Feed Mill Operations.pptx

Feed Mill Operations in an animal nutrition plant
By Dr Ameer Suhail A
Animal Nutrition Post Graduation Scholar

1. FEED MILL LAYOUT AND OPERATIONS Ameer Suhail A 22-MVM-04

2. OBJECTIVES OF FEEDMILL OPERATIONS To increase the productive value of feed To increase the consumption rate of feed To Increase the palatability of feed To increase the digestibility of feed To increase the nutritive value of feed To reduce the wastage of feed

3. POINT TO BE KEEP IN MIND WHILE SETTING A FEED MILL Project Cost Market Area ( Radius of 200 Kms )   Competition in the Market Selecting the site Project Feasibility

4. 001 002 003 004 005 006 007 008 009 mixer loader  stock bin feeder pelleting machine belt conveyor cooler  belt conveyor packing machine

5. LAYOUT OF RF FEED MILL

6. DIFFERENT TYPES OF FEED MILL 2 ton/hr feed mill 3-5 ton/hr feed mill 10 ton/hr feed mill 1-30ton/hr feed mill 50 ton/hr feed mill

7. 1-2 TPH

8. 2 – 5 TPH

9. 10 TPH

10. FEED MILL EQUIPMENTS AND OPERATIONS

11. FEED MILL OPERATIONS Feed mill is a Production Building produces feed for animals , Poultry and Fishes. Feed mills manufacture pellets, crumbles or mash and these products are shipped in bagged form.  The feed manufacturing process include: Raw material selection & storage Raw material weighing and grinding Mixing of dry ingredients and addition of liquids Pelleting of mixed feed (optional) Blended feed bagging, storage and dispatch

12. RAW MATERIAL SELECTION & STORAGE The raw materials coming into a feed process area will be checked by nutritionist to meet the nutrient requirements of the diet to be manufactured In order to ensure a continuous supply of raw materials at the mill, when some may only be seasonally available on the market, and to take advantage of price fluctuations, some form of storage will be necessary. Raw materials should arrive in good condition and in sacks which have not been used for the storage of fertilizer, pesticides or chemicals. Storage areas must be waterproof and well-ventilated , and provide protection against infestation by insects and vermin If materials are to be stored in bags they should be kept in a building having a concrete floor. The bags should be stacked a few inches above floor level.

13. INGREDIENT DUMPING UNIT

14. Continued… Ingredients can be transported by conveyor system. A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another over a fixed path. Bucket elevators Belt conveyors Paddle conveyors Drag chain conveyors

15. SCREW CONVEYOR A screw conveyor or auger conveyor is a mechanism that uses a rotating helical screw blade, called a " flighting ", usually within a tube, to move liquid or granular materials. Consists of a tube or U-shaped stationary trough through which a shaft-mounted helix revolves to push loose material forward in a horizontal or inclined direction. These are of different types i.e. inclined , horizontal and vertical screw conveyors.

16. BELT CONVEYOR A belt conveyor system consists of two or more pulleys (sometimes referred to as drums), with an endless loop of carrying medium—the conveyor belt that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler pulley. The conveyors can be operated horizontally or can be inclined as well.

17. DRAG/ PADDLE CONVEYOR Drag conveyors are a great complement to screw conveyors and belt conveyors and a requirement of many bulk material handling applications. The compact and versatile design allows drag conveyors to fit almost any plant layout GRAVITY CONVEYOR Loads are conveyed on rollers or skatewheels which are mounted in frames. Typically gravity conveyors are sloped in elevation to allow products to flow freely, taking advantage of the Earth’s gravity. these are mostly used in loading and unloading of trucks & Conveyance within picking areas.

18. CHAIN CONVEYORS Uses one or more endless chains on which loads are carried directly PNEUMATIC/VACUUM CONVEYOR Air pressure is used to convey materials through a system of vertical and horizontal tubes. It can be used for both bulk and unit movement of materials. Major advantages are that material is completely enclosed and it is easy to implement turns and vertical moves. The pressure and air flow used to convey the materials is generated by air movers such as positive displacement blowers or vacuums .

19. BUCKET ELEVATORS It is a type of vertical or inclined transport equipment that efficiently moves goods between floors, vessel or other structure. Elevator is generally powered by electrical motors that either drive traction cables or counterweight system like a hoist or pump hydraulic fluid to raise a cylindrical piston like jack. Generally it is preferred for short in distance compared to belt conveyor. It is more preferable to transport the materials vertically. 

20. RAW MATERIAL WEIGHING/BATCHING SYSTEM Large bin-type weighers are often used for raw materials which have been pre- ground or are free flowing and discharge readily from storage bins or silos.   Bin-type weighers may be mobile or stationary. Inline weighers which measure the quantity of material flowing over a small electronic sensor and volumetric dischargers are also available. Each bin consist of two parts : Concrete part and Hopper ( steel made ) For all major and minor ingredients, the equipment used for this includes screw conveyors which provide excellent proportioning control and scale hoppers above the mixer Bulk bag and hand dump stations are also frequently used to add ingredients to the feed mixture.

21. WEIGHING HOPPER Weigh batching hoppers are used for  weighing  dry products to dispense accurate amounts as required by downstream processes (mixer/packaging , etc .). A weigh hopper is suspended from load cells and can be installed above the mixer, a skip hoist or a belt conveyor that transports aggregates to the mixer. The hoist bucket itself can also function as a weigh hopper. The hoist bucket moves into a weighing unit where it rests on two load cells making it possible to use the hoist bucket as a weighing unit or for weight checks . 

22. RAW MATERIAL GRINDING  Grinding or particle-size reduction is a major function of feed manufacturing. Many feed mills pass all incoming ingredients through a grinder for several reasons : (a) clumps and large fragments are reduced in size, (b) some moisture is removed due to aeration, and (c) additives such as antioxidants may be blended . The grinding of ingredients generally improves feed digestibility, acceptability, mixing properties, pelletability , and increases the bulk density of some ingredients. It is accomplished by many types of manual and mechanical operations involving impact, attrition, and cutting.

23. Grinding Equipments … HAMMER MILL A typical hammer mill consists of a horizontal rotor assembly fitted inside a metal housing. The rotor assembly includes a shaft and several circular plates mounted on it with equal spaces between plates . Plates are having hammer pins on which swinging hammers are fitted. A perforated metal screen is forming either a full circle or half circle fits around the rotor assembly . The diameter of hole in screen is selected to match the desired particle size. A material inlet is typically located at the housing top and a material outlet is located below the housing . A flow deflector is mounted below the material inlet to deflect the material either way to assist grinding.

24. Grinding Equipments 2. ATTRITION MILLS Attrition mills use the hammermill principle to a certain extent; i.e., shattering by impact . However, they also impart a shearing and cutting action. Grinding is done between two discs equipped with replaceable wearing surfaces. One or both of these discs is rotated; if both, they rotate in opposite directions. When one disc is rotated, and the other stationary, the assembly is used for shredding and deferring. Often materials which have been coarsely ground by other mills, are passed through an attrition mill for blending or smoothing out an ingredient or mixture containing liquids which may have clumps. The discs of an attrition mill are generally in a vertical position so that materials not capable of reduction can pass by gravity out of the grinding area.

25. Grinding Equipments 3 ROLLER MILLS A combination of cutting, attrition , and crushing occurs in roller mills. These are smooth or corrugated rolls rotating at the same speed set at a pre-determined distance apart with material passing between the two. A tearing action may be added by operating the rolls at different speeds and by corrugations which are different for each roll; i.e., the top roll may have off-radial spiral corrugations and the bottom roll lateral corrugations. This last type, called a "Le Page cut" is used in making granules from hard pellets, as it provides a breaking surface without much impact to cause dust. Roll grinding is economical but limited to materials which are fairly dry and low in fat.  

26. Grinding Equipments 4 CUTTERS Rotary cutters are a type of grinder which reduces dry particle solids mainly by shearing with knife edges against a striking plate. The mill consists of a rotating shaft with four attached parallel knives and a screen occupying one fourth of the 360 degree rotation. The mill is best used to crack whole grains with a minimum of "fines". It is not used as a final process for reducing the size of ingredients  

27. AIR ASPIRATION SYSTEM Hammer Mill Air Aspiration system, an optimal grinding requires the right amount of intake of air, which is cleaned in the nozzle filters. This also guarantees an economic use of the Tear Drop Hammer Mill, the air is necessary to quickly transport the fine products from the area of the hammers through the grinding sieve and at the same time, to cool the biomass materials.

28. MIXING  It is the job of the mixer to produce a homogenous blend of all the raw materials desired in a formulation, such that at each feeding period each animal receives a balanced mixture of nutrients   Mixing often improves feed palatability if one or more of the raw materials is unpalatable to livestock  Concrete mixers : Small concrete mixers with electric or petrol engine drives are mobile low cost machines suitable for the manufacture of mixtures of dry ingredients or mixtures of wet feeds.   Conventional feed mixers : Two designs of mixers are most commonly found in the feed industry: the vertical (or fountain) mixer and the horizontal (or U-trough) mixer .

29. VERTICAL MIXERS Raw materials may enter the mixer either at the top, from the grinder, or at the base of the screw at a sack tipping point. After mixing for a pre-determined time, normally 10-15 minutes (although this time may be shorter in some mixes), the mixture is discharged into a bag or conveyed by bucket elevator to a storage bin or pelleter . Since many raw materials are dusty it is often desirable to include materials such as molasses, oils and fats in the formulations to reduce dustiness as well as to provide a source of nutrients.

30. HORIZONTAL MIXERS operate with a horizontally turning mixing shaft, the mixer is suitable for blending up to 8% liquids into a dry mix and therefore offers greater versatility if a wide range of rations are to be offered from one feed mill unit . It is preferable that fats and molasses be warmed before addition to the raw materials in the mixer and they should be added as the last ingredients

31. CONVEYOR MIXERS  Conveyor mixers are also available, particularly for farm use, and consist of a trapezoid metal box in which mixing is effected by slats extending almost the full width of the machine and which are carried on a pair of endless chains. Like the vertical mixer this machine is limited in its ability to blend liquids thoroughly into the mixture.

32. MOLASSES MIXING UNIT Molasses is an important  cheap source of energy Molasses is stored in MS storage tanks. Quality of molasses should be checked for its density prior to transfer to storage tank. Batch after getting mixed in batch mixer is fed mechanically to the mixed feed bin above molasses mixer  through  elevator . The mixed feed is fed to the molasses mixer , where molasses at around 45-50 degC from molasses heater is sprayed and mixed in controlled quantities . The molassed feed is either conveyed to finished feed bins for bagging if the feed is required in mash form or is allowed to ripen in a small bin for few minutes . The molassed feed is finally fed to pellet mill through its feeder and conditioner, if feed is to be produced in pellet form.

33. MAGNETIC SEPERATOR Magnetic seperator mainly used for iron impurity separation. It is used in grain mill, feed mill and brewing plant etc. The core part of it is made of ferromagnetic material, the shell of it adopts stainless steel, it is of high effect and less land occupy.

34. PELLETING Pelleting is a process in which mixed feed in powder form is converted into pellets by mechanical compression in combination with moisture and heat . Process is achieved by a set of rolls and die of suitable hole size and shape. As the die & roll rotate, the product passes through the nip of roll and die and pressed into die holes to make pellets . Has both physical and nutritional benefits of it. Among physical benefits, we can count - improved ease in handling, reduced ingredients segregation, less feed wastage and increased bulk density. Nutritional benefits - Decreased feed wastage, reduced selective feeding, decreased ingredients segregation, less time and energy expended on prehension , destruction of pathogenic organism, thermal modification of starch and protein, improved palatability.

35. PELLET MILL A  pellet mill , also known as a  pellet press ,  is a type of  mill  or  machine press  used to create  pellets  from powdered material. Pellet mills are unlike  grinding mills , in that they combine small materials into a larger, homogeneous mass, rather than break large materials into smaller pieces . pellet mill is mainly composed of 3 parts: pelletizing part drive engine drive system.

36. PELLET DIE & ROLL SHELL UNIT ASSEMBLY Remote roll adjust system Typical pellet mill die and roller hoist arrangement

37. COLD PELLETERS In cold pelleting, mixed feed is fed directly from a bin or auger into the die head at ambient (normal atmospheric) temperatures. Some water may be added, preferably in the mixer if the meal is too dry to bring it to approximately 15-16% moisture, but there is no heat treatment of the mixed meal before it enters the die . PELLET CONDITIONER Here, the mixed meal is directly pre-heated with dry steam. The steam preheats or conditions the meal to the preferred temperature and moisture content for pelleting according to the formulation of the mixture, for example, 65-121°C avg 80°C and 15-25% moisture  Generally, the quality of pellets (that is, resistance to break-down after pelleting and during handling) of a given mixture from a conditioner pelleter is marginally better than that from a cold pelleter , but the conditioner pelleter requires a boiler and associated water treatment plant to treat the feed water for the boiler. 

38. PELLET QUALITY Pellets should have a desired degree of hardness, and should also show high resistance to abrasion during handling and transport . PELLET BINDERS Some mixtures of raw materials do not bind well together when pelleted and require the addition of special binding agents. Molasses is often added at 2-5% to aid binding, but other binders include bentonite clays and lignosulphonates , and are added at the suppliers' recommended dosage levels, usually about 1-2%.

39.   COOLING & STABILISING The Pellet Cooler is used for cooling hot feed pellets from 80o C to ambient temperature. Cooling columns are on either side with central duct for conveying hot air. Wire mesh separates pellets from air. Set of flaps regulate flow of cold air inside the cooler. Thepellets while falling operate inside portion of the flaps and cold air is passed through stock of pellets. Basically three types of coolers used in the feed industry :  Vertical  Horizontal  Counter flow Pellets are then cooled from 80°C to ambient. 

40. DRYER Drying is the process that reduces grain moisture content to a safe level for storage, Proper Drying will maintain grain quality and minimize losses . PURPOSES OF DRYING  T o reduce the moisture content of rough rice to a level safe for storage. Drying of grain involves exposing grain to ambient air with low relative humidity or to heated air. This will evaporate the moisture from the grain and then the drying air will remove the moisture from the grain. 

41. TYPES OF DRYER Continuous flow dryer Conventional Continuous Flow Dryer Cross flow dryers Counter flow dryers Flash Dryer The fluidized bed dryer consists of a drying chamber with an air speed of around 2.3 m/s, a bed thickness of 10 cm in which the grain is exposed to the drying air for 10-15 minutes. Capacities of commercial units range from 1-10 t/h. A diesel burner or a rice hull furnace is used as heat source and a system for recycling 50- 70% of the drying air is provided to improve energy efficiency.

42. PARTS OF A DRYER Perforated metal sheets 44 rings Two blur fans 75 hp motor of each FD (forced) fan 50 hp motor Heat exchanger Rotary 3 hp motor Steam header Dryer panel Conveyer and elevator

43. CRUMBLING Pellet Crumblier is an essential equipment for the preparation of crumbled pellet feed. The pellets can then be diverted into the crumblier, if crumbles or granules are desired, or they can by-pass it. This is used for breaking the pellets into crumbs required for chicks which are 2-3 weeks old . Pellets are broken into pieces of the required size between the two rolls of the crumblier situated below the cooler/drier exit. The gap between the rolls can be adjusted to regulate the size of crumbs. The roller gap is adjusted with a hand wheel mechanism.

44. SCREENING SIEVE GRADING : Grading rotary sieve is made to grade and screen the pellets getting gone through crushing in the large or medium-sized animal feed . It is also used to clean the initial materials to process pellets. It is applicable for screening and classifying of mash or pellet feed. It is also can be used for cleaning of raw materials. Large pellets and very small particles with ground material are recycled through the pelleting machine .

45. BAGGING / PACKING Load Cell Type Bagging Machine : The Load Cell Type Bagging Machine or Bagging-Off- Weigher is an electronically controlled bagging machine. It is a heavy-duty machine for the repeated and accurate weighing in bags of products like pelleted or mashed feed, grains, sugar and cereals It consists of a bin hopper, feeder with slow-speed and high-speed drives, a weighment chute supported on load cells and a pneumatically operated bag clamp. The accuracy of the machine is 0.2 %. When bag put at mouth of cell, clump took message to sliding gate open for specific weight of feed dragging down in bag, as weight attained according to our input to load cell.

46. BOILER  The main function of a boiler is to heat water to generate steam Boiler broadly classified into two categories , Water tube Fire tube  PARTS OF BOILER : Three main thing to run the boiler FD (Forced) Fan; its function is forced the air into furnace (combustion chamber) to stimulate the fire, its running motor is 5 hp. ID (induced) Fan; it induced the air from main shell/ boiler to chimney, having motor 40hp. 3. Water Feed Pump also call multistage centrifugal pump; it consist of stages/ impellers, function of impeller is to increase pressure. Its pressure 1.5 times more than boiler inside pressure.

47. PARTS OF BOILER Continued … 3. Water Feed Pump also call multistage centrifugal pump; it consist of stages/ impellers, function of impeller is to increase pressure. Its pressure 1.5 times more than boiler inside pressure . OTHER PARTS Drying pipe; its function is to allow only steam to move out and filter the water drops. Rose pipe; it acts like a shower, prevent the water directly hitting on fire tubes Safety valve; It control the pressure up to 150psi, above its range that will open and save the over pressure problems in the boiler. Main hole; entry point for repairing purposes. Air valves; to remove vaccum from the boiler when again start after some time break.

48. PARTS OF BOILER Continued… Air valves; to remove vaccum from the boiler when again start after some time break Cyclone ; to separate ash and dust, allow smoke to release out Below down valve; for water discharge from the boiler. Water level gauge glass; to check water level. Stop valve; to stop the steam

49. Continued… Load cell message to pneumatically controlled cylinders to close the gates. As gate close clumps release and bag moves to sieving machine by belt conveyer. Here packing is completed and feed bag is either stored in store house or directly loaded to vehicle

50. STEAM FLOW From boiler to conditioner throughout steam line 4 inch and insulated. Distributer (Header) it get steam and distribute the steam to multiple lines, near to boiler, dryer and next pellet sides. Strainer : it is sieve type valve use to filter the particles from the steam to protect the seats of valve. Steam Trap: it is use to separate the water from the steam Pressure reducing valves: use to control the pressure in a constant way, use before the conditioner to avoid the over conditioning problems. At pellet side trapper valves separate the water this water comes back into boiler for recycling by two inch pipe line.

51. PLC (Programmable Logic Control)   This consists of a list of logic functions and instructions, which are successively processed through a program . CONTROL SYSTEM This a customizable software and hardware package. With a custom hardware and software solution you have the ability to monitor and completely control a facility from a PC. The operation of the PLC controller can be monitored and changed via the keyboard/mouse and the recipes/alarming log etc. The PLC graphically displays the information on a screen (touch screen or standard) and allows the user to manipulate the data on the PLC (start/stop motors, view outgoing batches etc.)

52. DUST FREE GODOWNS