400,000T/A Large Multifunctional Animal Feed Production Line In Brazil

（This is a large scale multifunctional animal feed production line in Brazil project for a Chinese customer to invest in and build a feed factory in Brazil. This feed factory can process 30t/h compound feed, 20t/h cattle and sheep concentrate feed, 20t/h concentrated feed, and 8t/h premix. Due to the large amount of investment, the project will be divided into multiple phases of construction.）

The customer of this multifunctional animal feed mill in Brazil project is a high-tech enterprise integrating feed research and development, production, sales and service. It is committed to providing high-quality, pollution-free products to the majority of livestock farmers. This customer's technology has built a production line with an annual output of 10,000 tons of feed.

At present, the feed market has good prospects and huge demand. The original animal feed production line can no longer meet the market demand. In order to adapt to the market, the client company decided to invest $8 million in the construction of a "feed production line technical transformation project" after sufficient inspection and research.

It mainly including: new dormitory building, new warehouse, adjustment of the original production workshop, technical transformation of the original production line and expansion of production capacity:

• The two production lines of raw livestock and poultry compound feed and concentrated feed (10,000 tons/a) will undergo technical transformation and capacity expansion, and the premix workshop will be used as an independent production line after capacity expansion;
• Added 2 new cattle and sheep feed production lines in the middle of the factory, 4 new high-end feed production lines (2 cattle and sheep feeds, 2 livestock and poultry feeds) on the east and north side of the factory, and added a fermented feed addition process.

The main products of the existing project are concentrated feed and compound feed (capacity: 10,000 t/a). After the expansion, the main products are concentrated feed, compound feed, premix and concentrate supplement (capacity: 400,000 t/a). , product plans are detailed in the table below.

After the reconstruction and expansion, the number of people in the entire multifunctional animal feed production line in Brazil project has increased to 50. The specific labor quota and work system are detailed in the table below:

This reconstruction and expansion of multifunctional animal feed production line in Brazil is carried out in the existing factory area.

The contents of the reconstruction and expansion include the technical transformation and capacity expansion of the original production line, the addition of 1 premix line, 2 new cattle and sheep feed production lines in the middle of the factory, and 2 new production lines on the east and north side of the factory.

2 Livestock and poultry feed production lines, 2 cattle and sheep production lines, including equipment replacement in the premix workshop; new fermentation feed technology; 2 new 2t/h gas boilers, 2 900t/seat silos; and a new dormitory building.

• Premix room (Workshop #1): Located on the southwest side of the factory building, covering an area of about 70m2, including 1 premix feed line, the mixer will be replaced to expand capacity (capacity: 15-60t/h).
• Production workshop (Workshop 2#): Located next to the premix room, it covers an area of about 110m2 and has 2 production lines for livestock and poultry feed. The equipment remains unchanged, and the capacity is expanded through debugging and increasing working hours.
• Production workshop (Workshop 3#): Located next to the livestock and poultry feed workshop, it covers an area of 110m2 and has 2 new production lines for cattle and sheep feed.
• Production workshop (Workshop 4#): located on the northeast side of the existing factory building (3200m2), covering an area of 450m2, with 2 new livestock and poultry feed production lines and 2 cattle and sheep feed production lines.
• Fermentation room: Located on the north side of the factory, the raw material warehouse is transformed into a fermentation room.

• Raw material warehouse: 1, a single-story building with a height of 8.2m and a construction area of 625m2. It is located on the north side of the factory and is used for raw material stacking.
• Finished product warehouse: 1, a single-story building with a height of 8.2m and a construction area of 1224m2. It is located on the south side of the factory building and is used for stacking finished products.
• Raw material silos: two 900t silos (sharing a pulse dust collector), located on the west side outside the factory building.

Boiler room: Located on the northwest side of the factory building, there are currently two 1t/h gas steam generators and two new 2t/h gas boilers.

• Office and laboratory: 1 building. The original laboratory will be demolished and a comprehensive office building will be built on the site to be used as office and laboratory. It is located on the north side of the factory area. The building covers an area of about 800m2.
• Dormitory building: 1 building. The existing dormitories in the factory area will be demolished and a new dormitory building will be built on the southwest side of the factory building with a construction area of about 800m2.
• Canteen: The original factory office is used and renovated as a canteen. It is located on the northwest side of the factory and covers an area of about 200m2.

The main raw and auxiliary materials usage and energy consumption of this multifunctional animal feed production line in Brazil project are shown in the table below:

The characteristics of the raw materials used in this multifunctional animal feed production line in Brazil project are as follows:

• Corn: a crop containing 8.5% protein, 4.3% fat, 73.2% sugar, 0.022% calcium, 21% phosphorus, 0.0016% iron, and also contains carotene, vitamins B1, B2, niacin, sitosterol, Lecithin, vitamin E, lysine, etc.
• Soybean meal: It is a by-product obtained after extracting soybean oil from soybeans. Its main components are: protein 40% to 48%, lysine 2.5% to 3.0%, tryptophan 0.6% to 0.7%, and methionine 0.5% to 0.7%.
• Wheat bran: It is the outermost skin of wheat. After wheat is processed by a flour mill, it becomes flour and bran. Wheat bran is the outer skin of wheat and is mostly used as feed.
• Wheat middlings: It is a by-product of wheat processing. It is mainly composed of fine bran crumbs and part of wheat endosperm. The protein content accounts for about 12.5%-17%. It contains 13 essential amino acids required for the growth of livestock and poultry. It is mainly used for feed.
• Calcium hydrogen phosphate: used as a food and feed additive to supplement the phosphorus and calcium elements in livestock feed.
• Stone powder: Feed-grade stone powder made from limestone, marble, and calcite as raw materials and crushed and processed as a calcium supplement in feed processing.
• 70% Lysine: It is an essential amino acid for mammals. Its content is low in cereals. It is an organic compound containing basic amino acids.
• Threonine: In biochemistry, it is a glycogenic and ketogenic amino acid, which has strong advantages as a feed additive.
• Choline: Added to feed to reduce the incidence of fatty liver in laying hens, promote growth, increase lean meat rate, and prevent tendinitis.
• Copper sulfate: Copper sulfate pentahydrate is a trace element that promotes growth. High content of copper in feed can make animal fur shiny and accelerate growth. Copper is one of the essential trace elements for animals. It plays an important role in the metabolic process of the animal body and participates in the metabolic process of the animal body. Once lacking, it will cause a variety of diseases. Copper sulfate should be supplemented in the feed for a long time.
• Bacteria: Contains a variety of microorganisms and complex enzymes, which can ferment feeds. Its function is to make up for the amino acids that are easily lacking in conventional feeds, and can quickly transform the nutrients of other roughage raw materials to enhance digestion, absorption and utilization.
• Soybean oil: It is an oil extracted from soybeans. It is light yellow. High-quality soybean oil with a temperature below zero degrees Celsius will have oil crystallization. Adding soybean oil to feed can improve feed palatability, provide animals with essential unsaturated fatty acids, reduce dust in production and feeding, and make the pelleting effect better.
• Molasses: It is a viscous, dark brown, semi-liquid object, mainly containing sucrose. Adding it to the feed can effectively improve the palatability of the feed, increase the water retention rate, optimize the growth and metabolism of rumen microbiota, and stimulate the digestion capacity of the rumen.

The existing project has 2 feed production lines, which produce livestock and poultry compound feeds and concentrated feeds. After technical transformation and capacity expansion, the premix production process that was originally part of the feed production line will be used as a separate production line, and 2 additional lines will be added to only produce cattle and sheep.

Once completed, the multifunctional animal feed production line in Brazil will produce compound feed, concentrate supplements, concentrated feeds and premixes; four more production lines will be added to produce compound feeds, concentrate supplements and concentrated feeds.

To expand the capacity of the original two production lines, it is only necessary to debug the equipment to the maximum processing capacity and increase the equipment running time, without adding new equipment.

As can be seen from the above table, after replacing the feed mixer, the production capacity of the twin-shaft paddle mixer is 240-960t/d, and the annual production capacity is 72,000-288,000t/a, which can fully meet the 58,000t premix for this multifunctional animal feed production line in Brazil project. /a capacity requirements.

The original livestock and poultry feed workshop equipment is reused, and capacity is expanded only through equipment debugging and increasing working hours.

The water used in this multifunctional animal feed production line in Brazil project mainly includes productive water and domestic water.

• Production water: boiler replenishment and cleaning water use groundwater, fermentation water, pure water preparation water, and spray tower water use tap water.
• Domestic water: This multifunctional animal feed making line in Brazil project has a staff canteen and accommodation building. Domestic water comes from tap water and is mainly used for employees' daily life and canteen water.

A rainwater and sewage diversion system is implemented in the project plant area. The multifunctional animal feed production plant in Brazil project wastewater is mainly domestic sewage, canteen wastewater, concentrated water generated from pure water preparation, boiler wastewater, and initial rainwater.

The canteen wastewater is treated in the grease trap and discharged into the factory septic tank together with domestic sewage. After being treated in the septic tank, it is used for greening and surrounding agricultural fertilizers. The water discharged from the spray tower is reused in the feed fermentation production process.

Before reconstruction and expansion: Boiler wastewater and concentrated water generated from pure water preparation were discharged into the septic tank in the factory area, and initial rainwater was discharged into the local river.

After reconstruction and expansion: Boiler wastewater and concentrated water generated from pure water preparation are discharged into the factory sedimentation tank. Initial rainwater is collected into the rainwater tank. After sedimentation treatment, it is used for greening around the factory area and is not discharged outside.

The power supply of the multifunctional animal feed production line in Brazil project relies on the existing power grid in the factory area and is supplied by the municipal government.

This multifunctional animal feed plant in Brazil project is equipped with fire extinguishers, fire hydrants and other fire-fighting equipment in accordance with the relevant requirements in the "Code for Fire Protection Design of Buildings".

There is a ring road around the workshop of this large Brazil animal feed mill plant project, convenient transportation and convenient transportation. Farmers and farmland are mainly on both sides of the transportation road. The raw materials and products of this project are transported in bags, and the amount of dust generated is very small.

This multifunctional animal feed production line in Brazil project has a laboratory set up in the factory, which is mainly used to detect the moisture, ash, crude protein, particle size, pH, vitamins, trace element content, etc. of feed products.

The reagents used mainly include sulfuric acid, sodium hydroxide, copper sulfate, potassium sulfate, selenium powder, boric acid, pH mixed indicator, sodium acetate, potassium chloride, potassium ferricyanide, glacial acetic acid, amylase, etc.

Solid waste such as testing waste liquid and cleaning waste liquid, disposable experimental supplies, waste packaging materials generated by the laboratory shall be collected in a classified manner and handed over to units with hazardous waste disposal qualifications for processing.

This reconstruction and expansion includes the expansion of the production capacity of the multifunctional animal feed manufacturing plant in Brazil project's raw livestock and poultry feed production line. The premix production process, which was originally only for the company's additive use, has become a new production line after technical transformation and expansion.

The products are not only used for the company's production of compound feed and concentrated feed. It is also sold externally.

A separate cattle and sheep feed production workshop #3 has been added, containing 2 production lines; a new workshop 4# has been added, containing 4 high-end livestock and poultry/cattle and sheep feed plants, and a new fermentation process (only a small amount of production, used to add to compound feed and concentrated feed to improve product quality), the specific process flow and pollution generation links are as follows.

The premix feed production process introduction:

01

Feeding

Pre-mix the raw materials with a proportion of less than 0.2% in the production formula, mix them evenly, package them, and label them for later use. The whole package of raw materials and the weighed fractional raw materials are manually fed to the feeding port.

02

Mixing

All materials enter the twin-shaft paddle mixer, mix for 90-120 seconds and then put the materials into the finished product hopper. The double-shaft paddle mixer is mainly composed of a body, a rotor, a discharging mechanism, a transmission part and a control part.

When working, the material is affected by two oppositely rotating rotor blades and undergoes multiple compound movements in the machine tank. The mixing mechanism simultaneously Including convective mixing, shear mixing and diffusion mixing.

03

Measuring and packaging

After the mixed products are weighed by the automatic quantitative packaging scale, the bags are sewn by the automatic bag sewing machine, manually stacked on the pallet, and forklifted into the finished product warehouse.

The livestock and poultry feed production workshop produces compound feed, concentrated feed, and concentrate supplementary feed. The poultry livestock cattle feed production line process flow is as follows:

01

Raw material reception and initial cleaning

The two feeding pits are used for powder feeding and pellet feeding respectively. Each feeding pit is equipped with a gas collecting hood connected to a pulse dust collector.

The granular materials are transported by the scraper to the lower port of the bucket elevator, and are lifted by the bucket elevator to the main workshop 6F (workshop 1F, workshop equipment is on the 6th floor). Impurities are removed through the primary cleaning screen and permanent magnet cylinder, and are not screened. The pellets are cleaned regularly and checked to see if they are usable.

If they are usable, they will be manually crushed and reused. If they are not usable, they will be treated as general solid waste. The pellets after removing impurities enter the bin to be crushed, and then enter the crusher for crushing.

The powder is transported by the scraper to the lower port of the bucket elevator, and is lifted by the bucket elevator to the main workshop 6F (workshop 1F, workshop equipment is on the 6th floor).

Impurities are removed through the primary cleaning screen and permanent magnet cylinder, and are not screened. The powder should be cleaned regularly. If it is usable, it will be dried naturally before reuse. If it is not usable, it will be treated as general solid waste.

02

Ingredients and mixing section

The crushed raw materials are distributed to 12 batching silos using a fully automatic rotary distributor, and then enter the twin-shaft paddle mixer through the batching scale.

At the same time, small materials (premix, fermentation materials) are manually added to the mixer from the small material hopper, add soybean oil simultaneously, and after mixing for 120 seconds, send the mixed materials to the buffer hopper.

03

Granulating, cooling and packaging sections

When the steam reaches 0.4-0.5MPa, the mixed materials will be transported from the buffer hopper through the scraper conveyor, and transported by the bucket elevator to the rotary distributor, then enter the granulation bin, and enter the granulation through the buffer hopper.

The animal feed pellet mill machine is used for granulation, and the granulated product is cooled by a counterflow cooler, and the cooling time is about 20 minutes.

If there is crumbles feed, adjust the pellet crumbler as required. The cooled feed pellets pass through the bucket elevator and install different grading screens according to the product particle size, and the qualified finished products are screened out and entered into the finished product warehouse. They are packed into bags according to the required specifications by a computerized automatic baling machine.

After the labels are stamped, they are sewn into the bag through a conveyor sewing machine. Inside the packaging bag, all label contents must be exposed. When discharging materials, check whether the color and particle size of the finished materials are normal. If any abnormalities occur, report them to relevant personnel.

In workshop #3, the production process of cattle and sheep feed is consistent with the existing livestock and poultry feed production line.

In workshop #4, a small amount of molasses is added to the compound feed of the cattle and sheep feed production line after pelleting, and then packaged. The pollution-generating process is the same as that of the workshop #3 production line.

The new livestock and poultry feed production line in workshop #4 has added a puffing process. The process flow is as follows:

01

Raw material reception and initial cleaning

After corn and soybean meal arrive at the factory, they are lifted by the elevator to two silos in the factory for storage. The raw materials are fed through the silo and feeding port, and then transported to the primary cleaning screen by a bucket elevator to separate larger particles and impurities; the screened raw materials are magnetically separated through a permanent magnet cylinder to separate the magnetic impurities.

02

Crushing section

The cleaned powder enters the batching bin, and the raw materials that need to be crushed are transported to the crushing bin. After a short stay, they are transported to the crusher through a closed pipeline for crushing, and then enter the batching bin.

03

Ingredient mixing section

According to the formula, the required raw materials are transported from the batching bin to the batching scale in a certain proportion, and fermentation materials, premixes, etc. are put into the feeding pit in front of the mixer, and oil is sprayed at the same time, and they are evenly mixed together in the mixer. Good raw materials enter the next bucket elevator.

04

Expansion cooling section

The mixed materials enter the silo to be expanded, and after quenching and tempering, enter the expander for expansion. The expanded materials are crushed and cooled. After cooling, they are crushed twice. After being crushed, they are lifted to the silo to be batched by the elevator.

05

Granulation and cooling section

The materials mixed according to the formula enter the silo to be granulated. After conditioning, they are transported to the animal sheep cattle feed pellet machine through a closed pipeline for granulation. The feed granules that need to be crushed will enter the three-roller crusher for crushing after cooling. The granules that do not need to be crushed will be cooled. Enter the rotary grading screen.

06

Finished product packaging section

The finished product enters the finished product warehouse for a short stay and is automatically weighed and packaged.

This animal feed production line in Brazil project uses purchased bacterial strains to produce fermented feed. After the feed, sugar, water and bacterial strains are manually mixed evenly, they are put into a special fermentation bag for feed fermentation (it is equipped with a one-way breathing valve, only air is out but not in).

The ratio of feed: water: sugar is calculated as 300:60:1. The fermented feed emits a slightly sweet and sour aroma, indicating successful fermentation. The fermentation cycle is (3-7 days). The fermented feed is added to the compound feed and other production lines for mixing to improve feed quality.

This process mainly produces fermentation waste gas (mainly a small amount of organic acids and trace amounts of alcohol). The nutrients left in the fermentation bags can be used for the next fermentation without cleaning. The damaged fermentation bags are stored in a corner of the fermentation room and are recycled regularly by the customer.

This animal feed production line in Brazil project has adopted the following environmental protection measures:

• Exhaust gas treatment:
  The existing dust-containing exhaust gas exhaust pipes in No. 2 of the livestock and poultry feed workshop are integrated from 5 to 2. The new cattle and sheep feed workshop in No. 3 is equipped with one 20m high exhaust pipe and one 15m high exhaust pipe.
  A new dust removal device was added to workshop #4, and a 20m high exhaust pipe and a 15m high exhaust pipe were installed. An 8m high exhaust pipe was added to the boiler room.
  The canteen has a new oil fume purification device with an efficiency of 80%, and the exhaust gas is discharged from the roof. A new water spray tower absorption device is added to the fermentation room, and the fermentation waste gas is purified and discharged through a 15m high exhaust pipe.
• Wastewater treatment:
  A new sedimentation tank with a volume of 8m3, a rainwater pool with a volume of 250m3, boiler wastewater, and concentrated water produced by pure water preparation in the laboratory will be used for plant greening after sedimentation treatment. After fermentation waste gas treatment, the wastewater is reused for fermentation production and is not discharged.
• Noise treatment:
  The noise of the newly built animal feed mill machine shall be treated with shock reduction, noise elimination and sound insulation.

The market for compound feed in Brazil is projected to register a CAGR of 5.1%, during the forecast period.

The feed segment in Brazil is the third-largest feed sector in the world. This is mainly attributed to the high production of raw materials in the country coupled with the enhanced consumption of meat. The domestic consumption of feed in Brazil is very high as it is a hub for meat production.

As corn and soybean meal prices continue to rise and put pressure on the animal feed industry plays a critical role in relieving financial pressure and instability, while ensuring a nutritious and complete diet for the animals. 

Some factors driving market are increasing livestock population worldwide, rising widespread of animal diseases, and increased population especially in the developing countries will encourage the growth of the compound feed market in the coming years.

In addition to this, increasing demand for good quality dairy and meat products, rapid increase in industrialization and focus of the advancements are other important factors that are anticipated to boost the compound feed market growth.