Shahzor Feeds ( Pvt.) Ltd.

Introduction: It is located at 13-Km Faisalabad road, sheikhpura.it is established in 1996 and area of the feed mill is 12 acres.The owner of this factory is Dr. Sabir .Shahzor feed mill is one of the biggest feed mill , as of capacity , in the country. In the beginning the feed mill was running only with a pellet mill and its production capacity was 14,400 Tons Per Month. Now a days this capacity has been increased up to 8, 35,200 Bags Or 41,760 Tons Per Month.It produces feeds both for poultry and large animal , but for large animal feed is produced only when is demanded Storage areas for raw material are consisting of 5 big godowns and 18 silos. Managerial Setup : Production Manager : Dr. Abid Maqbol Asst.Production Manager : Dr.Qamar-u-Zaman Mechanical Department Foreman : M.Arshad Electrical Department Foreman: M.Asif Lab. In charge : Khalid Mahmood Samplers: Mushraf , Sohail Receiving Operations : It consist of 1. Sampling 2. Unloading 1- Sampling: Sampling is done with a probe approximately from every bag , samples are taken in polythene bags ,and the evaluation of these samples is done in following ways :

1. Physically
1

Sialkot. shikarpur and jocabbabad Gurjanwala .Noshehra . Lahore Wazirabad.2. Gujrat. 60% Canola Meal Sun Meal Flower 8-13 0-5 8-20 4-7 2-5 seed 3-5 0-2 0-2 Multan Wazirabad. sheikhupura . Karachi Solvent Plant of Multan Karachi India Karachi Sugar Industries Inclusion Availability From 35-45 35-45 10-15 5 3-4 8-12 Central punjab Haripur and Mansehra Gujranwala. Guar Meal Soyabean Meal Fish Meal Molasses Cotton meal Bone Ash Bone Meal 2 . gujrat . Microscopically 3. Analysis Material Inclusion Level and Availability Sr. sheikhupura. Faislabad . Jalalpur Floor Mill Of Local Area Rafhan. Okara. Solvent Plant of Multan.# Ingredients 1 2 3 4 5 6 7 10 11 12 13 14 15 16 Maize Rice Broken Rice Polish Wheat Bran C.Daska.G. Lab.

Ash. P Moisture. EE. Aflatoxin Moisture. Ca. Ca Moisture. CP. EE. Moisture. CP. Ca & P: DCP Limestone (Chips) MCP Moisture. Moisture. Pepsin dig. CF. CP. Ash. EE. CP. Afla Toxin Moisture. POV Proposed analysis Sampling of different ingredients: Grains and their by products: 3 . Aflatoxin. CF. CF Moisture. NPN. CP. P Moisture. CP. CP. CF. KOH solubility Moisture. CP. Pepsin dig. Vegetable proteins: Soya bean meal Rape seed meal Canola meal Sunflower meal C. EE Moisture. salt (NaCl). CF. Ash Moisture. Cp. Ash. Salt. Grains & by products: Maize Rice tips Rice polish B. Ca. Animal proteins: Fish meal Feather meal (APC) D. Salt.Raw Materials and Their Tests In Shahzor Feeds: Ingredients A.

brown and husk are present. a. Canola meal: It is selected on the basis of physical appearance. ochratoxin. husk to tips proportion. and. Normally 1% toxin is acceptable and above is rejected. CF tests.Corn: Three varieties are common. It is also selected by physically appearance including smell. Rape seed meal: It is selected on the basis of moisture. sand. White c. moisture. then it is rejected. smell. CP levels. Rice tips: It is also selected on the basis of moisture and toxin level. texture. ash. salt. Physical appearance is also important if damage. If it fulfills the above standards then it is accepted otherwise rejected. Yellow b. chips etc). CP. CF tests. ash. Fiber tests and general appearance. It is selected on the basis of CP. It is selected on the basis of moisture. Wheat straw: It is by product of wheat. 4 . Red Material is selected on the basis of moisture and toxin level. Sunflower meal: It is selected on the basis of aflatoxin level. It has many standards and it accepted on the basis of physical appearance. Vegetable protein sources: Soybean meal: It imports from India. and zearalinone. CP. Toxins present in corn are aflatoxin. CP. fat. KOH solubility. Rice polish: It is by-product from rice mills and most valuable raw material. adulteration (like mud. moisture.

Bulk density of materials: Bulk density of material represents the mass per unit volume. P Test. It is selected on the basis of moisture. It can affect by moisture. moisture. ash and pepsin digestibility tests are applied on it. Mono calcium phosphate (MCP): It is selected on the basis of physical appearance. smell. Inorganic sources: Dicalcium phosphate ( DCP ): It is accepted on the basis of physical appearance. CP. moisture. Feather meal: It is also physically check. moisture. Ca test. It is commonly expressed as kg/ft3. Brownish and blackish color indicates bad quality. salt test and CP test. and P test. texture and adulteration Ingredients 5 Bulk density kg/ ft3 . Limestone/Chips: Color is white. Ca. Moisture. Ca.Animal proteins sources: Fish meal: It is selected on the basis of physical appearance.

Unloading and Storing of Materials: After sampling and selection. who’s gate is opened.40 13.05 11.Maize Rice polish Rice tips Wheat bran Soya bean meal Rape seed meal Sunflower meal Canola meal Fish meal Feather meal MCP DCP Chips 20.95 22. Grains are stored in silos. Silo Specifications: 6 .50 16. Silos: There are 18 silos of BROCK company in the mill. from where.10 21.80 2. medicines etc.25 27. a cyclone is attached with cleaner for removal of dust particles. dust particles .70 44.15 15.45 23. with the elevator carried to drum cleaner to remove adulterants like threads. materials are unloaded to their respective sires either in a) Godowns or b) Silos Godowns : There are 5 big godowns in the mill.05 10. they are unloaded in dumping pits. Godowns are used for the storage of vegetable and animal protein sources .00 17.15 14. After cleaning material is taken to the silo with elevator to top conveyer which take the material and empty it in the silo .

these are 7 in nos. within a stored grain mass have a direct impact upon the number of days that grain can be stored. of sheets along the diameter No. Production unit: Production is completed with the help following departments. The air is pumped by the fans into the silo which takes the moisture from grains and exhaust from vents on the roof of silo. detection system is an electronic device attached to special cables. The temp.Diameter of silo Height including cone Height excluding cone No. two fans are connected to each silo . and normally temp. Moisture content and temp. is checked once a week. suspended from the roof of the silo.Processing Section: Feed production is completed by the combination of following processes Receiving 7 . Two types of conveyers are used .054-0. of sheets along the length = 48 ft = 53 ft = 42 ft = 15 = 21 The capacity of a silo is determined by π r2 h × Bulk density of material . The cables contain temperature sensors at approximately two-meter vertical intervals. Material received from silo outlet with the help of gravity and discgarge conveyer.22 cubic meters of air per minute for each metric ton of grain. To control the moisture level and temp. one is upper conveyer ( for silo filling pupose ) and 2nd is for material receiving. 1) Production department 2) Mechanical department 3) Electrical department 4) Boiler section 5) Houdi operators 6) Loading Section 1. the requirement of air ranges between 0.

it is taken with elevator to the the top of production tower where material in ground form is passed through a scieve for its screening and with the help of rotory distributer material is taken in dosing bins . Premixes are added in mixers . for 100 ton of feed 175 kgs of premix is added. like choline chloride . coarse material is taken into the sifter . in shahzor one batch is of 3000 kgs . and shower the material during mixing. after cleaning . which are 18 in nos. Mixing: After batching material goes to mixers . while .After grinding of coarse material . There are two hammer mills and a roller body used for griding purpose in shahzor.Grinding Batching Mixing Pelleting Cooling Crumbling Grading Packing Receiving: Material is received in production unit from silos and godowns with the help of conveyers and elevators. . Pelleting: After mixing material is taken with the help of screw conveyer to the elevator which takes the material at the top of production tower and empties it into a sifter .and after sieving 8 . ribbon type mixer is used there . Sprinkler are connected to mixers which aid in liquid addition . material is grinded by hammer mill. Grinding and Batching: Material in two forms is received fine form and coarse form material. The fine material is taken directly to dosing bins witout grinding . Then material from different dosing bins is taken into scale hopper for batching according to fomula. Mixing of material is done for 2 minutes and the capacity of each mixer is 3 ton and speed of each mixer is 27 rpm.

is roller mill with rools . there are 3 pellet mills . but also decrease the microbial load from the material. In this section fabrication and maintenance is done. 2). we can divert the pellets from crumbler with the help of this valve. Each crumbler has two pairs of rollers . two of them are of capacity 20 ton/hr and one is of 18 ton/hr. medium or required size particles and fine size paricles. A by –pass valve is also present . one roller has spherical grooves it cuts the pellet into crumbs and 2nd roller has lengthwise groove which pushe down the pellets.material goes to pelleting bins. where automatic packing is done. one takes the fine size particles to pellet bins . Blower is attached is to cooler . the no. Pellet operator and helpers are required to run a pellet machine. of coolers is as of pellet machines . 8-10 bags are packed automatically/min. Then come into feeder which control the speed of material so material is fed to conditioner wher steam and mollase are added to this material . of pellets.From conditioner material goes to the pellet mill . Packing: The material is then packed into the bags. the separator separates these crumbs into three forms too large size particles .Mechanical Department: This department is under the supervision of mechanical foreman. pellets are distributed in cooler by the rotory distributer so pellets are evenly distributed in cooler to avoid lump formation. helpful for pelleting process . Crumbling: After discharging material comes from cooler to crumbler. There are three packing points in the mill . After the formation of crumbs these crumbs are taken to the elevator with the help of a belt . which sucks the air from cooler and exhaust it to atmosphere so to lower down the temp. Grading: These crumbs are taken into the separator with the elevator. Cooling: After pelleting .Here the temperature of material is 80 oC. 9 . 2nd takes the too large size particles into the cooler so for to pass these particles again into the crumbler for crumbling and the 3rd takes the medium or required size particles to the packaging bins. Three pipe lines are attached to each of three seperators. steam not only increase moisture content of material . The size of crumbs is adjusted with the distance between rollers by a roll adjustment. This mixture is changed into pellet form by the combination of die and roll shells.The discharging of pellets from cooler to crumbler is controlled by discharging gate attached to a 5 Hp motor. Following equipments are used for maintenance and fabrication. used to minimize the break down of crumbs.

5 ton of steam is required 5).Electrical Department: This section is under the supervision of electrical foreman.5 ton/hr . Water comes first through pump into water softening plant in which zeorolite and salts are added for its softening and softening of the water is checked with EDTA black arichrome sol. because direct supply of water without heating is not suitable for boiler.Houdi Operator: To convey the material from godowns and silos to dosing bins houdi operatore are required.Boiler Section: Boiler is run by a boiler engineer.a) Cutter b) Hand Grinder c) Gas Cutter d) Tool box kit e) Welding Plant 3). after softening water goes to feeder tank . . and the 2nd is of 5. 4). Boiler Working: There boiler fuel is furnace oil. There a generator of 910 kv capacity is present which is used in case of electrical failure. Boiler is used to produce steam to be used in production. Mash Production Plant: 10 . Steam goes to the production unit with the help of steam ducts. a step down transformer which step down the voltage as requirement of production unit. where steam coming from production unit is added to raise its temp.5 ton capacity/hr. There are two boilers in feed mill one is of capacity 3. Fire tube boiler is used there and the pressure limit in boiler is 150psi and if pressure increases from the limit it is released through safty vavle. which is in standby condition. if water with it gives blue color it is softened and if red then it is still hard . for production of 20 ton feed 1-1.

packed finished feed bags are loaded on vehicles and dispatched from the mil. in Shahzor Feed Mill Sr. (Mash) (Mash) (Crumbs) (Crumbs) (Crumbs) (Crumbs) (Crumbs) (Crumbs) (Crumbs) (Crumbs) (Crumbs) (Crumbs) (Crumbs) (Crumbs) Kind of feed Broiler starter Broiler starter Broiler starter crumbs Broiler starter crumbs control Broiler finisher crumbs control Broiler finisher crumbs Layer starter Layer grower Layer finisher Breeder starter Grower starter Layer breeder crumbs Broiler breeder pre-layer Broiler breeder male 6). From mash bin material comes into mash blender with the help of feeder.Material after cleaning and grinding comes in mash bin if we want to make mash feed. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 4 7A 9 9-C 9-Cb 10 1A 2A 3A 21 22 23 24 25 Feed No. Feed Nos. Analysis of feed Ingredients Different tests are done for the analysis of feed stuff in Shahzor which are given with their procedures as follows: 1-Moisture Test:  Mix the material thoroughly. Here molasses add into the material and then it comes into mash screener and it is ready for packing.Loading Section: In this section. 11 .

Add about 10ml commercial Sulfuric Acid in tube. Calculation: Wt.677g --------------------C =A+B-C/B×100 =47.  Calculation: % of Ash = (W2 – W1) /5* 100 3).  Weigh the Ash with crucible (W2). add about 5-10 ml D.W. Distillation 12 .0g --------------------B = 65.  After 2 hours put the Petri dish in Desicater for 10-15 min.  Heat the sample content crucible until the sample is charred.30 gm of finely ground Sample add 5gm Digestion Mixture on a butter paper. Digest this solution for 60 minutes in Digestive stove (light green color).  Transfer it in the furnace for 2 hours (Temperature 550oC). Take Petri dish and weigh  Take sample in petri dish of 20 gm with spatula. of sample Wt.  Weigh the Petri dish.  Weigh about 5gm sample in crucible. of Petri dish Wt. Then allow it to cool for 30 minutes. of Petri dish with sample after drying Moisture % = 47. Place it into the digestion tube.137+20-65. Set the temperature of stove on 420 C.  After 2 hours cool in a desicator.677/20×100= 7.  Take sample in Petri dish and put it in oven at 120 oC for 2 hours.737g --------------------A = 20.Crude Protein Test: Digestion       Weigh 0.30% 2)-Ash test: Weigh the crucible without sample (W1).

583 Determination of KOH solubility: Take1. transfer this solution in to the 1000 flask add about 500 ml D. add suitable amount of NaOH (Until distillate becomes Black) and turns its off. allow the distillation of Ammonia into the Boric Acid solution about 120-150 ml.5N Sulphuric Acid.2% KOH) solution in it.1 gm Methyl red in 100 ml Ethanol. then KOH solubility. 30ml H 2So4 and digest it for 3 hrs. Methyl red Indicator = 0.  Turn on the Alkali Switch.Stirrer it on a magnetic stirrer for 30 min. After stirring centrifuge the sample in 5 tubes for 15 min. KOH solubility = A-B×72. cool this solution.  Insert both pipes (NaOH pipe and D. Then add 7 ml of Methyl red Indicator + 10 ml of Bromocresol green Indicator and make the Volume 1000 ml with D.P = Burette Reading-B (blank) * 14.P×100 Urease Activity: Small amount of sample is taken in a petri dish.P.W. Add 5 g digestion mixture. Small amount of urea solution is poured on it. Calculation: % of C. Then distill. at 2700 rpm.W allow to cool and make the volume up to the 1000 ml with D. read the end point.  Turn on the Steam Switch.W pipe) in to its Solutions.5g sample in conical flask (500ml) and add 75ml (0. it is the portion of the meal which is soluble.9/C. titrate it and calculate the C. of tubes in kjeldahl flask.W. After 5 minutes . Accessories: Digestion Mixture =Potassium Sulphate 150 gm+ Copper Sulphate = 10 gm Boric Acid 2 % =20 gm Boric Acid in 100 ml hot D. After digestion make volume 250 ml. the color changes from green to light Purple. (it takes just 4-5 minutes) Titration  Titrate the distillate against 0.  Ensure the Water is always running. NaOH 40 % = 400 gm NaOH in 200 ml D.W. Then take 15 ml sample from supernatant. check the amount of reddish particles in sample from 13 . Take 20 ml Boric Acid (2 %) solution in a 250ml conical flask placed it on its position in the distillation unit.W and mix well.

Urea solution composition: KH2PO4 = 1.bottom side of the pettri dish. Red particles show urea solubility ( if red are less in amount .1775 14 .7015 gm K2HPO4 = 2. it means urea activity is less . if more it mean urea activity is more.

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