I specialise at the intersection of plant design, production performance, raw material behaviour, and aquafeed quality.
Below are cases showcasing the impact of my consultancy work.
Case 1: Changing conditioner settings to improve product expansion and higher extruder throughput
A producer struggled with limited expansion, unstable floatability, and throughput capped by extruder restrictions.
By redesigning the water- and steam-addition sequence during conditioning, we optimised the hydration time and shifted part of the starch cooking upstream.
This allowed the extruder to run with fewer restrictions, enabling higher output, more stable product expansion, and smoother operation across shifts.
Case 2: Introducing bulk density measurements to reduce off-spec production
One plant relied on slow, manual floatability tests that caused inconsistent density control and unnecessary rework.
A fast, standardised bulk-density measurement was introduced at the extruder, alongside product-specific bulk density targets defined for the client.
The result was tighter process control, fewer deviations, and a significant reduction in off-spec batches — improving both quality and efficiency.
Case 3: Improving dryer homogeneity to increase capacity and pellet strength
A manufacturer faced moisture variation, dryer bottlenecks, and reduced pellet durability.
Through airflow optimisation, bed‑depth adjustments, and improved distribution at the dryer inlet, moisture variation was dramatically reduced.
This allowed the plant to run at higher average moisture levels, strengthening pellets, reducing fines, and increasing overall dryer capacity.
Case 4: Eliminating glossy pellets and achieving uniform oil absorption
A plant producing high‑fat feeds struggled with glossy pellets, uneven colour, and oil leakage.
Oil preparation was optimised, temperature profiles stabilised, vacuum-coating phases refined, and improved dosing techniques introduced.
The result was uniform oil absorption, reduced gloss, and a cleaner, more stable pellet surface.
Case 5: Redesigning die geometry to improve pellet size uniformity
One manufacturer observed short and long pellets exiting the same die, indicating uneven flow.
The die approach geometry was redesigned to eliminate sharp turns and turbulence.
This improved flow uniformity, stabilised pellet length, and enhanced overall product consistency.
Case 6: Optimising vacuum coating system to reduce light and dark pellet variation
A producer faced colour variation caused by uneven oil distribution.
By improving mixing during vacuum phases, refining oil dosing, and introducing a nozzle-based application, uniform coating was achieved across all pellets.
The plant saw fewer customer complaints and more consistent product appearance.
Case 7: Improving Overall Equipment Effectiveness (OEE) as a tool for increasing operational performance
Several plants had OEE figures but lacked clear, actionable use of the data.
The definitions and methods for capturing availability, performance, and quality losses were reviewed and refined. Following this assessment, the results were translated into actionable steps for improving OEE. This involved prioritising the largest loss categories, connecting stops and speed losses to their root causes, improving follow-up routines, and using OEE as a daily improvement tool rather than merely a reporting metric.
This gave teams a clearer basis for reducing downtime, recovering lost capacity, and improving production efficiency.
Case 8: Helping a raw material supplier build aquafeed application evidence for a new post-extrusion ingredient
A raw material supplier wanted to introduce a new post-extrusion ingredient into aquafeed but needed small-scale coating trials to optimise the application method, understand handling behaviour, and generate practical evidence before approaching producers.
To support this, a small-scale, purpose-built mini-coater was developed and used for the client, creating a controlled way to test coating behaviour, refine dosage and application conditions, and identify practical constraints before exposing the supplier to the cost and complexity of a full-scale production trial.
The work helped the supplier understand where the product added value, which process limits had to be managed, and how to present credible evidence to aquafeed producers considering commercial use — moving the product from technical promise toward a stronger market introduction case.
Case 9: Guiding a new production line from concept to handover
A producer planning a new plant required more than equipment recommendations; they needed an independent guide without any stake in supplier selection to steer the process from the beginning.
The engagement began with a clear definition of actual needs, including the product portfolio, capacity, and operational constraints. Next, requests for quotation were issued to multiple suppliers based on those requirements, and assistance was provided in selecting the best-fit supplier(s). Support continued throughout the project, including reviewing technical drawings against the original requirements and best practices, identifying any shortcomings, and remaining involved through to the handover.
The result was a process in which customer requirements and best practices remained the reference point throughout, backed by independent technical judgment at every stage, giving them a supplier selection and project outcome they could trust, rather than having to navigate supplier claims alone.
Case 10: Hunting hidden losses: a dust and broken-pellet audit
A plant had no clear picture of where dust and broken pellets were coming from, with fines running well above best-in-class levels. Every percentage point above that benchmark carried a real, ongoing cost, as fines and off-spec product cannot be shipped and sold and need to be reprocessed — adding production time and cost that compounds with every percentage point above best-in-class.
A dust and broken-pellet audit was conducted to trace the losses to their source across the line, turning an invisible, ongoing cost into a prioritised, fixable list.
The result was a clear basis for action, giving the plant a path to bring dust and breakage down toward best-in-class levels and reduce the cost of reprocessing fines.
Do not hesitate to contact me if you have a question or would like to discuss a potential project or collaboration.