This is an expansion project of a fish feed plant in Indonesia. This project is to build a new factory building in the original factory area, with a total construction area of 14,508m2. The construction content mainly includes: main workshop, finished product workshop, raw material workshop, silo, boiler room, etc. The expansion project product is fish feed. After full load operation, it will form an annual production capacity of 100,000 tons of fish feed, with a total investment of 1.85 million US dollars.
Project background and origin
The customer is a research and development institution specializing in animal nutrition and health technology. Due to the shortage of premixes in the market, the customer decided to invest in the construction of a 10,000-ton annual nutritious feed production line project. The project was officially put into production in August 2008. The whole factory covers an area of 30,388m2, and the products are premixes and animal feed. The main construction content includes 1# workshop, 2# workshop, main workshop, office building, dormitory, etc.
With the development of the economy and the continuous improvement of people’s living standards, people’s demand for food such as protein is also increasing. High-quality protein mainly comes from aquatic products. The output of aquatic products in the wild environment is extremely small, and most of them rely on artificial breeding. Artificial breeding mainly uses feed processed from natural or natural ingredients to feed organisms, so that organisms can grow in a relatively short period of time and produce food that can be eaten by humans. Therefore, with the further prosperity of the aquaculture and other breeding markets, the market demand for high-quality, environmentally friendly and nutritious feed products is also increasing.
Against this background, the customer invested 1.85 million US dollars to purchase equipment and built a new fish feed plant in Indonesia on the basis of the existing plant to build the second phase expansion project (annual 100,000 tons of nutritious feed expansion project). The expansion project is expected to be put into production in October 2020. After full load operation, it will form an annual production capacity of 100,000 tons of fish feed.
The entire fish feed mill plant will form an annual production capacity of 10,000 tons of premixes, animal feed (including 6,000 tons of premixes and 4,000 tons of animal feed), and 100,000 tons of fish feed.
This fish feed plant in Indonesia project has 20 new employees, and the rest are deployed from the original engineering employees. The factory has a labor quota of 92 people, with a three-shift system of 8 hours per shift and 300 working days per year. All employees are accommodated in the factory area.
Construction scale
This fish feed plant in Indonesia project is to build a new factory building in the original factory area, with a total new building area of 14,508 m2. The construction content mainly includes: main workshop, finished product workshop, raw material workshop, silo, boiler room, etc. The product of the expansion project is fish feed. After full load operation, it will form an annual production capacity of 100,000 tons of fish feed. The main construction content of the expansion project is shown in the table below.
| Project composition | Scale | Remarks | ||
| Main engineering | Main workshop | 6F, covers an area of 1026.5m2, construction area of 6825m2, the first floor is the elevator base, the second floor is the drying room, the third floor is the granulation and batching room, the fourth floor is the assembly warehouse, the fifth floor is the warehouse top feeding room, the sixth floor is the screening and dust removal room. | Newly built | |
| Warehousing engineering | Silo | 1F, building area 378m2 | Newly built | |
| Finished product workshop | 1F, building area 2564m2 | Newly built | ||
| Raw material workshop | 1F, building area 4389m2 | Newly built | ||
| Auxiliary engineering | Staff dormitories, office buildings, staff canteens and other auxiliary projects are based on existing | Based on existing | ||
| Boiler room | 1F, building area 151m2 | Newly built | ||
| Machine repair room | 1F, building area 84m2 | Newly built (stacked abandoned equipment, no repairs) | ||
| Unloading shed | 1F, building area 117m2 | Newly built | ||
| Public engineering | Water supply | Newly added production water relies on the water supply system of the existing project, supplied by the municipality | Relying on the existing | |
| Power supply | New electricity consumption relies on the power supply system of the existing project, supplied by the local power supply bureau | Relying on the existing | ||
| Heating | 2 4/h steam boilers | New | ||
| Environmental protection engineering | Waste gas | Boiler waste gas | 1 8m exhaust pipe (1# exhaust pipe) | Newly built |
| Odor | 1 20m exhaust pipe (2# exhaust pipe) | Newly built | ||
| Process dust | 13 bag-type dust collectors, 1 20m exhaust pipe (2# exhaust pipe) | Newly built | ||
| Noise | Vibration reduction, vibration isolation measures, workshop wall sound insulation, etc. | Newly built | ||
| Wastewater | Grease trap + septic tank | Rely on existing | ||
| Solid Waste | One general solid waste temporary storage (covering an area of 10m2, storage volume of about 50m3) | Newly built | ||
Product plan and product quality standards
Product plan
The products of the fish feed plant in Indonesia expansion project are fish feed, including fry, fish species and edible fish feed, with an annual output of 100,000 tons.
Product quality standards
① Sensory requirements
Pellets of the same specification should be uniform in size, smooth in surface, uniform in color, free of mold, deterioration, agglomeration, odor, and insect breeding.
| Product type | Fish Fry Feed | Fish Fingerling Feed | Edible Fish Feed | |
| Particle Specifications | Particle Size, mm | ≤1.5 | 1.5～4.5 | ≥4.5 |
| Length, mm | Particle Size: Length 1: 0.5～2.0 | |||
The smell is normal, without moldy, rancid or other odors.
The pellet feed absorbs water for 20 minutes, and the dissolution rate is ≤15%.
②Physical and chemical indicators
| Item | Product Category | |||
| Fish fry feed | Fish fingerling feed | Edible fish feed | ||
| Mixing uniformity (variability coefficient, CV), % | ≤10.0 | |||
| Powdering rate, % | Expanded granular material | ≤1.0 | ||
| Crude protein, % | ≥45.0 | ≥42.0 | ≥40.0 | |
| Crude fat, % | Granular material | ≥7.0 | ||
| Powdered material | ≥3.0 | |||
| Crude fiber, % | ≤2.0 | ≤3.0 | ≤5.0 | |
| Moisture, % | Granular material | ≤11.0 | ||
| Powdered material | ≤10.0 | |||
| Calcium, % | ≤4.5 | |||
| Total phosphorus, % | ≥1.5 | ≥1.2 | ||
| Crude ash, % | ≤16.0 | |||
| Hydrochloric acid insoluble matter, % | ≤2.0 | |||
| Lysine, % | ≥2.0 | ≥1.8 | ≥1.6 | |
| Salt, % | ≤4.0 | |||
| Volatile basic nitrogen, mg/100g | ≤100.0 | |||
Consumption of raw and auxiliary materials
The main raw and auxiliary materials used in this fish feed plant in Indonesia project are shown in the following table:
| Item | Name | Required Quantity | Remarks | Maximum Storage Quantity | Storage Location |
| Raw and Auxiliary Materials | Fish Meal | 7,500 t/a | Powder, Purchased, Bags | 2,300 t | Raw Material Workshop |
| Wheat | 7,500 t/a | Pellets, Purchased, Bags | 2,300 t | Raw Material Workshop | |
| Flour | 10,000 t/a | Small materials, purchased from outside, bagged | 3,300 t | Raw material workshop | |
| Rice bran | 4,000 t/a | Powder, purchased from outside, bagged | 1,200 t | Raw material workshop | |
| Bean paste | 32,000 t/a | Pellet materials, Purchased from outside, bagged | 9,600t | Raw material workshop | |
| Cai Can | 32,500t/a | Pellets, purchased from outside, bagged | 9,800t | Raw material workshop | |
| Soybean oil | 5,000t/a | Liquid, purchased from outside, barreled | 1,500t | Raw material workshop | |
| Fish oil | 0.8 thousand t/a | Liquid, purchased from outside, barreled | 0.2 thousand t | Raw material workshop | |
| Trace elements | 0.3 thousand t/a | Small materials, purchased from outside, bagged | 0.9 thousand t | Raw material workshop | |
| Energy | Water | 20100m3/a | Municipal water supply | ||
| Electricity | 1.3 million kwh | Municipal power supply | |||
| Natural gas | 700,000 m3/a | Provided by PetroChina Gas Company |
Main production equipment for fish feed plant in Indonesia
This fish feed plant in Indonesia project has 2 fish feed production lines, and the main equipment is detailed in the table below.
| No. | Equipment Name | QTY |
| 1 | Raw Material Receiving and Cleaning System | 3 |
| 2 | First Crushing System | 2 |
| 3 | First Batching and Mixing System | 2 |
| 4 | Ultrafine Crushing System | 1 |
| 5 | Second Batching and Mixing System | 2 |
| 6 | Puffing System Pellet drying system | 2 |
| 7 | Spraying system | 2 |
| 8 | Puffed feed finished product packaging system | 2 |
| 9 | Powder recovery system | 1 |
| 10 | Auxiliary production system | 1 |
| 11 | Natural gas boiler (4t/h) | 2 |
| 12 | Silo | 8 |
Public works
(1) Water supply and drainage
Water supply: The fish feed plant in Indonesia project’s fresh water consumption is 20,100 m3/a, relying on the water supply system of the existing project.
Drainage: The plant area uses a diversion drainage system with separate drainage pipes for rainwater and sewage. Rainwater is discharged into the rainwater pipe network; the domestic sewage of the entire plant is treated in the grease trap and septic tank and then enters the sewage treatment plant through the park sewage pipe network for treatment. After the sewage treatment plant meets the standards, the tail water enters the local river.
(2) Power supply
According to the information provided by the owner, the project’s additional annual electricity consumption is about 1.3 million kWh. The additional electricity consumption relies on the power supply system of the original project and is supplied by the local power supply bureau.
(3) Natural gas
The natural gas consumption of the expansion project is 700,000 m3/a, which is connected by gas pipelines and provided by the gas company.
General layout
This fish feed plant in Indonesia project is a renovation and expansion project, which is mainly carried out on the basis of the existing project site. The total building area of the expansion project is 14,508m2. The construction content mainly includes: main workshop, finished product workshop, raw material workshop, silo, boiler room, etc.
The raw material workshop is to the west of the existing project 1# workshop, the boiler room and machine repair room are to the west of the raw material workshop, the unloading shed is located in the southwest corner of the raw material workshop, the main workshop and finished product warehouse are located to the north of the raw material workshop, and the silo is in the northwest corner of the raw material workshop. The general layout of the project has a smooth process flow, clear site functional division, compact and reasonable overall layout, good use of the existing site, small footprint, and land saving.
Process flow design of fish feed factory
The product of the fish feed plant in Indonesia expansion project is fish feed, including fry, fish species and edible fish feed, with an annual output of 100,000 tons. The production process and pollution production of the three feeds are the same, but the raw material ratio is different. The main process flow includes raw material reception and cleaning, crushing, batching and mixing, granulation drying, spraying, etc. The production process of this project is fully automated and closed except for feeding and packaging.
(1) Feeding and cleaning
After the raw materials are purchased, they must be inspected and qualified before they can be used. For the raw materials that have passed the inspection, the raw materials are first put into the silo, and then manually put into the feeding port of the “raw material receiving and cleaning system” at different feeding ports. Fences are set at the feeding ports to prevent large pieces of materials from entering and damaging the equipment. After cleaning and impurities are removed, the raw materials are sucked into the batching and mixing system through a micro-negative pressure system and pipelines.
The purpose of raw material cleaning is to remove impurities in the raw materials. Impurities not only affect the growth of animals, but also easily cause pipelines and equipment to be blocked, and even damage equipment (screens, ring molds, etc.). This project uses primary cleaning screens and permanent magnetic drums for raw material cleaning. The main equipment for raw material cleaning includes feeding hoppers and fences, scrapers, self-cleaning elevators, primary cleaning screens, permanent magnetic drums, rotary distributors, etc.
(2) Coarse crushing
The pellets that have passed the inspection and primary cleaning are sent from the silo to be crushed through the buffer bucket and into the crusher for coarse crushing. During the crushing process, the feed volume should be adjusted in time. When replacing the screen plate daily, the wear of the hammer should be checked and the hammer should be replaced or adjusted in time. During crushing, the destination of the crushed material should be confirmed to confirm whether it has reached the designated batching bin to avoid mixing.
(3) First batching and first mixing
The raw materials entering the “batch mixing system” are first classified and placed in each bin of the “batch bin group”. According to the requirements of the formula, the various raw materials involved in the batching are measured by the batching scale of the computer control system according to the formula ratio and enter the mixer in turn for mixing and batching. At the same time, flour is added through the “small material adding machine” and various raw materials are fully mixed in the mixer.
(4) Ultrafine grinding
Use the ultrafine grinding machine to ultrafinely grind the raw materials.
(5) Second batching and second mixing
The various raw materials processed in the previous process entering the second batching bin are weighed according to the feed formula ratio by the microcomputer control batching and enter the second mixer. At the same time, trace elements are added through the “small material adding machine” and fully mixed.
(6) Extrusion and drying
The material is quantitatively fed into the granulation bin, and is treated by high temperature (90-95°C) in the extruder. The feed is matured and reaches a certain uniformity through steam conditioning, so that the nutrients in the feed are easier to be digested and absorbed by fish. The extrusion time is about 13 seconds, and then the feed is extruded into uniform granules by the floating fish feed extruder machine. Since the feed after extrusion contains a certain amount of water, which is not conducive to storage, the feed is dried in a dryer after granulation to remove excess water.
(7) Spraying
The dried material is mixed with fish oil evenly through the spraying system.
(8) Cooling
The cooling of this project adopts high-volume countercurrent cooling, separated by a dust collector, and equipped with a wind shutoff.
(9) Packaging
The cooled granular material needs to be graded by a vibrating screen. According to different particle size classification, it is divided into three layers. The large particles on the top layer need to be crushed again, the middle layer enters the finished product bin, and the bottom layer returns to the granulation bin for re-granulation. The qualified products are automatically weighed and packaged by the packaging system and put into storage for sale.
Material Balance
The material balance for this fish feed plant in Indonesia project is as follows:
| No. | Input (t/a) | Output (t/a) | ||
| 1 | Material name | Material quantity | Product | 100000 |
| 2 | Fish meal | 7500 | Dust | 96.5 |
| 3 | Small Wheat | 7500 | Iron | 1 |
| 4 | Flour | 10000 | Water vapor | 2202.5 |
| 5 | Rice bran | 4000 | ||
| 6 | Bean Rice | 32000 | ||
| 7 | Caijiao | 32500 | ||
| 8 | Soybean oil | 5000 | ||
| 9 | Fish oil | 800 | ||
| 10 | Trace elements | 3000 | ||
| 11 | Subtotal | 102300 | Subtotal | 102300 |
If you are interested in this fish feed plant in Indonesia project, or want to build, expand or renovate a fish feed processing line, please feel free to contact RICHI MACHINERY to obtain information on the civil engineering plan, overall plant layout, process design, equipment configuration and quotation of the aqua feed plant!