Ar nepārtrauktu cilvēku dzīves līmeņa uzlabošanos un pieaugošo uzsvaru uz mājdzīvnieku biedrību, globālā lolojumdzīvnieku barības nozare pēdējos gados ir strauji attīstījusies. Mājdzīvnieki pakāpeniski tiek uzskatīti par svarīgiem ģimenes locekļiem, un viņu uztura veselība un pārtikas kvalitāte ir kļuvusi par mājdzīvnieku īpašnieku uzmanību. Tas ir veicinājis nepārtrauktu lolojumdzīvnieku barības apstrādes tehnoloģiju un aprīkojuma modernizāciju, augstākas prasības attiecībā uz drošību, uzturs, lolojumdzīvnieku barības garša un izskats. Mēs esam apņēmušies nodrošināt profesionālus ekstrūderus, kas īpaši izstrādāti pārtikas ražošanai, ar bagātīgu pieredzi lolojumdzīvnieku barības apstrādē, un var nodrošināt mērķtiecīgus apstrādes risinājumus dažāda veida mājdzīvnieku barībai, 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. Pet owners pay more and more attention to the nutritional composition of pet food, and products with natural, additive-free, functional (such as hair beauty, stomach nourishment, weight control) characteristics are more popular; second, diversification of product types. With the enrichment of pet types and the individual needs of pet owners, pet food has gradually developed towards segmentation, such as pet food for different ages (puppies, adult dogs, elderly dogs), different breeds, and different physical conditions; third, intelligence and efficiency of processing technology. In order to meet the large-scale production demand and ensure the stability of product quality, pet food processing enterprises are constantly introducing advanced processing equipment and intelligent control systems to improve production efficiency and reduce labor costs.
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, vitamīni, 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. Tajā pašā laikā, 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) are added to maintain the softness and moisture of the product. The processing process of semi-wet products also needs puffing treatment, but the puffing degree is lower than that of dry products. The product has the characteristics of soft taste and good palatability, which is suitable for pets with poor chewing ability (such as elderly pets, sick pets).
The processing difficulty of semi-wet products lies in the control of water content and the prevention of product deterioration. Tāpēc, in the processing process, it is necessary to strictly control the temperature and humidity of each link, and select appropriate preservatives and humectants to ensure the shelf life of the product.
1.2.3 Soft Puffed Products:
Soft puffed pet food has a water content of 15%-25%, which is a product between dry puffed and semi-wet products. Its processing process is similar to that of dry puffed products, but the formula and extrusion parameters are adjusted to make the product soft and elastic. Soft puffed products combine the advantages of dry and semi-wet products, with good palatability and easy digestion, which is suitable for a variety of pets.
1.2.4 Wet Canned Products:
Wet canned pet food has a water content of more than 70%, mainly using fresh meat, fish, vegetables and other raw materials, which are processed by cooking, canning, sterilization and other processes. Different from other types of products, wet canned products do not need puffing treatment, and their core processing links are cooking and sterilization. The product has the characteristics of rich nutrition, spēcīga garša un augsts mitruma saturs, kas ir piemērots mājdzīvniekiem, kuriem nepatīk dzeramais ūdens vai kuriem nepieciešama papildu barība.
Mitrā konservēto produktu pārstrādes atslēga ir nodrošināt izejvielu svaigumu un drošību, un stingri kontrolējiet sterilizācijas temperatūru un laiku, lai iznīcinātu kaitīgās baktērijas produktā un pagarinātu glabāšanas laiku. Tajā pašā laikā, ir jānodrošina, lai ēdiena gatavošanas un sterilizācijas procesā netiktu zaudētas produkta uzturvērtības sastāvdaļas.
1.2.5 Mājdzīvnieku uzkodas (vai Kārumi):
Mājdzīvnieku uzkodas ir mājdzīvnieku palīgbarība, galvenokārt izmanto mājdzīvnieku apbalvošanai, uzlabot garastāvokli un papildināt uzturu. Mājdzīvnieku uzkodu veidi ir dažādi, ieskaitot uzpūstas uzkodas, žāvētas gaļas uzkodas, saraustītas uzkodas, zobu uzkodas, utt. Among them, uzpūstas uzkodas veido lielu daļu, un to apstrādes process ir līdzīgs sausiem uzpūstiem produktiem, bet formula ir rafinētāka, un tiek pievienoti vairāk aromatizētāju un funkcionālu piedevu, lai apmierinātu mājdzīvnieku garšu un funkcionālās vajadzības.
Mājdzīvnieku uzkodām ir augstas garšas prasības, izskats un funkcionalitāte. Piemēram, zobu uzkodām ir jābūt noteiktai cietībai un tekstūrai, lai palīdzētu notīrīt mājdzīvnieka zobus un novērstu zobu akmeņu veidošanos; matu skaistumkopšanas uzkodām jāpievieno tādas sastāvdaļas kā lecitīns, lai palīdzētu uzlabot mājdzīvnieka matu kvalitāti. Tas prasa, lai ekstrūderim būtu laba elastība un regulējamība, lai tas atbilstu dažāda veida uzkodu apstrādes vajadzībām.
Ir vērts atzīmēt, ka izņemot konservētus produktus, vairums lolojumdzīvnieku barības veidu ir cieši saistīti ar uzpūšanās procesu. Puffing is not only the core part of pet food processing, but also directly affects the quality, taste, nutrition and digestibility of pet food. Tāpēc, choosing the right extrusion equipment and mastering the scientific extrusion technology are crucial for pet food processing enterprises.
2. Core Technology of Pet Food Processing: Extrusion Puffing Technology
Extrusion puffing technology is a key processing technology integrating mixing, mīcīšana, heating, extrusion and puffing. It has been widely used in the production of pet food due to its advantages of high production efficiency, good product quality, strong adaptability to raw materials and wide application range. In the processing of pet food, extrusion technology is mainly used to realize the puffing of raw materials, make the starch gelatinize, the protein denature, un uzlabo produkta garšu un sagremojamību. Tajā pašā laikā, tas var arī iznīcināt kaitīgās baktērijas izejvielās, nodrošināt lolojumdzīvnieku barības nekaitīgumu.
2.1 Lolojumdzīvnieku barības izejvielu raksturojums un prasības ekstrūzijas iekārtām
Lolojumdzīvnieku barības izejvielas galvenokārt ir gaļas produkti (piemēram, gaļas milti, fish meal, svaiga gaļa), cereal, soybean meal, vitamīni, minerals and other additives. Among them, gaļas produkti veido lielu daļu, padarot produktu ar spēcīgu viskozitāti. Šis raksturlielums izvirza īpašas prasības ekstrūzijas iekārtām:
Vienas skrūves ekstrūderi nav piemēroti lolojumdzīvnieku barības ekonomiskai ražošanai. Tā kā vienas skrūves ekstrūderim ir šaurs bīdes diapazons, slikta sūknēšanas jauda un nav pašattīrīšanās efekta. Apstrādājot viskozus materiālus, piemēram, gaļas produktus, ir viegli izraisīt materiāla uzkrāšanos, aizsprostojums un nevienmērīga sajaukšanās ekstrūdera mucā, kas ne tikai ietekmē ražošanas efektivitāti, bet arī noved pie nestabilas produkta kvalitātes. Turklāt, vienas skrūves ekstrūderim ir augsts enerģijas patēriņš, apstrādājot izejvielas ar augstu tauku saturu un augstu olbaltumvielu saturu, kas palielina uzņēmumu ražošanas izmaksas.
Divskrūvju ekstrūderi, no otras puses, ir acīmredzamas priekšrocības lolojumdzīvnieku barības ražošanā. Viņiem ir plašāks bīdes diapazons, efektīvāks sūknēšanas efekts un pašattīrīšanās efekts, kas var efektīvi atrisināt materiāla viskozitātes un uzkrāšanās problēmas. Divskrūvju ekstrūderis var nodrošināt vienmērīgu sajaukšanu, materiālu mīcīšana un ekstrūzija, pat apstrādājot izejvielas ar augstu tauku un svaigas gaļas saturu, tas var arī nodrošināt stabilu ražošanu un nemainīgu produktu kvalitāti. Tāpēc, lolojumdzīvnieku barības ražošanā, twin-screw extruders have become the main means of pet food puffing, and are widely used in the production of dry puffed products, semi-wet products, soft puffed products and pet snacks.
2.2 Working Principle of Screw Extrusion Puffing
The screw extrusion puffing process of pet food is a complex physical and chemical process, which involves the interaction of multiple factors such as temperature, spiedienu, shear force and time. The specific working principle is as follows:
Pirmkārt, raw material pretreatment. The powdery raw materials containing a certain amount of starch (more than 20%) are mixed uniformly according to the formula, and then sent to the tempering device for tempering treatment. The purpose of tempering is to adjust the moisture content and temperature of the materials, lai materiāli varētu sasniegt ideālo stāvokli pirms ievadīšanas ekstrūderī. Vispārīgi, materiālu mitruma saturs pēc rūdīšanas tiek kontrolēts 10%～27%, un temperatūra tiek paaugstināta līdz 70～98℃. Rūdīšanas procesa laikā, materiāli vienmērīgi absorbē ūdeni, kas veicina sekojošu cietes želatinizāciju un olbaltumvielu denaturāciju, un var arī samazināt ekstrūdera skrūves un mucas nodilumu.
Otrkārt, ekstrūzija un apkure. Rūdītie materiāli caur padeves ierīci nonāk skrūvju ekstrūzijas dobumā. Skrūves ekstrūzijas dobums sastāv no skrūves un mucas, un ekstrūzijas dobuma tilpums pakāpeniski samazinās gar ass virzienu. Kad skrūve griežas, tas nepārtraukti virza materiālus uz priekšu, un materiāli tiek pakāpeniski saspiesti skrūves un mucas iedarbībā, un spiediens ekstrūzijas dobumā pakāpeniski palielinās. Kompresijas pakāpe (materiāla tilpuma attiecība padeves galā pret tilpumu ekstrūzijas galā) var sasniegt 4-10, kas mainās atkarībā no mājdzīvnieku barības veida un izejvielu formulas.
Procesa laikā tiek stumts un izspiests ar skrūvi, materiāli tiek pakļauti spēcīgam bīdes spēkam un berzes spēkam. Bīdes spēku rada relatīvā kustība starp skrūvi un mucu, kā arī starp skrūvju lidojumiem. Tas var salauzt materiālu daļiņas, padarīt izejvielas un piedevas viendabīgākas, un veicina cietes želatinizāciju un olbaltumvielu denaturāciju. 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. Turklāt, 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.
Trešais, 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. Tajā pašā laikā, 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. Tajā pašā laikā, denaturētais proteīns var arī veidot tīkla struktūru, kas var ietīt cieti un citas sastāvdaļas, palīdzot saglabāt uzpūstā produkta formu.
Ceturtais, uzpūšanās un formēšana. Kad materiāli augstas temperatūras un augstspiediena stāvoklī ar skrūvi tiek nospiesti uz matricas galvu un lielā ātrumā tiek izspiesti no presformas cauruma, materiālu temperatūra un spiediens strauji pazeminās, jo tie pēkšņi atstāj ekstrūzijas dobumu un nonāk normālā atmosfēras vidē. Spiediena starpības un temperatūras starpības kombinētās darbības rezultātā, materiālos esošais ūdens ātri iztvaiko, materiālu apjoms strauji paplašinās (izplešanās ātrums var sasniegt 2–8 reizes), un materiāli tiek dehidrēti un ātri sacietē, veidojot porainu, kraukšķīgs vai mīksts uzpūsts produkts.
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. Piemēram, the particles of puppy food are smaller and shorter, while the particles of adult dog food are larger and longer.
Piektais, post-processing. The extruded puffed particles need to go through post-processing links such as drying, dzesēšana, 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. Piemēram, 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, ir viegli izraisīt materiāla aizsprostojumu un palielināt enerģijas patēriņu. Izejvielu mitruma saturs pirms rūdīšanas jākontrolē plkst 8%-12%. Ja mitruma saturs ir pārāk augsts, materiālus ir viegli pielīmēt pie skrūves un mucas, kas ietekmē izspiešanu un uzpūšanos; ja mitruma saturs ir pārāk zems, bīdes spēks un berzes spēks starp materiāliem ir nepietiekams, un cietes želatinizācija ir nepilnīga, kā rezultātā rodas vājš uzpūšanās efekts.
2.3.2 Rūdīšanas parametri:
Rūdīšanas parametri galvenokārt ietver rūdīšanas temperatūru, rūdīšanas laiks un mitruma saturs pēc rūdīšanas. Rūdīšanas temperatūra parasti ir 70–98 ℃. Ja rūdīšanas temperatūra ir pārāk zema, materiāli nevar vienmērīgi absorbēt ūdeni, un cietes želatinizācija ir nepietiekama; ja rūdīšanas temperatūra ir pārāk augsta, the materials may be caked in advance, affecting the subsequent extrusion. The tempering time is generally 2-5 minūtes, 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. Piemēram, 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 uz 600 apgr./min. 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. Tomēr, 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℃), galvenokārt, lai nodrošinātu materiālu vienmērīgu sajaukšanos un pilnīgu želatinizāciju.
Ekstrūzijas spiediens parasti ir 2–10 MPa. Spiedienu ekstrūzijas dobumā galvenokārt nosaka skrūves saspiešanas pakāpe, matricas cauruma izmērs un skrūves ātrums. Jo lielāks ir ekstrūzijas spiediens, the better the puffing effect, bet ja spiediens ir pārāk augsts, tas palielinās iekārtas enerģijas patēriņu un nodilumu; ja spiediens ir pārāk zems, uzpūšošais efekts ir vājš, un produkts ir vaļīgs un viegli salaužams.
2.3.4 Die Head struktūra:
Preses galviņas struktūra galvenokārt ietver numuru, presformu caurumu forma un izmērs. Formas cauruma forma nosaka uzpūstā izstrādājuma šķērsgriezuma formu, piemēram, apļveida, kvadrāts, trīsstūrveida un citas formas. Preses cauruma izmērs nosaka produkta sākotnējo diametru. Jo mazāks ir matricas cauruma izmērs, jo lielāks ekstrūzijas spiediens, and the better the puffing effect, bet ražošanas jauda tiks samazināta. Formēšanas caurumu skaits ietekmē ražošanas jaudu. Jo vairāk matricu caurumu skaits, jo lielāka ir ražošanas jauda, bet ir jānodrošina vienmērīgs spiediena sadalījums, lai izvairītos no nevienmērīgas produkta uzpūšanās.
3. Mūsu ekstrūderi: Priekšrocības un produktu sērija mājdzīvnieku barības ražošanai
Mēs jau sen esam iesaistījušies pētniecībā, pārtikas ekstruderu izstrāde un ražošana, un ir izstrādājuši virkni divu skrūvju ekstrūderu, kas īpaši piemēroti lolojumdzīvnieku barības ražošanai atbilstoši lolojumdzīvnieku barības apstrādes īpašībām un uzņēmumu vajadzībām. 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) and the barrel. This greatly extends the service life of the barrel, reducing the frequency of barrel replacement and the maintenance cost of the equipment.
Turklāt, we also provide professional barrel wear measurement services. Our technical team will regularly or irregularly detect the wear of the barrel for customers, accurately judge the wear degree of the barrel, and provide professional suggestions on barrel replacement. This ensures that customers only replace the barrel when it is really needed, avoiding unnecessary waste and reducing the operating cost of the equipment. Tajā pašā laikā, the screw of our extruder is also made of wear-resistant alloy steel, which has good corrosion resistance and wear resistance, and can adapt to the processing of high-fat, high-protein and high-salt raw materials.
3.1.2 Wide Application Range:
Mūsu divu skrūvju ekstrūderiem ir spēcīga pielāgošanās spēja un tie var apmierināt dažāda veida lolojumdzīvnieku barības apstrādes vajadzības, ieskaitot sausos uzpūstos produktus, semi-wet products, soft puffed products, mājdzīvnieku uzkodas un citi produkti. Ekstrūderis ir aprīkots ar augsta griezes momenta piedziņas sistēmu, maināma skrūves ātruma un spiediena mainīga vadības ierīce, kas nodrošina klientiem lielisku elastību, un to var pielāgot atbilstoši dažādām procesa prasībām un izejvielu formulām, lai sasniegtu vislabāko apstrādes efektu.
Ekstrūdera modulārais dizains ir vēl viena svarīga iezīme, kas paplašina tā pielietojuma diapazonu. Skrūve, muca, presformas galvai un citām ekstrūdera sastāvdaļām ir modulāra konstrukcija, kurus var brīvi kombinēt un nomainīt atbilstoši klienta īpašajām lietojuma vajadzībām. Piemēram, apstrādājot sausos uzpūstos produktus, klienti var izvēlēties skrūvi ar augstu saspiešanas pakāpi un vītnes galvu ar maziem veidņu caurumiem; apstrādājot pusmitru produktu, viņi var izvēlēties skrūvi ar vidēju kompresijas pakāpi un vītnes galvu ar lieliem caurumiem. Šis modulārais dizains ne tikai uzlabo aprīkojuma elastību un pielāgojamību, bet arī samazina aprīkojuma pārveidošanas izmaksas, kad klienti pielāgo savus produktu veidus.
3.1.3 Uzlabotas tehnoloģijas un uzticama procesu kontrole:
Mūsu ekstrūderi izmanto vismodernāko viedo vadības tehnoloģiju, kas var realizēt precīzu visa apstrādes procesa kontroli, nodrošinot gala produkta kvalitātes konsekvenci. Ekstrūderis ir aprīkots ar inteliģentu formulas atmiņas sistēmu, kurā var uzglabāt vairākas produktu formulu un apstrādes parametru kopas. When customers produce different products, they only need to call the corresponding formula and parameters, without repeated debugging, which not only saves time and improves production efficiency, but also maximizes the reduction of process errors and operator errors.
The intelligent control system also has real-time monitoring and alarm functions. It can monitor key parameters such as extrusion temperature, extrusion pressure, skrūves ātrums, material moisture content and production capacity in real time. If any parameter exceeds the set range, the system will issue an alarm prompt in time, and even automatically shut down the equipment if necessary, to avoid equipment failure and product quality problems. Turklāt, the control system adopts a touch screen operation interface, which is simple and intuitive, easy to operate, 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, forma, cietība, crispness and nutritional composition of the products are uniform, which can meet the strict quality requirements of pet food. Tajā pašā laikā, 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. Turklāt, 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, which are specially designed for pet food processing enterprises with medium and small production scales or initial entry into the industry. This series of extruders uses medium-torque gearboxes from leading European manufacturers, which have the advantages of stable performance, low noise, high efficiency and long service life. The medium-torque design can meet the processing needs of most pet food (such as dry puffed dog food, cat food, pet snacks), and at the same time, it has a reasonable price, which can help enterprises reduce the initial investment cost.
Runājot par konstrukcijas projektēšanu, the HTS BASIC series extruders adopt a twin-screw parallel structure, with a screw diameter ranging from 30mm to 65mm, and a compression ratio of 4～8, which can be adjusted according to the type of pet food. 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. The extruder is equipped with a PLC control system and a touch screen operation interface, which is simple and easy to operate. It can realize the automatic control of the production process, such as automatic feeding, automatic temperature control, automatic pressure control and automatic cutting.
One of the biggest advantages of the HTS BASIC series extruders is that they can provide flexible options through different configuration combinations. Customers can choose different screw types, mirst galvas, feeding devices, tempering devices and post-processing equipment according to their own product types, production capacity and budget, so as to form a production line suitable for their own needs. Piemēram, if a customer mainly produces dry puffed dog food, they can choose a screw with a high compression ratio, a circular die head, 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.
Turklāt, 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, muca, mirst galva) 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. Tajā pašā laikā, 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
When selecting extruders for pet food production, enterprises need to comprehensively consider their own production needs, product types, budget and other factors to ensure that the selected equipment can meet the actual production needs and bring maximum economic benefits. The following are some specific selection suggestions:
3.3.1 Determine the Type of Extruder According to Product Types:
Different types of pet food have different requirements for extruders. Piemēram, dry puffed products require extruders with high compression ratio, high extrusion temperature and pressure; semi-wet products require extruders with medium compression ratio and moderate extrusion temperature and pressure; pet snacks require extruders with good flexibility and adjustability. Enterprises should select the appropriate extruder type (twin-screw extruder is preferred) and configuration according to the main product types they produce.
3.3.2 Determine the Production Capacity of the Extruder According to the Production Scale:
Enterprises should select the extruder with appropriate production capacity according to their own production scale and market demand. If the production scale is small (daily output less than 1 ton), the HTS BASIC series extruders with production capacity of 100-300kg/h are suitable; if the production scale is medium (daily output 1-5 tonnas), the HTS BASIC series extruders with production capacity of 300-500kg/h are suitable; if the production scale is large (daily output more than 5 tonnas), it is recommended to choose our high-torque large-scale twin-screw extruders (production capacity more than 500kg/h).
3.3.3 Consider the Cost-Effectiveness of the 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, nodošana ekspluatācijā, apmācību, maintenance and spare parts supply services. Mums ir profesionāla pēcpārdošanas servisa komanda, kas var savlaicīgi reaģēt uz klientu vajadzībām un atrisināt dažādas problēmas, ar kurām klienti saskaras iekārtu lietošanā, nodrošinot normālu ražošanas līnijas darbību.
3.3.5 Apsveriet aprīkojuma elastību un paplašināmību:
Līdz ar tirgus pieprasījuma izmaiņām, uzņēmumiem var būt nepieciešams pielāgot savus produktu veidus un ražošanas apjomus. Tāpēc, izvēloties ekstrūderus, uzņēmumiem būtu jāņem vērā aprīkojuma elastība un paplašināmība. Mūsu ekstrūderi izmanto modulāru dizainu, ko var brīvi kombinēt un modernizēt atbilstoši uzņēmumu vajadzībām, aprīkojuma elastības un paplašināšanas uzlabošana, un iekārtu pārveidošanas izmaksu samazināšana.
4. Ekstrūzijas iekārtu pielietojums mājdzīvnieku barības ražošanā
Mūsu divu skrūvju ekstrūderi (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 Izejvielu sagatavošana:
Sausās uzpūstās mājdzīvnieku barības izejvielas galvenokārt ietver gaļas miltus (vistas milti, liellopu gaļas milti, fish meal), cereal (kukurūzas milti, kviešu milti, rīsu milti), soybean meal, vitamīni, minerālvielas, atraktanti un citas piedevas. Visas izejvielas ir jāpārbauda un jātīra, lai noņemtu piemaisījumus (piemēram, akmeņi, metāli) un nodrošināt izejvielu kvalitāti. Pēc tam izejvielas tiek sasmalcinātas pulverī ar daļiņu izmēru 80-100 mesh, kas veicina vienmērīgu sajaukšanos un pilnīgu plastificēšanu.
4.1.2 Sajaukšana:
Sasmalcinātas izejvielas tiek nosūtītas uz maisītāju saskaņā ar formulas attiecību vienmērīgai sajaukšanai. Maisīšanas laiks parasti ir 5-10 minūtes, nodrošinot visu izejvielu un piedevu vienmērīgu sadalījumu. Mikseris ir aprīkots ar svēršanas ierīci, kas var precīzi kontrolēt katras izejvielas devu, nodrošinot produkta formulas stabilitāti.
4.1.3 Rūdīšana:
Sajauktās izejvielas tiek nosūtītas uz rūdīšanas ierīci rūdīšanas apstrādei. Rūdīšanas temperatūra tiek kontrolēta 80-95 ℃, rūdīšanas laiks ir 3-5 minūtes, un mitruma saturs pēc rūdīšanas ir 15%-20%. Rūdīšanas procesa laikā, rūdīšanas ierīcē tiek ievadīts tvaiks, lai izejvielas vienmērīgi absorbētu ūdeni, kas veicina turpmāko ekstrūzijas uzpūšanos.
4.1.4 Ekstrūzijas uzpūšanās:
Rūdītās izejvielas tiek nosūtītas uz HTS BASIC sērijas divu skrūvju ekstrūderi ekstrūzijas uzpūšanai. Skrūves ātrums tiek kontrolēts pie 200-400 apgr./min, barošanas sekcijas ekstrūzijas temperatūra ir 70-90 ℃, kušanas sekcija ir 130-150 ℃, un homogenizācijas sekcija ir 160-170 ℃. Ekstrūzijas spiediens tiek kontrolēts 5-8 MPa, un kompresijas pakāpe ir 6-8. Under the action of high temperature, high pressure and shear force, izejvielās esošā ciete ir pilnībā želatinizēta, proteīns ir denaturēts, un materiāli tiek izspiesti no presformas galvas, veidojot uzpūstas sloksnes.
4.1.5 Griešana:
Uzpūstās sloksnes, kas izspiestas no presformas galviņas, tiek sagrieztas īsās vienāda garuma daļiņās ar rotējošo nazi, kas uzstādīts pie matricas galviņas. Daļiņu garums parasti ir 3-8 mm, kuru var regulēt, mainot rotējošā naža ātrumu.
4.1.6 Žāvēšana:
Sagrieztās uzpūstās daļiņas tiek nosūtītas uz žāvēšanas iekārtu žāvēšanai. Žāvēšanas temperatūra tiek kontrolēta 80-100 ℃, un žāvēšanas laiks ir 20-30 minūtes. Žāvēšanas mērķis ir samazināt daļiņu ūdens saturu līdz 10%-12%, so as to extend the shelf life of the product. Žāvēšanas iekārtas var izmantot lentes žāvētāju vai verdošā slāņa žāvētāju, kam ir vienmērīgas žāvēšanas priekšrocības un augsta efektivitāte.
4.1.7 Dzesēšana:
Žāvētās daļiņas tiek nosūtītas uz dzesēšanas iekārtu dzesēšanai. The cooling temperature is controlled at room temperature (20-25℃), and the cooling time is 10-15 minūtes. 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 Iepakojums:
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, utt. 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 (skrūves ātrums, temperatūra, spiedienu) directly affect the puffing effect and product texture; the drying parameters (temperatūra, time) 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
Mājdzīvnieku uzkodām ir augstas garšas prasības, izskats un funkcionalitāte, and our HTS BASIC series extruders, with their flexible configuration and precise parameter control, can well meet the processing needs of various pet snacks. Taking puffed dental snacks as an example, the process flow of production using our extruders is as follows:
Raw material preparation → mixing → tempering → extrusion puffing → cutting → drying → cooling → surface treatment → packaging.
4.2.1 Izejvielu sagatavošana:
The raw materials of puffed dental snacks mainly include corn flour, kviešu milti, potato starch, meat meal, vegetable fiber, calcium carbonate and other additives. Among them, vegetable fiber and calcium carbonate are added to improve the hardness and texture of the product, helping to clean the pet’s teeth. The raw materials are crushed into powder with a particle size of 100-120 mesh, which is conducive to the formation of the product and the improvement of the texture.
4.2.2 Sajaukšana:
The crushed raw materials are mixed uniformly in the mixer according to the formula ratio. The mixing time is 8-12 minūtes, ensuring that the vegetable fiber, calcium carbonate and other additives are evenly distributed in the raw materials.
4.2.3 Rūdīšana:
Sajauktās izejvielas tiek nosūtītas uz rūdīšanas ierīci rūdīšanas apstrādei. The tempering temperature is controlled at 75-90℃, rūdīšanas laiks ir 2-4 minūtes, un mitruma saturs pēc rūdīšanas ir 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 Ekstrūzijas uzpūšanās:
Rūdītās izejvielas tiek nosūtītas uz HTS BASIC sērijas divu skrūvju ekstrūderi ekstrūzijas uzpūšanai. Skrūves ātrums tiek kontrolēts pie 250-450 apgr./min, 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, un kompresijas pakāpe ir 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 Griešana:
Ekstrudētie uzpūstie izstrādājumi tiek sagriezti atbilstošos garumos ar rotācijas nazi. Izstrādājumu garums parasti ir 5-10 mm, kuru var pielāgot atbilstoši mājdzīvnieka izmēram.
4.2.6 Žāvēšana:
Sagrieztos produktus nosūta uz žāvēšanas iekārtu žāvēšanai. Žāvēšanas temperatūra tiek kontrolēta 75-95 ℃, un žāvēšanas laiks ir 15-25 minūtes. Ūdens saturs žāvētajos produktos tiek kontrolēts plkst 12%-14%, kas nodrošina produktam noteiktu cietību un kraukšķīgumu, un var efektīvi tīrīt mājdzīvnieka zobus.
4.2.7 Dzesēšana:
Žāvētos produktus dzesēšanas iekārtā atdzesē līdz istabas temperatūrai, kas ņem 8-12 minūtes.
4.2.8 Virsmas apstrāde:
Atdzesētie produkti tiek pakļauti virsmas apstrādei, lai uzlabotu produkta garšu un izskatu. Kopējā virsmas apstrāde ietver gaļas mērces izsmidzināšanu, pārklājuma siera pulveris, un iemērc pārtikas eļļā. The surface treatment amount is generally 3%-6% of the product weight.
4.2.9 Iepakojums:
The products after surface treatment are packaged by automatic packaging machine. The packaging should be sealed and moisture-proof to ensure the freshness and shelf life of the product.
Key technical points: The key to pet snack production is the design of the formula and the adjustment of extrusion parameters. The formula should meet the taste and functional needs of pets; the extrusion parameters should be adjusted according to the shape and texture requirements of the product, ensuring that the product has a good shape and texture. Our HTS BASIC series extruders have flexible parameter adjustment functions, which can meet the processing needs of different types of pet snacks.
4.3 Application in Semi-Wet Pet Food Production
Pusmitrā mājdzīvnieku barība ir maiga garša un laba garša, which is suitable for pets with poor chewing ability. Mūsu HTS BASIC sērijas ekstrūderus var izmantot arī pusmitrās mājdzīvnieku barības ražošanai, pielāgojot konfigurāciju un parametrus. Procesa plūsma ir šāda:
Izejvielu sagatavošana → sajaukšana → rūdīšana → ekstrūzijas uzpūšana → griešana → dzesēšana → iepakošana.
4.3.1 Izejvielu sagatavošana:
Pusmitrās lolojumdzīvnieku barības izejvielas galvenokārt ietver gaļas miltus, fish meal, cereal, soybean meal, mitrinātāji (propilēnglikols, sorbitol), konservanti, vitamīni un minerālvielas. Lai saglabātu produkta mitrumu, tiek pievienoti mitrinātāji, un tiek pievienoti konservanti, lai pagarinātu produkta glabāšanas laiku. The raw materials are crushed into powder with a particle size of 80-100 mesh.
4.3.2 Sajaukšana:
Izejvielas tiek vienmērīgi sajauktas maisītājā atbilstoši formulas attiecībai. The mixing time is 6-10 minūtes, nodrošinot vienmērīgu mitrinātāju un konservantu sadalījumu.
4.3.3 Rūdīšana:
Sajauktās izejvielas tiek nosūtītas uz rūdīšanas ierīci rūdīšanas apstrādei. The tempering temperature is controlled at 85-98℃, rūdīšanas laiks ir 3-5 minūtes, un mitruma saturs pēc rūdīšanas ir 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 Ekstrūzijas uzpūšanās:
Rūdītās izejvielas tiek nosūtītas uz HTS BASIC sērijas divu skrūvju ekstrūderi ekstrūzijas uzpūšanai. Skrūves ātrums tiek kontrolēts pie 150-300 apgr./min, 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, un kompresijas pakāpe ir 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 Griešana:
The extruded products are cut into short particles by the rotary knife, with a length of 4-8mm.
4.3.6 Dzesēšana:
The cut products are cooled to room temperature in the cooling equipment, kas ņem 10-15 minūtes. Cooling can prevent the product from deteriorating due to high temperature.
4.3.7 Iepakojums:
The cooled products are packaged by vacuum packaging machine. Vacuum packaging can effectively prevent the product from being oxidized and moldy, extending the shelf life of the product. The packaging specifications can be adjusted according to customer needs.
Key technical points: The key to semi-wet pet food production is the control of moisture content and the selection of humectants and preservatives. The moisture content of the product should be controlled at 25%-35%, and the humectants and preservatives should be selected according to the national food safety standards to ensure the safety of the product. Our HTS BASIC series extruders can accurately control the extrusion temperature and pressure, ensuring that the product has a stable moisture content and soft taste.
5. Solutions to Common Problems in Pet Food Extrusion Processing
In the actual production of pet food extrusion processing, enterprises often encounter various problems, 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 Risinājumi:
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; check the screw drive system, ensure that the screw speed is stable; extend the mixing time, ensure that the raw materials are mixed uniformly.
5.2 Poor Puffing Effect
5.2.1 Causes:
The main causes of poor puffing effect are: insufficient starch content of raw materials; too low or too high moisture content after tempering; too low extrusion temperature and pressure; too low screw speed; too large die hole size.
5.2.2 Risinājumi:
Adjust the product formula, increase the starch content of raw materials (to more than 20%); adjust the tempering parameters, control the moisture content after tempering at 10%～27%; increase the extrusion temperature and pressure, adjust the temperature of each section of the barrel and the screw speed; reduce the die hole size; check the screw wear, replace the worn screw.
5.3 Product Stickiness
5.3.1 Causes:
The main causes of product stickiness are: too high moisture content of the product; too high extrusion temperature; too high protein content of raw materials; insufficient drying of the product.
5.3.2 Risinājumi:
Reduce the moisture content of the product by adjusting the tempering parameters and drying parameters; reduce the extrusion temperature of the homogenizing section; adjust the product formula, reduce the protein content of raw materials appropriately; extend the drying time, ensure that the water content of the product meets the standard.
5.4 Product Deterioration
5.4.1 Causes:
The main causes of product deterioration are: insufficient sterilization during extrusion processing; too high water content of the product; poor packaging; improper storage.
5.4.2 Risinājumi:
Increase the extrusion temperature and pressure, ensure that the sterilization rate reaches more than 99%; control the water content of the product within the standard range; adopt vacuum packaging or nitrogen-filled packaging to improve the packaging effect; store the product in a dry, cool and ventilated warehouse, avoid high temperature and humidity.
5.5 Equipment Blockage
5.5.1 Causes:
The main causes of equipment blockage are: too high moisture content of raw materials; too large particle size of raw materials; impurities in raw materials; too low screw speed; wear of screw and barrel.
5.5.2 Risinājumi:
Reduce the moisture content of raw materials; crush the raw materials to the required particle size; clean the raw materials to remove impurities; increase the screw speed; check the wear of screw and barrel, replace the worn components.
6. Our Service System: Supporting You to Achieve High-Quality Production
We not only provide high-quality extruders for pet food production, bet arī nodrošina pilnu pakalpojumu sistēmu komplektu, no konsultācijām pirms pārdošanas, aprīkojuma izvēle, formulas dizains, uz instalāciju pārdošanā, nodošana ekspluatācijā, apmācību, un pēcpārdošanas apkope, tehniskās vadlīnijas, nodrošināt vienas pieturas pakalpojumus klientiem, palīdzot klientiem atrisināt dažādas ražošanas problēmas un panākt kvalitatīvu un efektīvu ražošanu.
6.1 Pirmspārdošanas serviss
Mūsu pirmspārdošanas servisa komanda sastāv no profesionāliem tehniskajiem darbiniekiem ar bagātīgu pieredzi lolojumdzīvnieku barības apstrādē. Mēs veiksim padziļinātu komunikāciju ar klientiem, lai izprastu viņu produktu veidus, ražošanas jauda, budžetu un citas vajadzības, un sniegt klientiem profesionālus konsultāciju pakalpojumus. Mēs ieteiksim klientiem piemērotāko ekstrūdera modeli un konfigurāciju, izstrādāt personalizētus ražošanas līniju risinājumus, un sniedziet detalizētus aprīkojuma parametrus, procesa plūsma un izmaksu budžets, helping customers make scientific decisions.
Turklāt, 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. Uzstādīšanas un nodošanas ekspluatācijā procesā stingri jāievēro aprīkojuma uzstādīšanas specifikācijas, lai nodrošinātu, ka ekstrūderis un tā atbilstošā palīgiekārta (mikseris, rūdīšanas ierīce, žāvētājs, garšvielu mašīna, utt.) ir precīzi uzstādīti un savienoti. Tehniķi atkļūdos visus iekārtas darbības parametrus atbilstoši klienta produkta formulai un ražošanas procesa prasībām, un veikt izmēģinājuma ražošanu, līdz produkta kvalitāte atbilst klienta gaidītajiem standartiem.
Tajā pašā laikā, mēs nodrošinām klienta ražošanas komandas darbības apmācību uz vietas, ieskaitot iekārtas pamatstruktūru un darbības principu, ikdienas darbības soļi, parametru regulēšanas prasmes, pamata defektu identificēšana un apstrāde. Mēs nodrošināsim arī detalizētu ekspluatācijas rokasgrāmatu un apkopes rokasgrāmatu, and answer the questions raised by the operators one by one to ensure that the customer’s staff can proficiently operate and manage the equipment independently after the training.
6.3 After-Sales Service
We have a perfect after-sales service system with a professional after-sales team and multiple service outlets to provide timely and efficient after-sales support for customers nationwide and even globally. We promise a rapid response mechanism: for customer’s equipment problems, we will give a solution within 24 hours after receiving the feedback; for on-site maintenance needs, our after-sales technicians will arrive at the customer’s production site as soon as possible according to the actual situation.
We provide regular equipment maintenance and inspection services for customers, 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.
Turklāt, we provide a long-term supply of genuine spare parts, with a large number of common spare parts (such as screw elements, mirst galvas, cutting knives, sealing rings) in stock to ensure the rapid supply of spare parts and minimize the equipment downtime caused by component damage. Sniedzam arī aprīkojuma tehniskās modernizācijas pakalpojumus, un var uzlabot vadības sistēmu, skrūvju konstrukcija un citas esošās iekārtas daļas atbilstoši klienta turpmākajām ražošanas paplašināšanas un produktu modernizācijas vajadzībām, lai iekārtas vienmēr varētu pielāgoties jaunākajām ražošanas prasībām.
7. Pilnīgi ekstruderu sērijas tehniskie parametri mājdzīvnieku barības ražošanai
Lai apmierinātu dažāda mēroga un produktu veidu lolojumdzīvnieku barības uzņēmumu daudzveidīgās ražošanas vajadzības, esam laiduši klajā pilnu divu skrūvju ekstrūderu produktu klāstu mājdzīvnieku barības apstrādei, ar HTS BASIC sēriju kā galveno, un paplašinātas HTS STANDARD un HTS PREMIUM sērijas, lai pielāgotos mazai un vidējai ražošanai, attiecīgi liela mēroga ražošana un augstākās klases pielāgota ražošana. Visas sērijas izmanto divu skrūvju ekstrūzijas galveno dizainu, ar pašattīrīšanos, augsta sūknēšanas efektivitāte un spēcīga bīdes pielāgošanās spēja, un ir lieliski saskaņoti ar lolojumdzīvnieku barības izejvielu augstas viskozitātes un augsta tauku satura īpašībām. Tālāk ir sniegta katras sērijas pilna tehnisko parametru tabula:
Tabula 1: Izcili tehniskie parametri Mājdzīvnieku barības divu skrūvju ekstrūderu sērija
lapa
| Parametru kategorija | HTS BASIC sērija (Ieeja/vidēja mēroga) | HTS STANDARTA sērija (Liela mēroga) | HTS PREMIUM sērija (Augstākās klases pielāgots) |
|---|---|---|---|
| Skrūvju struktūra | Paralēlā dubultskrūve, līdzrotējošs | Paralēlā dubultskrūve, līdzrotējošs | Paralēlā dubultskrūve, līdzrotējošs |
| Skrūves diametrs (mm) | 30/45/65 | 80/95/110 | 65/80/95/110 (pielāgojama) |
| Kompresijas pakāpe | 4:1 ~ 8:1 (regulējami) | 5:1 ~ 10:1 (regulējami) | 4:1 ~ 12:1 (pielāgojama) |
| Skrūves ātrums (apgr./min) | 150 ~ 500 (bezpakāpju frekvences pārveidošana) | 200 ~ 600 (bezpakāpju frekvences pārveidošana) | 100 ~ 700 (bezpakāpju frekvences pārveidošana) |
| Nominālais griezes moments (N·m) | 120 ~ 350 (Eiropas vidēja griezes momenta ātrumkārba) | 400 ~ 1200 (augsta griezes momenta pārnesumkārba) | 350 ~ 1500 (importēta augstas precizitātes ātrumkārba) |
| Ekstrūzijas temperatūra (℃) | 70 ~ 170 (3-sekcijas temperatūras kontrole) | 70 ~ 180 (5-sadaļa precīza temperatūras kontrole) | 60 ~ 190 (6-sadaļa inteliģenta temperatūras kontrole) |
| Ekstrūzijas spiediens (MPa) | 2 ~ 8 | 3 ~ 10 | 2 ~ 12 |
| Ražošanas jauda (kg/h) | 100 ~ 500 | 500 ~ 2000 | 200 ~ 2500 (pielāgojama) |
| Mucas materiāls | Nodilumizturīgs leģētais tērauds (nitrēta apstrāde, cietība ≥60 HRC) | Nodilumizturīgs leģētais tērauds (bimetāla kompozīts, cietība ≥65 HRC) | Importēts nodilumizturīgs leģētais tērauds (bimetāla kompozīts + lāzera apšuvums, cietība ≥70 HRC) |
| Skrūvju materiāls | Nodilumizturīgs leģētais tērauds (nitrēta apstrāde) | Nodilumizturīgs leģētais tērauds (bimetāla kompozīts) | Importēts nodilumizturīgs leģētais tērauds (pielāgots atbilstoši izejvielām) |
| Vadības sistēma | PLC + skārienekrāns, pamata formulas atmiņa (≤20 grupas) | PLC + rūpnieciskais skārienekrāns, formulas atmiņa (≤50 grupas) | Inteliģents PLC + mākoņa skārienekrāns, formulas atmiņa (neierobežots, mākoņkrātuve) |
| Sildīšanas metode | Elektriskā apkure + jaka ūdens dzesēšana | Elektriskā apkure + tvaika apkure + jaka ūdens dzesēšana | Elektriskā apkure/tvaika apkure (pārslēdzams) + jaka precīza ūdens dzesēšana |
| Barošanas metode | Vienas/divu skrūvju padeve (pēc izvēles) | Divu skrūvju diferenciāļa padeve + šķidruma padeves osta (eļļai/taukiem) | Daudzkanālu precīza barošana (cieta/šķidra/smērviela, neatkarīga mērīšana) |
| Pašattīrīšanās veiktspēja | Standarta pašattīrīšanās | Uzlabota pašattīrīšanās | Augstas efektivitātes pašattīrīšanās (pielāgota skrūvju sprauga) |
| Jauda (kW) | 15 ~ 45 | 55 ~ 160 | 37 ~ 200 (pielāgojama) |
| Kopējais izmērs (G × P × A, 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 (pielāgojama) |
| Weight (t) | 0.8 ~ 2.5 | 3.0 ~ 8.0 | 2.0 ~ 10.0 (pielāgojama) |
| Core Advantages | High cost-effectiveness, viegla darbība, suitable for initial pet food enterprises | Augsta jauda, zems enerģijas patēriņš, stabilu sniegumu, suitable for large-scale mass production | High precision, strong customization, multi-functional, suitable for high-end pet food/snack customized production |
Key Parameter Explanation
Kompresijas pakāpe: 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.
Muca & Skrūvju materiāls: 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.
Barošanas metode: 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.
Vadības sistēma: 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; tajā pašā laikā, optimizēt iekārtu struktūru, lai samazinātu troksni un atkritumu izvadīšanu, atbilst vides aizsardzības ražošanas standartiem.
Pielāgošanas iespēju paplašināšana: Mēs izveidosim elastīgāku produktu pielāgošanas sistēmu, un var pielāgot skrūves diametru, kompresijas pakāpe, padeves metode un citi ekstrūdera parametri atbilstoši klienta personalizētajām ražošanas vajadzībām (piemēram, īpašas formas mājdzīvnieku uzkodas, augstas klases funkcionālā mājdzīvnieku barība); tajā pašā laikā, mēs izstrādāsim atbilstošākas palīgiekārtas, lai izveidotu pilnībā automatizētu ražošanas līniju no izejvielu sajaukšanas līdz gatavā produkta iepakošanai.
Padziļināta tehnoloģiju un pakalpojumu integrācija: Būvēsim mājdzīvnieku barības apstrādes tehnoloģiju pētniecības un attīstības centru, Apvienojot aprīkojumu R & D ar produkta formulas izpēti, un nodrošināt klientiem integrētus risinājumus “iekārtas + formula + process”; tajā pašā laikā, paplašināsim tiešsaistes tehniskā servisa kanālu, nodrošināt 7 × 24 stundu tiešsaistes tehniskos norādījumus un kļūdu diagnostiku, un turpināt uzlabot pēcpārdošanas pakalpojumu efektivitāti.
9. Secinājums
Lolojumdzīvnieku barības ekstrūzijas uzpūšanas tehnoloģija ir mūsdienu lolojumdzīvnieku barības rūpnieciskās ražošanas pamatā, un ekstrūzijas iekārtu veiktspēja tieši nosaka ražošanas efektivitāti, lolojumdzīvnieku barības uzņēmumu produktu kvalitāte un konkurētspēja tirgū. Kā profesionāls pārtikas kvalitātes ekstrūzijas iekārtu piegādātājs, esam uzkrājuši bagātīgu pieredzi lolojumdzīvnieku barības pārstrādes jomā, un laida klajā pilnu divu skrūvju ekstrūderu produktu klāstu, ko pārstāv HTS sērija, kas lieliski atrisina augstās viskozitātes radītās apstrādes grūtības, augsts tauku saturs un daudzveidīgas lolojumdzīvnieku barības izejvielas.
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.