10T/H Livestock Pellet Feed Bagging Scale in Brazil

From the DCS series, the DCS-50K (gravity feed, high speed) was selected. Why this model?

• Gravity feed: Simple, reliable, works perfectly for dry livestock pellets
• High accuracy: ±0.2% dynamic = ±50 grams on 25kg (actual performance proved much better)
• Consistency: Digital load cells and anti-shock device ensure every bag is within spec
• Speed: 5-6 bags per minute – enough for their 10 ton/hour production
• PLC control: Maintains settings day after day, no drift
• Data logging: Can record bag weights for quality documentation

Roberto chose the DCS-50K with seam sealing only (sewn bags) – export bags are standard sewn paper.

What He's Packaging – Brazilian Livestock Pellets

Brazil is the world's largest beef exporter. Roberto's mill produces:

• Beef cattle grower pellets (5-6mm): 50% of production – 25kg bags for export, 40kg for domestic
• Dairy cow pellets (4-5mm): 30% of production – 25kg bags for export, 40kg for domestic
• Sheep feed pellets (3-4mm): 20% of production – 25kg bags

The raw materials are abundant in Mato Grosso:

• Corn (local – Mato Grosso is a top corn producer): 45-55%
• Soybean meal (local – Mato Grosso is Brazil's largest soybean producer): 20-25%
• Cottonseed meal (local – Brazil grows cotton): 10-15%
• Wheat bran (imported from southern Brazil): 5-10%
• Minerals and vitamins: 2-3%

The pellets are dry (11-12% moisture), free-flowing, durable – perfect for gravity feed.

Packaging for export: 25kg bags only. 800 bags per 20-foot container.

Installation – Precision from Day One

The DCS-50K arrived at the Port of Santos – Brazil's largest port, located in São Paulo state.

Shipping time from Qingdao to Santos is about 40-45 days (around the Cape of Good Hope or through the Panama Canal). The machine was packed in a 20-foot container with:

• DCS-50K main unit (gravity feeder, scale, PLC)
• Spare bag clamp rubbers (four sets)
• Spare pneumatic valves (two sets)
• Installation manual and electrical diagram in Portuguese

Customs clearance in Santos took about 7 days. Total landed cost was about 28% higher than the FOB price.

Installation took two days. The old scale (a Brazilian-made machine from the 1990s) was retired. The DCS-50K was positioned on a reinforced concrete platform. The electrical hookup was straightforward (380V, 60Hz – Brazil uses 60Hz, not 50Hz like most countries. RICHI provided a 60Hz-compatible motor.)

The pneumatic system required clean, dry air at 0.5MPa. Roberto upgraded his compressor with a dryer.

The calibration process was intensive. Roberto's quality team ran 200 test bags, weighing each on a certified scale. Results:

• Average error: 8 grams (0.032% of 25kg)
• Maximum error: 18 grams (0.072%)
• Standard deviation: 4.2 grams

The machine was ready.

Performance – Container Loading Optimized

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

Old Brazilian scale (before):

• Accuracy: ±80-150 grams (0.32-0.6% error)
• Bag weight variation: 24.85kg to 25.15kg typical
• Container loading: Could only load 780 bags (19,500kg) to leave margin for overweight – 20kg of unused capacity per container
• Annual loss from under-filled containers: 20kg/container × 1,600 containers/year = 32,000kg = 32 tons of unused capacity. At €400/ton freight value, that's €12,800
• Risk: Overweight containers (fines of $500-$1,000 each) – occurred 2-3 times per year

DCS-50K (after):

• Accuracy: ±10-20 grams (0.04-0.08% error)
• Bag weight variation: 24.99kg to 25.01kg typical
• Container loading: Can load 800 bags (20,000kg) consistently – full container capacity
• Annual gain from full containers: 32 tons of additional feed shipped without extra freight cost = €12,800 saved
• Overweight fines: Zero in six months

Giveaway reduction: From 0.3% average to 0.07% – about 104 tons/year saved (80,000 tons × 0.23%). At R$1,800/ton (about €300), that's R$187,200 (about €31,200) per year.

Container utilization gain: €12,800 per year

Total annual savings: Approximately €44,000

The machine cost delivered approximately €8,500. Payback period was about 2-3 months.

Customer Feedback – Roberto's Experience

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

"The old scale was a guessing game. Some bags were heavy, some were light. We had to underload our containers to avoid fines. That was wasted freight cost.

The DCS-50K changed everything. Every bag is within 20 grams of 25kg. We can load containers to full capacity – 800 bags exactly – without worrying about overweight fines. That's 32 tons of extra feed shipped every year without paying extra freight.

The accuracy is incredible. Our quality team does random checks every day. The worst bag we've seen was 22 grams off. Most are within 10-15 grams.

A few issues: The bag clamp rubbers wear out every 25,000 bags – about every 2 months at our volume. We buy them in packs of 20. The touchscreen is in English – my workers speak Portuguese. We printed Portuguese labels and stuck them on the screen.

The PLC data logging is useful. We record bag weights for each export shipment. If a customer questions a shipment, we have the data.

Would I recommend this machine? Yes. For any mill that exports, accuracy is not optional. The DCS-50K delivers."

Container Loading Math

The economics of container loading are simple:

• 20-foot container max gross weight: 24,000 kg
• Pallet weight: about 25 kg per pallet
• Bag weight: 25 kg
• Bags per pallet: 40 bags (1,000 kg)
• Pallets per container: 20
• Total bags per container: 800 bags (20,000 kg feed + 500 kg pallets = 20,500 kg – well under 24,000 kg)

With the old scale (25kg ± 100g average), the actual bag weight could be 25.1kg on average to avoid underweight. That's 800 × 0.1kg = 80kg extra weight per container. That doesn't exceed the limit, but it's giveaway. Actually, wait – if bags are heavier, that's more feed shipped, not less. The problem was underweight bags (24.9kg) that risked fines, or overweight bags (25.1kg) that increased freight cost? Let me clarify.

The real problem: To avoid underweight fines, Roberto set the scale to target 25.05kg average. Some bags were 25.15kg. That's giveaway. Other bags were 24.95kg – still legal but close to the limit. The variation meant he couldn't confidently load to full container capacity. He left margin – about 20kg of unused capacity per container.

With the DCS-50K, the average is 25.00kg with very little variation. He can load 800 bags confidently. No giveaway. No unused capacity.

Why Gravity Feed for Livestock Pellets

The DCS-50K uses gravity feed – the simplest feeding method. Here's why it was right for Roberto:

• Product type: Dry, free-flowing cattle pellets. No oil coating. Not sticky.
• Simplicity: Fewer moving parts than belt or auger systems. Less maintenance – important in Mato Grosso where service technicians may be far away.
• Speed: 5-6 bags per minute is plenty for their 10 ton/hour production.
• Accuracy: The digital load cells and anti-shock device deliver consistent accuracy, bag after bag.
• Data logging: The PLC records bag weights. Roberto's quality team uses this data for export documentation.

The Anti-Shock Device – Key to Consistency

The DCS-50K's anti-shock device stabilizes the scale during filling. When pellets drop into the bag, they create a shock load. Without anti-shock protection, the scale can overshoot or undershoot.

Roberto's installer adjusted the anti-shock device during commissioning. The result: consistent accuracy within 10-20 grams, bag after bag, hour after hour.

Data Logging for Export Documentation

The DCS-50K's PLC can record bag weights. Roberto's quality team downloads the data weekly. For each export shipment, they can produce a report showing:

• Date and time of each bag
• Target weight (25kg)
• Actual weight
• Deviation

If a customer questions a shipment, Roberto has the data. In six months, no customer has questioned a shipment.

The Sealing Method – Seam Only

Roberto uses seam sealing only – sewn bags. Why?

• Export bags are standard paper without plastic liner
• Buyers don't require heat sealing
• Simpler operation – one less thing to maintain

The workflow:

1. Operator puts empty bag on the clamp
2. Machine fills via gravity (6-8 seconds for 25kg)
3. Operator removes bag, places on conveyor
4. Second operator sews the top (15 seconds)
5. Second operator stacks on pallet (40 bags per pallet)
6. Forklift moves pallet to container loading area

Two operators, 5-6 bags per minute. The container loading area is separate – pallets are staged and loaded by a different team.

Shipping – Qingdao to Santos

The DCS-50K shipped from Qingdao to Port of Santos, Brazil – the largest port in Latin America.

Shipping time from Qingdao to Santos is about 40-45 days. The route can go through the Panama Canal or around the Cape of Good Hope depending on the season.

The machine was packed in a 20-foot container. Customs clearance in Santos took about 7 days. Total landed cost was about 28% higher than the FOB price – high freight and Brazilian import duties.

The truck transport from Santos to Mato Grosso was about 1,000km – roughly 15-18 hours.

What Roberto Learned – Lessons for Other Exporters

After six months of running the DCS-50K, Roberto shared several observations:

Lesson 1: Container optimization pays for the machine. The ability to load 800 bags per container instead of 780 added 32 tons of shipping capacity per year – about €12,800 in freight value. That alone covered the machine cost in 8 months.

Lesson 2: Data logging is essential for exports. Roberto's customers have never asked for bag weight data. But having it gives him confidence. If a customer ever questions a shipment, he has the records.

Lesson 3: Keep spare bag clamp rubbers. At 80,000 tons per year, Roberto goes through rubbers every 2 months. He buys them in packs of 20.

Lesson 4: Calibrate weekly. The load cell can drift in hot conditions (Mato Grosso summers are 35-40°C). Roberto calibrates every Monday morning. Takes 15 minutes.

Lesson 5: Train two operators on the PLC. Roberto has two operators trained to adjust settings, run calibrations, and download data. When one is on leave, the other can cover.

What RICHI Provided Beyond the Machine

RICHI provided several services that helped Roberto get the DCS-50K operational:

• Portuguese documentation: The manual and electrical diagram were provided in Portuguese.
• 60Hz motor: Brazil uses 60Hz power, not 50Hz. RICHI provided a 60Hz-compatible motor.
• Data logging setup: RICHI configured the PLC to record bag weights. Roberto's team was able to download data immediately.
• Remote support: When Roberto had questions about anti-shock adjustment, a RICHI technician walked him through it via WhatsApp video call. Total time: 25 minutes.

Is a Livestock Pellet Feed Bagging Scale Right for Your Operation?

For a feed mill that exports or supplies large farms with their own scales, the DCS-50K is the recommended choice.

Consider the DCS-50K if:

• Your product is dry pelleted feed
• You export or supply customers who weigh bags
• You want to optimize container loading
• Your annual production is 30,000-80,000 tons

Consider the DCS-50P*2 (twin-belt) if:

• Your annual production exceeds 80,000 tons
• You need more than 9 tons/hour bagging capacity

For Roberto's mill, the DCS-50K was the right investment. It eliminated container underloading, reduced giveaway by 0.23%, and paid for itself in less than three months.

Final Thoughts

If you're a feed mill that exports or supplies large farms, don't underestimate the value of accurate bag weights. Variation costs you in giveaway, in container utilization, and in customer trust.

The DCS-50K gravity-fed bagging scale delivers accuracy of ±0.2% dynamic – and often better. It's simple, reliable, and affordable. And with data logging, you can document every bag.

RICHI offers documentation in Portuguese, 60Hz motors, spare parts kits, and WhatsApp support. Contact RICHI Machinery through the website with your product type, bag sizes, and annual tonnage for a recommendation. Tell them about your export requirements – they can help you set up the data logging for container documentation.