Feed Manufacturing Technology –Issues and Challenges

Dennis Forte & Associates Pty. Ltd.P.O. Box 8179

Wodonga, 3690Victoria.

Phone / Fax (02) 6056 0004

Feed Manufacturing

Benefits of Processed Feeds

Improved Feed Efficiency

Reduced Segregation of Feed Ingredients

Reduced Losses (due to Fines etc)

Improved Feed Handling

Increased Bulk Density

Improved Flowability

Feed ManufacturingFeed Degradation

Significant Feed Degradation results due to:

Storage & Handling (at the Mill)

Transport

Storage & Handling (at the Farm)

The magnitude of the problem is dependent upon the Pellet Durability.

Feed ManufacturingFactors Influencing Feed Quality (Pellet Durability)

Formulation 40%

Grinding 20%

Conditioning 20%

Die Design (and Condition) 15%

Drying and Cooling 5%

“Factors Influencing Pellet Quality”, Feed Tech Vol. 5, No. 4, K.C. Behnke

Feed ManufacturingAn Overview of the Feed Manufacturing Process

Feed Manufacturing –Types of Preconditioners

Pressurized vs. Atmospheric

“Open” vs. “Weir” Designs

Vertical vs. Horizontal

Single Shaft vs. Twin Shaft

Single Stage vs. Multiple Stage

Feed Manufacturing - Preconditioning

A Single Shaft Preconditioner

Feed Manufacturing - Preconditioning

A Multi-Stage Preconditioner

Feed Manufacturing

Processing Options

Pellet Milling Technology (and Double Pelleting)

BOA Compacting Mills

Universal Pellet Cooker

Extrusion Technology

Feed ManufacturingA selection of typical Pelleted Feeds

Feed Manufacturing

Key Features of a typical Pellet Mill Assembly

FeederSteam

Preconditioner

Main

Drive MotorPellet Mill

Courtesy of Jesma-Matador

Feed Manufacturing

Key Features of a typical Pellet Mill Assembly

Mixing andConveying Paddles

Rollers andRoll Gap Adjustment

Courtesy of Buhler

Feed Manufacturing

Basic Operating

Principle of the

Pellet Mill

Feed ManufacturingThe BOA Compactor

Feed ManufacturingOperating Principle of the BOA Compactor

Feed Manufacturing

Wenger Manufacturing

Universal Pellet Cooker

Feed Manufacturing

Typical Pelleted Feed Products from the UPC

Feed ManufacturingA Selection of Extrusion Cooked Aquatic Feed Pellets

Courtesy of Clextral

Feed Manufacturing

Basic Extruder Functions

MixingPumping

Kneading / ShearingCompression

Heating / CoolingVenting (or Degassing)

InjectionsMultiple Feeds

Feed ManufacturingBasic Extruder Variants

Single Screw ExtrudersSingle StageTwo Stage“Long” vs. “Short” Screw

Twin Screw ExtrudersCo-rotating and IntermeshingCo-rotating and Non-intermeshingCounter-rotating and IntermeshingCounter-rotating and Non-intermeshing

Feed ManufacturingA Typical Extrusion Cooking Process

Feed ManufacturingFlow Components within the Extruder System

Single Screw Extruders Twin Screw Extruders

Feed Manufacturing

Processing Options

Pellet Milling Technology

Increasing

BOA Compacting Mills level of

Mechanical

Universal Pellet Cooker Shear

and improved

Extrusion Technology Pellet Quality

Feed Manufacturing

Process ComparisonMaximum Degree of

Process Temperature Moisture Pressure Fat CookPellet Press 60 – 100 12 – 18 - < 18 15 – 30

BOA C.M. 70 – 100 12 – 20 up to 2 < 20 20 – 35

Expander / Press 90 – 130 12 – 20 30 – 40 < 22 30 – 40

U.P.C. 120 – 140 12 – 22 30 – 40 < 22 35 - 50

Extrusion Cooker 120 – 160 12 – 30 30 – 60 < 26 40 –80