California Pellet Mill Co.

EQUIPMENT USED IN THE PELLETING PROCESS

The Pelleting System

The pelleting system is composed of several different machines designed to most efficiently
accomplish the pelleting task. A typical system arrangement with equipment names is shown in
Figure 1. While we will give more detailed information relative to the function of each machine
later, it would be advisable to first learn the names and relationships of these major processes.

After the feed has been mixed and before going to the pellet mill
it should go through a scalper. This removes everything such as
metal (ferrous and non-ferrous), stones, string, paper, wood,
feed lumps and gives a dressed feed into the bin above the
pellet mill. A pellet mill is not designed to pellet these
materials, let alone the animal stomach to digest them.

The pelleting process starts with a bin (Figure 1, Item 1) in which

the mixture of mash is stored. From there, the mash will flow
by gravity into the pellet mill (Figure 1, Item 2). This machine is
usually located on the ground or main work floor level. The
hot, extruded mash (pellets) flows by gravity into a cooler (Figure
1, Item 3) where it is held for three to six minutes while being
cooled and dried by a flow of air. The air is drawn through the
mass of pellets and passed into a dust collecting device, such as
a cyclone collector (Figure 1, Item 7). The dust from the outlet of
the collector (Figure 1, Item 8) is returned to the pellet mill to again
be compacted into a pellet.

From the cooler (Figure 1, Item 3), the product flows through or
around a pair of crumble rolls (Figure 1, Item 4). If we wish to
produce a relatively fine product, about the size of cracked corn,
then the pellets are passed between the crumble rolls to be
crushed (cracked) to a smaller size. If we wish to retain the full
pellet size then we flow around the crumble rolls. From the
crumble rolls the product flows into a bucket elevator (Figure 1,
Item 5) to be raised to a higher point in the structure where the
shaker (Figure 1, Item 6) is located.

Figure 1 The shaker separates the product into various sizes by passing
the material over several screens. Each screen is of a different
opening size. This separation permits the desired product to be separated from the larger or
smaller particles while being delivered to the finished product bin. The “overs” can be returned
to the pellet mill for repelleting or, in the case of crumbles, to the cooler, and in turn through the
crumble rolls for recrumbling. The fines or smaller material can be routed directly back to the
pellet premix bin and reprocessed through the pelleting system.

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 California Pellet Mill Co.

Supply Bins

The supply bin or bins must be adequate to store a sufficient quantity of feed immediately ahead
of the pellet mill to provide not only continuous operation of the pelleting unit but also
continuous operation of the mixer which provides mash to the pelleting unit. Other factors in the
feed mill design may dictate a need for greater available tonnage ahead of the pellet mill than
will be discussed here.

Generally speaking, the bin supply immediately ahead of the pellet mill should consist of at least
two bins, each of a capacity not less than three times the capacity of the batch mixer used to
supply feed to the pelleting unit. A bin installation of this type will usually result in an efficient
operation, both from a mixing and pelleting standpoint, and is the minimum. The maximum will
be determined by factors other than the pelleting installation.

These supply bins should be constructed so that there will be no bridging or surging. Variations
in the feed cause objectionable variations in the operation of the pellet mill. Generally, these bins
can best be constructed of sheet metal. Rectangular or square construction lends itself to the best
installation, however, round bins may also be used.

While several pages might be devoted to the subject of hopper design, it is sufficient to say that
the slope of the hopper sides should never be less than 60°. As many vertical sides as possible
should be incorporated into the design. Many feed mill engineers have used the excellent,
though more costly, design of having a small feed supply bin fed by start-and-stop conveyors
from the main supply bins. The small supply bin may have a capacity of less than 1,000 lb. and
should be equipped with bin level controls.

Pellet Mills

Thoroughly mixed ingredients, now called “mash” or “meal”, are allowed to flow by gravity into
a flow rate regulator called a “feeder” (Figure 2, Item 1).

Figure 2 - Component Parts of a Conventional Pellet Mill

1. Feeder
2. Conditioning Chamber
3. Pelleting Device
4. Speed Reduction Device
5. Motor
6. Base

The feeder is generally a screw-type with some variation in flight arrangement, such as single
flight, double flight, full pitch or one-half pitch to accommodate varying conditions. It is
equipped with some type of speed control, such as a variable speed electric drive. The purpose
of the feeder is to provide a constant, controlled and even flow of feed to the mixing and
pelleting operation. Any variation in this flow results in poor conditioning and a variable
product.

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 California Pellet Mill Co.

This feeder delivers a constant and prescribed amount of the “meal” to a “conditioning” chamber
(Figure 2, Item 2). Here the mash is thoroughly mixed with steam (heat and water) and other
desirable liquids, such as molasses.

A mixer is provided in order to properly condition the feed. Conditioning is almost universally
accomplished by the addition of controlled amounts of steam. Addition of steam supplies
moisture for lubrication, liberates natural oils and, in some cases, results in partial gelatinzation
of starches. Uniform conditions at this point are extremely important for optimum results.
Further, this mixer can be used for the addition of up to 6-8% molasses without special
attachments when properly equipped. Mixers are supplied in low speed (up to 125 RPM) and
high speed (125-500 RPM) models.

The conditioned mash then flows by gravity into the pellet mill die chamber (Figure 2, Item 3) where
rollers press the softened mash (Figure 3, Item 1) through the holes in a circular die (Figure 3, Item 2).
Stationary knives (Figure 3, Item 3) located outside the circular, rotating die cut off the shaped,
dense pellet at the proper length.

1. Meal or Mash
2. Pellets
3. Blades
4. Rollers
5. Die

Figure 3 - Typical Die & Roller Assembly used for Producing

Pellets

Most modern pellet mills used a ring type die turning about two fixed rollers, with the die and
rollers mounted in a vertical plane. A few mills are built with the dies and rollers in a horizontal
plane with the rollers turning within the stationary die. Obviously there are advantages to each
type of construction but more mills made today are of the vertical type.

In the pelleting unit, the conditioned mash is forced through holes in the die by roller pressure.
Die thickness is a factor in the production of high quality pellets and must be accurately balanced
with the formulation and conditioning. Starting with 24/64” pellets and above, some variation
in the amount and depth of taper incorporated into the entry of the holes in the die may be
necessary. Numerous other special entries are used in instances where satisfactory pellets cannot
be produced with standard entry and taper.

All pellet mills incorporate some type of speed reduction device, since die speeds are always less
than the conventional motor speeds. In some cases variation in die speed is desirable to produce
optimum results on individual groups of feeds. Speed reduction devices in use today include
direct coupled gear trains, V-belts, cog belts and combinations of belts and gear trains.
Currently, mills are being built with speed change mechanisms. Usually these speed change
mechanisms are in the form of gear shifts or two-speed motors. This provides two die speeds to
secure optimum results when a wide range of feeds is produced.