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Extrusion is an instrument of success!

If you read this page, obviously, you are interested in equipment for feed production or other extrusion products. Possibly, you’ve already heard of extrusion, possibly, even use extruder in a production, and may be, you only estimate in your mind whether it is advisable to purchase extrusion equipment. In any case, you will find out or will make sure once more, that extruder is a very serious instrument of earning money!

Extruders have found great application in pharmacology and food industry, building and metallurgy, agriculture and even energy! But whatever we produce, whether it is petfood, dry breakfasts or fuel briquettes at the heart of everything underlies barothermic process under the general name extrusion.

Many people in Ukraine, and in Russia also use extruders as a necessary unit in a technological process, not thinking about the benefit they bring! Let’s take, for example, a poultry farm with its own mixed feed factory. Change of fat free soybean oilcake (which, by the way, is the basic component of forage for poultries) into full-fat extruded soy allows to decrease feed production costs more than on 30%!

Arithmetic is simple: oilcake outvalues soy for 25%, soyaoil, in its turn, outvalues soy for 40%, and the average content of oil in soybeans is 20%. Taking into account that during feed processing we add at least 10% of oil into oilcake, by means of simple mathematical operation we can see that the ton of fat oilcake will cost on 60% more than ton of extruded beans. To be honest, we have to admit that some losses in moisture take place during the process of extrusion – the product is heated greately within an extruder (in case with soy above 150ºС), and as a result it vapours moisture intensively at the output. But still, agree that there's a world of difference between adding water and taking it away!

Here’s a suggested formula for you:

Certainly, it’s not difficult to count up your costs spent for the cooked feed-stuff and to compare it with that which is saled in supermarkets and pet-shops. It is a bright example of immediate gain income from the use of extruder. But why just extruder? – an unaware reader will ask. One can use, for example, pelleter or some kind of moulding press. That’s where we can describe in details – what is it all about the whole process of extrusion. In fact, extruder is an elaborate grinder in which the product is compressed by the screw flights. The process proceeds on high speed and pressure, wich leads to structural changes in the qualitative measures of the material. Besides, controllable heat supply takes place directly on the product. As a result of mechanical shearing, friction and steam effect the product is forced and spread out through the die openings.

Everybody from a child remembers corn sticks, which is nothing else but extruded corn groats. And now, just consider for a moment what would happen if you make a meal of 200 grammes of uncooked corn, even though if it is grinded up – you will get indigestion at best! At the same time 200 grammes of corn sticks will pleasantly dissolve in your stomach. Here’s another advantage of the extruder – almost complete digestion of extruded product by organism. Therefore cows, having a diet with the extruded feed, give much more milk, saplings gain weight much faster, poultry lay more eggs.

And what is more, extruder has another decisive advantage! Due to barothermic effect we get absolutely disinfected product – there is hardly anyone who could survive under the pressure in 50 atmospheres with the temperature of 150°C. Hence, there is an undeniable benefit – the possibility to use infected grain during feeed production!

We’ll make another example of the effective use of extruders. In agriculture, timber industry or in woodworking there are a lot of technological processes with such by-effect as enormous generation of wastes of plant origin, such as sawdust, straw, sunflower and rice husks, beet pulp, nutshell. A list may engage the whole page. These are either wasted or burnt inefficiently causing air pollution and problems with recycling. Handing and transportation of these materials is difficult due to their low bulk density. But what if we process them via extrusion? Lignin, contained in plant cells will polymerize under the the influence of high temperature and pressure within extruder. As a result we’ll get environment-friendly high density fuel briquette comparable by its calorific value with coal! It should be also noted that the whole process takes place without addition of any stuff (the binder is a natural lignin). The selling price of such briquette can reach 200 euro!

Bringing a result to all aforesaid, it is safe to say that the cost of the extruded product is much more higher than its cost before extrusion treatment.

I think it’s high time to add a spoon of tar. So, what does stop a buyer in his choise of extruder? Of course, it’s wide variety. Extruders are produced in many countries, thus a price can differ greatly! For example, Chinese extruder for soy processing with the productivity 500 kg/h can cost 4000 USD, but you will never find American or German ones for less than 50000 USD. The reasons of Chinese low prices are clear to everybody, but you have to be aware that you may be left alone with your problems such as wearing parts replacement. And what is so special with enormously expensive American one? Certainly, the point is in high quality of the materials employed, service maintenance and technology. It’s just technology which costs tons of money and which in fact turns out to be the description of technological process. So, what we can offer as a producer? First of all, it is equipment which is highly competitive with European extruders, with inexpensive durable spare parts and servicing. And above that all, you get the technology for free!

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