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Design, Fabrication and Performance Evaluation of a Single Screw Extruder for

the Production of Floating Fish Feed

Article in Journal of Scientific Research and Reports · August 2022

DOI: 10.9734/JSRR/2022/XXXXX

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 Journal of Engineering Research and Reports

Volume 23, Issue 12, Page 48-58, 2022; Article no.JERR.90252

ISSN: 2582-2926

Development and Performance

Evaluation of a Single Screw Extruder
for the Production of Floating Fish
Feed
A. P. Olalusi a, S. A. Olaoye a*, J. Isa a, A. S. Oyerinde a,
C. Ayo-Olalusi b and D. O. Adesuyi c
a
Department of Agricultural Engineering, School of Engineering and Engineering Technology,
Federal University of Technology, Akure, Nigeria.
b
Department of Biotechnology, Fish Nutrition Unit, Nigeria Institute for Oceanography and Marine
Research, Victoria Island, Lagos, Nigeria.
c
Department of Fisheries, School of Agriculture and Agricultural Technology,
Federal University of Technology, Akure, Nigeria.

Authors’ contributions

This work was carried out in collaboration among all authors. All authors read and approved the final
manuscript.

Article Information
DOI: 10.9734/JERR/2022/v23i12762

Open Peer Review History:

This journal follows the Advanced Open Peer Review policy. Identity of the Reviewers, Editor(s) and additional Reviewers,
peer review comments, different versions of the manuscript, comments of the editors, etc are available here:
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Received 06/09/2022
Accepted 12/11/2022
Original Research Article
Published 19/11/2022

ABSTRACT
An extruding machine for the production of floating fish feed was designed and fabricated.
Performance evaluation of the fabricated floating fish feed extruding machine was done. The
design of the hopper; shaft, barrel, screw and die of the machine were done using standard
equations. Effect of extrusion parameters which are moisture content (20% 25%, 30%, 35%, and
40%) die size (2 mm, 4 mm, 6 mm, 8 mm and 10 mm) and screw speed (150 rpm; 200 rpm, 250
rpm, 300 rpm and 350 rpm) on expansion ratio, floatability, specific mechanical energy and
efficiency were evaluated. The result shows that moisture content has significant effect on all the
_____________________________________________________________________________________________________

*Corresponding author: E-mail: [email protected];

J. Eng. Res. Rep., vol. 23, no. 12, pp. 48-58, 2022
 Olalusi et al.; J. Eng. Res. Rep., vol. 23, no. 12, pp. 48-58, 2022; Article no.JERR.90252

variables, as highest expansion ratio of 32% was obtained at 30% moisture content and 6 mm die
size. Highest feed floatability was 97% at 30% moisture content and 6 mm die size. The highest
specific mechanical energy of the machine was 30 kJ/kg at 40% moisture content and 4 mm die
size. Die size variation also shows high impact on the machine performance, showing highest
efficiency of 83% at 10 mm die size and 250 rpm while the floatation rate was 98% at 6mm die
size. Screw speed has significant effect on efficiency having the highest as 85% at 150 rpm and
floatability of 93% at 150 rpm while the specific mechanical energy of 29 kJ/kg was the highest at
350 rpm. Operation condition was at its best at 30% moisture content; 6 mm die size and 150 rpm
of screw speed. The feed moisture content, machine die size and screw speed have significant
effect on the performance of the machine. Careful selection and combination of these factors will
give optimum performance of the machine during extrusion of resin.

Keywords: Extrusion; floating fish feed; expansion; screw speed; die size.

1. INTRODUCTION from, ease of handling by man and aquacultures,

improved surface attractiveness, reduction in
Extrusion technology has been on the rise for percentage of food waste; while its nutritional
decades, it was initially known in the plastic benefits are good digestibility and high
industry and the metallurgical industry. Today; conversion rate. Extrusion machine is a good
agro processing and food processing industry device in the agro-process industry, for its ability
have inculcated the use of extrusion cooking to produce feeds faster and improve the
technology in their processing system [1]. Food nutritional value of the feed. Its performance
extruders or extrusion cookers are known to being dependent of its geometry (shape and
have high temperature and pressure with low size): control of product quality, improved
retention time cooking technique i.e. HTST - high digestibility and more extensive performance [8].
temperature short time equipment [2,3,4] Extruder component contain several static and
Extruders have been placed under two types kinematic parts for the objectives of its fabrication
which are single screw extruder SSE and twin - to be achieved. Static components of the
screw extruder TSE (self - cleaning extruder) machine are hopper; barrel, die, cooling jacket
according to Leszek [5]. The single screw and head etc. while the kinematic components
extruder is attributed to high temperature are motor shaft; chain, sprocket, screw conveyor
generated as a result of frictional force, between and cutting device. Also, it contains a feeding
the screw and the barrel and the heating element system to regulate the feeding rate. The
in the barrel. Fundamentally; extrude that are of objective of this research work is to design,
cereal based e.g. fish feed composite are easily fabricate and evaluate a floating fish feed
extruded directly into different shapes and sizes extruder.
with the use of die in different shapes and sizes
[2]. 2. MATERIALS AND METHODS

Demand for aquaculture produce for human 2.1 Material Selection and Production
consumption has been on the rise in the past Planning
decades which as necessities, the need to
improvise quick method of feeding for fishes, in In the Table 1 are the summary of the design
which pelleting the feed will be of good prerequisites and materials used in the
advantage, most fish feed in America are in fabrication of the machine component. All
pellet to improve the quality of aquaculture Anon materials were sourced locally after which
[6]. On the other hand, pelleted feeds produce examination was conducted on each of the
from pelletizer cannot give the expected quality component, to locate point and position they will
of feed. Feed produced by pelletizer will sink occupy. The below information was used to carry
immediately on water; while that of extruder will out production plane and later assembly plane.
surly float on water as a result of gelatinization Electrodes; hammer, block, sniper, welding
during processing - for aquaculture to consume it machine, cutting machine, grinding machine,
conveniently. According to Behnke [7], floating drilling machine, hack saw, vise and lathe
fish feed from extruder is considered better than machine, are the machine tools and equipment
sinking feeds because of it physical and used in fabrication and construction of this
nutritional benefits. Its physical benefits ranges machine.

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2.2 Machine Design

The design of this machine was done by putting into consideration of all mathematical constraints
being the dependent of engineering principles, inclusion of cost analysis and consideration of couple
with accessibility, ease of operation, stress and strain, durability, works and efficiency. The design of
this machine was divided into two sections:

Table 1. List of component parts of the machine

Component parts Dimension Material used Quantity

Hopper Ф300 × 435 mm Mild steel plate 1
Barrel Ф166 × 800 mm Stainless steel (aco pipe) 1
Feeder barrel Ф55 × 266 mm Stainless steel (aco pipe) 1
Screw conveyor Ф136 × 1000 mm (inner shaft), Stainless steel 1
Feeder screw conveyor Ф20 × 750 mm (sleeve pipe) Stainless steel 1
Die head plate Ф45 × 333 mm (inner pipe) Stainless steel 1
Frame Ф5 × 250 mm (sleeve pipe) Angle iron 6
Sprocket Ф172 × 20 mm Mild steel 1
Fasteners (bolt and nut) 4 mm × 4 mm Mild steel bold 20
Pillow bearing Ф350 mm Nut 6
Flat bar Ф15 × 50 mm Mild steel 2
Stainless steel welding Ф20 × 50 mm (for barrel casing) Stainless steel 1
Mild steel welding Ф60 - Mild steel 2 packets
Electrode Ф40 mm × 80 mm 2
Grinding disk Gauge 10 and 12 - 2
Electric motor - - 4
Feeder electric motor 22 horse power - 1
Chain 2 - 1
30 mm thickness - 1

(1) Design of the static components: this Where

involves the principles governing each V1 is the volume of the frustum of pyramid
3
component parts and mathematical cm ,
calculations on the factors that may affect V2 is the volume of the cub,
the design. These parts are, barrel, die, V3 is the volume of the hopper,
hopper, head and frame. h is the height of the frustum,
(2) Design of kinematic component: This B1 is the area of the top of the frustum,
encompasses component like chain and B2 is the area of base of the frustum,
sprocket unit, motor and screw conveyor L is the length of the cub,
design. B is the breath of the cub,
(3) Design Analysis: Hopper was designed H is the height of the cub,
with the intertwine of two shapes, for easy T is the Thickness of the hopper
flow of feed materials be it granular or
fine particle. This consists of a frustum of a (4)
pyramid and a cub, with their mathematical
proven below. Since;

Volume of the hopper = volume of a frustum of a Mass of hopper = density of mild steel ×
pyramid + volume of a cub volume of the hopper

(1) (5)

(2) Weight of the hopper = mass of the hopper ×

Acceleration due to gravity.
(3) (6)

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The flow factor f can be determined with the use 2.2.1 Determining mass flow rate of the
of known factors that determine the flow factor, symmetrical hopper
angle Θ, wall friction, internal friction and the
semi included angel of the metal. The discharge rate of the symmetrical hopper
was obtained by the use of Jenike, [10] equation.
(7)
(11)
(8)
Where:
Coefficient of friction between the surface of the
hopper and the feed materials is expressed in o
θ is semi included angle of the hopper ( )
terms of angle of phase θ that is m is discharge rate (Kg/ sec)
o 3
(9) is the bulk density (kg/m )
-2
g is gravity acceleration (9.807ms )
Δy and Δx are effective angle internal friction rise B is w (m), m = 0 in symmetric hopper
and run respectively. Area A = width W x Length L

(12)
(10)
= The stress acting on the hopper is given in the
assumption below by Jassen [11]

(13)
To get the wall friction angle from the rise and
run chart of [9]
g is the gravity constant to convert conversion
factor and w is the maximum width of the hopper.

(14)

2.2.2 Capacity design for a given electric

motor rating

The electric motor selected is able to start the

machine and run it effectively while fully loaded.
From,

o,
The semi included angle = 28 H= 2.47 and the
flow factor ff = 1,84 was obtained from [9]

(15)

Where:

P is power in watts,
F is rotational force acting on the shaft in
The minimum width of the symmetrical slot outlet newton (N)
hopper is 0.1161 (W × L)

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V is linear velocity of the electric motor shaft

-1
(ms )

Recall, Hence; our screw conveyor diameter is 0.101 m

(16)
(24)
M is mass of rotating shaft (kg)
a is angular acceleration of the shaft part Where is 4.0 for slow abrasive material,
o
-2
(rad/s ) inclination angle of conveyor ( ) is 0

(17) L = length of conveyor.

W is angular velocity of the motor (rad/s),

2.2.4 Design of pitch and pitch circle diameter

(18) The design of pitch diameter was done with the

use of this equation
Therefore, Force becomes

(19) (25)

And power becomes

We know that
(20)
(26)
(21)

(22)

2.2.3 Design of screw conveyor diameter and

(27)
power to drive conveyor
DO is outside diameter of the sprocket (m)
The diameter and power of the screw conveyor
D is diameter of the pitch circle
needed for material conveying at a flow rate of 3
T is number of teeth on the sprocket
kg/min. for capacity of segmented screw
d1 is diameter of the chain roller
conveyor was calculated from the use of
Spirakorsky and Dyachkov, [12].

(23)
2.2.5 Determining the velocity ratio of the
Where; chain drive

Q is capacity of screw conveyor The velocity ratio of the chain was determining
S is the screw pitch with the use of this equation
n is speed of conveyor-loading efficiency
p is free bulk density of the material (28)
c is loading factor depending on the inclined
angle to the horizontal for slow flowing Where;
abrasive material it was recommended that
N1 is the speed of rotation of smaller
S = 0.8D, = 0.125, C = 1our recommended
sprocket in rpm
minimum and maximum speed of conveyor
N2 is speed of rotation of lager sprocket in
is between 50 – 500rpm.
rpm
T1 is number of teeth in the smaller sprocket
T2 is number of teeth on the larger sprocket.

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2.2.6 Determination of chain length and its and being converted to heat energy that
center distance. transform the extrude – the work done by the
machine on the extruder which also called
The length of the chain was calculated from the specific mechanical energy of the machine.
use of this equation;

(29) (33)

(30) Where;
is the torque (Nm)
K = 64 SS is screw speed (rpm)
Fr is feed rate (kg/h)
Therefore; the length of the chain is
Calculation of machine torque was done with the
use of this equation.

(34)

2.2.7 Determination of the Center Distance (35)

The center distance between the center distance (36)

x was calculated with the use of this equation
Spivakovsky, (1967). The efficiency of the machine was determined
with the use of this mathematical equation.
]
Efficiency of the machine (ἠ) in (%) was done by
(31) determining the capacity of the machine (MC) in
(kg/min), Me the mean mass of the extrude in
(kg), T is the mean retention time (min) and Mi is
the mean initial mass of the resin.

2.4 Evaluation Parameters

The evaluation of the machine was performed in
a factorial design which consist of moisture
content, die size and screw speed each at five
different level. The different levels of moisture
2.2.8 Determination of power transmission in content are 20,25,30,35 and 40%, while the
chain different levels of die sizes are 2, 4, 6, 8 and
10mm and screw speed are 150, 200, 250, 300
Power transmitted by chain was derived from and 350 rpm respectively. This is the
Jenike (1964) equation experimental procedure that was used to
determine the effect of these extrusion factors on
(32) these extrusion variables that are considered:
expansion ratio, floatability, specific mechanical
Where; energy and machine efficiency.

W b is breaking load in newton’s, 2.5 Preparation of Samples

V is velocity of chain in m/s
n is factor of safety Soybean crud was use to replace ground nut
ks is service factor cake (GNC) in order to improve it level of
compatibility and reduce the percentage of oil in
2.3 Performance Evaluation of the the fish feed. Other components are soured from
Machine farm support Nigeria limited along Ilesa Owo
road Akure. The grinding was done in farm
Specific Mechanical Energy (SME): the support factory, to increase the rate of
amount of energy generated from the machine compatibility of the resin during extrusion

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process, by reducing the surface area of the of the composition before, during and after
component. Mixing of the component was done extrusion.
mechanically for uniform and appropriate mixing

Fig. 1. Extrusion machine and its exploded view

Table 2. Ingredient composition in percentage
Feed ingredients Percentage (%)
Maize 14
Soybean residue 30
Starch 10
Wheat bran 25
Soybean meal 10
Fish meal 10
Vitamin C 0.3
Methionine 0.4
Antioxidant 0.3

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3. RESULTS AND DISCUSSION The floatability of the extrude produced from the
machine was affected by moisture content. It has
3.1 Effect of Moisture Content on significant effect on the floatability of the feed at
Expansion Ratio, Floatability, 0.05 level of significant, while 97% highest
Specific Mechanical Energy and floatability was recorded at 30% moisture content
Efficiency of the Machine and the lowest at 40% moisture content of 66%
value; this is in agreement with Khater et al. [14]
Expansion ratio is the rate at which the extrude in their research on floation. Specific mechanical
expanded in relative to the die size, varying the energy was also significantly affected by
level of the moisture content and die size while moisture content; the lowest SME was obtained
the screw speed is kept constant. Moisture at 30% and the highest at 40% moisture content
content of the resin played important role in the 17 kJ/kg and 30 kJ/kg respectively. This is in
rate at which expansion takes place. The consonance with what Daood et al. [15]
expansion ratio increased initially as the moisture observed in their research work. The highest
content increases but later decreases with efficiency of the machine is 87% which was
increase in moisture content. The highest rate of obtained at 30% moisture content and 6 mm die
expansion was 32% which occurred at 30% size; while the lowest is 70% obtained at 40%
moisture content and 6 mm die size; while the moisture content. This is in-line with what Ojomo
lowest was 18% at 40% moisture content, et al. [16] came about in their research on
supported by Alam et al. [13], Olaoye et al. [4]. palletization.

100
35 2mm
2mm
Eexpansion Ratio(%)

Floatability Ratio(%)

30 4mm 4mm
90
6mm 6mm
25 8mm
80 8mm
10mm
20 10mm

15 70

10
20 25 30 35 40 60
20 25 30 35 40
Moisture Content(%)
Moisture Content(%)
90
35
Specific Mechanical Energy

85
Requirement(kJ/kg)

Efficiency(%)

30
2mm 80 2mm

4mm 4mm
25
75
6mm 6mm
20 8mm 70 8mm

10mm 10mm
65
15
20 25 30 35 40
20 25 30 35 40
Moisture Content(%)
Moisture Content(%)

Fig. 2. Graphical presentation of effect of moisture content on variables considered

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3.2 Effect of Die Size on Expansion Ratio, die size while the highest was recorded at 10mm
Floatability, Specific Mechanical die size (Fig. 3).
Energy Required and Efficiency
3.3 Effect of Screw Speed on Expansion,
Expansion ratio of the resin was affected by the Floatability, Specific Mechanical
differences in die sizes as we varied the die sizes Energy Requirement and Efficiency
during our research work. The highest expansion
ratio of 31% was recorded at 6mm die size while The variation in screw speed shows differences
the lowest expansion ratio of 19% was obtained in responses on the variables considered. The
at 2 mm die size; this is in similarity with the expansion ratio does not show much difference
result of Abubakar et al. [17]. Likewise; the at different level of screw speed. The highest
floatability ratio was at the zenith at 6 mm die expansion rate was observed at 150 rpm and
size of 98% while the lowest was at 10 mm die 30% moisture content while the lowest was
size of 77% value, this is intad with Khater et al. recorded at 250 rpm and 40% moisture content
[14]. Specific mechanical energy consumption of 32% and 20% respectively. Though; the effect of
30 kJ/kg was the highest at 2 mm die size, while screw speed on expansion ratio was insignificant
the lowest 17 kJ/kg at 10 mm die size Saheed et at 5% level of probability. Oduntan and Koya
al. [18] in their research work reported similar [20] had similar result at screw speed less than
result. Efficiency of the machine increase as the 150 rpm. The highest floatability ratio of 93% was
die size increases from 2mm to 10 mm, this is in recorded at 150 rpm while the lowest floatability
corroboration with what Ojo et al., [19] reported rate of 79% was observed at 300 rpm, Olaoye et
that the lowest efficiency was obtained at 2mm al. [4] also obtain a similar result. The specific

35 100
Expansion Rate(%)

95
Floatability Ratio(%)

30 150rpm
200rpm 150rpm
90
25 250rpm
200rpm
300rpm 85
20 250rpm
350rpm
80 300rpm
15 350rpm
75
10 2 4 6 8 10
2 4 6 8 10 Die Size(mm)
Die Size (mm)
35 85
mechanical energy riquired(kJ/kg)

81 150rpm
30
Efficiency(%)

150rpm 200rpm
77
25 200rpm 250rpm
250rpm 73
300rpm
20 300rpm
69 350rpm
350rpm
15 65
2 4 6 8 10 2 4 6 8 10
Die SIze(mm)
Die Size (mm)

Fig. 3. Graphical presentation of effect of die size on variables considered

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35 95
Expansion Ratio(%)

Floatability Ratio(%)
90
30
20% 20%
25% 85 25%
25
30% 30%
80
20 35% 35%
40% 75 40%
15 150 200 250 300 350
150 200 250 300 350
Screw Speed(rpm)
Screw Speed(rpm)

90
Specific Mechanical Energy

29 20%

Janse
27 25%
Efficiency(%) 85
20%
30%
(kJ/kg)

25

Janse Janse
25% 80 35%
30%
23

21 Janse
Janse 35% 75
40%

Janse
40%
19 70
150 200 250 300 350 150 200 250 300 350
Screw Speed(rpm) Screw Speed(rpm)

Fig. 4. Graphical presentation of effect of screw speed on variables considered

mechanical energy 29 kJ/kg was the maximum at die size. Specific mechanical energy was at the
350 rpm which may be as a result of increase in lowest at 30% moisture content and die sizes 6,
torque required, this is in contrast with what 8 and 10 mm. The efficiency of the machine was
stated by Folasayo and Zhongjie [21] stated that best at 30% moisture content and 6 mm die size.
energy consumption of single screw extruder has Die size has significant effect on expansion ratio
the lowest specific mechanical energy of 20 according the result, 6mm die size is the most
kJ/kg was obtained at 250 rpm. Efficiency was at efficient die size on this machine, due to it
the highest point of 88% at 150 rpm while the optimization on the variables considered.
lowest was 72% at 350 rpm. This result is similar Variation in screw speed gave different response
to what Salawu et al. [22] observed in their own on the variable considered, resulted to an
research work. Idowu et al., [3] gave a outcome that 150 rpm was the best speed of
consonance result in their experiment stating the operation for the machine.
significance of screw speed on the performance
of fabricated decorticating machine. COMPETING INTERESTS
Authors have declared that no competing
4. CONCLUSION interests exist.
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