5T/H Ruminant Feed Alfalfa Pellet Plant in Mexico

Client Background: A Family-Owned Dairy Enterprise Goes Industrial

The client in this This is a project about an alfalfa pellet plant in Mexico. case was a second-generation family-owned dairy farm located in the Bajío region—often referred to as the "breadbasket of Mexico" for its fertile soils and strong agricultural base. Unlike the cooperative case we examined earlier, this client operated independently, with a herd of over 1,200 dairy cows and an expanding presence in cheese and milk distribution.

Their challenge was straightforward but critical: fresh forage management was consuming too many resources. Alfalfa bales and silage were costly to transport, prone to spoilage, and inconsistent in nutritional value. With growing herd sizes, the farm required a stable, standardized, and storable form of feed to maintain consistent milk yields throughout the year.

When they approached RICHI Machinery, their request was precise:

“We need a pelletizing plant that can handle at least 5 tons per hour, specifically for ruminant feed, using our alfalfa production and by-products from our farm.”

Unlike the smaller-scale cooperative that had to scale back ambitions due to budget, this client had secured financing that allowed them to aim directly for a medium-scale industrial facility.

Raw Materials and Formula: Balancing Costs and Nutrition

In Mexico, alfalfa remains a cornerstone forage crop for dairy and beef cattle. However, pure alfalfa pellets can sometimes be too costly, especially when energy and fiber balance must be considered. This client opted for a balanced formulation that reduced costs while maintaining high digestibility.

The final feedstock mix agreed upon was:

• 70% alfalfa hay (bales, irrigated production)
• 20% corn stalks and husks (residues from the farm’s own maize production)
• 10% wheat bran and cottonseed meal (purchased from nearby suppliers)

This combination achieved several objectives:

• Alfalfa provided high protein and digestibility.
• Maize residues reduced raw material costs while improving fiber.
• Wheat bran and cottonseed meal enhanced energy and boosted pellet durability.

By leveraging their own crop residues, the client significantly lowered dependence on external forage purchases.

Production Process: Ruminant-Focused Pelletizing Technology

A 5t/h alfalfa pellet plant in Mexico requires a careful balance between throughput and flexibility. Unlike poultry feed, which requires finer grinding and strict nutrient precision, ruminant feed pellets prioritize fiber length, density, and digestibility. RICHI Machinery engineers customized the line with these factors in mind.

The process flow included:

1. Bale Breaking and Pre-Chopping
   Large alfalfa bales (450–600 kg) were first broken apart by an automatic bale breaker.
   Pre-choppers cut hay into lengths of 30–50 mm, suitable for grinding.
2. Grinding
   A high-capacity alfalfa hammer mill reduced material size to 6–8 mm—coarser than poultry feed—to maintain fiber structure beneficial for rumen function.
3. Mixing
   Corn stalks, bran, and cottonseed meal were added into a 3-ton horizontal paddle mixer.
   Uniform mixing ensured every pellet carried the right balance of protein, fiber, and energy.
4. Conditioning & Pelletizing
   A RICHI CZLH678 alfalfa pellet making machine was selected, capable of 5t/h throughput.
   Steam conditioning softened fibers, enhancing pellet binding and digestibility.
   Pellets of 8mm and 10mm diameters were produced, suitable for dairy cows.
5. Cooling & Screening
   Counterflow cooling reduced pellets from ~75°C to ambient temperature.
   Screens separated fines, which were recycled.
6. Bagging & Bulk Storage
   Pellets were bagged into 50 kg sacks for external sales.
   Bulk storage silos were also included for direct farm feeding.

This setup allowed the client to simultaneously serve their herd and sell surplus production to neighboring dairy and beef farms.

Main Equipment Supplied by RICHI Machinery

To meet the 5t/h target, the equipment list of alfalfa pellet plant in Mexico was significantly larger than the 1–2t/h project:

• Automatic bale breaker with conveyor system
• High-capacity pre-chopper for alfalfa bales
• hammer mill with dust collection
• horizontal paddle mixer
• RICHI CZLH678 grass pellet machine (rated for 5t/h alfalfa pellets)
• Counterflow cooler
• Rotary screener
• Semi-automatic bagging system with scale and sealer
• Bulk storage silos
• Electrical control system with touch-screen operation

The design allowed for modular expansion. Should the client wish to double capacity in the future, a second alfalfa-based ruminant feed pellet machine could be added without re-engineering the entire facility.

Investment and Cost Efficiency

The total project investment amounted to USD 160,000. While this was more than double the smaller 1–2t/h alfalfa pellet production line, it offered significantly better economies of scale.

With average alfalfa pellet market prices in Mexico ranging from USD 210–250 per ton, the client projected payback within 18–24 months, thanks to:

• Reduced spoilage of fresh forage
• Lower transportation costs (pellets are 3–4 times denser than baled hay)
• Sales of surplus pellets to regional farms
• Market Potential: Ruminant Pellets in Mexico’s Dairy Belt

The Bajío region, covering Guanajuato, Querétaro, and Michoacán, is Mexico’s dairy powerhouse. With hundreds of medium to large-scale dairy farms, the demand for consistent, easy-to-handle forage pellets is strong.

The advantages of alfalfa pellets for this market include:

• Uniform quality, reducing feed formulation risks.
• Lower storage requirements, freeing up space for other operations.
• Flexibility for both small and large farmers, since pellets can be used on farms without advanced feed handling infrastructure.

The client positioned themselves as both a producer-consumer (using pellets internally) and a regional supplier, capturing two revenue streams simultaneously.

RICHI's Services: Partnering Beyond Machinery

What distinguished RICHI Machinery in this alfalfa pellet plant in Mexico project was not only the quality of equipment but also the comprehensive services provided.

• Customized Plant Layout: Engineers visited the farm and designed a ruminant feed production line that integrated with existing buildings, avoiding costly new construction.
• Nutrition Guidance: RICHI's feed experts helped refine the 70/20/10 raw material formula, ensuring optimal ruminant performance.
• Training in Spanish: Operators received on-site instruction in their local language, ensuring rapid skill acquisition.
• Remote Monitoring: A digital control system allowed RICHI’s technical team to provide remote troubleshooting if needed.

This approach gave the family enterprise not just machines, but the confidence to run them efficiently and profitably.

Broader Impacts on Mexican Agriculture

The success of this 5t/h alfalfa pellet production line project highlights a critical point in Mexico's feed industry: medium-scale facilities are the bridge between small cooperatives and industrial giants. They allow family farms to:

• Achieve independence from external feed suppliers
• Create new income by selling pellets
• Strengthen their competitiveness in domestic and export dairy markets

In the bigger picture, such projects contribute to Mexico’s food security and its ability to compete internationally in beef and dairy exports.

Customer Testimonial

At the official launch, the client’s managing director summarized their experience:

“For years, we depended on fresh alfalfa and silage, but we were always vulnerable to seasonal shortages and price fluctuations. With this new pellet line from RICHI, we now have control over our feed supply. Not only do our cows receive consistent nutrition, but we also generate new income by selling to our neighbors. The professionalism of RICHI’s team—from design to training—was exceptional. This plant is more than an investment; it is the future of our farm.”

The 5t/h ruminant feed alfalfa pellet plant in Mexico represents a bold step for a mid-sized dairy enterprise ready to professionalize its feed operations. With USD 160,000 investment, the client gained a system that combined cost efficiency, nutritional stability, and market opportunities.

For RICHI Machinery, it was another chance to demonstrate that professional feed solutions are not one-size-fits-all. Whether for a cooperative starting small or a family farm scaling up, the key is to tailor technology to the client’s specific realities.

This case reinforces RICHI’s role not just as a machine supplier, but as a long-term partner in agricultural development across Latin America.