2–3 T/H Fine Powder Grinder for Pet Food in United Kingdom

Why Grain-Free Pet Food Required a Different Grinding Method

Peas, lentils and chickpeas behave differently from the cereals commonly used in conventional pet food. Their seed coats and internal structures can be difficult to break down uniformly, particularly when the formulation requires fine powder for consistent mixing and extrusion.

The manufacturer's existing animal feed hammer mill produced pulse particles typically measuring 300–500 μm. Although this was acceptable for some conventional recipes, the resulting powder was too coarse for the texture targets of its premium grain-free range. Output was also limited to approximately 1.2 T/H when processing these ingredients.

The company needed more than a higher-capacity grinder. It required closer control over the final particle-size distribution, repeatable results across different pulse varieties, and a dedicated machine that would not disrupt its established production schedule.

SWFL110 Fine Powder Grinder: Technical Configuration

RICHI recommended the SWFL110 Ultrafine Pulverizer because its ultrafine grinding and classification arrangement matched the manufacturer's fineness and throughput requirements. The rated capacity is 2–3 T/H, depending on the material characteristics, incoming particle size and required grinding fineness.

The separate grinding arrangement allowed the manufacturer to process pulse ingredients without repeatedly changing the setup of its existing hammer mill. It also gave the production team greater flexibility when scheduling conventional and grain-free products.

Raw Materials and Preparation Before Ultrafine Grinding

The grain-free formulations use yellow peas as a principal carbohydrate ingredient, alongside red lentils and chickpeas. Chicken meal supplies animal protein, while potato protein, poultry fat, vitamins and minerals contribute to the finished recipe. The precise proportions vary according to the nutritional requirements of each product.

Incoming pulses undergo preliminary size reduction before entering the SWFL110. Yellow peas and chickpeas are generally pre-crushed through a 2.0 mm screen, while red lentils can be prepared using a 1.5 mm screen. This step helps establish a more consistent feed condition for the fine grinding stage.

After preliminary crushing, the material enters the grinding chamber, where high-speed hammers reduce particle size. Airflow carries the ground material toward the classifier wheel. Particles that meet the required separation conditions proceed to collection, while coarser material returns for further grinding.

This arrangement is particularly useful when a pet food ingredient grinding machine must handle several pulse varieties. The team can adjust the operating settings according to the material and verify the result through sieve testing rather than assuming that one setting will work equally well for every batch.

Classifier Control for a Consistent Powder Size

For this project, the target was 100–150 μm. Achieving that range consistently was important because the manufacturer wanted a uniform flour-like ingredient before mixing and extrusion.

During commissioning, yellow peas were pre-crushed and processed through the SWFL110. A sieve test showed that approximately 93% of the sample passed a 100-mesh sieve with an opening of about 150 μm, while approximately 85% passed a 120-mesh sieve with an opening of about 125 μm.

These results provided a practical basis for adjusting the classifier and checking subsequent batches. Mesh designations are not interchangeable with micron measurements, so the manufacturer continued to evaluate the actual particle-size distribution against its production requirements.

The finer powder helped the formulation team obtain a more uniform mixture for extrusion. The grinder prepares the ingredient; the downstream extruder and its die determine the final kibble shape and dimensions.

Installation at the Yorkshire Pet Food Factory

The SWFL110 was shipped from Qingdao, China, to the Port of Immingham in the United Kingdom. Sea transit took approximately 30–35 days, followed by customs clearance and road transport to the Yorkshire facility.

Because the main grinder weighs approximately 5.5 tons, the installation plan accounted for foundation loading, vibration control, equipment access and maintenance clearance. The customer prepared a reinforced concrete foundation with vibration-damping mounts before positioning the machine.

The electrical installation was specified for a 415 V, 50 Hz, three-phase supply, with the site's electrical team responsible for confirming the final protective devices and cable sizing against the equipment documentation and applicable requirements.

Dust collection also required careful planning. Fine pulse flour can form combustible dust clouds, so the customer incorporated a dust collection arrangement with appropriate explosion-protection measures, including venting provisions selected for the installation. The delivered equipment package included the main grinding unit, classifier assembly, feeder, cyclone and airlock discharge components, spare wear parts, and English-language operating and electrical documentation.

Installation and commissioning took approximately two weeks. Initial trials focused on yellow peas, classifier adjustment, powder collection and verification of the finished particle size.

Production Results After Six Months

After six months of operation, the manufacturer reported improvements in both throughput and ingredient consistency. Its internal production records showed the following comparison for pulse grinding:

The finer ingredient powder supported a smoother, more uniform kibble texture. The manufacturer also reported that complaints concerning gritty product texture had stopped during the six-month observation period.

The reported palatability and in-vitro digestibility figures came from the manufacturer's own trials. They should be understood as results from this particular formulation and operating setup, not as guaranteed improvements for every grain-free pet food recipe.

At an average output of 2.2 T/H, an eight-hour shift produces approximately 17.6 tons of pulse flour. The manufacturer estimated annual throughput at about 4,500 tons for the dedicated grain-free line, while its wider business continued producing other dry pet food recipes.

Wear Parts, Cleaning and Daily Operation

Pulse ingredients place different demands on the grinding components from those encountered with conventional cereals. The Yorkshire team found that standard hammers wore more quickly when processing peas and lentils. Alloy-protected hammers extended the observed service interval, although actual wear depended on material characteristics and operating conditions.

The team also established separate preliminary screen settings for different pulse varieties and routinely checked powder fineness with sieve tests. This allowed operators to identify changes in incoming material and adjust the grinding settings when necessary.

Because fine powder production creates dust, the operating routine includes inspection of the grinding chamber, dust collection equipment and wear components. Regular cleaning and maintenance help limit buildup, support stable airflow and reduce the risk of unexpected production interruptions.

Investment and Commercial Considerations

The manufacturer reported a delivered equipment cost of approximately £52,000 and estimated a payback period of around nine months. These figures reflected its own production volumes, product positioning and commercial assumptions; actual returns will depend on equipment utilization, ingredient costs, maintenance, energy consumption and market demand.

The main investment advantage was the ability to improve one constrained process without replacing equipment that remained suitable for other products. The SWFL110 created a dedicated route for fine pulse grinding, while the original hammer mill continued serving conventional recipes.

For other pet food manufacturers in the United Kingdom, the appropriate solution depends on the target powder size, material characteristics and required throughput. A plant processing mainly cereals may have different requirements from one developing recipes around peas, lentils or chickpeas. These differences should be considered before selecting a fine grinding system.

A Dedicated Ultrafine Grinding Solution for Grain-Free Pet Food

This Yorkshire project demonstrates how an SWFL110 fine powder grinder for pet food can address the specific demands of pulse-based ingredient preparation. The 110 kW machine achieved an average output of 2.2 T/H in the manufacturer's application and provided a more controlled route to 100–150 μm powder.

Rather than rebuilding the entire production line, the manufacturer added one machine to handle the grinding duty that its existing hammer mill could not perform to the required standard. The resulting arrangement improved production flexibility and helped the company support its premium grain-free product range.

RICHI Machinery supplies ultrafine grinding equipment for pet food ingredient processing. For a project involving peas, lentils, chickpeas or other challenging raw materials, the recommended configuration should be based on the actual ingredients, incoming particle size, target fineness and production capacity. Contact RICHI Machinery to discuss the appropriate grinding arrangement for your pet food manufacturing facility.