1–1.5 T/H Chicken Feed Pellet Production System for Farm Use in Kenya

Project Profile and Equipment Configuration

The farm's annual feed requirement was assessed against its actual flock size and expected feed consumption. For a first-stage on-farm production plan, approximately 1,700–1,900 tonnes of pellets per year was a practical target, with purchased feed remaining available during demand peaks or periods of maintenance. The final production schedule would depend on actual feed formulations, machine utilization and seasonal operating conditions.

The SZLH250 was selected because its capacity matched the farm's phased production target without requiring the investment associated with a larger commercial pellet mill. Its nominal capacity is a reference for equipment selection rather than a guaranteed output for every formula. Actual throughput depends on die diameter, compression ratio, ingredient composition, moisture and conditioning conditions.

How the New Pelletizing Section Fits the Existing Farm

The project was designed to reuse as much of the farm's existing equipment as possible. The animal feed hammer mill continued to prepare maize and other suitable grains, while the vertical mixer blended ground ingredients before they entered the new pelletizing section.

1. Ground ingredients are discharged from the existing hammer mill and transferred to the mixer.
2. The vertical mixer machine blends grains, protein meals, mineral ingredients and other formula components.
3. The mixed mash enters a surge bin or controlled feeding arrangement before pelletizing.
4. The SZLH250 poultry feed pellet machine compresses the conditioned mash through the selected ring die.
5. Hot pellets pass into a counterflow cooler to remove heat and excess moisture.
6. The cooled product is screened as necessary and bagged for storage or use on the farm.

This arrangement avoids replacing functional upstream equipment simply to add pelleted feed production. It also creates a clear upgrade path: the farm can improve conveying, weighing, automation or packaging later without necessarily replacing the core pellet mill.

Ring Die Selection for Different Poultry Feed Types

The farm needed more than one pellet specification. Broiler diets change with bird age, while laying hens require a different nutrient balance and mineral inclusion. Interchangeable ring dies allow the same pellet mill to process different formulations, provided the die configuration and operating parameters are appropriate for each product.

These figures are initial operating references for the specified machine configuration. They should be verified during commissioning with the farm's actual formulas and ingredient moisture levels. A 3.5 mm pellet is more appropriate for many grower applications than for very young chicks. If the farm intends to produce starter feed for the youngest broilers, it should evaluate a smaller die or a crumbler for converting suitable pellets into starter crumbles.

The steam addition rate also needs to be adjusted to the formula and incoming material condition. As a starting point, the farm can evaluate approximately 5–6% steam addition for broiler grower feed, 4–5% for finisher feed and 3–4% for layer feed. These are process settings to validate, not fixed requirements for every batch.

Feed Formulations Based on Kenyan Ingredients

The farm can source several feed ingredients locally, including maize, rice bran and sunflower cake. Soybean meal and selected additives may be purchased through local distributors or import channels. Using these materials in a controlled formula can reduce reliance on finished commercial feed, but the nutrient value of each batch should be checked before formulation adjustments are made.

Illustrative broiler grower formula

Illustrative layer feed formula

These formulas are illustrative starting points rather than verified commercial rations for the customer's flock. A poultry nutritionist should balance protein, energy, amino acids, calcium, available phosphorus and other nutrients using laboratory analysis and the birds' production stage. The 10% limestone inclusion in the layer formula is not equivalent to 10% elemental calcium; total dietary calcium must be calculated from all ingredients.

Vegetable oil also requires attention during pelleting. Excessive oil added before the die can reduce friction and weaken pellet binding. Where the formula requires substantial oil addition, the farm should assess how much can be incorporated before pelleting and whether additional coating after cooling would be more suitable.

Steam Supply Was a Critical Part of the Upgrade

The initial steam arrangement used a small boiler rated at approximately 100 kg/h. During periods when incoming maize was wetter, the farm found it difficult to maintain consistent conditioning conditions. It subsequently upgraded the boiler to approximately 150 kg/h to provide a more reliable steam supply.

The experience illustrates why boiler selection cannot be based solely on the pellet mill's motor power. Steam demand changes with production rate, formulation, incoming moisture and the temperature required for conditioning. A boiler with insufficient usable steam output can restrict pellet quality and reduce effective throughput even when the pellet mill itself is correctly sized.

• Check incoming maize moisture and dry or store it appropriately before processing.
• Maintain stable steam pressure and ensure the steam delivered to the conditioner is suitable for feed processing.
• Adjust conditioning temperature and steam addition according to the feed formula rather than applying one setting to every product.
• Provide suitable boiler feed water and treatment according to the boiler manufacturer's requirements.
• Verify the electrical supply for the 22 kW pellet mill, existing 30 kW hammer mill, mixer, cooler, fans, conveyors and boiler before setting the final connected-load requirement.

The 150 kg/h figure represents the upgraded boiler's nominal capacity in this project. It should not be treated as a universal boiler specification for every SZLH250 feed pellet machine installation.

Installation Planning, Utilities and Staffing

Because the customer was expanding an existing farm operation, the installation needed to fit within the available building and work with the equipment already on site.

The space allowance is for preliminary layout planning, not a substitute for the manufacturer's general arrangement drawing. The final layout must provide access for die and roller maintenance, cooling equipment, steam piping, dust collection and safe movement of operators and bags.

The total electrical demand will be higher than the pellet mill's 22 kW main motor rating. The final supply and protection arrangement should be determined from the nameplate data of all operating equipment, particularly if an electric boiler is used.

What Changed After the Farm Started Making Its Own Pellets

The most important benefit was greater control over the timing and composition of feed production. Instead of relying entirely on deliveries from Nairobi, the farm could prepare its regular diets using available raw materials and schedule production around flock requirements.

The farm owner estimated that the investment recovered its cost within approximately eight months, based on avoided purchases of commercial feed. This is a site-specific estimate rather than a guaranteed payback period. Actual returns depend on maize and protein-meal prices, electricity and steam costs, labor, wear parts, machine utilization and the proportion of feed that can be produced economically on site.

The project also made it easier to identify production bottlenecks. Grinding and mixing capacity could be reviewed separately from pelletizing performance, while the boiler upgrade addressed a specific constraint in the conditioning process. This approach allowed the farm to improve the system step by step rather than replacing all of its equipment at once.

Customer Feedback After 14 Months

The main benefit has been a more dependable feed supply, especially when heavy rain affects deliveries from Nairobi. We can prepare our own feed and adjust production to our flock's needs instead of depending entirely on commercial pellets.

The steam supply was the main challenge during the early operating period. Our original 100 kg/h boiler struggled when the maize was wetter than usual, so we upgraded to a 150 kg/h unit. After adjusting the conditioning process and paying closer attention to raw material moisture, pellet quality became more consistent.

We have also been monitoring die wear and maintenance more carefully. The 3.5 mm die required attention after about 800 operating hours, while the 4.0 mm die remained in service after approximately 900 hours. The 4.5 mm layer die had produced around 1,500 tonnes. We are now evaluating another SZLH250 for our planned farm expansion.

The follow-up experience highlights two practical lessons for farm-scale pellet production. First, ring die selection and maintenance should be based on the actual formulation and operating conditions. Second, reliable steam conditioning and upstream moisture control are essential to obtaining consistent pellets from batch to batch.

Other Feed Applications for the SZLH250

With suitable dies and correctly balanced formulations, the SZLH250 can also be considered for other conventional livestock feed applications.

• Rabbit feed, commonly using pellets around 3–4 mm.
• Goat and sheep feed, commonly using pellets around 4–5 mm.
• Pig feed, with pellet diameter selected for the production stage and feeding system.
• Duck feed, with die selection and formulation adjusted to the birds' requirements.

The SZLH250 is a conventional ring die feed pellet mill, not a substitute for an extrusion system. Floating fish feed normally requires an extruder, while specialized shrimp feed may require additional conditioning and process controls to achieve the required water stability.

Shipping from Qingdao to Mombasa and Delivery to Thika

The pellet mill was shipped from Qingdao, China, to the Port of Mombasa, Kenya. The ocean freight leg took approximately 28 days in the project plan. After customs clearance, the equipment was transported inland by road to the Thika region, with total transit time estimated at about 38 days.

As delivery schedules vary with vessel routing, customs clearance and inland transport conditions, these figures should be treated as project-specific planning estimates rather than fixed transit guarantees.

Technical Support Before and After Installation

RICHI's support focused on integrating the pellet mill into the farm's existing production arrangement and resolving practical operating issues.

• Reviewed the existing hammer mill and mixer to identify the required integration points.
• Recommended the SZLH250 based on the first-stage output target.
• Provided guidance on ring die selection for broiler and layer feed.
• Advised on steam demand and the need to verify boiler capacity under actual operating conditions.
• Supplied installation information and a starter spare parts kit, including roller shells, die screws and belts.
• Provided remote commissioning assistance and guidance on adjusting steam conditioning for different feed types.

For a farm that is new to pelleted feed production, this type of support helps connect equipment selection with the daily realities of formulation changes, moisture variation, cleaning, maintenance and output planning.

Planning the Next Stage of On-Farm Feed Production

The farm is considering a second SZLH250 for a new broiler operation and evaluating a larger SZLH320 for a possible future feed sales business. These are different investment decisions. A second SZLH250 could provide additional capacity or operational flexibility for the farm, while a commercial feed sales operation would also require attention to raw material storage, batch traceability, product consistency, packaging and local feed regulations.

For poultry farmers in Kenya considering a similar upgrade, the first step is to compare the flock's actual feed consumption with the realistic output of the proposed equipment. The next is to determine which existing machines can be retained and which supporting systems need upgrading.

RICHI Machinery supplies ring die pellet mills and supporting feed processing equipment for farm-scale and commercial applications. If you are planning a chicken feed pellet production system for farm use in Kenya, provide your flock size, annual feed requirement, available raw materials, existing equipment and target pellet sizes. These details allow the equipment configuration, steam supply and production schedule to be assessed as one integrated system rather than as a standalone machine purchase.