An Introduction To Online Milling School

An Introduction to
Online Milling
School
Announcing the launch of Credo Online Milling School series
BROUGHT TO YOU BY
for Livestock Milling live streamed courses
© 2020 All Rights Reserved, Athene Consulting Co., Ltd, Progressus.

Online Milling School
• We are extremely pleased to announce the launch of
© 2020 All Rights Reserved, Athene Consulting Co., Ltd, Progressus
Credo Online Milling School series of Livestock

Milling live streamed courses www.onlinemillingschool.com
www.millingandgrain.com
• A collaboration between Progressus AgriSchools and
Milling and Grain magazine
• Assist the industry by focusing on the development

and up-skilling of its professionals www.progressus.asia
Online Milling School
• The series consist of a carefully crafted training
modules that address the most critical aspects

of livestock feed manufacturing and are to be
delivered by a variety of feed milling experts
that are ready to share their valuable
knowledge and know-how for the overall
betterment of the industry and its
professionals.
Schedule of Delivery
July – September 2020
ICT, UTC+7 CET
Credo Online Milling School Topics Dates

Time Time
Grinding Operations Wed, 22th July 2:00 p.m. 9:00 a.m.
Batching Operations Wed, 29nd July 2:00 p.m. 9:00 a.m.
Steam and Conditioning Wed, 5th Aug. 2:00 p.m. 9:00 a.m.
Mixing Operation Wed, 12th Aug. 2:00 p.m. 9:00 a.m.
Pelleting Process Wed, 19th Aug. 2:00 p.m. 9:00 a.m.
Raw material receiving and storage Wed, 26th Aug. 2:00 p.m. 9:00 a.m.
Other supporting Equipment Wed, 2nd Sep. 2:00 p.m. 9:00 a.m.
Quality Assurance and Quality Control Wed, 9nd Sep. 2:00 p.m. 9:00 a.m.
Feed Mill Management Wed, 16th Sep. 2:00 p.m. 9:00 a.m.
Feed mill Digitalization and Automation Systems Wed, 23th Sep. 2:00 p.m. 9:00 a.m.
Feed Mill Design and Construction Wed, 30rd Sep. 2:00 p.m. 9:00 a.m.
Each week there will be a 1.5 - 2.5 hours live delivery

Who will benefit and how?
WHO IS IT FOR
 Professionals that are involved in operating feed plants

 Technical professionals involved in supporting the feed mill industry
 Suppliers to the industry
 New entrants and professionals wishing to enhance their knowledge
about the feed mill industry
BENEFITS
 Gain the skills you need to accelerate your career in the field of feed
milling
 A practical way for professionals to learn more about a topic that is
supportive of their everyday business needs
Attending the Credo Online Milling School Series
 No prior experience in the field is required to get started
 You can choose to attend all or selected topics

 Attendance fee is at a low rate of USD30/person/session
 Simple sign up and you are ready to start building those critical
capabilities and knowledge
Register at
www.OnlineMillingSchool.com
Certificate of Completion
• In additional to knowledge and skills, a Certificate of Completion in
Feed Milling will be provided

• A certificate that could add value to your milling abilities
• The certificate will be provided to attendees that will complete all 12
modules
• Issued by Perendale and Progressus
Together we can make a difference!
Sponsor Opportunities
• Interested to show our industry that you are a supporter of people
development through education?

• You are more than welcome to be part of this initiative!
• We are always on the look for;
• Expert instructors
• Knowledge contributors
• Series sponsors
• For more information as to how to be part of this initiative please
contact us at: credo@progressus.asia OR tutit@perendale.co.uk
Coming your way soon!

Management of an
efficient
Grinding Operation
By Mr. Malcolm Gresswell
BROUGHT TO YOU BY

Why do we grind?
• Greater surface area for digestion & feed efficiency
• Expose to Heat, Moisture, Enzymes

• Ease of handling some materials
• Improve mixing characteristics
• Improve pelleting efficiency and pellet quality
Balance between what is optimal for nutrition & feed mill

• Oversized particles may block dies or
• create fracture points in pellets
• Uniform particle size leads to

• uniform cook and gelatinization of starches
Particle Size Analysis
• Perform a complete sieving test
• Use at least a 100gm sample

• Sieve over as many test sieves as possible and weigh the fraction on each sieve
• Calculate the geometric mean particle size, d50
• This is the mid point of distribution (50% coarser and 50% finer)
Particle Size Reduction
Percent on Particle Size Analysis
35 840 μ
30
25
20
15
10
-
4 6 8 10 14 20 30 40 50 70 100 140 200 270 Pan
Roller Mill L-NSD 2.134

U.S Sieve Hammermill L-NSD 2.449
Source: Roskamp
Principles for Grinding
• Influences on product quality
• Increase surface area of raw materials
• Improved mixing of raw materials
• Granulation size for specific feed types
• Grinding is the second biggest energy consumer
• Grinding is a safety hazard (temperature, air, dust)
• Correct installation and set up essential

Grinding and Particle Size and the Effect on
Pelleting
The size of the particles presented to the pellet mill will have a direct effect on its performance due
to:
• Steam penetration  Steam penetrates small particles to the core

 Steam unable to penetrate large particles completely, leaving the centre dry
• Bulk Density
• Energy consumption
• Die Life
• Returns or Fines
• Particles in Pellets adhere to one another by Heat and Moisture being added in the pelleting
process and after Formulation and Conditioning the correct particle size in the Grinding Process
has a 20% influence on the ability to pellet efficiently
Economics of Grinding
• Energy required to grind a given quantity of grain or mix
• Measured as Production Rate per Horsepower Hour

• Cost increases as particle size decreases
• Maintenance Costs
• Hammers and Screens
• Labour
• Daily Adjustments
• Screens and Hammer changes
Screens
• The smaller the hole size in the grinder screen, the greater the frictional heat build up within the
grinding.
• Higher temperature = higher moisture loss
• The “working part” of a grinder screen is the edge

or corner of each hole in the screen.
• As that edge wears the performance of the grinder (THP)

• will drop and the quality of the grind (sieve test)
• will vary (often more fine material)
Worn Screen Impact on Throughput
• The particle sees an shortened oval not a hole
• As the screen wears less material is able to pass through
• Hammermill capacity and efficiency decrease

Screens
• Due to costs of grinding (energy costs) it is false economy to leave grinder screens in for too long.
• The drop in performance and increase in cost per tonne by grinding through worn screens is far outweighed
by regular screen changing.
• For most feed milling operations, grinder screens should be of a staggered pattern, this ensures that the
entire cross sectional area of the screen is being used.
Source: Anderson
Screens
Correct and incorrect stagger arrangements of hole in screens
Hammermill Screens
Source: Anderson
Hammers
• Correct selection of hammers will influence:
• Hammermill performance
• Operating costs
• Capacity
• Screen wear
• A hammer has in most cases 4 corners available to be used
• Some mills use hammers with only 2 working corners
Source: LC Goh
Hammers- Hard Facing and Standard
Hard-Faced
Standard
Hammer
Source: LC Goh Hammer
Case hardened hammers: Self sharpening Concave wear
pattern
• The hammer self sharpens,

with efficient cutting edges on
each side of the hammer
• Despite of wear, the hammer

length remains full,
maintaining optimum short
distance to the screen
Comparison of Effectiveness of
Convex & Concave Cutting Surfaces
CONVEX
Source: LC Goh
CONCAVE
Particles tend to flow around streamlined convex surface

Efficient Hammer Pattern
Example of an
efficient hammer
pattern
Source: LC Goh
Feeder Hopper Bin
• Hammermill grinder requires continuous Feed Screw
feed supply
• Need a supply bin (often fitted with high Magnet
Air Intake
/ low indicators) Stone Trap
• Material in the supply bin should already Deflector
be “cleaned” to remove non ferrous

Screen
hazards Hammers
• Need to avoid damage to the grinder

screens or risk of dust explosion
Feeder Types
Effectiveness of the grinding is reliant on a full width feeder to ensure
material spread evenly across screens and hammers.

• Rotary Pocket Feeders
Product In
• Screw Feeders Air in
• Vibratory Feeders
Tramp Out
Clean
Product
Discharge
Source: LC Goh
Hammermill Protection
• Magnetic protection is needed to gain the best life of the working components of
the mill
• Tramp metal that enters a hammermill can knock holes in the screens, break
hammers
• Can also create a source of ignition that can trigger a dust explosion!!
Typical Arrangement of a Hammermill with Air-Assist
Aspiration Air Boosts Capacity, Reduces Heating and Dustiness
Style II Filter
Hammermill
Hammermill Plenum
Source: AirLanco
Flare Though Auger
Airlock
Management of an
efficient
Grinding Operation
Delivered by Mr. Malcolm Gresswell
BROUGHT TO YOU BY

BIG THANK YOU TO OUR SESSION SPONSORS
Together we can make a difference to the industry

This is our 5 Minute Break
VISIT OUR WWW.ONLINEMILLINGSCHOOL.COM

WEBSITE FOR
FULL PROGRAM
AND
INFORMATION
ON THE
UPCOMING
SESSIONS
This is our 5 Minute Break
ICT, UTC+7 CET
Time Time
Register at: www.OnlineMillingSchool.com

An Overview of Efficient
Conditioning for Livestock
feeds
By Mr. Finn Normann
BROUGHT TO YOU BY

Conditioning
The little sub-process making the big difference
Graphics. Courtesy by Andritz

Conditioning summary
Nutritional benefits of conditioning
• Hygienizes the feed, eliminating pathogens and moulds
• Pre-gelatinizes the starch of the feed, thereby improving feed

digestibility
• Activates the natural binding agents in the formula
• Allows for making sanitized mash feeds without subsequent pelleting

(i.e. layer feed)
Conditioning summary
Physical- and cost benefits of conditioning
Improving plastification of feed mash
• Improves pellet mill throughput (+ 100 -200%)
• Reduces pellet mill power consumption (kWh/ton) (-40 – 60%)
• Improves pellet physical quality, PDI
• Reduces abrasion and secures longer lifetime of pellet mill dies and rolls
• Improves feed formulation flexibility (allowing for least cost formulations)
• Allowing for increased liquid addition with less impact to pellet durability
Conditioning : Key objectives
• Homogeneous interaction between the mash and the Moistened Layer
steam (and liquids). The steam condenses on, and is

absorbed via the particle surfaces
• Retention time sufficient to ensure that heat and Dry core
= insufficient
moisture has completely been absorbed by the mash conditioning
particles up to the core. No particles with wet slippery
surface and no lumps.
• Controlled optimum retention time and temp relative to
the formula and final feed requirements. (documented)
• First in first out = same (narrow spread of) retention time
for all feed particles
Typical Conditioning conditions
Inlet
Rule of thumb
Mc: ~10-12%
Temp increases by 14 C for
Temp: 20 - 40C
Time: 0 each one % of steam added
Source: Muyang Group

Outlet
Gelatinization starts at Optimum conditions
Moisture > 13% Mc: ~ 16%
and Temp > 60 C Temp: 75 – 90 C
Time: > 45 Sec
Degree of starch gelatinization during conditioning
 Conditioning time 45 sec
Temp 95 C and Mc 23% (Conditioning before extrusion) provides ~30% gelatinization

Temp 85 C and Mc 17% (Conditioning before pelleting)
Temp 85 C and Mc 17% (Conditioning before pelleting) (dependent from type of starch
and particle size)
 Conditioning time in excess of

45 sec. has only limited effect on
pelleting performance in most
formulas.
 Conditioning time in addition to

45 sec may still be relevant to
meet requirements for feed
sanitation or liquid absorption
Conditioning time
A function of volume, degree of filling and throughput
The size of the conditioner Conditioner volume 50 l per tph is good practice
must match conditioning Equals ~ 45 sec. conditioning time
requirements Provided 45% of filling !
Source: Muyang Group
Too many conditioners are inefficient due to improper filling Most common problems:
If the filling is too low, the residence time is shorter than Level  Uneven level of filling
of filling must be checked routinely  Too little filling
Single shaft Conditioners Optimum level of filling
Optimum filling: ~45% filling

in full length between inlet
and outlet is optimum
 Secures good interaction

between mash and steam
 Secures maximum
utilization of retention
time
Too little filling Too high level of filling
 No time for conditioning  No proper steam
 No proper interaction distribution and
between steam and mash blending action
Conditioner paddle angle setting
Paddle setting influences mixing effect and level of filling = retention time
Paddle neutral Paddle push forward, Paddle push backwards,

Increasing filling Decreasing filling Strongly increasing filling /
/ retention retention
Direction Flow
Direction Flow Direction Flow

Adopted from: E Bortene
Cascade conditioner Adjustment of paddles
Example of configuration
Adjusting zone
Inlet
Scraper
Outlet
4th row
3rd row
2nd row
Adopted from: E Bortene 1st row
Cascade conditioner Adjustment of paddles
Example of configuration
Graphic is Courtesy by Andritz
Reverse paddles: Increases level of filling

Single shaft Conditioners
Single shaft conventional conditioners Many common features:
 Cylindrical stainless steel barrel

 Centered shaft in full length of barrel
 Mixer paddles mounted in rows on shaft
Image Source: Andritz
 Access doors for inspection and cleaning
 Gear or belt transmission drive
Small differences in design still make a big
Twin shaft conditioners
difference in performance
Image Source: Yemtar

Singleshaft Conditioners
Small differences in design make a big difference in performance
All steam infused at rear end of conditioner Steam infused gradually during conditioning
Image Source: CPM

Image Source: Andritz
Livestock conditioner combinations
Beliefs or objective facts driven solutions?
DDC conditioner followed Conventional conditioner
by 2 pcs conventional followed by 2 pcs

paddle conditioners. Hygienizer conditioners.
Steam is added in the DDC Steam is added in the

conventional conditioner.
The conventional
conditioners provide The 2 hygienizers (with
additional retention time electrical barrel heat
tracing) provide additional
Common set-up in Asia and controllable retention
Both in livestock and aqua time, First in-First out
Common set-up in Europe
and Latin America
A. B.
Graphics: Muyang Group Graphics: Buhler Group
An Overview of Efficient
Conditioning for Livestock
feeds
Delivered by Mr. Finn Normann
BROUGHT TO YOU BY

Schedule of Delivery
July – September 2020
ICT, UTC+7 CET

Time Time
Each week there will be a 1.5 - 2.5 hours live delivery

Thank you for attending!
BIG THANK
YOU TO OUR
SESSION
SPONSORS

An Introduction To Online Milling School

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

An Introduction To Online Milling School

Uploaded by

Copyright:

Available Formats

An Introduction to

for Livestock Milling live streamed courses

© 2020 All Rights Reserved, Athene Consulting Co., Ltd, Progressus.

Credo Online Milling School series of Livestock

• Assist the industry by focusing on the development

modules that address the most critical aspects

Credo Online Milling School Topics Dates

Each week there will be a 1.5 - 2.5 hours live delivery

 Professionals that are involved in operating feed plants

 You can choose to attend all or selected topics

Feed Milling will be provided

development through education?

Coming your way soon!

© 2020 All Rights Reserved, Athene Consulting Co., Ltd, Progressus.

• Expose to Heat, Moisture, Enzymes

Balance between what is optimal for nutrition & feed mill

• Uniform particle size leads to

• Use at least a 100gm sample

Roller Mill L-NSD 2.134

• Increase surface area of raw materials

• Improved mixing of raw materials

• Granulation size for specific feed types

• Grinding is the second biggest energy consumer

• Grinding is a safety hazard (temperature, air, dust)

• Correct installation and set up essential

• Steam penetration  Steam penetrates small particles to the core

• Measured as Production Rate per Horsepower Hour

• Higher temperature = higher moisture loss

• The “working part” of a grinder screen is the edge

• As that edge wears the performance of the grinder (THP)

• As the screen wears less material is able to pass through

• Hammermill capacity and efficiency decrease

• The hammer self sharpens,

• Despite of wear, the hammer

Particles tend to flow around streamlined convex surface

• Material in the supply bin should already Deflector

be “cleaned” to remove non ferrous

• Need to avoid damage to the grinder

material spread evenly across screens and hammers.

• Screw Feeders Air in

© 2020 All Rights Reserved, Athene Consulting Co., Ltd, Progressus.

Together we can make a difference to the industry

VISIT OUR WWW.ONLINEMILLINGSCHOOL.COM

Register at: www.OnlineMillingSchool.com

© 2020 All Rights Reserved, Athene Consulting Co., Ltd, Progressus.

Graphics. Courtesy by Andritz

• Hygienizes the feed, eliminating pathogens and moulds

• Pre-gelatinizes the starch of the feed, thereby improving feed

• Activates the natural binding agents in the formula

• Allows for making sanitized mash feeds without subsequent pelleting

• Improves pellet mill throughput (+ 100 -200%)

• Reduces pellet mill power consumption (kWh/ton) (-40 – 60%)

• Improves pellet physical quality, PDI

• Improves feed formulation flexibility (allowing for least cost formulations)

steam (and liquids). The steam condenses on, and is

Source: Muyang Group

Temp 95 C and Mc 23% (Conditioning before extrusion) provides ~30% gelatinization

 Conditioning time in excess of

 Conditioning time in addition to

Source: Muyang Group

Optimum filling: ~45% filling

 Secures good interaction

Paddle neutral Paddle push forward, Paddle push backwards,