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Making Feed Pellets

Making Feed Pellets

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A feed mill needs to produce pellets in a hygienic way with the least costs and the highest efficiency. This cannot be realised without the close relationship between the operators in the field and the engineers at the drawing table.
A feed mill needs to produce pellets in a hygienic way with the least costs and the highest efficiency. This cannot be realised without the close relationship between the operators in the field and the engineers at the drawing table.

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Published by: Milling and Grain (formerly GFMT) on Jul 29, 2010
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Digital Re-print - July | August 2010

Making Feed Pellets

Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

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Feed Pellets

Feature

Feature

Feed Pellets

Feed Pellets
A
feed mill needs to produce pellets in a hygienic way with the least costs and the highest efficiency. This cannot be realised without the close relationship between the operators in the field and the engineers at the drawing table.
our industry - which is not specifically known for its innovative power," says the company.

Making

treatment (kneading and shearing) and thermal treatment (time/temperature). Especially the last feature has become essential in feed manufacturing. Through higher temperatures the feed is hygienised and bacteria are already killed in the conditioner. CPM was at the forefront of this development with the introduction of the hygieniser or super conditioner. This piece of equipment has shown to be an extremely efficient con-

have to be by-passed or discarded before pelleting. CPM has overcome this problem “CPM was at the by developing the ‘Hot Start Mixer’, forefront of this which functions as a buffer in the development start-up of the conditioning process. with the The paddles and screw in the first section of the hygieniser at startintroduction of up turn in reversed direction until the hygieniser the mash has reached the required or super temperature and then the direction conditioner” is changed and the mash can flow through the hygieniser. There is no longer any need for a by-pass and the full batch of feed can ditioner before pelleting and it is much be used without chance of recontamination. cheaper than an expander, which is also often used. Specialist in pelleting Table 1 shows die differences between an Around 50 percent of all pellet mills expander and die hygieniser. used in the world are made by CPM. So the company, indeed, can call itself a specialist in pelleting. Hot start mixer Pelleting is not just the use of a machine One small thing was still a problem: when starting the conditioning process the first that turns ground and mixed ingredients into approximate 100 kg of a new run did not pellets, it is a process and begins after the reach the required temperature and would grinding process with conditioning, followed

Conditioning with hygieniser

Through this cooperation equipment manufacturer CPM Europe, in Amsterdam, The Netherlands, has been able to launch many ‘firsts’ which have later been adopted and copied to become industry standards. Plant operators working in the feed industry often consider the handling of their pelleting equipment to be an art. Manufacturers of these machines consider their businesses to be closely related to science. But this science can learn from the pelleting ‘artists’ by developing and implementing demands and views from practice. The engineers at CPM Europe are the last ones to deny that practice is closely intertwined with their work on the computer controlled drawing programs. "Our close relationship between practice and our ability to translate practical improvements into factual equipment, has delivered us almost always a competitive advantage which is especially valuable in
18 | July - august 2010

CPM is active in the grinding and pelleting section of the Table 1: Comparison of expander and CPM hygieniser as a feed manufacconditioner before pelleting turing process. Expander CPM hygieniser Before pelleting the feed mash needs Maximum formulation flexibility Formulation fat level 8% max to be treated 250 kW drive installed 2.2 kW drive installed before it enters 12 kWh/tone average (expander + 8 kWh per tone average (hygieniser + the pellet mill. pellet mill) pellet mill) This condi$0.75 per tone wearing items No wearing items tioning of the Increased parts wear with limestone mash has sevor oyster shell eral advantages. No sensitivity for abrasive elements in Proper condiin formulation formulation tioning ensures High skill required to operate Very simple to operate a better pellet quality (hardDown time risk due to blocking No down time risk ness, durability) High starch formulation increases No sensitivity for high starch resulting in betblocking risk formulations ter conversion Moisture content in pellets difficult to Moisture content in pellets simple to rates with the maintain maintain animals. High temperatures effect sensitive Simple and accurate temperature Conditioning elements like vitamins control improves pellet Controlled product retention time for mill capacity, Product retention time is not controlled optimum salmonella destruction
Grain

reduces electrical power use and reduces wear of dies and rollers. Furthermore, with conditioning more difficult (cheaper and/or) ingredients can be used. Conditioning is a combination of moisture addition (steam and/or water), mechanical

Since 1883

Roll Speed

Since 1883

Quick die change

Higher capacity & better quality with Roll Speed Measurement
• Enhanced control over pellet quality • Improved steam addition control • No more overloads • Cost effective

Replace your die in less then 20 minutes. Use the best die for each purpose • Easy • Safe • Quick • Mechanical • Cost saving
- Quick die change clamp - Pneumatic operated die hoist - Lineator

H2X/2100155

CONTACT CPM/Europe BV Distelweg 89, 1031 HD Amsterdam, The Netherlands, Phone +31 20 494 61 11, Fax +31 20 636 42 94, info@cpmeurope.nl

H2X/2100155

CONTACT CPM/Europe BV Distelweg 89, 1031 HD Amsterdam, The Netherlands, Phone +31 20 494 61 11, Fax +31 20 636 42 94, info@cpmeurope.nl

■ HIGH PERFORMANCES ■ LOW COST MAINTENANCE ■ MAXIMUM SAFETY ■ LONG LIFETIME ■ WWW.CPMEUROPE.NL

■ HIGH PERFORMANCES ■ LOW COST MAINTENANCE ■ MAXIMUM SAFETY ■ LONG LIFETIME ■ WWW.CPMEUROPE.NL

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July - august 2010 | 19

Feed Pellets

Feature

by die actual pelleting and then cooling of the hot pellets and where applicable the addition of fats.

ity without stopping the production. Energy efficiency is also depending on the method of power transmission in die pellet mill. For this reason CPM pellet mills operate with a gear box instead of double V-belt drive. Gearbox transmission has a high efficient power transmission. For a 250kW with an operating time of 6000 hours per year and an energy price of eight eurocents per kWh this would mean an energy cost of €120,000. At 11 percent higher efficiency this would mean a saving of 13,200 in the advantage of a gear box drive.

With this system two people can remove a die in less than four minutes and the same people can fit a new die in less than five minutes. The quick die change clamp can also be mounted on existing machines that have been supplied by CPM in the past 10 years.

Roll speed measurement
The latest innovation is the roll speed measurement, which has been in operation for testing over one year and is now mature to sell on the CPM Pellet mills. The new integrated roll speed measure ment device works with very little maintenance and high accuracy. It was observed that with clean die and rollers, the roll speed measurement allowed an automatic 'zero-positioning' of the Lineator. Until now this 'zero-positioning' proved to be a rather subjective interpre tation by various operators. Different operators can 'pre-load' the rollers differently against the die to set the zero-position. With the roll speed measurement the zero-position is set at the moment both rollers are rotating at nominal speed. In practice, influencing the pellet quality is reached by using a thicker die or BOA-compactor or expander. Now CPM introduced another option with roll speed measurement system together with a Lineator. The operator can safely move the rollers from the die and creating a “variable die” and so influence the pellet quality, all this can be done due to the roll speed measurement. The roll speed measurement continuously measures the roll speed so that it stays above a certain speed, so that the die doesn’t choke. Due to this “variable die” specifications less die changes are needed and the different batch are made with the optimal “variable die.”

Pelleting is also about energy consumption.
The way the die and the die rolls are positioned largely deter mine how much energy can be added to the product. There is a close relationship between energy consump tion and pellet quality. The more energy is put into the pellet the better its quality will be. At the pellet mill this is limited to maximum 20kWh/ tonne. The consumption of energy is also dependent on the roller distance to the die. An increase in roller distance will result in higher energy consumption. To be able to manage this process CPM developed the lineator, which enables die operator to adjust the roller distances while pelleting and thus give himself the opportunity to influence pellet qual20 | July - august 2010

Quick die change
Every pellet plant operator knows the burden of changing a die. Not only is it a heavy and time consuming job, it also adds considerably to the down-time of the plant. The CPM engineering group in Amsterdam has developed a quick die change system for its 32" and 36" pellet mills. The objective was to have the pellet mill up and running with a new die only 30 minutes after the end of the previous run. This means that for the actual (hot) die change only 20 minutes are being reserved. To meet this objective CPM installed a pneumatic die hoist, automatic knives positioning, automatic roller adjust type lineator, 18 segments die clamp type bear claw and pre-assembled die with stiffening ring and rotary cone.

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inforMation:

CPM Europe B V Distelweg 89 Amsterdam, NL-1031 HD The Netherlands
Tel: +31 20 4946111 Fax: +31 20 6364294 Email: info@cpmeurope.nl Website: www.cpmeurope.nl

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This digital Re-print is part of the July | August 2010 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on www.docstoc.com.

LINKS

August

2010

• See the full issue

In this issue:
• Technical design and equipment - Key to improving feed quality and nutrition

• Mycotoxin testing: ready for this year’s harvest?

Visit the GFMT website Contact the GFMT Team Subscribe to GFMT

• Added value by Flour Heat Treatment

• •

• Making Feed

Pellets

• Factors affecting pelleting and energy consumption • Fusarium mycotoxins

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All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these have been used as point of sale materials, promotional materials for shows and exhibitions etc). If you are interested in getting this article re-printed please contact the GFMT team for more information on - Tel: +44 1242 267707 - Email: jamest@gfmt.co.uk or visit www.gfmt.co.uk/reprints

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