60T/H Livestock Feed Mill in Russia

The client's company was established on December 14, 2016. The company's business scope includes: livestock and poultry breeding, breeding of fine seeds; grain purchase, feed processing and sales; crop planting; forest cultivation, planting and sales; livestock product processing and sales; livestock machinery sales; pig manure treatment, etc.

With the continuous development of Russia's livestock and poultry breeding industry and Russia's emphasis on agriculture, the market demand for livestock and poultry feed products is also growing. In order to meet the market demand and provide feed for the customer company's farms, the Russian customer invested $1.7 million to build a 60t/h livestock feed mill in Russia with an annual output of 300,000 tons.

• Construction scale: This 60t/h livestock feed mill in Russia project covers an area of 26667m², with a construction area of 66796.58m². The main construction contents include: main workshop, silo area, production complex building, external comprehensive building and other infrastructure.
• Main equipment: The animal feed mill machine includes 300,000 tons of feed processing equipment. Aerodynamic systems, grain conveying equipment and other ancillary production equipment. After the project is completed, 300,000 tons of feed will be processed annually.
• Labor capacity and work system: This project has a labor capacity of 50 people and implements a two-shift work system with an 8-hour work system per shift. Work 310 days per year.

• Main workshop: Located in the middle of the factory, six floors, concrete frame structure.
• Office buildings: 4 office buildings are planned to meet the functions of office, conference and accommodation
• Machine repair & boiler room: located in the central and western part of the factory, on the first floor, steel structure.
• Restaurant: Located in the central and western part of the factory, brick-concrete, first floor.
• Guard room: located in the west-central part of the north-central part of the factory, brick-concrete.
• Firefighting pool: underground pool.
• Accident emergency pool: underground pool, 800m³.
• Storage: weighing scale room, waste bag room, 1000T silo, 250T silo, raw material workshop.
• Feeding shed: located on the west side of the silo, steel structure.

The water for this 60 t/h livestock feed mill in Russia project is provided by an existing self-contained well at the factory site, and the water quality and quantity meet the water needs of the project. The total fresh water consumption of the project is 2961m3/a, including domestic water and greening water.

The boiler water for this project is purchased soft water, and the volume of purchased soft water is 97.96m3/d (30367.6m3/a). Domestic water consumption is 6m3/d (1860m3/a).

Greening water is calculated as 0.6 m3/(m2·a), and greening water consumption is 8.67m3/d (2688 m3/a), of which 4.8m3/d is gray water purified by sewage treatment equipment, and fresh water is 3.87m3/d (1199.7 m3/a).

The wastewater in this 60 t/h livestock feed mill in Russia project is mainly boiler drainage and domestic sewage (including canteen wastewater). The amount of boiler wastewater produced is approximately 1.96m3/d (607.6m3/a).

Boiler wastewater is used for dust suppression in the factory area and for cleaning the workshop. Canteen wastewater is discharged into the grease trap for treatment and then into the factory septic tank.

Other domestic sewage is directly discharged into the factory septic tank and then treated by integrated sewage treatment equipment before being used for factory greening.

The electricity consumption of this 60 t/h livestock feed mill in Russia project is approximately 6.9 million kWh/a, which is provided by the local power supply network and can meet the electricity demand.

It is used by a 6t/h boiler in the livestock feed production line project. The boiler operation time is 16h/d and it operates 310 days a year. The natural gas (gaseous) consumption is 1.35 million m³/a (equivalent to liquid consumption of 2250m³/a). The boiler of this project Natural gas is stored in 1 LNG-30m³ storage tank, and natural gas that meets local standards will be purchased.

01

Raw material receiving and cleaning process:

The purchased corn, wheat, meal and other raw materials that meet the production requirements are sent through independent feeding, receiving and cleaning systems.

• The entire corn, wheat, and meal transport vehicle enters the feeding shed, closes the rolling shutter door, and feeds in the hydraulic flap truck unloading method.
• There are 2 sets of dust removal systems at the feeding port. The material is transported to the double-cylinder primary cleaning screen through the scraper conveyor and bucket elevator at the feeding port.
• After cleaning, it can enter the permanent magnetic drum to remove iron, or it can enter the combined vibrating screen to further clean impurities. The material is screened out by the two cleaning screens.
• The impurities are transported from the buffer bin to the impurity recovery vehicle via a belt conveyor; after iron removal, the materials are transported to the silo by a bucket elevator and scraper conveyor. Meal feeding is done manually.
• The material is transported to the cylindrical primary cleaning screen through the feeding port scraper and bucket elevator. After cleaning, it enters the permanent magnet drum to remove iron.
• After iron removal, the material is transported to the spiral steel plate auxiliary material bin by the bucket elevator and scraper.

02

Main workshop raw material receiving and screening process:

• Corn/wheat is transported to the main workshop by scraper and bucket elevator. After passing through the elevator, it enters the cylindrical primary cleaning screen to clean impurities.
  After cleaning, it enters the permanent magnetic drum to remove iron. After iron removal, it is measured by a flow scale. After measurement, it enters the warehouse to be crushed through the distributor.
• Meal is transported to the main workshop by augers, scrapers and bucket elevators. After passing through the bucket elevator, it enters the cylindrical primary cleaning screen to clean impurities.
  After cleaning, it enters the permanent magnetic drum to remove iron and then enters through the distributor. The warehouse to be crushed.
• Powdered auxiliary materials are fed into the raw material warehouse, and the auxiliary material receiving system is equipped with an automatic unpacking and feeding system. The material is dusted at the feeding port.
  After passing through the scraper, it is transported by the bucket elevator and then enters the powder cleaning screen to clean impurities. After cleaning, it enters the permanent magnetic drum to remove iron. After iron removal, it enters the batching bin through the distributor.

03

Raw material crushing, puffing, and batching process:

The main raw material is crushed. If it is corn, it enters the grain extruder for puffing. It is crushed after cooling, and enters the batching bin through the flow pump. Each raw material is proportioned according to the feed formula and uses a specific electronic batching device.

All powdery raw materials (including feed additives) are electronically measured from their respective intermediate silos and sent to the mixer for full mixing before entering the granulation process.

04

Mixing and granulation process:

After crushing, the raw grain, auxiliary materials, and soybean oil enter the batching bin and are sealed and transferred to the mixer, where the premix is fed, then steam granulated by animal feed pellet machine, cooled, and packaged for storage.

05

Finished product packaging process:

Weigh, bag and seal the feed products.

• The dust generated in the wheat/corn feeding process is treated by a sealed feeding shed + 2 sets of pulse bag dust collectors and then discharged from the 15m high exhaust pipe.
• The dust generated in the wheat/corn primary cleaning process is treated with closed equipment + cyclone dust collector + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• The dust generated in the wheat/corn primary cleaning process is treated with closed equipment + cyclone dust collector + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• The dust generated during the meal feeding process is treated by a sealed feeding shed + 3 sets of pulse bag dust collectors and then discharged from a 15m high exhaust pipe.
• The dust generated in the initial cleaning process of meal is treated with closed equipment + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• The dust generated in the auxiliary material feeding process is treated with a gas collection hood + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• The dust generated in the material screening (pellet) process of the main workshop is processed by closed equipment + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• The dust generated in the material screening (powder) process of the main workshop is processed by closed equipment + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• The dust generated in the pulverizing process of the pulverizer #1 is treated with closed equipment + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• The dust generated in the 2# crushing process of the pulverizer is processed by closed equipment + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• The dust generated in the puffing and cooling processes is treated with closed equipment + cyclone dust collector and then discharged from the 43m high exhaust pipe.
• The dust generated in the premix feeding process is treated with a gas collection hood + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• The dust generated in the granulation cooling 1# process is treated with closed equipment + cyclone dust collector and then discharged from the 43m high exhaust pipe.
• The dust generated in the granulation cooling 2# process is treated with closed equipment + cyclone dust collector and then discharged from the 43m high exhaust pipe.
• The dust generated in the granulation cooling 3# process is treated with closed equipment + cyclone dust collector and then discharged from the 43m high exhaust pipe.
• The dust generated in the finished product packaging process is treated with a gas collection hood + pulse bag dust collector and then discharged from the 15m high exhaust pipe.
• Natural gas boilers use low-nitrogen burners. The flue gas generated by burning natural gas is discharged through an 8m-high exhaust pipe, and a nitrogen compound analyzer is installed at the discharge port.
• The oil fume in the canteen is collected by the air collection hood and then enters the oil fume purifier for treatment before being discharged.

Boiler sewage is used for dust suppression and cleaning workshops in the 60 t/h livestock feed mill in Russia project. Canteen sewage is discharged into the septic tank through the grease trap.

Domestic sewage is directly discharged into the septic tank. The sewage in the septic tank is passed through the integrated sewage treatment equipment (8m3/d) After treatment, it is used for greening the factory area.

This 60 t/h livestock feed mill in Russia project uses low-noise equipment and perform basic vibration reduction on noise-generating equipment and sound insulation on the factory building.

Set up a waste bag room with an area of 18m2. The permanent magnet cylinder produces iron impurities and waste packaging bags. The impurities are collected and filtered out and temporarily stored in the waste bag room.

The permanent magnet cylinder produces iron impurities and waste packaging bags for external sale and treatment; Garbage and sieved impurities are collected and disposed of by the sanitation department.YouTube

Russia is the world's largest exporter of wheat and one of the world's largest producers of sugar and timber. Therefore, Russia has abundant agricultural resources, including raw materials for the production of feed.

The production of feed in Russia is mainly divided into two types:

• Industrial production type:
  Mainly based on large-scale industrial production, using large-scale production methods to manufacture feed.
• Small-scale supply type:
  mainly covers local small-scale feed manufacturers and farmers producing their own feed. 

Although Russia has the resources and conditions to produce feed, there are still some problems in Russian feed production, as follows:

• Insufficient supply:
  In Russia, the production capacity of the livestock industry is far from meeting the demand for domestic livestock products. Some livestock products need to be imported from other countries, resulting in high demand for feed but insufficient supply.
• Unstable quality:
  Due to the continuous improvement of agricultural production and technological levels, the production quality of Russian feed is constantly improving, but there are still problems of unstable quality, leading to insufficient or unbalanced nutrition in the feed.

With the continuous improvement of technology and changes in market demand, the production of Russian feed will undergo some changes. The specific manifestations are as follows:

• Refined production: Russian feed manufacturers will pay more attention to the control of production processes and product quality assurance to produce refined feed.
• Green and environmental protection: The production of green and environmentally friendly feed is also a future trend. Russia will be committed to creating environmentally friendly feed production.

Russian animal husbandry and feed are interrelated, and the quality and nutrition of feed directly affect the development of animal husbandry. Russia is a large agricultural country, and its livestock industry is also in a stage of rapid development. The demand for animal poultry livestock feed will continue to increase in the future.

The Russian feed market has broad prospects, mainly due to the rapid development of Russia's livestock industry and the growth of market demand. In the future, with the development of technology and the increasing consumer demand for nutritionally balanced and high-quality feed, the Russian feed market will have huge development potential.