0.5-0.8 T/H Pet Feed Pellet Drying Belt Machine in Italy

Breakage Challenge in Small Breed Kibble Production

A specialty pet food manufacturer in Emilia-Romagna, near Bologna, Italy, produces approximately 6,000 tons annually of small breed dog food.

Their products are sold in pet specialty stores across Italy, Switzerland, and Austria.

The kibble is only 5–6mm in diameter – delicate and fragile.

Their existing tower dryer used high-velocity hot air that tumbled the kibble aggressively, resulting in a 15–20% breakage rate.

Fines and dust were present in every bag, and customers frequently complained about "dusty food."

The manufacturer sought a drying method that does not tumble the product, preserving kibble integrity.

RICHI Solution: DHG-500 Electric Belt Dryer

After evaluating the application requirements, RICHI Machinery recommended the DHG-500 electric belt dryer.

The electric model was selected because the facility had no steam boiler – the DHG-500 runs on electricity only.

Key Selection Criteria

• No tumbling: Kibble sits stationary on the belt – zero breakage from impact
• Gentle airflow: Low-velocity air does not damage delicate pellets
• Capacity: 21 m² drying area – sufficient for 0.5–0.8 tons/hour
• 5-layer design: Uniform drying without product movement
• Compact footprint: Fits within the client's existing facility layout

Product Specifications: Small Breed Kibble

Italian pet food standards are rigorous. The small breed kibble formulation includes:

• Chicken meal (local – Italy has excellent poultry): 30–35% – protein source
• Rice (local – Italy grows Arborio rice): 25–30% – carbohydrate source
• Pea starch (imported): 10–15% – binder
• Chicken fat (local): 8–10% – energy source
• Beet pulp (local): 5–8% – fiber
• Vitamins and minerals: 2–3%

Kibble Physical Specifications

• Diameter: 5–6mm
• Length: 8–10mm
• Exit moisture from extruder: 24–26%
• Target final moisture: 8–10%
• Fragility: High – breaks easily under tumbling

Engineering & Customization: RICHI's Technical Expertise

RICHI's engineering team conducted a thorough pre-sale application review to match the dryer configuration to the delicate product requirements.

The belt mesh specification was customized to 1mm openings – finer than standard 2–3mm mesh – preventing small kibble from falling through the belt.

A graduated temperature profile was engineered across the 5 layers to prevent thermal stress cracking:

• Layer 1: 95°C – gentle surface drying
• Layer 2: 90°C – continued drying
• Layer 3: 85°C – reduced temperature
• Layer 4: 80°C – gentle finishing
• Layer 5: 75°C – final drying

RICHI also provided dust management guidance, including a compressed-air belt cleaning protocol to maintain airflow efficiency and product hygiene.

Logistics & Installation: Module Shipping & On-Site Commissioning

The DHG-500 was shipped from Qingdao to the Port of Ravenna on Italy's Adriatic coast.

Shipping time was approximately 30–35 days via the South China Sea, Indian Ocean, Suez Canal, and Mediterranean route.

The machine was disassembled into modular components and securely packed in a 20-foot container.

Customs clearance at Ravenna took approximately 4 days. The total landed cost was about 22% higher than the FOB price.

Road transport from Ravenna to Bologna covered approximately 80km, taking about 1 hour.

Installation & Commissioning

The client's team prepared a concrete foundation – a 200mm reinforced slab – as the DHG-500 measures approximately 8 meters in length.

Electrical hookup required 400V, 50Hz three-phase (Italian standard). The 50kW heater required a 120-amp breaker.

A RICHI field service engineer conducted on-site supervision during installation and led the commissioning process.

During the first test run with small breed kibble at 25% moisture, the belt speed was set to 20 minutes per layer – total drying time 100 minutes across 5 layers.

Layer thickness was calibrated to 15mm using a spreading gate, with hourly quality checks.

Output moisture reached 9%, and breakage rate dropped to under 2% – down from 18% with the previous tower dryer.

Operator Training

RICHI provided comprehensive on-site training for the client's production team, covering belt tension adjustment, mesh cleaning procedures, temperature profile optimization, and routine maintenance.

Documentation, including the manual and electrical diagrams, was provided in Italian for ease of use.

Performance Results: Six Months of Operation

Before (Tower Dryer)

• Breakage rate: 15–20% (fines and dust)
• Fines in bags: 5–8% by weight
• Production loss: 900–1,200 tons/year of broken product
• Customer complaints: 10–15 per month about "dusty food"
• Energy consumption: 120 kWh/ton

After (DHG-500 Belt Dryer)

• Breakage rate: 1.5–2% (90% reduction)
• Fines in bags: <1% by weight
• Production loss: 90–120 tons/year (saving over 800 tons annually)
• Customer complaints: Zero in six months
• Energy consumption: 85 kWh/ton (29% reduction)

Production Output

• Input moisture: 24–26%
• Output moisture: 8–10%
• Throughput: 0.7 tons/hour of dried kibble
• Daily output (16 hours): 11.2 tons
• Annual output: 3,500 tons (small breed line only)

Financial Impact

• Breakage reduction: 15% to 1.5% = 13.5% improvement
• Annual production: 3,500 tons × 13.5% = 472 tons saved
• Value of saved product: 472 tons × €1,500/ton = €708,000/year
• Machine cost delivered: approximately €45,000
• Payback period: approximately 1 month based on product savings alone

Why Belt Drying Is Essential for Delicate Small Kibble

Small kibble (5–6mm) is inherently fragile. Belt drying offers distinct advantages over tower dryers:

• No tumbling: Tower dryers use rotating drums or fluidized beds that tumble the product. Belt dryers keep the kibble stationary – no impact, no breakage.
• Gentle airflow: Low-velocity air (1–2 m/s) vs. high-velocity air (5–10 m/s) in tower dryers – less force on delicate pellets.
• Uniform drying: The 5-layer design ensures consistent moisture distribution, avoiding over-drying that makes kibble brittle.
• Low temperature: 85°C vs. 120–150°C in tower dryers – reduced thermal stress on delicate pellets.
• Fine mesh: 1mm openings prevent small kibble from falling through the belt.

Critical Operating Parameters for Small Kibble

Belt Mesh Selection

Standard belt mesh (2–3mm openings) allows small kibble to fall through. For this application, fine mesh was essential:

• Mesh opening: 1mm
• Wire diameter: 0.5mm
• Open area: 35%

The client purchased two spare belts with the machine and replaces them every 6 months as part of routine maintenance.

Layer Thickness Management

• Too thick (25mm+): Kibble at the bottom gets crushed by weight above
• Too thin (under 10mm): Low throughput
• Optimal: 15mm – maintained via spreading gate with hourly checks

Belt Cleaning Protocol

Fine dust builds up on the mesh over time. RICHI recommended a weekly cleaning schedule using compressed air – a 30-minute procedure performed every Friday.

Customer Feedback

After six months of operation, the client's production manager provided the following assessment:

"Small breed kibble is delicate. Tower dryers were destroying it – we were losing almost 20% of production to dust and fines. Customers complained about dusty bags.

The DHG-500 changed that. The kibble sits stationary on the belt. No tumbling. No aggressive air movement. Breakage dropped from 18% to under 2%. The bags are clean. Customers are happy.

The 5-layer design gives us 100 minutes of gentle drying. The temperature is low – only 85°C. The kibble comes out perfect – no cracks, no dust.

Operational notes: The belt mesh needs to be fine – 1mm openings – so small kibble doesn't fall through. Layer thickness is critical – 15mm maximum for tiny kibble. Belts need weekly cleaning – fine dust builds up.

Would I recommend this machine? Yes. For any manufacturer of delicate, small kibble, belt drying is the only way to prevent breakage. The DHG-500 paid for itself in a month."

RICHI's Value-Added Services

Beyond the machine itself, RICHI provided comprehensive support to ensure project success:

• Italian documentation: Full manual and electrical diagram provided in Italian
• Mesh customization: Fine mesh (1mm) specifically recommended and supplied for small kibble
• Temperature profiling: Graduated temperature guidance for delicate product drying
• Spare parts kit: Recommended kit based on production volume – including belts, heater elements, and sensors
• Remote technical support: Video call assistance for belt tension adjustment and troubleshooting
• On-site training: Comprehensive operator training covering all aspects of machine operation and maintenance

Is a Belt Dryer Right for Your Pet Food Operation?

Belt drying is recommended for pet food manufacturers producing delicate, small kibble if the following apply:

• Kibble diameter is under 8mm
• Breakage issues exist with tower dryers
• Capacity requirement is 0.5–1.0 tons/hour
• Product appearance and bag cleanliness are priorities

Consider the larger DHG-1000 model if capacity requirement is 1.0–1.5 tons/hour.

A Proven Investment for Delicate Pet Food Production

For the Italian small breed pet food manufacturer, the DHG-500 belt dryer proved to be the right investment.

It reduced breakage from 18% to under 2%, saved 472 tons of product annually (€708,000), and paid for itself within one month.

For pet food manufacturers producing small or delicate kibble, tower dryers cause breakage due to tumbling action, resulting in dust, fines, and unhappy customers.

The DHG-500 belt dryer keeps kibble stationary on the belt – no tumbling, no breakage, gentle airflow at low temperature – delivering perfect, intact kibble with no dust.

For delicate pet food, the math is simple: belt drying = no breakage = higher yield = faster payback.