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INDUSTRIAL MANUFACTURE OF COMPOUND FOOD FOR MARINE SPECIES

Mr. J. J. SABAUT

The aim of industrial manufacture of compound food is to feed animals in rearing, while ensuring their maximum growth at the lowest production cost and preserving optimal hygiene.

The perfectioning of compound food for aquaculture was started in the fifties and became widely used in the seventies with the development of salmonculture in fresh and marine water.

Food is an essential element for all animal production. It can represent 40 to 60% of the production costs, depending on the methods employed and the species reared.

The constraints defining which is to be manufactured and what industrial structures are to be built so as to ensure the coverage of the rearing needs, are as follows :

- knowledge of the species reared and of food needs.

- availability of raw materials: nature, price, stockage, renewals,

- importance and divisions of the rearings,

- variations in the seasonal needs concerning the quality and quantity of food.

1. Knowledge of the species reared and their nutritive requirements

On the contrary to land animals, fish have great requirements of proteins. These are carnivorous species mostly, which require quality proteins, rich in the essential amino-acids.

The species requirements are shown in table 1 and 2.

These species do not make good use of carbohydrate as a source of energy. Important inputs of fatty matter, rich in unsaturated fatty acids, ensures this requirement while at the same time giving the necessary fatty acids.

Depending on the species, the fatty inputs vary from 8to 15% of the ration which comprehends 40 to 50% of proteins.

All compound food manufacturers, depending on their competance and especially on the technological capacities of their facilities, define the food ranges having specified characteristics.

In table, the sea-bass food composition, commercialized by the Aqualim Company as shown, along with the table for the daily distribution of food, expressed in live weight percentages of fish.

2. Availability of raw materials

Essential raw materials, employed in compound food for aquaculture have high proteinic content.

For fish meal, along with the local production available in numerous countries, meal found on the world market is employed. This comes from big exporting countries: Norway, danemark, Island, Peru.

In any case, it is very important to define the type of fish meal, as their characteristics can vary considerably from one product to another. It is also necessary to ensure the non-oxydation of the constituent fatty matters, as when not verified, these products would be inadequate and even toxic for the animals being reared.

Other proteinic mater of animal origin is also employed, such as meat meal, blood meal, hydrolysates, lactoserums, yeast, etc…

Among the vegetable proteins, the most commonly employed, although in smaller amounts, are soya meal and whole cooked soya beans, distillery solubles, wheat or corn granules, lucerns, cereals, and wheat by-products.

The diverse characteristics of these products are shown in table 4, 5, 6 and 7.

For the manufacturer, the between these products depends on the formulation objectives, the analytic characteristics, the price and supply possibilities. The calculations are carried out by means of a computer and optimization programmes which takes all these constraints into account.

All the products and in particular animal meal should be stocked properly, so to ensure perenniality of their nutritive qualities. It should be advisable to ensure a proper rotation of the stocks thus avoiding that they become stable oxydate. This depends on the buying facilities of the local products and on importation. In relation with the food qualities to be manufactured for a given period. Avoiding stocking over many months especially in high temperatures.

3. Technological aspects

At this necessary to cover the food requirements of the species reared, it is alos essential to distribute standard size food particles, suitable to the size of the mouth of the fish during the production cycle. The particle sizes vary from a hundred microns to ten millimeters. This presentation aspect is of prime importance.

The manufacture of compound food is based on the caking of dry meal by compressing it through circular die holes having different diameters (See figure 1).

This technic, commonly employed for the production of compound food for land animals has been adapted, which led to the construction of very specialized units for the manufacture of compound food in aquaculture.

Certain constaints have been remarked. They result principally in the following points :

- As little dust as possible and good caking (pelleter) of the particles is required so as to limit losses and pollution of the rearing waters.

- The proteinic products which are base of the formulation are difficult products to manipulate, mince or cake and require properly adapted technical solutions.

- Specific and costly investments are required to manufacture the food particles of less than 2 mm in diameter.

- Finally, due to the improvement in knowledge on the nutritive requirements of fish, it becomes imperative to incorporate more and more quantities of fatty materials, which lead to the requirement of the appropriate technical solutions.

Indeed, from a standard diagramme, such as given in figure 2, it was necessary to modify and innovate on it, which means a unit for the manufacture of fish food is quite original when compared to that for land animal food.

The animal food industry is a heavy industry which requires high investments for a feeble return. The raw materials make up more than 605 if the cost price of the food manufactured.

To define the production capacity of one unit, the rearing divisions which would buy the food must be well known, along with their capacities and their production cycles. There are indeed important seasonal variations concerning quantity and quality.

Each manufacture has its own particularities which must be studied according to the market requirements and production perpectives over the next 10 years. The raw material supply conditions must be taken into account (in bulk or in sacks) together with the availability of a specialized manual labour and the deswired automatization level of the circuits of the whole unit.

TABLE No 1

ESTIMATE OF THE PROTEINIC REQUIREMENTS OF CERTAIN FISH (1)

species Crude proteinic requirement in the food ensuring optimal growth
  (g/kg) 
Rainbow trout(Salmo gairdneri)400–450 
Carp(Cyprinus carpio)380 
Chinooksalmon(Oncorhynchus tshawytgcha)400 
Japanese ell(Anguilla Japonica)445 
plaica(Pleuonetea Platessa)500 
Royal sea-bream(Chrysophrys aurata)400 
Herbivorous carp(ctenopharyngodon idella)410–430 
Japanese red sea-bream(Chrysophrys major)550 
Seriola(Seriola quinqueradiata)550 

(1) by C.B.COWEY, 1978

TABLEAU No 2

The essential amino acid requirements of six species of fish

 Chinook a
Salmon
Japanese b
Eel
Carp bCarp cRainbow c
Trout
Tilapia dChannel e
Catfish
Arginine2.4 (6.0/40)1.7 (4.0/42)1.6 (4.3/30.5)1.52 (3.8/40)01.40 (3.5/40)<1.59 (4.0/40)1.03 (4.29/24)
Histidine0.7 (1.8/40)0.8 (1.9/42)0.8 (2.1/38.5)0.50 (1.4/40)0.64 (1.6/40)ND0.37 (1.54/24)
Isoleucine0.9 (2.2/41)1.5 (3.6/42)0.9 (2.5/38.5)0.92 (2.3/40)0.96 (2.4/40)ND0.62 (2.58/24)
Leucine1.6 (3.9/41)2.0 (4.8/42)1.3 (3.3/38.5)1.64 (4.1/40)1.76 (4.4/40)ND0.84 (3.50/24)
Lysine2.0 (5.0/40)2.0 (4.8/42)2.2 (5.7/38.5)2.12 (5.3/40)2.12 (5.3/40)1.62 (4.1/40)1.50 (5.00/30)
Methionine0.6 (1.5/40)1.2 (2.9/42)1.2 (3.1/38.5)0.64 (1.6/40)0.72 (1.8/40)<0.53 (1.33/40)0.56 (2.34/24)
 Cys = 1%Cys = 0%Cys = 0%Cys = +Cys = +Cys = 0.74%60% replaceable by Cys
  0.9 (2.1/42)0.8 (2.1/38.5)    
  Cys = 1%Cys = 2%    
Phenylalanine1.7 (4.1/41)2.2 (6.2/42)2.5 (0.6/38.5)1.10 (2.9/40)1.24 (3.1/40)ND1.20 (5.0/24)
 Try = 0.4%Tyr = 0%Tyr = 0%Tyr = +Tyr = +   Total Tyr +
  1.2 (2.9/42)1.3 (3.4/38.5)   Phen
  Tyr = 2%Tyr = 1%   50% Phen
Threonine0.9 (2.2/40)1.5 (3.6/42)1.5 (3.9/38.5)1.32 (3.3/40)1.36 (3.40)ND0.53 (2.21/24)
Tryptophan0.2 (0.5/40)0.4 (1.0/42)0.3 (0.8/38.5)0.24 (0.6/40)0.20 (0.5/40)ND0.12 (0.5/24)
Valine1.3 (3.29/40)1.5 (3.6/42)1.4 (3.6/38.5)1.16 (2.9/40)1.24 (3.1/40)ND0.71 (2.96/24)
Total12.3 (30.49)14.8 (3504)13.7 (35.8)11.28 (28.2)11.64 (29.1) 70.48 (30.92)

a Data for chinook salmon and rat from Merts (1969)

b Data for Japanese eel and carp from Mose (1979)

c Data for Rainbow trout and carp from Ogino (1980)

d Data for tilmpia from Jackson & Capper (1982)

e Data for Channel catfish from Wilson et al. (1977, 1978, 1980; Harding et al, (1977); Robinson etal. (1978, 1990a, b, 1981) Values are expressed as grams per 100g of dry diet. In paranthesis the numerators are grams per 100g of protein and the denorinators are the percent total dietary protein.

TABLE No 3RATION CHART - WHOLE NUTRIMENT FOR SEA - BASS

GRANULOMETRIESWeight of sea-bass/in
g
TEMPERTAURE PATTERN
below 15° C15° to 19° C19° to 23° C23° to 26° C26° to 28° C28° and +
1st stageInf. to 0,5Unlimited distribution depending on the appetite of the fish
2nd stage0,5 to lFeed according to the fish appetite44,24,543
3rd stage1 to 33,24,24,543
crumbs3 to 82,83,03,33,02,9
1,5 mm8 to 152,52,73,02,72,5
2 mm15 to 351,92,32,62,32,0
3, 2 mm35 to 1001,31,62,01,8,1.5
4, 5 mm100 to 5001,11,41,91,61,3
6 mmSup. to 5001,11,41,81,61,3

This chart indicates the quantity of feed in Kg for 100 kg of fish to be distribute daily according to the type of nutriment and the rearing water temperature.

Remarks: The ration bases must be adapted to the particular condition of each rearing control the dissolved oxygen content.

ANALYTIC GUARATEES WHOLE NUTRIMENT FOR SEA BASS

GranulometriesHumidity
%
gross %
proteins
Fats
%
Cellulose
%
Minerales
%
1st stage small grain105612213
2nd "   "   "105612213
3rd "   "   "105612213
Crumbs 4th stage105212213
Granulars 1,5 mm105212213
    "    2 mm104915313
    "    3,2 mm114615313
    "    4,5 mm114615313
    "    6 mm114615313

TABLE No 4 - ANIMAL MEAL

 Meat Fish
45505560 Fish
60
Anchovy
65
sardine
65
smelt
68
herring
70
soluble
Centesimal Composition
Dry material93939393 929292929250
Crude proteins45505560 606565687230
Fatty materials101099 1075,501094
Cellulose---- ------
Nitrogen Fece extract3343 356,50206
Minerals35302522 191515121110
Calcium121087 544,50430,10
Total phosphore54,503.503,30 32,502,702,5020,50
Assim. phosphore54,503.503,30 32,502,702,5020,50
D.N.M. Ruminants36,0040,0046,8051,00 51,0055,3058,3058,5061,9026,40
Energy
RawKcal/Kg3618390341364287 447345614483488849112328
Poultry           
Metabolisable
"1870207022702400 29502880280031003200430
Pork           
Digestible
"2930316033203480 354035403430391044101900
Metabolisable
"2660275028702990 305030302920336037801640
Net
"1790191019401980 207019601850225024901090
Net
"0,830,890,900,92 0,960,910,861,051,160,51
Ruminants           
Digestible
TD FP 10061656870 777775838342
Net
UF/Kg0,700,770,830,66 1,011,010,981,141,140,56
Net
UA/Kg0,560,820,670,68 0,730,690,660,800,820,33
Amino-acids percents of Raw Products
LYSINE2,162,532,783,12 4,575,085,124,485,061,37
METHIONINE0,600,680,740,80 1,571,811,831,931,850,42
METHIONINE + CYSTINE0,991,101,201,55 2,142,382,412,552,440,60
THREONINE1,361,541,682,06 2,442,722,752,942,890,70
TRYPTOPHANE0,180,200,220,36 0,620,960,500,700,770,11
ARGININE3,103,393,723,81 3,523,763,713,573,671,28
GLYCINE6,487,548,497,24 4,333,934023,844,122,57
GLYCINE + SERNE6,239,5110,459,83 6,796,436,586,516,843,27
HISTDINE0,660,810,891,05 1,261,611,571,291,381,09
ISOLEUCINE1,311,441,581,95 2,593,083,063,172,300,90
LEUCINE2,522,843,123,79 4,194,844,805,245,161,37
PHENYLALANINE1,431,561,722,02 2,272,712,722,652,750,70
PHENYLALANINE + TYPOSINE2,372,622,683,38 4,164,854,914,784,671,16
VAUNE2,042,142,352,78 2,953,473,533,763,801,00

Digestible nitrogenous materials D.N.M.

Total digestible food T.D.F

Forage Unit F.U.

Starch Unit S.U.

TABLE 5Animal by-products
Dairy products
fats

 Animal by-products Dairy productsFats
 Feather mealSlaughter. byBlood meal Skimmed milkLacto serumButter milkLardFatSoya oilCorn oil
 products  
Centesimal composition
Dry material909090 95959599999999
Crude proteins83,506085 351332----
Fatty material2,50141 11599999999
Cellulose1,502.50- -------
Nitrogen Feed extract--- 517248----
Minerals2,5013,504 8910----
- Calclum0,203,800,30 1,300,901,30----
- Total Phosphore0,752,200,25 10,701----
- Assim. Phosphore0,752,200,25 10,701----
D.N.M. Ruminants66,8048,0086,00 33,3011,7028,80----
Energy
RawKcal/Kg535448254938 4179378642579207920792079207
Poultry           
MetabolisableKcal/Kg234030002760 2770217029008200711090208800
Pork           
DigestibleKcal/Kg-39303650 3870350040608650865086508650
MetabolisableKcal/Kg-34403060 3570338037808370837083708370
NetKcal/Kg-24701800 2300227025808370837083708370
NetUF/Kg-1,150,84 1,071,061,203,893,893,893,89
Ruminats           
DigestibleTD Fp 100--80 8585852182182182,18
NetUF/Kg--1,05 1,161,161,163,703,703,703,70
NetUA/Kg--0,71 0,700,700,722,402,402,402,40
Amino acids percent of raw products
LYSINE1,372,238,05 2,911,052,27----
METHIONINE0,431,171,02 0,790,200,64----
METHIONINE + CYSTINE4,172,101,76 1,100,470,99----
THREONINE3,561,983,74 1,520,771,50----
TRYPTOPHANE0,400,451,01 0,450,140,45----
ARGININE6,683,723,68 1,210,291,18----
GLYCINE6,542,843,81 0,662,250,73----
GLYCINE + SERINE6,346,218,03 2,590,852,45----
HISTIDINE4,300,755,40 0,990,220,89----
ISOLEUCINE4,802,260,91 1,940,751,76----
LEUCINE6,914,0811,07 3,371,192,91----
PHENYLALANINE4,111,746,12 1,700,381,53----
PHENYLALANINE + TYROSINE6,452,238,53 3,450,712,97----
VALINE7,052,867,90 2,300,722,04----

Digestible nitrogenous materials D.N.MThese indicative energetic values are given for fresh chickens. There seems to be differences for laying hens and turkeys
Total digestible food T.D.F
Forage Unit F.U.
Starch Unit S.U.

TABLE 6Cereal by-products

 Soft wheat Hard wheat wheat
wheatWhite BranSecond BranFine BranGermswheatBranBran
Centesimal composition
Dry material8888888888 888888 88
Crude proteins1515161526 161615 12
Fatty materials344,504,508 3,504,504 12
Cellulose13,507103 1,50910,50 5
Nitrogen Feed extract6763565346,50 64,5054,5054 51
Minerals22,504,505,504,50 2,5044,50 8
- Calclum0,050,080,100,150,07 0,100,150,15 0,06
- Total Phosphore0,300,600,901,201 0,900,901 1,40
- Assim. phosphore0,100,200,300,400,33 0,300,300,33 0,47
D.N.M. Ruminants13,5012,8013,1011,7023,90 14,4013,1011,70 8,50
Energy
RawKcal/Kg39223954391438574266 394439343872  4096
Poultry           
MetabolisableKcal/Kg30502750210014003080 302020001200  3100
Pork           
DigestibleKcal/Kg36303240292026003630 363028902600  3280
MerabolisableKcal/Kg34803100278024703390 347027502740  3120
NetKcal/Kg25002220198017802450 249019501760 2450
NetOF/Kg1,161,030,920,821.14 1,160,910,82  1,14
Ruminants           
DigestibelTD FP LOC8079705982 807061  75
NetUF/Kg1,101080,900,701,13 1,100,900,72 1,00
NetUA/Kg0,790,750,630,500,81 0,790,630,50 0,76
Amino acids percent of raw products
LYSINE0,470,580,720,591,45 0,450,870,53 0,59
METHIONINE0,240,240,250,210,43 0,250,240,22 0,25
METHIONINE + CYSTINE0,540,540,580,510,83 0,570,550,53 0,52
THREONINE0,420,450,530,480,83 0,460,520,47 0,44
THYPTOPHANE0,200,200,210,200,24 0,210,210,20 0,10
ARGININE0,810,961,111,041,84 0,821,130,95 0,95
GLYCINE0,600,690,850,811,36 0,580,790,68 0,61
GYLCINE + SERINE1,261,321,521,442,36 1,291,471,35 1,14
HISTIDINE0,350,360,400,390,88 0,360,410,36 0,32
ISOLEUCINE0,540,520,540,490,84 0,590,550,54 0,45
LEUCINE0,970,930,.960,891,52 1,030,980,95 0,81
PHENYLALANINE0,640,600,590,570,89 0,720,620,63 0,52
PHENYLALANINE + TYROSINE1,051,011,030,981,93 1,201,061,03 0,92
VALINE0,630,710,780,721,25 0,710,760,72 0,69

Digestible nitrogenous materials D.N.M

Total digestible food T.D.F

Forage Unit F.U.

Starch Unit S.U.

TABLE 7CEREALS

 OatsHulled OatsNaked OatsSoft WheatForage WheatHard WheatCornBarleyPaddy RiceRyeMillet
Centesimal composition
Dry material8787878787878787878787
Crude proteins10,501416111113,5091081010
Fatty materials4,30552224221,503
Cellulose10222,502,502,502,50592,502,50
Nitrogen Feed extract59,206462707067,2070,2067,5063,507170
Minerals3221,501,501,801,802,504,5021,50
- Calclum0,100,100,100,050,050,050,010,060,060,070,04
- Total Phosphore0,350,350,350,350,350,350,300,350,300,300,30
- Assim. Phoaphore0,120,120,120,120,120,120,100,120,100,100,10
D.N.M. Ruminants 8,30--8,908,9011,106,607,406,507,908,60
Energy
RawKcal/Kg38363969400137863786381338663729361537233822
Poultry           
MetabolisableKcal/Kg25503190319030803080305033702700265028003250
Pork           
DigestibleKcal/Kg26803830-34303430344035003130272033103490
MetabolisableKcal/Kg25803680-33303330332034103050266032203400
NetKcal/Kg18902680-23802380236024902180192022902450
NetUF/Kg0,881.25-1,111,111,101,161,010,891,061,14
Ruminants           
DigestibleTD FP 10084--7979798375747772
NetUF/Kg0,79--1,081,081,081,151,000,981,050,35
NetUA/Kg0,60--0,760,760,750,810,670,660,750,76
Amino acids percent of raw products
LYSINE0,420,550,620,310,310,360,250,370,280,400,23
METHIONINE0,170,230,250,170,170,220,190,170,180,180,16
METHIONINE + CYSTINE0,470,620,710,420,420,540,390,400,360,450,34
THREONINE0,340,450,490,310,310,380,320,340,280,340,33
TRYPTOPHANE0,150,200,230,120,120,120,160,090,120,100,11
ARGININE0,650,851,080,530,510,620,400,510,610,560,39
GLYCINE0,500,660,770,430,420,530,330,420,360,460,33
GLYCINE + SERINE0,981,301,500,930,921,140,770,840,740,890,79
HISTIDINE0,210,280,330,240,240,290,250,220,170,230,22
ISOLEUCINE0,410,550,550,400,400,500,340,380,320,350,44
LEUCINE0,740,981,070,720,720,891,170,700,590,631,38
PHENYLALANINE0,510,680,850,480,510,620,450,510,390,440,53
PHENYLALANINE + TYROSINE0,881,151,450,780,841,020,810,830,740,730,96
VALNE0,550,730,660,490,470,600,480,530,480,510,55

Digestible nitrogenous materials D.N.M

Total digestible food T.D.F

Forage Unit F.U.

Starch Unit S.U.

Figure N<sup>o</sup> 1

Figure No 1

1 - Emptying of raw materials 16 - Mixing
4 - WeighingFIGURE No 218 - Caking press
6 - premixingBase Unit24 Vertical cooling system
9 - Grinding 31 - Reserve and sacking
FIGURE N<sup>o</sup> 2

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