10-12T/D Expansion Extruder for Grains in United States

From the dry extrusion table, the RCYP200G was selected. Why this model?

• Dry process: No boiler, no steam – runs on electricity only
• Soybean capacity: 1.7-2.3 tons per hour – enough for their daily requirement
• Bypass protein: Extrusion denatures protein, creating rumen-bypass characteristics
• Multi-purpose: Can also process corn for flaking or expansion
• Heavy-duty construction: Built for continuous operation in a feedlot environment

Tom chose the dry extruder because they had no steam boiler and didn't want to install one. The RCYP200G runs on a 132kW motor – plenty of power for their 10-12 tons per day requirement.

What He's Processing – Nebraska Soybeans

Nebraska is a major soybean-producing state. Tom's feedlot sources:

• Raw soybeans (local – within 50 miles): 100% of their soybean input
• Other ration ingredients: Corn, distillers grains, minerals, roughage

The raw soybeans arrive at 10-12% moisture. They are cleaned to remove stones and foreign material, then hammer-milled to a coarse meal (about 1,000-1,500 microns). The ground soybeans are then fed into the RCYP200G extruder.

The extrusion process for bypass soybeans:

1. Ground soybeans enter the extruder barrel
2. Screw rotation generates friction and heat (140-160°C)
3. Shear forces disrupt cell walls and denature proteins
4. The extruded material exits through a die plate
5. The expanded soybeans are then cooled and flaked or ground

The final product is full-fat, expanded soybeans with excellent bypass protein characteristics (35-40% bypass compared to 25-30% for raw soybeans).

Installation – No Boiler, No Steam Lines

The RCYP200G expansion extruder arrived at the Port of Houston – one of the largest ports in the US, located on the Gulf Coast. From there, it was trucked about 800 miles north to Nebraska.

Shipping time from Qingdao to Houston is about 25-30 days. The machine was packed in a 40-foot container (the RCYP200G is large) with:

• RCYP200G extruder main unit (132kW motor)
• Spare screw and barrel sections (one set)
• Spare die plates (three different hole sizes)
• Belt and pulley kit
• Cooling fan system
• Installation manual and electrical diagram in English

Customs clearance in Houston took about 3 days – very efficient. Total landed cost was about 22% higher than the FOB price.

Installation took two weeks. Tom's team prepared a concrete foundation in advance – the RCYP200G weighs about 4.5 tons. They poured a 200mm reinforced slab with anchor bolts.

The electrical hookup required a 460V, 60Hz three-phase supply (US standard). RICHI provided a 60Hz-compatible motor. The 132kW motor required a 200-amp breaker – Tom's electrician handled the installation.

No boiler was needed. No steam lines. No water treatment. This was the main advantage of dry extrusion.

The first test run was with hammer-milled soybeans at 11% moisture. The extruder started, the temperature climbed, and within 15 minutes, expanded soybeans were coming out of the die. The product temperature was 150°C. Tom's team let it cool, then ground it into meal. Lab tests showed excellent bypass protein levels.

Performance – Consistent Bypass Protein, Lower Cost

After six months of operation, Tom documented the following results:

Old machine (before):

• Cost of extruded soybeans: $550/ton delivered
• Annual usage: 3,000 tons = $1,650,000
• Freight cost: included in price but estimated at $50/ton
• Quality: variable – supplier's product varied by batch

DCS-50P belt-fed scale (after):

• Raw soybean cost: $380/ton (local)
• Energy cost (extruder): $15/ton (at $0.10/kWh)
• Labor and overhead: $10/ton
• Maintenance and parts: $5/ton
• Total in-house cost: $410/ton
• Annual cost for 3,000 tons: $1,230,000
• Annual savings: $420,000 (about 25% reduction)

Production output:

• Rated capacity: 1.7-2.3 tons/hour
• Actual output: 2.0 tons/hour average
• Daily output (10 hours): 20 tons – more than enough for their needs
• Runs 150 days per year to produce 3,000 tons

Quality improvements:

• Bypass protein: increased from 28% (supplier average) to 38% (in-house)
• Fat content: full-fat soybeans (18-20% oil) vs defatted meal – improved energy density
• Consistency: batch-to-batch variation reduced to ±2%

The machine cost delivered approximately $95,000. Payback period was about 3 months.

Customer Feedback – Tom's Experience

Here's what Tom said after six months (paraphrased from a conversation):

"The extruded soybeans we were buying were fine, but the freight was expensive and the quality varied. Some batches were darker than others. Some had lower bypass protein. We couldn't control it.

"The RCYP200G changed that. We control everything now – the raw beans, the extrusion temperature, the final grind. Our bypass protein is consistently 38-40%. The cattle are doing well – we've seen a slight improvement in average daily gain since switching to in-house extruded soybeans.

"The dry extrusion was the right choice because we don't have a boiler. The machine runs on electricity only. We plugged it in, connected the power, and started making extruded soybeans. It's that simple.

"A few operational notes: The temperature control is critical for bypass protein. Too low (under 130°C) and you don't get enough denaturation. Too high (over 170°C) and you damage the amino acids. We keep it at 145-155°C. We check the temperature every hour.

"The screw and barrel wear. After about 8,000 tons, the flights show wear. We bought spare parts with the machine. At our volume (3,000 tons/year), the original screw should last 2-3 years.

"Would I recommend this machine? Yes. For any feedlot that wants to control their own bypass protein production, dry extrusion is the way to go. No boiler. Lower cost. Better quality control."

Why Dry Extrusion for Bypass Protein

Dry extrusion uses mechanical friction to generate heat. No external steam is needed. Here's why it was right for Tom:

• No boiler required: Tom's feedlot had no boiler. Installing one would have cost $100,000+ plus annual maintenance. Dry extrusion eliminated that cost.
• Full-fat product: Wet extrusion often involves solvent extraction to remove oil. Dry extrusion produces full-fat soybeans – the oil remains, providing additional energy for cattle.
• Bypass protein: The heat and shear of extrusion denature the soybean proteins, creating rumen-bypass characteristics. Lab tests showed 38-40% bypass protein – excellent for high-producing cattle.
• Consistent product: The RCYP200G's temperature control system maintains stable output. Tom's product is consistent batch to batch.

The Science of Bypass Protein

Here's what happens inside the extruder for soybeans:

1. Feed zone: Ground soybeans enter the barrel. The screw moves them forward.
2. Kneading zone: Friction increases. Temperature rises to 100-120°C. Cell walls begin to rupture.
3. Cooking zone: Temperature reaches 140-160°C. Shear forces denature proteins. The 2S and 7S globulin proteins unfold, reducing rumen degradability.
4. Die zone: Material exits through a die plate. Pressure drops. The product expands slightly.

The result is full-fat, expanded soybeans with:

• 38-40% bypass protein (compared to 25-30% for raw soybeans)
• 18-20% oil (energy source)
• Anti-nutritional factors (trypsin inhibitors) deactivated

Tom's nutritionist was pleased with the lab results. The extruded soybeans are now a key component of their finishing ration.

The Multi-Purpose Capability

One of the features Tom appreciated is the machine's versatility. By changing the die plate and screw configuration, the RCYP200G can also process:

• Corn for flaking: Produces steam-flaked corn substitute for feedlot rations
• Full-fat soybeans (as they are doing)
• Barley expansion for brewing or feed
• Peas and other pulses for protein concentrates

Tom plans to experiment with corn expansion next. If successful, he can produce both expanded soybeans and expanded corn on the same machine.

Shipping – Qingdao to Houston

The RCYP200G shipped from Qingdao to Port of Houston, Texas – one of the busiest ports in the United States.

Shipping time from Qingdao to Houston is about 25-30 days. The route goes across the Pacific, through the Panama Canal, and across the Gulf of Mexico.

The expansion extruder was packed in a 40-foot container. Customs clearance in Houston took about 3 days. Total landed cost was about 22% higher than the FOB price.

The truck transport from Houston to central Nebraska was about 800 miles – roughly 12-14 hours.

What Tom Learned – Lessons for Other Feedlots

After six months of running the RCYP200G expansion extruder for grains, Tom shared several observations:

• Lesson 1: Dry extrusion is perfect for feedlots without boilers. The cost savings are significant. No steam system to maintain. No water treatment.
• Lesson 2: Temperature control is critical for bypass protein. Too low, and you don't get enough denaturation. Too high, and you damage amino acids. Tom's target is 145-155°C. He checks the temperature every hour.
• Lesson 3: Moisture control matters. Soybeans at 10-12% moisture extrude well. If moisture is too low (below 9%), the extruder runs too hot. If too high (above 13%), the expansion is weak. Tom tests every load of soybeans.
• Lesson 4: Cooling is essential. The expanded soybeans exit at 140-160°C. They need to cool to ambient temperature before grinding or storing. Tom installed a horizontal cooler (purchased separately) – cost about $15,000. Money well spent.
• Lesson 5: Spare parts are worth having. The screw and barrel wear over time. Tom bought a spare set with the machine. He expects the original to last 2-3 years at his volume. When it wears, he'll swap in the spare and have the worn one rebuilt locally.

What RICHI Provided Beyond the Machine

RICHI provided several services that helped Tom get the RCYP200G operational:

• English documentation: The manual and electrical diagram were in clear English.
• 60Hz motor: The US uses 60Hz power. RICHI provided a 60Hz-compatible motor.
• Bypass protein guidance: RICHI provided temperature recommendations for optimal bypass protein based on their testing.
• Spare parts kit: RICHI recommended a spare parts kit based on Tom's volume. He ordered it with the machine.
• Remote support: When Tom had questions about die plate selection, a RICHI technician walked him through it via video call. Total time: 30 minutes.

Is an Expansion Extruder for Grains Right for Your Operation?

For a cattle feedlot looking to produce high-bypass protein in-house, the dry extruder is an excellent choice.

Consider the RCYP200G (132kW) if:

• Your soybean requirement is 1.5-2.5 tons per hour (10-15 tons per day)
• You don't have a boiler on site
• You want full-fat, expanded soybeans with high bypass protein
• You also want flexibility to expand corn or other grains

Consider a smaller model (RCYP160G, 110kW) if:

• Your soybean requirement is 1.0-1.5 tons per hour

For Tom's feedlot, the RCYP200G expansion extruder for grains was the right investment. It reduced ingredient costs by 25%, improved bypass protein consistency, and paid for itself in three months.

Final Thoughts

If you're a cattle feedlot still buying extruded soybeans from a supplier, consider bringing extrusion in-house. The cost savings are significant – 25% or more. The quality control is better. And you eliminate freight costs.

The RCYP200G dry expansion extruder for grains makes full-fat, expanded soybeans with no boiler required. It runs on electricity only. It's powerful, efficient, and produces consistent bypass protein.

For feedlots, the math is simple: extruded soybeans cost less to make than to buy, and the quality is better.

RICHI offers documentation in English, 60Hz motors, spare parts kits, and remote support. Contact RICHI Machinery through the website with your daily soybean requirement, current soybean cost, and facility details for a recommendation. Tell them about your feedlot application – they can help you size the extruder properly and recommend temperature settings for optimal bypass protein.