We plan and realize plants destined to operators in the livestock industry for animal feed production. We are able to offer “turnkey plants” or to provide single parts of the production line, thereby improving one or more production phases.
Our machinery, combined with our skills and expertise, are capable of improving all the production phases.
ENTIRE PRODUCTION PROCESS
Upon receiving a request for a feed mill, we send a form for the client to fill out: in order to draw closer to the final solution the client desires, a layout is drawn up along with a quotation. In the event that such quotation is deemed interesting, a visit is paid to the client so as to discuss and perfect a final layout, pursuant to which a finalized offer is made.
We calculate the capacity and number of raw material silos based on the utilized products (barley, bran, maize, oat, etc), on the production of animal feed/per hour and the time frame for procuring the same.
We are capable of extracting the raw materials and carrying out the weighing, based on the recipe of the product to realize (chicken feed, pig feed or other animal feed) and on recording the extracted weights for the sake of updating the raw material warehouse.
The milling of extracted products is carried out with traditional “knife” grinders or with disc grinders, so as to secure a lower energy consumption.
Based on the feed mill’s production capacity and on the type of animal feed recipe to produce, some products (vitamins, enzymes, minerals, proteins, etc) are sent to the mixer, whenever requested, through an automatic system of extraction and big-bag weighing.
The micro-dosing can be either manual o automatic.
In the manual mode, the operator prepares the additives to be added into the mixer, as per the recipe, and whenever requested he directly inserts the prepared product by hand into the mixer. In the automatic mode, the products to be added into the mixer are extracted with screws, autonomously weighed and sent to the mixer. This solution significantly quickens the manufacturing process, avoids weighing errors on the part of staff, and keeps the product warehouse constantly updated.
All the products making up the recipe, previously extracted and weighed, are collected in the mixer. The mixing time is set in automatic mode, according to the animal feed one wants to produce. Again in line with the recipe, liquids (lecithin, choline, enzyme, molasses, etc) are transported in heated pipes sprayed over the product during the mixing and counted through a litre counter. If the client prefers the manual micro-dosing, a post for loading animal feed additives by hand is set up.
The pelletting phase allows the transformation of the mixing obtained into pellets by pressing it inside the “pelletting” press, where the following factors jointly operate: heat, humidity and compression. The main organs of the pelletting press are the die plate and the rollers.
The significant factors (as regards the part of the plant involved in this phase) during the pressing are:
• die plate: thickness, working surface, die plate speed, die plate pressing channels, the so-called “holes”
• distance between die plate-roller
Said factors vary depending on the physical and chemical properties of the mixing entering the press in relation to the product (pellet) which the feed-stuff seller intends obtaining.
The pellet exiting the press is tender, hot and humid. In this phase, the pellet has a temperature ranging between 60°C and 85°C, with a humidity of about 17%.
In order to stabilize the pellet and enhance quality (thereby avoiding rifts), it is necessary for it to pass through the cooling phase. This phase takes place inside the coolers.
The cooler is placed directly under the press, where the pellet is cooled through air sucked from the outside at a temperature 5 degrees higher than that of the surrounding environment.
When the pellet is cooled, it is necessary to consider the following aspects:
• during the displacement from the press to the cooler, the pellet should not be excessively stimulated, as it is still tender and thus potentially subject to rifts;
• it is necessary to identify a suitable cooling time: neither too short, otherwise the pellet would retain too much internal heat (hence humidity), thereby compromising both its structure and its fluidity (being sticky), nor too long/intense, given that the pellet would dry up significantly and too quickly, thereby creating rifts with a resultant increase of its abrasive force;
• the smaller-size pellet cools down before the larger-size one;
• the pellet should be uniformly distributed in the cooler;
• the air speed in the cooler should approximately correspond to 0.5 m/s in the countercurrent coolers ranging between 0.8 and 1.5 m/s.
If the air speed in the cooler is too high:
• the pellet heat decreases too quickly;
• there is scant extraction of humidity;
• the drying of the pellet takes place only superficially;
• the humidity retained inside the pellet will entail a rift or cracks in its surface, thereby occasioning greater abrasion.
If the air speed is too low:
• the pellet heat will be extracted slowly, hence not to the desired extent
•a high extraction of humidity will occur
The type of cooler are BELT-LIKE HORIZONTAL COOLER or COUNTERCURRENT (FEED PELLET) COOLER.
The cleaner enables the separation of the animal feed cube from dust and miscellaneous waste. The dusts are introduced into the manufacturing system, whereas the discards are sent to a bag set aside for that function.
In order to further personalize the product, some clients envisage the oiling of the animal feed cube, which is carried out automatically according to the recipe elaborated by the system. The pipe transporting the oiling is fully heated.
The silos of the finished products are calculated on the basis of the production and type of animal feed produced.
The final product can be sent to an automatic packaging system, alternatively, through loading bellows the client can load the truck tanks.
In order to avoid contaminations of different dusts and give rise to an unhealthy environment, the whole production cycle is equipped with filters positioned where dusts are generated.