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Recycling wet extruder start-up material into reusable value
Wet start-up material from extrusion contains valuable raw materials. But in many aqua feed plants, this material is difficult to reuse directly.
It is wet, unstable and often unsuitable for direct return to the production process. As a result, valuable material may end up as waste, even though it still contains recoverable nutritional and production value.
The Process Integration Recycling Unit is designed to solve this challenge.
By drying and converting wet extruder start-up material into a stable rework powder, the unit helps aqua feed producers reduce raw material loss, improve resource utilisation and recover more value from the extrusion process.
From wet start-up material to stable rework powder
During extruder start-up, wet material is generated before stable production conditions are reached. This material can be difficult to handle, store and reintroduce into the process without the right treatment.
The Recycling Unit processes the material through a compact hot-air batch drying system. The wet material is fed into a combined mixing and drying chamber, where it is disintegrated while hot air removes moisture.
The result is a dry, stable powder that can be returned to the rework silo and reused in the production process.
Controlled and repeatable drying
A key advantage of the Recycling Unit is process control.
Drying time, mixing time and air temperature are controlled through the integrated control system, helping ensure a consistent and repeatable drying process. This gives producers a more reliable basis for handling start-up material and reducing variation in the rework stream.
Exhaust air from the process can also be connected to a local odor reduction system, supporting better environmental control around the drying process.
Compact integration into existing production
The Recycling Unit is designed as a compact and practical solution for extrusion-based aqua feed production.
The system includes:
• Intake hopper
• Inlet and outlet screw conveyors
• Mixer
• Air heat exchanger
• Fan
• Filter
• Control system
• Electrical installation
The unit is delivered in main sections for easier transport and assembly. Special configurations can also be provided where installation conditions are challenging or space is limited.
Key benefits for aqua feed producers
The Process Integration Recycling Unit helps producers:
• Recover wet extruder start-up material
• Produce dry and storable rework powder
• Reduce raw material loss
• Improve resource utilisation
• Create a controlled and repeatable drying process
• Integrate the solution into existing production layouts
For many producers, this is a practical way to recover value from material that would otherwise be difficult to reuse.
Technical overview
The Recycling Unit is based on a hot-air batch drying process and is designed for wet extruder start-up material.
Typical technical data includes:
• Capacity: 350–600 kg per batch
• Drying time: 1–2 hours
• Dimensions: approx. 4.0 × 4.0 × 4.5 m
• Transport volume: 20 ft container
• Weight: approx. 4,000 kg
• Installed motor power: 23.4 kW
• Steam consumption: approx. 300 kg/h
• Compressed air: approx. 150 l/min
• Exhaust air: approx. 2,500 m³/h
Improving resource efficiency in aqua feed production
Raw material efficiency is becoming increasingly important in aqua feed production. Reducing waste is not only a matter of cost. It is also about improving the overall use of valuable ingredients and creating more responsible production processes.
The Process Integration Recycling Unit provides a focused solution for recovering wet start-up material from extrusion and converting it into a reusable powder.
It is a practical step towards better resource utilisation, lower material loss and more efficient aqua feed production.
Process Integration develops engineering solutions for efficient, reliable and resource-conscious aqua feed production — from individual process units to fully integrated plants.
