muyang my series single-screw extruder
DESCRIPTION
The extrusion provides for production of many products with great superiority in comparison with other technologies. Because it integrates functions of different equipments in a single process when extruding in most cases, the procedures of mixing, extruding, cutting, cooking, forming and drying process in a certain degree can be carried out at the same time.TRANSCRIPT
Application
Machine highlights
Technical parameters
Extrusion process
Production reference
Wear parts
Muyang MY series Single-screw Extruder is suitable for both the sinking and
floating aquafeed production.
It is also widely used for pet food production.
As for other applications in new fields, please consult Muyang technical
experts.
Application
Protruding-end pellet
Widened
Extrusion
Capability
Application
Flat-end pellet Oil-rich pellet (17%)
Varied in shape and color
Small pellet (Φ 1.0 mm)
Application
Technical parameters
Extrusion process
Production reference
Wear parts
Machine highlights
Structure highlights
Anti-bridge feeder
Conditioner
Extrusion parts
Water and steam pipeline system
Cutter device
Control system
Support bracket
Conditioner
Principal machine
Cutter device
MY single-screw extruder
Ensure smooth and precise feeding
Anti-bridge feeder
Anti-bridge design;
Batch type automatic feeding;
Gravimeter for flow detection
and variable-frequency motor
for flow control together with
the computer, make up a
closed-loop circle for feeding
control.
Feeding accuracy is 0.1kg.
Anti-bridge feeder
MaterialFlow control
Computer
Flow settings
Feedback
Flow detection
Filling level : 0% Filling level : 40% Filling level : 60%
Optimal paddle configuration
to increase material filling level,
prolong conditioning time and
improve gelatinization of
product, which finally
contributes to high capacity of
extrusion production.
SCTZ Conditioner (DDC)
Gelatinization (%) & Conditioning time (s)
Ge
latin
izatio
n
%
Conditioning time (sec.)
Steam Water
Steam
Combining a one-cylinder conditioner with a DDC conditioner, the SPTZ complex
conditioner can improve not only the extrusion capacity but also the quality of
extrudates.
SPTZ Complex Conditioner
Conditioner configured to single-screw extruder
No. Model SCTZ Conditioner (DDC)SPTZ Complex Conditioner
1 MY-135 SCTZ 28
2 MY-165 SPTZ 33
3 MY-215 SPTZ 39
4 MY-265 SPTZ 45
0 30 60 90 120 150 180 210 240
60
50
40
30
20
10
gela
tiniza
tion
%
conditioning time (sec.)
Note: Fresh water fish formulation, conditioner temperature 98 , conditioning water 24%. ℃
Complex
conditioner
DDC conditioner
Gelatinization can be around 15% higher
Comparison of gelatinization
L/D=13.1 to increase material retention time in the extruder;
Combining the shearing effects of both screw and shear lock to increase
extrusion efficiency and pellet uniformity;
New material applied in the manufacturing of wear parts, which prolongs the
service life by 2-3 times and ensure stable production.
Principal machine
Steam and water pipeline system
Steam to extruder chamfer
Steam impurity drainage
Water to
jacket
Steam to jacket
Water drainage
condensate drainage
New cutter device to ensure long time stable running;
A gap usually is generated between cutting knives and the die plate after long time running
and wearing. And it should be eliminated in order to obtain good appearance extrudates;
The new cutter device applied can eliminate the gap during production without down-time.
Cutter device
Hand wheel
Cutter Motor Positionin
g lock
Muyang automatic control system
can simplify operation and
eliminate the impact of manual
operation;
All production data could be
recorded for production
management;
Advanced European control
elements applied to ensure
precise and reliable control;
Available of three control modes:
manual, commissioning and
automatic.
Control system
Single-screw VS. Twin-screw (1)Item Single-screw
extruderTwin-screw extruder Remarks
Conveying manner
Feed mash is convoyed forward by friction and stickiness
Feed mash is forced to slid forward
Single-screw extruder conveys material mainly by friction, resulting in relatively high wearing and power consumption.
Granular of finished pellet
>1.5 mm >1.5mm<1.5 mm
The product of single-screw extruder is limited because of the non-uniform distributed heat and kneading effect.
Ingredient adaptability
Common( limited by moisture content and fat content of ingredients)
Wider (incl. ingredient rich of moisture and fat)
Single-screw extruder can not adapt to the ingredients that of small friction .
Max. fat% ≤10% > 17%(could be up to 25%) Fat helps to reduce friction.
Max. H2O% 10% ~ 30% 5% ~ 95% Moisture helps to reduce friction.
Heat distribution of feed mash
Common Uniform
Steam flashing performance
Common Excellent
Shearing force when extruding
Strong Common Single screw extruder is of larger backward pressure and shearing force.
Single-screw VS. Twin-screw (2)
Item Single-screw extruder Twin-screw extruder Remarks
Backflow phenomenon
Common Rare Gap between screw and chamber wall of single-screw extruder is larger.
Pressure on die Non-uniform and will affect capacity
Uniform Material in single-screw extruder is liable to flow back.
Product quality, safety and variety
Good in quality and safety, but the variety is limited
Excellent in quality and safety with a wide variety
Twin-screw extruder is of uniform mechanical and thermal effect as well as high moisture content.
Running Stable and occasional blockage
Stable and reliable
Operation Required good experience
Ease of operation and control
Production pressure of single-screw extruder is more sensitive to the formula.
Production Efficiency
Common High Twin-screw of good conveying and extruding efficiency.
Power consumption Relatively high Relatively low Twin-screw of good conveying and extruding efficiency.
Machine price Relatively cheap Relatively expensive Twin-screw is more complicate in construction.
Capacity Common Relatively high
Application
Machine highlights
Extrusion process
Production reference
Wear parts
Technical parameters
No. Model Main motor ( kW )
Screw dia.(mm)
Pet food( kg/h )
Floating aquafeed( kg/h )
Sinking aquafeed( kg/h )
1 MY-135 90 135 1600~2500 1600~2500 500~1500
2 MY-165110
1652000~3500 2000~3500 2000~3000
160 3000~6000 3000~6000 2000~4000
3 MY-215
250
215
6000~9000 6000~9000 3000~6000
315 8000~12000 8000~12000 3000~6000
4 MY-265 400 265 10000~15000 10000~15000 5500~12000
Capacity of MY series Single-screw Extruders
Capacity & die opening area
Floating aquafeed:
Die opening area (mm2)
Capacity(t/h)=——————————————
200~250mm2/t · h
Sinking aquafeed:
Die opening area (mm2)
Capacity(t/h)=——————————————
550~600mm2/t · h
Process parameter control for floating aquafeed production
Parameters Single-screw extruder
Temperature prior to die discharging 125-135 ℃
Moisture prior to die discharging 25-27%
Bulk density after discharge 320~440kg/m3
Moisture of extruded product21-24%
(Flash by 3-4%)
Pressure of discharging barrel 34-37 atmos
Floating-sinking knee point 480kg/m3
Process parameter control for sinking aquafeed production
Parameters Single-screw extruder
Conditioning moisture 19-23%
Conditioning temperature 80℃
Bulk density after discharge 490~550kg/m3
Moisture of extruded product 22-27%
Pressure of discharging barrel 20-29 atmos
Final gelatinization 90-95%
Requirements to formulation
Materials Floating feed Sinking feed
Starch ≥ 20% ≥ 10%
Oil ≤ 5% 4%~12%
Fat ≤ 17% (single-screw) _____
Extrusion coefficient 1.8 1.1-1.3
Note that the feed formulation should not contain too much animal protein,
especially that for floating aquafeed.
Die hold dia.Φ ( mm ) Max. granular of ground material ( mm )1.0 0.1
1.5 0.15
2.0 0.3
2.5 0.5
3.0 0.8
4.0 1.0
5.0 1.2
>5.0 1.2
Requirements to formulation
For aquafeed production, the granular of ground material usually should be controlled at
20 mesh (0.85mm), for the production with die hole smaller than 1.5mm, make sure at least
98% material could pass through the 60 mesh sieve.
Fiber in the formulation should be clean away in time to ensure smooth operation,
especially for the production of small aquafeed.
1. Environment temperature for normal use is within -10 ~ +40 ;℃
2. Relative moisture content for normal use is within 30~85%;
3. Altitude for normal use is lower than 1000 m;
4. Keep the room where extruder working clean and ventilated;
5. Keep the extruder far away from corrosive gas, explosive gas and steam;
6.Power supply : refer to motor nameplate ; air pressure ≧ 0.6Mpa;
7.Keep enough space around the extruder for easy operation, repair and maintenance;
8.Make sure the machine is level.
9.The vibration should not exceed12 mm·s-1
Requirements to working condition
Under other working conditions, please consult Muyang technical experts.
Application
Machine highlights
Technical parameters
Production reference
Wear part
Extrusion process
After extrusion, drying, coating, cooling and grading, the finished product of expanded
aquafeed is featured by controllable density, wide raw material adaptability, good water
stability and high feed conversion ratio.
See Fig.1~Fig.4, the four common aquafeed extrusion processes. Those shown in
Fig1. and Fig.2 are recommended.
Extrusion process
No. Item
Extruder
MY135 MY165E MY215 MY215 MY265
1 Main power (kW) 90 160 250 315 400
2 Aquafeed capacity (t/h) 1.5 ~ 2.0 3.0 ~ 6 6.0 ~ 8.0 6.0 ~ 11.0 10.0 ~ 15.0
3Steam
aspiration system
Fan T40No4 N=1.5Kw
n=2900rpm
5-48-12NoN=3Kw
n=2900rpm
Cyclone / X55-Φ700
Airlock / GFZY-6
Air pipe dia.(mm)
Branch pipe dia. Φ150mm;Manifold pipe dia. Φ200mm
Branch pipe dia. Φ200mm;Manifold pipe dia. Φ250mm
4Belt conveyor (high
temperature resistance, 80 ~ 90℃, free of oil)
TDSG40 TDSG50
5 Dryer MGLZ22/ SKGW150-4 SKGD2000-5 SKGD2000-6 SKGD2000-8 SKGD2400-8
6Steam
exhaust system
Induced-draft fan
5-48-12NoN=7.5kw
n=2900rpm
4-72- No N=18.5Kwn=1800rpm
4-79- No N=22Kw
n=1800rpm
4-79- No N=30Kw
n=1600rpm
4-68NoN=55Kw
n=1000rpm
Cyclone X55-Φ1000 X55-Φ1800 X55-Φ2000 X55-Φ2400 X55-Φ2200x2
Airlock GFZY-8 GFZY-10
Air pipe dia.(mm)
Φ340 Φ400+Φ480/Φ600 Φ480/Φ700 Φ610/Φ800 Φ800/Φ1000
Process configuration
7Elevator (high
temperature resistance belt, 80 ~ 100℃)
TDTGq36/23 TDTGq40/23 TDTGq40/28 TDTGq50/28TDTGq50/
32
8 Grading sifter SFJH80X SFJH110x SFJH130x SFJH140x SFJH153x9 Volume of coating bin 1 ( m3) 3 ( m3) 4 ( m3) 6 ( m3)10 Continuous liquid coater SYPL SYPL SYPL SYPL SYPL11 Vacuum liquid coater SYPZ90 SYPZ120 SYPZ150 SYPZ200
12 Airlock SLNF16x
(SLNF14x(QD))SLNF22x
(SLNF19x(QD))SLNF24x SLNF28x SLNF32x
13
Aspirat
ion system
for cooling
Fan 5-48-12NoN=7.5kw
n=2900rpm
4-72Ⅱ NoN=15kw
n=2900rpm
4-7Ⅱ NoN=18.5kw
n=2900rpm
4-72N=30kw
n=1800rpm
4-68N=37kw
n=1800rpm
Cyclone X55-Φ1000 X55-Φ1400 X55-Φ1600 X55-Φ1800
X55-Φ2400X55-
1600x2Airlock GFZY-8 GFZY-10
Are pipe dia.(mm)
Φ340 Φ530 Φ610 Φ700 Φ800
14 Grading surge hopper Effective volume equal to that of mixer effective volume
15 Ultra-fine grading sifter SXFQ60 ( with 40 mesh screen, capacity up to 3t/h ) SXFQ60 ( with 40 mesh screen, capacity up to 5t/h )
16Bagging machine ( belt
feeder type ) LCS-50-BZ
Note: ①Equip an air-draft hood for the aspiration system over the outlet of extruder ; ② A movable chute, which serves as a by-pass for conveying
product between extruder and conveyor, should be equipped. The belt conveyor is reversed; ③circulating air system for drying should be equipped
according to the operation manual; ④ There should have a straight chute over the dryer with at least 500mm to ensure feeding efficiency.
Process configuration for pneumatic conveying
Application
Machine highlights
Technical parameters
Production reference
Wear parts
Pelleting process
Currently, there are over 100 sets of Muyang MY series single-screw extruder
stably running in China and around the world. Satisfied customers include CP Group,
DaChan Food, Gold Coin, New Hope Group, Tongwei Group, etc.
Production reference
…………
Application
Machine highlights
Technical parameters
Production reference
Wear parts
Process configuration
Extruding rotor
For MY series single-screw
extruder, the screws, pressing locks
and kneading locks of extruding rotor
are all wear parts.
Usually, the operating life of the
extruding screw is about 12,000 tons.
Extruding rotor
Screw
Pressing lock Kneading lock
Extruding chamber
Fixed shear lock
Wear part
Note : For MY series single-screw extruder, all liners (6
sections) for extruding barrel and wear rings in fixed shear locks
are wear parts.
liner of discharge chamber
Liner of feeding
chamber
Liner of pressure-relief chamber
Liner of middle section chamber
Discharge assembly
Die plate assembly
Die plate
Die plate holder Distributing cone
Cutter support bracket
Fixed holder
Pressure regulated ring
Venturi element
Cutter structure
Among above parts, cutting knife is wear part.
Cutter motor
Cutter shaft
Knife carrier
Knife holder
Cutting knife
Reducing motor: SEW, NORD, FLENDER, FALK…
Pneumatic/Hydraulic components: FESTO, SMC, YSC, Spirax Sarco …
Bearing: SKF, NSK, HWL…
Electric components: Honeywell, Omron, Schneider, Schmersal …
Wear parts from Muyang supplier
……
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