shnmp feed processing and production technology - Central Institute ...

SHNMP FEED PROCESSING ANDPRODUCTION TECHNOLOGY4vf fClRA BUI.I,'F:TIN No. 13MARCH 20007 yo?-8, (-@--)%-Ern o3Xf CENTRAL INSTJTUTE OF BRACKISHWATER AQUACULTURE(Ind~an Council of Agricultural Research)101-B. MAHALINGAPURAM MAIN ROAD, CHENNAI - 600 034.WIP H*ILARFfd?WjW h ?k,

SHRIMP FEED PROCESSING ANDPRODUCTION TECHNOLOGYS. AHAMAD ALI. C. GOPAL AND J.V. RAMANACIBA BULLETIN No. 13March 2000CENTRAL INSTITUTE OF BRACKISHWATER AQUACULTURE(Indian Courr~l of Agricultural Research)101-B, MAHALINGAPURAM MAIN ROAD. NUNGAMBAKKAM.CHENNAI-600 034

Published by :Dr. G. R. M. RmDirectorCentral Institute of Bnckishwater AquacultureChennai - 600 034.Edited by :Shri S. Srinivasagam,Shri M. Kathirvcl &Dr. (Smt) Munawar Sultana,Senior ScientistsCover Photos:A Ring-Die pellet mill (left)Shrimp feed pellets (top right)Pellets extrusion from the Die (bottom right)Back cover :Wet laboratory for shrimp feed evaluationPrinted at:M/s. BJ Grapham1 5, Alagr Perumal Koil First SvcetVadapalani, Chennai - 600 026.

PREFACEbeed is one ofthe Imponant and major Inputs in shrimp aquaculture Availabilityof good quality feeds at competltlve prices to the shrimp farmers IS essential forshrimp culture development in the country. The important shr~mp feeds available inInd~are very expensive. It is In this context that the Central Institute olBrackishwaterAquaculture had come forward to undertake a Research and Development projcctfor the development of feed technology Ibr semi-intensive culture of tiger shrimp andthe Indian wh~te shr~mp u~th the financial assistance from the Department ofBrotechnology, Govt of Ind~a. New Delh~ Tlie project was successfully completedresult~ng In the development of ~nd~genous shr~rnp feed processing and product~ontechnology The Tccli~iology Hullet~n.~ hrought out based on the ~nlornlatlon ge~~cratcdand experlencc ga~ned In the prolec;)lt is hoped that th~s lccd technology will hcut1l17ed for conl~ncrc~al product~on of ~nd~genous shrimp feeds in Ind~and makesthc~n ava~lahle to the shr~nlp farnmers at a compet~t~vc prlceI w~sh to record 111) appreclat1o!l to Dr. S A Ail. I'r~nc~pal Scient~sl. Dr.C Gopal. Sc~entist (senlor scale). I)r .I V Ramana. Sc~cnt~st and all others whowere assoc~ated u ~ th the project lor hr~np~ng out th~s puhl~rat~on.Chennar - 3320th March. 2000Dr (j.K.M. RAO1)irector

CONTENTSINTRODUCTIONPAGE No.1DIETARY REQUIREMENTS OF PENAEID SHRIMPFEED RAW MATERIALSFEED FORMULATIONSPROCESSING AND PRODUCTION OF FEEDSWATER STABILITYFEEDING AND FEED MANAGEMENT INSHRIMP FARMINGCOSTS & RETURNS ANLYSISACKNOWLEDGEMENTSREFERENCES FOR FURTHER READING

INTRODUCTIONIn India shrimp farming has emerged as a commercial enterprise as a resultof the phenomenal growth during the last decade. Parallel to this growth thefeed industry also developed in India and has become the central focal point inshrimp aquaculture. Both imported as well as indigenous feeds are marketed inthe country. Since the imported feeds are expensive inspite of the duty reliefsgiven by the government, the indigenous feed industry mainly caters to theneeds of farmers in producing the supplementary feeds, using empiricalformulations. As development of nutritionally balanced feeds is one of themajor contributing factors for growth of shrimp farming, the Central Instituteof Bnckishwater Aquaculture undertook a mission-oriented research project onnutritional studies of candidate species, namely, Tiger shrimp (Pmaeur monodon)and Indian white shrimp (P. indicnr), identification and evaluation of suitablefeed materials, formulation of balanced feeds and development of processing andproduction technologies using indigenously available raw materials andmachinery. The Instirute has developed shrimp feed technology for processingand production of different grades (Starter, Grower and Finisher) of pelletedshrimp feeds for semi-intensive culture of both tiger and Indian white shrimps.The feeds were tested in yard experiments and also in grow-out ponds,which gave appreciable growth and feed conversion ratio (FCR). It is expectedthat indigenous shrimp feed technology developed by this Institute would helpin producing quality and cost effective feeds for shrimp culture and becomesubstitute for imponed feeds and help in saving valuable foreign exchange forthe country.

DIETARY REQUIREMENTS OF PENAEIDSHRIMPUnderstanding the nutritional requirements of candidate species of shrimpis essential before formulatig balanced feeds. Shrimp feed should have adequateenergy for growth and survival, which is contributed by the three majornutrients, namely, protein, fat and carbohydrate. The feeds should havevitamins and minerals to avoid their deficiencies. Based on the availableinformation, the dietary requirements of tiger and Indian white shrimps aresummarised in Table 1.Table 1. Dietarv reauirernnts of P. monodon and P. indicusNutrientsL- ..-- .. - . . -. ..PROTEIN (%)Euentail aminoacids (%)ArginincHistidinclsolcucincLeuclnckl,"tit?oninrPhenylalanineThnoninc2,yinc. . . . . . . . . .Ptnreus monodon.. . -.- ----.35 .46Penaeus indicu--30.42Euential fatty acids %)Linolcic acid 18 jn6)Linolenic acid (le:3n.3Eicos~pntacnoic acid 10:Sn-3)Dqos? hrunoic arii (22dn.3)Lec~thin (%%Cholesterol (%)TOTAL ENERGY(kca1/100g) 280. 370350. 400

-Table 1. (Contd.)MINEMLS--Nutrient,Source : Alagarrwami and Ali (1999.2000).h e m mo~odo~2.0 - 2.51.2 - 1.40.7 . 0.90.08 - 0.1560 - 8080-10040-508-100.8 - 1.01 4.0 5.00.6 - 0.81 0.17-0.21+ - .-. - -.Prnaew idiw0.5 . 0.6I .051.26Trace240Trace13.6-- - - '-VITAMINS (mglkg)IRiboflavin I 4C 80Thiamine 120 IWPyridoxine 120Pantothenic acid 10075Niacin ' 150250Folic acid 5IBiotin 1 .O !Vitamin BIZ

FEED RAW MATERIALSIdentification and selection of raw materials is essential for formulatingsuccessful feeds. The indigenous animal and plant raw materials, which wereanalysed and tested for tiger and white shrimp are given in Table 2. Protein isthe essential component of feed. The animal protein is indispensable forbalancing the essential amino acids. The proportion of protein sources of animalorigin is carefully fixed along with the plant protein sources in the feeds.Suitable carbohydrate sources, lipids rich in poly unsaturated fatty acids(PUFA), phospholipid and cholesterol, vitamin and minerals are identified andincorporated in the feed formulations. .,A list of feed raw material suppliers is given in Annexure I.Table 2. Proximate composition of selected feed ingredientsPercent on dry weight basisIngredientMoisture Crude Crude Crude NFE Ash---TlrLn 1 ,t .- --- --- - -- ---Fiber 1Fish mealPrawn head mealS uid niealdantis shrimp mealClam meat mealSoybean mealGround nut cakeSunflowrr cakeGingell cakewheat XourRice flourMaida flourCorn starchTspiocca flourYeastSV~N~~M- - 75.69Trace8.8510.691.75TraceTrace1 .oa

FEED FORMULATIONSThe raw materials selected for feed formulations are proportioned in sucha way that the protein, lipid and energy requirements of shrimp are met with.Generally, three grades of feeds are formulated to suit the growing stages ofshrimp, namely post-larvae, juveniles dnd adults (marketable size). These gradesare Starter, Grower and Finisher. Fish meal, squid meal, prawn head meal andmantis shrimp meal are selected as animal protein sources. Besides havingrepresentative levels of essential amino acids, these materials possess goodattractant properties for shrimp. Shrimps are attracted to feed throughchemoreceptors, which are distributed all over their body. Substances like freeaminoacids present in feed act as attnctants for shrimp. Such attractants andflavours are needed in shrimp feed for quick consumption and effectiveutilisation of feed.Among the plant protein sources, soybedn meal is one of the superioringredients. Gingelly cake and sunflower cake are sparingly used along withsoybean meal to balance the protein levels and also the essential amino acidprofiles. Fish oil and lecithin (soya) are used to meet the PUFA andphospholipid needs respectively. Wheat flour and tapioca starch used are goodsources of carbohydrate. Vitamin and mineral mixtures are prepared by mixingindividual vitamins and minerals dnd homogenising them or commercialproducts are procured and used. Binders may be selected from among guargum,wheat gluten and polymethylocarbamide.To prevent oxidation of fat in feed, antioxiddnts such as Butylatedhydroxyamisole (BHA) (0.01 - 0.021 of fat content) or Butylated hydrox...toluene (BTA) (0.01 - C.O2% of fat content) or Ethoxyquin (150 mg/kg of feed)are used. Mould inhibitors such as Sodium or Calcium Propionate at the rate of0.2 to 0.5Oh of the feed are added.

The required nutrient levels for the different grades of feeds for tigershrimp and white shrimp are given in Table 3.Table 3.Required nutrient levels in different grades of shrimp feeds forsemi-intensive fanningNutrientTiger shrimpWhite shrimp4

6.3. Steam conditioningThe homogenized feed mixture is steam conditioned by passing throughsteam chambers in three stages for gaining moisture, binder-raw materialinteraction, gelatinization of starch and finally sterilization of feed. Steaming offeed also facilitates lubrication of feed material to pass through the pelleting die.The steam conditioning chambers are genenlly attached to the pellet mill itself.These can ako be separately installed so that the process is completed before thefeed mix enters the pelleting die.6.4. PelletizationShrimp feeds are produced in pellet form. Ring-die pellet mill is used forcommercial production of shrimp feed. The feed production technologydescribed here is based on the ring-die pellet mill, which is indigenouslyavailable. It has three steam conditioning chambers attached to it. The feedmixture after passing through the steam conditioning chambers enters thepelleting chamber which has a rotating die and two rollers. The feed mixturewith adequate level of moisture (16-17O/o) is compacted into pellets as it passesthlough the de. The pellets are cut with an attached knife assembly. The lengthof the pellet can be regulated by adjusting the knife. The smooth working of thepelleting machine and the quality of feed pellets depend on the moisture level inthe feed just before it enters the pelleting chamber, temperature and consistencyof the feed mixture. Moisture levels from 15 to 18% are found to worksatisfactorily. Higher moisture levels make the feed lumpy and choke thepelleting die. Similarly, the lower moisture levels also choke the die due toinsufficient lubrication for the material to pass through.6.6. Preparation of different grades of feedsThe nutrient levels for starter, grower and finisher grade feeds for shrimpare presented in Table No. 3. The physical shape and size of feeds play animportant role in feed consumption and feed efficiency by the growing shrimp.

m --ti11lbrcnt siyccl~cs. t3 - Stcanl hloicr.C - Hammcr null, D - Micro-pulverizerA - I'cllci i~~ill \~~ril

Different gradesof feeds : I . I're-starter. 2. Startcr 1.3. Starter 11,4. Starter 111.5. Grower, 6. FinisherI. Commercial packing of shrimp feeds dm

~:\I~L.I IIIICIII;II SCIIII-III~CIISI\~C 11~cr 'rI11-1till) cul~urc pond K - Sccil stoch111gL - Feed clicck tray. M -Cultured shr~mp grown on tndige~lous feed.

Soon after stocking, the post-larvae need starter feed in granular fonn of 200 to500 micron size. The size of feed should be increased to 1.0 mm as the shrimpsgrow to 2-5 g. The shrimps require grower feed in the pellet form of 1.8 to 2mm diameter with 3-5 mm length, when they attain a weight of 15-20 g. Afterthat, finisher feed with pellet size of 3-5 mm in length and 2.0 - 2.5 mm in&meter is used for feeding.The granular feeds of 200 microns, 500 microns and 1.0 nlm size areprepared from the pellets by passing through a c~ulnblt~. dnci appropriate sizesieves. The finer particles are recycled. The grower and Ln~her grddes aredirectly produced in pellet mill using the required size pellcting die and cuttingdevice.5.6. DryingShrimp feed pellets coming out of the ring-die prllet mill will have amoisture level of 12-14% depending upon the initid1 nloisrure. This does notrequire long drying of pellets. However, ir is necessary to reduce the moisturebelow 10% for a good shelf-life of the feed. Otherwise mould (fungus) growthmay develop leading to feed spoilage. The feed is therefore dried for a shortperiod by passing through a hopper type drier/cooler, in which, the feed ispassed from the top of the hopper as the dry/cool hot air rises upwdrcis.5.7. Feed packing and storingShrimp feed is packed in lamindred IiDP bags of 25 kg each. The feed bagsshould be packed properly so that the feed does not absorb moisture easily. Thefeed bags are stored by stacking one over the other in a well ventilated premises.Storing of feed at lo°C helps in keeping the shelf-life of the feed for long.5.8. Flow diagram of feed processingThe processing and production of shrimp feed is summarised in a flowdiagram (Fig. 1).

WATER STABILITYShrimp feed pellets should retain the shdpe (should not disintegrate) for areasonable time when they are put into water column for feeding shrimp. Thiscould be achieved by using suitable binding materials. This is known as waterstability of feed. Srarch present in feed formulation acts as binder if it isproperly gelatinized. In ring-pellet mill the moisture level in feed is only 16.17%which is not sufficient to fully gelatinizr the starch. Hrnce, additional bindersare used, namely, guargum, wheat gluten and polymethylocarbarnide(commercial name Aquastab). The feed pellets produced using these bindershave a stability of 6-8 hours in water.

FEEDING AND FEED MANAGEMENT INSHRIMP FARMINGThe feeds developed are suitable for semi-intensive farming of Penaenstnonodon (tiger shrimp) and P. indicus (white shrimp). It is recommended that2the stocking densities can be between 10 to 20 / m when the production levelswould be around 2000 to 4000 kg/lia/crop.Feed conversion ratio of 1.6 to 2.0 : 1 could be obtained depending uponthe feed management and water quality. The recommended feeding schedules(based on results obtained in a farmer's fields) are given in Table 4.Table 4 Rate of fcedlng and qurntlty of feed glven In a semr-lntensirreculture of P monodon wrrh d stocklng rate of 13 /m2, Area. 1 lid-. - 7- - - , - b. -- - -" -^_" --'( ttlture prr~od Akerdge Survlvdl R~re of fced~ng Quant~t of(Week after %eight of Po) Vlof feed uselper Istotk~ng)shr~tnp (g) w"gh') week (kg) jTotal frrds used: 4174 kg; ?'ot.~l shrimp production: 2450 kg; FCR : 1.70 : 112

COSTS AND RETURNS ANALYSISThe shrimp feed mill consists of the following m~chiner~ for processingraw materials and producing feed: hammer nlill and micro-pulvrriser forginding of raw materials, sieve assembly for ohtaining uniform panicle size forall the ingredients; horizontal ribbon mixer for preparing homogeneous feedmix; steam boiler for steam conditioning of feed mix and imp.1rting binding:ring-die pellet mill for producing desired size feed pellets and hopper type drier -cooler for drying and cooling the feed and packing ni~~~ri~ls for packing. '1'11~capacity of feed mill and dpproxim'~tr costs of infrastructure and nl.~cIiinery aregiven below.A. FIXED COSTS(Capacity of the feed mill: 1 tonne feed per hour; Minirnunl production: 2000tonnes per annum)Capacity &SpecificationApproximate cost(Rs in lakhs)A building with asbestos roofing 350 sq. mt 10.50Hammer millMicropulverizer1 tonne/hr. 2.00full circle1 tonndhr. 2.50screenless, cycloneseparator, air lock,air ducting, canvas bag filter

Homogenizer(mixer)Siwe wemblySteam boilerRing-die pellet millPellet crumblerAncillariesConveyor systemInstallation chargesTotalB OPERATIOANAL COSTS (per annum)Salaries & wagesDesignation No. RsSupervisor 1 0.48Technician Qvfechanical) 1 0.30Technician (Electrical) 1 0.30Skilled workers 10 1.80I ror.ne/batch 1.33(Ribbon mixer)Rotating drum typewith variable meshscreen facility200 kg steam/hr.10 kg/cm2 pressureLDO as fuel1 tonne/hr.three steam conditioners,3 dies ( 2.5 mm, 2.3 mm &2.0 mm) 75 HP motor1 tonne/hr.Vertical hopper type withraising hot/cool airfrom below200 kg/hr.twin-roller.adjustable gap motor driven(Rs in lakhs)2.88

Cost of production of 2000 tonns of feedFe* materials (@ Rs 22,000/- per ton)Electricity & water chargesPacking costMaintenance costContingenciesInterest on fixed cost (@ 18O/o)Depreciation on machinery (@ 10°/o)TotalC. RETURNSSale price of 2000 tonnes of feed(@ Rs. 30/- per kg)D. GROSS PROFIT (C - B)

ACKNOWLEDGEMENTSThe financial support received from the Depdrunent of Biotechnology,Govt, of India, New Delhi for the research Project on development of shrimpfeed technology is gratefully acknowledged. The authors express their sincerethatnks to Dr. K. Alagarswami, former Director and Dr.G.R.M. Rao, presentDirector, Central Institute of Brackishwater Aquaculture, Chennai for theirconstant encouragement in carrying out the work. Thanks are due to Sri.A.R.Nazar, Srnt. B. Sarnpoornarn, Sri. Am1 Vasu and Sri. T. Vaitheeswaran,Senior Research Fellows and Sri. P. Selvakumar, Technical Assistant, for theirassociation in the project work.

REFERENCES FOR FURTHER READINGALAGARSWAMI, K. and S. A. ALI. 1999 -2000. Indigenous feeds for shrimpfarming - Development and assessment in cornparision with importedfeeds. In : Aquaculture Feed and Health. (Eds.) George John and A. S.Ninawe, Biotech Consortium India Ltd, New Delhi, p. 56-66.CHUANG, J.L. 1990. The Nutrition of Prawns. F.Hoffmann-La Roche Ltd.,Vitamins and Fine Chemicals Division, Animal Nutrition and Health,4002 Basel, Switzerland, 62 pp.FAO. 1978 Fish Feed Technology. In: Aquaculture Developinent and' Coordination Programme. ADCP/REP/BO/I~: 289-325.HALVER, J.E. and TIEWS, K. (Eds.) 1979. Finfish Nutrition and Fish FeedTechnology, Vol. 11: 613 pp.HASTINGS, W.H. and D. HIGGS. 1980. Feed Milling Processes. In: Fish FeedTechnology, FAO/UNDP, Rome, p. 293 - 313.KANAZAWA, A. 1985. Nutrition of penaeid prawns and shrimps. FirstIntermtional Confmmce on Cnlntnre of pcnaeid prawns/shrimps,SEAFDEC Aquaculture Department, Iloilo city, Philippines, p. 123-130.NEW, M.B. 1987. Feed and feeding of fish and shrimp. FAO/UNDP: 275pIUNDP/FAO. 1980. Fish Feed Technology. 395 pp.

List of suppliers of feed raw mateialsANNEXURE -IAmalgam Aquaculture Applications Ltd.,Amalgam House, Bristow Road,Willingdon Island, COCHIN - 682 003,Kerala.Janatha Fish meal & oil productsManur Fisheries RoadKOTA - 576 221, Karnataka.RAll marine orductsfish meal, 5 simp meal,fish oil etc.Fish meal & fish oilKarnataka Fisheries Development - do -Corporation,Fish n~eal plant, Baithkole,KARWAR - 581 302. Kdrndtdkd.Mukkd oil and sr? food Industries,Mission Street,MANGALORE - 575001, Kdrnatdkd.Noorsons Cresent Industries,22(d), Sewrce Cross,MUMBAI - 400 015. Maharashtra.Rhidyd,VEKAVAL . 382 269, Gujarat.S.ikthi Soy~s I.imitcd,180, Race Course Ro.~d.COlMBATORE - 611 018,Tamil Nadu.Soya Good K~ch i.~ll~itrd,A-3, Nrliru Sr~d~ii~ii (opposite),J~yanagr, SHIMOGA - 577 201,K~rnatdkd.

Indras A encies (P) Ltd.,128, WaQ~ax Road,CHENNAI - 600 003, Tamil Nadu.S.R.V. & Co.,2, Subbar~ya Street,Nungambakkam,CHENNAI - 600 034, Tamil Nadu.Southern India Aquaculturist,No.8, Giri Road, T.Nagar,CHENNAI - 600 017, Tamil Nadu.Bharat Starch Industries,12, DLF Industrid] Ared,13/7 Mathura Road,FARIDABAD - 121003, Uttar Pradesh.Bharat Starch Industries,205, Thambu Cherty Street,CHENNAI - 600 001, Tamil Nadu.Punjab Maize Products Ltd.,A-8, DLF Industrial Estate,FARIDABAD - 121 003, Uttar Prddesh.Om Muruga Energy Feeds,SP 122, Industrial Estate,3rd Main Road , (opp. Telephone Exchange),Ambatcur, CHENNAI-600 058, Tamil Nddu.M/s. P. A. P. Sahib & Co.,Dry Fish Merchants & Commission agents,11, Wall Tax Road,CHENNAI - 600 079, Tamil Nadu.Soybean meal &Soya lecithinFeed bindersAll feed materialsGel starch (binder)& Corn glutenWheat gluten (binder)Soya cake, dry fish etc.,Dry fish, prawn head,mantis shnmp etc.,

ANNEXURE - I1List of suppliers of feed mill machinery1. Cremach Designs,893/4. G.I.D.C. Industrial Estate,Makarpura,BARODA - 390 010,Gujarat.2, Precision Products,2007, Phase IV, GIDC Estate,Vatva,AHMEDABAD - 382 445, Gujarat.3. Spectoms Engineers Pvt. Ltd.,Purushottarn Estate,Bahucha rji Road,BARODA 390 018, G~jatdi.4. Forms and Gears,L-3, Industrial Estate,Guindy,CHENNAI - 600 032, Tamil Nadu.5. Basic Technology Pvt. Ltd.,2/2B, Nandy Street,CALCUTTA - 700 029, West Bengal.6. Naz Industries,Autonagar,VIJAYAWADA - 520 007,Andhra Pndesh.Whole feed mill machinery& installation-do-Ring-die pellet millPilot scale extruder onlySmall-scale feed productionunits