Best Solution Industrial Scale 48T/H Tilapia Fish Feed Factory For Producing Commercial Tilapia Feed With Floating And Sinking Types

Aerial view of the 48t/h fish feed factory project

In order to speed up the development of the aquaculture industry, increase the income of farmers, and improve the competitiveness of agriculture, the market vigorously develops the aquatic feed processing industry. This large fish feed factory project was proposed under this background.

The large-scale automatic fish feed production line project invested and constructed by the client company, Baiyang Fish Feed Company, is located in Wenchang City, Hainan Province, mainly producing food for tilapia.

The best solution large capacity tilapia fish feed factory for producing commercial tilapia feed project is designed with 3 fish feed processing lines, 2 extruded fish feed production lines with an annual output of 30,000 tons and 1 fish pellet feed processing line with an annual output of 40,000 tons, with a total annual production capacity of 100,000 tons.

The original land and house of this project originally belonged to another company—— Hainan Yubao Feed Co., Ltd. However, due to the adjustment of the investment direction of the company, in January 2018, the entire fish feed factory and fish feed making equipment and other ancillary facilities were sold to this best solution industrial scale tilapia fish feed factory project customer - Hainan Baiyang Fish Feed Ltd.

Therefore, this industrial scale 48t/h tilapia fish feed factory for producing commercial tilapia feed project was based on the transformation of the original factory, and a new extruded fish feed processing line was added, and the related construction and trial production has been completed in May 2019.

Work system and labor quota

According to the needs of production, the 48t/h fish feed factory project works 260 days a year and implements a shift system of 8 hours per shift.

The large scale fish feed factory project has a workforce of 30 people, 20 of whom live in the factory. It can be calculated that the output of this big capacity fish feed factory project is 8333t/m, 385t/d, 48t/h (20-21t/h for tilapia food pellets, 28-29 t/h for tilapia floating fish feed).

Construction content and scale

Baiyang Fish Feed Factory Project covers an area of ​​about 13333.33m² and a total construction area of ​​about 9405.98m², including production workshops, warehouses, office and living buildings, dormitory buildings and other supporting facilities.

Product plan

Main raw and auxiliary materials and energy consumption

The large scale 48t/h tilapia fish feed factory project mainly uses soybean meal, rapeseed meal, wheat by-products, fish meal, etc. as the main raw materials, plus corn distiller's grains and oil bran as auxiliary raw materials to produce high-quality aquatic feed. The raw materials are all purchased from outsourcing.

Physical and chemical properties of main raw and auxiliary material

• DDGS:

  corn distiller's grains, is the trade name of distiller's grains protein feed, that is, dry distiller's grains containing soluble solids. In the process of fermenting ethanol from corn as raw material, the starch is converted into ethanol and carbon dioxide, and other nutrients such as protein, fat, fiber, etc. are left in the lees.

  The typical nutritional value of American DDGS used in this tilapia fish feed factory project is: more than 26% crude protein, more than 10% crude fat, 0.85% lysine and 0.75% phosphorus.

  Its appearance is yellow-brown-dark brown, with high soluble content and high drying temperature, and the color deepens. It has a fermented smell, contains organic acids, and has a slightly sour taste.

• Rapeseed meal:

  Rapeseed meal is rich in lysine, macro and trace elements, among which the content of calcium, selenium, iron, magnesium, manganese and zinc is higher than that of soybean meal, and the phosphorus content is twice that of soybean meal.

  It is rich in sulfur-containing amino acids, which is what soybean meal lacks, so it can play a balancing and complementary role when combined with soybean meal.

• Soybean meal:

  Soybean meal is a by-product obtained from soybean extraction of soybean oil. The main components are: protein 40%~48%, lysine 2.5%~3.0%, tryptophan 0.6%~0.7%, methionine 0.5%~ 0.7%.

  The protein content of soybean meal used in this tilapia fish feed factory project is about 46%. It is in the form of irregular fragments, the color is light yellow to light brown, and the taste has the aroma of roasted soybeans.

• Fishmeal:

  Fishmeal is a commercial product obtained by removing the edible part of fish, or whole fish that lacks market value. Fish meal is in the form of brown powder or cake.

  Specifically, the above-mentioned raw materials are squeezed to remove oil. The purpose of fish meal is that it is rich in protein and can be used as animal feed. This tilapia fish feed factory project uses fish meal imported from Ecuador with a protein content of 64.56%.

• Wheat:

  Wheat is rich in starch, protein, fat, minerals, calcium, iron, thiamine, riboflavin, niacin and vitamin A.

• Oil bran:

  Oil bran is the product of rice processing, which is the middle part of the rice. It has high protein content and is called oil bran when it has not been squeezed out of bran oil.

  It has a very simple grain fragrance and is a good raw material for feeding poultry, livestock and fish. After the oil bran is pressed, it is divided into rice bran oil (rice bran crude oil) and bran meal (or bran cake). Light yellow powder, fresh and sweet smell.

Main fish feed machine of the 48t/h tilapia fish feed factory

Fish feed manufacturing process

There are three fish feed lines in this 48t/h tilapia fish feed factory project, one compound feed production line for fish and two extruded fish feed production lines.

Pelletized fish feed making process

1. Feeding section

   The types of raw materials used in the project include powders and pellets. The powder does not need to be coarsely pulverized.

   After passing through the scraper conveyor and bucket elevator, it enters the cylinder primary cleaning sieve. After removing large impurities, it enters the permanent magnet cylinder to remove iron impurities and participates in the first batching;

   The granules need to be coarsely pulverized. After passing through the scraper conveyor and bucket elevator, they enter the cylinder primary cleaning screen.

   After removing large impurities, they enter the permanent magnet cylinder to remove iron impurities, and then enter the silo to be pulverized. After coarse crushing, it enters the batching bin through the elevator and distributor to participate in the first batching.

   First coarse pulverization is the pretreatment process of ultrafine pulverization in aquatic feed processing, to ensure stable product quality.

2. First batching and mixing section

   The first batching is mainly the preparation of public raw materials, that is, the preparation of materials with larger proportions in the tilapia fish food formula. This process is mainly completed by electronic batching scales.

   After the batching is completed, it enters the first mixing. The first batching and mixing is the pretreatment process of ultra-fine pulverization, which can reduce the variation range of material particle size, improve the working condition of the pulverizer, and improve the pulverization efficiency, guarantee the quality of products.

3. Second crushing section

   Due to the low food intake, short digestive tract and poor digestion ability of aquatic animals, the crushing particle size of aquatic feed is required to be very fine, and the crushing process must be carried out.

   In the secondary crushing process, the primary mixed materials are lifted into the silo to be crushed, and then into the fish feed crusher.

4. Second mixing section

   Each raw material enters the secondary fish feed mixer after secondary batching. There is an artificial feeding port above the secondary fish feed mixer for the addition of trace additives, and two liquid addition devices are provided on the fish feed mixer, which are used for the addition of oil and molasses respectively.

   In the secondary mixing process, all materials must be fully mixed, and the coefficient of variation CV is less than 5%. After the material is finely pulverized and mixed with secondary ingredients, it enters the granulated material for the granulation and curing process.

5. Granulation and maturation section

   First, the powdered feed is conditioned with steam or water, and then pressed into columns or other shaped granules by a fish pellet machine, and the material is further matured by adding steam. The pelletizing fish feed pelleting line needs about 2.04t/h of steam, and the water consumption is 16.32m3/d.

6. Cooling section

   Using the principle of air cooling to cool the product through a pellet feed cooler or cooling tower.

7. Product Grading and Packaging section

   The cooled fish pellets feed are lifted and crushed into the grading screen for grading. The grading screen is generally composed of two layers of sieves, and the material on the upper sieve needs to be returned to the crusher for crushing;

   The fish feeds under the sieve of the lower sieve is generally fine powder, which can be returned to the silo to be reshaped. The fish feeds pellets on the lower sieve is the finished product, which directly enters the finished product warehouse, and then is weighed and packaged.

8. Into the finished product warehouse and register section

   The fully packaged finished products are transported to the finished product warehouse for stacking in an orderly manner according to the requirements, and registered in the computer.

Fish feed extrusion process

1. Feeding section

   The types of raw materials used in the 48t/h tilapia fish feed factory project include powders and pellets. The powder does not need to be coarsely pulverized. After passing through the scraper conveyor and bucket elevator, it enters the cylinder primary cleaning sieve.

   After removing large impurities, it enters the permanent magnet cylinder to remove iron impurities and participates in the first batching;

   The granules need to be coarsely pulverized. After passing through the scraper conveyor and bucket elevator, they enter the cylinder primary cleaning screen.

   After removing large impurities, they enter the permanent magnet cylinder to remove iron impurities, and then enter the silo to be pulverized. After coarse crushing, it enters the batching bin through the elevator and distributor to participate in the first batching.

   First coarse pulverization is the pretreatment process of ultrafine pulverization in aquatic feed processing, work efficiency to ensure stable product quality.

2. First batching and mixing section

   The first batching is mainly the preparation of public raw materials, that is, the preparation of materials with larger proportions in the tilapia fish food formula. This process is mainly completed by electronic batching scales.

   After the batching is completed, it enters the first mixing. The first batching and mixing is the pretreatment process of ultra-fine pulverization, which can reduce the variation range of material particle size, improve the working condition of the fish feed pulverizer.

3. Second crushing section

   Due to the low food intake, short digestive tract and poor digestion ability of aquatic animals, the crushing particle size of aquatic feed is required to be very fine, so the crushing process is required.

   In the secondary crushing process, the primary mixed materials are lifted into the silo to be crushed, and then into the crusher. The tiny hairs formed during the process.

4. Second Mixing section

   Each raw material enters the secondary fish feed mixer after secondary batching. There is an artificial feeding port above the secondary fish feed mixer for the addition of trace additives, and two liquid addition devices are provided on the feed mixer, which are used for the addition of oil and water respectively.

   In the secondary mixing process, all materials must be fully mixed, and the coefficient of variation CV is less than 5%. After the material is finely pulverized and mixed with secondary ingredients, it enters the puffing and drying process.

5. Tempering and Puffing section

   In the extrusion and puffing process, the material is cooked under high temperature, high humidity and high pressure for a period of time.

   During this process, the physical and chemical properties of the material change drastically (mainly starch gelatinization, protein denaturation), and the material extruded from the die hole, the water in the feed is converted from liquid to gaseous state, and is emitted from the feed, causing the material to expand, forming the so-called extruded feed.

   Because this feed not only has the advantages of general hard pellet feed - good palatability, avoids automatic grading of products and is easy to transport, but also has unique advantages - high degree of starch gelatinization in the feed , protein is easier to digest, reduces waste in feeding process, and improves the utilization rate of animal feed;

   It has excellent floatability, which is convenient for observing the feeding situation of fish and can control water pollution to the greatest extent.

   The steam water consumption added to the product in the raw material expansion process is about 3.65t/h, that is, the water consumption is 29.2m3/d.

6. Drying section

   The fish feed dryer includes a vertical dryer and a horizontal dryer for fish pellets. After the tilapia fish feed is formed, it will form moist and soft tilapia fish feed (with a moisture content of 25% to 30%). Drying is carried out to reduce the moisture content of the tilapia fish feed to about 13%.

7. Spraying section

   After the tilapia fish feed is dried, it enters the external spraying system. By coating the surface of the pellet feed with oil, vitamins, flavorings, etc., it can not only meet the energy demand of fish, but also reduce the loss of heat-sensitive substances during processing.

   And it can improve the palatability of the feed and reduce the powder content. After the tilapia fish feed passes through the external spraying system, it needs to be cooled and crumbled.

8. Cooling section

   Using the principle of air cooling to cool the product through a fish feed pellet cooler or cooling tower.

9. Product grading and packaging section

   The cooled tilapia fish food are lifted and crushed into the grading screen for grading. The grading screen is generally composed of two layers of sieves. The tilapia fish food on the upper sieve needs to be returned to the crusher for crushing; the tilapia fish food under the sieve of the lower sieve is generally fine powder, which can be returned to the puffing bin for re-forming; the tilapia fish food on the lower sieve is finished products, directly into the finished product warehouse, and then weighed and packaged.

10. Enter finished goods warehouse and register section

    The complete packaged finished products are transported to the finished product warehouse for stacking in an orderly manner according to the requirements, and registered in the computer.

General floorplan and layout

The main entrance of the large capacity 48t/h tilapia fish feed factory project is set in the east, connected by a factory road to Wenqing Avenue, and a ring lane is set up in the 48t/h tilapia fish feed factory project area to connect with the entrances, exits and walkways of each building.

The 48t/h tilapia fish feed factory project mainly includes two functional areas, namely production workshop and office building. The north side is mainly the green belt and the fish feed factory passage, and the south side is the office building, finished product workshop, main workshop and boiler room, raw material workshop, and living area from east to west.

The 48t/h tilapia fish feed factory production area adopts a combined layout. According to the 48t/h tilapia fish feed factory fish feed production process, the buildings and large outdoor equipment such as raw material input, production and processing, finished product packaging, storage and transportation are reasonably arranged.

Utilities of the 48t/h tilapia fish feed factory

1. Water Supply

   The water used in this 48t/h tilapia fish feed factory project is mainly domestic water, boiler water and greening water, of which the domestic water and boiler water are provided by the municipal water supply network, which can meet the requirements of production and domestic water.

2. Drainage

   The fish feed production process of this 48t/h tilapia fish feed factory project does not produce production waste water. Since the production process needs to maintain dry conditions, the workshop site will not be cleaned.

   Therefore, the sewage generated by the fish feed factory project is mainly domestic sewage, and the evaporation and loss rates are calculated at 20%, and the domestic sewage production is about 6.0m3/d.

   Because the municipal sewage pipe network around the fish feed factory project has not been perfected, the current domestic sewage of the fish feed factory project is treated by septic tanks and then regularly pumped out to be used as agricultural fertilizer.

3. Power

   The annual power consumption of the 48t/h tilapia fish feed factory project is about 80,000 kWh, which is directly supplied by the municipal power grid, and the 48t/h tilapia fish feed factory project does not have a separate generator.

4. Heating

   The 48t/h tilapia fish feed factory project is equipped with 2t/h and 4t/h steam boilers, the fuel is biomass fuel, and the daily consumption is 1t/d.