正大鱼料生产设备及工艺1课件

1、鱼料生产粗粉碎 COARSE原料仓 RAW MATERIAL BIN配料 WEIGHTING细粉碎 FINE GRINDING 第一次混合 FIRST MIXING投料1 INTAKE 1 投料2 INTAKE 2过筛 SCREEN第二次混合SECOND MIXING鱼油鱼料生产工艺流程FISH FEED PRODUCTION PROCESS FLOW鱼料生产工艺流程 FISH FEED PRODUCTION PROCESS FLOW蒸汽 STEAM水 WATER膨化 EXTRUSION干燥 DRYING冷却 TEMP. REDUCTION油脂喷涂 FAT COATING筛分 SIZING包装

2、 PACKING蒸汽 STEAM鱼油 FISH OIL使用膨化机的鱼料生产Fish Feed Production by Extruder 鱼料生产主要设备Fish Feed Production Machine膨化机 Extruder烘干机 Dryer油脂喷涂机 Fat Coating冷却器 Cooler膨化制粒机 EXTRUDER分料圆桶 CIRCULAR BIN 喂料器 FEEDER调质器 CONDITIONER膨化机 EXTRUDER主要构成 Main Components 膨化过程 EXTRUSION膨化过程是用螺杆螺套将料送入膨化机内,使原料接受搓揉、打磨、搅拌及内部剪切的一种过程

3、，在这个过程中，热量骤升，原料细胞壁遭到破坏，由于热、水份、高压及时间的共同作用而对原料进行蒸煮，淀粉因此变成糊状形成所谓的“糊化” ，同时，淀粉、蛋白、脂肪结构发生变形形成所谓的“塑化” ，从而可获得各种各样所需要的形状。is the process of feeding raw material through screw that causes kneading, grinding, mixing, inner shear force. This time heat has been occurred and cell wall will break away. The factor o

4、f heat, moisture, high pressure, time make material cooked. Starch will change status to gelatin called “Gelatinization” . Mean time the structure of starch, protein, fat will be changed call “Plasticization” . This can form many shapes as require 膨化过程 EXTRUSION 因螺套内的压力高于大气压力,当料挤出压模时，压力便会骤减而产生爆破与迅速膨

5、胀，故有空气泡生成。 Since the pressure inside screw is higher than atmosphere pressure, when material pass DIE out. The pressure has been changed rapidly that causes blast and expansion. Air bubbles will take place. 膨化过程也可以称作HT/ST过程(高温 / 瞬时) Extrusion process also can be called as HT/ST process (High Tempera

6、ture / Short Time) 优点 Advantages- 减少微生素与氨基酸损失 Less vitamin and amino acid loss- 减少营养成分损失 Less nutrient loss 1. 压力 2. 温度 120-150 C Temperature 120-150 C 3. 水份 24-28 % Moisture 24-28 % 用膨化机制粒：Pelletization by EXTRUDER - 膨化前的料应满足 : 水份16%, 温度 90 C Pre-extruded feed should : moisture 16%, temperature 90

7、C - 水份 24-28 %, 温度 120-150 C时熟化效果好 Feed will be good cooked at moisture 24-28 %, temperature 120-150 C - 借助于压模和切刀可以控制原料形状与密度。 Be able to control the shape and density by DIE and pellet cutSource : Feed Tech IV 1994 膨化过程 EXTRUSION作用：储存料与保证原料连续送入膨化机。分料圆桶内的料位不应低于桶高的 1/3 以防止蒸汽倒窜与湿料粘桶。Function is staying

8、 and keeping feed in order to feed to EXTRUDER constantly. The feed level in circular bin should not less than 1/3 of bin for the purpose of preventing contrary steam and stuck of wet feed.分料圆桶 CIRCULAR BIN分料圆桶 CIRCULAR BIN分料圆桶 CIRCULAR BIN双出口 2 outlets单出口 1 outlet分料圆桶 CIRCULAR BIN作用 Function1. 将料从分

9、料圆桶推送到搅拌罐 Drag feed from Circular Bin to Mixing Cylinder2. 喂料器电机转速必须能够改变以便可按照操作工的 要求或针对不同品种的料的需要控制送入搅拌罐与 膨化器的料量大小。 Motor of Feeder have to be able to change revolution in order to control the amount of feed drag to Mixer and Extruder as Operator requirement or suitable condition of each kind of feed

10、.3. 喂料器的种类：最常用的是螺旋式（绞龙） the kind of Feeder, mostly use Screw Feeder喂料器 FEEDER 主要部件 The components of Feeder1. 箱体 : 外部件 Feeders case : outer component2. 桨叶 : 有二根轴，桨叶装在上面用于将料扫入绞龙。 Paddle : there are 2 shafts and paddle for sweeping feed to screw3.绞龙: 连续地推送料到搅拌罐 Screw : feed to Mixing Cylinder constant

11、ly喂料器 FEEDER喂料器 FEEDER 喂料器 FEEDER喂料器 FEEDER作用 ：使料均匀地搅拌与混合，添加蒸汽提高水份与温度。 它是料熟化的一个初期过程，料的水份大约为 16- 20 %,熟化时间 2 4 分钟, 温度 90 C 熟化时间 2 4 分钟, 温度 90 C Function : mixing and blending homogeniously and adding steam for moisture and temperature increase. This is a preliminary process for cooking. Feed moisture

12、 is approximately 16 20 %, spend 2 4 minutes, temperature 90 C搅拌罐或预调质器MIXING CYLINDER OR PRECONDITIONER当有油或脂肪要添加到预调质器时，因为油会覆盖料的表面而阻止水的渗入，故添加点应尽可能最接近排料口。* In case of there is oil or fat adding in Preconditioner, should be nearest discharge point as possible. Due to the fact that the oil will cover fe

13、ed surface and block water penetration.搅拌罐或预调质器MIXING CYLINDER OR PRECONDITIONER出口进口Reverse Pitch 25%Neutral Pitch 50%Forward Pitch 25%搅拌罐或预调质器MIXING CYLINDER OR PRECONDITIONER 搅拌罐有二种型式：MIXING CYLINDER has 2 types 1. 压力熟化器 PRESSURE COOKER 2. 调质器 CONDITIONER2.1 单轴调质器 SINGLE SHAFT CONDITIONER 2.2 差径调质

14、器 DIFFERENTIAL DIAMETER CONDITIONER搅拌罐或预调质器MIXING CYLINDER OR PRECONDITIONER单轴调质器 SINGLE SHAFT CONDITIONER转速高，可获得好的搅拌效果但调质时间短，只有30秒或更少Operate at high speed for good blending.Retention time is low ,about 30 seconds or less151 rpm.单轴调质器 SINGLE SHAFT CONDITIONER83 rpm.166 rpm.调质时间 2-4分钟Retention time 2

15、-4 minutes系统设计 System design : 大轴（低速轴）上 较长的搅拌时间。 Long mixing time in bigger shaft (low speed)- 小轴（高速轴）上 较好的搅拌效应 Good mixing effect in smaller shaft (high speed)差径调质器 DIFFERENTIAL DIAMETER CONDITIONER 1.单轴调质器桨叶调整 : Mixing paddle setting : SINGLE SHAFT CONDITIONER 2.差径调质器桨叶调整 : Mixing paddle setting :

16、 DIFFERENTIAL DIAMETER CONDITIONER桨叶的调整方式Mixing Paddle Settings 单轴调质器中桨叶调整 Mixing paddle setting : SINGLE SHAFT CONDITIONER 差速调质器中桨叶调整 Mixing paddle setting : DIFFERENTIAL DIAMETER CONDITIONER 差速调质器中桨叶调整 Mixing paddle setting : DIFFERENTIAL DIAMETER CONDITIONER右轴 Right 左轴 Left右轴 Right shaft123456789

17、101112131415+15+15+15+15+15+15+15+15+15+15+15+15-15-15-15右轴Right shaft161718192021222324252627282930-15-15-15-15-15-15-15-15-15-15-15-15-15-15-15右轴Right shaft313233343536373839404142434445-15-15-15-15-15-15-15-15-15-15-15-15-15-15-15右轴Right shaft464748495051525354555657585960-15-15-15-15-15-15-15-15

18、-15-15-15-15-15-15-15 桨叶角度 BEATER PITCH ANGLE左轴Left shaft123456789101112131415+15+15+15+15+15+15+15+15+15+15+15+15+15+15+15左轴Left shaft161718192021222324252627282930+15+15+15000000000000左轴Left shaft313233343536373839404142434445000000000000-15-15-15左轴Left shaft464748495051525354555657585960-15-15-15

19、-15-15-15-15-15-15-15-15-15-15-15-15桨叶角度 BEATER PITCH ANGLE桨叶调整的结果 Result of mixing paddle setting0 Wenger 型 DDC 预调质器Wenger Model 16DDC Pre-conditioner2000平均调质时间(秒)Average Retention Time (sec)50100150200250250035003000450040005000湿料流速 (kg/hr)40% Fill30% Fill50% Fill20% Fill10% Fill作用：使料混合，通过提高压力，增高温

20、度与增大剪切力 熟化料并通过压模以20 Bar压力、120 - 150C温 度、 30秒时间与24 28 %压模表面处水份成型。Function is for blending feed, increase pressure, increase temperature and shear force to cook material and formed shape by DIE with 20 Bar pressure, 120 - 150C temperature, spend 30 seconds, at DIE surface moisture 24 28 %.膨化机 EXTRUDER

21、Source : Feed Tech IV 1994 1. 外套 HEAD 2. 螺套 SLEEVE 3. 螺杆 SCREW 4. 汽锁 STEAMLOCK膨化机的主要部件 The important parts of EXTRUDER 外套是内装螺套与轴的外部部件，具有二层夹套，可提供水以冷却或加热。有的外套内可安装蒸汽喷嘴以将蒸汽喷入料中。外套中重要的零件就是螺套。 is a outside part which cover screw and shaft. There are 2 layers of Jacket, the water can be supplied in to cool

22、 down or heat up. Some HEAD can be installed steam nozzles to spray steam into the feed. The important component of HEAD is Sleeve.外套 HEAD有 4 种型式： There are 4 types进料外套 INLET HEAD中间外套 CENTER HEAD出料外套 FINAL HEAD 特殊外套 SPECIAL HEAD 外套 HEAD进料外套是将料推送到中间外套的进口。 is the entrance, deliver to the Center Head外套

23、 HEAD 中间外套 CENTER HEAD 安装在中间部位，具有一个夹套用以将料冷却或加热到均匀的状态。 Install at the center part. There is an Jacket to cool down or heat up for feed homogeneous conditioning.外套 HEAD出料外套 FINAL HEAD 装有定距块与压模的末端部件，具有夹套用以冷却与加热。 is terminal part which fastened with the Spacer and Die. Ther is the Jacket for cooling dow

24、n and heating up.外套 HEAD特殊外套 SPECIAL TYPE 这种型式可专门用于沉性料生产。它有透气口用以释放压力与降低温度，但它没有冷却或加热夹套。 This type can specially be applied with sink feed. There is an Vent to release pressure and temperature of feed. But this type does not have the Jacket for cooling down and heating up. 透气孔 Vent外套 HEAD 有二种型式： There

25、 are 2 types1. 直螺纹沟槽 STRAIGHT RIB2. 斜螺纹沟槽 SPIRAL RIB 螺套 SLEEVE直螺纹沟槽 STRAIGHT RIB 朝前送料慢，料有时还倒退，可帮助搓揉料与增高压力而提高料的熟化程度。 This type, feed moving forward is slow and some will contrary moving backward. This can help kneading material and increasing pressure cause more cooking level. 螺套 SLEEVE 斜螺纹沟槽 SPIRAL

26、RIB 朝前送料比直螺纹沟槽型快，但料的熟化程度要差一些。 This type, feed moving forward is faster than the straight rib type. This type cooking level is poorer than the straight rib type.螺套 SLEEVE具有混合、朝前送料作用。 Function Blending, Moving feed forward螺杆 SCREWPITCHFLIGHTHEIGHTROOTDIAMETERSCREW TERMINOLOGYSINGLE FLIHTPITCHLENGTH- 螺

27、纹 螺蚊表面， 螺纹区域, 用来推送料。螺杆具有朝前推送料的功能。 Flight Screw surface, flight area, is for deliver feed. Screw has an function as push material forward.- 螺距 螺纹相对于螺旋轴（螺杆）变化的程度（绕轴一圈上升的距离） Pitch Degree of pitch is relative to Root shaft.- 螺纹根 由螺纹环饶的螺旋轴（螺杆）的刚性部分。 Root Rigid part or the part of screw shaft, surround with the flight.螺杆类型 : Type and operation of Screw :连续螺纹螺杆 FLIGHT UNCUT SCREW非连续螺纹螺杆 CUT FLIGHT SCREW特殊形式螺杆 SPECIAL TYPE SCREW螺杆 SCREW 1. 连续螺纹螺杆 FLIGHT UNCUT SCREW1.1 连续单螺纹螺杆 SINGLE FLIGHT UNCUT SCREW 送料速度非常快。 This type of s