1000KG Feed Mixer Machine for Improving Feed Digestibility in South Africa

The feedlot already had a hammer mill for grinding maize and a tub grinder for processing hay bales. What they lacked was a high-performance mixer capable of producing a uniform total mixed ration (TMR) where every mouthful had the same nutrient composition. They needed a machine that could handle light, fibrous hay particles and dense, heavy grain particles without separation, and that could incorporate 3% molasses without forming sticky clumps.

After analyzing samples of their diet components —ground maize (2.5mm particle size), chopped buffalo grass hay (15-20mm), cottonseed meal, and liquid molasses—we recommended the SLHSJ2.0A twin-shaft paddle mixer with an 18.5kW motor and a batch capacity of 1,000 kg. This model's dual opposing paddle shafts create a fluidized mixing zone that keeps even light hay particles suspended, preventing segregation. The feedlot purchased one unit as a standalone replacement for their old vertical mixer.

Why Improved Mixing Uniformity Directly Affects Digestibility

In a beef feedlot, feed digestibility starts with mixing. If the ration is not uniform, the rumen microbes cannot adapt to a consistent substrate. The feedlot nutritionist had conducted a particle size separation test on batches from their old mixer: the coefficient of variation (CV) was consistently above 15%, meaning that some animals were getting finishing rations while others were effectively getting maintenance rations. This variation also increased the risk of sub-acute ruminal acidosis (SARA) in cattle that received more grain than intended.

The SLHSJ series mixers achieve a CV of under 5% after three to four minutes of mixing time, which the nutritionist confirmed would be sufficient to stabilize rumen fermentation across the pen. The twin-shaft design also has a lower shaft speed (about 40 rpm) than competitor models, which reduces particle size degradation – important for maintaining the effective fiber length needed for rumen health.

Machine Selection and Mixing Parameters for the Feedlot Ration

The feedlot selected the SLHSJ2.0A from our SLHSJ series of twin-shaft paddle mixers. This model features chain drive (durable and easy to maintain in remote locations), carbon steel construction, and a batch capacity of 1,000 kg. 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 five seconds, dumping the batch directly into a TMR feed wagon.

The mixing parameters that gave the best digestibility results were:

• Mixing time per batch: 3.5 minutes (reduced from 4 minutes after they optimized the loading sequence)
• Loading sequence: Hay first (chopped to 15mm), then half the grain and protein meal, then the molasses, then the remaining grain, and finally the mineral premix on top
• Filling level: 85% of the trough volume (1.7 cubic meters of material in a 2.0 cubic meter mixer). Overfilling reduced mixing quality.
• Discharge: Pneumatic gate opens after mixing completes, gravity drop into a waiting TMR trailer

One critical adjustment was slowing down the addition of molasses. When they poured it too fast, the molasses would form sticky balls with the ground maize. By adding it through the spray nozzles over a 30-second period while the mixer was running, the molasses coated the particles evenly without clumping.

What the Ground and Mixed Feed Is Used For

The feedlot produces a single finishing ration for all 8,000 head, but they adjust the feeding rate by pen based on average weight. The ration formula is:

• 35% ground maize (2.5mm screen, processed through their RICHI hammer mill)
• 25% chopped buffalo grass hay (15mm length, processed through their tub grinder)
• 15% wet brewers' grains (purchased from a brewery in Johannesburg, 70% moisture)
• 10% cottonseed meal (local protein source)
• 8% molasses
• 5% limestone and salt
• 2% feed additives (ionophores and vitamins)

The mixed feed is delivered to each pen by a TMR mixer wagon. The feedlot manager reported that the SLHSJ2.0A reduced batch-to-batch variation significantly. Before, samples taken from different parts of the old mixer showed crude protein differences of up to 3 percentage points.

After installing the twin-shaft mixer, the variation dropped to under 0.5 percentage points. This consistency allowed the nutritionist to lower the safety margin on protein inclusion, saving about R150,000 ($8,000 USD) per year in ingredient costs.

Average daily gain (ADG) across the feedlot increased from 1.4 kg per day to 1.62 kg per day – a 16% improvement – which the manager attributes primarily to more consistent energy intake. The incidence of SARA (diagnosed by fecal consistency scoring) dropped by 70% in the first six months after the mixer was installed.

Why the Feedlot Chose the SLHSJ Series Over Competitors

The feedlot manager evaluated three options before selecting RICHI:

• A European twin-shaft mixer: R1.2 million ($65,000 USD), 14-week lead time
• A locally assembled South African mixer: R850,000 ($46,000 USD), 8-week lead time, but with a smaller motor and lighter construction
• RICHI SLHSJ2.0A: R380,000 ($20,500 USD) delivered, 8-week lead time, full 12-month warranty, and a comprehensive spare parts kit included

Beyond price, the deciding factor was the pre-sale material testing. RICHI engineers replicated the feedlot's exact ration in Qingdao, measured the mixing uniformity coefficient (CV of 3.2% after 3.5 minutes), and sent them a video of the mixing process. Seeing their own ingredients (samples they had air-freighted) being mixed to a uniform consistency built the trust that no brochure could provide.

Customer Feedback After 14 Months of Operation

We spoke with the feedlot manager about 14 months after installation. Here is what he told us:

"This feed mixer machine for improving feed digestibility has done exactly what we hoped. Before, we had trouble with cattle sorting through the feed – they would eat the maize and leave the hay.

The twin-shaft action keeps everything suspended. The hay particles are coated with molasses, so the cattle cannot separate them from the grain. The pen riders say the bunks are consistently cleaner after feeding, which means less waste and better intake.

The only maintenance issue we have seen is wear on the paddle tips after about 2,500 batches, which is reasonable given that we mix abrasive cottonseed meal and hay. The spare paddle set we ordered with the machine still sits in storage – we have not needed it yet. The chain drive has required tensioning once, which our mechanic did in 20 minutes."

The feedlot has since ordered a second SLHSJ mixer – a smaller SLHSJ1.0A – for mixing custom mineral blends and medicated premixes. The manager says having a dedicated mixer for additives prevents cross-contamination and allows tighter control of micronutrient inclusion rates.

Other Applications of the SLHSJ Mixer in Southern Africa

The twin-shaft paddle mixer is highly versatile beyond beef feedlots. In Southern Africa, similar mixers are used for:

• Dairy TMR production: Mixing fresh grass silage, maize silage, ground maize, protein meal, and minerals for high-producing Holsteins
• Swine feed production: Blending ground maize, soybean meal, and premixes for grower and finisher pigs
• Poultry feed pre-mixing: Creating base mixes of micro-ingredients before final blending in larger ribbon mixers
• Organic fertilizer mixing: Composting manure with rock phosphate and lime to produce uniform fertilizer blends
• Pet food production: Combining rendered meat meal, grains, and vitamins before extrusion

The feedlot manager also noted that they have used the mixer to blend salt licks (mixing salt with trace minerals) for their backgrounding cattle. The high shear action of the paddles breaks down any clumps in the salt, producing a free-flowing product.

Logistics: Shipping from Qingdao to Durban

The SLHSJ2.0A mixer machine was shipped from Qingdao to the Port of Durban – about 28 days at sea. Durban is South Africa's busiest container port and the primary gateway for the North West Province. From Durban, the customer arranged truck transport to Klerksdorp, approximately 600 kilometers inland.

The total transit time was about 38 days. The mixer was shipped in a single 40-foot high-cube container, fully assembled except for the motor and the pneumatic discharge gate, which were packed separately. The customer's team installed the motor and connected the electrical controls in less than a day.

Pre-Sale Services We Provided

Before the feedlot placed their order, we offered:

• Ingredient density and flowability testing: We analyzed their ground maize, hay, cottonseed meal, and molasses to determine the optimal mixing time and paddle speed
• Mixing uniformity validation: We produced a batch of their custom ration, sampled it at 30-second intervals, and sent them a laboratory report showing CV values at each time point
• Molasses addition system design: We custom-designed the spray nozzles to provide a fine mist that coats particles uniformly without creating sticky masses
• Load cell integration: We provided a three-point load cell kit so the feedlot can precisely batch ingredients by weight rather than by volume
• Operator training video: We created a step-by-step video in English, showing the correct loading sequence to prevent bridging in the mixer

The feedlot manager later told us that the operator training video was particularly useful because they hired new staff three months after installation, and the video allowed them to train the new employees without waiting for a RICHI engineer to return to the site.

Plans for a Second Mixer

The feedlot is now planning to purchase a larger SLHSJ4.0A with a 2,000 kg batch capacity to handle increased production volume. The new mixer will be used for a different ration – a backgrounding diet for newly arrived calves that contains a higher proportion of roughage and lower energy.

The farm intends to dedicate the existing SLHSJ2.0A to the finishing ration, avoiding flavor carryover between the two diets. The feedlot manager estimates that having dedicated mixers will eliminate the need for a clean-out batch between ration changes, saving about 30 minutes of downtime per day.

Across South Africa, a feed mixer machine for improving feed digestibility is no longer just for large commercial feedlots. Smaller feedlots and mixed farms are discovering that uniform mixing pays for itself in lower feed costs and faster weight gain.

RICHI Machinery supplies the full range of SLHSJ twin-shaft mixers as well as SLHJ single-shaft paddle mixers and SLHY ribbon mixers to livestock operations throughout Africa. For more information or to schedule a material test at our Qingdao facility, contact RICHI Machinery today.