With years of experience in high-quality engineering of animal feed plants in 100+ countries around the world, RICHI is a reliable feed factory supplier no matter the scale of the plant or the farm. Our feed plant machinery is state-of-the-art equipment for feed mill plants, with our own in-house research and development department ensuring solutions suitable for your specific needs. In RICHI you will find a partner with more than 25+ years of experience, which means we have the knowledge to find the best customized feed production solution for you.Get Price & Support
Richi Machinery is a leading feed plant machinery manufacturer and feed factory project service provider in the whole supply chain of feed production business. RICHI has many years of experience with sales and designing of animal feed plants with capacities ranging from 1 t/h to 100 t/h all over the world - from small farm feed plants to large industrial/commercial feed plants producing feed for poultry, livestock or aquaculture. No matter where in the world and no matter which requirements the customer may have to the new feed factory for animal, RICHI has a matching solution.
RICHI feed factory equipment provides the opportunity of grinding and proportioning feed for various livestock, poultry, aqua, pet, premix, powder, etc. We offer the complete package of equipment and accessories for your animal feed mill factory. On this page, you will find information on RICHI's previous international animal feed factory projects and learn about our feed line process and feed equipment.
Types Of Feed Factory For Sale：
How to start animal feed factory? There are many feed line types we can supply. A feed factory project is not the simple combination of different products, but a whole system with different parts match together. We start with customer's actual feed production demand and take a comprehensive view of the project. We build up the feed manufacturing system, equip with the most suitable feed factory machines, and complete the delivery from consultation, design and operation.
Below we will explain the feed processing methods and the construction of feed factories for 3 most common feed type.
In the long-term natural selection and artificial selection, poultry has developed the characteristics of rapid growth, strong adaptability to life, fast reproduction, wide eating habits, and high feed utilization. According to the physiological characteristics, nutritional requirements and raw material characteristics of poultry feed, combined with engineering construction and production practice experience, we will provide you with excellent poultry feed production technology and engineering design services.
How to start animal feed business for poultry feed? Professional poultry feed plant production technology ensures the freshness of raw materials and the efficient balance of nutrition; excellent equipment and accessories to reduce operating costs, reduce residues and avoid cross-contamination; excellent control technology to achieve production automation, intelligence and traceability, Ensure feed safety. The design of raw material storage, the automatic warehousing of bagged raw materials, the automatic design of small material system, the automatic control of stand-alone equipment, the use of automatic packing and palletizing devices reduce the use of labor.
How to start animal feed production for cattle feed? Based on the physiological characteristics, nutritional requirements and raw material characteristics of ruminants, combined with decades of engineering construction and production practice experience, we will carefully provide you with a system solution for ruminant meals. The professional production process ensures the freshness of raw materials and the efficient balance of nutrition; high-performance equipment and accessories to reduce operating costs, reduce residues and avoid cross-contamination; stable control technology to achieve production automation, intelligence and traceability, ensure cattle feed safety.
Compared with terrestrial animals, aquatic animals are different in terms of living environment, living habits and physiological functions. Aquatic feed has its own particularities:
RICHI always adheres to customer-centric, provides EPC one-stop service, and tailors high-quality pellet production line processing solutions and processing equipment for customers. Whether it is pre-sales, in-sales or after-sales links, we always actively listen to customer needs, combined with the actual feedback from tens of thousands of users at home and abroad, continue to improve and upgrade, develop high-precision products, and sincerely provide customers with professional services.
Our service pursues refinement and standardization. From pre-sale technical consultation to after-sale maintenance, we always put the interests of customers first, and provide customers with meticulous and considerate services.
Richi Machinery has an advanced three-dimensional digital design platform, professional research and development of new products and new processes. RICHI focuses on design and innovation, responds promptly and fully supports your design needs. We do not stop at the boundaries of standardization, and flexibly build a design that suits you.
According to the actual needs of customers, multiple sets of animal feed factory business plans are formulated for comparative analysis, and reasonable plans are selected to realize private customization. Our services run through all aspects of on-site terrain and environment survey, feed production line process design, raw material testing, cost requirement analysis, project investment budget, equipment installation and commissioning.
Richi Machinery, as a trusted partner of feed companies, has always been professionally creating stable and reliable feed production lines for customers, creating value for customers, and contributing to the development of social economy and feed industry in China and the world. All of our feed mill equipment is designed, produced, assembled, and tested in accordance with ISO international quality certification system standards. The sales network covers more than 100 countries and regions around the world.
Feed factory near me:
Are you looking for animal feed factory near me? Whether you are searching for cattle feed factory near me, poultry feed factory near me, fish feed factory near me or chicken feed factory near me, please see below some typical overseas studies done by RICHI List of items and see if there is the country you are looking for.
|Ruminant feed factory in Hong Kong,China||Feed factory Malaysia||Animal feed factory in Singapore|
|Animal feed processing plant Indonesia||Cow feed factory in Afghanistan||Animal feed factory in Philippines|
|Cattle feed manufacturing plant Saudi Arabia||Animal feed factory in Thailand||Cattle feed factory in United States|
|Feed factory in Egypt||Emirates feed factory||Chicken feed manufacturing plant Uzbekistan|
|Animal feed factory Europe||Fish feed factory in UK||Animal food processing plant in Belgium|
|Animal feed factory in Lithuania||Animal feed factory in Netherlands||Animal feed factory in Moldova|
|Animal feed factory in Russia||Animal feed factory in New Zealand||Chicken feed plant in Australia|
|Animal feed factory in Papua New Guinea||Animal feed factory in Salvador||Animal feed factory in Oman|
|Animal feed factory in Palestine||Animal feed factory in Israe||Cattle feed factory in South Africa|
|Feed concentrate factory Kazakhstan||Broiler feed factory in Angola||Feed line poultry farm in Tanzania|
|Animal feed factory in Zimbabwe||Animal feed factory in Kenya||Animal feed factory in Mauritania|
|Animal feed factory in Sudan||Animal feed factory in Algeria||Animal feed factory in Malawi|
|Animal feed processing plant in Ethiopia||Animal feed making plant in Senegal||Animal feed factory in Gambia|
|Animal feed factory in Nigeria||Animal feed factory in Cote d'Ivoire||Dairy feed factory in India|
|Feed mill factory in Burkina Faso||Feed mill factory in Argentina||Fish feed mill factory in Bolivia|
|Animal feed factory in Salvador||Animal feed factory in Colombia||Feed miller factory in Portugal|
|Feed mill factory in France||Fish feed factory in Pakistan||Feed factory in UAE|
|Feed mill factory Qatar||Saudi feed premixes factory||Animal feed factory Turkey|
High-quality feed ingredients, scientific feed formula and processing parameter standards, reasonable processing equipment and technology are the three basic elements to ensure the quality of compound feed. Among them, the first two are mainly participated and determined by the purchasing department, technology department, and quality control department.
The feed factory mainly ensures the reasonable processing and manufacturing of feed ingredients. The cost of raw materials accounts for 70%-85% of the cost of feed, and with the integration of the global economy, the price of raw materials mainly depends on the relationship between supply and demand. Therefore, there is greater uncertainty. With the emphasis and implementation of fine management in feed mills, the competition in cost control capabilities during feed production and processing has gradually highlighted its importance.
The cost of feed factory production and processing refers to the various production expenses incurred by the feed factory for the production of products or the provision of labor services, including various direct material expenses and manufacturing expenses. Direct material costs include raw material expenditures (which can be further divided into raw material consumption and raw material loss), transportation costs, woven bags, labels, and sewing threads.
Manufacturing expenses refer to the various expenses incurred by the feed factory for the organization and management of production, including workshop staff wages, piece-rate wages, welfare fees, labor insurance fees, social insurance fees, depreciation fees, rental fees, environmental protection expenditures, power costs (electricity, Coal expenses, diesel oil), maintenance expenses and other manufacturing expenses (office expenses, travel expenses, reception expenses, daily necessities, etc.).
The purpose of tapping the potential and reducing consumption of the feed factory is mainly to carry out scientific and reasonable cost control for the feed manufacturing process after eliminating the cost of feed raw material consumption, so as to achieve the purpose of reducing the cost of the feed plant production process and creating benefits for the feed enterprise.
1. Electricity bill in feed factory
Electricity costs account for the largest proportion of power costs in feed plants, and crushing is not only a necessary process in feed processing, but also one of the processes with the highest power consumption. The power consumption of the animal feed grinder accounts for about 40% of the total power consumption of the feed factory. The electrical consumption of the feed pellet milling machine accounts for about 30% of the total power consumption of the feed lines. There are three key operating parameters for the feed pellet making machine operation: steam supply, feeding speed, ring die and pressure roller gap. The main methods to reduce the power consumption of the feed factory are:
2. Coal fee in feed factory
Some animal feed factories use natural gas or oil as boiler fuel, and the steam cost of oil-fired gas-fired boilers is more than three times higher than that of coal-fired boilers. When coal-fired boilers are used, animal feed mills can promote the settlement of coal payments based on the amount of steam, rather than the settlement of coal payments by weight. Because it is difficult to ensure the quality of coal by weight settlement, it is easy to adulterate.
When the feed factory promotes the settlement of coal payments based on the amount of steam, it is necessary to pay attention to the amount of steam that is settled every month, because the data of the steam flow meter can be adjusted, and the feed mill factory needs to prevent the boiler workers and coal suppliers from having illegal transfer of benefits. Theoretically speaking, the amount of steam used should be less than 5% of the total amount of granulation..
Feed mill plants also need to regularly check whether the steam pipeline leaks, whether the steam-water separator is working properly, whether the burner is performing maximum efficiency, etc. Special attention should be paid to the quality of coal. The poor quality of coal causes the steam pressure before decompression to not reach 0.6-0.8 MPa, and it is difficult to provide dry saturated steam for the feed pelletizer machine, which affects the pelleting efficiency and pellet quality, and also leads to feed tempering moisture is low, which increases the loss of raw materials.
Regularly check the insulation of steam pipes to minimize heat loss and coal consumption. Feed factories should arrange production reasonably to avoid poor production connection. For example, when the steam reaches the use pressure, the steam-using equipment is not ready; or the steam-using equipment is ready, and the steam fails to meet the requirements for a long time, resulting in a waste of steam and a reduction in production efficiency. In the production arrangement of pellets, it is best to achieve continuous production to avoid waste caused by exhaust and condensate discharge every time the animal feed pelletizing machine is turned on.
3. Reasonable control of parts inventory in animal feed factory
The vulnerable parts directly used in the production of animal feed mill plants include ring dies, press rollers, hammers, screens, hoppers, belts, bearings, motors, sewing machine parts, gears, sprockets, etc. The feed production factory manager should analyze the monthly maintenance expenses, strengthen the management of the whole process of maintenance parts procurement, and focus on:
For example, although the price of stainless steel ring dies with the same compression ratio and the same diameter is much higher than that of alloy steel ring dies, the quality assurance time, service life and wear resistance of stainless steel ring dies are unmatched by alloy steel ring dies, the use cost is lower than the alloy steel ring die.
Even if they are all stainless steel ring dies, the quality varies from manufacturer to manufacturer. According to the calculation of SZLH420 feed pelleting machine stainless steel laminating film 6,500 yuan/piece, if each ring die can produce 16,000 tons, the cost of laminating film is 0.41 yuan/t; if each laminating film can only produce 8,000 tons, then laminating The cost is 0.81 yuan. In addition, it should be noted that frequent film changes will have a serious impact on the time limit and output of the film.
4. Reasonably control maintenance costs in animal feed factory
The reasons for the high maintenance costs: First, they do not pay attention to the restorative maintenance of feed factory equipment and tools, and buy new ones at every turn; Second, the maintenance level is low, resulting in high costs for repeated maintenance, especially the number of medium and large repairs; The loss of repair parts is large, including poor quality of procurement, shoddy parts, lost, stolen, and damaged parts; fourth is the lack of monitoring of the procurement of parts in various feed factories, resulting in high procurement costs.
Fifth is the high cost of maintenance auxiliary materials (steel, steel, etc.) Welding rods, oxygen, acetylene, grinding wheels, cutting saw blades, etc.); Sixth, the preventive maintenance of feed plant equipment is insufficient, resulting in high maintenance costs after the equipment is completely paralyzed. The failure of equipment should be prevention first and repair second. Through sound routine maintenance, the failure rate can be greatly reduced and the normal production can be ensured.
Generally, the wind speed in the cooling duct is controlled at 15-20m/s. In addition, it is easier to control the moisture of the finished material by adjusting the height of the cooling tower material level device. This requires frequent attention to the moisture result of the finished material in the laboratory for timely adjustment.
In addition, an effective means to reduce the loss of raw materials is to monitor and add moisture online during the entire feed factory production process, especially to monitor the moisture of the feed after crushing, mixing, tempering, and the finished material. Under the premise of ensuring safety, the animal feed mixer or the modulation drum implements water addition to reduce the water loss of raw materials.
5. Speed up the upgrading of process equipment in animal feed making plant
With the development of the feed industry, in recent years, the progress of my country's feed processing equipment upgrades has been accelerated, and the degree of specialization of feed produciton equipment has continued to increase. Feed processing equipment manufacturers have introduced new energy-saving and high-efficiency specialized processing equipment to feed factories.
Improving production efficiency, reducing production costs, realizing the stability of product processing quality, and increasing the added value of products have obvious effects. Feed mill plants should actively adopt equipment that can save energy, reduce consumption, and have low operating costs, especially for those animal feed pellet production lines and equipment that have been in operation for many years, with high energy consumption, low production efficiency, and poor safety performance.
When upgrading equipment, try to consider fully implementing automated operations. For example, a 5t/h animal feed line with manual feeding, automatic batching and manual finished product stacking is compared with a 40t/h automatic feeding, automatic batching and mechanized stacking feed line. The latter requires fewer production workers, but the production capacity varies greatly.
Under the premise of producing the same amount of feed, the labor cost of the latter is much lower than that of the former. The reason for the high labor cost is that the feed line production process is limited, the automation and mechanization of the feed production line are low, and more labor has to be used, and the labor intensity of the workers is high, the loading and unloading process costs are high, and the per capita production efficiency is low.
Therefore, the entire feed manufacturing process from the raw materials entering the workshop to the stacking of finished products is fully automated to reduce the scope of manual operations as much as possible, which not only saves labor costs, but also saves time, space, safety and other production costs. More importantly, as long as the equipment is normal, the production volume and quality are stable, while manual operation is affected by human ability and work enthusiasm, and the production volume and quality are unstable.
When conditions permit, it is possible to explore and promote automatic bulk feeding and bulk finished product transportation modes to save labor costs and packaging material costs for feeding, packaging and unloading.
6. Loss of raw materials in feed mill factory
The cost of feed ingredients in a feed factory accounts for about 70-85% of the production cost. Whether the loss of raw materials can be controlled at a reasonable level is an important indicator of the management level of a feed factory. Feed mills need to strictly implement the weighing system and inventory system of raw materials and finished materials, so as to find and analyze the causes of abnormal losses every month (or every half month) in time.
The reasons for the loss of raw materials during feed processing include: dust loss (discharge, crushing and dust removal, cooling and dust removal, equipment and conveying pipelines are not tightly sealed, resulting in material leakage); moisture loss (unloading, storage, crushing, cooling); Error loss (raw material weighing, batching scale, packaging scale, etc.); deterioration and other losses (raw material or finished material deterioration, raw material impurity content, material scale not cleaned up in time, bag broken, rodent damage, stolen, etc.).
Feed plants need to pay great attention to the loss of dust in the form of dust. For example, in some feed plants, corn unloading sheds and soybean meal unloading sheds are sealed on both sides and the roof.
They can be transformed into three sides and roof sealed, leaving only one side to enter and exit the vehicle, so that the air volume of convection is greatly reduced, so that soybean meal and corn Dust settles naturally, reducing the loss of dust blown away by the wind. It is recommended that qualified feed factories choose automatic hydraulic unloading platforms as much as possible to minimize the dust loss during the unloading process of bulk raw materials.
For many feed plants, the water loss during feed processing accounts for more than 50% of the raw material loss. Feed factories should pay close attention to the moisture content in the finished feed. Normal moisture content is an important indicator. Too high moisture content will cause the feed to be easy to mold, and too low moisture will increase the loss of the animal feed factory, and the moisture content is too high. Or too low is not conducive to the palatability of the finished material.
Generally, the temperature of the finished material is not higher than the ambient temperature by 5 degrees, and the moisture is less than 13%. Water loss mainly occurs in the storage, crushing, and cooling links. In the storage link, the feed factory should minimize the stock of raw materials in the summer silo to prevent the high temperature from evaporating a large amount of water.
In the crushing process, excessive crushing should be avoided, the temperature in the crushing chamber should be reduced, the air pressure and suction volume of the pulse fan should be controlled, and the crushing efficiency should be improved to control the water loss of the crushing.
For example, after replacing the animal feed crusher in a feed factory, the crushing efficiency increased by 25%. Calculated based on the 0.5% moisture loss in the normal crushing process, after replacing the crusher, the output will increase by 25%.
It is conservatively estimated that the moisture loss in the crushing process will be reduced by 0.13%. Based on the monthly production of 10,000 tons of finished materials by the animal feed factory (the raw materials to be crushed are calculated at 80%), the loss can be reduced: 10,000 tons * 0.13% * 80% = 10.4 tons, calculated at 3,000 yuan per ton of finished materials, Can reduce the loss of 31,200 yuan. In the feed plant cooling process, the ventilation volume, time, speed, and material level of the cooling tower should be adjusted according to different seasons.
7. Comprehensive consideration of raw material costs and processing and manufacturing costs
Comprehensively consider and balance the relationship between the cost of raw materials and the production cost of the feed factory, which may be an important indicator for evaluating the level of formulation technology. For example, viscous raw materials with a large amount of sugar are cheap, but their processing performance is poor.
Because of their large sugar content, they are easy to stick to the warehouse and equipment, which not only affects the efficiency of mixing. The load becomes heavier, causing problems such as slower removal of the auger at the bottom of the mixer and low production efficiency. In severe cases, the belt of the hoist may break.
For another example, adding multiple liquid ingredients to the same formula will prolong the mixing time, reduce batches of ingredients, and increase production costs; the more complex the composition of the formula, the longer the batching cycle, that is, the lower the production efficiency, and the higher the production cost.
Therefore, the feed factory must communicate with the formulator in time about the processing performance and processing cost of different raw materials. When considering the composition of the formula, the formulator must consider not only the cost of the raw materials, but also the production and processing performance of the feed raw materials.
8. Strengthen the training of employees and cadres in animal feed plants
The quality of the staff in the feed factory determines the cost and quality of the production process in the feed factory. To this end, on the one hand, we should strengthen the training of employees in key technical positions, encourage employees to conduct vocational skills appraisal, encourage employees to participate in various training and learning, and at the same time strengthen safety awareness management to reduce the occurrence of safety accidents. Key positions such as central control, machine repair, electrician, pelletizer, boiler worker, etc.
The level of operation of these personnel directly affects the efficiency of equipment and the cost of feed processing. In terms of salary and treatment, these key technical positions can be appropriately tilted. On the other hand, it is necessary to strengthen the cultivation of employees' loyalty to the company, do a good job in their career planning, stimulate their enthusiasm, initiative and creativity, and formulate incentives for the process of evaluating employees' production costs.
At present, the cost control of feed processing involves feed processing technology, feed plant equipment, electrical and mechanical control, feed nutrition, operation management of the production process, and on-site logistics management.
Not only is the director of the feed factory required to have strong management capabilities, but also the director of the feed factory is required to have comprehensive professional knowledge in order to do a good job in the on-site management, feed equipment management, and quality management of the feed production process, so as to achieve reasonable scheduling of the production process And effective control, so as to control the cost of the production process. To this end, it is necessary to train and become a professional production manager for feed factory directors.
9. Scientific management in animal feed factory
Dirty, messy, and poor are common problems in most animal feed plants. The raw materials in the warehouse are not neatly stacked, the different raw materials are mixed with each other, the raw materials in the inventory are not marked, the raw materials are scattered on the floor, the dripping is serious, and the rodent damage is rampant. There is a lot of garbage in the workshop, raw materials are piled up everywhere, packaging and labels are littered, and recycled materials are everywhere without marking. The ground, feed manufacturing equipment, doors, windows, and roof are all dust and cobwebs.
For this reason, feed mill plants should pay attention to scientific and refined management of daily work on the production site. Only by adopting scientific on-site management methods and grasping the real situation of the site, can it be possible to carry out refined management of the feed factory in a targeted manner and take measures to reduce costs.
The on-site management system of the feed factory includes: quality control system, energy-saving control system, environmental control system, equipment management system, logistics control system, process control system, production operation standardization system, etc.
Commonly used methods of on-site management in feed factories include: 6S management, lean production management, quality cost management (QCM), total production maintenance management (TPM), ISO14000, ISO18000, etc., which can be cross-used in the process of production management These management methods continuously implement the standardization, standardization and institutionalization of production process management.
For each cost control point, come up with a specific implementation plan, and through PDCA (plan, implement, check, improve) and SCDA (standardize, implement, check, improve) circular operation to achieve gradual improvement and continuous reduction the cost of the feed factory manufacturing process.
10. Control safety costs in animal feed company
If the feed factory does not have a strong awareness of safety management, there are hidden safety hazards at the production site, which will lead to many safety accidents and high safety costs. Therefore, the feed factory must do a good job in the prevention of fire safety, fire prevention, dust explosion prevention, equipment damage and personal safety problems.
Feed plants can save energy and reduce consumption through formula design and raw material procurement, such as the following two points:
(1) According to the maximum power load of the feed factory, the variability and relative independence of the power load of different workshops, the number and capacity of transformers should be reasonably determined. For feed companies with obvious off-peak seasons, two transformers can be installed, two transformers or the larger one in the peak season, and one or the smaller one in the off-season. This can greatly save basic electricity costs and reduce transformer losses.
(2) Reasonably design and use reactive power compensation equipment to prevent the power supply bureau from charging reactive power compensation fees and overcompensation.
(3) Use frequency converter to drive some equipment that requires more than one operating speed.
(4) Putting the transformer close to the power consumption center can reduce the power loss of the line and the investment of the wire.
(5) Choose appropriate lighting brightness and energy-saving lamps in the design.
(6) Reasonably adopt automatic control system to reduce the cost and unreliability of manual control.
(7) In the design, the horizontal conveying distance of materials should be minimized, and gravity should be used as much as possible to realize the flow of materials and reduce the use of power.
(8) Low energy consumption equipment should be selected in the design. For example, the belt conveyor in the horizontal conveying equipment has the lowest energy consumption, followed by the scraper conveyor and the screw conveyor. The bucket elevator in the vertical conveying equipment has the lowest power consumption, and the pneumatic conveying equipment has the lowest energy consumption.
The highest power consumption; among the crushing equipment, the new feed hammer mill and the new micro-pulverizer have lower energy consumption per unit; among the mixers, the new single-shaft and double-shaft paddle mixers have lower unit energy consumption; granulation among the equipment, the feed pellet making machine equipped with the new conditioner will have lower electricity consumption per unit production and the countercurrent cooler will have lower electricity consumption per unit production; among the extrusion extruders, the electricity consumption per unit production of the wet extrusion extruder will be low.
(9) In the design, the correct process combination should be carried out, and reasonable auxiliary equipment should be equipped to ensure the high efficiency of the production system and the reduction of energy consumption. For example, the reasonable design of the suction system of the animal feed grinder in the crushing system, the design of the cooling air network in the granulation system, etc., the output matching of different equipment in the same section and the mutual matching between different sections must be reasonable to ensure stable and efficient production.
(10) Scientifically design steam production system. In feed processing, the production of steam is the main energy consumption in addition to electricity in the feed factory. First of all, it is necessary to reasonably determine the maximum amount of steam used, and then determine the rated steam output of the boiler. Second, the appropriate fuel and boiler form should be selected according to the characteristics of different regions and the supply and price of fuel to reduce the cost of steam production. At present, the main fuels used in China are coal, oil and natural gas. In the future, other fuels may also be used.
Third, it is necessary to rationally design the steam pipeline, and to meet the requirements of steam supply, use excellent steam control instruments and valves to reduce the heat loss of steam.
Fourth, it is necessary to insulate the steam pipeline to reduce heat loss. Fifth, it is necessary to reasonably recover the available heat, such as the recovery of condensed water and the recovery of heat in the flue gas. The boiler room should be as close as possible to the main steam-using equipment to reduce the length of the steam pipeline. Conduct insulation, reduce heat loss.
(11) Scientifically design the compressed air system. First, the amount and pressure of compressed air should be reasonably determined, and high-performance compressed air equipment and control instruments should be selected. Second, the size of the compressed air pipeline should be correctly determined.
The processing of compound feed is the key to ensuring the performance of feed products and the economy of the animal feed factory. With advanced equipment and good processing technology, it not only saves manpower and material resources, but also obtains excellent products. Therefore, monitoring the quality of each process in the production process plays an important role in the quality control of compound feed products.
In addition, measuring ingredients in strict accordance with the requirements of the feed formula to ensure the normal progress of the entire feed plant manufacturing process is the focus of the quality control of the compound feed production process. The following is an overview of the quality control in each processing process of compound feed, in order to provide a theoretical reference for its large-scale and specialized production.
(1) Quality control of raw material cleaning in feed factory
The main raw materials and auxiliary materials should be cleaned and iron-removed. Organic impurities should not exceed 50mg/kg, the diameter should not exceed 10mm, magnetic impurities should not exceed 50mg/kg, and the diameter should not exceed 2mm. In order to ensure safety, the feeding pit should be Equipped with a grid sieve with a bar spacing of 30 to 40mm to remove impurities.
Before the feed material is crushed or the powder is pelletized, the process of removing impurities and iron should also be carried out. In addition, the staff should regularly check the working conditions of the cleaning equipment and magnetic separation equipment to see if there is any damage or plugging, etc., and regularly clean up the residual materials of various mechanical equipment.
（2）Quality control of raw material crushing in feed factory
The crushing process of feed mainly controls the crushing particle size and its uniformity. Too large or too small feed particles will lead to the occurrence of feed segregation, thereby destroying the uniformity of feed products.
Each type of livestock and poultry has a suitable feed size range, such as the compound feed for piglets, growing and finishing pigs, and the pre-compound feed for broilers, and the compound feed for laying-back chickens (pre-phase). 99% of the compound feed passes through the 2.8mm woven sieve, and there must be no whole grains. Grains, the 1.4mm woven sieve is not more than 15%. The operator of the animal feed grinding machine should always pay attention to the crushing capacity of the crusher and the particle size of the material discharged from the animal feed hammer mill crusher.
One of the reasons for the abnormal crushing capacity of the animal feed crusher (the current of the crusher is too small) is that the screen of the crusher has been leaked and the particle size of the material is too high. If there are whole grains or the grain size is too coarse, the machine should be shut down in time to check whether there are holes in the grinder screen or the gap between the screen and the side baffle is formed. Secondly, check the pulverizer frequently for heat generation.
If there is heat, eliminate the material blocking of the pulverizer in time and observe whether the current of the pulverizer is overloaded. Finally, check whether the hammer of the crusher is worn or not, and check the screen for leaks, leaks and misalignment every shift.
(3) Quality control of ingredients in feed factory
①Raw material metering and batching in feed factory
According to the technological requirements of compound feed production, there are currently two main methods of metering and batching. One is to meter the raw materials without crushing. This method is to perform metering and compounding according to the requirements of the formula before the raw materials are crushed. Good raw materials are crushed, mixed and granulated.
The advantage of this process is that it is more convenient to pulverize, and the same raw material only needs to be stored in one place, which saves feed storage space. The disadvantage is that there is a large error between the compound feed product produced and the formula. The higher the moisture content of the raw material, the greater the weight loss after crushing, which not only affects its absolute proportion in the formula, but also affects the relative proportion of the entire mix and other raw materials..
A better way to overcome this shortcoming is to increase the insurance coefficient of feed measurement. Generally, the loss in the processing process can be considered at 5% to 10%. For feed with higher water content and larger raw material particle size, the insurance ratio can be appropriately increased. The second method of batching is to smash the raw materials to measure the batching, that is, the raw materials are firstly pulverized according to a uniform specification and then stored separately, and then the pulverized raw materials are metered and matched according to the requirements of the formula, and the mixing and granulating processes are directly carried out after being matched.
The process error is relatively small, but the storage space is increased. A raw material must be stored in at least two places. Medium and large-scale compound feed production is generally produced in this way. The measurement is relatively accurate, and the compounding error is relatively small. The measurement is based on the formula requirements. With cooperation, it is easy to achieve the nutritional quality required by the feed making formula.
②Measurement of trace components in feed factory
The compounding and measuring of micro-components is complicated and error-prone. In compound feed, such components mainly include vitamins, trace elements, non-nutritive additives, calcium, phosphorus, and salt, etc. The metering and compounding of these components should be done in accordance with the mixer once. Mix the amount, calculate the amount that all the micro feed should be added, and then divide it into several parts and concentrate them separately.
For example, all added vitamins are grouped together as one part, trace elements, calcium, phosphorus and table salt are grouped together as one part, and non-nutritive additives are grouped together as one part, or only two parts, one part is mineral, the other part of the feed is other trace feed ingredients, including synthetic amino acids.
After preparation, add the prepared micro-ingredients in each batch according to the requirements and make a record. In order to reduce the loss of micro-ingredients, the mineral element part is added to the animal feed mixing machine at the end. Other micro-elements should not be added at the same time as the mineral elements. Use energy feed or protein feed to separate into the mixer. Do not directly contact the wall of the mixer. After all the premixed parts of the compound feed are added to the animal feed mixer, start mixing.
(4) Quality control of mixing in feed factory
The quality control of feed mixing is closely related to the correct operation of the mixing process. During feed plant production, attention should be paid to the order of addition of raw materials. Generally, the larger amount of raw materials should be added first, and the smaller amount of raw materials should be added later, such as vitamins in the premix, trace elements and drugs.
When adding oil and other liquid raw materials, spray it from the nozzle on the upper part of the feed mixer machine, and spray it in mist as much as possible to prevent the feed from clumping or forming small balls. Before the liquid raw materials are added, all the dry raw materials must be mixed uniformly, and the mixing time shall be extended accordingly.
The remaining materials in the mixer should be cleaned up when changing the variety. The best mixing time depends on the type of the mixer and the nature of the raw materials. Generally, the mixer manufacturer provides a reasonable mixing time. If the mixing time is not enough, the mixing will be uneven. If the time is too long, it will cause separation due to excessive mixing.
Attention should be paid to the control points of mixing. When mixing, you must choose a suitable mixer. Generally, the ribbon mixer is used more. This model has higher production efficiency and fast discharge speed. Although the cone planetary mixer is expensive, the equipment performance is good, and the material residue is small, the mixing uniformity is high, and liquid raw materials such as grease can be added.
It is a more suitable pre-mixing equipment. The uniformity of mixing and the best mixing time should be checked regularly. Too long or too short will affect the uniformity of the material mixing, and the gap between the ribbon and the bottom shell should be adjusted in time, and the mixer should be maintained and repaired regularly to eliminate material leakage and clean up residues.
When changing the formula, the animal feed mixer equipment must be thoroughly cleaned to prevent cross contamination. The medicated feed that is cleaned is usually buried deep or burned, and the recovered material from the vacuum cleaner must not be directly sent to the mixer, and then processed after the components are tested.
The pre-mixing operation should be separated from the main mixing operation to avoid cross-contamination. The conveying distance of the finished product should be minimized to prevent feed grading. After the pre-mixed feed is mixed, it is best to bag directly.
(5) Quality control of product forming in feed factory
The productivity and quality of the formed feed are not only related to the performance of the animal feed pellet forming equipment, but to a large extent depend on the performance of the raw material forming and the quenching and tempering process. The granulation process conditions are based on the physical and chemical properties of the main raw materials in the feed formula and the granulation performance of the diet.
It mainly includes the conditioning of the materials for forming, that is, the steam pressure, temperature, moisture, and conditioning time. The pelleting quality includes feed forming quality and nutritional quality.
The feed mill pelleting process includes cold pressing pelleting and steam hot pressing pelleting. For suckling pig and piglet feed, hot pressing pelleting is better, and the technical process required for hot pressing pelleting is more complicated.
Not only proper mechanical equipment is required, but also proper steam quality, that is, the proper interaction between steam, feed and machinery, can produce high-quality hot-pressed pellets. Control the appropriate steam pressure, temperature in the conditioner (about 80℃) and tempering time (usually about half a minute, if necessary, double conditioners can be used to ensure the quality of tempering) and pelleting speed to obtain high-quality pellets.
During the animal feed plant pelletizing process, attention should be paid to the inspection and maintenance of the animal feed pellet making equipment. The magnets on the animal feed pellet mill granulator should be cleaned every shift, iron slag should be removed, the wear of the die and roller, and the cooler should be checked for material accumulation, and the crusher should be checked regularly the wear of roller teeth and cutters and the working condition of the steam trap are to ensure the quality of steam entering the conditioner, and check the screen surface of the grading screen for damage, blockage and adhesion every shift to ensure the grading effect.
The conditioning treatment before pelleting has a great impact on improving the pelleting performance and pellet forming rate of the feed. Generally, the conditioning time is 10-20s. Extending the conditioning time can improve the conditioning effect.
In addition, it is necessary to control the steam pressure and the condensed water content in the steam. After conditioning, the moisture content of the feed is 16%-18%, the temperature is 68-82℃, and the pressure roller is adjusted to when the pressure mold rotates at a low speed. Only touch the high point position of the die, which can minimize the mutual contact and reduce wear.
(6) Packaging quality management in feed factory
The staff should check in advance whether the packaging scale is working properly, the set weight should be consistent with the required weight of the packaging, the error should be controlled within 1% to 2%, and the packaged feed and packaging bags and feed labels should be checked for correctness. Packers must pay attention to the appearance of the feed at any time, and deal with any abnormalities in time to ensure the quality of the seam bag, and no seams or drops.
The key to quality management lies in the management of personnel. Qualified quality controllers must be familiar with the animal feed production process, and should be regular in the operation of feed equipment.
Equipment failures affecting quality and incorrect operations that violate operating procedures should be pointed out in time. Every day, check whether the theoretical amount of additive inventory is consistent with the actual amount, read the records carefully, calibrate the measuring instruments, and ask the statutory metrology department to repair and calibrate the measuring instruments every year, and know the feed factory production plan, and follow the production plan with the warehouse. Whether the inventory monitoring production plan is reasonable or not.
It is necessary to check whether additives are invalid due to too long inventory. Manual addition ports should be checked frequently to prevent less, more or accidental additions of additives, grease, whey powder, etc., and the mixer should be adjusted every quarter to ensure that the feed mixer's Mixing uniformity (CV) 5%. It is necessary to regularly supervise the workshop, and regularly clean up the mixer, pit, cellar, silo, buffer bin, granulating system and packaging system, especially the conditioner, feeder, exhaust pipe and air shutoff of the granulating system After cleaning, spray anti-chemical drugs.
The anti-chemical drugs must be harmless to humans and animals and have very few residues. In addition, pay attention to check whether the crushing particle size meets the requirements of the finished product, whether the grinder screen is broken, whether the granulating system is blocked, whether the exhaust pipe is broken, whether the granulating parameters are proper, whether the granulating effect meets the requirements, etc.
In animal feed factory production, it is necessary to select appropriate mechanical equipment and excellent technology, measure ingredients in accordance with the requirements of the feed formula, strictly grasp the key elements of each link, follow regulatory management, and pay attention to social and economic benefits to ensure the processing quality of finished feed products.
Richi Machinery is a professional manufacturing enterprise integrating scientific research and development, manufacturing, sales and service. We have developed and manufactured multifunctional pelletizers, grinders, mixers, dryers and more than ten categories and more than 30 models of complete machine products are widely used in feed, biomass, organic fertilizer, pet supplies, solid waste recycling, chemical industry, road construction and other fields. All RICHI products have passed ISO9001:2008 international quality system certification, EU CE certification and Customs Union CU-TR certification, successfully serving more than 2,000 customers in more than 100 countries and regions around the world.Get Price & Service
In RICHI, every equipment and every pellet production line business plant can be customized. We will formulate multiple sets of pellet production process plans for comparative analysis according to the actual needs of customers, select a reasonable plan, and realize private customization. Our services run through all aspects of on-site terrain and environment survey, production line process design, raw material testing, cost requirement analysis, project investment budget, equipment installation and commissioning.
We adhere to the ISO9001 quality management system, and strictly implement international standards for product design and manufacturing processes. In terms of management systems, there are product quality accountability systems, product quality accountability systems, and safety production management systems; in terms of management tools, QC quality control management, SPC statistical process control, sampling inspection and measurement system analysis are used for quality control, to achieve effective control of the entire process of equipment production, and never let go of any quality hidden dangers that may affect customer operations.Get Price & Service
RICHI has always been adhering to the spirit of craftsmanship to make every detail good, especially in the link of equipment preparation and delivery, we follow the standardized process: preparation order check-equipment factory quality inspection-packing list re-inspection-scientific packaging and transportation, ensure the safe and non-destructive delivery of equipment. According to customer needs, RICHI installation engineers will guide the construction of site infrastructure, equipment installation and commissioning and trial operation of the entire production line throughout the process. When the relevant project indicators reach the design standards, the client will carry out the project acceptance.
We have built a team of nearly 100 technical engineers to solve a series of problems in the project from consultation, site survey, sample analysis to plan design, installation and commissioning, and maintenance. We provide comprehensive and systematic training for the technical staff of each customer to better serve the customer's project needs. After the technicians have finished their studies, RICHI will provide follow-up technical support services, and the training engineers will follow up the project use effects in the later stage to ensure the stable operation of the customer's project.Get Price & Service