Regarding the addition of fats, it has been well established that there are limitations to pre-pellet fat inclusion. Inclusion of high (>5%) fat in the mixer compromises pellet durability. However, with higher utilisation of high protein and low energy co-products (e.g. canola meal or DDGS) in broiler diets, higher levels of fat inclusion are required. In this scenario, high level of fats can be incorporated in pellets post-pelleting with the use of vacuum coating and minimising fines in the feed.
Vacuum coating is a physical process, in which air inside the pellet pores is pumped out to create a near vacuum, then pellets are mixed with liquid (fats, bioactives, nutraceuticals) and pressure then released which “pulls” the coated liquid deep into the pellet pores. Vacuum coating is used primarily for aqua and pet feeds; which are extruded not pelleted. Lower density (e.g. higher porosity) in extruded feed allows incorporation of higher amounts of liquid by vacuum coating. Whereas the high density of pellets causes challenges for use of vacuum coating. However, by developing diet formulation, pellets with high porosity and low density can be processed without reducing pellet durability (PDI). This will improve the use of vacuum coating for higher inclusion of fats and heat sensitive bioactives in broiler pellets.
FEEDTECH vacuum coaters are designed to spray high percentages of fats and other liquids on pellets and extruded feed in vacuum conditions. By installing a vacuum coater next to the drying, before the cooling units, it is possible to include up to 30% fats in extruded fish feeds.
Comparing to fat dosing on die:
► More accurate dosing and better distribution throughout the feed
► No contamination in pellet mill or extruder.
► Considerably simpler and cleaner process.
► Provides maintenance of Pellet Durability Index (PDI).
► Reducing wastage of product losing with fines.
In terms of nutritional value:
► Increasing in absorption of solvent in oil vitamins in animals’ digestive system.
► Better utilization of feeds so the process plays an increasingly important role both in terms of high nutritive value and better chemical and physical features of the pellets.
► Increases energy density.
► Versatile operation and compact design Low energy consumption
► Volume:500 – 2800 liters
► Line capacities: 3000 to 20,000 kg/h, depending on the amount of liquid added
► Minimum volume: 25% of the nominal volume
► Maximum volume: 110% of the nominal volume
► Maximum percentage of added liquids is 24% (excluding fat and oil which is already present in the product)
Aquatic feed plants:
Addition of pigments and micro-ingredients as well as oil up to 30%
Pet food plants:
Addition of micro-ingredients, aromas as well as oils and fats up to 17%
Addition of Phytase enzymes and vegetable oil up to 8%
► Standard in normal steel and suitable for 200 mbar of absolute under pressure.
► In 304 or 316L stainless steel
► Integrated sub-hopper with butterfly valve
► Vacuum pump
► Liquid dosing pumps
► Powder feed
► Weighing system
► Mixing tanks for various liquids
► Drive provided by two motor reducers
Types of Vacuum Coater
Check the table comprising the different types of Vacuum Coater designed and manufactured by FEEDTECH, which are available with variable level of motor power, capacity and dimensions.
You may have particular preference or requirements that will be considered and appreciated by FEEDTECH Engineering Team.