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Feed Mill DesignAnd

Feed Processing

By

E.GnanamoorthiHead- Engineering Services,

Optima life Sciences Pvt Ltd.

Feed Mill Overall View

Feed Mill General Drawing

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Processing flow chart

Processing flow chart

Raw Material Arrival

Need to allot the place

Need to submit bill and PO details to office for verification

After Verification need to provide Serial number and Unloading Time, If sample pass means.

Inform to QC department for sample test.

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Lab Test

Need to do following Basic test

Moisture Test

Protein Test

Funguses test

Unloading

If Silo Need to do pre

cleaningNeed to put

greasing to bearing area of screw conveyer

Need to check Oil level in the gear box

If Lot SystemNeed To allot permanent

place to unload the particular material

High ratio material have to unload nearest place to grinding point

Lotting up to safety level only.

Need to maintain proper ventilation method

Need to implement FIFO method

Batching system

Have to set the correct quantity from the correct Bin as per formula

The batching is the main roll in feed quality

In proper batching will affect the feed quality

It will lead to raw material stock variation.

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Medicine & Oil Batching

Have to Maintain color code bags for individual item

Do not keep with out color coding medicine bag

Have to mix the medicine timely with raw material in mixer

Have to mix oil with raw material in the mixer

Grinding

The grinding means “reduction of particle size of raw material”

And also the second largest power consumer in the feed plant

Grinding

Can process wide range of raw material

Produce wide range of particle size

Can process too fibrous material

Less costMinimum maintenance

costParticle will be spherical

in shape with surface polished

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Grinding

The velocity or tip speed of the hammer is critical for proper size reduction

Tip Speed (meter per minute)=∏Dn

∏ = 3.14

D = diameter of hammer tip in meter

N = Shaft rpm

Tip speed range between 5000 to 7000 rpm

Grinding

An abnormal temperature rise in the material means the operation losing the efficiency

Differential Temperature “ Delta T(ΔT)’’

If ΔT is more then 5⁰C means, need to improve the system efficiency

Grinding

Mark 1’’ by 1’’ square

Area of sieve (closed area )= L × B

Area of one hole = ∏d²/4

Open area in the sieve = L × B × ( n∏d²/4)

Note :- all dimensions should be in inch

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Effect of high ΔT

Evaporate moisture in r/m

Significant loss in weight

Condensation in mill and transportation system surface

Corrosion

Ingredients residues

Cross – Contamination

Mould problem

Mixer

Paddle Mixer

Ribbon Mixer

Twin shaft mixer

Continuous mixer

Features influencing in mixer performance

Ingredient particle size and shape

Ingredient density and static charge

Sequence of ingredient addition

Amount of ingredient addition

Rotational speedMixer DesignCleanness of mixer Maintenance of the mixer

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Mixer performance Test

Data Analysis

%CV = s÷ŷ x 100

Ŷ = ∑y ÷ n

s = √s²

s² = ( ∑(yi²)-n ŷ²) ÷n-1

% CV = % co-efficient of variation

s = standard deviation

s² = variation

Ŷ = mean

∑ = sum

yi = individual sample analysis results

n = total number of samples

Conditioner

The main aim of conditioning is to optimize the nutritional quality of the feed

Reduces microbial activity

Increases starch gelatinization

Enhances pellet durability

Conditioner

The Following three factors are important in conditioningRetention timeMoisture contentTemperature

Generally Single or dual barrel arrangement.

Each barrel contains paddles revolving at speed

Duration time varies between 10 sec to 60 sec

It can sometimes controlled by the angle of the paddles, which should be checked frequently for wear

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Conditioner – Retention Time and temperature Increasing retention

time improves the pellet quality

Retention time is from 30 sec to 45 sec approximately

The temperature of feed after conditioning will be from 80⁰C to 85⁰C

Moisture addition will be approximately 3.75% to 4%

Steam can't provide the moisture more then 6% during conditioning

Pelleting

The main aim of pelleting is to optimize the physical quality of the feed

The most capital and energy intensive operation in feed manufacturing operation

Increased nutrient availability

Decreased energy requirement for feed consumption

Reduced feed pathogen load

Increased bulk density (Lower trucking cost)

Reduced feed shrinkage (Less material cost as dust

Pelleting

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Pellet Press

Pelleting Efficiency

Pellet must present the following characteristics

Good appearance Dust free Without crakes Uniform length Hard – Sufficient only to

withstand pressures during storage

Durable – the most important characteristic of all. It must be during enough to withstand the handling it will receive between manufacture to feeding to stock

Efficiency of pelleting means producing pellets of good physical quality at the optimum ratio of output to energy consumption by the press.

Pelleting efficiency is defined as the amount of energy (KWh used to produce one tonne of pellets (Kwh/T))

Efficiency Calculation

Pellet presses are controlled manually or by computer. Either way, It is essential to understand the requirements for effective operation and control, in order to optimize production rate and pellet quality.

The following points outline start-up, running and stopping procedure for a conventional pelleting press.

The efficiency of your pellet press can be calculated as follows Determine pelleting production rate (T/h) Determine average press motor current Determine plant voltage Apply the following formulas to find the

press power in KW and the pelleting efficiency

Power (KW)=A × Voltage × √3 ×Power factor

•T/H 1000

• (Assume a power factor of 0.93 unless known)

• Pellet Efficiency (KWh/T) = (KW/(T/H))

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Die Selection

It is depending on the raw material and formulation.

There is a wide range available from low compression (thin dies wide counter-bored parallel holes) up high compression (thick dies with well or taper bored holes)

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Die Specification and Material Guidelines

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Die Care

Check bores and track for scoring, burring and poor machining before fitting die to press.

Some dies are supplied “ pre run – in” and the holes are plugged with an oily material. this is removed by hand feeding the press with whole cereal, after that die has been fitted and while the press is running.

If the holes of the new die are empty, then it is preferable to plug them prior to commencing production by hand feeding whole pellets.

Care should betaken when starting production not to “{over feed “ the die i.erun the die in gently

After running for approximately one hour, stop the press and inspect the die track and roller to ensure all holes are running.

Avoid “ face to face” roller/die contact. If blocked solid: soak in oil. Then try to re-

start. If unsuccessful. Punch out or drill out. Never Strike a die with steel tool. Protect die from metal object by fitting

magnets. Punch out ant tramp metal which manages

to enter the die. Log the use of your die

Roller Setting (Manual)

Under – Adjusted rollsCreate excessive roller

slip. Heat and possible Consequent die blockage, thus seriously affecting production output. However, pellet durability generally improves as rolls are moved away from the die face, but press capacity is sacrificed and pellet length is more varied.

Correct roller setting is essential for optimum pellet quality, press capacity and die/roller life.

If the rolls are set too tight, The die will flex excessively and

may finally creak. It also increases the possibility of metal- to- metal contact.

Thus rolling over the ends of the holes on the die and creating excessive wear and splitting of roller shells.

Close fitting rolls generally maximize press capacity.

Knife Setting

Knives are used to control the length of pellets as they leave the die. The setting position will depending in the required pellet length.

The shearing or tearing action of the knives on the soft pellets as they leave the die create fines.

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Pellet Durability Index

PDI is defined as the percentage of pellets in the finished pellet feed Feed = Pellet + Fines PDI = Pellet X 100 Feed Testing method: KSU tumbling can, Holmen tester, Kahl tester

COOLER

Temperature: 80 to 85°C Moisture: 15% ±1%

Environmental

Ambient temperature and moisture same as mash

Hot Air

COOLER

• Coolers are designed to extract heat and surplus moisture created during pelleting, thereby increasing the strength of the pellet.Most of the modern feed

mills are using the counter-flow coolers

Average moisture content of pellet feed after cooler is 11.5%

• The temperature of pellet feed after cooler is ambient

• temperature only

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Crumblier

For every young poultry, even small pellets may be too large, thus intake is reduced

Crumbs overcome this problem and still provide a nutritionally balanced diet.

4mm pellets are used and constant and even feed into the crumblier is essential.

Setting the rolls too close results in mashing the pellets rather then breaking them. The meal created is then returned for re-pelleting, consequently production efficiency is reduced.

It is also important that the rolls are well maintained. Ensuring that the flutes are sharp.

Sifters

Sifters are generally located immediately after the cooler and before discharge into bulk road tanker or packing area.

The screens in the sifter should be checked periodically to see that the perforations are not blind, worn or damaged.

Queries???

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Thank You!Thank You!