Feed Manufacturing Technology Issues and Challenges

Dennis Forte & Associates Pty. Ltd. P.O. Box 8179 Wodonga, 3690 Victoria. 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 Manufacturing
Feed 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 Manufacturing
Factors Influencing Feed Quality (Pellet Durability) Formulation Grinding Conditioning Die Design (and Condition) Drying and Cooling 40% 20% 20% 15% 5%

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

Feed Manufacturing
An 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 Manufacturing
A selection of typical Pelleted Feeds

Feed Manufacturing
Key Features of a typical Pellet Mill Assembly
Feeder Steam Preconditioner

Main Drive Motor Pellet Mill

Courtesy of Jesma-Matador

Feed Manufacturing
Key Features of a typical Pellet Mill Assembly
Mixing and Conveying Paddles

Rollers and Roll Gap Adjustment

Courtesy of Buhler

Feed Manufacturing

Basic Operating Principle of the Pellet Mill

Feed Manufacturing
The BOA Compactor

Feed Manufacturing
Operating Principle of the BOA Compactor

Feed Manufacturing
Wenger Manufacturing Universal Pellet Cooker

Feed Manufacturing
Typical Pelleted Feed Products from the UPC

Feed Manufacturing
A Selection of Extrusion Cooked Aquatic Feed Pellets

Courtesy of Clextral

Feed Manufacturing Basic Extruder Functions

Mixing Pumping Kneading / Shearing Compression Heating / Cooling Venting (or Degassing) Injections Multiple Feeds

Feed Manufacturing Basic Extruder Variants

Single Screw Extruders
Single Stage Two Stage Long vs. Short Screw

Twin Screw Extruders

Co-rotating and Intermeshing Co-rotating and Non-intermeshing Counter-rotating and Intermeshing Counter-rotating and Non-intermeshing

Feed Manufacturing
A Typical Extrusion Cooking Process

Feed Manufacturing
Flow Components within the Extruder System
Single Screw Extruders Twin Screw Extruders

Feed Manufacturing
Processing Options
Pellet Milling Technology BOA Compacting Mills Universal Pellet Cooker Extrusion Technology Increasing level of Mechanical Shear and improved Pellet Quality

Feed Manufacturing
Process Comparison
Process Pellet Press BOA C.M. Expander / Press U.P.C. Temperature 60 100 70 100 90 130 120 140 Moisture 12 18 12 20 12 20 12 22 12 30 Maximum Pressure Fat < 18 up to 2 30 40 30 40 30 60 < 20 < 22 < 22 < 26 Degree of Cook 15 30 20 35 30 40 35 - 50 40 80

Extrusion Cooker 120 160