1.1-2.9 T/H Grain Extruder for Animal Feed in Brazil

From the wet extrusion table, the RCYP160G (110kW with preconditioner) grain extruder for animal feed was selected. Why this model?

• Dry process with preconditioner: Steam injection for optimal starch gelatinization and protein denaturation
• Capacity: 1.1-1.4 tons/hour for corn, 2.0-2.9 tons/hour for soybeans – perfect for their needs
• Multi-purpose: Can process both corn and soybeans on the same machine
• Anti-nutritional factor elimination: Heat and shear destroy trypsin inhibitors in soybeans
• Starch gelatinization: Achieves 85-90% gelatinization for optimal digestibility

João chose the wet extruder because they had steam available and wanted the highest possible digestibility for their piglet starter feed.

What He's Processing – Brazilian Corn and Soybeans

Brazil is a major producer of both corn and soybeans. Santa Catarina grows significant amounts of both. João's mill sources:

• Corn (local – within 100km): For starch gelatinization
• Soybeans (local): For full-fat soybean meal with bypass protein and energy

The raw corn arrives at 13-14% moisture. It is hammer-milled to pass through a 2-3mm screen. The raw soybeans are cleaned and also hammer-milled to a coarse meal.

The extrusion process for piglet feed ingredients:

For corn:

1. Corn flour enters the preconditioner
2. Steam (100-110°C) is added to raise moisture to 22-25%
3. Preconditioned corn enters the extruder barrel
4. Temperature rises to 120-140°C. Starch gelatinizes (85-90%)
5. Expanded corn exits the die, is cooled, and ground into flour

For soybeans:

1. Soybean meal enters the preconditioner
2. Steam (110-120°C) is added – higher temperature needed to destroy trypsin inhibitors
3. Preconditioned soy enters the extruder barrel
4. Temperature reaches 140-160°C. Trypsin inhibitors are destroyed (>95% reduction)
5. Expanded soybeans exit, are cooled, and ground

The final products are highly digestible corn starch (90%+ digestibility) and full-fat soybean meal with no anti-nutritional factors.

Installation – Using Existing Steam

The RCYP160G grain extruder for animal feed arrived at the Port of Santos – Brazil's largest port, located in São Paulo state. From there, it was trucked about 600km south to Santa Catarina.

Shipping time from Qingdao to Santos is about 35-40 days. The machine was packed in a 40-foot container with:

• RCYP160G extruder main unit (110kW motor)
• Preconditioner (7.5kW) with steam and water injection ports
• Spare screw and barrel sections (one set)
• Die plates (three different sizes for corn and soy)
• Spare knives and cutting head assembly
• Installation manual and electrical diagram in Portuguese

Customs clearance in Santos took about 7 days. Total landed cost was about 25% higher than the FOB price.

Installation took two weeks. João's team already had a boiler on site (8 bar steam). They ran steam lines to the preconditioner, installed pressure regulators, and added a water treatment system.

The electrical hookup required 380V, 60Hz three-phase (Brazil uses 60Hz in most regions). RICHI provided a 60Hz-compatible motor. The 110kW motor required a 250-amp breaker.

The first test run was with corn. The preconditioner added steam to bring the moisture to 24%. The extruder ran smoothly. The expanded corn had good puffing – about 3x expansion. Lab tests showed 88% starch gelatinization. Excellent.

The second test run was with soybeans. Higher temperature needed – 150°C at the die. Trypsin inhibitor activity was reduced by 96% – well within safe levels for piglets.

Performance – Higher Digestibility, Lower Cost

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

Before (buying extruded ingredients from supplier):

• Extruded corn cost: R$1,200/ton (about €200/ton) delivered
• Extruded soy cost: R$1,800/ton (about €300/ton) delivered
• Annual usage: 1,200 tons corn + 800 tons soy = R$2,880,000 (about €480,000)

After (in-house with RCYP160G):

• Raw corn cost: R$600/ton
• Raw soybean cost: R$900/ton
• Energy (electricity + steam): R$100/ton for corn, R$120/ton for soy
• Labor and overhead: R$50/ton
• Maintenance and parts: R$30/ton
• Total in-house cost (corn): R$780/ton (saving R$420/ton)
• Total in-house cost (soy): R$1,100/ton (saving R$700/ton)
• Annual savings: (1,200 × 420) + (800 × 700) = R$504,000 + R$560,000 = R$1,064,000 (about €177,000)

Production output:

• Corn: 1.2 tons/hour actual (rated 1.1-1.4)
• Soy: 2.4 tons/hour actual (rated 2.0-2.9)
• Daily output (10 hours): 12 tons corn or 24 tons soy – more than enough
• Runs 200 hours for corn, 100 hours for soy annually to meet needs

Quality improvements:

• Corn starch gelatinization: 88% (supplier averaged 82%)
• Soy trypsin inhibitor reduction: 96% (supplier averaged 92%)
• Piglet performance: Reduced scours by 30% (farm feedback)
• Feed conversion ratio: Improved by 5%

The grain extruder cost delivered approximately R$550,000 (about €92,000). Payback period was about 6 months.

Customer Feedback – João's Experience

Here's what João said after six months (paraphrased from a conversation, translated from Portuguese):

"The supplier's extruded ingredients were fine, but they were expensive and the quality varied. Some batches of extruded corn had lower gelatinization. Some batches of extruded soy had higher trypsin inhibitor levels. We couldn't control it.

"The RCYP160G changed that. We control everything now – the raw grains, the steam addition, the extrusion temperature. Our corn gelatinization is consistently 85-90%. Our soy trypsin inhibitor reduction is consistently 95-98%. The piglets are doing better – less scours, better growth.

"The wet extrusion with preconditioner was the right choice because we already had a boiler. The preconditioner gives us precise control over moisture and temperature. Without it, dry extrusion would be less consistent.

"A few operational notes: The die plates wear faster with soybeans – the oil and fiber are abrasive. We change die plates every 400 hours for soy, 600 hours for corn. We bought spare plates with the machine.

"The steam pressure needs to be stable. We had some fluctuations early on. We installed a pressure regulator and accumulator tank – problem solved.

"Would I recommend this machine? Yes. For any pig feed manufacturer making starter feed, extruded corn and soy are essential. The RCYP160G delivers consistent quality at lower cost."

Why Wet Extrusion for Piglet Feed

Piglets have immature digestive systems. Here's why wet extrusion is critical:

• Starch gelatinization: Raw corn starch is crystalline and difficult for piglets to digest. Extrusion melts the crystalline structure, making starch available to enzymes. Gelatinization of 85%+ is recommended for piglet starter feed.
• Trypsin inhibitor destruction: Raw soybeans contain trypsin inhibitors that block protein digestion and cause scours. Heat treatment (140-160°C) destroys these inhibitors. Wet extrusion achieves this consistently.
• Full-fat soybeans: Extrusion allows the use of full-fat soybeans (18-20% oil) rather than defatted meal. The oil provides energy for fast-growing piglets.
• Palatability: Extruded grains have a pleasant, toasted flavor that piglets prefer.

João's nutritionist tested the extruded products:

• Raw corn: 65% digestibility
• Extruded corn (RCYP160G): 88% digestibility
• Raw soybeans: Trypsin inhibitor activity = 40 mg/g
• Extruded soybeans (RCYP160G): Trypsin inhibitor activity = 1.5 mg/g (96% reduction)

The results speak for themselves.

The Preconditioner – Key to Consistency

The preconditioner is what makes wet extrusion different from dry extrusion. Here's how João uses it:

For corn:

• Steam injection: 100-110°C
• Moisture target: 22-25%
• Residence time: 45 seconds

For soybeans:

• Steam injection: 110-120°C
• Moisture target: 18-20% (lower than corn because soybeans have their own oil)
• Residence time: 60 seconds

The preconditioner ensures consistent moisture and temperature entering the extruder. This results in consistent expansion and gelatinization.

Multi-Purpose Capability

One of the features João appreciated is the machine's versatility. By changing the die plate and adjusting the preconditioner settings, the RCYP160G can process:

• Corn for piglet feed (high gelatinization)
• Soybeans for full-fat meal (trypsin inhibitor destruction)
• Corn-soy blends (50:50 mix for complete starter concentrate)
• Barley and wheat for other animal feeds

João plans to experiment with barley next for their grower feed line.

Shipping – Qingdao to Santos

The RCYP160G shipped from Qingdao to Port of Santos, Brazil – the country's largest port.

Shipping time from Qingdao to Santos is about 35-40 days. The route goes across the Pacific, through the Panama Canal, and down the Atlantic coast of South America.

The machine was packed in a 40-foot container. Customs clearance in Santos took about 7 days. Total landed cost was about 25% higher than the FOB price.

The truck transport from Santos to Santa Catarina was about 600km – roughly 8-10 hours.

What João Learned – Lessons for Other Pig Feed Manufacturers

After six months of running the RCYP160G, João shared several observations:

• Lesson 1: Wet extrusion is worth it for piglet feed. The preconditioner provides consistent moisture and temperature, resulting in higher and more consistent gelatinization and trypsin inhibitor reduction.
• Lesson 2: Steam quality matters. Wet steam (low quality) causes inconsistent preconditioning. João installed a steam separator to ensure dry, saturated steam. The difference was noticeable.
• Lesson 3: Die plates wear – keep spares. Soybeans are more abrasive than corn. João changes die plates every 400 hours for soy, 600 hours for corn. He bought 4 plates with the machine.
• Lesson 4: Test your ingredients. Not all corn is the same. João tests each batch of corn for moisture and hardness. He adjusts the preconditioner settings accordingly. Took 2 weeks to develop the procedure, but now it's routine.
• Lesson 5: Cooling is essential. Extruded products exit at 120-150°C. They need to cool to ambient temperature before grinding or storing. João installed a horizontal cooler (purchased separately) – cost about R$80,000 (€13,000). Money well spent.

What RICHI Provided Beyond the Machine

RICHI provided several services that helped João get the RCYP160G operational:

• Portuguese documentation: The manual and electrical diagram were provided in Portuguese.
• 60Hz motor: Brazil uses 60Hz power. RICHI provided a 60Hz-compatible motor.
• Steam quality guidance: RICHI provided recommendations for steam pressure and quality for optimal preconditioning.
• Spare parts kit: RICHI recommended a spare parts kit based on João's volume – including spare die plates, knives, and screw sections.
• Remote support: When João had questions about trypsin inhibitor reduction temperatures, a RICHI technician walked him through the testing via video call. Total time: 1 hour.

Is a Grain Extruder for Animal Feed Right for Your Operation?

For a pig feed manufacturer producing starter feed for piglets, a wet extruder with preconditioner is the standard.

Consider the RCYP160G (110kW with preconditioner) if:

• You need 1.0-1.5 tons/hour of extruded corn or 2.0-3.0 tons/hour of extruded soy
• You have steam available on site (or are willing to install a boiler)
• You want 85%+ starch gelatinization and 95%+ trypsin inhibitor reduction
• You need flexibility to process both corn and soybeans

Consider a smaller model (RCYP140G, 75kW) if:

• Your volume is lower (0.5-1.0 tons/hour corn)

Consider a larger model (RCYP200G, 132kW or 160kW) if:

• Your volume is higher (1.5-2.5 tons/hour corn or 3.0-4.5 tons/hour soy)

For João's pig feed mill, the RCYP160G was the right investment. It reduced ingredient costs by 30-40%, improved piglet health, and paid for itself in six months.

Final Thoughts

If you're a pig feed manufacturer producing starter feed for piglets, extruded corn and soybeans are essential. Raw grains just don't work for young pigs – digestibility is too low, and anti-nutritional factors cause scours.

The RCYP160G wet grain extruder for animal feed with preconditioner produces highly digestible corn starch (85-90% gelatinization) and safe, full-fat soybean meal (95%+ trypsin inhibitor reduction). It runs on steam and electricity. It's flexible, efficient, and built for feed-grade production.

For piglet feed, the math is simple: in-house extrusion costs less than buying extruded ingredients, and the quality is better. Healthier piglets, better feed conversion, lower costs.

RICHI offers documentation in Portuguese, 60Hz motors, steam quality guidance, spare parts kits, and remote support. Contact RICHI Machinery through the website with your daily corn and soy requirements, current costs, and facility details for a recommendation. Tell them about your piglet feed application – they can help you size the extruder properly and recommend temperature settings for optimal gelatinization and trypsin inhibitor reduction.