Extrusion curing pressurized pulverization integrated machine, high-curing aquatic feed processing system and processing method

Abstract

The present application relates to the field of aquatic feed processing equipment, and discloses an extrusion, cooking, pressurizing and crushing integrated machine and a high-cooking aquatic feed processing system. The extrusion and cooking cavity and the closed crushing cavity of the integrated machine are connected in series, and the end of the extrusion screw is connected with a crushing knife. At least one blocking ring is arranged on the screw to realize partition pressurization. The inner wall of the crushing cavity is provided with crushing external teeth, and the crushing knife is provided with crushing internal teeth, so that the material is crushed by attrition under pressure. The matching system is connected in series through a feed bin, a conditioner, a dispersion homogenizer and a granulator, and finally the formed powder is packaged. The technical effects are as follows: the gelatinization degree of the cooked material is increased from 20-25% to 40-60%, the crushing fineness reaches 90% passing 20 mesh, and the physical properties of 1.0mm diameter granular feed are uniform; the pressure gradient of the crushing zone is reduced, the physical property difference caused by flash evaporation is avoided, and the water stability of the feed can be significantly improved. The scheme is specially used for high-cooking aquatic feed production of shrimps, crabs and fish.

Description

Technical Field

[0001] This invention relates to the field of feed processing technology, and in particular to a mechanical device for the maturation and pulverization of aquatic feed, as well as a method for processing highly matured and uniformly sized aquatic feed. Background Technology

[0002] In the aquatic feed industry, it is very common to use pellet mills to process shrimp, crab, and fish feed. Pellet-processed shrimp, crab, and fish feed usually has the following problems: insufficient stability in water, insufficient soaking time, long softening and thorough cooking time, and low degree of cooking.

[0003] To address the aforementioned issues, existing technologies utilize retainers to significantly extend the conditioning time, commonly known as the "retainer + pelleting" process for processing shrimp, crab, and fish feed. A retainer is installed before the pellet mill, allowing the material to undergo a longer conditioning period before entering the mill for pelleting, hoping to resolve these problems. To ensure sufficient conditioning time, the retainer is often configured with two or even three layers, improving the quality of the shrimp and crab feed pellets produced. However, several problems remain: ① Overall gelatinization is improved, but there's still a gap; ② During the prolonged conditioning period in the retainer, the lack of effective mixing leads to highly uneven conditioning, resulting in 20-30% of the finished pellets exhibiting poor water stability due to insufficient stabilization time; ③ The pellets contain a relatively high amount of powder, resulting in a high powdering rate. When the pellets are placed in water, some of the feed dissolves during the feeding process of shrimp, crab, and fish.

[0004] In existing technologies, the second common process is the "expansion + pelleting" process. For example, patent application number CN201420357951.X, entitled "A Pelletizing Machine for Feed," is a typical example of this "expansion + pelleting" process. Similarly, patent application number CN201521134927.0, entitled "An Expanding Pelletizing Machine for Feed Production," is also a typical example of this process. The use of an expander significantly improves the overall maturation of the material. This process is perfectly suitable for producing livestock and poultry feed, as the improved overall maturation level greatly enhances feed digestibility and absorption, ultimately leading to better aquaculture results. However, this processing method presents significant problems when producing shrimp, crab, and fish feed, especially when processing small-particle aquatic feed such as pond shrimp (around φ1.0mm in diameter). Each particle of these small-particle feeds weighs less than 1 gram. For the finished feed products, we need to ensure good water stability for each pellet, preventing cracking and disintegration during soaking and rinsing. This requires extremely uniform material temperature, maturation time, and moisture content during processing, achieving consistency in physical properties down to 0.1 grams per gram. Expanders do not meet this requirement. While the material is compressed inside an expander under high temperature and pressure, which ensures proper maturation, the main issue lies in the expander's discharge location. Expanders typically use annular discharge, whether pull-type or top-type (e.g., the discharge mechanism of a softening machine as described in CN202021029867.7). When the material leaves the expander, it is always in block form. As the material containing a certain amount of moisture exits the high-temperature, high-pressure expander and enters a normal temperature and pressure environment, some of the surface moisture will flash-evaporate instantly, while the internal moisture evaporation will be much less significant. Meanwhile, during the flash evaporation process, the surface temperature of the lumpy material drops significantly, while the internal temperature decreases even less. This results in highly uneven moisture and temperature distribution throughout the material. Even with subsequent agitation, it's impossible to achieve uniform moisture and temperature for every gram of such unevenly distributed material. We need to feed this material into a pellet mill and process it into granules with a diameter of φ1.0mm and a weight of less than 1 gram. However, current processing equipment and techniques cannot guarantee consistent water stability for each granule.

[0005] In existing technology, another improvement to expanders involves installing a template. The template eliminates the clumps of material extruded by the expander, resulting in individual pellets. However, the holes on the template cannot be made to φ1.0mm; typically, 8-20mm holes are used to extrude the material. While the resulting 8-20mm pellets have slightly more uniform moisture content than the previously mentioned clumps, uneven moisture distribution between the surface and interior of each pellet still exists. Furthermore, this improvement adds the steps of installing and disassembling the template, and adjusting the cutter, thus increasing the operational complexity of the production line. These are significant reasons why feed mill workers are reluctant to use such equipment when processing pelleted feed. Summary of the Invention

[0006] One of the objectives of this invention is to provide an integrated extrusion, maturation, and crushing machine that allows materials to be crushed under pressure after maturation, thus avoiding uneven moisture distribution between the material's interior and surface due to flash evaporation. This ensures that the material has consistent physical properties, including consistent temperature, consistent moisture content, and consistent degree of maturation.

[0007] Therefore, the technical solution of the present invention is: an integrated extrusion maturation and pressure pulverization machine, comprising an extrusion maturation chamber, an extrusion screw being fitted inside the extrusion maturation chamber, one end of the extrusion screw being connected to a transmission mechanism, an inlet for conditioning material being provided on the upper side of one end of the extrusion maturation chamber, the other end of the extrusion maturation chamber being connected to a sealed pulverization chamber, and a pulverizing blade being connected to the other end of the extrusion screw; at least one blocking ring being provided on the extrusion screw; the sealed pulverization chamber is a cylindrical shape with openings at both ends, one end being its inlet end and the other end being its outlet end, the inlet end being sealed to the extrusion maturation chamber, and the outlet end being the outlet for pulverized material, the inner circular surface of the sealed pulverization chamber being provided with external pulverizing teeth, and the outer periphery of the pulverizing blade being provided with internal pulverizing teeth that cooperate with the external pulverizing teeth, the section where the external pulverizing teeth and the internal pulverizing teeth cooperate to form a pulverization zone.

[0008] During operation, the material is pressurized by the extrusion screw, causing the temperature of the conditioned material to rise and reach the required maturation level. The degree of gelatinization of the material increases to 40-60%. The maturated material, in a clump form, enters the crushing zone under sealed pressure. The outer and inner crushing teeth rotate relative to each other, crushing the material. This invention combines the structure of an extrusion puffing machine and a crusher, integrating their functions into one device. On the one hand, it increases the degree of maturation of the material during the extrusion maturation process; on the other hand, it effectively crushes the maturated, clump-like material to achieve sufficient fineness. Compared with existing technologies, the advantages of this invention are: in the crushing zone, the pressure of the material gradually decreases, avoiding flash evaporation of moisture that would cause differences in moisture content and density between the material's interior and surface; because there is no flash evaporation, the temperature, moisture content, and degree of maturation are consistent throughout the material, resulting in consistent material properties. This device is suitable for processing aquatic feed, especially for processing pelleted feed with a diameter as small as 1.0 mm, and can produce higher quality shrimp, crab, and fish pelleted feed.

[0009] Furthermore, the outer crushing teeth are straight teeth, and the inner crushing teeth are multi-headed spiral teeth. The inner crushing teeth can also be composed of multiple segments of staggered straight teeth, with adjacent staggered straight teeth circumferentially offset. The spiral tooth structure not only crushes the material but also continuously pushes the material towards the outlet. The multi-segmented staggered straight teeth include at least two segments, which ensures a reduction in the material pressure gradient and prevents flash evaporation of moisture in the material.

[0010] Furthermore, the aspect ratio of the crushing zone is L / D = 0.3-2.1, where L is the length of the crushing zone and D is the outer diameter of the tooth tip of the crushing internal teeth. Within this aspect ratio range, the material remains in the zone for a sufficiently long time, allowing the material pressure to decrease slowly during crushing, thus preventing flash evaporation of moisture. The preferred rotational speed is 400-800 rpm.

[0011] A further improvement of the present invention is that the extrusion screw includes a feeding screw, a curing screw one and a curing screw two, and there are three blocking rings, wherein the blocking ring one is disposed between the feeding screw and the curing screw one, the blocking ring two is disposed between the curing screw one and the curing screw two, and the blocking ring three is disposed between the curing screw two and the crushing blade.

[0012] A further improvement lies in the fact that the extrusion curing chamber is composed of multiple unit segments with equal inner diameters connected consecutively. The root diameters of the feeding screw, curing screw one, and curing screw two gradually increase from the inlet of the conditioning material towards the other end of the extrusion curing chamber, or the screw's helical lead gradually decreases, so as to achieve a gradual compression effect on the material. The extrusion curing chamber can be manufactured in segments, reducing the difficulty of manufacturing and installation; this structure can also ensure that the material is gradually pressurized, and that the feeding screw, curing screw one, and curing screw two are subjected to uniform force along their length.

[0013] The second objective of this invention is to provide a high-maturity aquatic feed processing system, comprising a silo, an arch-breaking silo, a feeder, a conditioner, an integrated extrusion maturation and crushing machine, a homogenizer, a pellet mill, a stabilizer, a cooler, an elevator, a primary screening device, a finished product silo, a gate, a secondary screening device, and a packaging system, all connected sequentially from the upper outlet to the lower inlet. A pellet mill steam suction system is provided between the pellet mill and the stabilizer to remove steam generated at the pellet mill outlet, preventing condensate from entering the small pellets and thus avoiding excessive moisture content and mold growth in individual pellets. The cooler shell is connected to the cooler suction system. A single-layer conditioner is preferred, although a double-layer conditioner is also acceptable; three or more layers are unnecessary. A retainer is also unnecessary. Steam is added to the material through the conditioner, ensuring uniform conditioning, temperature, and moisture content. The temperature of the pellets exiting the stabilizer is reduced, typically to no more than 5°C above ambient temperature, allowing for long-term storage of the feed pellets.

[0014] A third objective of this invention is to provide a method for processing highly cooked aquatic feed, which utilizes the aforementioned highly cooked aquatic feed processing system and includes the following steps:

[0015] 1) The raw materials enter the conditioner from the silo through the arch-breaking silo and the feeder. The temperature of the conditioned material is 80-100℃, the moisture content is 15-20%, and the gelatinization degree is 20-25%.

[0016] 2) After conditioning, the material enters the extrusion and maturation chamber through the conditioning material inlet, and the extrusion screw speed is maintained at 450-800 rpm. After extrusion and maturation by the extrusion screw, the temperature of the material reaches 105-120℃, the moisture content remains unchanged, and the degree of gelatinization is 40-60%. At this time, most of the material is extruded and agglomerated together, forming clumps.

[0017] 3) The lumpy material is continuously pushed into the crushing zone under pressure by the extrusion screw. The outer and inner crushing teeth rotate relative to each other, grinding and crushing the material. The material pressure gradually decreases from the inlet to the outlet of the sealed crushing chamber, eventually reaching atmospheric pressure. Because the pressure reduction process is slow, the water in the material will not flash vaporize in large quantities, and the moisture content is maintained at 15-20%. The resulting material is characterized by a certain amount of moisture, uniform moisture content, sufficient particle fineness (approximately 85% passing through a 20-mesh sieve), and improved gelatinization.

[0018] 4) The material passes through the homogenizer, pellet mill, stabilizer, cooler, elevator, and primary screening device in sequence before entering the finished product silo; the steam in the material at the pellet mill outlet is drawn away by the pellet mill steam suction system, and the hot air in the cooler shell is drawn away by the cooler suction system.

[0019] 5) Open the gate and perform secondary screening using a secondary screening device to remove fine powder. The coarse powder is then bagged by the packaging system.

[0020] This method can be used to produce pelleted feed with a diameter as small as 1.0 mm. The overall degree of maturation of each pellet is improved and the consistency is very ideal. Each pellet has excellent stability in water, avoiding the problem of individual or partial pellets easily disintegrating in water. The powder content of the feed is greatly reduced, down to below 0.1‰. The nutrients in the feed are more easily absorbed by shrimp, crabs and fish, and the feed conversion ratio is significantly improved. Attached Figure Description

[0021] Figure 1 This is a connection diagram of the high-maturity aquatic feed processing system of the present invention.

[0022] Figure 2 A schematic diagram of the overall structure of the extrusion, curing, and crushing integrated machine.

[0023] Figure 3 for Figure 2 A top view of the integrated extrusion, curing, and crushing machine.

[0024] Figure 4 A partial structural diagram of an integrated extrusion, curing, and crushing machine.

[0025] Figure 5 This is a schematic diagram of the extrusion curing chamber structure.

[0026] Figure 6 for Figure 4 A schematic diagram of the structure along direction A.

[0027] Figure 7 This is a schematic diagram of the three-dimensional structure of a sealed pulverizing chamber.

[0028] Figure 8 This is a schematic diagram of the end face structure of a sealed crushing chamber.

[0029] Figure 9 This is a three-dimensional diagram of a structure consisting of an extrusion screw and a crushing blade.

[0030] Figure 10 for Figure 9 A magnified view of part B in the image.

[0031] Figure 11 This is a plan view of another structure for the extrusion screw and crushing blade.

[0032] Figure 12 This is a perspective view of another structure of the extrusion screw and crushing blade.

[0033] Figure 13 for Figure 12 A magnified view of part C.

[0034] Figure 14 Table 5 shows the test results of whether the fineness of the material reaches the target (90% passing 20 mesh) under different rotation speeds when the length-to-diameter ratio of the crushing zone is changed.

[0035] In the diagram, 1 is the hopper, 2 is the arch-breaking hopper, 3 is the feeder, 4 is the conditioner, 5 is the integrated extrusion, maturation, pressurization, and pulverization machine, 6 is the homogenizer, 7 is the granulator, 8 is the granulator steam suction system, 9 is the stabilizer, 10 is the cooler, 11 is the cooler suction system, 12 is the elevator, 13 is the primary screening device, 14 is the finished product hopper, 15 is the gate, 16 is the secondary screening device, 17 is the packaging system, 18 is the transmission components, 19 is the bearing housing, and 20 is the extrusion maturation chamber. 21. Sealed crushing chamber; 21a. Crushing outer teeth; 22. Discharge cover; 23. Front support; 24. Base; 25. Motor; 26. Conditioning material inlet; 27. Drive shaft; 28. Locking bolt; 29. ​​Crushing blade; 29a. Spiral teeth; 29b. Offset straight teeth; 30. Blocking ring three; 30a. Guide groove; 31. Curing screw two; 32. Blocking ring two; 33. Curing screw one; 34. Blocking ring one; 35. Feeding screw; 36. Extrusion screw. Detailed Implementation

[0036] like Figure 2-13 As shown, a pressing and pulverizing integrated extrusion and ripening machine 5 is described. Its overall structure includes a frame, a motor mount on one side of the frame, a motor 25 mounted on the motor mount, a front support 23 at the front end of the frame, and an extrusion and ripening chamber 20 mounted on the frame and the front support 23. An extrusion screw 36 is fitted inside the extrusion and ripening chamber 20. One end of the extrusion screw 36 is connected to a transmission mechanism, specifically via a bearing housing 19 and a transmission component 18, which in turn connects to the motor 25. A conditioning material inlet 26 is located on the upper side of one end of the extrusion and ripening chamber 20, and the other end of the extrusion and ripening chamber 20 is connected to a sealed pulverizing chamber. The screw 36 is connected to the other end of the extrusion screw 36, which is connected to a crushing blade 29. The extrusion screw 36 is provided with three blocking rings. The sealed crushing chamber 21 is a cylindrical shape with two open ends. One end is its inlet end and the other end is its outlet end. The inlet end is sealed to the extrusion and maturation chamber 20, and the outlet end is the outlet of the crushed material. The outlet of the crushed material is provided with a discharge cover 22. The inner circular surface of the sealed crushing chamber 21 is provided with crushing outer teeth 21a, and the outer periphery of the crushing blade 29 is provided with crushing inner teeth that cooperate with the crushing outer teeth 21a. The section where the crushing outer teeth 21a and the crushing inner teeth cooperate form a crushing zone.

[0037] like Figure 6-8 As shown, the external crushing tooth 21a can be a straight tooth, such as... Figure 9 , 10 As shown, the internal crushing teeth can be multi-start helical teeth 29a. For example... Figure 11-13 As shown, the internal crushing tooth can also be composed of multiple segments of staggered straight teeth 29b, with adjacent staggered straight teeth 29b being circumferentially staggered.

[0038] The length-to-diameter ratio of the crushing zone is L / D = 0.3-2.1, where L is the length of the crushing zone and D is the outer diameter of the tooth tip of the crushing inner tooth.

[0039] like Figure 4 , 11 As shown, the extrusion screw 36 includes a feeding screw 35, a first curing screw 33, and a second curing screw 31. There are three blocking rings: a first blocking ring 34 is located between the feeding screw 35 and the first curing screw 33; a second blocking ring 32 is located between the first curing screw 33 and the second curing screw 31; and a third blocking ring 30 is located between the second curing screw 31 and the crushing blade 29. The blocking rings are used to prevent material backflow. Their facing side is conical, with guide grooves 30a on the conical surface. The diameter of the blocking ring is larger than the outer diameter of the screw thread of the extrusion screw 36. A gap is left between the blocking ring and the extrusion curing chamber 20 to allow material to pass through. This divides the extrusion screw 36 into a feeding zone, a first curing zone, a second curing zone, and a crushing zone outside the end of the extrusion screw 36. During operation, the feeding zone, the first curing zone, and the second curing zone exhibit a progressively increasing pressure trend.

[0040] Furthermore, the extrusion curing chamber 20 is composed of multiple unit segments with equal inner diameters connected one after another. The root diameters of the feeding screw 35, curing screw one 33 and curing screw two 31 gradually increase from the conditioning material inlet 26 to the other end of the extrusion curing chamber 20, or the screw pitch gradually decreases, so as to gradually compress the material.

[0041] During operation, the material is pressurized by the extrusion screw 36, causing the temperature of the conditioned material to rise and reach the required maturation level. The degree of gelatinization of the material increases to 40-60%. The maturated material, in a clump form, enters the crushing zone under sealed pressure. The outer crushing teeth 21a and the inner crushing teeth rotate relative to each other, crushing the material. This invention combines the structure of an extrusion puffing machine and a crusher, integrating their functions into one device. On the one hand, it increases the degree of maturation of the material during the extrusion maturation process; on the other hand, it effectively crushes the maturated, clump-like material to achieve sufficient fineness. Compared with the prior art, the beneficial effects of this invention are: in the crushing zone, the pressure of the material gradually decreases, avoiding flash evaporation of moisture that would cause differences in moisture and density between the inside and surface of the material; because there is no flash evaporation of moisture, the temperature, moisture content, and degree of maturation are consistent throughout the material, resulting in consistent material properties. This device is suitable for processing aquatic feed, especially for processing pellet feed with a diameter as small as 1.0 mm, and can produce higher quality shrimp, crab, and fish pellet feed.

[0042] like Figure 1As shown, this is a high-maturity aquatic feed processing system, with the aforementioned extrusion-maturation-pressurization-pulverization integrated machine 5 as one of its key pieces of equipment. It includes a hopper 1, an arch-breaking hopper 2, a feeder 3, a conditioner 4, the extrusion-maturation-pressurization-pulverization integrated machine 5, a homogenizer 6, a pellet mill 7, a stabilizer 9, a cooler 10, an elevator 12, a primary screening device 13, a finished product hopper 14, a gate 15, a secondary screening device 16, and a packaging system 17, all connected sequentially from the upper-level outlet to the lower-level inlet. A pellet mill steam suction system 8 is installed between the pellet mill 7 and the stabilizer 9 to remove the steam generated at the outlet of the pellet mill 7, preventing condensate from entering the small pellets and thus avoiding excessive moisture content in individual pellets, which could lead to mold growth. The shell of the cooler 10 is connected to the cooler suction system 11. The preferred solution for conditioner 4 is to use a single-layer conditioner. A double-layer conditioner can also be used, but there is no need to use a triple-layer or higher conditioner. Furthermore, a retainer is unnecessary. Steam is added to the material as it passes through conditioner 4, ensuring uniform conditioning and achieving uniform temperature and moisture content. The temperature of the pellets exiting stabilizer 9 is reduced, typically to no more than 5°C above ambient temperature, allowing for long-term storage of the pelleted feed.

[0043] The present invention also provides a method for processing highly cooked aquatic feed, which utilizes the above-mentioned highly cooked aquatic feed processing system and includes the following steps:

[0044] 1) The raw materials enter the conditioner 4 from the silo 1 through the arch-breaking silo 2 and the feeder 3. The temperature of the conditioned material is 80-100℃, the moisture content is 15-20%, and the gelatinization degree is 20-25%.

[0045] 2) After conditioning, the material enters the extrusion and maturation chamber 20 through the conditioning material inlet 26, and the extrusion screw 36 is kept at a speed of 450-800 rpm. After being extruded and matured by the extrusion screw 36, the temperature of the material reaches 105-120℃, the moisture content remains unchanged, and the degree of gelatinization is 40-60%. At this time, most of the material is extruded and agglomerated together, forming a clump.

[0046] 3) The lumpy material is continuously pushed by the extrusion screw 36 into the crushing zone under pressure. The outer crushing teeth 21a and the inner crushing teeth rotate relative to each other, grinding and crushing the material. The material pressure gradually decreases from the inlet end to the outlet end of the closed crushing chamber 21, eventually reaching atmospheric pressure. Because the pressure reduction process is slow, the water in the material will not flash vaporize in large quantities, and the moisture content is maintained at 15-20%. The resulting material is: containing a certain amount of moisture, with uniform moisture content, sufficient particle fineness (approximately 85% passing through a 20-mesh sieve), and improved gelatinization.

[0047] 4) The material passes through the homogenizer 6, pellet mill 7, stabilizer 9, cooler 10, elevator 12, and primary screening device 13 in sequence before entering the finished product silo 14; the steam in the material at the outlet of pellet mill 7 is drawn away by the pellet mill steam suction system 8, and the hot air in the shell of cooler 10 is drawn away by the cooler suction system 11.

[0048] 5) After opening the gate 15, the material undergoes secondary screening via the secondary screening device 16. Fine powder is removed by screening, and coarse powder is bagged via the packaging system 17. The degree of gelatinization is a key indicator for the processed materials in the equipment described in this invention; the degree of gelatinization needs to reach 40-60%. The degree of gelatinization is mainly determined by the parameters of the screw components in the first and second curing zones.

[0049] Fineness of grinding is the second key indicator of the equipment described in this invention. In the production process of the pellet mill 7, according to production experience, it is generally believed that when the fineness of grinding reaches 90% (below 20 mesh), the quality of the pellets will reach the ideal state when the material with such fineness is used to produce pellet feed with a particle diameter of φ1.0mm. That is, only when the fineness of grinding reaches 90% (below 20 mesh) can the material achieve a state of uniform moisture, uniform temperature and uniform degree of maturation.

[0050] Therefore, the acceptance criteria for the equipment described in this invention are: when the degree of gelatinization reaches 40-60%, the fineness of the pulverization reaches 90% passing through 20 mesh.

[0051] This method can be used to produce pelleted feed with a diameter as small as 1.0 mm. The overall degree of maturation of each pellet is improved and the consistency is very ideal. Each pellet has excellent stability in water, avoiding the problem of individual or partial pellets easily disintegrating in water. The powder content of the feed is greatly reduced, down to below 0.1‰. The nutrients in the feed are more easily absorbed by shrimp, crabs and fish, and the feed conversion ratio is significantly improved.

[0052] The following are specific experimental methods used to verify the technical effects of the present invention:

[0053] The above-described process and equipment are used to produce shrimp feed with a particle diameter of 1.0 mm. The formula uses the raw material formula in Table 1. Before the raw materials enter the process described in this invention, the fineness of the material is 92% (passing through 80 mesh). The material mixing uniformity (CV) is ≤5%.

[0054] Table 1 Raw Material Formula

[0055] 1 flour 18％ 2 Paste-like and oil-based raw materials 10％ 3 Animal protein raw materials 14％ 4 Plant protein raw materials 49％ 5 Other (additives) 9％ 6 total 100％

[0056] The production parameters are shown in Table 2. In the original technology, the production capacity of the same type of pellet mill for producing 1.0mm shrimp feed is 2.5-2.6t / h. Using the technology of this invention, the production capacity can be increased to more than 3.2t / h, which is an increase of 28-44%.

[0057] In addition, the conditioning temperature can be increased from around 85℃ in the original technology to over 95℃, and the conditioning moisture content can also be significantly increased to around 18%, while eliminating the powder spitting problem commonly seen in granulator production.

[0058] Table 2 Production Parameters

[0059]

[0060]

[0061] Comparing the finished product indicators, the bulk density of the product using the new process is increased to about 700 g / L, an increase of approximately 40 g / L. The powder content reaches 0.1‰, which is an ideal indicator. In the original technology, the powder content was usually only about 0.5‰, showing a very significant improvement.

[0062] More importantly, the degree of gelatinization has increased from about 25% to over 53%. This high degree of gelatinization results in excellent digestibility and absorption after feeding, leading to a significant increase in the feed conversion ratio.

[0063] Table 3 Finished Product Indicators

[0064] 1 Finished product density 698g / l 702g / l 2 Powder content 0.1‰ 0.1‰ 3 water stability No cracks after 10 hours No cracks after 10 hours 4 Appearance Smooth and beautiful Smooth and beautiful 5 Color Dark color Dark color 6 Gelatinization degree 53％ 55％

[0065] As can be seen from the above working process, in order to ensure that the pressure of the material gradually decreases in the crushing zone and avoid flash evaporation of moisture, the residence time of the material cannot be too short. Therefore, the length-to-diameter ratio L / D of the crushing zone and the rotation speed of the equipment are key parameters.

[0066] Key factor variable 1: Rotor speed 100rpm, 150rpm, 200rpm, 250rpm, 300rpm, 350rpm, 400rpm, 450rpm, 500rpm, 550rpm, 600rpm, 650rpm, 700rpm, 750rpm, 800rpm, 850rpm, 900rpm, 1000rpm.

[0067] Key variable two: The length-to-diameter ratio of the crushing zone = L / D, the length of the crushing zone L, and the diameter D of the end of the extrusion and curing zone. In this equipment test, D = 200mm, and L was designed to be 20mm, 40mm, 60mm, 80mm, 100mm, 120mm, 160mm, 200mm, 240mm, 300mm, 360mm, 420mm, 500mm, 600mm, 700mm, and 800mm respectively.

[0068] Table 4. Aspect Ratio (L / D) and Length Change Values ​​of the Crushing Zone

[0069]

[0070]

[0071] In this comparative experiment, the length of the grinding zone was mainly changed, and different rotation speeds were adjusted during the production process. First, the fineness of the final product was tested; only when the fineness met the requirements was the degree of gelatinization tested. The preferred configuration of this invention is achieved only when both the fineness and the degree of gelatinization are simultaneously satisfied. Other parameters remained constant, such as: the feed rate was maintained at 3.2 t / h, the conditioner temperature was maintained at 95℃, and the moisture content of the material at the conditioner outlet was maintained at 18%.

[0072] like Figure 14 Table 5 shows the test results for whether the material fineness meets the target (90% passing 20 mesh) under different rotational speeds by changing the aspect ratio of the crushing zone. The test results are as follows:

[0073] Firstly, when the rotation speed is not higher than 400 rpm, the material is relatively coarse after passing through the crushing zone due to the low rotation speed. Therefore, low rotation speed cannot be used. Even if the length of the crushing zone is increased, the material with the required fineness cannot be obtained.

[0074] Secondly, when the crushing zone is too short (L / D = 0.1-0.2), the fineness of the material is relatively coarse, which is also a parameter that can be excluded.

[0075] Third, when the speed is too high, reaching 850 rpm or above, the main unit current of the equipment will be too high, or it may directly cause overcurrent, preventing production. Therefore, high speeds above 850 rpm can also be ruled out.

[0076] Fourth, when the grinding zone is too long and L / D≥2.5, the grinding fineness is insufficient at low speeds. After the speed is increased (between 450-750 rpm), the fineness of the material meets the requirements, but the current is relatively high at this time, which is not suitable for economical production. When the speed is further increased to above 800 rpm, the equipment starts to overcurrent and cannot produce normally.

[0077] Therefore, the optimal parameters are an aspect ratio of L / D = 0.3-2.1 in the crushing zone and a rotation speed of 450-800 rpm. Within this range, the conditions are considered ideal.

[0078] This invention is not limited to the above embodiments. Based on the technical solutions disclosed in this invention, those skilled in the art can make some substitutions and modifications to some of the technical features without creative effort, and all such substitutions and modifications are within the protection scope of this invention.

Claims

1. An integrated extrusion, curing, and crushing machine, comprising an extrusion and curing chamber, wherein an extrusion screw is fitted inside the extrusion and curing chamber, one end of the extrusion screw is connected to a transmission mechanism, and a conditioning material inlet is provided on the upper side of one end of the extrusion and curing chamber, characterized in that: The other end of the extrusion and maturation chamber is connected to the sealed crushing chamber, and the other end of the extrusion screw is connected to a crushing blade; the extrusion screw is provided with at least one blocking ring; the sealed crushing chamber is a cylindrical shape with two open ends, one end being its inlet end and the other end being its outlet end. The inlet end is sealed to the extrusion and maturation chamber, and the outlet end is the outlet for the crushed material. The inner circular surface of the sealed crushing chamber is provided with crushing outer teeth, and the outer periphery of the crushing blade is provided with crushing inner teeth that cooperate with the crushing outer teeth. The section where the crushing outer teeth and the crushing inner teeth cooperate form a crushing zone. The extrusion screw includes a feeding screw, a first curing screw, and a second curing screw. There are three blocking rings: the first blocking ring is located between the feeding screw and the first curing screw; the second blocking ring is located between the first and second curing screws; and the third blocking ring is located between the second curing screw and the pulverizing blade. The length-to-diameter ratio of the pulverizing zone is L / D = 0.3-2.1, where L is the length of the pulverizing zone and D is the outer diameter of the tooth tip of the pulverizing inner teeth. The extrusion screw rotates at 450-800 rpm. During operation, the extrusion screw applies pressure in stages, increasing the gelatinization degree of the conditioned material to 40-60%. Most of the cured material forms clumps and enters the pulverizing zone under sealed pressure for pulverization. During pulverization, the material pressure decreases slowly to prevent flash evaporation of moisture.

2. The integrated extrusion, curing, and pulverizing machine according to claim 1, characterized in that: The outer crushing teeth are straight teeth, and the inner crushing teeth are multi-headed spiral teeth.

3. The integrated extrusion, curing, and pulverizing machine according to claim 1, characterized in that: The outer crushing teeth are straight teeth, and the inner crushing teeth are composed of multiple segments of staggered straight teeth, with adjacent staggered straight teeth being circumferentially staggered.

4. The integrated extrusion, curing, and pulverizing machine according to any one of claims 1-3, characterized in that: The extrusion curing chamber is composed of multiple unit segments with equal inner diameters connected one after another. The root diameter of the feeding screw, curing screw one and curing screw two gradually increases from the inlet of the conditioning material to the other end of the extrusion curing chamber, or the spiral lead of the screw gradually decreases.

5. A high-maturity aquatic feed processing system, characterized in that: The system includes a hopper, an arch-breaking hopper, a feeder, a conditioner, an integrated extrusion, maturation, pressurization, and pulverizing machine as described in any one of claims 1-3, a homogenizer, a granulator, a stabilizer, a cooler, an elevator, a primary screening device, a finished product hopper, a gate, a secondary screening device, and a packaging system, all connected sequentially from the upper-level outlet to the lower-level inlet. A granulator steam suction system is provided between the granulator and the stabilizer, and the shell of the cooler is connected to the cooler suction system.

6. A method for processing highly cooked aquatic feed using the highly cooked aquatic feed processing system according to claim 5, characterized in that... Includes the following steps: 1) The raw materials enter the conditioner from the silo through the arch-breaking silo and the feeder. The temperature of the conditioned material is 80-100℃, the moisture content is 15-20%, and the degree of gelatinization is 20-25%. 2) After conditioning, the material enters the extrusion and maturation chamber through the conditioning material inlet, and the extrusion screw speed is maintained at 450-800 rpm. After extrusion and maturation by the extrusion screw, the temperature of the material reaches 105-120℃, the moisture content remains unchanged, and the degree of gelatinization is 40-60%. At this time, most of the material is extruded and agglomerated together, forming clumps. 3) The lumpy material is continuously pushed by the extrusion screw and enters the crushing zone under pressure. The outer and inner crushing teeth rotate relative to each other, grinding and crushing the material. The material pressure gradually decreases from the inlet end to the outlet end of the sealed crushing chamber, eventually reaching a normal pressure state. The water in the material will not flash vaporize in large quantities, and the moisture content is maintained at 15-20%. 4) The material passes through the homogenizer, pellet mill, stabilizer, cooler, elevator, and primary screening device in sequence before entering the finished product silo; the steam in the material at the pellet mill outlet is drawn away by the pellet mill steam suction system, and the hot air in the cooler shell is drawn away by the cooler suction system. 5) Open the gate and perform secondary screening using a secondary screening device to remove fine powder. The coarse powder is then bagged by the packaging system.

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