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BAICSEM 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 613 (2020) 012018 doi:10.1088/1755-1315/613/1/012018

Overview of feed granulation technology and technical means

for its implementation

D A Blagov1, A Ya Gizatov2, D R Smakuyev3, V I Kosilov4, V A Pogodaev5 and S

A Tamaev6
1
Institute of Technical Support of Agriculture – branch of the Federal Scientific
Agroengineering Center VIM, 38/11Schors st., Ryazan, Russian Federation
2
Bashkir State Agrarian University, 34 50-letiya Oktyabrya Str., Ufa, Russian
Federation
3
North-Caucasian state Academy, 36 st. Stavropolskaya, Cherkessk, Russian Federation
4
Orenburg State Agrarian University, 18 Chelyuskintsev st., Orenburg, Russian
Federation
5
North Caucasus Fed-eral Agricultural Research Center, 49 st. Nikonova, Mikhailovsk,
Russian Federation
6
Closed joint stock Company “Sadko”, Batetsky District, Novgorod Region

E-mail: aspirantyra2013@gmail.com

Abstract. The choice of methods for storing feed and the processes of their processing in farms
is the most important task for maintaining the qualitative composition of feed components, which
determined the relevance of our work. In this work, we consider the technology of feed
granulation, its features, as well as the technical means used for this process. Two granulation
technologies (wet and dry) were analyzed and the advantages and disadvantages of each were
identified. Quantitative and qualitative characteristics of feed before and after granulation are
considered. The positive effect of granular feed on the breakdown of protein in young cattle, a
high digestibility, and, consequently, an increase in the productivity of animals is observed. It
should be noted that the granulation of waste processing industry can extend their shelf life and
increase overall nutritional value. In addition, processed granular waste in combination with
other feeds can replace up to 50.0% of grain in the diets of farm animals. The paper gives a brief
analysis of the main manufacturers of industrial granularizers with a ring matrix, as well as the
technical characteristics of their products. This analysis confirms the popularity of feed
granulation in the Russian Federation, which is confirmed by a wide range of manufactured
equipment of various capacities.

1. Literature review
Technological solutions for the rational use of food and agricultural raw materials allows extracting
additional profit [1–5]. Technical solutions introduced at the enterprises of the agro-industrial complex
and the food industry should be characterized by the ease of use [6–10]. Processing and storage of feed
on the farm has always been an urgent task. Processing on the farm is often reduced to crushing grain
feed and feeding them in the form of flour with succulent feed. The disadvantages of this method is,
firstly, the unsatisfactory storage of such food, as it is hygroscopic and can accumulate not only moisture
in itself, but also be affected by mycosis. Secondly, bulk feeds are more difficult to transport and some
may be lost during delivery. Thirdly, loose feeds have a high consumption, since the bulk product is at
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
BAICSEM 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 613 (2020) 012018 doi:10.1088/1755-1315/613/1/012018

the bottom of the feeders and some animals and birds cannot collect it, and it remains not eaten. The use
of feed granulation technology allows us to solve the problems of storage of feed obtained, logistics and
complete eating of feed mixtures.

2. Material and research methods

In this paper, analytical and comparative methods of information analysis were used. The work of
scientists involved in the problem of maintaining the quality of feed and its processing were studied.

3. Research results
Granulation is a technological process in which raw materials in a loose state are compacted into grains
(granules) with desired properties. There are two granulation technologies used in production (figure 1).
Pelletizing technology consists in compressing dusty, powdery particles of raw materials moistened with
liquid, at wetting repeatedly in balls due to surface tension of the wetting liquid. The moisture content
of the raw materials should be between 30.0-35.0%. The resulting granules using this technology have
a porous structure and therefore lend themselves well to drying. The disadvantage of pelletizing is the
need for zero grinding with a final product moisture content of 12.0-14.0%.
The technology of pressing organic raw materials to obtain granular feed is divided into two types:
wet and dry.

Granulation

Rolling Pressing

Wet Dry

Figure 1. Types of granulation.

The wet method of pellet pressing is to add hot water (70.0-80.0 ° C) to dilute the granular mixture
by 30.0-35.0%. The mixture is quite plastic. The granules obtained by this technology become denser
and dissolve in water slowly. This granulation technology is used mainly in the manufacture of feed for
fish farming. The disadvantage of this technology is the additional drying of finished granules, which
increases production time and, in turn, affects the cost of products.
The dry granulation method is carried out without adding a significant amount of water to the feed
mixture. Additionally, steam, as well as wet excipients, which improve the quality of the final product
or the pressing technology itself, can be fed into the granulated mixture. A feature of dry granulation is
the application of two methods of processing the mixture. The first method is based on the effect of hot
steam on the feed mixture at a pressure of 0.2-0.4 MPa in a granulator mixer. The steam processed
mixture is brought to a moisture content of 15.0-16.0% and a temperature of 75.0°C. This steam
treatment allows changing the chemical characteristics of the feed. For example, protein denaturation,
dextrinization and gelatinization of starch occur when exposed to steam temperature and its high
penetrating power. The physicochemical changes in the nutrients of the feed mixture are given to
increase the digestibility of the future granular feed. The second method is based on the use of excipients.
Various liquid fats, molasses, loose bentonites are introduced into the mixture. Thanks to these

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BAICSEM 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 613 (2020) 012018 doi:10.1088/1755-1315/613/1/012018

components, the granulated mass becomes more plastic, and they also provide additional enrichment
with nutrients (energy, fatty acids, sugars, etc.). The introduction of binders into the feed mass for
granulation should be no more than 3.0% of the total mass (the fat content of 5.0% leads to the fragility
of the granules). Adding binders can replace steaming. However, both methods can be used to improve
the quality of the obtained granules. The quality of the granules is determined by such indicators as
strength and stiffness (hardness). It should be borne in mind that feed granules should not be too hard,
otherwise the animals will refuse their consumption. The hardness of the obtained granules should be in
the range from 2.8 to 3.0 kg for poultry and less than 2.0 kg for pigs, the granule strength index is 88.0%,
the content of small particles is not more than 12.0%. The quality of the granules is affected by a high
protein content, which provides plasticization making the finished product more durable. The high
content of corn grains in the mixture makes the granule brittle. The inclusion of molasses has a positive
effect on strength and reduces dust production 11–13.
Dry granulation technology allows recycling waste of alcohol, beer, sugar, flour, etc. industry
receiving highly nutritious feed (figure 2).

before after
Beer grains

before after
Beet pulp
Figure 2. Type of raw materials before and after granulation.

Granulation of waste from the processing industry can extend its shelf life and increase overall
nutritional value. For example, beer pellet has a very high humidity (80.0%), therefore it cannot be
stored, as it turns sour very quickly. In addition, various pathogenic fungi can develop in it. After
granulation of this raw material, its characteristics change qualitatively. The moisture content of beer
pellet granules is not more than 10.0%, the content of crude protein is 25.0%, digestible is 17.0%, raw
fat is 9.95%, mineral part is 2.40%. Beet pulp has even more moisture compared to grains 92.0-95.0%.
As well as bard, pulp quickly deteriorates, so it needs to be processed quickly. When granulating 100.0
kg of pulp, about 8.0 kg of dry concentrated feed is obtained. The content of crude protein in granulated

3
BAICSEM 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 613 (2020) 012018 doi:10.1088/1755-1315/613/1/012018

pulp is at the level of 8.0%, ash is 4.0%, NFEV is 66.0%, crude fiber is 22.0%. Processed granular waste
in combination with other feeds can replace up to 50.0% of grain in the diets of farm animals. In addition,
granular feeds have good digestibility, which positively affects the productivity of animals.
Studies of A. Antonovich conducted in the field of digestion showed that the use of granular high-
protein feed in the diets of young cattle allowed increasing the degree of protection of crude protein in
the rumen (table 1) 14.

Table 1. Disintegration in the rumen and the degree of protection of crude protein protein feed.
Feed Nitrogen, Drymatter, Crudeprotei Disintegrati Degreeofprotecti
% % n, % on of crude on, %
protein in
the rumen,
%
Groundlupine 5.75 93.6 35.93 - -
Lupinegranular 4.41 93.1 27.56 - -
Groundlupineafterfistul 4.57 96.5 28.56 47.7 52.3
as
Lupinegranularafterfist 5.02 96.7 31.37 38.3 61.7
ulas

As can be seen from the table, the degree of protection of granular feed was 61.7%, which is 9.4 %
higher than using simple grinding.
The experiments performed by B.A. Dzagurov on feeding granulated beer vinasse and bentonite in
laying hens rations showed a significant increase in bird productivity by 10.1%, an increase in the
incubation egg yield by 2.0% [5–7]. Granulation technology is a universal solution to a number of
problems in meeting the needs of animal husbandry in high-quality feeds with a high shelf life.
Any technology includes a number of necessary machines for its implementation. In this case, the
main machine is a granulator. Granulators for the production of feed can be divided into two main
features: the type of matrix used and the volume of production. By design, the matrices are divided into
flat and roundabout (figure 3).

Flat Roundabout
Figure 3.Types of granulator matrices.

4
BAICSEM 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 613 (2020) 012018 doi:10.1088/1755-1315/613/1/012018

Flat matrices are used by granulators with productivity up to 1000 kg/ h, roundabout in industrial
machines from 1000 kg/h and more. In the Russian market, industrial granulators with a roundabout
matrix are represented by the brands OGM, GKM, DG (figure 4).

Figure 4. Granulators of the OGM, GKM brand.

Granulators of the presented brands are produced in Russia, which positively affects their price and
after-sales service. OGM granulators were created on the basis of the Soviet OGM-0.8 and OGM-1.5
with the introduction of some design improvements.
Russian companies engaged in the production of equipment for granulation are actively working to
improve their products (table 2).

Table 2. Comparison of manufactured circular granulators.

Firm Brand Power, kW Productivity, t / h
Agricultural Technologies and GKM-200K 15.75 0.8
Machines, Russia GKM -250K 19.25 1.5
GKM -320K 39.95 3.0
GKM -320 47.95 4.0
GKM -350 58.75 5.0
GKM -400 97.70 7.0
GKM -508 141.0 12.0
Sloboda Engineering Plant, Russia ОГМ-1.5 90.0 3.0
Dosa-Agro, Russia DG-4N/2 50.15 3.6
DG -5N/2 60.15 5.0
DG -6N/2 80.15 6.0
DG -7N/2 95.15 7.0
DG -8N/2 122.10 8.0
DG -10N/2 141.70 10.0
DG -12N/2 168.0 12.0
DG -15N/2 194.70 15.0
DG -20N/2 233.20 20.0
ALB GROUP, Russia OGM-1.5M- 75.0 0.9-2.5
75

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BAICSEM 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 613 (2020) 012018 doi:10.1088/1755-1315/613/1/012018

OGM -1.5M- 90.0 1.0-3.0

90
OGM -1.5M- 110.0 1.5-4.0
110
OGM -1.5M- 132.0 3.5-7.0
132

At the same time, the main efforts of the researchers are aimed at improving the reliability of
equipment, reducing energy consumption, wear of working bodies, noise levels and the complexity of
maintenance, providing more effective disinfection of feed, improving the management of the
granulation process [15–22]. As can be seen from the data presented in table 2, the domestic range of
industrial granulators can cover any needs of the agricultural producer.

4. Conclusion
Thus, considering the technology of granulation, it was found that the quality of the resulting product is
affected by both the selected method for producing granules and the choice of raw materials. The effect
of alfalfa granular feed on protein breakdown and its degree of protection has been demonstrated. A
brief review of Russian granulators showed that this technology is in demand in the domestic market,
which shows a large assortment of manufactured products of various capacities.

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