking feed. But a growing number of hybrid catfish varieties (Clarias gariepinus x Clarias batrachus) prefer feeding at the surface, especially in warmer months.

A feed mill in Perak had been producing sinking catfish feed for ten years. Farm customers kept asking for a floating alternative. The mill owner decided to expand.

He already had hammer mills, mixers, belt dryers, and bagging lines for sinking feed production. What he needed was a floating catfish feed extruder in Malaysia that could produce 1.5-2.0 tons per hour of highly expanded, water-stable floating pellets.

After studying options, he purchased one SPHS120*2 extruder from RICHI. RICHI has supplied similar floating feed extrusion systems to customers across Southeast Asia, including catfish feed producers in Malaysia, Thailand, Indonesia, Vietnam, the Philippines, Cambodia, and Laos.

The twin-screw technology has proven itself for high-expansion floating feed production in tropical climates. The mill owner's decision to add floating feed production has opened a new market segment without cannibalizing his sinking feed business.

Project Background – The Shift to Floating Feed for Hybrid Catfish

Traditional African catfish are bottom feeders. They prefer sinking pellets. Hybrid catfish are different. They swim throughout the water column and will readily take floating feed.

Malaysian hybrid catfish production has increased 25% annually for five years. Farmers raising hybrids want floating feed because they can see the fish feeding and adjust rations in real time. No feed waste sinks to the bottom and pollutes the pond.

The mill owner calculated that floating catfish feed would command a 15-20% price premium over sinking feed. Production cost would be similar. The margin was attractive.

He already had customers who bought sinking feed from him. Many also raised hybrids and currently bought floating feed from a competitor. He could capture that business.

Why the SPHS120*2 was the Right Choice

The SPHS120*2 floating catfish feed extruder in Malaysia has a 90kW main motor and twin screws with 120mm diameter. Output is rated at 1.5-2.0 tons per hour for floating feed.

The mill planned to run one shift per day, producing about 12 tons per day. That would be enough to supply 80-100 medium hybrid catfish farms.

The 90kW motor runs on the mill's existing 150A three-phase service. No electrical upgrade needed. The twin-screw design provides precise control over expansion, which is critical for floating feed.

The mill owner considered buying a larger SPHS150*2 but decided the extra capacity was unnecessary for his initial floating feed volume. The smaller machine also has a lower spare parts cost.

Raw Materials – Higher Starch for Better Floating

Floating feed requires more starch than sinking feed. The mill developed a formulation for hybrid catfish floating feed with higher wheat flour content.

Standard floating formulation:

• 30% wheat flour (starch source)
• 25% soybean meal
• 20% fish meal
• 15% rice bran
• 5% corn gluten meal
• 5% vegetable oil

Total starch is about 25%. The sinking feed formulation has only 15% wheat flour.

The mill also uses a different fish meal source for floating feed. Imported fish meal from Peru has higher fat content (8-10%) than local fish meal (5-6%). The higher fat helps with expansion during extrusion.

Moisture entering the extruder is 26-28% for floating feed, compared to 23-24% for sinking.

The conditioner heats the mash to 92-95°C. The extruder barrel has four heating zones: 60°C, 80°C, 105°C, and 110°C.

Die pressure is maintained at 25-30 bar – much lower than the 50-55 bar used for sinking feed. The mill runs the screws at 380 RPM for maximum expansion.

Pellet Sizes and Floating Performance

The floating catfish feed extruder in Malaysia produces three floating pellet sizes:

• Fry feed: 1.5mm
• Fingerling feed: 3mm
• Grow-out feed: 4.5mm and 6mm

The 4.5mm pellets float for 25-30 minutes in still water at 28°C. The mill tested the pellets in a 1-meter column. They remained at the surface for 28 minutes on average.

Hybrid catfish are aggressive feeders and typically consume floating pellets within 5-8 minutes. The float time is more than adequate. The 6mm pellets float for 20-25 minutes, which is still acceptable.

Transition from Sinking Feed to Floating Feed Production

The mill did not replace its sinking feed line. The new extruder runs alongside the old sinking feed press. The mill now offers both products.

Farmers raising traditional catfish buy sinking feed. Farmers raising hybrids buy floating feed. Some farmers with mixed ponds buy both.

The mill manager says the floating feed line has attracted 60 new customers who previously bought imported feed from Thailand. The floating feed business now accounts for 35% of the mill's aquaculture revenue.

Shipping – From Qingdao to Port Klang

The SPHS120*2 floating catfish feed extruder was shipped from Qingdao in July. The port of destination was Port Klang, Malaysia's largest seaport, located about 45 kilometers from Kuala Lumpur.

Sea freight took 12 days. Customs clearance at Port Klang took 4 days. Malaysian customs is efficient.

Import duty on extrusion equipment from China under ASEAN agreements is 0%. SST (sales and service tax) is 10% but recoverable. The total landed cost was 14% above the FOB price.

From Port Klang, the machine traveled 200 kilometers by truck to the mill in Perak. Installation took two weeks.

Installation and Operator Training

Installation was supervised by a service engineer from RICHI's distributor in Shah Alam. The SPHS120*2 required a level concrete foundation. RICHI provided detailed installation drawings in English and Malay. The mill's electrician handled the 415V three-phase connection.

Five operators trained for one week. They learned:

• How to adjust the conditioner temperature
• How to change dies
• How to clean the die face
• How to set the cutter speed
• How to monitor pellet expansion

The operators also learned how to diagnose common problems:

• Low expansion means low moisture or low conditioner temperature
• Sticky dough means too much moisture
• Surging means inconsistent feedstock

Problems During the First Two Months

Three problems required attention.

First, the floating pellets were not consistent. Some pellets floated well; others sank. The problem was uneven conditioning. The mill installed a new set of conditioner paddles with a more aggressive mixing profile. Moisture variation dropped from 4% to 1%. Float time became consistent.

Second, the cutter blade wore out after 200 hours. The high-expansion pellets are abrasive. The mill switched to a ceramic-coated cutter blade. Blade life increased to 800 hours.

Third, the pellets had a rough surface. Malaysian farmers prefer smooth pellets. The mill added 2% vegetable oil to the post-extrusion coater. The oil filled surface imperfections, producing smooth, glossy pellets that farmers preferred.

Customer Feedback – What Hybrid Catfish Farmers Say

The mill's sales team visited 50 hybrid catfish farms in the first three months. Feedback was positive.

A farmer in Perak reported that feed conversion ratio improved from 1.7 to 1.5 after switching to floating feed. He could see his fish feeding, so he adjusted rations more precisely.

Another farmer in Johor said his pond water stayed clearer. Floating feed produced no waste on the pond bottom. He reduced pond cleaning frequency by 50%.

A third farmer in Pahang reported faster growth. His fish reached harvest size two weeks earlier. He attributed the faster growth to the better digestibility of extruded floating feed.

The mill now has 120 regular customers for floating catfish feed and sells 200-250 tons per month.

Additional Products – Other Feeds on the Same Extruder

The SPHS120*2 floating catfish feed extruder in Malaysia is not limited to catfish floating feed. The mill produces three other floating feeds:

• Tilapia floating feed – made with lower fish meal (15%) and higher wheat flour (40%). Popular in northern Malaysia.
• Floating koi feed – for ornamental ponds. The koi formula includes spirulina for color enhancement.
• Floating turtle feed – for farms raising softshell turtles. The turtle feed has higher calcium content. The mill adds ground oyster shell to the recipe.

Operational Data After Nine Months

The mill's production manager shared operational data.

The floating catfish feed extruder in Malaysia runs 1,200 hours total. Production breakdown:

• Catfish floating feed: 55%
• Tilapia floating feed: 25%
• Koi feed: 15%
• Turtle feed: 5%

Die life data:

• 4.5mm catfish die: 1,100 hours
• 3mm fingerling die: 900 hours
• 1.5mm fry die: 650 hours

The 90kW main motor draws 86kW at normal load for floating feed. Power cost is about 45 ringgit per hour. Acceptable. The mill has become a regional leader in floating catfish feed production.

Technical Support from RICHI

RICHI's distributor in Shah Alam provided extensive support. A service engineer visited the mill three times during the first two months. He helped dial in the screw configuration for floating feed and trained the maintenance team on preventive maintenance.

RICHI had extensive Southeast Asian experience, having supplied floating catfish feed extruders to:

• Other mills in Malaysia
• Producers in the Central Plains region of Thailand
• Mills in Java, Indonesia
• Operations in the Mekong Delta, Vietnam

The engineer brought expansion data from these installations. The mill used that data to optimize their settings. RICHI also provided a 24/7 WhatsApp support line. The mill has used it three times.

The Future of Floating Feed Production in Malaysia

Malaysia's hybrid catfish industry continues to grow. Floating feed is gaining acceptance among farmers who see the benefits: better feed conversion, clearer pond water, and faster growth.

The mill in Perak proved that locally produced floating feed can compete with imports from Thailand. Other feed mills are taking notice. At least three have visited the facility since the extruder started running.

RICHI Machinery has received inquiries from mills in Malaysia, Indonesia, and the Philippines. For any feed producer looking to enter the floating catfish feed market, the same opportunity exists.

The floating catfish feed extruder in Malaysia that the Perak mill purchased is not the largest model. But it has the expansion control and reliability that Southeast Asian producers need.

One SPHS120*2 floating catfish feed extruder in Malaysia, a starch-rich formulation, and a commitment to consistent floating performance. That was enough to create a floating feed that Malaysian hybrid catfish farmers now prefer over imported alternatives.