Ngokuthuthuka okuqhubekayo kwamazinga okuphila abantu kanye nokugcizelela okwandayo kokuhambisana nezilwane ezifuywayo, imboni yokudla kwezilwane ezifuywayo emhlabeni wonke iye yathuthuka ngokushesha eminyakeni yamuva. Izilwane ezifuywayo kancane kancane zibhekwa njengamalungu abalulekile omndeni, kanye nempilo yabo yokudla kanye nekhwalithi yokudla sekuyinto abagxile kuyo abanikazi bezilwane ezifuywayo. Lokhu kukhuthaze ukuthuthukiswa okuqhubekayo kobuchwepheshe bokulungisa ukudla kwezilwane ezifuywayo kanye nemishini, ukubeka phambili izidingo eziphakeme zokuphepha, umsoco, ukunambitheka nokubukeka kokudla kwesilwane. Sizibophezele ekuhlinzekeni ama-extruder angochwepheshe aklanyelwe ukukhiqizwa kokudla, onolwazi olucebile ekucutshungulweni kokudla kwezilwane ezifuywayo, futhi ingahlinzeka ngezixazululo ezihlosiwe zokucubungula izinhlobo ezahlukene zokudla kwezilwane ezifuywayo, ukusiza amabhizinisi ukuthuthukisa ukusebenza kahle kokukhiqiza, qinisekisa ikhwalithi yomkhiqizo, futhi uthole inzuzo emqhudelwaneni wezimakethe oshubile.
Lesi sihloko sizogxila emkhakheni wokudla kwezilwane ezifuywayo, ukuchaza kabanzi ngobuchwepheshe bokucubungula ukudla kwezilwane ezifuywayo, isimiso sokusebenza se-screw extrusion puffing, izinzuzo extruders yethu, kanye nokusetshenziswa okuqondile kwemishini ye-extrusion ekukhiqizeni ukudla kwezilwane ezifuywayo. Izophinde yengezelele nemingcele enemininingwane yobuchwepheshe, imininingwane yokucubungula kanye namaphuzu obuhlungu bezimboni ukuze kucebise okuqukethwe, ukuhlangabezana nemfuneko yokubalwa kwamagama ye 3000-4000 amazwi, futhi inikeze ireferensi ebanzi nephrofeshinali yezinkampani ezifanele kanye nabasebenzi embonini yokudla kwezilwane ezifuywayo.
1. Uhlolojikelele Lwemboni Yokudla Kwezilwane Ezifuywayo kanye Nezici Zokucubungula
1.1 Isimo Samanje kanye Nendlela Yokuthuthukiswa Kwemboni Yokudla Kwezilwane Ezifuywayo
Eminyakeni yakamuva, imakethe yokudla kwezilwane ezifuywayo emhlabeni wonke ikhombise ukukhula okuqhubekayo. Iqhutshwa izici ezifana nokwanda kwenani lezilwane ezifuywayo, ukuthuthukiswa kwemiqondo yokusetshenziswa kwezilwane ezifuywayo, kanye nokuthuthukiswa kwabahlali’ amandla okuthenga, isidingo sekhwalithi ephezulu, ukudla okufuywayo okunomsoco nokusebenzayo kuye kwaqhubeka nokukhuphuka. Ngokwezibalo ezifanele zedatha, usayizi wemakethe yokudla kwezilwane ezifuywayo emhlabeni jikelele udlulile 100 izigidigidi zamadola aseMelika, futhi kulindeleke ukuthi kugcinwe izinga lokukhula 5%-8% eminyakeni embalwa ezayo. Phakathi kwazo, ukudla kwesilwane esifuywayo esomile, njengohlobo lomkhiqizo ojwayelekile, akhawunti ngaphezu 60% yemakethe yokudla kwezilwane ezifuywayo isiyonke, kulandele imikhiqizo esemathinini emanzi, imikhiqizo engamanzi kanye nokudla okulula kwezilwane ezifuywayo.
Intuthuko yemboni yokudla kwezilwane ezifuywayo ibonakala kakhulu ezicini ezintathu: kuqala, umsoco kanye nempilo. Abanikazi bezilwane ezifuywayo banaka kakhulu ukwakheka kokudla okunomsoco, kanye nemikhiqizo enemvelo, i-additive-free, ukusebenza (njengobuhle bezinwele, ukondliwa kwesisu, ukulawula isisindo) izici zithandwa kakhulu; okwesibili, ukuhlukahluka kwezinhlobo zemikhiqizo. Ngokucebisa izinhlobo zezilwane ezifuywayo kanye nezidingo zomuntu ngamunye zabanikazi bezilwane ezifuywayo, ukudla kwezilwane ezifuywayo kuye kwathuthuka kancane kancane kubheke ekuhlukaniseni, njengokudla kwezilwane ezifuywayo iminyaka ehlukene (imidlwane, izinja ezindala, izinja ezindala), izinhlobo ezahlukene, kanye nezimo zomzimba ezahlukene; okwesithathu, ubuhlakani nokusebenza kahle kobuchwepheshe bokucubungula. Ukuze kuhlangatshezwane nesidingo esikhulu sokukhiqiza nokuqinisekisa ukuzinza kwekhwalithi yomkhiqizo, amabhizinisi okucubungula ukudla kwezilwane ezifuywayo ahlala ethula imishini yokucubungula ethuthukisiwe kanye nezinhlelo zokulawula ezihlakaniphile ukuze kuthuthukiswe ukusebenza kahle kokukhiqiza nokunciphisa izindleko zabasebenzi..
Ngokumelene nalesi sizinda, ubuchwepheshe be-extrusion puffing, njengobuchwepheshe obuyisisekelo bokucubungula ukudla kwezilwane ezifuywayo (ikakhulukazi imikhiqizo ekhukhumele eyomile), isibe ukhiye wokunquma izinga lokudla kwezilwane ezifuywayo kanye nokuncintisana kwamabhizinisi. Ama-extruder ethu aqeqeshiwe okukhiqiza ukudla kwezilwane athuthukiswa ngokuphendula izici zomkhakha kanye nesidingo semakethe, okungaxazulula ngempumelelo amaphuzu ezinhlungu ekucutshungulweni kokudla kwezilwane ezifuywayo futhi kusize amabhizinisi ukuba afinyelele ukukhiqizwa kwekhwalithi ephezulu nokusebenza kahle.
1.2 Ukuhlukaniswa Kokudla Kwezilwane Ezifuywayo kanye Nezici Zako Zokucubungula
Ukudla kwezilwane ezifuywayo kunezindlela ezihlukahlukene zokuhlukanisa, ezingahlukaniswa zibe izinhlobo ezahlukene ngokusho kobuchwepheshe bokucubungula, okuqukethwe kwamanzi, ifomu lomkhiqizo nokusetshenziswa. Phakathi kwazo, ngokobuchwepheshe bokucubungula kanye nokuqukethwe kwamanzi, ukudla kwezilwane ezifuywayo ikakhulukazi ihlukaniswe imikhiqizo eyomile ekhukhumele, imikhiqizo semi-manzi, imikhiqizo ethambile ekhukhumele, imikhiqizo esemathinini emanzi kanye nokudla okulula (noma ukuphatha). Uhlobo ngalunye lokudla kwezilwane ezifuywayo lunezici zalo ezihlukile zokucubungula kanye nezidingo zemishini, Ngokulandelayo:
1.2.1 Imikhiqizo Ephuhlisiwe Eyomile:
Ukudla kwesilwane esifuywayo esomile kuwuhlobo oluvame kakhulu lokudla kwezilwane ezifuywayo, ngokuqukethwe kwamanzi 10%-12%. Imikhiqizo yayo eyinhloko ihlanganisa ukudla kwenyama, ukudla kwenhlanzi, okusanhlamvu (ukolweni, ukolweni, irayisi), ubhontshisi wesoya, amavithamini, amaminerali nezinye izithasiselo. Inqubo yokucubungula imikhiqizo ekhukhumele eyomile ihlobene eduze nenqubo yokukhukhumeza, okudinga ukusetshenziswa kwemishini yokukhukhumeza i-extrusion ukucubungula izinto zokusetshenziswa zibe yimikhiqizo eyimbudumbudu enosayizi ofanayo, ukunambitheka okumnandi kanye nokunambitheka okuhle. Izici zemikhiqizo ekhukhumele eyomile ziyimpilo ende yeshalofu, isitoreji esikahle kanye nezinto zokuhamba, kanye nezindleko zokukhiqiza eziphansi, ezifanele ukukhiqizwa ngezinga elikhulu futhi ezidumile phakathi kwabanikazi bezilwane ezifuywayo.
Isidingo esibalulekile sokucutshungulwa kwemikhiqizo ekhukhumele ukuthi izinto ezingavuthiwe zidinga ukukhukhumala ngokuphelele, ukuze isitashi ezintweni zokusetshenziswa zigcwaliswe ngokuphelele nge-gelatinized, okusiza ukugayeka kokudla kanye nokumuncwa kwezilwane ezifuywayo. Ngesikhathi esifanayo, umkhiqizo udinga ukuba nobulukhuni obuthile kanye nokucwebezela ukuze uhlangabezane nezidingo zokuhlafuna izilwane ezifuywayo futhi usize ukuhlanza amazinyo azo. Lokhu kubeka izidingo eziphezulu kumfutho we-extrusion, izinga lokushisa kanye nesivinini sesikulufu se-extruder.
1.2.2 Imikhiqizo Semi-Wet:
Ukudla kwezilwane ezifuywayo ezimanzi kancane kunokuqukethwe kwamanzi 25%-35%, okuphakathi kwemikhiqizo eyomile nemanzi. Izinto zayo ezingavuthiwe zifana nemikhiqizo ekhukhumele eyomile, kodwa ama-humectants amaningi (njenge-propylene glycol, i-sorbitol) zengezwa ukuze kugcinwe ukuthambile nomswakama womkhiqizo. Inqubo yokucubungula imikhiqizo emanzi kancane nayo idinga ukwelashwa kokukhukhumala, kodwa izinga lokukhukhumala liphansi kunelemikhiqizo eyomile. Umkhiqizo unezici zokunambitheka okuthambile kanye nokunambitheka okuhle, elungele izilwane ezifuywayo ezinekhono elibi lokuhlafuna (njengezilwane ezifuywayo ezindala, izilwane ezifuywayo ezigulayo).
Ubunzima bokucutshungulwa kwemikhiqizo emanzi bulele ekulawuleni okuqukethwe kwamanzi kanye nokuvimbela ukuwohloka komkhiqizo.. Ngakho-ke, ohlelweni lokucubungula, kuyadingeka ukulawula ngokuqinile izinga lokushisa kanye nomswakama wesixhumanisi ngasinye, bese ukhetha izilondolozi kanye nama-humectants afanelekile ukuze uqinisekise impilo yeshalofu yomkhiqizo.
1.2.3 Imikhiqizo Ethambile:
Ukudla kwesilwane esifuywayo okuthambile kunokuqukethwe kwamanzi 15%-25%, okuwumkhiqizo phakathi kwemikhiqizo ekhukhumele eyomile kanye nemanzi kancane. Inqubo yayo yokucubungula iyafana neyemikhiqizo ekhukhumele eyomile, kodwa imingcele yefomula kanye ne-extrusion iyalungiswa ukuze wenze umkhiqizo uthambe futhi unwebeka. Imikhiqizo ethambile ekhukhumele ihlanganisa izinzuzo zemikhiqizo eyomile nemanzi kancane, enambitheka kahle kanye nokugaya kalula, elungele izinhlobonhlobo zezilwane ezifuywayo.
1.2.4 Imikhiqizo Esemathinini Emanzi:
Ukudla kwesilwane esifuywayo okusemathinini okumanzi kunokuqukethwe kwamanzi angaphezu kuka 70%, ikakhulukazi usebenzisa inyama entsha, izinhlanzi, imifino kanye nezinye izinto zokusetshenziswa, ezicutshungulwa ngokupheka, ukupheka, ukuvala inzalo nezinye izinqubo. Ihlukile kwezinye izinhlobo zemikhiqizo, imikhiqizo esemathinini emanzi ayidingi ukwelashwa kokukhukhuma, futhi izixhumanisi zabo eziyinhloko zokucubungula ukupheka nokuvala inzalo. Umkhiqizo unezici zokudla okucebile, ukunambitheka okuqinile kanye nomswakama ophezulu, elungele izilwane ezifuywayo ezingawathandi amanzi okuphuza noma ezidinga umsoco owengeziwe.
Isihluthulelo sokucutshungulwa kwemikhiqizo esemathinini emanzi ukuqinisekisa ukusha nokuphepha kwezinto ezingavuthiwe, futhi ulawule ngokuqinile izinga lokushisa lokuvala inzalo kanye nesikhathi sokubulala amagciwane ayingozi emkhiqizweni futhi andise impilo yeshalofu. Ngesikhathi esifanayo, kuyadingeka ukuqinisekisa ukuthi izingxenye zokudla okunomsoco zomkhiqizo azilahleki ngesikhathi sokupheka kanye nenqubo yokuvala inzalo.
1.2.5 Izilwane ezifuywayo (noma Iziphambeko):
Ukudla okulula kwezilwane ezifuywayo kungukudla okusizayo kwezilwane ezifuywayo, ikakhulukazi esetshenziselwa ukuklomelisa izilwane ezifuywayo, ngcono imizwa yabo futhi wengeze umsoco. Izinhlobo zokudla okulula kwezilwane ezifuywayo zihlukahlukene, kuhlanganise nokudla okulula okukhukhumele, ukudla okulula kwenyama, ukudla okulula, ukudla okulula kwamazinyo, njll. Phakathi kwazo, ama-snacks akhukhumele ahlanganisa ingxenye enkulu, futhi inqubo yabo yokucubungula ifana nemikhiqizo ekhukhumele eyomile, kodwa ifomula icwengisiswe kakhulu, kanye nama-flavoring agents amaningi kanye nezithasiselo ezisebenzayo zengezwa ukuze kuhlangatshezwane nezidingo zokunambitheka kanye nokusebenza kwezilwane ezifuywayo.
Ukudla okulula kwezilwane ezifuywayo kunezidingo eziphezulu zokunambitha, ukubukeka nokusebenza. Ngokwesibonelo, ukudla okulula kwamazinyo kudingeka kube nobulukhuni obuthile kanye nokuthungwa ukusiza ukuhlanza amazinyo esilwane esifuywayo futhi kuvimbele ukubala kwamazinyo.; Ukudla okulula okuhlobisa izinwele kudinga ukwengeza izithako ezifana ne-lecithin ukusiza ukuthuthukisa ikhwalithi yezinwele zesilwane esifuywayo.. Lokhu kudinga i-extruder ukuthi ibe nokuguquguquka okuhle kanye nokulungiswa ukuze kuhlangatshezwane nezidingo zokucubungula zezinhlobo ezahlukene zokudla okulula.
Kuyaphawuleka ukuthi ngaphandle kwemikhiqizo ekheniwe, izinhlobo eziningi zokudla kwezilwane ezifuywayo zihlobene eduze nenqubo yokukhukhumeza. Ukukhukhumeza akuyona nje ingxenye eyinhloko yokucubungula ukudla kwezilwane ezifuywayo, kodwa futhi kuthinta ngqo izinga, ukunambitha, umsoco kanye nokugayeka kokudla kwesilwane esifuywayo. Ngakho-ke, ukukhetha imishini efanele ye-extrusion kanye nokuba nobuchule kubuchwepheshe besayensi be-extrusion kubalulekile emabhizinisini okucubungula ukudla kwezilwane ezifuywayo.
2. Ubuchwepheshe obuyinhloko bokucubungula ukudla kwezilwane ezifuywayo: I-Extrusion Puffing Technology
Ubuchwepheshe be-Extrusion puffing buyinhloko yokucubungula ubuchwepheshe obuhlanganisa ukuxuba, ukuxova, ukushisa, extrusion kanye ukukhukhumala. Isetshenziswe kabanzi ekukhiqizeni ukudla kwezilwane ezifuywayo ngenxa yezinzuzo zayo zokusebenza kahle kokukhiqiza, izinga lomkhiqizo elihle, ukuzivumelanisa nezimo okuqinile kuzinto ezingavuthiwe kanye nobubanzi bohlelo lokusebenza olubanzi. Ekucutshungulweni kokudla kwezilwane ezifuywayo, ubuchwepheshe be-extrusion busetshenziswa kakhulu ukubona ukukhukhumeza kwezinto ezingavuthiwe, yenza isitashi gelatinize, i-protein denature, futhi uthuthukise ukuthandeka nokugayeka kokudla komkhiqizo. Ngesikhathi esifanayo, kungaphinde kubulale amagciwane ayingozi ezintweni ezingavuthiwe, qinisekisa ukuphepha kokudla kwezilwane ezifuywayo.
2.1 Izici Zokudla Kwezilwane Ezifuywayo Nezimfuneko Zezinsiza Zokukhipha
Izinto ezisetshenziswayo zokudla kwezilwane ezifuywayo ikakhulukazi yimikhiqizo yenyama (njengokudla kwenyama, ukudla kwenhlanzi, inyama entsha), okusanhlamvu, ubhontshisi wesoya, amavithamini, amaminerali nezinye izithasiselo. Phakathi kwazo, imikhiqizo yenyama yenza ingxenye enkulu, ukwenza umkhiqizo ube ne-viscosity eqinile. Lesi sici sibeka phambili izidingo ezikhethekile zemishini ye-extrusion:
Ama-extruder ane-screw single awafanele ukukhiqizwa kwezomnotho kokudla kwezilwane ezifuywayo. Ngoba i-extruder yesikulufu esisodwa inobubanzi obuncane bokugunda, amandla okumpompa ampofu futhi akukho mphumela wokuzihlanza. Lapho ucubungula izinto ze-viscous ezifana nemikhiqizo yenyama, kulula ukubangela ukunqwabelana kwezinto, ukuvinjelwa kanye nokuxuba okungalingani emgqonyeni we-extruder, okungathinti nje ukusebenza kahle kokukhiqiza, kodwa futhi kuholela kwikhwalithi yomkhiqizo engazinzile. Ngaphezu kwalokho, i-single-screw extruder isebenzisa amandla aphezulu lapho icubungula izinto zokusetshenziswa ezinamafutha amaningi kanye namaprotheni amaningi, okwandisa izindleko zokukhiqiza zamabhizinisi.
I-Twin-screw extruders, Ngokolunye uhlangothi, babe nezinzuzo ezisobala ekukhiqizeni ukudla kwezilwane ezifuywayo. Banobubanzi obubanzi bokugunda, umphumela wokupompa osebenza ngempumelelo kanye nomphumela wokuzihlanza, ezingaxazulula ngempumelelo izinkinga ze-viscosity yezinto ezibonakalayo nokuqoqwa. I-twin-screw extruder ingabona ukuxubana okufanayo, ukuxova nokukhishwa kwezinto, ngisho nalapho kucutshungulwa izinto zokusetshenziswa ezinamafutha amaningi kanye nenyama entsha, futhi ingaqinisekisa ukukhiqizwa okuzinzile kanye nekhwalithi yomkhiqizo engaguquki. Ngakho-ke, ekukhiqizeni kwangempela kokudla kwezilwane ezifuywayo, ama-twin-screw extruder asephenduke indlela eyinhloko yokukhukhumeza ukudla kwezilwane ezifuywayo, futhi asetshenziswa kakhulu ekukhiqizeni imikhiqizo ekhukhumele eyomile, imikhiqizo semi-manzi, imikhiqizo ethambile ekhukhumele kanye nokudla okulula kwezilwane ezifuywayo.
2.2 Umgomo Osebenzayo We-Screw Extrusion Puffing
I-screw extrusion puffing process yokudla kwesilwane esifuywayo iyinqubo eyinkimbinkimbi ngokomzimba namakhemikhali, okubandakanya ukusebenzisana kwezinto eziningi ezifana nezinga lokushisa, ingcindezi, phuca amandla nesikhathi. Umgomo othize wokusebenza umi kanje:
Okokuqala, ukwelashwa kwempahla eluhlaza. Izinto zokusetshenziswa eziyimpuphu eziqukethe inani elithile lesitashi (Ngaphezu kwe 20%) zixubene ngokulinganayo ngokwefomula, bese ithunyelwa emshinini wokuthambisa ukuze yolashwe. Inhloso yokufudumeza ukulungisa umswakama kanye nezinga lokushisa kwezinto, ukuze izinto zokwakha zifinyelele esimweni esifanele ngaphambi kokungena ku-extruder. Ngokuvamile, umswakama wezinto ezisetshenziswayo ngemuva kokushiswa kulawulwa ku-10%～27%, futhi izinga lokushisa likhuphukele ku-70℃98℃. Ngesikhathi senqubo yokushisa, izinto zimunca amanzi ngokulinganayo, okuyinto ehambisana ne-gelatinization elandelayo yesitashi kanye nokuguqulwa kwamaprotheni, futhi kunganciphisa ukuguga kwesikulufu se-extruder kanye nomgqomo.
Okwesibili, extrusion futhi bafudumale. Izinto ezithambile zingena ku-screw extrusion cavity ngedivayisi yokuphakelayo. I-screw extrusion cavity yenziwe ngesikulufu kanye nomgqomo, futhi umthamo we-extrusion cavity uyancipha kancane kancane eduze kwesiqondiso se-axis. Lapho isikulufu sizungeza, iphushela izinto phambili ngokuqhubekayo, futhi izinto zokwakha zicindezelwa kancane kancane ngaphansi kwesenzo se-screw kanye nomgqomo, futhi ingcindezi emgodini we-extrusion ikhula kancane kancane. Isilinganiso sokucindezela (isilinganiso sevolumu yento ekupheleni kokuphakelayo kuya kuvolumu ekugcineni kwe-extrusion) ingafinyelela ku-4～10, okuhlukahluka kuye ngohlobo lokudla kwesilwane esifuywayo kanye nefomula yezinto ezingavuthiwe.
Ngesikhathi senqubo yokuphushwa nokukhishwa ngesikulufu, izinto ezisetshenziswayo zingaphansi kwe-shear force enamandla kanye namandla okungqubuzana. Amandla okugunda akhiqizwa ukunyakaza okuhlobene phakathi kwesikulufu kanye nomgqomo, kanye naphakathi kwezindiza eziyisikulufa. Ingaphula izinhlayiya zezinto, yenza izinto zokusetshenziswa kanye nezithasiselo zixube ngokulinganayo, futhi ukhuthaze i-gelatinization yesitashi kanye ne-denaturation yamaprotheni. Amandla okungqubuzana akhiqizwa phakathi kwezinto kanye nodonga lwangaphakathi lomgqomo, kanye naphakathi kwezinhlayiya zezinto ezibonakalayo, okungadala ukushisa okuningi, okuhambisana nokushisisa kwezinto. Ngaphezu kwalokho, ngokwezidingo zokucubungula, umusi ungageleza ngebhantshi lomgqomo ukushisa izinto phakathi kwezindonga, ukuze izinto ezingaphakathi kwe-extrusion cavity zisesimweni sokushisa okuphezulu kanye nengcindezi ephezulu. Izinga lokushisa ku-extrusion cavity ngokuvamile lilawulwa ku-120℃180℃, futhi ingcindezi ilawulwa ku-2～10MPa.
Okwesithathu, isitashi gelatinization kanye amaprotheni denaturation. Ngaphansi kwesenzo sokushisa okuphezulu, umfutho ophezulu kanye namandla okugunda, isitashi ezintweni zimunca amanzi futhi andise, isakhiwo sekristalu siyabhujiswa, futhi iguqulwa ibe yisimo se-amorphous, okuthiwa isitashi gelatinization. I-starch gelatinization ingathuthukisa ukugayeka kokudla kwezilwane ezifuywayo, ngoba isitashi se-gelatinized kulula ukubola ngama-enzyme wokugaya wezilwane ezifuywayo. Ngesikhathi esifanayo, isitashi se-gelatinized singakwazi futhi ukuthuthukisa i-viscosity namandla okubopha kwezinto, 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. Ngesikhathi esifanayo, the denatured protein can also form a network structure, which can wrap the starch and other components, helping to maintain the shape of the puffed product.
Okwesine, puffing and shaping. When the materials in the high-temperature and high-pressure state are pushed to the die head by the screw and extruded from the die hole at a high speed, the temperature and pressure of the materials drop sharply because they suddenly leave the extrusion cavity and enter the normal atmospheric environment. Under the combined action of pressure difference and temperature difference, the water in the materials evaporates rapidly, the volume of the materials expands rapidly (the expansion rate can reach 2～8 times), and the materials are dehydrated and solidified quickly to form a porous, crisp or soft puffed product.
After extrusion from the die hole, the puffed materials are cut into short particles of uniform length by the cutting device (rotary knife) installed at the die head. The length of the particles can be adjusted by changing the speed of the rotary knife to meet the requirements of different types of pet food. Ngokwesibonelo, izinhlayiya zokudla komdlwane zincane futhi zifushane, kuyilapho izinhlayiya zokudla kwenja yabantu abadala zikhudlwana futhi zinde.
Okwesihlanu, ngemuva kokucubungula. Izinhlayiya ezikhukhumeziwe ezikhishiwe zidinga ukudlula izixhumanisi zangemuva kokucubungula ezifana nokomisa, ukupholisa, isinongo nokupakishwa ukuze kube imikhiqizo yokugcina yokudla kwezilwane ezifuywayo. Ukomisa kuwukwehlisa izinga lamanzi ezinhlayiya ebangeni elijwayelekile (10%-12% ngemikhiqizo eyomile), ukuze kunwetshwe impilo yeshalofu yomkhiqizo. Ukupholisa ukwehlisa izinga lokushisa lezinhlayiya ezomisiwe ekamelweni lokushisa, vimbela umkhiqizo ukuthi ungamaki futhi uwohloke. I-seasoning iwukufafaza ama-flavour agents, ezikhangayo nezinye izithasiselo ebusweni izinhlayiya ukuthuthukisa ukunambitheka komkhiqizo. 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, usayizi wezinhlayiyana, moisture content and nutritional composition of raw materials have a great impact on the puffing effect. Ngokwesibonelo, 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 Imeshi. 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, it is easy to cause material blockage and increase energy consumption. The moisture content of raw materials before tempering should be controlled at 8%-12%. If the moisture content is too high, 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. Ngokwesibonelo, 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 ku 600 rpm. The higher the screw speed, the greater the shear force and friction force received by the materials, the higher the extrusion temperature and pressure, and the better the puffing effect. Nokho, 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: ingxenye yokudla, melting section and homogenizing section. The temperature of the feeding section is lower (70～90℃), which is mainly to prevent the materials from caking and ensure the smooth feeding; the temperature of the melting section is medium (120～150℃), which is mainly to promote the melting and plasticization of the materials; the temperature of the homogenizing section is higher (150～180℃), which is mainly to ensure the uniform mixing and full gelatinization of the materials.
Extrusion pressure is generally 2～10MPa. The pressure in the extrusion cavity is mainly determined by the compression ratio of the screw, the die hole size and the screw speed. The higher the extrusion pressure, the better the puffing effect, but if the pressure is too high, it will increase the energy consumption and wear of the equipment; if the pressure is too low, the puffing effect is poor, and the product is loose and easy to break.
2.3.4 Die Head Structure:
The die head structure mainly includes the number, shape and size of die holes. The shape of the die hole determines the cross-sectional shape of the puffed product, such as circular, square, triangular and other shapes. The size of the die hole determines the initial diameter of the product. The smaller the die hole size, the greater the extrusion pressure, and the better the puffing effect, but the production capacity will be reduced. The number of die holes affects the production capacity. The more the number of die holes, the higher the production capacity, but it is necessary to ensure that the pressure distribution is uniform, so as to avoid uneven puffing of the product.
3. Our Extruders: Advantages and Product Series for Pet Food Production
We have long been engaged in the research, development and production of food-grade extruders, and have developed a series of twin-screw extruders specially suitable for pet food production according to the characteristics of pet food processing and the needs of enterprises. Our extruders have the advantages of low operating cost, wide application range, advanced technology and reliable process control, which can meet the processing needs of various types of pet food and help enterprises improve production efficiency and product quality.
3.1 Main Advantages of Our Extruders
3.1.1 Low Lifetime Operating Cost:
We focus on the durability and economy of the equipment, and adopt high-quality materials and advanced manufacturing technology to ensure that the extruder has a long service life and low operating cost. The inner wall of the barrel is made of high-quality wear-resistant alloy steel, which has extremely strong wear resistance and can effectively resist the wear caused by the friction between the materials (especially the materials containing hard particles such as bone meal) 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.
Ngaphezu kwalokho, 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. Ngesikhathi esifanayo, 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 Ibanga Lohlelo Olubanzi:
Our twin-screw extruders have strong adaptability and can meet the processing needs of various types of pet food, including dry puffed products, imikhiqizo semi-manzi, imikhiqizo ethambile ekhukhumele, 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, umgqomo, 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. Ngokwesibonelo, 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.
Isistimu yokulawula ehlakaniphile nayo inokuqapha kwesikhathi sangempela nemisebenzi ye-alamu. Ingakwazi ukuqapha amapharamitha angukhiye njengezinga lokushisa le-extrusion, ingcindezi ye-extrusion, isivinini sesikulufa, umswakama obalulekile kanye namandla okukhiqiza ngesikhathi sangempela. Uma noma iyiphi ipharamitha idlula ububanzi obumisiwe, uhlelo luzokhipha ukwaziswa kwe-alamu ngesikhathi, futhi nokuvala ngokuzenzakalelayo okokusebenza uma kunesidingo, ukugwema ukwehluleka kwemishini kanye nezinkinga zekhwalithi yomkhiqizo. Ngaphezu kwalokho, uhlelo lokulawula lwamukela isixhumi esibonakalayo sokusebenza kwesikrini sokuthinta, okuyinto elula futhi enembile, kulula ukusebenza, futhi inganciphisa izidingo zomsebenzisi.
3.1.4 Ukuzinza Kwekhwalithi Yomkhiqizo Okuhle:
Ngenxa yesistimu yokulawula ehlakaniphile ethuthukisiwe, ukuxuba umfaniswano kanye plasticization egcwele materials, imikhiqizo ecutshungulwa ama-extruder ethu inekhwalithi ezinzile. Usayizi wezinhlayiyana, umumo, ubulukhuni, crispness and nutritional composition of the products are uniform, which can meet the strict quality requirements of pet food. Ngesikhathi esifanayo, 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 Ukusebenza Okuphezulu Kokukhiqiza:
Ama-twin-screw extruder ethu asebenza kahle kakhulu ekukhiqizeni, ephakeme kakhulu kunaleyo ye-single-screw extruder. The production capacity of our extruders ranges from 100kg/h to 2000kg/h, engahlangabezana nezidingo zokukhiqiza zezikali ezihlukene zamabhizinisi (encane, eliphakathi nelilikhulu). 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. Ngaphezu kwalokho, 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, umsindo ophansi, 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.
Mayelana nomklamo wesakhiwo, 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 ukunemba kwemishini nokwelashwa kokushisa, 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, amakhanda afe, izinsiza zokudla, 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. Ngokwesibonelo, 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.
Ngaphezu kwalokho, 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, umgqomo, fa ikhanda) 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. Ngesikhathi esifanayo, 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. Ngokwesibonelo, 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 amathani), 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 amathani), 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, ukuthunywa, ukuqeqeshwa, 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. Ngakho-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 Ukulungiswa Kwempahla Engahluziwe:
The raw materials of dry puffed pet food mainly include meat meal (chicken meal, beef meal, ukudla kwenhlanzi), okusanhlamvu (corn flour, wheat flour, rice flour), ubhontshisi wesoya, amavithamini, 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 Imeshi, which is conducive to uniform mixing and full plasticization.
4.1.2 Ukuxuba:
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%. Ngesikhathi senqubo yokushisa, 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. Ngaphansi kwesenzo sokushisa okuphezulu, umfutho ophezulu kanye namandla okugunda, 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 Ukomisa:
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%, ukuze kunwetshwe impilo yeshalofu yomkhiqizo. 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℃), futhi isikhathi sokupholisa sinjalo 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 Ukupakisha:
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, njll. 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 (isivinini sesikulufa, izinga lokushisa, ingcindezi) directly affect the puffing effect and product texture; the drying parameters (izinga lokushisa, isikhathi) 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
Ukudla okulula kwezilwane ezifuywayo kunezidingo eziphezulu zokunambitha, ukubukeka 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 Ukulungiswa Kwempahla Engahluziwe:
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 kwazo, 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 Imeshi, which is conducive to the formation of the product and the improvement of the texture.
4.2.2 Ukuxuba:
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℃, the melting section is 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 Ukomisa:
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 Ukupakisha:
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 izilwane ezifuywayo ezinekhono elibi lokuhlafuna. 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 Ukulungiswa Kwempahla Engahluziwe:
The raw materials of semi-wet pet food mainly include meat meal, ukudla kwenhlanzi, okusanhlamvu, ubhontshisi wesoya, 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 Imeshi.
4.3.2 Ukuxuba:
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℃, the melting section is 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 Ukupakisha:
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 Izixazululo:
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 Izixazululo:
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 Izixazululo:
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 Izixazululo:
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 Ukuvinjwa Kwezisetshenziswa
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 Izixazululo:
Yehlisa umswakama wezinto ezingavuthiwe; uchoboze izinto zokusetshenziswa zibe usayizi wezinhlayiyana ezidingekayo; Hlanza izinto zokusetshenziswa ukuze ususe ukungcola; khulisa isivinini sesikulufa; hlola ukuguga kwesikulufa nomgqomo, buyisela izingxenye ezigugile.
6. Uhlelo lwethu lwesevisi: Ukukusekela Ukuze Uzuze Ukukhiqizwa Kwekhwalithi Ephezulu
Asinikezi kuphela ama-extruder ekhwalithi ephezulu okukhiqizwa kokudla kwezilwane ezifuywayo, kodwa futhi unikeze isethi ephelele yezinhlelo zesevisi, kusukela ekubonisaneni kwangaphambi kokuthengisa, ukukhethwa kwemishini, umklamo wefomula, ekufakweni kokuthengiswayo, ukuthunywa, ukuqeqeshwa, kanye nokugcinwa kokuthengiswa ngemuva kokuthengisa, isiqondiso sobuchwepheshe, ukuhlinzeka ngezinsizakalo zokuma okukodwa kumakhasimende, ukusiza amakhasimende ukuxazulula izinkinga ezihlukahlukene ekukhiqizeni futhi azuze ukukhiqizwa kwekhwalithi ephezulu nokusebenza kahle.
6.1 Isevisi yangaphambi kokuthengisa
Ithimba lethu lesevisi yangaphambi kokuthengisa lakhiwe abasebenzi bezobuchwepheshe abanolwazi olucebile ekucubunguleni ukudla kwezilwane ezifuywayo. We will conduct in-depth communication with customers to understand their product types, umthamo wokukhiqiza, 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.
Ngaphezu kwalokho, 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, isomisi, seasoning machine, njll.) 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.
Ngesikhathi esifanayo, 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 Isevisi yangemuva kokuthengisa
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.
Ngaphezu kwalokho, we provide a long-term supply of genuine spare parts, with a large number of common spare parts (such as screw elements, amakhanda afe, 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:
Ithebula 1: Technical Parameters of Excellence Pet Food Twin-Screw Extruder Series
表格
| Parameter Category | HTS BASIC Series (Entry/Mid-scale) | HTS STANDARD Series (Okukhulu) | HTS PREMIUM Series (High-end Custom) |
|---|---|---|---|
| Screw Structure | I-parallel twin-screw, ukujikeleza ngokubambisana | I-parallel twin-screw, ukujikeleza ngokubambisana | I-parallel twin-screw, ukujikeleza ngokubambisana |
| Isikulufa Ububanzi (mm) | 30/45/65 | 80/95/110 | 65/80/95/110 (customizable) |
| Compression Ratio | 4:1 ~ 8:1 (iyalungiseka) | 5:1 ~ 10:1 (iyalungiseka) | 4:1 ~ 12:1 (customizable) |
| Isivinini 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) |
| I-Extrusion Pressure (I-MPa) | 2 ~ 8 | 3 ~ 10 | 2 ~ 12 |
| Amandla Okukhiqiza (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) |
| Isistimu yokulawula | I-PLC + touch screen, basic formula memory (≤20 groups) | I-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 (ngokuzikhethela) | 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) |
| Isisindo (t) | 0.8 ~ 2.5 | 3.0 ~ 8.0 | 2.0 ~ 10.0 (customizable) |
| Core Advantages | High cost-effectiveness, ukusebenza okulula, suitable for initial pet food enterprises | Okukhiphayo okuphezulu, ukusetshenziswa kwamandla okuphansi, ukusebenza okuzinzile, 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.
Umgqomo & Screw Material: The gradient material selection is to adapt to different raw material abrasiveness—HTS BASIC for ordinary meat meal/cereal raw materials, HTS STANDARD/ PREMIUM for raw materials containing bone meal, calcium powder and other hard particles, effectively extending the service life of core components.
Feeding Method: The multi-channel feeding port of HTS PREMIUM series can realize the precise addition of liquid raw materials (such as fresh meat slurry, vegetable oil) and grease, which is suitable for the production of high-fat, high-protein high-end pet food.
Isistimu yokulawula: 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, ukusebenza kahle, 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) liyakhula, 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; ngesikhathi esifanayo, 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, isilinganiso sokucindezela, 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); ngesikhathi esifanayo, 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 “imishini + formula + inqubo”; ngesikhathi esifanayo, 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. Isiphetho
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, futhi yethule uhla olugcwele lwemikhiqizo ye-twin-screw extruder emelwe uchungechunge lwe-HTS, okuxazulula ngokuphelele ubunzima bokucubungula obubangelwa i-viscosity ephezulu, amafutha aphezulu kanye nezinto zokusetshenziswa ezihlukahlukene zokudla kwezilwane ezifuywayo.
Ama-extruder ethu anezinzuzo zezindleko zokusebenza eziphansi zokuphila konke, wide application range, advanced technology and reliable process control, futhi afakwe uhlelo oluphelele lwesevisi yokuma okukodwa kusukela ekuthengisweni kwangaphambili kuya ekuthengisweni kwangemva kokuthengisa. Imingcele yezobuchwepheshe enemininingwane futhi elungisekayo yochungechunge ngalunye ingahlangabezana nezidingo zokukhiqiza zamabhizinisi okudla kwezilwane ezifuywayo zezikali ezihlukene nezinhlobo zomkhiqizo., kusukela ezingeni lokungena lokudla okukhukhumele okomile kuya ekudleni okulula okusebenzayo okwenziwe ngokwezifiso.
Esikhathini esizayo, ngokuthuthukiswa okuqhubekayo kwemboni yokudla kwezilwane ezifuywayo, sizoqhubeka nokuthatha ukuqanjwa kabusha kwezobuchwepheshe njengomongo, thatha isidingo samakhasimende njengomhlahlandlela, and constantly optimize and upgrade our extrusion equipment and service system, striving to provide more efficient, ukonga amandla, 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.