ANDRITZ upgrades Expansion Control System with major efficiency gains

NETHERLANDS –  ANDRITZ has introduced version 2.0 of its Expansion Control System (ECS), aimed at improving energy efficiency, maintenance performance, and feed quality in aquafeed processing. 

The upgrade was presented at Victam International 2026. 

It builds on a system the company developed 25 years ago, which became a standard tool for controlling pellet density and quality across the global feed industry after its initial patent expired.  

The latest version addresses operational gaps identified over years of industrial use, focusing on reducing energy consumption, simplifying maintenance, and improving process stability. 

A key technical advancement in ECS 2.0 is the redesigned mechanical layout. 

The system now features interchangeable plates, which allow for faster replacement of wear parts, significantly reducing downtime and labour requirements for mill operators. 

Furthermore, the connection between the ECS and the knife housing has been redesigned with a new sealed configuration to increase installation speed and improve system stability during continuous production.  

Efficiency gains are particularly notable regarding compressed air usage. 

ANDRITZ reports that ECS 2.0 cuts air consumption by 50% to 80% compared to previous versions. 

As compressed air generation is a major cost driver for feed mills, this upgrade offers substantial financial relief. 

Industry Director of Aqua and Pet at ANDRITZ, Gunnar Hallmann, noted that a typical mill spending US$34,229 annually on compressed-air electricity could see these costs fall to approximately US$6,845. 

By using controlled pressurisation within the knife housing to manage pellet expansion, the system provides precise control over feed density for sinking aquafeeds, resulting in more consistent product quality and improved feed conversion ratios for farmers.  

Industry trends in extrusion technology and digital automation

The launch of ECS 2.0 arrives at a time when the aquafeed industry is grappling with rising raw material costs and the necessity for more flexible production lines. 

As farmers demand higher protein content and specialised textures, such as water-stable pellets for intensive shrimp farming, equipment manufacturers are pushing toward twin-screw extrusion technology. 

This shift allows for greater recipe flexibility compared to traditional single-screw extruders. 

Major industry players like Bühler are similarly focusing on extrusion innovation, recently highlighting how automated feeding systems, which rely on accurate acoustic monitoring of aquatic animals, require the high-quality, consistent pellet structures that these advanced systems provide.  

Beyond hardware, the broader industry trend is leaning heavily into automation and digital integration. 

With global labour shortages making it difficult to recruit and retain experienced mill operators, there is increasing pressure to adopt systems that minimise human intervention while ensuring strict food safety and traceability. 

ANDRITZ is responding to this demand by expanding its portfolio of integrated turnkey solutions, having recently achieved a record order intake in early 2026, securing large-scale projects globally. 

As sustainability targets tighten, producers are looking to optimise their entire production lifecycle, with companies like Cargill also investing in pilot-scale extrusion facilities to accelerate the development of circular feed solutions. 

This reflects a broader industrial movement in which machinery is no longer just a production tool but a data-driven component of a modern, efficient, and traceable feed business.

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