Producing Quality Aquafeeds with Insta-Pro Dave Albin, PhD Applied Nutrition Technologist dalbin@insta-pro.com

Aquaculture Demand Increasing Aquaculture is fastest-growing sector in ag Global demand for seafood, animal protein Limited wild fish catches (FAO) Million metric tons

Varied Aquaculture Production Fish farming systems around the world Ponds, intensive raceways, tanks, open-ocean aquaculture in nets, etc. Various species used - fresh and saltwater finfish, shellfish, carnivores vs. omnivores, etc. Feed and nutrient requirements: Nutrient requirements vary; in some cases, not well defined Buoyancy differences of pellets Size differences of pellets (small fish may need crumbles) Tremendous economic pressures due to the high costs of some essential ingredients (fish meal and oil) Extruders, aux. equip. – optimal fish nutrition in pellets

Medium Shear Extrusion (MS3000) to make shaped products, like pellets for fish feed

Medium Shear Extrusion (MS3000) to make shaped products, like pellets for fish feed Complete aqua diet (formulated for appropriate species, age, mixed {pulverized and sifted for small pellets})

Medium Shear Extrusion (MS3000) to make shaped products, like pellets for fish feed Preconditioner (mixing, steam heat, moisture)

Medium Shear Extrusion (MS3000) to make shaped products, like pellets for fish feed Extruder (cooking via friction, homogenizing, forcing diet forward)

Medium Shear Extrusion Basic principles of operation HTST PROCESS time ~130ºC 15 – 20 sec

Mixing & Cooking Section Product flow inside extruder barrel Longitudinal fluting allows back flow Shear lock acts as flow control valve

Medium Shear Extrusion (MS3000) to make shaped products, like pellets for fish feed Dies and cutterhead (shaping & sizing pellets, cutting)

Cutterhead Assembly

Dies Plates and Fish Pellets 1.5 mm plate 2.0 mm plate

Dies Plates and Fish Pellets 1.5 mm plate 2.0 mm plate 2.1 mm pellets 2.7 mm pellets

Equipment Research Continuing…

Equipment Research Continuing… 1.0 mm plate = 1.4 mm pellets for juvenile fish 1 cm

Example: Fingerling Carp Diet Ingredient % Nutrient ExPress® soy meal 28 Dry matter 87.9 Wheat 27 Crude protein 32.6 Wheat gluten meal 17 Crude fat 5.8 Wheat bran 15 Crude fiber 4.1 Menhaden fish meal 5 Dicalcium phosphate 2.8 Fish + veg oil 2.0 Vitamins/minerals to 100% Approx. 30 g BW Floating pellets: 2 mm Please note: example purposes only using data from Manomaitis and Cremer (2004); all ingredients should be analyzed for nutrient content, and formulations should meet local requirements

Example: Grower Salmonid Diet Ingredient % Nutrient Fish meal 41 Dry matter 91.9 Corn gluten meal 12 Crude protein 49.5 Soybean meal 8 Crude fat 19 Wheat midds/protein concentrates/veg oil 16.8 Ash 9.2 Corn starch 2 Vitamins/minerals ~90% For extrusion Fish oil (external coated) 10 After extrusion and drying Approx. 100 g BW Sinking pellets: 3 mm Please note: example purposes only using data from Tibbetts et al. (2013); all ingredients should be analyzed for nutrient content, and formulations should meet local requirements

Example: Catfish Pellets MS3000 exceeds industry standard of 80-85%; well gelatinized starch (“% cook”) is required to optimize digestibility and performance

Southern Illinois University Fish feeding experiment Insta-Pro produced fish feed, sent to SIU Hybrid striped bass Fingerling, 20 g Fed until body weight more than doubled One diet – soybean meal, wheat, fish meal – based, with soy and fish oils (38% CP, 11% fat) Same diet processed in different ways Two extruder temperatures (108 and 127oC) Three pellet sizes (3.5, 4.5, and 6 mm) Small, ideal, and large & mixtures of different sizes

Extrusion temperature Optimize for growth

Extrusion temperature Optimize for growth

Extrusion temperature Optimize for juvenile fish intake

Extrusion temperature Optimize for juvenile fish intake 127oC 108oC

Extrusion temperature Maximized palatability, growth Extruder 127oC Pellet Mill (similar or lower temperature) 108oC

Pellet size Uniform pellets = less fish variation

MS3000 – Fish Feed Plant

Conclusions Aquaculture is diverse, rapidly growing, and constantly changing Insta-Pro and aquaculture: Equipment and knowledge to make complete aquafeeds for outstanding performance Fish studies allow high-quality pellet production Small and inexpensive enough for start-up operations, but scalable to allow for sustainable growth Insta-Pro recognized around the world for durable equipment, and a focus on quality feed products Also includes oilseed, by-products, and human product processing

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