Insta Pro International
Contact: Karl Arnold
10104 Douglas Ave.
Des Moines, IA 50322
U.S.
Phone: 800-369-8946
Fax: 515-276-5749
We help you make the best quality ingredients available.
We Supply Technology and Equipment (Extruders / Oil Expellers / Oil Refineries / Complete Feed Plants) for the following:
Extrusion
* Full-Fat Oilseeds
* Human Food
* Ethanol By-Product Processing
* Pet Food
* Aquatic Feed
* Specie Specific Feed Ingredients
* By-Product Processing
Mechanical Oil Extraction
* All Oil Bearing Seeds
* No Chemicals
* Natural Oils & Protein
* Specialty Seed, Organic, Non GMO
Oil Refining
* Small Scale
* Skid Mounted
* Environmentally Friendly
* Pre-Assembled
AQUATIC FEED
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In aquatic feed manufacturing, Insta-Pro® dry extrusion offers several advantages over conventional steam conditioning and ring die pelleting: greater formulation flexibility, better feed conversion rates, starch gelatinization of more than 90%, more options in physical size and shape, greater water stability and physical integrity, and higher fat absorption capacity. Pellet size can be 2.5 mm and larger.
It has been established that extruded aquatic feed leads to improved feed efficiency and less problems with disease. The floatability of the feed, for top feeding species, has allowed more control of feed quantity and reduced waste.
The Insta-Pro® method of dry extrusion utilizes friction as the sole source of heat in the extruder barrel, accompanied by pressure and attrition, to properly cook and expand aquafeed products. For manufacturing of floating aquatic feeds, a steam preconditioner is used to condition the product mix before it enters the extruder barrel. The preconditioner, mounted on top of the extruder, may be used for other aquafeed applications to increase production capacity, reduce the mechanical wear on the extruder barrel, and reduce energy consumption per weight unit of finished product.
Important factors that affect the quality of extruded aquatic feeds are: formulation, pre-extrusion handling, extrusion control, post-extrusion handling.
Insta-Pro® International is the equipment manufacturing division of Triple "F", Inc., a diversified agribusiness company headquartered in Des Moines, Iowa. Triple "F", Inc. was founded in 1961 and specializes in specialty nutrition and extrusion processing through its Pharmtech and Insta-Pro® International divisions.
In 1969, Triple "F" patented the dry extrusion technology to process soybeans. The dry extrusion technology was an immediate success and Insta-Pro® International was created to manufacture and market dry extruders. The dry extrusion method cooks, dehydrates and sterilizes feed and food ingredients.
Today, our customers operate Insta-Pro® extruders in 89 countries around the world. Their range of products is very diverse - from human foods and full-energy soybeans to pet foods and bio-processing.
Insta-Pro® International has also developed the ExPress® system which combines Insta-Pro® dry extruders with Insta-Pro® continuous oil presses for the mechanical extraction of oil from various oilseeds.
Through our commitment to research and development, led by specialists in animal and human nutrition, we are finding new applications for the dry extrusion process on an ongoing basis. We believe that the key to our future is in bringing more value to our global customers on a community based level.
Our customer service goal is to make the process of buying, installing and operating your Insta-Pro® equipment as easy and efficient as possible.
Plant Design
Our engineers can provide you with a custom layout of your plant made to fit your building.
Start-up and Training
Start-up and training on site is provided for all new equipment installations.
Technology Support
Our product specialists and nutritionists will be available to answer all your questions for as long as you operate Insta-Pro® equipment purchased from us. Technology support includes providing advice on formulation of extruded products and their use in feed or food rations.
Workshops
Informational and Operator workshops are held several times a year to demonstrate specific applications of the Insta-Pro® equipment. The workshops include demonstration of equipment in operation and meetings with current owners. There is no attendance fee.
Spare Parts
We keep a large inventory of spare parts ready for shipment. Genuine Insta-Pro® parts last longer and give a consistently high product quality. By using data from our R & D Facility and our customers, we continuously look for ways to improve our parts by giving them more resistance to operational wear and tear. New parts can be ordered by fax or e-mail through our Contact Information page.
Shipping Services
Our highly qualified logistics staff can arrange for delivery of your Insta-Pro® equipment or spare parts order to any location around the world. We can find the fastest or the most cost-effective delivery options, depending on your needs.
Multi-Lingual Staff
Our staff members in Des Moines speak several foreign languages to make communications easier: Spanish, Chinese, Russian, Arabic and Sinhalese.
Ethanol By-Product Processing
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Insta-Pro® Extrusion Technology
ADDING VALUE TO DDG & DDGS THROUGH
INSTA-PRO EXTRUSION TECHNOLOGY
A novel method of adding value to Distillers Grains with or without the solubles was developed. The procedure capitalizes on the technology of extrusion with or without the use of steam to add-value to the dry milling process in terms of reducing the energy input needed to dry the DDG or DDGS, enhance their nutritional value through co-extruding with oilseeds including but not limited to soybeans or any other ingredient available locally that can improve the amino acids profile, the energy values and reduce the total crude fiber. Such improvement will allow the utilization of the resulting extruded products termed (XDS* and XDS plus*) in all livestock, poultry feed, pet food and aquaculture.
The following documents are in MS Word format.
* Typical Analysis of Extruded DDGS/Soy (XDS plus)
* Advantages to Ethanol Plant
* Product Advantage
* Schematic Dry Milling Ethanol and XDS Plus Feed Production Process
Insta-Pro® equipment finds application in processing a variety of food products. The earliest application was in processing supplementary food products which are blends of cereals and legumes used in nutrition intervention programs around the world. The World Food Program uses Insta-Pro® systems for this application in several countries. The ability of the extruder to cook the product, gelatinize starch, deactivate anti-nutritional factors and reduce microbial loads purely by heat of friction has contributed to the popularity of these extruders.
The advent of the ExPress® process made it possible to manufacture high quality protein flours from soybean and other oilseeds for human consumption. Fat-reduced soy flour of superior nutritional, sensory and microbiological quality is generated cost-effectively through the ExPress® System.
While the basic extruder performs the functions of cooking and gelatinizing starch, accessory forming and shaping equipment is available to impart specific geometry to the products. By judicious combination of the ingredients and process parameters, products can be expanded to provide desired density and texture. A variety of snack type foods and half products can be produced from a wide range of raw ingredients.
In more recent times, Insta-Pro® International has developed and adapted its extruders to produce textured protein products such as textured soy protein. It was demonstrated that the design of the extruders provides for generating very high shear rates. Hence, fat-reduced soy flour produced by the ExPress® process is being used to produce textured soy protein even though protein solubility levels are lower and residual oil content is higher than the industry norms for textured soy protein production. This ability also enables the production of an all natural textured soy product because the ExPress® system is a purely mechanical process involving extrusion and oil pressing.
Commercialization of the Extrusion and Pressing (ExPress®) technology by Insta-Pro International has offered the oilseed processing industry with an alternative approach to extracting vegetable oil by purely mechanical means. This method involves the conditioning of oilseeds by dry extrusion followed by pressing of oil using continuous screw presses. Industries have adopted this technology to process oilseeds with plants of rated capacities as low as 5 Tons/Day to those over 100 Tons/Day. The ExPress method has the advantages of modest investment in equipment, flexible scale of operation, a non-solvent process, and the ability to assure identity preservation during processing.
Insta-Pro has established a strategic partnership with Technochem International, Inc. of India; a manufacturer of small-scale oil refineries for 30 years, to offer custom made small-scale oil refineries to the ExPress industry around the world.
Insta-Pro Refineries are customized to combine the capacity requirement with the best technology option from the standpoints of system cost, product quality, operational cost, regulatory compliance and environmental impact. Total batch refining systems are available for plants of very small capacities. Semi-continuous and fully continuous systems are available for higher capacity plants. Within the framework of regulatory compliance and product quality considerations, materials of construction are selected from stainless steel, mild steel or other acceptable materials. Systems using conventional technology for alkali refining, bleaching and deodorizing (RBD) are supplied when this is appropriate to customer need. When more sophistication is warranted, systems are supplied for physical refining with it's inherent advantages of recovering free fatty acids in pure form and low environmental load. The recovery of deodorizer vapor is accomplished by using steam ejectors and barometric condensers when least cost is the primary consideration. More environmentally friendly systems using surface condensers are supplied when this is desirable or mandatory. In keeping with recent trends in the oil refining industry, Insta-Pro refineries are supplied with packed column technology in the deodorizers when the cost can be justified.
Insta-Pro refineries are skid-mounted in modular fashion. Each system is fabricated in several modules. The modules are designed in a way that they can be transported in shipping containers. The components within each module are pre-assembled before shipment. This approach minimizes the extent of engineering work required at the customer's site and accelerates the process of installation and commissioning once the equipment arrives at the site.
Insta-Pro refineries carry standard warranty terms for the equipment component and for the system performance in terms of end product quality.
Insta-Pro® dry extrusion of oilseeds has been used for the past 33 years to:
* De-activate anti-nutritional factors and growth inhibitors
* Improve digestibility
* Rupture oil cells
Dry extrusion produces a full-energy oilseed meal. ExPress®, a system consisting of Insta-Pro® extruders and horizontal screw presses, allows for the removal of up to 75% of the available oil from most oilseeds.
ExPress® systems can be used to produce all-natural oils and meals from identity-preserved crops. No steam is used in the ExPress® system, which guarantees that no external moisture will be added to the oil.
Soybeans are the most widely grown oilseed in the world. Raw soybeans contain many anti-nutritional factors, including:
* Trypsin and chymotripsin inhibitors (inhibit protein digestion)
* Lectins (decrease the digestibility of nitrogen-free extract)
* Urease (a concern for ruminant diets)
* Allergenic factors (reduce nutrient absorption)
* Lipase and Lipoxygenase (peroxidation and beany flavor)
Independent university studies have shown the Insta-Pro® dry extrusion process to be the most effective way of reducing the effect of these anti-nutritional factors to safe levels without degrading valuable protein. In animal rations, dry extruded soybeans consistently produce better average daily gain with less feed, as compared to other types of soybean processing.
ExPress® system allows production of all-natural soybean oil, which can be used for human consumption without extensive refining. The oil has a very pleasant color, aroma and taste. Dry extrusion releases tocopherols, the natural anti-oxidants contained in soybeans. ExPress® soybean oil has the highest level of tocopherols, which makes it stable for months under normal storage conditions. Tocopherols also keep dry extruded soybean meal from going rancid for a period of months.
For production of full-energy soybeans, without oil extraction by the ExPress® system, Insta-Pro® extruders can be fitted with optional steam Preconditioners. Steam Preconditioners double production capacity of the extruders and reduce mechanical wear.
An important consideration for swine and poultry producers is that the Insta-Pro® soybean meal has improved amino acids digestibility, which results in less nitrogen being released into the environment.
Cottonseed contains a toxic pigment called gossypol, which can be reduced through the use of dry extrusion. Although cottonseed meal is not recommended for use in the diets of monogastric animals, dry extruded cottonseed meal is a very valuable ingredient in ruminant rations due to its high by-pass protein (55-60%), higher amino acids digestibility and fiber quality compared to chemically extracted or cold-pressed cottonseed.
Cottonseed oil obtained through the ExPress® system is used for human consumption after chemical refining.
Rapeseed (Canola) in its raw form contains tannins and glucosinolates. The latter are hydrolyzed into toxic compounds when the seed is broken, which causes metabolic problems in pigs and poultry. Dry extrusion prevents hydrolysis of glucosinolates.
Full-energy rapeseed meal is rarely used due to its high oil content (up to 40%). Rapeseed is most effectively processed with the ExPress® system to obtain natural oil and low-fat meal. Alternatively, rapeseed can be extruded in combination with a low-oil legume, such a field beans or peas, which also need heat processing. The resulting product would have half the oil content of raw rapeseed, low inhibitor levels, and high available energy.
Sunflower has the highest oil content of all oilseeds (up to 55%). ExPress® system is able to produce high quality natural sunflower oil suitable for bottling after mechanical filtration. ExPress® sunflower meal is a valuable ingredient in feed rations.
Peanuts contain anti-nutritional factors similar to soybeans, which makes it necessary to properly process them for best results in feed rations.
Other oilseeds may be processed as well. Please contact us for more information.
PET FOOD
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Insta-Pro® extruders have been used for dry pet food production since the 1970's. As with other shaped products, Insta-Pro® extrusion process offers pet food manufacturers considerably more flexibility than other processes due to a wider range of possible ingredients and low-cost production options.
Basic pet foods can be produced without the use of steam preconditioningand post-extrusion drying, which reduces the initial investment in the processing line and operating costs. This is achieved without reduction in the nutritional quality or palatability of the product being manufactured.
Steam preconditioning increases production capacity, improves shaping ofpet foods, and reduces wear on the extruder barrel, although it may require drying of the product after extrusion. As with other shaped products, fine grinding prior to extrusion is essential to ensure a good pellet shape. Additional flavoring, vitamins and fat can be added by spraying after extrusion.
Palatability is one of the most important factors in pet food. High temperatureand pressure of the dry extrusion process have been shown to increase palatability of pet foods. Insta-Pro® extrusion also achieves sterilization of extruded products, which creates an additional safety margin for the producer.
INSTA-PRO®
EXTRUSION RECYCLING SYSTEMS
FOR
BY-PRODUCTS
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Insta-Pro® dry extruders have been utilized since 1985 to process high moisture by-products from the animal and food industry.
Numerous papers have been published in scientific journals testifying to the quality of extruded by-products and the importance of this technology for a cleaner environment, reduction of feed cost and adding value to what otherwise has been considered waste.
The sterilization that can be achieved by the dry-extrusion process makes it possible to safely process by-products that can potentially contain disease causing micro organisms. By-products encountered most often include hatchery waste, farm mortalities, litter and manure, slaughter house by-products, fish waste and other marine by-products.
RESEARCH AND DEVELOPMENT
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Cooperative Research At Academic Institutions:
The company supports basic and applied research projects at reputed academic institutions when the subject of such research is synergistic with the company's interest in validating the application of its equipment and technologies. Basic research behind a number of technologies and processes commercialized by the company have been carried out at academic institutions. When the need arises, the company also contracts specific research projects of its own interest to the Universities. Insta-Pro® International has placed its equipment as part of continuing research agreements at the following Universities:
Iowa State University
Iowa State - Biomass Center
Kansas State University
Oceanic Institute, Hawaii
Ping Tung University, Taiwan
Texas A & M University
Texas Tech University
University of Illinois
University of Missouri
University of Nebraska
University of North Carolina
University of Northern Iowa / ABIL
USDA ARS Lubbock, Texas
Utah State University
COMPLETE AND SPECIALTY
FEED PRODUCTS
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Complete diets may be extruded for a whole range of applications: feed forfur-bearing animals, horse treats, pig and calf starters, to name a few. The beneficial effects of extrusion will vary with species, age and type of ration being fed. But, in general, extrusion will increase protein digestibility, make more energy available, reduce fiber content in the diet and improve its digestibility.
Deactivation of enzymes, inhibitors, pathogens and starch gelatinization are especially important when formulating diets for young animals.
Insta-Pro® International developed a non-protein nitrogen (NPN) product forruminants. That product, called Golden ProTM, is an extruded combination of non-protein nitrogen and starch from grain sources. Golden ProTM provides controlled ammonia release, serves as a high-quality energy source in the form of gelatinized starch, has excellent palatability, and has been proven in field trials to perform as well as natural protein.
Although dry extrusion is the most effective mechanical way of reducing trypsin inhibitor level in soybeans (to approximately 15 mg/gr.), further reduction can be achieved through the use of MX-ProTM premix in conjunction with extrusion. Soybeans extruded with MX-ProTM are used in swine growing, finishing and gestation rations, poultry rations and pet foods. A variation of MX-ProTM extruded soybeans with added fat is designed to significantly strengthen the reproductive ability of sows.
MX-ProTM LTITM (low trypsin inhibitor) family of products are soy flours with a trypsin inhibitor level of 5 mg/gr. that are used to replace milk or fish protein in sensitive species, such as baby pigs, young calves, fur-bearing animals and fish. Some MX-ProTM LTITM products are formulated with a high protein content (50%).
Extruded Heat Treated Protein (HTPTM) has low solubility, which increases the proportion of protein bypassing the rumen without being converted to microbial protein. Ruminants can therefore utilize it more efficiently. University research and field data have shown that HTPTM can provide amino acids to improve milk yield in high-producing dairy cows, as well as daily gain and feed efficiency of feedlot animals when the protein requirement is greater than that which can be met by microbial protein alone.
Extruded oilseed/cereal combinations can be a very valuable and economical source of protein and energy in animal rations. Extrusion reduces anti-nutritional factors contained in most oilseeds to safe levels, while at the same time improving the digestibility of starch.
Other specialty products may utilize locally available ingredients to minimize the cost of feed rations.
