90,000 TPY Multi-Grain Puffed Feed Ingredient Production Line in India

Project Background: From Trader to Value-Added Processor

India's livestock and aquaculture sectors are experiencing unprecedented growth, driven by rising domestic demand for animal protein. However, feed manufacturers often struggle with the availability of consistent, high-quality ingredients that maximize feed conversion ratios. The client, traditionally a distributor of raw grains, identified a significant opportunity to move up the value chain by processing these grains into superior, pre-cooked feed ingredients.

The decision to install this puffed grain production line in India was based on several key market insights:

• Enhanced Feed Efficiency: Puffing (extrusion) thermally processes the grains, gelatinizing starches and denaturing anti-nutritional factors present in raw soybeans, leading to significantly improved digestibility for fish and poultry.
• Supply Chain Stability: By creating a processed product, the client could offer feed mills a more consistent and reliable ingredient compared to fluctuating raw grain quality.
• Market Differentiation: The production of specialized, high-value ingredients allowed the client to carve out a niche in the competitive feed ingredient market.
• Operational Flexibility: The ability to process multiple grains (soybean, corn, rapeseed) on a single line provided a crucial buffer against the price volatility of any single commodity.

The 90,000 TPY capacity was carefully calibrated to achieve significant market penetration while maintaining operational agility and a manageable capital outlay.

Raw Material Sourcing: Leveraging India's Agricultural Diversity

A key strength of this puffed grain production line in India is its ability to utilize a variety of locally sourced grains, providing inherent flexibility in raw material procurement. The client leverages its established network in the agricultural heartlands of Gujarat and neighboring states to secure non-GMO soybeans, corn, and rapeseed.

The production process is designed to be adaptable, with minor adjustments allowing for seamless switching between different grain types. This flexibility is a critical risk mitigation strategy in the Indian agricultural context, where crop availability and pricing can vary.

Production Process: The Science of Starch Gelatinization

The core technology of this puffed grain production line in India is the wet extrusion process. This thermo-mechanical cooking method is ideal for deactivating anti-nutritional factors in soybeans and gelatinizing starch in corn, thereby unlocking the full nutritional potential of the grains for animal feed.

A Detailed Walk-Through of the Flexible Production Process:

1. Receiving and Pre-Cleaning: Grains are delivered by truck and pneumatically conveyed into dedicated silos. The first processing step involves passing the grains through a cleaning sieve to remove foreign materials like stones, stalks, and dust, which are collected for disposal.
2. Primary Grinding: The cleaned whole grains are fed into hammer mills. Reducing the particle size is essential for creating a uniform meal that will hydrate and cook evenly in the extruder. This stage generates dust, which is immediately captured by an integrated dust collection system.
3. Conditioning and Expansion (Puffing) : The ground meal is conditioned with direct steam, increasing its moisture and temperature. It is then fed into the RICHI twin-screw extruder. Inside the extruder barrel, the meal is subjected to high temperature, pressure, and shear force. This combination instantly cooks the material. The sudden pressure drop as the product exits the die causes the superheated water to flash into steam, "puffing" the product and creating a porous, low-density structure.
4. Cooling and Drying: The hot, moist puffed pellets are conveyed through a vertical cooler where ambient air is blown through the product bed. This critical step reduces the temperature and moisture content to a safe level for storage and packaging, preventing mold growth.
5. Secondary Grinding and Packaging: The cooled puffed pellets are ground into a coarse meal to the specific particle size required by feed millers. The final product is automatically weighed and packaged into 50 kg bags for distribution.

Core Equipment: Engineered for Flexibility and Efficiency

For this multi-purpose puffed grain production line in India, the client needed robust equipment capable of handling different grains with quick changeover times. RICHI Machinery provided a complete, integrated line designed for this exact purpose. The total equipment package was valued at $620,000.

Environmental Management and Compliance

• Emissions Control: Dust from the grinding operations is effectively controlled by a network of pulse-jet bag filters, with emissions vented through a 15-meter stack. The use of purchased steam eliminates on-site combustion emissions.
• Water and Waste Management: The process itself is not water-intensive. Sanitary wastewater is treated in a septic system. Solid waste is minimized; screening waste is disposed of, and all collected nutrient-rich dust is recycled back into the product.
• Noise Control: High-noise equipment is housed within the enclosed factory building, and operational schedules are managed to comply with local noise regulations.

Economic Viability and Market Impact

The business case for this puffed grain production line in India is robust, driven by the significant value addition from processing raw grains into a specialized feed ingredient.

• Machinery & Equipment (from RICHI): $620,000
• Site Preparation, Installation, & Civil Works: $180,000
• Working Capital: $50,000
• Total Project Investment: $850,000

The premium price commanded by puffed feed ingredients, combined with strong demand from the feed sector, results in an attractive return on investment, with a payback period projected to be under 3 years.

The RICHI Advantage: A Tailored Partnership

RICHI Machinery was selected for our ability to deliver a flexible and robust solution tailored to the Indian market's unique needs. Our support included:

• Flexible Process Design: We engineered the line for easy switching between soybean, corn, and rapeseed processing, a critical requirement for the client.
• Comprehensive Training: We provided extensive training to the client's operators on managing the line for different products.
• Local Service Support: We established a reliable channel for technical support and spare parts to ensure minimal operational downtime.

Seizing the Opportunity in India's Feed Industry

The successful commissioning of this puffed grain production line in India highlights a significant opportunity in the country's agro-processing sector. As the demand for efficient and sustainable animal protein production grows, the need for high-quality, processed feed ingredients will only intensify.

For entrepreneurs and companies looking to invest in the value-added agriculture segment, establishing a puffed grain production line in India represents a strategic and profitable venture. The combination of readily available raw materials, a booming end-market, and proven processing technology creates a compelling investment proposition.

Interested in developing your own feed ingredient processing business?

Contact RICHI Machinery to explore how our technology and expertise can help you capitalize on this growing market. From single-ingredient lines to multi-purpose facilities, we deliver solutions for success.

Driving efficiency in animal nutrition through advanced processing.