Amul Feed Plant

Feed Plant of 1600 TPD for Animal Feed Production set up at Gujarat, India.

1. AMUL NEW FEED PLANT 1600 TPD
PELLETS
Conceptual Equipments And Services
Pvt. Ltd, India.
Present……..

2. FEED PLANT VIEW

3. FEED PLANT LAYOUT MODEL

4. High Lights for 1600 TPD Feed Plant
Main Features:
Unique Raw Material Storage System.
All raw materials are stored after cleaning.
Major Raw Material stored in Flat Storage
24 chambers each on two sides . Total 48
chambers.
Raw Material dumping limited to three locations.
One of theLargest Flat Storage Systems.
Four Grains Storage Silos.

5. High Lights for 1600 TPD Feed Plant
Main Features:
Two Production lines of 800 TPD each.
1600 TPD up to the Grinding Mills
Unique flat storage compartment filling
system with telescopic conveyor.
Filling with extended discharge chute.
Material temperature monitored.
Feeding to the plant through dumpers
and intake conveyors.

6. High Lights for 1600 TPD Feed Plant
Main Features:
Hammer Mill of 50 TPH
Batch Mixer of 4000 KG per Batch
Pellet Mill Of 40 Tons per hour Geared
Unit.
Geared pellet Mill of this capacity in
Cattle Feed Plant, first time in India.
Pellet Cooler 45 TPH.
Bagging through Automatic Bagging
station and gravity feed electronic bagging
machines.

7. High Lights for 1600 TPD Feed Plant
Main Features:
First Floor bagging arrangement.
Five trucks can be loaded at time.
Storage facility in silo after production.
Production de linked from bagging &
dispatch.
Filled Bag handling through an
automated conveying system.

8. Flat Storage System
Open Flat storage system with 24
chambers on each side. Total 48
chambers. Each chamber has 450 tons of
storage capacity.
DORB & Cakes will be stored in Flat
Storage.
Grains will be stored in Silo.
Four Flat Bottom silo of 500 Tons storage
capacity.

9. Advantage of Flat Storage System
Utilization of maximum area for storage.
All raw material is stored after cleaning.
Waste material collection at designated
points outside the plant area.
All space utilized by cleaned raw material.
Bag handling limited to dumping area only.
Empty bag handling limited to dumping
area only.
Main Man movement limited to truck
unloading and dumping area.
Minimum personal engaged for raw material
dumping to the production line.

10. Flat Storage Conveyor Discharge

11. Flat Storage Doors

12. Flat Storage Chamber

13. Flat Storage Telescopic Conveyor

14. Four Silo of 500 ton storage capacity.
Cleaning system after the material dump
Conveyor at the bottom directly feeding to
plant.
Automatic temperature controller provided.
Level sensors on each silo.
Provision for a second set of silo provided.
Silo Storage System

15. Silo Storage

16. Silo Storage System

17. Grinding Operation
One Hammer mill of 50 TPH from Andritz
with aspiration unit.
One feeder and air assisted system for removal
of stones.
Magnet on feeder for removal of ferrous
material.
Mill runs on lower speed at 1440 RPM. 400 Kw
motor
Directly coupled motor.
The Second hammer mill of same capacity to
be added on expansion.

18. HAMMER MILL

19. Mixing Unit
One single rotor blender from Andritz.
4000 kg(8000 liter) capacity.
Unique mixing rotor.
Mixes in lesser time.
Drive Power 75 KW.
Drive RPM 23.5.
Air vent between mixer and surge bin.
The second Mixer will be added on Expansion.

20. HORIZONTAL MIXER

21. Molasses Mixer
Molasses Mixer From Andritz with molasses
injection arrangement.
This will be between the pellet mill and
conditioner .
Steam also can be injected to the mixer if
needed.
Molasses addition 10%

22. Conditioning Unit
Special design conditioner from Andritz.
Multipoint controlled injection nozzles.
Small percentage of an additional liquid can
be injected.
Large volume giving adequate retention time.
Stainless Steel construction

23. FEEDER AND CONDITIONER

24. Pelleting Lines
Pellet Mills from Andritz.
Pellet mill capacity 40 TPH
Pellet Diameter 8 mm.
Two press roll assemblies.
Inlet chute with pneumatic by pass flap
Automatic greasing.
Controls with AS32CS SCADA system, with
remote service provision via modem.
Computer control with various operation for
the operation of the mill.
Roller/Die crane with two speed motor.

25. PELLET MILL

26. Pellet Cooler
Counter Current Cooler to handle 40 to 45
TPH.
Two blower with two cyclones and aspiration
line.
Hydraulic operated moving trays for pellet
discharge.
Optimized controls for the effective cooling
and removal of moisture.

27. PELLET COOLER

28. Pellet Sieve
Separate pellet Sieve for each line.
Totally enclosed units.
Efficient sieving operations.
Fines conveyed back for re pelleting.

29. PELLET SIEVE

30. Bagging Lines
Silo to store cooled pellets. 60 Tons each silo
One automatic bagging station with stitching
machine.
Three Net weight Bagging machines for
bagging in jute bags.
Bagging and dispatch de linked from
production.
Computer control for this entire operation.
Conveyors with sensors to load the truck or to
divert the bags for stacking.
Sensors on bin for status of material
monitored.

31. Bagging Machines

32. Molasses Storage
Two Tanks of 5000 tons each
Four Unloading Pump with two as standby.
Molasses Heater with steam heating.
Molasses day tank in the plant.
Feed Pumps from the tank to the molasses
mixer.

33. Molasses Distribution

34. Electrical Panels
Separate MCC for different sections.
All motors operated through VFD.
Section wise MCC provided.
Auto power factor controls for each of the MCC
separate
Auto Load control system on hammer mill and
pellet mill.

35. Aspiration Units
Aspiration units at dumping points.
Independent aspiration for hammer mill.
Spot filters for the conveyors and Elevators.
Breathers provided instead of aspiration unit
on hoppers and Bins.

36. 4000 Kg Steam generation Boiler.
Briquettes used as fuel.
Full automated operation.
Steam supply to process plant and molasses
tank heating system.
Steam Generation

37. Boiler House

38. Automation Of the Plant
Centralized computer system.
Use of Scada and DCS system.
Use of speed sensors in all conveyors and
elevators.
Use of belt alignment monitor in elevators.
Use of explosion windows in elevator.
Monitor consumption of steam, molasses, air, and
electricity through monitoring meters.
Pellet mill monitoring with details of spare part
consumption and life.

39. Automation Of the Plant
Conveyor elevator status monitored.
Bagging and dispatch monitored.
Batching and raw material status monitored.
Raw material temperature at the storage points
monitored.
Premix operations monitored.
Molasses consumption and status in tanks
monitored.
Steam consumption monitored,
Reports generated as per requirement.

40. Scada Screens –Elevator Load

41. Scada Screen-Batch Handling

42. Scada Screen –Pellet Mill Load

43. Scada Screen-Die Press Roll Details

44. Manuals For Machines
The manuals for the Andritz process machines can
be accessed from Scada.
The Spare parts list fort process machines can be
accessed from the system.
Easy identification possible with search facility.

45. Sample Manual Access

46. Airline Distribution

47. Summary
Flat Storage to store 19200 tons
Silo to store 2000 Metric tons.
Molasses tanks to store 10000 tons in two tanks.
Briquette fired boiler of 4 tons per hour steam
generation.
Air compressor of 540 cfm air capacity.
Batching System to batch 4 tons per batch.
Hammer Mill of 50 tons per hour.
Batch Mixer to handle 8000 liters per batch.
Pellet Mill of Capacity 40 tons per hour.
Cooler to handle 45 tons per hour.
Three Gravity fed Net weight bagging
Machines.
One automatic bagging machine

48. Contact Details
Registered Office:
Conceptual Equipments And Services Pvt. Ltd.
6/1302, Daffodil, Puliyankavu Road,
Karingarapully, Palakkad,
Kerala, India –678551
Phone: [phone].
E mail: [email protected]

49. Contact Details
Factory:
Conceptual Equipments And Services Pvt. Ltd.
486/B-2, G.I.D.C. Makarpura, Baroda,
Gujarat, India –390010
Phone: [phone]
E mail: [email protected]