1-2T/H Pet Feed Ultrafine Crusher in Italy

From the ultrafine grinder table, the SWFL90 (90kW) was selected. Why this model?

• Fine grinding: 80-200 mesh (75-180 microns) – can achieve 100-120 mesh (120-150 microns)
• Capacity: 1.0-2.0 tons/hour – matches their 6-8 ton/day requirement
• Tiny kibble: Fine flour creates strong dough for small-diameter extrusion
• Classifier wheel: Ensures consistent particle size
• Digestibility: Senior dogs digest finer particles more easily

Marco chose the SWFL90 pet feed ultrafine crusher because their existing hammer mill couldn't achieve the required fineness for tiny kibble.

What He's Processing – Italian Pet Food Ingredients

Italy has a sophisticated pet food industry. Marco's company uses high-quality ingredients:

• Chicken meal (local – Italy has a large poultry industry): 30-35% – primary protein
• Rice (imported or from northern Italy): 25-30% – carbohydrate source
• Pea starch (imported): 10-15% – grain-free binder
• Chicken fat (local): 10-15% – energy source
• Beet pulp (local – Italy grows sugar beets): 5-10% – fiber for digestive health
• Vitamins and minerals: 2-3%

The challenge is grinding the chicken meal and rice to 100-120 microns. Chicken meal is abrasive and wears hammers quickly. Rice is hard and requires significant energy to grind fine.

The grinding process for tiny kibble:

1. Pre-crushed material (through 1.5mm screen – finer than standard) enters the grinder
2. High-speed hammer rotor impacts particles
3. Classifier wheel separates fine particles from coarse
4. Coarse particles return for regrinding
5. Fine particles (100-120 microns) exit with airflow

The final product is ultra-fine powder that creates strong dough for 5mm kibble.

Installation – Precision Setup

The SWFL90 pet feed ultrafine crusher arrived at the Port of Ravenna – a major port on the Adriatic coast, located about 80km from Bologna.

Shipping time from Qingdao to Ravenna is about 30-35 days. The machine was packed in a 20-foot container with:

• SWFL90 grinder main unit (90kW motor)
• Classifier wheel assembly (7.5kW)
• Feeder (1.5kW)
• Spare hammers and screens (alloy-protected for abrasive chicken meal)
• Cyclone and airlock discharge
• Installation manual and electrical diagram in Italian

Customs clearance in Ravenna took about 4 days. Total landed cost was about 22% higher than the FOB price.

Installation took two weeks. Marco's team prepared a concrete foundation – the SWFL90 weighs about 4.5 tons. They poured a 200mm reinforced slab with vibration-damping mounts.

The electrical hookup required 400V, 50Hz three-phase (Italian standard). The 90kW motor required a 200-amp breaker.

The air system required ducting to a dust collector. Marco installed a high-efficiency baghouse filter.

The first test run was with chicken meal (pre-ground through 1.5mm screen – finer than the standard 2.0mm). The classifier wheel was set to 2,900 RPM. A sieve test showed 92% passing through 120 mesh (125 microns). Perfect for tiny kibble.

Performance – Tiny Kibble, Strong Structure

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

Before (hammer mill only – 250-300 microns):

• Particle size: 250-300 microns (60-70 mesh)
• Kibble diameter: Could not produce 5mm reliably – pellets crumbled
• Kibble breakage rate: 25-30% (broken kibble in bags)
• Extruder throughput: 1.4 tons/hour (limited by dough quality)
• Customer complaints: Not applicable (product not launched)

After (SWFL90 ultrafine crusher – 100-120 microns):

• Particle size: 100-120 microns (120-150 mesh)
• Kibble diameter: 5mm produced reliably with 5% breakage rate
• Kibble breakage rate: 5-7% (80% improvement)
• Extruder throughput: 1.9 tons/hour (36% increase)
• Customer feedback: Positive – "perfect size for my senior dog"

Production output:

• Rated capacity: 1.0-2.0 tons/hour
• Actual output with 1.5mm pre-screen: 1.3 tons/hour average
• Daily output (8 hours): 10.4 tons – sufficient for their new line
• Annual production through fine grinder: 2,500 tons

Quality improvements:

• Kibble uniformity: ±0.3mm variation (vs ±1.0mm before)
• Breakage rate: Reduced from 25-30% to 5-7%
• Extruder throughput: Increased by 36%
• Digestibility: Improved by 8% (lab tested)

The pet feed crusher machine cost delivered approximately €44,000. Payback period was about 12 months based on reduced breakage and increased throughput.

Customer Feedback – Marco's Experience

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

"We spent months trying to make 5mm kibble with our hammer mill. It didn't work. The pellets crumbled. We were about to abandon the project.

"The SWFL90 saved the product. The ultra-fine flour creates strong dough. The 5mm kibble holds together. The breakage rate dropped from 25% to 5%. We launched the product. Customers love it.

"The classifier wheel at 2,900 RPM gives us 100-120 micron flour. The hammer mill couldn't get below 250 microns. The difference is dramatic.

"A few operational notes: The pre-screen is critical. We use a 1.5mm screen instead of 2.0mm. This reduces capacity but improves fineness. The hammers wear – about 500-600 hours with chicken meal. We bought upgraded alloy hammers – they last 700-800 hours. The classifier wheel needs monthly balancing at high speed.

"Would I recommend this machine? Yes. For any pet food manufacturer making small kibble, ultra-fine grinding is essential. The SWFL90 delivers the particle size that makes tiny kibble possible."

Why Ultra-Fine Grinding for Small Kibble

Small kibble has different requirements than standard kibble. Here's why ultra-fine grinding is critical:

Kibble diameter vs particle size: The ratio of particle size to kibble diameter matters. For a 10mm kibble, 300-micron particles are 3% of diameter. For a 5mm kibble, 300-micron particles are 6% of diameter – twice as large relative to the kibble. These larger relative particles create weak points.

Die hole size: Small kibble requires small die holes (5-6mm). Coarse particles can block small die holes. Fine flour flows through easily.

Dough strength: Fine particles create a more uniform dough with fewer weak points. The dough can be extruded into smaller shapes without crumbling.

Senior dogs: Senior dogs often have dental issues. They need kibble that crumbles easily when chewed – but not before. Fine flour creates kibble that is strong in the bag but soft when chewed.

Marco's testing showed:

• 300-micron flour: 25% breakage for 5mm kibble
• 200-micron flour: 12% breakage for 5mm kibble
• 120-micron flour: 5% breakage for 5mm kibble

The SWFL90 pet feed ultrafine crusher in Italy achieves 100-120 microns.

The Classifier Wheel – Key to Ultra-Fine Grinding

The SWFL90 pet feed ultrafine crusher's classifier wheel is what makes ultra-fine grinding possible. Here's how Marco uses it for small kibble:

1. Pre-crushed ingredients (1.5mm pre-screen) enter the grinding chamber
2. Hammers impact particles
3. Airflow carries particles toward the classifier wheel
4. The classifier wheel spins at 2,800-3,000 RPM (higher than standard)
5. Ultra-fine particles (below cutoff) pass through
6. Coarse particles return for regrinding

Marco's settings:

• Chicken meal: 2,900 RPM (100-120 micron target)
• Rice: 2,800 RPM (120-150 microns – rice is harder)
• Pea starch: 3,000 RPM (100 microns)

The result is consistent ultra-fine particle size.

Pre-Screen Size – Critical for Fineness

For standard grinding (150-200 microns), a 2.0mm pre-screen is sufficient. For ultra-fine grinding (100-120 microns), Marco uses a 1.5mm pre-screen.

The finer pre-screen reduces capacity (from 1.6 t/h to 1.3 t/h) but improves final fineness. The classifier wheel doesn't have to work as hard to separate coarse particles.

Marco keeps both screen sizes and switches based on product:

• 2.0mm for 150-200 micron target
• 1.5mm for 100-120 micron target

Alloy Hammers – Essential for Chicken Meal

Chicken meal is abrasive. It wears standard hammers quickly. The SWFL90's alloy-protected hammers last 700-800 hours with chicken meal – 40% longer than standard hammers.

Marco bought a spare set with the machine. He swaps hammers every 6-8 months.

Classifier Wheel Balancing

At high speeds (2,800-3,000 RPM), the classifier wheel needs to be perfectly balanced. Marco's team checks the balance every 3 months. An unbalanced wheel causes vibration and inconsistent particle size.

The SWFL90's vibration sensor alerts Marco if imbalance occurs. In six months, no imbalance has been detected.

Shipping – Qingdao to Ravenna

The SWFL90 pet feed ultrafine crusher shipped from Qingdao to Port of Ravenna, Italy – a major port on the Adriatic coast.

Shipping time from Qingdao to Ravenna is about 30-35 days. The route goes through the South China Sea, past Singapore, across the Indian Ocean, through the Suez Canal, and across the Mediterranean.

The machine was packed in a 20-foot container. Customs clearance in Ravenna took about 4 days. Total landed cost was about 22% higher than the FOB price.

The truck transport from Ravenna to Bologna was about 80km – roughly 1 hour.

What Marco Learned – Lessons for Other Pet Food Manufacturers

After six months of running the SWFL90, Marco shared several observations:

Lesson 1: Pre-screen size affects final fineness. For 100-120 micron target, use 1.5mm pre-screen. For 150-200 micron target, use 2.0mm pre-screen.

Lesson 2: Classifier speed needs to be higher for ultra-fine grinding. Standard speeds (2,500-2,700 RPM) produce 150-200 microns. For 100-120 microns, run at 2,800-3,000 RPM.

Lesson 3: Chicken meal wears hammers faster than grains. Plan for 700-800 hour hammer life. Keep spares.

Lesson 4: Small kibble needs fine flour. Don't try to make 5mm kibble with 250-micron flour. It won't work.

Lesson 5: Test particle size every shift. Marco uses a sieve shaker. The target is 90% passing 120 mesh (125 microns).

What RICHI Provided Beyond the Machine

RICHI provided several services that helped Marco get the SWFL90 operational:

• Italian documentation: The manual and electrical diagram were provided in Italian.
• Pre-screen recommendation: Based on the 100-120 micron target, RICHI recommended using a 1.5mm pre-screen.
• Classifier speed guidance: RICHI provided recommendations for achieving 100-120 micron particle size.
• Alloy hammer recommendation: Based on the abrasive chicken meal, RICHI recommended upgraded alloy hammers.
• Remote support: When Marco had questions about classifier wheel balancing, a RICHI technician walked him through it via video call. Total time: 30 minutes.

Is a Pet Feed Ultrafine Crusher Right for Your Operation?

For a pet food manufacturer producing small kibble (under 6mm), ultra-fine grinding is essential.

Consider the SWFL90 if:

• Your target particle size is 100-150 microns (120-150 mesh)
• Your capacity requirement is 1-2 tons/hour
• You produce kibble under 6mm diameter
• You need flour fine enough for small die holes

Consider a larger model (SWFL110 or SWFL130) if:

• Your capacity requirement is 2-4 tons/hour

For Marco's specialty pet food plant, the SWFL90 was the right investment. It enabled 5mm kibble production, reduced breakage by 80%, and paid for itself in 12 months.

Final Thoughts

If you're a pet food manufacturer wanting to produce small kibble for small breed or senior dogs, don't underestimate the importance of particle size. Coarse flour creates weak pellets that crumble. Ultra-fine flour creates strong dough that extrudes into perfect tiny kibble.

The SWFL90 pet feed ultrafine crusher produces 100-120 micron flour – fine enough for 5mm kibble. The classifier wheel ensures consistency. The alloy hammers last longer with abrasive ingredients. The result is tiny kibble that stays intact in the bag but crumbles easily when chewed.

For small kibble, the math is simple: finer flour = stronger pellets = less breakage = happier customers.

RICHI Machinery offers documentation in Italian, alloy hammers, pre-screen recommendations, and remote support. Contact RICHI Machinery through the website with your target kibble size, capacity requirement, and ingredients for a recommendation. Tell them about your small kibble application – they can help you select the right grinder and classifier settings for optimal results.