by Marcel Franitza, Industry Director Animal Feed, at Andritz Feed & Biofuel, Denmark
Andritz Feed & Biofuel leads the charge with Complete Plant Solutions and advanced automation and digitalisation, redefining efficiency, quality, and sustainability in the Aqua Feed industry.
In recent years, the global aquaculture sector has shown resilience, particularly in Latin America, where despite challenges, demand for aqua products remains robust, evidenced by a 3.87 percent growth. This enduring demand is pushing the aqua feed industry to innovate, emphasizing sustainable, nutritious, and high-quality feed options. As consumer expectations evolve, the industry is set for substantial growth and innovation, adapting to new market requirements with enhanced product offerings.
However, while lucrative, the aqua feed industry faces a multitude of challenges that can impact production and market presence. Key among these are sustainability concerns, with a growing push for environmentally friendly sourcing of ingredients. Fluctuations in the availability and cost of crucial inputs like fish meal and soybean meal pose further challenges, impacting production economics. Moreover, strict regulatory requirements, the need for continual nutritional innovation, evolving consumer preferences, and supply chain vulnerabilities further complicate the landscape. Adding to this, ensuring product quality and safety is paramount to maintaining consumer trust and satisfaction.
Michel Pereira, Global Application Manager, and Ivan Harjacek, Head of Product Group Digital Solutions, at Andritz Feed & Biofuel, explain how Andritz is not only tackling these challenges, but establishing new ways forward in the aqua feed industry through innovative solutions and state-of-the-art technologies.
180 Years of Industry Leadership
Spanning an impressive 180 years, Andritz has continuously evolved to meet the changing demands of the industry. “We began by crafting machines that emphasize operational excellence and precise control, which are fundamental for producing high-quality, safe products,” Michel says. “Over the decades, our focus on continuous development has led us to expand beyond just supplying machinery. We now provide comprehensive plant solutions and global dedicated support, being a full-fledged partner in our customers’ success.” This evolution has given rise to the Andritz Complete Plant Solutions.
“The benefits of choosing Andritz’s Complete Plant solutions are significant. We simplify the entire plant lifecycle, boosting reliability and reducing complexity. Our cutting-edge designs and technologies notably enhance operational efficiency and lower total ownership costs,” Michel explains. “Our approach of streamlined project management improves and simplifies the customer experience by offering a single contact point for their aqua feed operations.”
When compared to a single equipment supplier, plant solutions partners differ in that the depth of expertise can be drawn upon across the full value chain with an in-depth understanding of how each stage of the process impacts the final product.
As Michel highlights, “Plant improvements can be achieved only through an ongoing process of identifying and eliminating bottlenecks to always ensure the plant is running at full plant capacity. As a partner with unmatched experience we can help aqua feed manufacturers spot potential efficiency drains and optimize operations for maximum output.”
Andritz’s Customer-Centric Approach
At the heart of Andritz’s approach is a deep commitment to collaboration, working closely with customers to devise solutions that precisely meet their specific needs and objectives.
“A universal solution doesn’t work in our field. We tailor our strategies to meet the distinct demands and conditions of each project, aligning with customer requirements,” Michel explains. “We engage in detailed discussions with our customers, absorbing their requirements and aspirations before formulating the ideal solutions. This ensures our solutions are custom fit to the customer’s operational needs and strategic plans.”
Recognising the unique challenges and demands of running an aqua feed plant, Andritz’s tailored solutions are backed by global service. “We are always there for our customers, at every stage of the plant’s lifecycle, from design and planning to commissioning and maintenance,” he says.
Driving Innovation and Efficiency with Automation & Digitalization
Andritz is dedicated to future-proofing their customers’ operations through scalable technological innovations. “Our advanced automation and digitalisation (AD) solutions streamline operations, boost operational efficiency, and reduce downtime,” Ivan explains, likening these solutions to the musculature and cognition of a body that requires intelligent direction. “Utilising data analytics and machine learning, our technologies can foresee maintenance needs, optimise resource distribution, and enable proactive management decisions. Our Metris digital platform, supported by robust cybersecurity measures, positions our customers at the forefront of operational efficiency, regulatory compliance, and sustainability.”
Underlining the synergy between innovation, technology and strategy, Ivan further points out that “By integrating our complete plant solutions with our AD technology, we offer more than just future proofing for businesses. We provide tools that transform current operational management and implementation.”
Dryer Ace Revolutionizes Drying Technology for Aqua Feed Manufacturers
Delving further into their AD offering, Ivan draws an example from Andritz Dryer ACE – a transformative digital solution that is at the forefront of drying technology. “This innovative digital system marks a significant advancement in process control technology designed to dramatically decrease process variability of 20-60 percent. With Dryer ACE, aqua feed manufacturers can expect not only increased throughput and enhanced product quality but also substantial energy savings, in the range of 150-350k € annually,” Ivan explains. “One of the standout features of Dryer ACE is its capability to automatically adjust for variations in particle size and recipe changes, which ensures optimal drying conditions without the need for manual intervention.”
This automation helps maintain high-quality output and consistent product excellence, crucial for aqua feed manufacturers striving to meet industry standards, as well as consumer expectations.
The vision: fully autonomous aqua feed plants by 2027
Looking forward, Andritz is not just focusing on innovation but also on sustainability and operational efficiency. The aim is to establish fully autonomous plants by 2027, supported by ongoing investments in automation and digitalization, which have already proven transformative for operational efficiency and sustainability in other industries, such as Pulp & Paper and Hydro.
“The impact of our automation and digital solutions is clear, having delivered significant benefits across industries. Our customers have seen remarkable decreases in energy use, as well as up to 16 percent increase in throughput,” Ivan notes. Beyond energy efficiency and enhanced productivity, Andritz’s solutions proactively monitor and mitigate risks, ensuring asset protection and continuous operation. This approach not only enhances sustainability through lower energy use and optimised raw material management but also boosts yield and operational advantages.
When choosing Andritz, aqua feed manufacturers cannot only meet the current industry demands but also position themselves for future growth and success. “Our integrated approach ensures that every aspect of production is optimised, from energy use to ingredient handling, all tailored to the unique needs of each project. With the support of our global expert team, from initial assessment through to ongoing operational support, we guarantee a seamless integration and unmatched performance,” says Michel.
In an industry where quality, efficiency, and sustainability are more important than ever, Andritz promises to keep pushing boundaries. “We work every day to develop solutions that ensure that our customers’ operations are thriving, resilient, and standing the test of time. Partnering with ANDRITZ means that you will always be at the forefront of operational excellence, always advancing and never standing still,” Michel concludes.
