Ngokuphucuka okuqhubekayo kwemigangatho yokuphila kwabantu kunye nogxininiso olukhulayo kubuqabane bezilwanyana zasekhaya, Ishishini lehlabathi lokutya kwezilwanyana zasekhaya liye lakhula ngokukhawuleza kwiminyaka yakutshanje. Izilwanyana zasekhaya ngokuthe ngcembe zigqalwa njengamalungu abalulekileyo entsapho, kunye nempilo yabo yokutya kunye nomgangatho wokutya ibe yingqwalasela yabanini bezilwanyana zasekhaya. Oku kukhuthaze ukuphuculwa okuqhubekayo kobugcisa bokwenza ukutya kwezilwanyana zasekhaya kunye nezixhobo, ukubeka phambili iimfuno eziphezulu zokhuseleko, isondlo, incasa kunye nenkangeleko yokutya kwesilwanyana. Sizimisele ukubonelela ngee-extruders ezichwephesha ezilungiselelwe ngokukodwa ukuveliswa kokutya, ngamava atyebileyo okwenziwa kokutya kwezilwanyana zasekhaya, kwaye inokubonelela ngezisombululo zokusetyenzwa ezijoliswe kuzo kwiindidi ezahlukeneyo zokutya kwezilwanyana zasekhaya, ukunceda amashishini ukuphucula ukusebenza kakuhle kwemveliso, qinisekisa umgangatho wemveliso, kwaye ufumane inzuzo kukhuphiswano oluqatha lwemarike.
Eli nqaku liza kugxininisa kwintsimi yokutya kwezilwanyana, Ukucacisa nzulu ngobugcisa bokwenza ukutya kwezilwanyana zasekhaya, umgaqo osebenzayo we-screw extrusion puffing, iingenelo extruders zethu, kunye nokusetyenziswa okuthe ngqo kwezixhobo ze-extrusion kwimveliso yokutya kwesilwanyana. Iya kongeza kwakhona iiparitha zobugcisa ezineenkcukacha, iinkcukacha zenkqubo kunye namanqaku entlungu yoshishino ukutyebisa umxholo, ukuhlangabezana nemfuno yokubalwa kwamagama ye 3000-4000 amazwi, kunye nokubonelela ngereferensi ebanzi kunye neyobungcali kumashishini afanelekileyo kunye neengcali kwishishini lokutya kwezilwanyana zasekhaya.
1. Isishwankathelo soShishino lokuTya kwezilwanyana ezifuywayo kunye neempawu zokuLungisa
1.1 Imeko yangoku kunye neNdlela yoPhuhliso yoShishino lokuTya kwezilwanyana ezifuywayo
Kule minyaka yangoku, Imarike yokutya kwezilwanyana zasekhaya ibonise ukukhula okuzingileyo. Iqhutywa zizinto ezifana nokwanda kwenani lezilwanyana zasekhaya, ukuphuculwa kwengqiqo yokusetyenziswa kwezilwanyana zasekhaya, kunye nokuphuculwa kwabahlali’ amandla okuthenga, imfuno yomgangatho ophezulu, ukutya okunesondlo kunye nokusebenza kwezilwanyana ezifuywayo kuye kwaqhubeka nokunyuka. Ngokweenkcukacha-manani ezifanelekileyo zedatha, imarike yokutya kwezilwanyana zasekhaya igqithile 100 iibhiliyoni zeedola zaseMelika, kwaye kulindeleke ukuba kugcinwe izinga lokukhula kwe 5%-8% kwiminyaka embalwa ezayo. Phakathi kwabo, ukutya kwesilwanyana sasekhaya esomileyo, njengolona hlobo lwemveliso yesiqhelo, akhawunti ngaphezu 60% yentengiso yokutya kwezilwanyana zasekhaya iyonke, kulandele iimveliso ezimanzi ezinkonkxiweyo, iimveliso semi-manzi kunye pet snacks.
Indlela yophuhliso lweshishini lokutya kwezilwanyana zasekhaya ibonakaliswa ikakhulu kwimiba emithathu: Ekuqaleni, isondlo kunye nempilo. Abanini bezilwanyana ezifuywayo bahlawula ingqalelo ngakumbi nangakumbi ekubunjweni kwesondlo sokutya kwezilwanyana, kunye neemveliso ezinendalo, ukongeza-free, esebenzayo (njengobuhle beenwele, ukutya kwesisu, ukulawula ubunzima) iimpawu zithandwa kakhulu; Isibini, ukwahlukana kweentlobo zeemveliso. Ngokutyetyiswa kweentlobo zezilwanyana zasekhaya kunye neemfuno zomntu ngamnye zabanikazi bezilwanyana zasekhaya, ukutya kwezilwanyana zasekhaya kuye kwaphuhliswa ngokuthe chu ukuya kukwahlulwa, njengokutya kwesilwanyana seminyaka eyahlukeneyo (iinjana, izinja ezindala, izinja ezindala), iintlobo ezahlukeneyo, kunye neemeko zomzimba ezahlukeneyo; Isithathu, ubukrelekrele kunye nokusebenza kakuhle kobugcisa bokucubungula. Ukuze kuhlangatyezwane nemfuno enkulu yemveliso kunye nokuqinisekisa ukuzinza komgangatho wemveliso, Amashishini okulungisa ukutya kwezilwanyana zasekhaya ahlala esazisa izixhobo zokusetyenzwa eziphambili kunye neenkqubo zokulawula ezikrelekrele ukuphucula imveliso esebenzayo kunye nokunciphisa iindleko zabasebenzi..
Ngokuchasene nale mvelaphi, itekhnoloji yokukhupha i-extrusion, njengobuchwephesha obungundoqo bokwenziwa kokutya kwezilwanyana zasekhaya (ingakumbi iimveliso ezikhukhumeleyo ezomileyo), iye yaba sisitshixo ekumiseleni umgangatho wokutya kwezilwanyana zasekhaya kunye nokhuphiswano lwamashishini. Iingcali zethu zokukhupha ukutya kwezilwanyana zasekhaya ziphuhliswa ukuphendula kwiimpawu zoshishino kunye nemfuno yemarike, ezinokuthi zisombulule ngokufanelekileyo amanqaku eentlungu ekusebenzeni kokutya kwezilwanyana kunye nokunceda amashishini afezekise umgangatho ophezulu kunye nemveliso esebenzayo.
1.2 Ukuhlelwa kokutya kwezilwanyana zasekhaya kunye neempawu zayo zokuLungisa
Ukutya kwezilwanyana zasekhaya kuneendlela ezahlukeneyo zokuhlela, ezinokuthi zahlulwe zibe ziindidi ezahlukeneyo ngokweteknoloji yokucubungula, umxholo wamanzi, ifom yemveliso kunye nokusetyenziswa. Phakathi kwabo, ngokobuchwephesha bokucubungula kunye nomxholo wamanzi, ukutya kwesilwanyana sahlulwe ikakhulu kwiimveliso ezomileyo ezikhukhumeleyo, iimveliso semi-manzi, iimveliso ezithambileyo ezikhukhumele, iimveliso ezinkonkxiweyo ezimanzi kunye nokutya (okanye ukuphatha). Udidi ngalunye lokutya kwesilwanyana luneempawu zalo ezizodwa zokusetyenzwa kunye neemfuno zezixhobo, ngoku Landelayo:
1.2.1 Iimveliso eziPhuhliweyo ezomileyo:
Ukutya kwesilwanyana sasekhaya esomileyo lolona hlobo luqhelekileyo lokutya kwesilwanyana sasekhaya, ngomxholo wamanzi we 10%-12%. Izinto zayo eziphambili ziquka ukutya kwenyama, ukutya kwentlanzi, i-cereal (umbona, ingqolowa, irayisi), ukutya kweembotyi zesoya, iivithamini, iiminerali kunye nezinye izongezo. Inkqubo yokwenziwa kweemveliso ezomileyo ezikhukhumeleyo inxulumene ngokusondeleyo nenkqubo yokukhukhumala, efuna ukusetyenziswa kwezixhobo zokufunxa i-extrusion ukusetyenzwa kwemathiriyeli ekrwada kwiimveliso zegranular ezinobungakanani obufanayo, incasa ecocekileyo kunye nencasa elungileyo. Iimpawu zeemveliso ezikhukhumeleyo ezomileyo ziphila ixesha elide, indawo yokugcina kunye nokuthutha, kunye nexabiso eliphantsi lemveliso, ezilungele imveliso enkulu kwaye zithandwa phakathi kwabanini bezilwanyana zasekhaya.
Eyona mfuno iphambili yokusetyenzwa kweemveliso ezomileyo ezikhukhumeleyo kukuba imathiriyeli ekrwada kufuneka idunyiswe ngokupheleleyo, ukwenzela ukuba isitashi kwizinto eziluhlaza zigcwele i-gelatinized, eluncedo ekutyiseni nasekufunxeni izilwanyana zasekhaya. Ngaxeshanye, imveliso kufuneka ibe nobulukhuni obuthile kunye nokuqaqamba ukuhlangabezana neemfuno zokuhlafuna zezilwanyana zasekhaya kunye nokunceda ukucoca amazinyo abo.. Oku kubeka iimfuno eziphezulu kuxinzelelo lwe-extrusion, ubushushu kunye nesantya se-screw se-extruder.
1.2.2 Iimveliso zeSemi-Wet:
Ukutya kwezilwanyana ezifuywayo okungamanzi kunomthamo wamanzi 25%-35%, ephakathi kweemveliso ezomileyo nezimanzi. Izinto zayo eziluhlaza zifana neemveliso ezikhukhumeleyo ezomileyo, kodwa humectants ngakumbi (njengepropylene glycol, i-sorbitol) zongezwa ukugcina ukuthamba kunye nokufuma kwemveliso. Inkqubo yokwenziwa kweemveliso ze-semi-wet nayo ifuna unyango lokufunxa, kodwa iqondo lokukhukhumala lisezantsi kunelo leemveliso ezomileyo. Imveliso ineempawu zencasa ethambileyo kunye nencasa entle, elungele izilwanyana zasekhaya ezingakwazi ukuhlafuna (ezifana nezilwanyana zasekhaya ezindala, izilwanyana zasekhaya ezigulayo).
Ubunzima bokulungiswa kweemveliso ezimanzi bulele kulawulo lwesiqulatho samanzi kunye nokuthintela ukuwohloka kwemveliso.. Ngoko ke, kwinkqubo yokucubungula, kuyimfuneko ukulawula ngokuthe ngqo ubushushu kunye nokufuma kwekhonkco ngalinye, kwaye ukhethe izilondolozo ezifanelekileyo kunye ne-humectants ukuqinisekisa ubomi beshelufu yemveliso.
1.2.3 Iimveliso eziPhuhliweyo ezithambileyo:
Ukutya kwesilwanyana sasekhaya okuthambileyo kunomthamo wamanzi 15%-25%, eyimveliso phakathi kweemveliso ezomileyo ezikhukhumeleyo kunye neziphantse zibemanzi. Inkqubo yayo yokucubungula iyafana naleyo yeemveliso ezomileyo ezikhukhumeleyo, kodwa i-formula kunye ne-extrusion parameters zihlengahlengiswa ukwenza imveliso ithambile kwaye i-elastic. Iimveliso ezithambileyo ezikhukhumeleyo zidibanisa izibonelelo zeemveliso ezomileyo kunye nesiqingatha-manzi, ngencasa elungileyo kunye nokugaywa lula, elungele iindidi zezilwanyana zasekhaya.
1.2.4 Iimveliso ezimanzi ezinkonkxiweyo:
Ukutya kwezilwanyana ezinkonkxiweyo ezimanzi kunomthamo wamanzi angaphezu kwe 70%, ikakhulu usebenzisa inyama entsha, intlanzi, imifuno kunye nezinye izinto ekrwada, ezicutshungulwa ngokuphekwa, ukunkonkxa, ukuvala inzala kunye nezinye iinkqubo. Ukwahluka kwezinye iintlobo zeemveliso, iimveliso ezimanzi ezinkonkxiweyo azifuni unyango lokukhukhumala, kunye namakhonkco abo okusebenza angundoqo kukupheka kunye nokuvala inzala. Imveliso ineempawu zesondlo esityebileyo, incasa eyomeleleyo kunye nesiqulatho sokufuma okuphezulu, elungele izilwanyana zasekhaya ezingawathandiyo amanzi okusela okanye ezifuna isondlo esongezelelweyo.
Isitshixo sokusetyenzwa kweemveliso ezimanzi ezinkonkxiweyo kukuqinisekisa ukutsha kunye nokhuseleko lwemathiriyeli ekrwada, kwaye ulawule ngokungqongqo ubushushu bokuvala inzala kunye nexesha lokubulala iibhaktheriya ezinobungozi kwimveliso kunye nokwandisa ubomi beshelufu. Ngaxeshanye, kuyimfuneko ukuqinisekisa ukuba izakhi zondlo zemveliso azilahleki ngexesha lokupheka kunye nenkqubo yokuvala inzalo.
1.2.5 I-Pet Snacks (okanye Ukuphatha):
I-Pet snacks kukutya okuncedisayo kwizilwanyana zasekhaya, ikakhulu isetyenziselwa ukuvuza izilwanyana zasekhaya, ukuphucula umoya wabo kunye nokongeza isondlo. Iintlobo ze-snacks zezilwanyana zahlukene, kuquka namashwamshwam akhukhumeleyo, amashwamshwam inyama eyomileyo, amashwamshwam, amashwamshwam amazinyo, njl. Phakathi kwabo, amashwamshwam akhukhumeleyo abangela umlinganiselo omkhulu, kunye nenkqubo yabo yokucubungula iyafana neemveliso ezikhukhumeleyo ezomileyo, kodwa ifomula icocwe ngakumbi, kunye ne-flavoring agents ezingaphezulu kunye nezongezo ezisebenzayo zongezwa ukuhlangabezana nencasa kunye neemfuno ezisebenzayo zezilwanyana zasekhaya.
Iisnacks ezifuywayo zineemfuno eziphezulu zokungcamla, inkangeleko kunye nokusebenza. Umzekelo, amashwamshwam amazinyo kufuneka abe nobulukhuni obuthile kunye noburhabaxa ukunceda ukucoca amazinyo esilwanyana sasekhaya kunye nokuthintela ukubala kwamazinyo.; I-snacks ehombisa iinwele kufuneka yongeze izithako ezinje nge-lecithin ukunceda ukuphucula umgangatho weenwele zesilwanyana.. Oku kufuna ukuba i-extruder ibe nokuguquguquka okulungileyo kunye nokulungelelaniswa ukuhlangabezana neemfuno zokusetyenzwa kweentlobo ezahlukeneyo ze-snacks..
Kuyafaneleka ukuba uqaphele ukuba ngaphandle kweemveliso ezinkonkxiweyo, uninzi lweentlobo zokutya ezifuywayo zinxulumene ngokusondeleyo nenkqubo yokufunxa. Ukufunxa akuphela nje inxalenye ephambili yokutya kwesilwanyana, kodwa ikwachaphazela ngokuthe ngqo umgangatho, incasa, isondlo kunye nokwetyisa kokutya kwesilwanyana. Ngoko ke, ukukhetha izixhobo ezichanekileyo zokukhupha kunye nokuqonda itekhnoloji yesayensi ye-extrusion kubalulekile kumashishini okulungisa ukutya kwezilwanyana zasekhaya..
2. Itekhnoloji engundoqo yokuPhathwa kokuTya kwezilwanyana: Extrusion Puffing Technology
Itekhnoloji ye-Extrusion puffing yeyona nto iphambili yetekhnoloji yokudibanisa ukuxuba, ukuxova, ukufudumeza, extrusion kunye nokudumba. Isetyenziswe ngokubanzi kwimveliso yokutya kwesilwanyana ngenxa yeenzuzo zayo zokusebenza kakuhle kwemveliso, umgangatho omhle wemveliso, ukulungelelaniswa okunamandla kwizinto ezikrwada kunye noluhlu olubanzi lwesicelo. Ekulungisweni kokutya kwesilwanyana, Itekhnoloji ye-extrusion isetyenziselwa ukuqaphela ukudumba kwemathiriyeli ekrwada, yenza i-starch gelatinize, iprotein denature, kunye nokuphucula incasa kunye nokugaywa kwemveliso. Ngaxeshanye, inokubulala iintsholongwane eziyingozi kwimathiriyeli ekrwada, qinisekisa ukhuseleko lokutya kwesilwanyana.
2.1 Iimpawu zeSilwanyane sokutya kweMathiriyeli ekrwada kunye neeMfuno zeSixhobo sokuXhobisa
Izinto ezikrwada zokutya kwezilwanyana zezilwanyana ikakhulu ziyimveliso yenyama (njengokutya kwenyama, ukutya kwentlanzi, inyama entsha), i-cereal, ukutya kweembotyi zesoya, iivithamini, iiminerali kunye nezinye izongezo. Phakathi kwabo, iimveliso zenyama akhawunti umlinganiselo omkhulu, ukwenza imveliso ibe ne-viscosity eyomeleleyo. Olu phawu lubeka phambili iimfuno ezikhethekileyo zezixhobo ze-extrusion:
I-extruders ye-screw enye ayifanelekanga ukuveliswa kwezoqoqosho kokutya kwesilwanyana. Ngenxa yokuba i-extruder-screw extruder inoluhlu olumxinwa lokucheba, amandla okumpompa kakubi kwaye akukho siphumo sokuzicoca. Xa kusetyenzwa izinto ezibonakalayo ezifana neemveliso zenyama, kulula ukubangela ukuqokelelana kwezinto, ukuvaleka kunye nokuxuba okungafaniyo kwi-barrel extruder, engachaphazeli nje ukusebenza kakuhle kwemveliso, kodwa ikwakhokelela kumgangatho wemveliso ongazinzanga. Ukwengeza, i-extruder ye-screw enye isetyenziswa kakhulu amandla xa ilungisa izinto ezinamafutha aphezulu kunye neprotheni ephezulu, nto leyo eyandisa iindleko zemveliso yamashishini.
I-twin-screw extruders, kwelinye icala, zineengenelo ezicacileyo kwimveliso yokutya kwezilwanyana zasekhaya. Zinoluhlu olubanzi lokucheba, isiphumo esisebenzayo sokumpompa kunye nesiphumo sokuzicoca, enokusombulula ngempumelelo iingxaki ze-viscosity yezinto kunye nokuqokelela. I-twin-screw extruder inokuqonda ukuxubana okufanayo, ukuxova kunye nokukhutshwa kwezinto, naxa ulungisa izinto eziluhlaza ngamafutha aphezulu kunye nomxholo wenyama entsha, inokuqinisekisa imveliso ezinzileyo kunye nomgangatho wemveliso ongaguqukiyo. Ngoko ke, kwimveliso yokwenene yokutya kwesilwanyana, i-twin-screw extruders ibe yeyona ndlela iphambili yokufunxa ukutya kwesilwanyana, kwaye zisetyenziswa ngokubanzi kwimveliso yeemveliso ezomileyo ezikhukhumeleyo, iimveliso semi-manzi, iimveliso ezithambileyo ezikhukhumeleyo kunye namashwamshwam esilwanyana sasekhaya.
2.2 Umgaqo wokuSebenza we-Screw Extrusion Puffing
Inkqubo ye-screw extrusion puffing yokutya kwesilwanyana yinkqubo entsonkothileyo yomzimba kunye neekhemikhali, ebandakanya intsebenziswano yezinto ezininzi ezifana nobushushu, uxinzelelo, ukucheba amandla kunye nexesha. Umgaqo othile wokusebenza ngolu hlobo lulandelayo:
Ekuqaleni, ukunyangwa kwezinto ekrwada. Umgubo wezinto eziluhlaza eziqulethe isixa esithile sestatshi (engaphezulu kwe 20%) zixutywe ngokufanayo ngokwefomula, kwaye emva koko ithunyelwe kwisixhobo sokuthambisa ukuze kunyangwe. Injongo yokufudumala kukulungelelanisa ukufuma kunye nobushushu bezinto eziphathekayo, so that the materials can reach the ideal state before entering the extruder. Generally, 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.
Isibini, 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. I-friction force yenziwa phakathi kwezinto kunye nodonga lwangaphakathi lombhobho, ngokunjalo naphakathi kwamasuntswana ezinto eziphathekayo, enokuvelisa ubushushu obuninzi, ehambelana nokufudumeza kwezinto. Ukwengeza, ngokweemfuno zokusetyenzwa, umphunga unokuhamba ngebhatyi yombhobho ukutshisa izinto phakathi kweendonga, ukwenzela ukuba izinto eziphathekayo kwi-extrusion cavity zikwisimo esiphezulu sokushisa kunye noxinzelelo oluphezulu. Iqondo lobushushu kwi-extrusion cavity lilawulwa ngokubanzi kwi-120℃ 180℃, kwaye uxinzelelo lulawulwa kwi-2～10MPa.
Isithathu, isitashi gelatinization kunye neprotein denaturation. Ngaphantsi kwesenzo sokushisa okuphezulu, uxinzelelo oluphezulu kunye namandla okucheba, isitashi kwizinto ezifunxa amanzi kwaye zanda, isakhiwo sekristale sichithwa, kwaye iguqulwa ibe yimeko ye-amorphous, 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. Ngaxeshanye, 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. Ngaxeshanye, the denatured protein can also form a network structure, enokusonga istatshi kunye namanye amacandelo, ukunceda ukugcina imilo yemveliso ekhukhumeleyo.
Isine, ukudumba kunye nokubumba. Xa izinto ezikwimeko yobushushu obuphezulu kunye noxinzelelo oluphezulu zityhalelwa kwintloko yokufa ngesikrufu kwaye zikhutshwe kumngxunya wokufa ngesantya esiphezulu., iqondo lobushushu kunye noxinzelelo lwezixhobo zehla kakhulu ngenxa yokuba ngequbuliso zishiya i-extrusion cavity kwaye zingene kwindawo eqhelekileyo ye-atmospheric.. Ngaphantsi kwesenzo esidibeneyo sokungafani koxinzelelo kunye nokuhluka kweqondo lokushisa, amanzi kwizinto eziphathekayo aphuphuma ngokukhawuleza, umthamo wezinto eziphathekayo wanda ngokukhawuleza (izinga lokwandisa lingafikelela kumaxesha angama-2～8), kwaye izixhobo ziphelelwe ngamanzi kwaye ziqiniswe ngokukhawuleza ukwenza i-porous, imveliso ekrazukileyo okanye ethambileyo.
Emva kwe-extrusion ukusuka kumngxuma wokufa, 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. Umzekelo, 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, Ukupholisa, 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, ikakhulu kuquka iimpawu zemathiriyeli ekrwada, tempering parameters, iparameters extrusion kunye ne-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, umxholo wokufuma kunye nokwakhiwa kwesondlo sezinto eziluhlaza kunempembelelo enkulu kwimpembelelo yokukhukhumeza. Umzekelo, umxholo wesitashi wezinto eziluhlaza uchaphazela ngokuthe ngqo izinga lokwandiswa kwemveliso. Okukhona uphezulu umxholo wesitatshi (phakathi koluhlu oluthile), ngcono ifuthe lokufunxa, kwaye inkulu isantya sokwandiswa kwemveliso. Ubungakanani besuntswana lemathiriyeli ekrwada kufuneka bufane, ngokubanzi 80-100 umnatha. Ukuba ubungakanani besuntswana bukhulu kakhulu, izinto eziphathekayo azilula ukuba zixutywe ngokufanayo kwaye zenziwe ngeplastiki ngokupheleleyo, echaphazela umphumo wokudumba; ukuba ubungakanani bamasuntswana buncinci kakhulu, kulula ukubangela ukuvaleka kwezinto kunye nokwandisa ukusetyenziswa kwamandla. Isiqulatho sokufuma semathiriyeli ekrwada phambi kokuba kushushu kufuneka kulawulwe 8%-12%. Ukuba isiqulatho sokufuma siphezulu kakhulu, the materials are easy to stick to the screw and barrel, affecting the extrusion and puffing; if the moisture content is too low, the shear force and friction force between the materials are insufficient, and the starch gelatinization is incomplete, resulting in poor puffing effect.
2.3.2 Tempering Parameters:
Tempering parameters mainly include tempering temperature, tempering time and moisture content after tempering. The tempering temperature is generally 70～98℃. If the tempering temperature is too low, the materials cannot absorb water evenly, and the starch gelatinization is insufficient; if the tempering temperature is too high, the materials may be caked in advance, affecting the subsequent extrusion. The tempering time is generally 2-5 imizuzu, 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. Umzekelo, 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, ikakhulu ibandakanya isantya screw, ubushushu be-extrusion kunye noxinzelelo lwe-extrusion. Screw speed generally ranges from 100 ukuya 600 rpm. Isantya esiphezulu se-screw, Okukhona kukhulu amandla okucheba kunye namandla okukhuhlana afunyanwa zizixhobo, the higher the extrusion temperature and pressure, and the better the puffing effect. Nangona kunjalo, ukuba isantya se-screw siphezulu kakhulu, ixesha lokuhlala lezinto kwi-extrusion cavity lifutshane kakhulu, resulting in incomplete starch gelatinization and uneven mixing; ukuba isantya sokujija sisezantsi kakhulu, amandla okucheba kunye namandla okukhuhla awanelanga, and the puffing effect is poor.
Extrusion temperature is generally controlled at 120～180℃, which is divided into three sections: icandelo lokutyisa, 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. Uxinzelelo kwi-cavity ye-extrusion inqunywe ngokukodwa ngumlinganiselo wokunyanzeliswa kwe-screw, ubungakanani bomngxuma wokufa kunye nesantya sokujija. Ukuphakama koxinzelelo lwe-extrusion, ngcono ifuthe lokufunxa, 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. Inani lemingxuma yokufa lichaphazela umthamo wemveliso. The more the number of die holes, amandla emveliso aphezulu, kodwa kuyimfuneko ukuqinisekisa ukuba ukuhanjiswa koxinzelelo kufana, so as to avoid uneven puffing of the product.
3. Extruders zethu: Advantages and Product Series for Pet Food Production
Kudala sizibandakanya kuphando, 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) 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.
Ukwengeza, 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. Ngaxeshanye, 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 Uluhlu olubanzi lwesicelo:
Our twin-screw extruders have strong adaptability and can meet the processing needs of various types of pet food, including dry puffed products, iimveliso semi-manzi, iimveliso ezithambileyo ezikhukhumele, pet snacks and other products. The extruder is equipped with a high-torque drive system, variable screw speed and pressure variable control device, which provides excellent flexibility for customers, and can be adjusted according to different process requirements and raw material formulas to achieve the best processing effect.
The modular design of the extruder is another major feature that expands its application range. The screw, umphanda, die head and other components of the extruder adopt a modular design, which can be freely combined and replaced according to the customer’s specific application needs. Umzekelo, when processing dry puffed products, 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. 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, isantya sokujija, 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. Ukwengeza, 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, ukumila, hardness, crispness and nutritional composition of the products are uniform, which can meet the strict quality requirements of pet food. Ngaxeshanye, 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 UFaneka oluPhezulu lweMveliso:
I-twin-screw extruders yethu inemveliso ephezulu yokusebenza kakuhle, 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. Ukwengeza, 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.
In terms of structural design, 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. I-extruder ixhotyiswe ngenkqubo yokulawula ye-PLC kunye ne-interface yokusebenza kwesikrini sokuchukumisa, which is simple and easy to operate. It can realize the automatic control of the production process, such as automatic feeding, ulawulo lobushushu oluzenzekelayo, ukulawula uxinzelelo oluzenzekelayo kunye nokusika okuzenzekelayo.
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, kufa iintloko, izixhobo zokutya, tempering devices and post-processing equipment according to their own product types, umthamo wemveliso kunye nohlahlo lwabiwo-mali, ukuze benze umgca wemveliso olungele iimfuno zabo. Umzekelo, 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.
Ukwengeza, 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, umphanda, fa intloko) 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. Ngaxeshanye, 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. Umzekelo, 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 tons), 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 tons), it is recommended to choose our high-torque large-scale twin-screw extruders (production capacity more than 500kg/h).
3.3.3 Qwalasela iNdleko-Ngempumelelo yeSixhobo:
The cost-effectiveness of the equipment is an important factor that enterprises need to consider. Amashishini akufuneki anikele ingqalelo kuphela kwiindleko zokuqala zotyalo-mali lwezixhobo, kodwa kwakhona uqwalasele iindleko zokusebenza kwexesha elide (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, ukugunyazisa, uqeqesho, maintenance and spare parts supply services. We have a professional after-sales service team, which can respond to customer needs in a timely manner and solve various problems encountered by customers in the use of equipment, ensuring the normal operation of the production line.
3.3.5 Consider the Flexibility and Expandability of the Equipment:
With the changes of market demand, enterprises may need to adjust their product types and production scales. Ngoko ke, when selecting extruders, enterprises should consider the flexibility and expandability of the equipment. Our extruders adopt a modular design, which can be freely combined and upgraded according to the needs of enterprises, improving the flexibility and expandability of the equipment, and reducing the cost of equipment transformation.
4. Application of Extrusion Equipment in Pet Food Production
Our 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 Raw Material Preparation:
The raw materials of dry puffed pet food mainly include meat meal (chicken meal, beef meal, ukutya kwentlanzi), i-cereal (corn flour, wheat flour, rice flour), ukutya kweembotyi zesoya, iivithamini, minerals, attractants and other additives. All raw materials need to be inspected and cleaned to remove impurities (such as stones, metals) and ensure the quality of raw materials. The raw materials are then crushed into powder with a particle size of 80-100 umnatha, which is conducive to uniform mixing and full plasticization.
4.1.2 Mixing:
The crushed raw materials are sent to the mixer according to the formula ratio for uniform mixing. The mixing time is generally 5-10 imizuzu, ensuring that all raw materials and additives are evenly distributed. The mixer is equipped with a weighing device, which can accurately control the dosage of each raw material, ensuring the stability of the product formula.
4.1.3 Tempering:
The mixed raw materials are sent to the tempering device for tempering treatment. The tempering temperature is controlled at 80-95℃, the tempering time is 3-5 imizuzu, and the moisture content after tempering is 15%-20%. During the tempering process, steam is injected into the tempering device to make the raw materials absorb water evenly, which is conducive to the subsequent extrusion puffing.
4.1.4 Extrusion Puffing:
The tempered raw materials are sent to the HTS BASIC series twin-screw extruder for extrusion puffing. The screw speed is controlled at 200-400 rpm, the extrusion temperature of the feeding section is 70-90℃, the melting section is 130-150℃, and the homogenizing section is 160-170℃. The extrusion pressure is controlled at 5-8MPa, and the compression ratio is 6-8. Ngaphantsi kwesenzo sokushisa okuphezulu, uxinzelelo oluphezulu kunye namandla okucheba, the starch in the raw materials is fully gelatinized, the protein is denatured, and the materials are extruded from the die head to form puffed strips.
4.1.5 Ukusika:
The puffed strips extruded from the die head are cut into short particles of uniform length by the rotary knife installed at the die head. The length of the particles is generally 3-8mm, which can be adjusted by changing the speed of the rotary knife.
4.1.6 Drying:
The cut puffed particles are sent to the drying equipment for drying. The drying temperature is controlled at 80-100℃, and the drying time is 20-30 imizuzu. The purpose of drying is to reduce the water content of the particles to 10%-12%, so as to extend the shelf life of the product. The drying equipment can adopt belt dryer or fluidized bed dryer, which has the advantages of uniform drying and high efficiency.
4.1.7 Ukupholisa:
The dried particles are sent to the cooling equipment for cooling. The cooling temperature is controlled at room temperature (20-25℃), and the cooling time is 10-15 imizuzu. 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 Ukupakishwa:
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. Iimpawu zokupakisha zinokuhlengahlengiswa ngokweemfuno zabathengi, such as 1kg/bag, 5kg/ibhegi, 10kg/ibhegi, njl. Emva kokupakisha, iimveliso zigcinwe kwindawo eyomileyo, Isitora esipholileyo nesingena umoya.
Key technical points: The key to dry puffed pet food production is to control the extrusion parameters and drying parameters. The extrusion parameters (isantya sokujija, ubushushu, uxinzelelo) directly affect the puffing effect and product texture; the drying parameters (ubushushu, 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
Iisnacks ezifuywayo zineemfuno eziphezulu zokungcamla, inkangeleko kunye nokusebenza, 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 Raw Material Preparation:
The raw materials of puffed dental snacks mainly include corn flour, wheat flour, potato starch, meat meal, vegetable fiber, calcium carbonate and other additives. Phakathi kwabo, 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 umnatha, which is conducive to the formation of the product and the improvement of the texture.
4.2.2 Mixing:
The crushed raw materials are mixed uniformly in the mixer according to the formula ratio. The mixing time is 8-12 imizuzu, ensuring that the vegetable fiber, calcium carbonate and other additives are evenly distributed in the raw materials.
4.2.3 Tempering:
The mixed raw materials are sent to the tempering device for tempering treatment. The tempering temperature is controlled at 75-90℃, the tempering time is 2-4 imizuzu, and the moisture content after tempering is 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:
The tempered raw materials are sent to the HTS BASIC series twin-screw extruder for extrusion puffing. The screw speed is controlled at 250-450 rpm, the extrusion temperature of the feeding section is 70-85℃, icandelo lokunyibilika yi-120-140℃, and the homogenizing section is 150-160℃. The extrusion pressure is controlled at 4-7MPa, and the compression ratio is 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 Ukusika:
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 Drying:
The cut products are sent to the drying equipment for drying. The drying temperature is controlled at 75-95℃, and the drying time is 15-25 imizuzu. 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 Ukupholisa:
The dried products are cooled to room temperature in the cooling equipment, which takes 8-12 imizuzu.
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. The surface treatment amount is generally 3%-6% of the product weight.
4.2.9 Ukupakishwa:
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
Semi-wet pet food has a soft taste and good palatability, elungele izilwanyana zasekhaya ezingakwazi ukuhlafuna. Our HTS BASIC series extruders can also be used for the production of semi-wet pet food by adjusting the configuration and parameters. The process flow is as follows:
Raw material preparation → mixing → tempering → extrusion puffing → cutting → cooling → packaging.
4.3.1 Raw Material Preparation:
The raw materials of semi-wet pet food mainly include meat meal, ukutya kwentlanzi, i-cereal, ukutya kweembotyi zesoya, humectants (propylene glycol, i-sorbitol), preservatives, vitamins and minerals. The humectants are added to maintain the moisture of the product, and the preservatives are added to extend the shelf life of the product. The raw materials are crushed into powder with a particle size of 80-100 umnatha.
4.3.2 Mixing:
The raw materials are mixed uniformly in the mixer according to the formula ratio. The mixing time is 6-10 imizuzu, ensuring that the humectants and preservatives are evenly distributed.
4.3.3 Tempering:
The mixed raw materials are sent to the tempering device for tempering treatment. The tempering temperature is controlled at 85-98℃, the tempering time is 3-5 imizuzu, and the moisture content after tempering is 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:
The tempered raw materials are sent to the HTS BASIC series twin-screw extruder for extrusion puffing. The screw speed is controlled at 150-300 rpm, the extrusion temperature of the feeding section is 75-90℃, icandelo lokunyibilika yi-120-140℃, and the homogenizing section is 140-150℃. The extrusion pressure is controlled at 2-5MPa, and the compression ratio is 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 Ukusika:
The extruded products are cut into short particles by the rotary knife, with a length of 4-8mm.
4.3.6 Ukupholisa:
The cut products are cooled to room temperature in the cooling equipment, which takes 10-15 imizuzu. Cooling can prevent the product from deteriorating due to high temperature.
4.3.7 Ukupakishwa:
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. Iimpawu zokupakisha zinokuhlengahlengiswa ngokweemfuno zabathengi.
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 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; 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 Solutions:
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 Solutions:
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 Solutions:
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, Isitora esipholileyo nesingena umoya, 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 Solutions:
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, but also provide a complete set of service systems, from pre-sales consulting, equipment selection, formula design, to in-sales installation, ukugunyazisa, uqeqesho, 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, umthamo wemveliso, 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.
Ukwengeza, 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. The installation and commissioning process will strictly follow the equipment installation specifications to ensure that the extruder and its matching auxiliary equipment (mixer, tempering device, dryer, seasoning machine, njl.) are accurately installed and connected. Technicians will debug all operating parameters of the equipment according to the customer’s product formula and production process requirements, and conduct trial production until the product quality meets the customer’s expected standards.
Ngaxeshanye, we provide on-site operational training for the customer’s production team, including equipment basic structure and working principle, daily operation steps, parameter adjustment skills, basic fault identification and handling. We will also provide a detailed operation manual and maintenance manual, 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.
Ukwengeza, we provide a long-term supply of genuine spare parts, with a large number of common spare parts (such as screw elements, kufa iintloko, 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:
Itheyibhile 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 |
| I-Screw Diameter (mm) | 30/45/65 | 80/95/110 | 65/80/95/110 (customizable) |
| Compression Ratio | 4:1 ~ 8:1 (iyahlengahlengiswa) | 5:1 ~ 10:1 (iyahlengahlengiswa) | 4:1 ~ 12:1 (customizable) |
| Isantya seScrew (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) |
| Uxinzelelo lwe-Extrusion (MPa) | 2 ~ 8 | 3 ~ 10 | 2 ~ 12 |
| Isakhono seMveliso (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) |
| Control System | 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 (optional) | 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) |
| Weight (t) | 0.8 ~ 2.5 | 3.0 ~ 8.0 | 2.0 ~ 10.0 (customizable) |
| Core Advantages | High cost-effectiveness, easy operation, 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.
Umphanda & 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, Iiprotheyini eziphezulu zokutya kwezilwanyana zasekhaya.
Control System: Umsebenzi wokugcina ifu we-HTS PREMIUM uchungechunge unokuqonda ukulungiswa kwepharamitha ekude kunye nokubeka iliso kwidatha yokuvelisa, olulungele amashishini ukwenza ulawulo lwemveliso ekrelekrele.
8. Uphuhliso lwexesha elizayo lweTekhnoloji ye-Pet Food Extrusion kunye noYilo lwethu
Ngokuphuculwa okuqhubekayo kweshishini lehlabathi lokutya kwezilwanyana zasekhaya, Imarike yokutya kwezilwanyana zasekhaya ibonisa iindlela ezintsha zophuhliso ezifana nokuphela okuphezulu, ukusebenza, ukwenziwa ngokwendalo kunye nokwahlukahlukana, ebeka phambili iimfuno eziphezulu nezingqongqo ngakumbi kwitekhnoloji yokulungisa ukutya kwezilwanyana zasekhaya kunye nezixhobo.
8.1 Iindlela zoPhuhliso lweTekhnoloji ye-Pet Food Extrusion
Intelligent and Digital Processing: Ukudityaniswa kwe-Intanethi yeshishini, ubukrelekrele bokwenziwa kunye nezixhobo ze-extrusion ziya kuba yinto eqhelekileyo. 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. Ukuqukumbela
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.