3–4 T/H Chicken Feed Pelletizer for Feed Processing System in Ethiopia

Why the Plant Added a Pelletizing Stage

The factory already operated hammer mills for maize grinding and a twin-shaft paddle mixer with a 3,000 kg batch capacity. These machines remained suitable for preparing poultry feed mash, so replacing them would have added investment without addressing the plant's main limitation.

The missing equipment was a feed pellet mill capable of converting conditioned mash into uniform pellets. By adding one machine, the manufacturer could serve customers who preferred pelleted feed while continuing to supply mash to farms using their established feeding practices.

This phased investment also made capacity planning more manageable. A 3–4 T/H pellet mill can theoretically produce 9,000–12,000 tons over 3,000 productive hours, before downtime and process losses. It would not independently pelletize the plant's entire 60,000-ton annual output. Instead, it provided a starting capacity for the new product category while the existing system continued supporting the broader business.

SZLH320 Chicken Feed Pelletizer: Technical Specifications

RICHI recommended the SZLH320 ring die pellet mill with a 37 kW main motor. The plant selected three dies to accommodate different poultry feed products, allowing the operator to change configurations according to the production schedule.

The 3.5 mm die was designated for the plant's starter-feed product, the 4.0 mm die for finisher feed, and the 4.5 mm die for layer feed. Actual output varies with the formulation, grinding fineness, conditioning conditions and die configuration. The selected pellet diameters should also be checked against bird age and feeding requirements; very young chicks may require smaller crumbles or mini-pellets.

Feed Formulations Using Ethiopian Agricultural Ingredients

Locally available maize formed the main energy component of the plant's broiler feed. Wheat bran and noug cake, a byproduct of Ethiopian oilseed processing, provided additional formulation options. Soybean meal and other protein ingredients were included according to the nutritional requirements of each product.

Broiler Starter Feed

The plant's example starter formulation was based on the following ingredient proportions:

• 50% ground maize
• 20% soybean meal
• 10% wheat bran
• 6% noug cake
• 5% vegetable oil
• 4% fishmeal
• 5% vitamin and mineral premix

The formulation totals 100%. It provides a starting point for evaluating ingredient handling and pellet formation, but commercial use requires nutritional verification. Crude protein, metabolizable energy, digestible amino acids, minerals and the quality of individual raw materials must be assessed before the diet is approved for a specific broiler growth stage.

Layer Feed

For laying hens, the plant used a separate formulation containing maize, soybean meal, wheat bran and limestone:

• 45% ground maize
• 15% soybean meal
• 12% wheat bran
• 10% limestone
• 6% noug cake
• 5% vegetable oil
• 7% vitamin and mineral premix

This formulation also totals 100%. Its final calcium content must be calculated from the actual ingredients and premix specification rather than inferred from the limestone inclusion rate alone. Layer diets require particular attention to calcium availability, phosphorus balance and the nutritional requirements of the hens.

Noug cake was one of the materials requiring close monitoring. Its fiber and residual oil content can vary between batches, affecting mash flow, conditioning and pellet durability. The plant therefore needed to adjust inclusion rates and processing conditions according to the quality of the incoming material rather than relying on one fixed operating recipe.

Integrating the Pellet Mill with Existing Equipment

The SZLH320 poultry feed pellet machine was installed as an additional stage within the existing feed processing system. The project retained the upstream hammer mills and paddle mixer, while modifying the material flow to supply the new pellet mill and return finished pellets to the cooling stage.

• Grinding and mixing: Existing equipment continued preparing the formulated mash.
• Surge bin: A new buffer bin was installed before the pellet mill to support a steadier material supply.
• Steam conditioning: A new boiler rated at approximately 500 kg/h was installed to provide steam for the pelleting process.
• Pellet cooling: The existing cooler was relocated downstream of the pellet mill.
• Electrical controls: The control system was extended to accommodate the new equipment and operating signals.

The surge bin helped separate batch mixing from the continuous pelletizing stage. It provided a buffer between the mixer and pellet mill, reducing the need for both machines to discharge at exactly the same moment.

After pelleting, the hot product passed through the relocated cooler before further handling. Cooling was necessary to remove excess heat and moisture introduced during conditioning, helping the pellets retain their structure during storage and transportation. The finished product also needed appropriate screening and handling to control fines before packaging or bulk delivery.

Steam Conditioning and Pellet Quality

The plant's initial operating settings varied by product. Broiler starter mash was conditioned at approximately 85–90°C, finisher feed at 80–85°C, and layer feed at 70–75°C. Indicative steam addition ranged from 3% to 7%, depending on the formulation and required pellet characteristics.

These figures served as starting settings rather than universal operating requirements. Actual steam consumption depends on incoming mash moisture, ingredient composition, steam quality and the target durability. The plant also needed to ensure that the boiler could maintain sufficient pressure and flow while the pellet mill operated at the intended production rate.

RICHI's technical consultation covered a preliminary steam-demand range of approximately 250–350 kg/h for the pelletizing process. Although the selected boiler was rated at 500 kg/h, effective available steam output depended on operating pressure, steam quality, distribution losses and the needs of other connected equipment. The final system therefore required commissioning checks under actual production conditions.

Noug cake presented a particular challenge because its fibrous and oily characteristics could affect pellet formation. The production team found that adjusting its inclusion rate and conditioning settings helped improve consistency. Regular checks of pellet durability, moisture and fines were important for determining whether a formulation change had achieved the desired result.

Operating Experience After 14 Months

Approximately 14 months after delivery, the plant manager reported that the SZLH320 had accumulated around 3,000 operating hours. The mill generally ran for 10 hours per day, five days per week, although actual operating time depended on production schedules and maintenance.

The reported service experience differed by die size. The 3.5 mm starter die had lasted approximately 800 hours, the 4.0 mm finisher die around 1,000 hours, and the 4.5 mm layer die remained in service after approximately 1,200 hours. These figures reflected the customer's particular materials and operating practices rather than guaranteed replacement intervals.

“Adding the pelletizer has allowed us to supply products that our customers had been requesting. We can continue making mash feed while offering pellets to farms that prefer them. We have also learned more about the relationship between ingredient quality and pellet durability.

“Noug cake was one of the main challenges because its characteristics vary between batches. We adjusted the formulation and steam settings to improve pellet consistency. As demand grows, we plan to expand our pelletizing capacity with another SZLH320.”

The operating experience reinforced the importance of recording throughput, steam use, die condition and finished-product quality. These records helped the plant identify formulation-related problems and establish a more reliable basis for maintenance and future capacity planning.

Shipping the SZLH320 to Ethiopia

The feed pellet machine was shipped from Qingdao, China, to the Port of Djibouti, Ethiopia's principal maritime gateway. From Djibouti, the cargo continued by road for approximately 850 km to the Debre Zeit area.

Before delivery, the customer prepared the installation location, electrical connection and material-transfer arrangements. RICHI provided system-integration guidance, wiring diagrams, a recommended spare-parts package and remote commissioning assistance. This support was particularly important because the new pellet mill had to work with machinery already installed at the factory.

The installation also required the plant to coordinate the pellet mill, steam boiler, cooler and conveying equipment as one process. Checking interlocks, material flow and operating sequences helped the team establish a more consistent production routine.

Expanding Pelleted Feed Production in Ethiopia

The manufacturer subsequently ordered a second SZLH320 to respond to growing demand for pelleted poultry feed and was evaluating the SZLH350 for a future expansion. Additional capacity would allow the company to increase its share of pelleted products without immediately replacing the entire processing system.

For feed manufacturers in Debre Zeit, Addis Ababa and other Ethiopian poultry-producing areas, the appropriate investment depends on the required product mix, operating hours, raw-material availability and capacity of existing equipment. A pellet mill should be selected as part of the complete process, including grinding, mixing, steam generation, cooling and finished-feed handling.

This project demonstrates how a chicken feed pelletizer for feed processing system in Ethiopia can help a manufacturer move beyond mash production through a targeted equipment upgrade. The SZLH320 provided the missing pelletizing stage, while existing machinery continued to serve the broader feed manufacturing operation.

RICHI Machinery supplies ring die pellet mills and related feed processing equipment for manufacturers upgrading existing plants or planning new production facilities. By evaluating the required capacity, feed formulations, pellet dimensions and available utilities, buyers can identify a practical configuration for their own production objectives.