With the continuous improvement of people’s living standards and the increasing emphasis on pet companionship, the global pet food industry has developed rapidly in recent years. Pets are gradually regarded as important members of the family, and their dietary health and food quality have become the focus of pet owners. This has promoted the continuous upgrading of pet food processing technology and equipment, putting forward higher requirements for the safety, nutrition, taste and appearance of pet food. We are committed to providing professional extruders specially designed for food production, with rich experience in pet food processing, and can provide targeted processing solutions for various types of pet food, helping enterprises improve production efficiency, ensure product quality, and gain an advantage in the fierce market competition.
This article will focus on the field of pet food, in-depth elaborating on pet food processing technology, the working principle of screw extrusion puffing, the advantages of our extruders, and the specific application of extrusion equipment in pet food production. It will also supplement detailed technical parameters, process details and industry pain points to enrich the content, meet the word count requirement of 3000-4000 words, and provide comprehensive and professional reference for relevant enterprises and practitioners in the pet food industry.
1. Overview of the Pet Food Industry and Processing Characteristics
1.1 Current Situation and Development Trend of the Pet Food Industry
In recent years, the global pet food market has shown a steady growth trend. Driven by factors such as the increase in the number of pets, the upgrading of pet consumption concepts, and the improvement of residents’ purchasing power, the demand for high-quality, nutritious and functional pet food has continued to rise. According to relevant data statistics, the global pet food market size has exceeded 100 billion US dollars, and it is expected to maintain a growth rate of 5%-8% in the next few years. Among them, dry puffed pet food, as the most mainstream product type, accounts for more than 60% of the total pet food market, followed by wet canned products, semi-wet products and pet snacks.
The development trend of the pet food industry is mainly reflected in three aspects: first, nutrition and health. Ang mga may-ari ng alagang hayop ay nagbibigay ng higit at higit na pansin sa nutritional na komposisyon ng pagkain ng alagang hayop, at mga produktong may natural, walang additive, functional (tulad ng pagpapaganda ng buhok, pagpapakain sa tiyan, kontrol ng timbang) ang mga katangian ay mas popular; pangalawa, pagkakaiba-iba ng mga uri ng produkto. Sa pagpapayaman ng mga uri ng alagang hayop at ang mga indibidwal na pangangailangan ng mga may-ari ng alagang hayop, unti-unting nabuo ang pagkain ng alagang hayop patungo sa segmentasyon, tulad ng pagkain ng alagang hayop para sa iba't ibang edad (mga tuta, matatandang aso, matatandang aso), iba't ibang lahi, at iba't ibang pisikal na kondisyon; pangatlo, katalinuhan at kahusayan ng teknolohiya sa pagproseso. Upang matugunan ang malakihang pangangailangan sa produksyon at matiyak ang katatagan ng kalidad ng produkto, ang mga negosyo sa pagpoproseso ng pagkain ng alagang hayop ay patuloy na nagpapakilala ng mga advanced na kagamitan sa pagpoproseso at mga intelligent na sistema ng kontrol upang mapabuti ang kahusayan sa produksyon at mabawasan ang mga gastos sa paggawa.
Against this background, extrusion puffing technology, as the core technology of pet food processing (especially dry puffed products), has become the key to determining the quality of pet food and the competitiveness of enterprises. Our professional extruders for pet food production are developed in response to the characteristics of the industry and market demand, which can effectively solve the pain points in pet food processing and help enterprises achieve high-quality and efficient production.
1.2 Classification of Pet Food and Its Processing Characteristics
Pet food has a variety of classification methods, which can be divided into different types according to processing technology, water content, product form and use. Among them, according to the processing technology and water content, pet food is mainly divided into dry puffed products, semi-wet products, soft puffed products, wet canned products and snacks (or treats). Each type of pet food has its own unique processing characteristics and requirements for equipment, as follows:
1.2.1 Dry Puffed Products:
Dry puffed pet food is the most common type of pet food, with a water content of 10%-12%. Its main raw materials include meat meal, fish meal, cereal (corn, wheat, rice), soybean meal, vitamins, minerals and other additives. The processing process of dry puffed products is closely related to the puffing process, which requires the use of extrusion puffing equipment to process the raw materials into granular products with uniform size, crisp taste and good palatability. The characteristics of dry puffed products are long shelf life, convenient storage and transportation, and low production cost, which are suitable for large-scale production and popular among pet owners.
The key processing requirement of dry puffed products is that the raw materials need to be fully puffed, so that the starch in the raw materials is fully gelatinized, which is conducive to the digestion and absorption of pets. At the same time, the product needs to have a certain hardness and crispness to meet the chewing needs of pets and help clean their teeth. This puts high requirements on the extrusion pressure, temperature and screw speed of the extruder.
1.2.2 Semi-Wet Products:
Semi-wet pet food has a water content of 25%-35%, which is between dry and wet products. Its raw materials are similar to dry puffed products, but more humectants (such as propylene glycol, sorbitol) ay idinagdag upang mapanatili ang lambot at kahalumigmigan ng produkto. Ang proseso ng pagproseso ng mga semi-wet na produkto ay nangangailangan din ng puffing treatment, ngunit ang antas ng puffing ay mas mababa kaysa sa mga tuyong produkto. Ang produkto ay may mga katangian ng malambot na lasa at mahusay na kasiyahan, na angkop para sa mga alagang hayop na may mahinang kakayahan sa pagnguya (tulad ng matatandang alagang hayop, mga alagang hayop na may sakit).
Ang kahirapan sa pagproseso ng mga semi-wet na produkto ay nakasalalay sa kontrol ng nilalaman ng tubig at ang pag-iwas sa pagkasira ng produkto. Samakatuwid, sa proseso ng pagproseso, ito ay kinakailangan upang mahigpit na kontrolin ang temperatura at halumigmig ng bawat link, at pumili ng naaangkop na mga preservative at humectants upang matiyak ang buhay ng istante ng produkto.
1.2.3 Soft Puffed Products:
Ang soft puffed pet food ay may nilalamang tubig na 15%-25%, na isang produkto sa pagitan ng dry puffed at semi-wet na mga produkto. Ang proseso ng pagproseso nito ay katulad ng sa mga dry puffed na produkto, ngunit ang mga parameter ng formula at extrusion ay inaayos upang gawing malambot at nababanat ang produkto. Pinagsasama ng malambot na puffed na mga produkto ang mga pakinabang ng tuyo at semi-basa na mga produkto, na may mahusay na lasa at madaling pantunaw, na angkop para sa iba't ibang mga alagang hayop.
1.2.4 Mga Produktong Basang Latang:
Ang basang de-latang pagkain ng alagang hayop ay may nilalamang tubig na higit sa 70%, pangunahing gumagamit ng sariwang karne, isda, gulay at iba pang hilaw na materyales, na pinoproseso sa pamamagitan ng pagluluto, canning, isterilisasyon at iba pang mga proseso. Iba sa ibang uri ng produkto, Ang mga basang de-latang produkto ay hindi nangangailangan ng paggamot sa puffing, at ang kanilang mga pangunahing link sa pagproseso ay pagluluto at isterilisasyon. Ang produkto ay may mga katangian ng masaganang nutrisyon, strong palatability and high moisture content, which is suitable for pets who do not like drinking water or need supplementary nutrition.
The key to the processing of wet canned products is to ensure the freshness and safety of raw materials, and strictly control the sterilization temperature and time to kill harmful bacteria in the product and extend the shelf life. At the same time, it is necessary to ensure that the nutritional components of the product are not lost during the cooking and sterilization process.
1.2.5 Pet Snacks (or Treats):
Pet snacks are auxiliary food for pets, mainly used to reward pets, improve their mood and supplement nutrition. The types of pet snacks are diverse, including puffed snacks, dried meat snacks, jerky snacks, dental snacks, etc. Among them, puffed snacks account for a large proportion, at ang kanilang proseso sa pagpoproseso ay katulad ng mga dry puffed na produkto, ngunit ang formula ay mas pino, at higit pang mga ahente ng pampalasa at functional additives ay idinagdag upang matugunan ang panlasa at functional na mga pangangailangan ng mga alagang hayop.
Ang mga meryenda ng alagang hayop ay may mataas na pangangailangan para sa panlasa, hitsura at pag-andar. Halimbawa, Ang mga meryenda sa ngipin ay kailangang magkaroon ng isang tiyak na tigas at texture upang makatulong sa paglilinis ng mga ngipin ng alagang hayop at maiwasan ang dental calculus; Ang mga meryenda na nagpapaganda ng buhok ay kailangang magdagdag ng mga sangkap tulad ng lecithin upang makatulong na mapabuti ang kalidad ng buhok ng alagang hayop. Ito ay nangangailangan ng extruder na magkaroon ng mahusay na flexibility at adjustability upang matugunan ang mga pangangailangan sa pagproseso ng iba't ibang uri ng meryenda.
Ito ay nagkakahalaga ng noting na maliban sa mga de-latang produkto, karamihan sa mga uri ng pagkain ng alagang hayop ay malapit na nauugnay sa proseso ng puffing. Ang puffing ay hindi lamang pangunahing bahagi ng pagproseso ng pagkain ng alagang hayop, ngunit direktang nakakaapekto sa kalidad, panlasa, nutrisyon at pagkatunaw ng pagkain ng alagang hayop. Samakatuwid, Ang pagpili ng tamang kagamitan sa pag-extrusion at pag-master ng teknolohiyang pang-agham na extrusion ay mahalaga para sa mga negosyo sa pagpoproseso ng pagkain ng alagang hayop.
2. Pangunahing Teknolohiya ng Pagproseso ng Pagkain ng Alagang Hayop: Teknolohiya ng Extrusion Puffing
Ang teknolohiya ng extrusion puffing ay isang pangunahing teknolohiya sa pagpoproseso na nagsasama ng paghahalo, pagmamasa, pag-init, extrusion at puffing. Ito ay malawakang ginagamit sa paggawa ng pagkain ng alagang hayop dahil sa mga bentahe nito ng mataas na kahusayan sa produksyon, magandang kalidad ng produkto, malakas na kakayahang umangkop sa mga hilaw na materyales at malawak na saklaw ng aplikasyon. Sa pagproseso ng pagkain ng alagang hayop, Ang teknolohiya ng extrusion ay pangunahing ginagamit upang mapagtanto ang pagbuga ng mga hilaw na materyales, gawing gelatinize ang almirol, ang protina denature, at pagbutihin ang palatability at digestibility ng produkto. At the same time, maaari din itong pumatay ng mga nakakapinsalang bakterya sa mga hilaw na materyales, tiyakin ang kaligtasan ng pagkain ng alagang hayop.
2.1 Mga Katangian ng Mga Hilaw na Materyales ng Pagkain ng Alagang Hayop at Mga Kinakailangan para sa Extrusion Equipment
Ang mga hilaw na materyales ng pagkain ng alagang hayop ay pangunahing mga produktong karne (tulad ng meat meal, fish meal, sariwang karne), cereal, soybean meal, vitamins, minerals and other additives. Among them, Malaking bahagi ang mga produktong karne, ginagawang malakas ang lagkit ng produkto. Ang katangiang ito ay naglalagay ng mga espesyal na kinakailangan para sa mga kagamitan sa pagpilit:
Ang mga single-screw extruder ay hindi angkop para sa pang-ekonomiyang produksyon ng pagkain ng alagang hayop. Dahil ang single-screw extruder ay may makitid na saklaw ng paggugupit, mahinang pumping capacity at walang epekto sa paglilinis sa sarili. Kapag nagpoproseso ng malapot na materyales tulad ng mga produktong karne, madaling maging sanhi ng akumulasyon ng materyal, pagbara at hindi pantay na paghahalo sa extruder barrel, na hindi lamang nakakaapekto sa kahusayan ng produksyon, ngunit humahantong din sa hindi matatag na kalidad ng produkto. Bilang karagdagan, ang single-screw extruder ay may mataas na pagkonsumo ng enerhiya kapag nagpoproseso ng mataas na taba at mataas na protina na mga hilaw na materyales, na nagpapataas ng gastos sa produksyon ng mga negosyo.
Mga twin-screw extruder, sa kabilang banda, may malinaw na mga pakinabang sa paggawa ng pagkain ng alagang hayop. Mayroon silang mas malawak na saklaw ng paggugupit, mas epektibong pumping effect at self-cleaning effect, na maaaring epektibong malutas ang mga problema ng materyal na lagkit at akumulasyon. Maaaring mapagtanto ng twin-screw extruder ang pare-parehong paghahalo, pagmamasa at pagpilit ng mga materyales, kahit na sa pagproseso ng mga hilaw na materyales na may mataas na taba at sariwang nilalaman ng karne, masisiguro rin nito ang matatag na produksyon at pare-pareho ang kalidad ng produkto. Samakatuwid, sa aktwal na produksyon ng pagkain ng alagang hayop, Ang mga twin-screw extruder ay naging pangunahing paraan ng pagbuga ng pagkain ng alagang hayop, at malawakang ginagamit sa paggawa ng mga tuyong pinatuyong produkto, semi-wet products, soft puffed na produkto at meryenda ng alagang hayop.
2.2 Prinsipyo ng Paggawa ng Screw Extrusion Puffing
Ang proseso ng pagbubuga ng screw extrusion ng pagkain ng alagang hayop ay isang kumplikadong prosesong pisikal at kemikal, na kinabibilangan ng interaksyon ng maraming salik gaya ng temperatura, presyon, puwersa at oras ng paggugupit. Ang tiyak na prinsipyo ng pagtatrabaho ay ang mga sumusunod:
Una, pretreatment ng hilaw na materyal. Ang pulbos na hilaw na materyales na naglalaman ng isang tiyak na halaga ng almirol (higit sa 20%) ay pinaghalong pantay ayon sa formula, at pagkatapos ay ipinadala sa tempering device para sa tempering treatment. Ang layunin ng tempering ay upang ayusin ang moisture content at temperatura ng mga materyales, so that the materials can reach the ideal state before entering the extruder. Sa pangkalahatan, the moisture content of the materials after tempering is controlled at 10%～27%, and the temperature is raised to 70～98℃. During the tempering process, the materials absorb water evenly, which is conducive to the subsequent gelatinization of starch and denaturation of protein, and can also reduce the wear of the extruder screw and barrel.
Pangalawa, extrusion and heating. The tempered materials enter the screw extrusion cavity through the feeding device. The screw extrusion cavity is composed of a screw and a barrel, and the volume of the extrusion cavity gradually decreases along the axis direction. When the screw rotates, it pushes the materials forward continuously, and the materials are gradually compressed under the action of the screw and the barrel, and the pressure in the extrusion cavity gradually increases. The compression ratio (the ratio of the volume of the material at the feeding end to the volume at the extrusion end) can reach 4～10, which varies according to the type of pet food and the formula of raw materials.
During the process of being pushed and extruded by the screw, the materials are subjected to strong shear force and friction force. The shear force is generated by the relative movement between the screw and the barrel, as well as between the screw flights. It can break the particles of the materials, make the raw materials and additives mix more uniformly, and promote the gelatinization of starch and denaturation of protein. The friction force is generated between the materials and the inner wall of the barrel, as well as between the material particles, which can generate a lot of heat, which is conducive to the heating of the materials. Bilang karagdagan, according to the processing needs, steam can flow through the barrel jacket to heat the materials between the walls, so that the materials in the extrusion cavity are in a high-temperature and high-pressure state. The temperature in the extrusion cavity is generally controlled at 120～180℃, and the pressure is controlled at 2～10MPa.
Third, starch gelatinization and protein denaturation. Under the action of high temperature, high pressure and shear force, the starch in the materials absorbs water and expands, the crystal structure is destroyed, and it is converted into an amorphous state, which is called starch gelatinization. Starch gelatinization can improve the digestibility of pet food, because the gelatinized starch is easier to be decomposed by the digestive enzymes of pets. At the same time, the gelatinized starch can also improve the viscosity and binding force of the materials, making the extruded products have good shape and texture.
In addition to starch gelatinization, the protein in the materials will also undergo denaturation under the action of high temperature and high pressure. Protein denaturation refers to the change of the spatial structure of protein molecules without changing the primary structure, which can improve the solubility and digestibility of protein, and make the pet food have better palatability. At the same time, the denatured protein can also form a network structure, which can wrap the starch and other components, helping to maintain the shape of the puffed product.
Fourth, puffing and shaping. When the materials in the high-temperature and high-pressure state are pushed to the die head by the screw and extruded from the die hole at a high speed, the temperature and pressure of the materials drop sharply because they suddenly leave the extrusion cavity and enter the normal atmospheric environment. Under the combined action of pressure difference and temperature difference, the water in the materials evaporates rapidly, the volume of the materials expands rapidly (the expansion rate can reach 2～8 times), and the materials are dehydrated and solidified quickly to form a porous, crisp or soft puffed product.
After extrusion from the die hole, the puffed materials are cut into short particles of uniform length by the cutting device (rotary knife) installed at the die head. The length of the particles can be adjusted by changing the speed of the rotary knife to meet the requirements of different types of pet food. Halimbawa, the particles of puppy food are smaller and shorter, while the particles of adult dog food are larger and longer.
Fifth, post-processing. The extruded puffed particles need to go through post-processing links such as drying, cooling, seasoning and packaging to become the final pet food products. Drying is to reduce the water content of the particles to the standard range (10%-12% for dry products), so as to extend the shelf life of the product. Cooling is to reduce the temperature of the dried particles to room temperature, prevent the product from caking and deteriorating. Seasoning is to spray flavoring agents, attractants and other additives on the surface of the particles to improve the palatability of the product. Packaging is to pack the seasoned particles into bags or cans to ensure the hygiene and safety of the product and facilitate storage and transportation.
2.3 Key Factors Affecting Screw Extrusion Puffing Effect
The effect of screw extrusion puffing directly affects the quality of pet food. There are many factors affecting the puffing effect, mainly including raw material characteristics, tempering parameters, extrusion parameters and die head structure. Mastering these key factors and making scientific adjustments can ensure the stability of the puffing effect and the consistency of product quality.
2.3.1 Raw Material Characteristics:
The type, particle size, moisture content and nutritional composition of raw materials have a great impact on the puffing effect. Halimbawa, the starch content of raw materials directly affects the expansion rate of the product. The higher the starch content (within a certain range), the better the puffing effect, and the larger the expansion rate of the product. The particle size of raw materials should be uniform, generally 80-100 mesh. If the particle size is too large, the materials are not easy to be mixed uniformly and plasticized fully, which affects the puffing effect; if the particle size is too small, madaling maging sanhi ng pagbabara ng materyal at pagtaas ng pagkonsumo ng enerhiya. Ang moisture content ng mga hilaw na materyales bago ang tempering ay dapat na kontrolin sa 8%-12%. Kung ang moisture content ay masyadong mataas, ang mga materyales ay madaling dumikit sa tornilyo at bariles, nakakaapekto sa extrusion at puffing; kung ang moisture content ay masyadong mababa, ang puwersa ng paggugupit at puwersa ng friction sa pagitan ng mga materyales ay hindi sapat, at hindi kumpleto ang gelatinization ng starch, na nagreresulta sa mahinang puffing effect.
2.3.2 Mga Parameter ng Tempering:
Pangunahing kasama sa mga parameter ng tempering ang temperatura ng tempering, oras ng tempering at moisture content pagkatapos ng tempering. Ang temperatura ng tempering ay karaniwang 70～98 ℃. Kung ang temperatura ng tempering ay masyadong mababa, ang mga materyales ay hindi maaaring sumipsip ng tubig nang pantay-pantay, at hindi sapat ang gelatinization ng starch; kung ang temperatura ng tempering ay masyadong mataas, the materials may be caked in advance, affecting the subsequent extrusion. The tempering time is generally 2-5 minuto, which should be adjusted according to the type of raw materials and the moisture content. The moisture content after tempering is 10%～27%, which varies according to the type of pet food. Halimbawa, the moisture content of dry puffed products after tempering is generally 15%-20%, while that of semi-wet products is 22%-27%.
2.3.3 Extrusion Parameters:
Extrusion parameters are the most important factors affecting the puffing effect, mainly including screw speed, extrusion temperature and extrusion pressure. Screw speed generally ranges from 100 sa 600 rpm. The higher the screw speed, the greater the shear force and friction force received by the materials, the higher the extrusion temperature and pressure, and the better the puffing effect. Gayunpaman, if the screw speed is too high, the residence time of the materials in the extrusion cavity is too short, resulting in incomplete starch gelatinization and uneven mixing; if the screw speed is too low, the shear force and friction force are insufficient, and the puffing effect is poor.
Extrusion temperature is generally controlled at 120～180℃, which is divided into three sections: feeding section, melting section and homogenizing section. The temperature of the feeding section is lower (70～90℃), which is mainly to prevent the materials from caking and ensure the smooth feeding; the temperature of the melting section is medium (120～150℃), which is mainly to promote the melting and plasticization of the materials; the temperature of the homogenizing section is higher (150～180℃), which is mainly to ensure the uniform mixing and full gelatinization of the materials.
Extrusion pressure is generally 2～10MPa. The pressure in the extrusion cavity is mainly determined by the compression ratio of the screw, the die hole size and the screw speed. The higher the extrusion pressure, the better the puffing effect, but if the pressure is too high, it will increase the energy consumption and wear of the equipment; if the pressure is too low, the puffing effect is poor, and the product is loose and easy to break.
2.3.4 Die Head Structure:
The die head structure mainly includes the number, shape and size of die holes. The shape of the die hole determines the cross-sectional shape of the puffed product, such as circular, square, triangular and other shapes. The size of the die hole determines the initial diameter of the product. The smaller the die hole size, the greater the extrusion pressure, and the better the puffing effect, but the production capacity will be reduced. The number of die holes affects the production capacity. The more the number of die holes, the higher the production capacity, but it is necessary to ensure that the pressure distribution is uniform, so as to avoid uneven puffing of the product.
3. Our Extruders: Advantages and Product Series for Pet Food Production
We have long been engaged in the research, development and production of food-grade extruders, and have developed a series of twin-screw extruders specially suitable for pet food production according to the characteristics of pet food processing and the needs of enterprises. Our extruders have the advantages of low operating cost, wide application range, advanced technology and reliable process control, which can meet the processing needs of various types of pet food and help enterprises improve production efficiency and product quality.
3.1 Main Advantages of Our Extruders
3.1.1 Low Lifetime Operating Cost:
We focus on the durability and economy of the equipment, and adopt high-quality materials and advanced manufacturing technology to ensure that the extruder has a long service life and low operating cost. The inner wall of the barrel is made of high-quality wear-resistant alloy steel, which has extremely strong wear resistance and can effectively resist the wear caused by the friction between the materials (especially the materials containing hard particles such as bone meal) at ang bariles. Ito ay lubos na nagpapalawak sa buhay ng serbisyo ng bariles, pagbabawas ng dalas ng pagpapalit ng bariles at ang gastos sa pagpapanatili ng kagamitan.
Bilang karagdagan, nagbibigay din kami ng mga propesyonal na serbisyo sa pagsukat ng pagsukat ng barrel wear. Regular o hindi regular na matutukoy ng aming technical team ang pagsusuot ng barrel para sa mga customer, tumpak na hatulan ang antas ng pagsusuot ng bariles, at magbigay ng mga propesyonal na mungkahi sa pagpapalit ng bariles. Tinitiyak nito na pinapalitan lamang ng mga customer ang bariles kapag ito ay talagang kinakailangan, pag-iwas sa hindi kinakailangang basura at pagbabawas ng gastos sa pagpapatakbo ng kagamitan. At the same time, ang turnilyo ng aming extruder ay gawa rin sa wear-resistant na alloy steel, na may magandang corrosion resistance at wear resistance, at maaaring umangkop sa pagproseso ng mataas na taba, mataas na protina at mataas na asin na hilaw na materyales.
3.1.2 Malawak na Saklaw ng Application:
Ang aming mga twin-screw extruder ay may malakas na kakayahang umangkop at maaaring matugunan ang mga pangangailangan sa pagproseso ng iba't ibang uri ng pagkain ng alagang hayop, kabilang ang mga tuyong pinatuyong produkto, semi-wet products, soft puffed products, meryenda ng alagang hayop at iba pang produkto. Ang extruder ay nilagyan ng high-torque drive system, variable na bilis ng turnilyo at pressure variable control device, na nagbibigay ng mahusay na kakayahang umangkop para sa mga customer, at maaaring iakma ayon sa iba't ibang mga kinakailangan sa proseso at mga formula ng hilaw na materyal upang makamit ang pinakamahusay na epekto sa pagproseso.
Ang modular na disenyo ng extruder ay isa pang pangunahing tampok na nagpapalawak ng saklaw ng aplikasyon nito. Ang turnilyo, bariles, die head at iba pang mga bahagi ng extruder ay nagpatibay ng isang modular na disenyo, na maaaring malayang pagsamahin at palitan ayon sa partikular na pangangailangan ng customer sa aplikasyon. Halimbawa, kapag nagpoproseso ng mga tuyong puffed na produkto, customers can choose a screw with a high compression ratio and a die head with small die holes; when processing semi-wet products, they can choose a screw with a medium compression ratio and a die head with large die holes. This modular design not only improves the flexibility and adaptability of the equipment, but also reduces the cost of equipment transformation when customers adjust their product types.
3.1.3 Advanced Technology and Reliable Process Control:
Our extruders adopt the most advanced intelligent control technology, which can realize the precise control of the entire processing process, ensuring the consistency of the final product quality. The extruder is equipped with an intelligent formula memory system, which can store multiple sets of product formulas and processing parameters. Kapag ang mga customer ay gumagawa ng iba't ibang mga produkto, kailangan lang nilang tawagan ang kaukulang formula at mga parameter, nang walang paulit-ulit na pag-debug, na hindi lamang nakakatipid ng oras at nagpapabuti ng kahusayan sa produksyon, ngunit pinapakinabangan din ang pagbawas ng mga error sa proseso at mga error ng operator.
Ang intelligent control system ay mayroon ding real-time na pagsubaybay at mga function ng alarma. Maaari nitong subaybayan ang mga pangunahing parameter tulad ng temperatura ng extrusion, presyon ng pagpilit, bilis ng turnilyo, materyal na moisture content at kapasidad ng produksyon sa real time. Kung lumampas ang anumang parameter sa hanay na itinakda, maglalabas ang system ng alarm prompt sa oras, at kahit na awtomatikong isara ang kagamitan kung kinakailangan, upang maiwasan ang pagkabigo ng kagamitan at mga problema sa kalidad ng produkto. Bilang karagdagan, ang control system ay gumagamit ng interface ng pagpapatakbo ng touch screen, na simple at intuitive, madaling patakbuhin, and can reduce the professional requirements for operators.
3.1.4 Good Product Quality Stability:
Due to the advanced intelligent control system, uniform mixing and full plasticization of materials, the products processed by our extruders have stable quality. The particle size, shape, hardness, crispness and nutritional composition of the products are uniform, which can meet the strict quality requirements of pet food. At the same time, the extrusion puffing process can effectively kill harmful bacteria in the raw materials (such as Salmonella, Escherichia coli), with a sterilization rate of more than 99%, ensuring the safety of pet food and reducing the risk of pet food safety incidents.
3.1.5 High Production Efficiency:
Our twin-screw extruders have high production efficiency, which is much higher than that of single-screw extruders. The production capacity of our extruders ranges from 100kg/h to 2000kg/h, which can meet the production needs of different scales of enterprises (small, medium and large). The high-torque drive system and optimized screw design of the extruder can effectively improve the conveying capacity and plasticization efficiency of materials, reducing the residence time of materials in the extrusion cavity and improving production efficiency. Bilang karagdagan, the self-cleaning function of the twin-screw extruder can reduce the time of equipment cleaning and maintenance, further improving production efficiency.
3.2 HTS BASIC Series Extruders: A Cost-Effective Choice for Pet Food Enterprises
The HTS BASIC series extruders are a cost-effective product series independently developed by us, na espesyal na idinisenyo para sa mga negosyo sa pagpoproseso ng pagkain ng alagang hayop na may katamtaman at maliliit na antas ng produksyon o paunang pagpasok sa industriya. Ang seryeng ito ng mga extruder ay gumagamit ng mga medium-torque na gearbox mula sa mga nangungunang tagagawa sa Europa, na may mga pakinabang ng matatag na pagganap, mababang ingay, mataas na kahusayan at mahabang buhay ng serbisyo. Maaaring matugunan ng medium-torque na disenyo ang mga pangangailangan sa pagproseso ng karamihan sa pagkain ng alagang hayop (tulad ng tuyong pagkain ng aso, pagkain ng pusa, meryenda ng alagang hayop), at kasabay nito, ito ay may makatwirang presyo, na makakatulong sa mga negosyo na bawasan ang paunang gastos sa pamumuhunan.
Sa mga tuntunin ng disenyo ng istruktura, ang HTS BASIC series extruders ay gumagamit ng twin-screw parallel structure, na may diameter ng tornilyo mula 30mm hanggang 65mm, at isang compression ratio na 4～8, na maaaring iakma ayon sa uri ng pagkain ng alagang hayop. The barrel is made of wear-resistant alloy steel, with a built-in heating element and a cooling system, which can accurately control the temperature of each section of the barrel. The screw is made of wear-resistant and corrosion-resistant alloy steel,经过 precision machining and heat treatment, which has good wear resistance and corrosion resistance.
In terms of performance parameters, the HTS BASIC series extruders have a screw speed range of 150～500 rpm, which can be steplessly adjusted. The extrusion temperature can be controlled at 120～170℃, and the extrusion pressure can be controlled at 2～8MPa. The production capacity of this series of extruders ranges from 100kg/h to 500kg/h, which is suitable for medium and small-sized pet food processing enterprises. Ang extruder ay nilagyan ng isang PLC control system at isang touch screen operation interface, na simple at madaling patakbuhin. Maaari itong mapagtanto ang awtomatikong kontrol ng proseso ng produksyon, tulad ng awtomatikong pagpapakain, awtomatikong kontrol ng temperatura, awtomatikong kontrol sa presyon at awtomatikong pagputol.
Isa sa mga pinakamalaking bentahe ng HTS BASIC series extruders ay na maaari silang magbigay ng mga flexible na opsyon sa pamamagitan ng iba't ibang kumbinasyon ng configuration. Maaaring pumili ang mga customer ng iba't ibang uri ng turnilyo, mamatay ulo, mga kagamitan sa pagpapakain, tempering device at post-processing equipment ayon sa kanilang sariling mga uri ng produkto, kapasidad ng produksyon at badyet, upang bumuo ng isang linya ng produksyon na angkop para sa kanilang sariling mga pangangailangan. Halimbawa, kung ang isang customer ay pangunahing gumagawa ng dry puffed dog food, maaari silang pumili ng isang tornilyo na may mataas na ratio ng compression, isang pabilog na ulo ng mamatay, a high-efficiency tempering device and a drying cooling line; if a customer mainly produces pet snacks, they can choose a screw with a medium compression ratio, a special-shaped die head and a seasoning line.
Bilang karagdagan, the HTS BASIC series extruders have the advantages of easy maintenance and low maintenance cost. The modular design of the equipment makes the replacement of components (such as screw, bariles, mamatay ulo) more convenient and quick. Our after-sales service team will provide professional installation, commissioning and training services for customers, ensuring that customers can use the equipment smoothly. At the same time, we also provide a complete range of spare parts supply services, which can quickly provide customers with the required spare parts, reducing the downtime of the equipment.
3.3 Selection Suggestions for Pet Food Extruders
Kapag pumipili ng mga extruder para sa produksyon ng pagkain ng alagang hayop, kailangang komprehensibong isaalang-alang ng mga negosyo ang kanilang sariling mga pangangailangan sa produksyon, mga uri ng produkto, badyet at iba pang mga kadahilanan upang matiyak na ang mga napiling kagamitan ay maaaring matugunan ang aktwal na mga pangangailangan sa produksyon at magdala ng pinakamataas na benepisyo sa ekonomiya. Ang mga sumusunod ay ilang partikular na mungkahi sa pagpili:
3.3.1 Tukuyin ang Uri ng Extruder Ayon sa Mga Uri ng Produkto:
Ang iba't ibang uri ng pagkain ng alagang hayop ay may iba't ibang mga kinakailangan para sa mga extruder. Halimbawa, ang mga dry puffed na produkto ay nangangailangan ng mga extruder na may mataas na compression ratio, mataas na temperatura at presyon ng pagpilit; Ang mga semi-wet na produkto ay nangangailangan ng mga extruder na may medium compression ratio at moderate extrusion temperature at pressure; ang mga meryenda ng alagang hayop ay nangangailangan ng mga extruder na may mahusay na flexibility at adjustability. Dapat piliin ng mga negosyo ang naaangkop na uri ng extruder (mas gusto ang twin-screw extruder) at pagsasaayos ayon sa mga pangunahing uri ng produkto na kanilang ginagawa.
3.3.2 Tukuyin ang Production Capacity ng Extruder Ayon sa Production Scale:
Dapat piliin ng mga negosyo ang extruder na may naaangkop na kapasidad ng produksyon ayon sa kanilang sariling sukat ng produksyon at pangangailangan sa merkado. Kung maliit ang sukat ng produksyon (araw-araw na output na mas mababa sa 1 tonelada), ang mga HTS BASIC series extruder na may kapasidad ng produksyon na 100-300kg/h ay angkop; kung katamtaman ang sukat ng produksiyon (araw-araw na output 1-5 tonelada), ang mga HTS BASIC series extruder na may kapasidad ng produksyon na 300-500kg/h ay angkop; kung malaki ang sukat ng produksiyon (araw-araw na output ng higit sa 5 tonelada), inirerekomendang piliin ang aming high-torque large-scale twin-screw extruders (kapasidad ng produksyon na higit sa 500kg/h).
3.3.3 Isaalang-alang ang Cost-Effectiveness ng Equipment:
The cost-effectiveness of the equipment is an important factor that enterprises need to consider. Enterprises should not only pay attention to the initial investment cost of the equipment, but also consider the long-term operating cost (such as energy consumption, maintenance cost, spare parts cost). Our HTS BASIC series extruders have the advantages of reasonable price, low energy consumption and low maintenance cost, which are cost-effective choices for medium and small-sized enterprises.
3.3.4 Pay Attention to the After-Sales Service of the Equipment:
The after-sales service of the equipment is crucial for the normal operation of the production line. Enterprises should select manufacturers with perfect after-sales service systems, which can provide professional installation, pagkomisyon, pagsasanay, maintenance and spare parts supply services. Mayroon kaming propesyonal na pangkat ng serbisyo pagkatapos ng benta, na maaaring tumugon sa mga pangangailangan ng customer sa isang napapanahong paraan at malutas ang iba't ibang mga problema na nakatagpo ng mga customer sa paggamit ng kagamitan, tinitiyak ang normal na operasyon ng linya ng produksyon.
3.3.5 Isaalang-alang ang Flexibility at Expandability ng Equipment:
Sa pagbabago ng demand sa merkado, maaaring kailanganin ng mga negosyo na ayusin ang kanilang mga uri ng produkto at antas ng produksyon. Samakatuwid, kapag pumipili ng mga extruder, dapat isaalang-alang ng mga negosyo ang flexibility at expandability ng kagamitan. Ang aming mga extruder ay gumagamit ng modular na disenyo, na maaaring malayang pagsamahin at i-upgrade ayon sa mga pangangailangan ng mga negosyo, pagpapabuti ng kakayahang umangkop at pagpapalawak ng kagamitan, at pagbabawas ng gastos sa pagbabago ng kagamitan.
4. Application ng Extrusion Equipment sa Pet Food Production
Ang aming twin-screw extruders (including HTS BASIC series) have been widely used in the production of various types of pet food, and have achieved good application effects. The following will introduce the specific application of our extrusion equipment in different types of pet food production, including process flow, equipment configuration and key technical points.
4.1 Application in Dry Puffed Pet Food Production
Dry puffed pet food is the most widely used product type in the pet food industry, and our HTS BASIC series extruders are especially suitable for its production. The process flow of dry puffed pet food production using our extruders is as follows:
Raw material preparation → mixing → tempering → extrusion puffing → cutting → drying → cooling → seasoning → packaging.
4.1.1 Paghahanda ng Hilaw na Materyal:
Ang mga hilaw na materyales ng dry puffed pet food ay pangunahing kinabibilangan ng meat meal (pagkain ng manok, pagkain ng baka, fish meal), cereal (harina ng mais, harina ng trigo, harina ng bigas), soybean meal, vitamins, mineral, mga pang-akit at iba pang mga additives. Ang lahat ng mga hilaw na materyales ay kailangang siyasatin at linisin upang maalis ang mga dumi (tulad ng mga bato, mga metal) at tiyakin ang kalidad ng mga hilaw na materyales. Ang mga hilaw na materyales ay dinudurog sa pulbos na may laki ng butil ng 80-100 mesh, na nakakatulong sa pare-parehong paghahalo at ganap na plasticization.
4.1.2 Paghahalo:
Ang mga durog na hilaw na materyales ay ipinadala sa panghalo ayon sa ratio ng formula para sa pare-parehong paghahalo. Karaniwan ang oras ng paghahalo 5-10 minuto, tinitiyak na ang lahat ng mga hilaw na materyales at additives ay pantay na ipinamamahagi. Ang panghalo ay nilagyan ng isang aparato sa pagtimbang, na maaaring tumpak na makontrol ang dosis ng bawat hilaw na materyal, tinitiyak ang katatagan ng formula ng produkto.
4.1.3 Tempering:
Ang pinaghalong hilaw na materyales ay ipinadala sa tempering device para sa tempering treatment. Ang temperatura ng tempering ay kinokontrol sa 80-95 ℃, ang tempering time ay 3-5 minuto, at ang moisture content pagkatapos ng tempering ay 15%-20%. During the tempering process, Ang singaw ay ini-inject sa tempering device upang ang mga hilaw na materyales ay sumipsip ng tubig nang pantay-pantay, na kaaya-aya sa kasunod na extrusion puffing.
4.1.4 Extrusion Puffing:
Ang mga tempered raw na materyales ay ipinapadala sa HTS BASIC series twin-screw extruder para sa extrusion puffing. Ang bilis ng tornilyo ay kinokontrol sa 200-400 rpm, ang temperatura ng extrusion ng seksyon ng pagpapakain ay 70-90 ℃, ang natutunaw na seksyon ay 130-150 ℃, at ang homogenizing section ay 160-170 ℃. Ang presyon ng pagpilit ay kinokontrol sa 5-8MPa, at ang compression ratio ay 6-8. Under the action of high temperature, high pressure and shear force, ang almirol sa mga hilaw na materyales ay ganap na gelatinized, ang protina ay na-denatured, at ang mga materyales ay pinalabas mula sa ulo ng mamatay upang bumuo ng mga puffed strips.
4.1.5 Pagputol:
Ang puffed strips na na-extrude mula sa die head ay pinuputol sa mga maiikling particle ng pare-parehong haba ng rotary knife na naka-install sa die head. Ang haba ng mga particle ay karaniwang 3-8mm, na maaaring iakma sa pamamagitan ng pagbabago ng bilis ng rotary knife.
4.1.6 pagpapatuyo:
Ang mga cut puffed particle ay ipinapadala sa kagamitan sa pagpapatuyo para sa pagpapatuyo. Ang temperatura ng pagpapatayo ay kinokontrol sa 80-100 ℃, at ang oras ng pagpapatayo ay 20-30 minuto. Ang layunin ng pagpapatuyo ay upang mabawasan ang nilalaman ng tubig ng mga particle sa 10%-12%, so as to extend the shelf life of the product. Ang kagamitan sa pagpapatayo ay maaaring gumamit ng belt dryer o fluidized bed dryer, na may mga pakinabang ng pare-parehong pagpapatayo at mataas na kahusayan.
4.1.7 Paglamig:
Ang mga tuyong particle ay ipinadala sa mga kagamitan sa paglamig para sa paglamig. The cooling temperature is controlled at room temperature (20-25℃), and the cooling time is 10-15 minuto. Cooling can prevent the particles from caking and deteriorating, and ensure the crispness of the product.
4.1.8 Seasoning:
The cooled particles are sent to the seasoning equipment for seasoning. The seasoning can be spray seasoning or mixing seasoning. Common seasonings include chicken flavor, beef flavor, fish flavor and other attractants, as well as vegetable oil, salt and other additives. The seasoning amount is generally 2%-5% of the particle weight, which can be adjusted according to the taste needs of pets.
4.1.9 Packaging:
The seasoned particles are sent to the packaging equipment for packaging. The packaging equipment can adopt automatic packaging machine, which can realize automatic weighing, bagging, sealing and labeling. The packaging specifications can be adjusted according to customer needs, such as 1kg/bag, 5kg/bag, 10kg/bag, etc. After packaging, the products are stored in a dry, cool and ventilated warehouse.
Key technical points: The key to dry puffed pet food production is to control the extrusion parameters and drying parameters. The extrusion parameters (bilis ng turnilyo, temperatura, presyon) directly affect the puffing effect and product texture; the drying parameters (temperatura, oras) directly affect the water content and shelf life of the product. Our HTS BASIC series extruders have precise parameter control functions, which can ensure the stability of the extrusion process and the consistency of product quality.
4.2 Application in Pet Snack Production
Ang mga meryenda ng alagang hayop ay may mataas na pangangailangan para sa panlasa, hitsura at pag-andar, and our HTS BASIC series extruders, with their flexible configuration and precise parameter control, mahusay na matugunan ang mga pangangailangan sa pagproseso ng iba't ibang meryenda ng alagang hayop. Ang pagkuha ng puffed dental snacks bilang isang halimbawa, ang proseso ng daloy ng produksyon gamit ang aming mga extruder ay ang mga sumusunod:
Paghahanda ng hilaw na materyal → paghahalo → tempering → extrusion puffing → pagputol → pagpapatuyo → pagpapalamig → paggamot sa ibabaw → packaging.
4.2.1 Paghahanda ng Hilaw na Materyal:
Ang mga hilaw na materyales ng puffed dental na meryenda ay pangunahing kinabibilangan ng harina ng mais, harina ng trigo, patatas na almirol, pagkain ng karne, hibla ng gulay, calcium carbonate at iba pang mga additives. Among them, Ang hibla ng gulay at calcium carbonate ay idinagdag upang mapabuti ang tigas at pagkakayari ng produkto, tumutulong sa paglilinis ng mga ngipin ng alagang hayop. Ang mga hilaw na materyales ay dinudurog sa pulbos na may laki ng butil ng 100-120 mesh, na nakakatulong sa pagbuo ng produkto at pagpapabuti ng texture.
4.2.2 Paghahalo:
The crushed raw materials are mixed uniformly in the mixer according to the formula ratio. The mixing time is 8-12 minuto, ensuring that the vegetable fiber, calcium carbonate and other additives are evenly distributed in the raw materials.
4.2.3 Tempering:
Ang pinaghalong hilaw na materyales ay ipinadala sa tempering device para sa tempering treatment. The tempering temperature is controlled at 75-90℃, ang tempering time ay 2-4 minuto, at ang moisture content pagkatapos ng tempering ay 18%-22%. The tempering process should ensure that the raw materials absorb water evenly, but not too much, so as to avoid the product being too soft.
4.2.4 Extrusion Puffing:
Ang mga tempered raw na materyales ay ipinapadala sa HTS BASIC series twin-screw extruder para sa extrusion puffing. Ang bilis ng tornilyo ay kinokontrol sa 250-450 rpm, the extrusion temperature of the feeding section is 70-85℃, the melting section is 120-140℃, and the homogenizing section is 150-160℃. The extrusion pressure is controlled at 4-7MPa, at ang compression ratio ay 5-7. The die head adopts a special-shaped die hole (such as cylindrical, spiral, striped), so that the extruded product has a special shape and texture, which is conducive to cleaning the pet’s teeth.
4.2.5 Pagputol:
The extruded puffed products are cut into appropriate lengths by the rotary knife. The length of the products is generally 5-10mm, which can be adjusted according to the size of the pet.
4.2.6 pagpapatuyo:
The cut products are sent to the drying equipment for drying. The drying temperature is controlled at 75-95℃, at ang oras ng pagpapatayo ay 15-25 minuto. The water content of the dried products is controlled at 12%-14%, which ensures that the product has a certain hardness and crispness, and can effectively clean the pet’s teeth.
4.2.7 Paglamig:
The dried products are cooled to room temperature in the cooling equipment, which takes 8-12 minuto.
4.2.8 Surface Treatment:
The cooled products are subjected to surface treatment to improve the palatability and appearance of the product. Common surface treatments include spraying meat sauce, coating cheese powder, and dipping in edible oil. Ang halaga ng paggamot sa ibabaw ay karaniwang 3%-6% ng timbang ng produkto.
4.2.9 Packaging:
Ang mga produkto pagkatapos ng paggamot sa ibabaw ay nakabalot sa pamamagitan ng awtomatikong packaging machine. Ang packaging ay dapat na selyadong at moisture-proof upang matiyak ang pagiging bago at buhay ng istante ng produkto.
Key technical points: Ang susi sa paggawa ng meryenda ng alagang hayop ay ang disenyo ng formula at ang pagsasaayos ng mga parameter ng extrusion. Dapat matugunan ng formula ang panlasa at functional na pangangailangan ng mga alagang hayop; dapat ayusin ang mga parameter ng extrusion ayon sa mga kinakailangan sa hugis at texture ng produkto, pagtiyak na ang produkto ay may magandang hugis at pagkakayari. Ang aming HTS BASIC series extruders ay may mga flexible parameter adjustment function, na maaaring matugunan ang mga pangangailangan sa pagproseso ng iba't ibang uri ng meryenda ng alagang hayop.
4.3 Application sa Semi-Wet Pet Food Production
Ang semi-wet pet food ay may malambot na lasa at magandang lasa, na angkop para sa mga alagang hayop na may mahinang kakayahan sa pagnguya. Ang aming HTS BASIC series extruders ay maaari ding gamitin para sa produksyon ng semi-wet pet food sa pamamagitan ng pagsasaayos ng configuration at mga parameter.. Ang daloy ng proseso ay ang mga sumusunod:
Paghahanda ng hilaw na materyal → paghahalo → tempering → extrusion puffing → pagputol → paglamig → packaging.
4.3.1 Paghahanda ng Hilaw na Materyal:
Ang mga hilaw na materyales ng semi-wet pet food ay pangunahing kasama ang meat meal, fish meal, cereal, soybean meal, mga humectants (propylene glycol, sorbitol), mga preservatives, bitamina at mineral. Ang mga humectants ay idinagdag upang mapanatili ang kahalumigmigan ng produkto, at ang mga preservative ay idinagdag upang mapahaba ang buhay ng istante ng produkto. Ang mga hilaw na materyales ay dinudurog sa pulbos na may laki ng butil ng 80-100 mesh.
4.3.2 Paghahalo:
Ang mga hilaw na materyales ay pinaghalong pantay sa panghalo ayon sa ratio ng formula. The mixing time is 6-10 minuto, pagtiyak na ang mga humectants at preservatives ay pantay na ipinamamahagi.
4.3.3 Tempering:
Ang pinaghalong hilaw na materyales ay ipinadala sa tempering device para sa tempering treatment. The tempering temperature is controlled at 85-98℃, ang tempering time ay 3-5 minuto, at ang moisture content pagkatapos ng tempering ay 22%-27%. The tempering process should ensure that the raw materials absorb water fully, so that the product has a soft taste.
4.3.4 Extrusion Puffing:
Ang mga tempered raw na materyales ay ipinapadala sa HTS BASIC series twin-screw extruder para sa extrusion puffing. Ang bilis ng tornilyo ay kinokontrol sa 150-300 rpm, the extrusion temperature of the feeding section is 75-90℃, the melting section is 120-140℃, and the homogenizing section is 140-150℃. The extrusion pressure is controlled at 2-5MPa, at ang compression ratio ay 4-6. The extrusion temperature and pressure are lower than those of dry puffed products, so as to avoid excessive puffing of the product and ensure that the product is soft.
4.3.5 Pagputol:
The extruded products are cut into short particles by the rotary knife, with a length of 4-8mm.
4.3.6 Paglamig:
The cut products are cooled to room temperature in the cooling equipment, which takes 10-15 minuto. Cooling can prevent the product from deteriorating due to high temperature.
4.3.7 Packaging:
The cooled products are packaged by vacuum packaging machine. Ang vacuum packaging ay epektibong makakapigil sa produkto na ma-oxidized at maamag, pagpapahaba ng buhay ng istante ng produkto. The packaging specifications can be adjusted according to customer needs.
Key technical points: Ang susi sa semi-wet pet food production ay ang kontrol ng moisture content at ang pagpili ng mga humectants at preservatives. Ang moisture content ng produkto ay dapat kontrolin sa 25%-35%, at ang mga humectants at preservative ay dapat piliin ayon sa pambansang pamantayan sa kaligtasan ng pagkain upang matiyak ang kaligtasan ng produkto. Ang aming HTS BASIC series extruders ay tumpak na makokontrol ang extrusion temperature at pressure, tinitiyak na ang produkto ay may matatag na nilalaman ng kahalumigmigan at malambot na lasa.
5. Mga Solusyon sa Mga Karaniwang Problema sa Pagproseso ng Extrusion ng Pagkain ng Alagang Hayop
Sa aktwal na produksyon ng pet food extrusion processing, ang mga negosyo ay madalas na nakakaranas ng iba't ibang mga problema, such as uneven product particle size, poor puffing effect, product stickiness, product deterioration and other problems, which affect production efficiency and product quality. Based on our rich experience in pet food processing, we summarize the common problems, causes and solutions, hoping to help enterprises solve practical problems in production.
5.1 Uneven Product Particle Size
5.1.1 Causes:
The main causes of uneven product particle size are: uneven speed of the rotary knife; uneven die hole size; uneven feeding speed; unstable screw speed; uneven mixing of raw materials.
5.1.2 Solutions:
Check and adjust the rotary knife, ensure that the rotary knife speed is uniform and the cutting edge is sharp; check the die head, replace the die head with uneven die hole size; adjust the feeding device, ensure that the feeding speed is uniform; suriin ang sistema ng screw drive, siguraduhin na ang bilis ng turnilyo ay matatag; pahabain ang oras ng paghahalo, tiyakin na ang mga hilaw na materyales ay pinaghalong pantay.
5.2 Hindi magandang Puffing Effect
5.2.1 Causes:
Ang mga pangunahing sanhi ng mahinang puffing effect ay: hindi sapat na nilalaman ng almirol ng mga hilaw na materyales; masyadong mababa o masyadong mataas ang moisture content pagkatapos ng tempering; masyadong mababa ang temperatura at presyon ng extrusion; masyadong mababang bilis ng turnilyo; masyadong malaking sukat ng die hole.
5.2.2 Solutions:
Ayusin ang formula ng produkto, dagdagan ang nilalaman ng almirol ng mga hilaw na materyales (sa higit sa 20%); ayusin ang mga parameter ng tempering, kontrolin ang moisture content pagkatapos ng tempering sa 10%～27%; dagdagan ang temperatura at presyon ng pagpilit, ayusin ang temperatura ng bawat seksyon ng bariles at ang bilis ng turnilyo; bawasan ang laki ng die hole; suriin ang suot ng tornilyo, palitan ang sira na tornilyo.
5.3 Pagkadikit ng Produkto
5.3.1 Causes:
Ang mga pangunahing sanhi ng pagiging malagkit ng produkto ay: masyadong mataas na moisture content ng produkto; masyadong mataas na temperatura ng extrusion; masyadong mataas na nilalaman ng protina ng mga hilaw na materyales; hindi sapat na pagpapatuyo ng produkto.
5.3.2 Solutions:
Bawasan ang moisture content ng produkto sa pamamagitan ng pagsasaayos ng tempering parameters at drying parameters; bawasan ang temperatura ng extrusion ng homogenizing section; ayusin ang formula ng produkto, bawasan ang nilalaman ng protina ng mga hilaw na materyales nang naaangkop; pahabain ang oras ng pagpapatayo, siguraduhin na ang nilalaman ng tubig ng produkto ay nakakatugon sa pamantayan.
5.4 Pagkasira ng Produkto
5.4.1 Causes:
Ang mga pangunahing sanhi ng pagkasira ng produkto ay: hindi sapat na isterilisasyon sa panahon ng pagpoproseso ng extrusion; masyadong mataas na nilalaman ng tubig ng produkto; mahinang packaging; hindi tamang imbakan.
5.4.2 Solutions:
Taasan ang temperatura at presyon ng extrusion, tiyakin na ang antas ng isterilisasyon ay umabot ng higit sa 99%; kontrolin ang nilalaman ng tubig ng produkto sa loob ng karaniwang hanay; magpatibay ng vacuum packaging o nitrogen-filled na packaging upang mapabuti ang epekto ng packaging; iimbak ang produkto sa isang tuyo, cool and ventilated warehouse, iwasan ang mataas na temperatura at halumigmig.
5.5 Pagbara ng Kagamitan
5.5.1 Causes:
Ang mga pangunahing sanhi ng pagbara ng kagamitan ay: masyadong mataas na moisture content ng mga hilaw na materyales; masyadong malaking laki ng butil ng mga hilaw na materyales; mga impurities sa hilaw na materyales; masyadong mababang bilis ng turnilyo; pagsusuot ng tornilyo at bariles.
5.5.2 Solutions:
Bawasan ang moisture content ng mga hilaw na materyales; durugin ang mga hilaw na materyales sa kinakailangang laki ng butil; linisin ang mga hilaw na materyales upang alisin ang mga dumi; dagdagan ang bilis ng turnilyo; suriin ang pagkasira ng turnilyo at bariles, palitan ang mga pagod na bahagi.
6. Ang aming Sistema ng Serbisyo: Pagsuporta sa Iyong Makamit ang De-kalidad na Produksyon
Hindi lamang kami nagbibigay ng mga de-kalidad na extruder para sa produksyon ng pagkain ng alagang hayop, but also provide a complete set of service systems, from pre-sales consulting, equipment selection, formula design, to in-sales installation, pagkomisyon, pagsasanay, and after-sales maintenance, technical guidance, to provide one-stop services for customers, helping customers solve various problems in production and achieve high-quality and efficient production.
6.1 Pre-Sales Service
Our pre-sales service team is composed of professional technical personnel with rich experience in pet food processing. We will conduct in-depth communication with customers to understand their product types, kapasidad ng produksyon, budget and other needs, and provide professional consulting services for customers. We will recommend the most suitable extruder model and configuration for customers, design personalized production line solutions, and provide detailed equipment parameters, process flow and cost budget, helping customers make scientific decisions.
Bilang karagdagan, we also provide formula design services. Our technical team will design the most suitable product formula for customers according to the taste, nutrition and functional requirements of pet food, combining the processing characteristics of our extrusion equipment, helping customers improve the competitiveness of their products in the market. We can also provide raw material selection suggestions according to customers’ cost control needs, balancing product quality and production cost.
6.2 In-Sales Service
After the customer places an order, we will arrange professional technicians to provide on-site installation and commissioning services for the equipment. Ang proseso ng pag-install at pag-commissioning ay mahigpit na susunod sa mga detalye ng pag-install ng kagamitan upang matiyak na ang extruder at ang katugmang pantulong na kagamitan nito (panghalo, tempering device, pampatuyo, makinang pampalasa, atbp.) ay tumpak na naka-install at konektado. Ide-debug ng mga technician ang lahat ng operating parameter ng kagamitan ayon sa formula ng produkto ng customer at mga kinakailangan sa proseso ng produksyon, at magsagawa ng pagsubok sa produksyon hanggang sa matugunan ng kalidad ng produkto ang inaasahang pamantayan ng customer.
At the same time, nagbibigay kami ng on-site operational training para sa production team ng customer, kabilang ang pangunahing istraktura ng kagamitan at prinsipyo ng pagtatrabaho, araw-araw na mga hakbang sa operasyon, mga kasanayan sa pagsasaayos ng parameter, pangunahing pagkilala at paghawak ng fault. Magbibigay din kami ng detalyadong manual ng pagpapatakbo at manual ng pagpapanatili, at sagutin ang mga tanong na itinaas ng mga operator nang paisa-isa upang matiyak na ang mga kawani ng customer ay maaaring mahusay na magpatakbo at pamahalaan ang kagamitan nang independyente pagkatapos ng pagsasanay.
6.3 Serbisyong After-Sales
Mayroon kaming perpektong after-sales service system na may propesyonal na after-sales team at maraming service outlet para magbigay ng napapanahon at mahusay na after-sales na suporta para sa mga customer sa buong bansa at maging sa buong mundo. Nangangako kami ng mabilis na mekanismo ng pagtugon: para sa mga problema sa kagamitan ng customer, magbibigay kami ng solusyon sa loob 24 oras pagkatapos matanggap ang feedback; para sa mga pangangailangan sa pagpapanatili sa lugar, ang aming mga after-sales technician ay darating sa production site ng customer sa lalong madaling panahon ayon sa aktwal na sitwasyon.
Nagbibigay kami ng mga regular na serbisyo sa pagpapanatili at inspeksyon ng kagamitan para sa mga customer, including regular detection of key components such as screw, barrel and gearbox, lubrication and maintenance of the transmission system, and calibration of the control system parameters. For the barrel wear measurement service we have launched, our technicians will regularly detect the wear degree of the barrel inner wall with professional instruments, issue a detailed wear report, and put forward targeted replacement and maintenance suggestions to ensure that customers only replace components when necessary and reduce unnecessary production costs.
Bilang karagdagan, we provide a long-term supply of genuine spare parts, with a large number of common spare parts (such as screw elements, mamatay ulo, cutting knives, sealing rings) in stock to ensure the rapid supply of spare parts and minimize the equipment downtime caused by component damage. We also provide technical upgrade services for the equipment, and can upgrade the control system, screw structure and other parts of the existing equipment according to the customer’s subsequent production expansion and product upgrade needs, so that the equipment can always adapt to the latest production requirements.
7. Complete Technical Parameters of Extruder Series for Pet Food Production
In order to meet the diverse production needs of pet food enterprises of different scales and product types, we have launched a full range of twin-screw extruder products for pet food processing, with the HTS BASIC series as the core, and extended HTS STANDARD and HTS PREMIUM series to adapt to small and medium-sized production, large-scale production and high-end customized production respectively. All series adopt the core design of twin-screw extrusion, with self-cleaning, high pumping efficiency and strong shear adaptability, and are perfectly matched with the characteristics of high viscosity and high fat of pet food raw materials. The following is the complete technical parameters table of each series:
Table 1: Technical Parameters of Excellence Pet Food Twin-Screw Extruder Series
表格
| Parameter Category | HTS BASIC Series (Entry/Mid-scale) | HTS STANDARD Series (Large-scale) | HTS PREMIUM Series (High-end Custom) |
|---|---|---|---|
| Screw Structure | Parallel twin-screw, co-rotating | Parallel twin-screw, co-rotating | Parallel twin-screw, co-rotating |
| Diameter ng tornilyo (mm) | 30/45/65 | 80/95/110 | 65/80/95/110 (customizable) |
| Compression Ratio | 4:1 ~ 8:1 (adjustable) | 5:1 ~ 10:1 (adjustable) | 4:1 ~ 12:1 (customizable) |
| Screw Speed (rpm) | 150 ~ 500 (stepless frequency conversion) | 200 ~ 600 (stepless frequency conversion) | 100 ~ 700 (stepless frequency conversion) |
| Rated Torque (N·m) | 120 ~ 350 (European medium-torque gearbox) | 400 ~ 1200 (high-torque gearbox) | 350 ~ 1500 (imported high-precision gearbox) |
| Extrusion Temperature (℃) | 70 ~ 170 (3-section temperature control) | 70 ~ 180 (5-section precise temperature control) | 60 ~ 190 (6-section intelligent temperature control) |
| Extrusion Pressure (MPa) | 2 ~ 8 | 3 ~ 10 | 2 ~ 12 |
| Kapasidad ng Produksyon (kg/h) | 100 ~ 500 | 500 ~ 2000 | 200 ~ 2500 (customizable) |
| Barrel Material | Wear-resistant alloy steel (nitrided treatment, hardness ≥60 HRC) | Wear-resistant alloy steel (bimetallic composite, hardness ≥65 HRC) | Imported wear-resistant alloy steel (bimetallic composite + laser cladding, hardness ≥70 HRC) |
| Screw Material | Wear-resistant alloy steel (nitrided treatment) | Wear-resistant alloy steel (bimetallic composite) | Imported wear-resistant alloy steel (customized according to raw materials) |
| Sistema ng Kontrol | PLC + touch screen, basic formula memory (≤20 groups) | PLC + industrial touch screen, formula memory (≤50 groups) | Intelligent PLC + cloud touch screen, formula memory (unlimited, cloud storage) |
| Heating Method | Electric heating + jacket water cooling | Electric heating + steam heating + jacket water cooling | Electric heating/steam heating (switchable) + jacket precise water cooling |
| Feeding Method | Single/double screw feeding (opsyonal) | Twin-screw differential feeding + liquid feeding port (for oil/fat) | Multi-channel precision feeding (solid/liquid/grease, independent metering) |
| Self-Cleaning Performance | Standard self-cleaning | Enhanced self-cleaning | High-efficiency self-cleaning (customized screw gap) |
| Power (kW) | 15 ~ 45 | 55 ~ 160 | 37 ~ 200 (customizable) |
| Overall Dimension (L×W×H, m) | 2.8×1.2×1.8 ~ 4.0×1.5×2.2 | 4.5×1.8×2.5 ~ 6.0×2.2×3.0 | 3.0×1.5×2.0 ~ 7.0×2.5×3.2 (customizable) |
| Timbang (t) | 0.8 ~ 2.5 | 3.0 ~ 8.0 | 2.0 ~ 10.0 (customizable) |
| Core Advantages | High cost-effectiveness, madaling operasyon, suitable for initial pet food enterprises | High output, low energy consumption, stable performance, suitable for large-scale mass production | High precision, strong customization, multi-functional, suitable for high-end pet food/snack customized production |
Key Parameter Explanation
Compression Ratio: The adjustable range is designed for different pet food types—low compression ratio (4:1~6:1) for semi-wet pet food, medium ratio (6:1~9:1) for dry puffed food, and high ratio (9:1~12:1) for high-density functional pet snacks.
Barrel & Screw Material: The gradient material selection is to adapt to different raw material abrasiveness—HTS BASIC for ordinary meat meal/cereal raw materials, HTS STANDARD/ PREMIUM for raw materials containing bone meal, calcium powder and other hard particles, effectively extending the service life of core components.
Feeding Method: The multi-channel feeding port of HTS PREMIUM series can realize the precise addition of liquid raw materials (such as fresh meat slurry, vegetable oil) and grease, which is suitable for the production of high-fat, high-protein high-end pet food.
Sistema ng Kontrol: The cloud storage function of HTS PREMIUM series can realize remote parameter adjustment and production data monitoring, which is convenient for enterprises to carry out intelligent production management.
8. Future Development of Pet Food Extrusion Technology and Our Layout
With the continuous upgrading of the global pet food industry, the pet food market is presenting new development trends such as high-endization, functionalization, naturalization and diversification, which puts forward higher and more stringent requirements for pet food extrusion processing technology and equipment.
8.1 Development Trends of Pet Food Extrusion Technology
Intelligent and Digital Processing: The integration of industrial Internet, artificial intelligence and extrusion equipment will become a mainstream trend. The extruder will realize real-time monitoring of the whole production process, automatic adjustment of parameters, and predictive maintenance of equipment through sensors and cloud computing, reducing human intervention and improving the stability and consistency of product quality.
Adaptation to Natural and High-quality Raw Materials: With the increasing demand for natural pet food, extrusion equipment needs to be optimized for processing fresh meat, fresh vegetables and other raw materials with high moisture and high activity, reducing the loss of nutritional components of raw materials in the extrusion process and retaining the original flavor and nutrition of raw materials.
High Efficiency and Energy Saving: Under the background of global energy conservation and emission reduction, pet food extrusion equipment will pay more attention to energy efficiency optimization, through the improvement of screw structure, heating method and transmission system, reducing unit energy consumption and improving production efficiency, realizing green production.
Customization and Diversification: The market demand for personalized pet food (such as pet food for different breeds, ages, physical conditions, and functional pet snacks) is growing, which requires extrusion equipment to have stronger customization and flexibility, and can quickly switch production processes and parameters to meet the production of multiple varieties and small batches of products.
8.2 Our Technical Layout and Future Planning
Facing the development trend of the pet food industry, we adhere to the concept of technological innovation driven by market demand, and continue to increase R & D investment in pet food extrusion equipment, focusing on the following aspects of research and development and optimization:
Intelligent Upgrading of Equipment: We will integrate more high-precision sensors and intelligent control algorithms into our extruder series, realize the automatic matching of extrusion parameters and product formulas, and launch a cloud management platform for production data, so that customers can monitor production status, analyze production data and optimize process parameters remotely.
Optimization of Raw Material Adaptability: We will develop a special screw structure and tempering process for fresh meat, high-fiber and other natural raw materials, reduce the shear force and heating time of raw materials in the extrusion process, and add a low-temperature puffing function to the high-end series to maximize the retention of the nutritional components and flavor of raw materials.
Energy Saving and Emission Reduction Improvement: We will adopt more efficient transmission systems and heating methods, such as permanent magnet synchronous motors and heat recovery devices, to reduce the energy consumption of the equipment by 15% ~ 20% on the basis of the original; at the same time, optimize the equipment structure to reduce noise and waste discharge, meeting the environmental protection production standards.
Expansion of Customization Capabilities: We will build a more flexible product customization system, and can customize the screw diameter, compression ratio, feeding method and other parameters of the extruder according to the customer’s personalized production needs (such as special-shaped pet snacks, high-end functional pet food); at the same time, we will develop more matching auxiliary equipment to form a fully automated production line from raw material mixing to finished product packaging.
Deep Integration of Technology and Service: We will build a pet food processing technology research and development center, combining equipment R & D with product formula research, and provide customers with integrated solutions of “equipment + formula + process”; at the same time, we will expand the online technical service channel, provide 7×24-hour online technical guidance and fault diagnosis, and further improve the efficiency of after-sales service.
9. Konklusyon
Pet food extrusion puffing technology is the core of modern pet food industrial production, and the performance of extrusion equipment directly determines the production efficiency, product quality and market competitiveness of pet food enterprises. As a professional provider of food-grade extrusion equipment, we have accumulated rich experience in the field of pet food processing, and launched a full range of twin-screw extruder products represented by the HTS series, which perfectly solve the processing difficulties caused by the high viscosity, high fat and diverse raw materials of pet food.
Our extruders have the advantages of low lifetime operating cost, wide application range, advanced technology and reliable process control, and are equipped with a complete one-stop service system from pre-sales to after-sales. The detailed and adjustable technical parameters of each series can meet the production needs of pet food enterprises of different scales and product types, from entry-level dry puffed food to high-end customized functional snacks.
In the future, with the continuous development of the pet food industry, we will continue to take technological innovation as the core, take customer demand as the guide, and constantly optimize and upgrade our extrusion equipment and service system, striving to provide more efficient, energy-saving, intelligent and customized pet food processing solutions for global customers. We are willing to grow together with pet food enterprises, and contribute to the development of the pet food industry with high-quality equipment and professional services, creating more safe, nutritious and delicious pet food for pet families around the world.