1/11/2019

Feed Mill Design

And
Feed Processing
By
E.Gnanamoorthi
Head- Engineering Services,
Optima life Sciences Pvt Ltd.

Feed Mill Overall View

Feed Mill General Drawing

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Processing flow chart

Processing flow chart

Raw Material Arrival

 Need to allot the place
 Need to submit bill and
PO details to office for
verification
 After Verification need to
provide Serial number
and Unloading Time, If
sample pass means.
 Inform to QC department
for sample test.

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Lab Test
Need to do following
Basic test
Moisture Test
Protein Test
Funguses test

Unloading
If Silo If Lot System
Need To allot permanent
Need to do pre place to unload the
cleaning particular material
Need to put High ratio material have
to unload nearest place to
greasing to bearing grinding point
area of screw Lotting up to safety level
conveyer only.
Need to check Oil Need to maintain proper
ventilation method
level in the gear box Need to implement FIFO
method

Batching system
 Have to set the correct
quantity from the
correct Bin as per
formula
The batching is the
main roll in feed quality
In proper batching will
affect the feed quality
It will lead to raw
material stock variation.

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Medicine & Oil Batching

 Have to Maintain color
code bags for individual
item
 Do not keep with out
color coding medicine bag
 Have to mix the medicine
timely with raw material
in mixer
 Have to mix oil with raw
material in the mixer

Grinding
The grinding means
“reduction of particle
size of raw material”
And also the second
largest power consumer
in the feed plant

Grinding
 Can process wide range of
raw material
 Produce wide range of
particle size
 Can process too fibrous
material
 Less cost
 Minimum maintenance
cost
 Particle will be spherical
in shape with surface
polished

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Grinding
 The velocity or tip speed
of the hammer is critical
for proper size reduction
 Tip Speed (meter per
minute)=∏Dn
 ∏ = 3.14
 D = diameter of hammer
tip in meter
 N = Shaft rpm
 Tip speed range between
5000 to 7000 rpm

Grinding
An abnormal
temperature rise in the
material means the
operation losing the
efficiency
Differential
Temperature “ Delta
T(ΔT)’’
If ΔT is more then 5⁰C
means, need to improve
the system efficiency

Grinding
Mark 1’’ by 1’’ square
Area of sieve (closed
area )= L × B
Area of one hole =
∏d²/4
Open area in the sieve =
L × B × ( n∏d²/4)
Note :- all dimensions
should be in inch

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Effect of high ΔT
 Evaporate moisture in
r/m
 Significant loss in weight
 Condensation in mill and
transportation system
surface
 Corrosion
 Ingredients residues
 Cross – Contamination
 Mould problem

Mixer
Paddle Mixer
Ribbon Mixer
Twin shaft mixer
Continuous mixer

Features influencing in mixer

performance
 Ingredient particle size
and shape
 Ingredient density and
static charge
 Sequence of ingredient
addition
 Amount of ingredient
addition
 Rotational speed
 Mixer Design
 Cleanness of mixer
 Maintenance of the mixer

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Mixer performance Test

Data Analysis % CV = % co-efficient of
%CV = s÷ŷ x 100 variation
Ŷ = ∑y ÷ n s = standard deviation
s² = variation
s = √s²
Ŷ = mean
s² = ( ∑(yi²)-n ŷ²) ÷
∑ = sum
n-1
yi = individual sample
analysis results
n = total number of
samples

Conditioner
The main aim of
conditioning is to
optimize the nutritional
quality of the feed
Reduces microbial
activity
Increases starch
gelatinization
Enhances pellet
durability

Conditioner
The Following three  Generally Single or dual
factors are important in barrel arrangement.
conditioning  Each barrel contains
Retention time paddles revolving at
speed
Moisture content
 Duration time varies
Temperature between 10 sec to 60 sec
 It can sometimes
controlled by the angle of
the paddles, which should
be checked frequently for
wear

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Conditioner – Retention Time and
temperature
Increasing retention
time improves the
pellet quality
Retention time is from
30 sec to 45 sec
approximately
The temperature of
feed after conditioning
will be from 80⁰C to
85⁰C
Pelleting
 The main aim of pelleting
is to optimize the physical
quality of the feed
 The most capital and
energy intensive
operation in feed
manufacturing operation
Pelleting
1/11/2019
 Moisture addition will
be approximately
3.75% to 4%
 Steam can't provide
the moisture more
then 6% during
conditioning
 Increased nutrient
availability
 Decreased energy
requirement for feed
consumption
 Reduced feed pathogen
load
 Increased bulk density
(Lower trucking cost)
 Reduced feed shrinkage
(Less material cost as dust
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Pellet Press

Pelleting Efficiency
 Pellet must present the following  Efficiency of pelleting
characteristics means producing pellets of
 Good appearance good physical quality at the
 Dust free optimum ratio of output to
 Without crakes energy consumption by the
 Uniform length press.
 Hard – Sufficient only to  Pelleting efficiency is
withstand pressures during
storage defined as the amount of
 Durable – the most important energy (KWh used to
characteristic of all. It must produce one tonne of
be during enough to pellets (Kwh/T))
withstand the handling it will
receive between manufacture
to feeding to stock

Efficiency Calculation
 Pellet presses are controlled manually or by  The efficiency of your pellet press can be
computer. Either way, It is essential to understand calculated as follows
the requirements for effective operation and  Determine pelleting production rate (T/h)
control, in order to optimize production rate and
pellet quality.  Determine average press motor current
 The following points outline start-up, running and  Determine plant voltage
stopping procedure for a conventional pelleting  Apply the following formulas to find the
press. press power in KW and the pelleting
efficiency
 Power (KW)=A × Voltage × √3 ×Power
factor
•
T/H 1000
• (Assume a power
factor of 0.93
unless known)
• Pellet Efficiency
(KWh/T) =
(KW/(T/H))

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Die Selection
It is depending on the
raw material and
formulation.
There is a wide range
available from low
compression (thin dies
wide counter-bored
parallel holes) up high
compression (thick dies
with well or taper bored
holes)

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Die Specification and Material

Guidelines

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Die Care
 Check bores and track for scoring, burring  Avoid “ face to face” roller/die contact.
and poor machining before fitting die to  If blocked solid: soak in oil. Then try to re-
press. start. If unsuccessful. Punch out or drill out.
 Some dies are supplied “ pre run – in” and  Never Strike a die with steel tool.
the holes are plugged with an oily material.  Protect die from metal object by fitting
this is removed by hand feeding the press magnets.
with whole cereal, after that die has been
fitted and while the press is running.  Punch out ant tramp metal which manages
 If the holes of the new die are empty, then it to enter the die.
is preferable to plug them prior to  Log the use of your die
commencing production by hand feeding
whole pellets.
 Care should betaken when starting
production not to “{over feed “ the die i.e
run the die in gently
 After running for approximately one hour,
stop the press and inspect the die track and
roller to ensure all holes are running.

Roller Setting (Manual)

 Under – Adjusted rolls
Create excessive roller
slip. Heat and possible
Consequent die blockage,
thus seriously affecting
production output.
However, pellet durability
generally improves as
rolls are moved away
from the die face, but
press capacity is sacrificed
and pellet length is more
varied.
 Correct roller setting is essential for
optimum pellet quality, press
capacity and die/roller life.
 If the rolls are set too tight,
 The die will flex excessively and
may finally creak. It also
increases the possibility of
metal- to- metal contact.
 Thus rolling over the ends of
the holes on the die and
creating excessive wear and
splitting of roller shells.
 Close fitting rolls generally
maximize press capacity.

Knife Setting
Knives are used to
control the length of
pellets as they leave the
die. The setting position
will depending in the
required pellet length.
The shearing or tearing
action of the knives on
the soft pellets as they
leave the die create
fines.

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Pellet Durability Index

PDI is defined as the percentage of pellets in the

finished pellet feed
Feed = Pellet + Fines
PDI = Pellet X 100
Feed
Testing method:
KSU tumbling can, Holmen tester, Kahl tester

COOLER
Temperature: Hot Air
80 to 85°C
Moisture:
15% ±1%

Ambient
temperature
and moisture
Environmental
same as mash

COOLER
• Coolers are designed to
extract heat and surplus
moisture created during
pelleting, thereby increasing
the strength of the pellet.
 Most of the modern feed
mills are using the counter-
flow coolers
 Average moisture content
of pellet feed after cooler
is 11.5%
• The temperature of pellet feed
after cooler is ambient
• temperature only

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Crumblier
 For every young poultry, even small
pellets may be too large, thus intake
is reduced
 Crumbs overcome this problem and
still provide a nutritionally balanced
diet.
 4mm pellets are used and constant
and even feed into the crumblier is
essential.
 Setting the rolls too close results in
mashing the pellets rather then
breaking them. The meal created is
then returned for re-pelleting,
consequently production efficiency is
reduced.
 It is also important that the rolls are
well maintained. Ensuring that the
flutes are sharp.

Sifters
 Sifters are generally
located immediately after
the cooler and before
discharge into bulk road
tanker or packing area.
 The screens in the sifter
should be checked
periodically to see that
the perforations are not
blind, worn or damaged.

Queries???

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Thank You!

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