1 Ton Feed Mixer Machine for Feed Plant Efficiency Optimization in Indonesia

Before contacting us, the mill had been quoted by a Taiwanese manufacturer for twin-shaft paddle mixers, but the price—over $85,000 USD per unit—was too high to replace both mixers.

A feed industry consultant who had visited our factory recommended RICHI as a more affordable option that offered comparable mixing performance and faster cycle times.

The mill already had upstream equipment: a bale breaker and hammer mill for grinding maize (2.0mm screen), a separate grinder for soybean meal, and a micro-dosing system for vitamins and minerals. What they needed was a high-speed, high-uniformity mixer that could handle a batch every 3-4 minutes to keep up with their poultry feed production line.

After analyzing their feed samples at our testing facility, we recommended the SLHSJ2.0A twin-shaft paddle mixer with an 18.5kW motor and a batch capacity of 1,000 kg. The twin-shaft design reduces mixing time by 30-40% compared to ribbon mixers, directly addressing the mill's bottleneck. The mill purchased one unit initially, with an option for a second mixer later.

How Mixer Efficiency Affects Overall Feed Plant Throughput

In a commercial feed mill, every minute of downtime or extended mixing time translates directly into lost production. The mill's pelleting line could process 8 tons per hour, but the old ribbon mixers could only supply 6.5 tons per hour because of the long mixing cycles and frequent breakdowns. The plant manager calculated that upgrading the mixing section alone could increase overall plant output by 15-20% without adding any other equipment.

Twin-shaft paddle mixers like the SLHSJ series achieve a CV of under 5% in 2.5 to 3.5 minutes, compared to 6-8 minutes for ribbon mixers. This speed advantage comes from the counter-rotating paddle design, which creates a fluidized mixing zone and reduces the time needed for particle distribution. The mill's quality control team tested the first batches from the SLHSJ2.0A and found a CV of 3.8% after 3 minutes – meeting their target with room to spare. They eventually reduced the mixing time to 2.5 minutes, increasing the mill's effective mixing capacity to 12 tons per hour (enough to supply the pelleting line with excess capacity).

Machine Selection and Process Parameters for Broiler Feed

The mill selected the SLHSJ2.0A from our SLHSJ series of twin-shaft paddle mixers. The chain drive is well-suited to the tropical conditions in Surabaya (high humidity, occasional dust) because it is less sensitive to moisture than direct-coupled systems.

The 18.5kW motor draws about 35 amps at 380V, which was within the capacity of their existing electrical supply. The mixer is equipped with a pneumatic drop-bottom discharge that opens in under 5 seconds, directly feeding a bucket elevator that delivers the mash to the pellet mill conditioner.

The optimized process parameters were:

• Mixing time per batch: 2.5 minutes (down from 8 minutes on the old mixer)
• Number of batches per hour: 20 batches (20 tons per hour mixing capacity)
• Loading sequence: Half of the base grain (maize) first, then all the protein meals and minerals, then the remaining grain, then the liquid fat and molasses added over 30 seconds
• Filling level: 80% of the effective volume (1.6 cubic meters of material)

One challenge in tropical Indonesia is the high ambient temperature (often 32-35°C in the mill). The fat and molasses addition tended to clump when the ingredients were warm. The solution was to install a chilled water jacket on the liquid addition lines, which kept the fat at 25°C even on hot days. After this adjustment, the liquid was uniformly distributed without clumping.

What the Mixed Feed Is Used For

The mill produces two main products for the poultry market in East Java:

Broiler starter feed (for chicks 0-21 days):

• 45% ground maize (2.0mm)
• 25% soybean meal (46% protein)
• 12% wheat flour
• 8% fishmeal (local)
• 5% vegetable fat
• 3% molasses
• 2% minerals and vitamins

Broiler finisher feed (for chicks 22-35 days):

• 50% ground maize
• 20% soybean meal
• 12% wheat bran
• 8% palm kernel meal (local byproduct)
• 5% vegetable fat
• 3% molasses
• 2% minerals and vitamins

The mill reported that the new mixer reduced batch-to-batch variation significantly. Before, samples taken from the same formula on different days showed crude protein differences of up to 1.8 percentage points. After installing the SLHSJ2.0A, the variation dropped to under 0.5 percentage points – well within Indonesian feed safety standards. The mill also reduced the safety margin on protein inclusion, saving about 280 million rupiah ($18,000 USD) per year in ingredient costs.

The plant manager reported that the faster mixing cycles increased the mill's effective output from 6.5 tons per hour to 9.5 tons per hour – a 46% improvement – without adding any other equipment. The payback period for the mixer was under six months.

Why the Feed Mill Chose the SLHSJ Series Over Competitors

The plant manager evaluated three options before selecting RICHI:

• A Taiwanese twin-shaft mixer: $85,000 USD, 14-week lead time
• A locally assembled Indonesian mixer: $58,000 USD, 10-week lead time, but with a smaller motor and lighter construction
• RICHI SLHSJ2.0A: $28,500 USD delivered, 8-week lead time, full 12-month warranty, and a comprehensive spare parts kit

Beyond price, the deciding factor was the pre-sale material testing. RICHI engineers replicated the mill's broiler starter ration in Qingdao, measured the CV at 30-second intervals, and sent them a video of the mixing process. Seeing their own ingredients being mixed to a CV of under 5% in 2.5 minutes built confidence that no brochure could provide.

Customer Feedback After 12 Months of Operation

We spoke with the plant manager about a year after installation. Here is what he told us:

This feed mixer machine for feed plant efficiency optimization has exceeded our expectations. Our old ribbon mixers were the bottleneck in our production line. The SLHSJ2.0A cuts mixing time by two-thirds and produces a more uniform product. We have increased our output by nearly 50% without adding labor or expanding our building.

The only maintenance we have performed is lubricating the chain monthly and checking the paddle tip clearance. After 8,000 batches, the paddles show minimal wear. The pneumatic discharge gate has been trouble-free.

The mill has since purchased a second SLHSJ mixer – a SLHSJ4.0A with 2,000 kg batch capacity – for a new feed line being built in a different part of the plant. The plant manager says having dedicated mixers for broiler and layer feed prevents cross-contamination and eliminates clean-out downtime.

Other Applications of the SLHSJ Mixer in Indonesian Feed Mills

• Layer feed production: Mixing ground maize, soybean meal, limestone, and oyster shell for calcium supplementation
• Aquafeed pre-mixing: Creating base blends of fishmeal, soybean meal, and wheat flour before fine grinding
• Swine feed production: Blending ground maize, rice bran, soybean meal, and premixes for grower pigs
• Organic fertilizer mixing: Composting poultry litter with rice husks and minerals

The plant manager noted that they have also used the mixer to blend mycotoxin binders into incoming grain shipments during the wet season, protecting downstream feed from aflatoxin contamination.

Logistics: Shipping from Qingdao to Surabaya

The SLHSJ2.0A was shipped from Qingdao to the Port of Tanjung Perak in Surabaya – about 12 days at sea (short route). Surabaya is Indonesia's second-largest seaport and the main gateway for East Java. From the port, the customer arranged truck transport to the feed mill, approximately 15 kilometers inland. The total transit time was about 18 days – the fastest delivery of any mixer the mill had ever purchased.

Pre-Sale Services We Provided

• Batch testing with their formula: We replicated their exact broiler starter ration in Qingdao and provided a full mixing uniformity report (CV values at 30-second intervals)
• Heat analysis for liquid addition: We tested fat and molasses addition at different temperatures to find the optimal viscosity for clump-free distribution
• Control system integration: We provided PLC programming that tracks the number of batches per hour and alerts operators when maintenance is due
• Spare parts inventory planning: We recommended a spare parts kit based on their expected 16-hour-per-day operation
• Operator training video in Bahasa Indonesia: We had the video professionally translated and narrated, which the plant manager said was very helpful for training shift workers

The plant manager later told us that the batch testing gave him the confidence to reduce the mixing time from 4 minutes (their initial estimate) to 2.5 minutes – a decision that increased their line output significantly without compromising quality.

Plans for Additional Mixers

The feed mill is now planning to purchase a third SLHSJ mixer for a new aquaculture feed line. Aquafeed has different mixing requirements than poultry feed (smaller particle sizes, higher fat inclusion), but the twin-shaft paddle design can handle the range. The plant manager estimates that the new line, with a dedicated mixer, will add 30,000 tons per year of capacity.

Across Indonesia, a feed mixer machine for feed plant efficiency optimization is increasingly seen as a strategic investment, not just an equipment purchase. With feed demand growing at 8-10% annually, Indonesian feed mills need to increase output without proportionally increasing plant size or labor.

RICHI Machinery supplies the full range of SLHSJ twin-shaft mixers, SLHJ single-shaft paddle mixers, and SLHY ribbon mixers to feed mills throughout Southeast Asia and beyond. For more information or to schedule a material test at our Qingdao facility, contact RICHI Machinery today.