1.5–2 T/H Twin Screw Extruder Machine in Denmark

Project Overview and Equipment Configuration

The investment focused on improving extrusion flexibility while keeping the scope of the project manageable. The new machine was selected around the manufacturer's intended product range and reference throughput rather than the maximum capacity available from a larger model.

For this Danish manufacturer, the main consideration was whether the new extruder could accommodate different product requirements without creating additional bottlenecks elsewhere in the factory. The available throughput therefore needed to be evaluated alongside recipe characteristics, conditioning requirements, die configuration and the capacity of the downstream dryer.

SPHS120×2 Twin Screw Extruder Specifications

The selected model incorporates a twin-screw extrusion arrangement with a dedicated feeding and conditioning system. The feeder regulates the supply of prepared mash, while conditioning prepares the material for extrusion. The screw configuration, moisture level, temperature, screw speed and die arrangement all influence the final product.

The listed motor ratings provide an initial basis for electrical planning, but the final supply specification must also account for starting methods, auxiliary equipment, protective devices and the factory's electrical infrastructure. The rated throughput is a reference range rather than a guaranteed output for every fish feed or pet food formulation.

Two Product Groups, Different Extrusion Requirements

One reason for selecting a twin screw extruder was the manufacturer's intention to process both aquafeed and pet food. Although the products share some equipment requirements, their formulation and processing targets are not identical.

As preliminary product targets, fish feed may use pellet diameters of approximately 1.5–4 mm, while dry dog and cat kibble may use approximately 5–12 mm. These are indicative ranges for product planning, not confirmed die sizes for this installation. Final dimensions depend on the intended product, feeding requirements, die design and cutter configuration.

The production team also needs separate formulation and process records for each product family. Moving between aquafeed and pet food requires an appropriate changeover and cleaning procedure, along with checks on the suitability of the shared equipment for the intended feed safety and traceability requirements.

Raw Materials Available to Danish Feed Manufacturers

The raw material strategy for this type of Danish operation can combine locally available agricultural ingredients with specialized protein and fat sources purchased from qualified suppliers. The formulation must be developed separately for each product rather than relying on one common recipe for fish and pet food.

• Wheat and barley can provide starch and contribute to the energy content of suitable formulations.
• Peas and field beans can provide plant protein and other nutrients, depending on the recipe.
• Fishmeal and fish oil can be used in appropriate aquafeed formulations, subject to ingredient specifications and sourcing requirements.
• Suitable poultry meal and other approved protein ingredients can be incorporated into pet food recipes where nutritionally appropriate.
• Rendered fats and vegetable oils can help adjust energy levels and support the desired product characteristics.
• Vitamin-mineral premixes supply nutrients according to the requirements of the target fish or pet food product.

Ingredient variability matters as much as the ingredient list itself. Moisture, starch content, protein level, fat content and particle size can affect extrusion stability. The operator should therefore monitor incoming material quality and adjust the processing parameters to the actual formulation.

How the Extruder Fits into the Existing Production Process

The machine upgrade was intended to retain the factory's existing preparation and drying stages while improving the extrusion section. The practical process sequence is as follows.

1. Grinding and preparation. Raw materials are ground to the particle size required by the relevant formula.
2. Mixing. Ground ingredients, protein sources and premixes are blended to achieve a uniform mash before extrusion.
3. Feeding and conditioning. The prepared mash enters the extruder's feeding and conditioning system, where moisture and heat are adjusted to suit the recipe.
4. Twin-screw extrusion. The material is cooked and shaped through the selected die. Screw configuration, operating conditions and formulation influence expansion and product structure.
5. Cutting and drying. The extrudate is cut to the required length and dried to the moisture specification appropriate for the finished product.
6. Cooling and finishing. The product is cooled and, where required, screened or transferred for additional processing such as fat coating in pet food production.

Before connecting the new unit, the plant needs to confirm that its existing dryer can handle the intended product mix. Aquafeed and pet food can have different moisture-removal requirements, bulk densities and downstream finishing needs. Retaining existing equipment is practical only when its capacity and operating range match the new production plan.

Installation Planning, Utilities and Staffing

A single-machine retrofit can reduce the scope of an investment, but it still requires a detailed review of the installation area, utilities and maintenance access. The following figures and requirements are preliminary planning guidance rather than verified as-built data for the Danish facility.

These planning allowances should not replace a site-specific engineering review. The final layout must also provide safe access to inspection points, electrical panels and moving components, together with appropriate dust control, ventilation and maintenance isolation arrangements.

Commissioning Priorities for Fish Feed and Pet Food

The operating team needs to establish separate process settings for each product family rather than using one temperature and moisture profile for every recipe. The initial commissioning work should focus on product quality, machine loading and downstream performance.

• Verify the prepared mash's moisture, particle size and feeding consistency.
• Establish suitable conditioning conditions for each formulation.
• Confirm the selected die and cutter settings against the required pellet diameter and shape.
• For floating fish feed, evaluate expansion, water stability, durability and buoyancy.
• For pet food, check kibble dimensions, density, texture and moisture after drying.
• Record motor load, throughput and product quality so that subsequent adjustments can be based on operating data.
• Confirm that the dryer and downstream handling system remain stable at the intended production rate.

These checks are particularly important when an existing single-screw extruder is being replaced by a twin-screw system. Even when the nominal capacity appears suitable, the new machine may require different conditioning settings, material feeding arrangements and downstream adjustments to achieve the intended product specification.

Food Safety, Cleaning and Product Changeovers

Producing aquafeed and pet food in the same facility requires a documented approach to ingredient handling, cleaning, traceability and product changeovers. Machine construction and accessible cleaning points can support hygienic operation, but they do not by themselves establish compliance with Danish or EU requirements.

The manufacturer should verify the ordered machine's food-contact materials and cleaning provisions, maintain suitable ingredient and batch records, and ensure that the production process meets the applicable feed hygiene and product safety obligations.

For a plant handling different formulations, a practical changeover procedure should include:

1. Stopping and isolating the equipment according to the safe operating procedure.
2. Removing residual material from accessible product-contact areas and associated transfer points.
3. Applying the validated cleaning procedure required for the product transition.
4. Checking the next recipe, die and cutter settings before restarting.
5. Recording the changeover and verifying the first finished product against the applicable quality requirements.

Future Opportunities for the Danish Facility

The new extruder gives the manufacturer a basis for evaluating additional products without immediately replacing the complete production line. Potential development work includes alternative floating fish feed formulations, different kibble geometries and selected premium pet food recipes.

Each proposed product should first be assessed for formulation compatibility, processing requirements, die configuration, drying capacity and commercial demand. A twin screw extruder provides processing flexibility, but not every recipe or finished product can be introduced without additional trials or equipment adjustments.

A Targeted Extrusion Upgrade for Feed Producers in Denmark

This project illustrates how a twin screw extruder machine in Denmark can serve as the core of a single-machine upgrade when a feed producer wants to broaden its product range while retaining suitable existing equipment. The SPHS120×2 provides a reference throughput of 1.5–2 T/H, with its actual output depending on the recipe, process settings and complete line configuration.

For aquafeed and pet food manufacturers considering a similar investment, the key is to evaluate the extruder alongside raw material characteristics, product specifications, utilities, drying capacity and cleaning requirements. RICHI Machinery can assist with model selection, process configuration and integration planning so that the proposed equipment matches the factory's actual production objectives.