Pelleted Feed
This is Ridley Aquafeeds manufacturing process which is broken down in to 5 steps; storage, preconditioning, drying, cooling and packing.
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Step 1
Raw material storage, weighing, mixing and grinding
Purchased raw materials are delivered into the mill and following quality control testing is put into a silo. These are locked off to prevent the addition of an incorrect raw material.
When a recipe is required to be manufactured it is weighed out in two tonne batches and finely ground. This provides improved physical and nutritional quality of the finished feed. This 'mash' of mixed raw materials is then stored in a silo prior to the preconditioner.
Step 2
Preconditioning, pressing and post conditioning
This is the cooking process in the manufacture of pelleted prawn feed. The mash needs to be cooked in order to make a discrete pellet. Starch in the form of wheat or wheat flour needs to be cooked or gelatinised while proteins in the diet are plasticised. This forms the matrix that holds the structure of the pellet and maintains water stability.
When feeding prawns, the water stability is vital for the performance of the feed. The feed is broadcast into the ponds and then once in the water the feed must remain intact for a minimum of two hours. In order to get this water stability the feed is pre- and post conditioned.
Live steam is added to the mash to start the gelatinisation of the starch in the mash – this is the preconditioning. High temperatures, pressures and shear forces in the pellet press further gelatinise the starch and form the pellet. Finally the product is held at a set temperature and moisture to finish the gelatinisation in a process of post conditioning.
When feeding prawns, the water stability is vital for the performance of the feed. The feed is broadcast into the ponds and then once in the water the feed must remain intact for a minimum of two hours. In order to get this water stability the feed is pre- and post conditioned.
Live steam is added to the mash to start the gelatinisation of the starch in the mash – this is the preconditioning. High temperatures, pressures and shear forces in the pellet press further gelatinise the starch and form the pellet. Finally the product is held at a set temperature and moisture to finish the gelatinisation in a process of post conditioning.
Step 3
Drying
As the product leaves the post conditioner it is moist and this needs to be dry to make the pellet shelf stable therefore preventing mould growth. It also allows the pellet to harden to aid with handling on farm and allow correct feed performance. The starch in the pellet continues to cook in the dryer so it is very important to control the heat so the product does not over dry and burn. On leaving the drier the product is about 8% moisture (depending on the product).
Steps 4 & 5
Cooling and packaging
The feed needs to be cooled down to prevent cooking and make the product shelf stable. If the pellet is to hot going into the bag then condensation can form on the bag and this will lead to mould production. Final sieving of the product is performed just prior to packing in order to reduce the level of dust and fines. Depending on the product, feed is bagged into 20kg, 500kg or 1000kg bags and sent either to our designated warehouse or direct to the farm.
Feed is packaged into bags designed to be stored in cool dry conditions.
While the bag structure is such that they are water resistant, small holes in the bag 'designed to allow product to breath' prevent them from being waterproof.
Feed is packaged into bags designed to be stored in cool dry conditions.
While the bag structure is such that they are water resistant, small holes in the bag 'designed to allow product to breath' prevent them from being waterproof.
Last updated: 2008-02-02