Download - The Batching & Mixing Processes
![Page 1: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/1.jpg)
The Batching & Mixing
Processes
![Page 2: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/2.jpg)
Presentation Outline • Function of the batching & mixing
processes
• Batching system design considerations
• Types of mixers and factors effecting mixer performance
• Testing mixers
• The importance of feed uniformity on animal performance
![Page 3: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/3.jpg)
Introduction • The batching/mixing processes are the
heart of the feed mill…
• The objective is to bring together the
ingredients called for in the formula, in the
correct proportion, and blend them
together creating a uniform mixture in a
minimum amount of time.
• The Nutritionist’s Assumption…
![Page 4: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/4.jpg)
NUTRITIONIST’S ASSUMPTION…
The batching/mixing
process is the heart of the
feed mill…
![Page 5: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/5.jpg)
Introduction
Larger batch sizes
Larger mixers
Shorter mixing times
More ingredients
• Employee mistakes
Speed vs. accuracy
Not every mouth full is the exact same…
![Page 6: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/6.jpg)
Today’s Batching Systems
![Page 7: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/7.jpg)
Batching System
![Page 8: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/8.jpg)
Batching System
![Page 9: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/9.jpg)
Batching System
![Page 10: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/10.jpg)
Batching System • Scales
– According to the National Institute of Standards and Technology Handbook 44, scales with capacities greater than 500 lbs. can deviate up to 0.1% of the capacity.
– Consequently, scales need to be sized in accordance with the quantity of product being weighed.
– Licensed feed mills need to have the scales and metering devices certified annually (CGMPs, Section 225.30)
![Page 11: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/11.jpg)
Batching System • Load Cells
– Don’t operate load cells above the rated capacity
– Adequately protect the load cell cable and don’t carry the load cell by the cables
– Don’t allow build up of debris around the load cell and load cell mounts
– Check for corrosion damage to load cell and mounting
– Don’t weld near the load cell
![Page 12: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/12.jpg)
Batching System
![Page 13: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/13.jpg)
VERTICAL MIXER
Advantages Low initial investment
Low maintenance cost
Small footprint
Can be installed on a
scale
Disadvantages Long mixing time
Poor clean out
Low inclusion of
liquids
![Page 14: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/14.jpg)
Source: Marion Mixers
PADDLE MIXER
Advantages
Good for fibrous and high
mineral diets
Works well with diets high in
molasses
Disadvantages
Poor side-to-side mixing
action
Dead spots in corners
![Page 15: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/15.jpg)
IMPROVED MIXER DESIGN
![Page 16: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/16.jpg)
FEED FLOW
FEED FLOW
Main Mixing Zone
Main Mixing Zone
RIBBION MIXERS
Short mixing time
Good mixing action
Good clean out
![Page 17: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/17.jpg)
Mixers
![Page 18: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/18.jpg)
Low cost - Good mixing action - Mixes small batches
DRUM MIXER
![Page 19: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/19.jpg)
Source: AMANDUS KAHL Source: Hayes & Stolz Mfg. Co.
CONTINUOUS MIXERS
Used to bring ingredients together in constant proportions;
Mixtures including high levels of liquid ingredients;
Most common are the ‘cut-and-folded screw’ and paddles.
![Page 20: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/20.jpg)
Mixing Cycle
Dry load
Hands add
Dry mix
Liquids add
Wet mix
Discharge
![Page 21: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/21.jpg)
Liquid Addition
![Page 22: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/22.jpg)
Liquid Addition to the Mixer
• Fat Sources – inedible tallow and grease
• 77% of what is produced goes into the feed industry
• Categories
– Beef or pork fat
– Poultry
– Restaurant grease
– AV blend
![Page 23: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/23.jpg)
Fat Quality
• Stability – rancidity
• Free of pesticides
• Certified as being negative for chick edema
• Free of heavy metals
• Free of water
![Page 24: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/24.jpg)
Storage of Fat
• Typically, feed fats should be stored at 120-130 degrees F.
• Higher temps may be desired (180 F) , but it will cost more.
• Cone bottom tanks are desirable. The fat needs to be recirculated to maintain uniform temperature
![Page 25: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/25.jpg)
Fat Storage
• All fat lines should be heated with heat tape or wrapped heat coils
• Filters should be installed on unloading lines prevent impurities from entering storage tanks
• Also have filters after the storage tanks
• Piping sizing is very important, work with someone who knows what they are doing!
![Page 26: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/26.jpg)
Pumps & Meters
• Heart of the system
• Most common types of pumps in the feed industry:
– Centrifugal pumps
– Piston pumps
– Gear pumps
![Page 27: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/27.jpg)
Centrifugal Pumps
• Used with less viscous liquids
• Conveys liquids under low pressure and over short distances
• Not recommended for animal fats
![Page 28: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/28.jpg)
Piston pumps
• Higher maintenance problems
• Only recommended for thin liquids
![Page 29: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/29.jpg)
Gear Pumps
• Common in the feed industry
• Relatively low maintenance
• Viking pumps are very popular in the industry
• Can pump both hot and cold material, and thick/thin material
• Request durable material to reduce headaches
![Page 30: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/30.jpg)
Know your load requirements
• What is the capacity of the system
• What horsepower pump is needed
• Electrical requirements:
– Distance
– Pipe heat tracing
– Don’t use under- or over-sized motors
– Work with your supplier to make sure the motors has adequate torque (Design B, C, D motors)
![Page 31: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/31.jpg)
Disassembly Condition for Rebuilding
![Page 32: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/32.jpg)
• Be Gentle and Control your temper!
![Page 33: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/33.jpg)
Metering • Problems:
– Unsteady flow from the pump
– Gear slippage
– Inconsistent product characteristics
– Pressure, volume, temperature changes
– Frequent calibration is recommended
![Page 34: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/34.jpg)
Records
• Liquids inventory
• Pump maintenance
• Electrical maintenance
• Spare parts
• With good records management can make intelligent decisions for good results
![Page 35: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/35.jpg)
Testing Mix Uniformity
• Marker Selection
– Accuracy assay
– Assay ease
– Cost of the assay
– Test performed on site
– Marker must be from a single
source
![Page 36: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/36.jpg)
Sample
Drug (g/ton)
Deviation from Mean
Deviation Squared
1 110 8.6 73.96
2 115 13.6 184.96
3 92 -9.4 88.36
4 89 -12.4 153.76
5 102 -0.4 0.16
507 501.2
Mean = 507
5 = = 101.4
Variance = ∑d2
n - 1
∑xi
n
= 125.3
Standard
Deviation = √ 125.3 = 11.2
Coefficient
of
Variation
= 11.2
101.4
501.2
4
std
mean = X 100 X 100 = 11 %
√ = variance
=
Testing Mix Uniformity
![Page 37: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/37.jpg)
Marker Comparison Mix Time (min)
Item,% 0.5 2.5 5.0
DL-Methionine 23.86 14.56 9.47
Lysine-HCl 19.75 16.00 8.70
Crude Protein 7.73 7.29 6.86
Chloride Ion (as sodium chloride) 20.26 12.75 15.08
Phosphorus 13.72 6.46 6.27
Manganese 36.25 20.80 17.59
MicrotracerTM Red #40 (count) 21.77 11.72 15.08
MicrotracerTM Red #40 (absorbance) 21.13 20.52 16.88
MicrotracerTM RF-Blue Lake 32.49 20.09 18.64
Roxarsone (3-Nitro®) 30.24 25.15 25.54
Semduramicin (Aviax®) 27.40 16.11 11.23
(Clark et al., 2007)
![Page 38: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/38.jpg)
HOW IMPORTANT IS DIET
UNIFORMITY TO THE ANIMAL?
![Page 39: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/39.jpg)
107
2816
12
0
25
50
75
100
125
0 0.5 2 4
%
MIX UNIFORMITY AND CV FOR
CHROMIUM IN NURSERY DIETS
Mix time, min
CV
, %
Traylor et al. 1994
![Page 40: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/40.jpg)
267
379 383 402
200
300
400
500
0 0.5 2 4446
533546 558
350
450
550
650
0 0.5 2 4
Mix time, min
Mix time, min
AD
G,
g
Gain
:Feed
, g
/kg
Traylor et al. 1994
DIET UNIFORMITY EFFECTS ON
NURSERY PIGS
![Page 41: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/41.jpg)
54
15 1310
5
40
75
0 0.5 2 4
%
MIX UNIFORMITY AND CV FOR SALT
IN FINISHING DIETS
Mix time, min
CV
, %
Traylor et al. 1994
![Page 42: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/42.jpg)
777807 793 787
500
800
1100
0 0.5 2 4
No trt effect (P > 0.15)
264 278 275 273
100
275
450
0 0.5 2 4
No trt effect (P > 0.15)
Mix time, min
Mix time, min
AD
G,
g
Ga
in:F
eed
, g
/kg
Traylor et al. 1994
DIET UNIFORMITY EFFECTS ON
FINISHING PIGS
![Page 43: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/43.jpg)
Average daily gain (g) 23.60a 30.00b 30.30b
Average daily feed intake (g) 43.10 51.50 52.70
Feed efficiency (f:g) 1.82a 1.72b 1.74b
40.50a 12.10b 9.70b
----------- Salt CV (%) ----------
a,b Means within a row differ significantly (P < 0.05)
DIET UNIFORMITY EFFECTS ON
BROILERS
![Page 44: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/44.jpg)
Broilers CV < 15%
Nursery pigs CV < 20%
Finishing pigs CV < 30%
Recommendations
…based on minimal data
![Page 45: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/45.jpg)
Quantity/criticality of ingredient
(Diet Complexity)
Nutritional consequences vs.
medication delivery
Deficiency/Toxicity Limits
Ease of modifying process
parameters
OTHER CONSIDERATIONS
![Page 46: The Batching & Mixing Processes](https://reader031.vdocuments.us/reader031/viewer/2022013001/61ca8835a2a5580763048dcb/html5/thumbnails/46.jpg)
Questions