40-50T/H Feed Mill Factory in Kazakhstan

This project is a large-scale compound feed mill factory in Kazakhstan, capacity 40-50 tons per hour. This feed mill factory project has a total area of 14069.14m² and a total construction area of 10574.00m². It is mainly engaged in the production and sales of feed.

The investment in equipment alone for this 40-50t/h feed mill factory in Kazakhstan project is US$1.8 million. The project includes 5 compound feed production lines (3 * poultry feed production lines, 1 * pig feed plant, 1 * extruded fish feed production line).

The products of this project are duck compound feed, chicken compound feed, etc. feed, pig compound feed and fish compound feed, with a total production capacity of 240,000 tons/year.); raw material and finished product warehouses, vertical silo areas, waste gas and waste water treatment facilities, office buildings, and staff canteens.

• Production workshop: 5-story, steel structure, covering an area of 729m², with a construction area of 3240m²; equipped with 5 compound feed production lines, with a total production capacity of 240,000 tons/year;
• Raw material warehouse: Single-story, steel structure, construction area 2862m²;
• Finished product warehouse：Single-story, steel structure, construction area 1980m²;
• Vertical silo area：Covers an area of 471m²;
• Office building: 4 floors, brick-concrete structure, covering an area of 287m2 and a construction area of 1112m²; (half of the first floor is used as a restaurant)
• Wastewater treatment facilities：One third-level septic tank with a volume of approximately 50m³;
• Waste gas treatment facilities：8 pulse bag dust collectors, 1 15-meter-high exhaust pipe, a set of oil fume purifier, and workshop ventilation system;
• Water supply and drainage system：The feed mill factory in Kazakhstan project's water supply is connected to the park; the project's drainage adopts a rainwater and sewage diversion system, and the sewage is discharged into the sewage pipe network and finally into the sewage treatment plant;
• Power supply system：The electricity used by the project is connected to the park, and the annual electricity consumption is about 23 million kilowatt hours.

The products of this feed mill factory in Kazakhstan project are duck compound feed, chicken compound feed, pig compound feed and fish compound feed, with a total production capacity of 240,000 tons per year.

The feed product types include:

• Duck compound feed (small duck compound feed, fat duck compound feed, laying duck compound feed)
• Chicken compound feed (small chicken compound feed, medium chicken compound feed, large chicken compound feed, laying hen compound feed)
• Pig compound feed (small pig compound feed, medium pig compound feed, large pig compound feed, lactating sow feed, pregnant sow feed)
• Fish compound feed (grass carp compound feed, tilapia compound feed)

The main production equipment of the large compound feed mill factory in Kazakhstan project is as follows:

The following are the main raw materials and raw material consumption used in the products of this feed mill factory in Kazakhstan project:

In order to let you further understand the feed raw materials used in the formulation, the following will briefly introduce to you the physical properties of the raw materials used in this feed mill factory in Kazakhstan project:

• Corn: Corn is also called corn, corn, and pearl rice. It is rich in nutrients, protein, and cellulose; moisture ≤14.5%, crude protein ≥8.0%, bulk density ≥680g/L. It is mainly used for food, feed, and industrial raw materials.
• Soybean meal: Soybean meal is generally in the shape of irregular fragments, light yellow to light brown in color, and tastes like roasted soybeans. The main components of soybean meal are: protein 40% to 48%, lysine 2.5% to 0.0%, tryptophan 0.6% to 0.7%, and methionine 0.5% to 0.7%. The biggest use of soybean meal is as the main raw material for making livestock and poultry feed. It can also be used to make cakes, health foods, cosmetics and antibiotic raw materials.
• Rice bran meal: Rice bran meal is a by-product of the production of rice bran oil. Rice bran meal not only contains high protein, crude fiber, minerals and other substances, but is also rich in vitamins B, E, manganese, potassium, silicon, amino acids and other nutrients. Rice bran meal quality standards: protein content: 15-16%, moisture <13%, residual oil <1.5%.
• Wheat bran: wheat bran, moisture ≤ 13%, crude protein ≥ 15%, by-product of wheat flour processing, wheat yellow, flake or powdery. Rich in fiber and vitamins, its main uses include food, medicine, feed ingredients, wine making, etc.
• Corn distillers grains: a product obtained by distilling and extracting alcohol from yeast-fermented corn or corn mixture, and then concentrating and drying at least three-quarters of the solid content in the remaining residue. It has the characteristics of high protein, available phosphorus and high vitamin content. The protein content is 22% and the linoleic acid content is 2.3%.
• Rapeseed meal: Rapeseed meal refers to the by-product of rapeseed oil extraction. Its crude protein content should be more than 32% and its crude fiber content should be less than 12%. Rapeseed meal is rich in lysine, macro and trace elements. The content of calcium, selenium, iron, magnesium, manganese and zinc is higher than that of soybean meal. The phosphorus content is twice that of soybean meal. It is also rich in sulfur-containing amino acids. , which is lacking in soybean meal, so it can play a balancing and complementary role when used together with soybean meal.
• Peanut meal: Peanut meal is a product obtained by squeezing and refining oil from peanut kernels. Peanut meal has high nutritional value. Its metabolizable energy is the highest among meal feeds. The crude protein content is close to soybean meal, up to more than 48%. The arginine content is as high as 5.2%, which is the highest among all animal and plant feeds. The lysine content is only about 50% of soybean cake, and the methionine, lysine, and threonine contents are all low. Amino acids can be balanced by adding synthetic amino acids or adding other protein feeds.
• Calcium phosphate: a chemical that is the reaction product of phosphoric acid and calcium. This product is a white powder; odorless, tasteless, easily soluble in dilute hydrochloric acid or dilute nitric acid, moisture ≤ 4%, calcium: 20-23.5% ;Total phosphorus ≥17.0%, citrate-soluble phosphorus ≥15.5%, phosphorus ≤0.18%.
• Stone powder: Stone powder is commonly known as limestone and calcium powder. The calcium content is 32%, which is heavy calcium carbonate. Properties of heavy calcium carbonate: white powder, colorless and odorless. Stable in air. Almost insoluble in water and insoluble in alcohol. It is a commonly used powdery inorganic filler with high chemical purity, high inertness, not easy to react chemically, good thermal stability, will not decompose below 400°C, high whiteness, low oil absorption, low refractive index, soft, dry, It does not contain crystal water, has low hardness and low wear value, is non-toxic, tasteless, odorless, and has good dispersibility.
• Salt: The main chemical component of salt, sodium chloride (chemical formula NaCl), accounts for 99% of table salt. It is a white, odorless crystalline powder. The melting point is 801°C and the boiling point is 1413°C. It is slightly soluble in ethanol, propanol and butane. It becomes plasma after being miscible with butane and is easily soluble in water.
• Lysine: Lysine is the basic unit of protein and is used as a food fortifier and feed additive. Feed grade lysine additive is L-lysine salt, which is white or slightly yellow crystalline powder, tasteless or with a slight special smell. Commercial lysine is mostly L-lysine hydrochloride, with a purity of more than 98.5%, containing 79.24% L-lysine, 15.3% nitrogen, and 19.76% hydrochloric acid, which is equivalent to 95.8% crude protein. Metabolism Energy (poultry) is 16.7MJ/kg.

• Production capacity: The feed mill factory in Kazakhstan project has a total of 60 employees, all of whom have room and board in the factory.
• Work system: About 350 working days per year, two shifts, each shift working about 8 hours.

The energy consumption of this feed mill factory in Kazakhstan project is shown in the table:

The nature of the land is Class II industrial land. The feed mill factory in Kazakhstan project is engaged in feed production and sales. It is a relatively lightly polluting project. It is far from the residential area and is not upwind of the residential area. The location of the project is reasonable.

According to the characteristics of the natural topography and peripheral roads, the factory area of this feed mill factory in Kazakhstan project is arranged in a plane layout with the entrance and exit located in the west of the factory area and connected to the road outside the factory in the west.

The raw material area, production area and finished product area are arranged from east to west in the factory area. From a production perspective, the material flow is reasonable and the production operation is smooth, which is conducive to the organization and implementation of the production process. (Find RICHI on YouTube )

According to the type of feed that the customer wants to process, the 40-50t/h feed mill factory production process designed by our customer includes two types:

• Pelletizing process: used to process duck feed, chicken feed and pig feed
• Extrusion process: used to process puffed fish feed

Below, RICHI will describe the two processes in detail.

01

Raw material reception and cleaning

Bulk raw materials are transported into the factory by vehicles, and are automatically unloaded at the raw material discharge port.

A waste gas collection and treatment system is installed above the discharge port, and a pulse dust collector is used to collect and recycle the raw material dust generated by the unloading and reuse it as raw materials.

The raw materials enter the powder cleaning screen through the scraper conveyor and bucket elevator to remove large impurities, then enter the permanent magnet cylinder to remove iron impurities, and then directly enter the batching bin.

02

Crushing section

The materials to be crushed (corn, soybean meal) are fed from the top feed port through the feeder matched with this machine, and enter the crushing chamber from the left or right through the feed guide plate.

They are struck by the high-speed rotating hammer and rubbed by the sieve plate. Under the action, the materials are gradually crushed, and are discharged from the base outlet through the screen holes under the action of centrifugal force and air flow.

03

Ingredients

After automatic PLC measurement, various materials are transported through the auger into the batching scale in proportion to ensure that the material weight tolerance is within the range allowed by the company.

04

Mixing:

The materials enter the mixing system after automatic batching, and the various materials are fully mixed, and the mixing uniformity exceeds 93%. This section is a key section to ensure feed quality.

This section uses a high-efficiency double-shaft paddle mixer, and multiple liquid addition devices can be set up according to the needs of the formula.

During the mixing process, the flow rate and optimal time of liquid addition are controlled by a microcomputer to ensure that the liquid raw materials and solid phase raw materials are fully mixed evenly.

In order to reduce cross-contamination of feed raw materials and improve the working environment, a pulse bag dust filter is installed on the hand feeding device to return the dust of the added raw materials to the original process line. The mixed ultra-fine powdered feed enters the subsequent expansion and granulation process.

05

Conditioning

After mixing, the powder enters the modulator. The material is exposed to high humidity and high temperature in the steam. Generally, the temperature of the material in the modulator is about 60-95°C and the moisture is about 15%, so that the material can be fully preheated.

06

Pelleting

The conditioned raw materials enter the animal feed pellet machine for granulation.

07

Cooling

Use a counter-flow cooler to cool down the feed pellets to ensure that the feed temperature is 3-5°C higher than room temperature and the moisture content is below 12%.

08

Packaging and storage

After cooling, the granules or crumbled pelletes are screened out through a grading screen to remove a small amount of finely crumbled pellets and then enter the finished product warehouse. They are packaged and stored in the warehouse using automatic measurement.

09

Finished product

Qualified feed pellets product, ready for sale.

01

Raw material reception and cleaning

This process is the same as the raw material receiving section of livestock and poultry feed.

02

Batching

After automatic PLC measurement, various materials are transported through the auger into the batching scale in proportion to ensure that the material weight tolerance is within the range allowed by the feed mill factory.

03

Primary mixing

After the computer batching system batches the ingredients according to the formula requirements in the central control room, the primary mixing is performed. Primary mixing is the preliminary mixing of materials.

04

Secondary crushing

After primary mixing, it enters the secondary crushing section for secondary crushing, so that the particle size of the material reaches 90% and passes through a 60-mesh screen.

05

Secondary mixing

After secondary crushing, it enters the secondary mixer to fully mix various materials, and the mixing uniformity exceeds 93%. This section is a key section to ensure feed quality. This section uses a high-efficiency double-shaft paddle mixer, and multiple liquid addition devices can be set up according to the needs of the formula.

06

Conditioning

After mixing, the powder enters the modulator. The material is exposed to high humidity and high temperature in the steam. Generally, the temperature of the material in the modulator is about 100°C and the moisture is about 25%, so that the material can be fully preheated and matured.

07

Extrusion

The tempered raw materials enter the twin screw extruder for expansion.

08

Drying

The drying process of feed mill factory in Kazakhstan project is equipped with a gas-water separation device, and the exhaust gas will not appear white smoke.

09

Oil spray cooling

Spraying an appropriate amount of soybean oil on the surface of expanded pellet feed can increase the energy level of the feed and improve the appearance quality of fish feed.

10

Packaging and storage

Similar to the production process of livestock and poultry feed pellets, the cooled pellets enter the finished product warehouse and are packaged and stored in the warehouse using automatic measurement.

Up to now, Richi Machinery has exported more than 20 complete sets of equipment for pellet production lines and more than 100 stand-alone equipment to Kazakhstan.

Our pellet production line projects in Kazakhstan mainly cover poultry feed processing, ruminant feed processing, fish feed processing, fish feed pellet processing, sunflower seed shell pellet processing, oil residue pellet processing, waste paper pellet processing, grass pellet processing, and fish feed processing , shrimp feed processing and cat litter particle processing and other fields.

In response to customer needs in different fields, we customize the feed mill and pellet production lines with various processes or you can chose from a selection of standardized design, offering a quick and easy order processing.

Besides equipment for the entire process chain from intake to packed product, we also support you with training sessions, technology know-how, automation expertise, services, retrofits and plant engineering.