5–6 T/H Animal Pellet & Mash Feed Production Line in Zimbabwe

In late 2024, a Zimbabwean agribusiness investor from Mashonaland West province contacted RICHI Machinery with the following inquiry:

“May I have price for 5–6t/h machine. I would prefer a machine that can both pelletize the feed and can produce mashed products.”

The customer explained that his business supplied feed to both medium-sized poultry farms and cattle farmers. Poultry farmers demanded pelletized feed for broilers and layers, while cattle producers preferred mash feed, which they often mixed with forages and silage. To serve both markets with one production line, the customer required a dual-function system.

After several rounds of technical discussions, customized layout design, and financial negotiations, the customer decided to invest in a fully automated 5–6t/h animal feed production line, with a total equipment cost of USD 183,970. The contract was officially signed on October 30, 2024.

Raw Materials in Zimbabwe

Zimbabwe has a strong agricultural base, which supplies a variety of raw materials suitable for animal feed production. For this project, the customer planned to use:

• Maize (corn) – the country’s most important staple crop, widely available and affordable.
• Soybean meal and sunflower meal – locally processed oilseed meals as key protein sources.
• Wheat bran – a by-product from flour mills.
• Cottonseed cake – abundant in cotton-growing regions like Gokwe and Muzarabani.
• Groundnut shells and meal – from small-scale peanut processors.
• Fish meal – imported or locally sourced from Lake Kariba.
• Limestone and dicalcium phosphate – for calcium and phosphorus supplementation.
• Vitamin and mineral premixes – imported additives to balance rations.

The diversity of these ingredients makes Zimbabwe an ideal place for feed production. Importantly, feed formulations are species-specific. For instance, poultry diets include maize, soybean meal, fish meal, and premixes, while cattle feeds use maize bran, cottonseed cake, and sunflower meal, usually in mash form.

Process Flow and Technology of the 5–6 t/h Line

The RICHI-designed animal pellet & mash feed production line in Zimbabwe allows the operator to switch between mash feed and pellet feed seamlessly, without the need for major adjustments. This flexibility was a decisive factor for the client.

Step 1: Raw Material Reception and Storage

Grains like maize and wheat bran are delivered in bulk, while protein meals are delivered in bags. Materials are weighed, sampled for quality, and stored in separate silos and warehouses.

Step 2: Crushing

Whole maize and other grains are crushed using RICHI hammer mills, ensuring particle sizes are adjusted according to feed type:

• Poultry feed: finer grind.
• Cattle feed: coarser grind to improve rumen digestion.

Step 3: Batching and Mixing

The heart of feed quality lies in precise batching. The line is equipped with an automatic batching scale connected to PLC controls, ensuring accuracy within ±0.3%. Ingredients are mixed in a double-shaft paddle mixer, ensuring uniformity with a coefficient of variation (CV) below 5%.

Step 4: Conditioning and Pelletizing

When pellet feed is required, the mixed mash is sent to an animal feed pellet machine where it is conditioned with steam before being compressed into pellets. Pellet sizes (3.5 mm for broilers, 4 mm for layers, 6 mm for cattle) are adjustable by changing dies.

Step 5: Cooling, Crumbling, and Screening

Fresh pellets exit at ~80–90°C and are cooled to room temperature in a counterflow cooler. For young poultry, a crumbler breaks pellets into smaller sizes. A vibrating screener removes fines, which are recycled back.

Step 6: Mash Feed Bypass

When producing mash feed, the mixed meal bypasses the pellet mill and is directly conveyed to packaging. This dual-route design allows the plant to serve both pellet and mash feed customers without disrupting operations.

Step 7: Packaging and Storage

• Mash feed: packed in 50 kg bags.
• Pellet feed: packed in both 50 kg and jumbo bags, depending on customer demand.

Main Equipment Supplied

The USD 183,970 investment included a full feed line of equipment with robust automation:

• Raw material silos and conveyors.
• High-efficiency hammer mill with cyclone.
• Automatic batching system with multiple ingredient bins.
• Double-shaft paddle mixer.
• RICHI ring die feed pellet mill (5–6t/h capacity).
• Steam conditioning system.
• Counterflow cooler and pellet crumbler.
• Vibrating screener.
• Dual packaging lines (50 kg and jumbo bag).
• Full PLC control system with recipe management.

The ability to integrate both pellet and mash routes in one plant makes this configuration unique in Zimbabwe’s feed industry.

Why This Project Is Important

• Dual-functionality: The animal pellet & mash feed production line in Zimbabwe can produce both mash and pellets, increasing market coverage.
• Adaptability to local raw materials: Designed for maize, cottonseed cake, sunflower meal, and bran, common in Zimbabwe.
• Automation: Reduces labor dependence, which is critical given Zimbabwe’s fluctuating labor market.
• High ROI: With feed demand growing rapidly, payback is expected within 1.5–2 years.

Market Prospects for Animal Feed in Zimbabwe

Zimbabwe has over 12 million poultry birds, growing dairy herds, and beef cattle that are central to both domestic consumption and export markets.

• Poultry industry: The main consumer of pellet feed. Broiler production in peri-urban Harare and Bulawayo continues to expand.
• Cattle industry: Mash feed demand is increasing due to seasonal feed shortages during the dry season.
• Export potential: With regional integration, Zimbabwe could supply feed to Zambia, Mozambique, and Botswana.

The shift from traditional farm-mixed feed to professional feed mills is accelerating, making this project a strategic investment.

Raw Material Formulation Examples

For this animal pellet & mash feed production line in Zimbabwe project, RICHI engineers helped the client design feed formulas adapted to Zimbabwe’s conditions:

• Broiler starter (pelletized): 55% maize, 25% soybean meal, 10% wheat bran, 5% fish meal, 3% sunflower meal, 2% premix.
• Layer mash: 50% maize, 20% soybean meal, 15% wheat bran, 10% sunflower meal, 3% limestone, 2% premix.
• Cattle mash: 40% maize bran, 25% cottonseed cake, 20% sunflower meal, 10% maize grain, 3% mineral mix, 2% premix.

These examples highlight the flexibility of the 5–6t/h plant in serving different livestock sectors.

Financial Outlook

With a 5–6t/h animal pellet & mash feed production line in Zimbabwe, the client can produce around 36,000–40,000 tons of feed per year.

• Production cost: ~USD 250–280/ton.
• Selling price: USD 400–450/ton (depending on species and season).
• Annual revenue potential: USD 14–16 million.

With Zimbabwe's feed deficit, this plant is projected to capture a significant share of the local market.

RICHI's Services in the Project

RICHI Machinery provided more than just animal feed machines:

• Customized design integrating pellet & mash routes.
• On-site installation and commissioning in Zimbabwe.
• Training for local operators on both mash and pellet production.
• Spare parts support with fast delivery.
• Long-term technical service contract to ensure uninterrupted operations.

Customer Evaluation

After signing the contract, the Zimbabwean client shared his impression of RICHI:

“Our biggest challenge was finding a supplier who could design one line that handles both pellet feed for poultry and mash feed for cattle. Many suppliers only offered one or the other. RICHI was different. Their team listened to our needs and customized the process flow exactly as we wanted. The machines are well-built, and the automation is impressive. We are confident that this investment will give us a strong position in the Zimbabwean feed market. RICHI has proven to be a professional partner.”

The 5–6t/h animal pellet & mash feed production line in Zimbabwe is not just another animal feed factory project—it represents the modernization of Zimbabwe's feed industry. By integrating dual functionality, automation, and local raw material adaptability, this project sets a benchmark for medium-scale feed plants in Southern Africa.

For investors, feed millers, and livestock producers across Africa, this case study demonstrates that RICHI Machinery provides practical, profitable, and future-ready feed solutions.

Looking to build a feed mill in Africa? Contact RICHI today—our engineers are ready to design the right solution for your market and raw materials.