10T/H Pure Alfalfa Hay Bale Pellet Plant in Mexico

Client Profile: An Agricultural Exporter Diversifies into Forage

Unlike the small cooperative and dairy-focused family enterprise described in earlier case studies, this client came from a different background. They were an agricultural export company, originally specializing in fruits and vegetables bound for the U.S. and Canadian markets.

In recent years, however, two factors pushed them to diversify:

• Water constraints in traditional fruit-growing regions reduced profitability.
• Global forage demand, especially from Middle Eastern countries that struggle to produce their own alfalfa, surged.

The company already owned large irrigated tracts of land in Chihuahua, perfectly suited for alfalfa production. Instead of exporting bulky hay bales, they decided to add value through pelletization—producing a uniform, dense, and easily transportable product that could command higher prices in export markets.

Their requirements to RICHI Machinery were clear:

“We want a line that can handle 10 tons per hour, using only alfalfa as the raw material. The pellets must meet international standards for export, with high durability and consistent size.”

This request required not just equipment but a system designed for global competitiveness.

Raw Material Characteristics: 100% Pure Alfalfa

This alfalfa hay bale pellet plant in Mexico project differed sharply from the earlier two in its raw material mix. Whereas the smaller and mid-sized Mexican plants blended alfalfa with maize residues or bran, this plant would rely exclusively on 100% alfalfa.

The reasoning was simple:

• Export buyers (Saudi Arabia, UAE, China) often demand pure alfalfa pellets to ensure nutritional consistency.
• Certification and labeling are easier when no other ingredients are included.
• Pure alfalfa pellets can command higher prices, sometimes up to USD 280–320 per ton depending on quality.

The raw alfalfa was harvested in large round bales (350–450 kg each), with moisture levels of 12–15% at the time of processing. This made it ideal for pelletization without excessive drying.

Process Design: Industrial-Scale Pellet Production

Handling 10 tons of material per hour requires not only powerful equipment but also streamlined logistics. RICHI Machinery designed a complete process flow tailored to pure alfalfa:

1. Bale Breaking and Pre-Processing

Hydraulic bale breaker capable of handling large round bales automatically.

Conveyor-fed to reduce labor requirements.

2. Grinding

A twin-hammer mill system was installed to maintain consistent throughput.

Particle size was reduced to 5–6 mm, balancing pellet density with ruminant digestibility.

3. Pelletizing

A pair of RICHI CZLH678 grass pellet machines, each rated at 5t/h, ran in parallel.

Pellet sizes of 8mm and 10mm were produced, with die materials specifically designed for fibrous crops.

Double-layer steam conditioning ensured proper binding and reduced power consumption during pellet pressing.

4. Cooling and Screening

A large counterflow cooler reduced pellet temperatures from ~80°C to ambient.

Vibrating screens separated fines, which were automatically recycled back into the system.

5. Bagging and Bulk Loading

Pellets were packaged into 25kg and 50kg export-standard bags with printed labels.

A bulk loading station allowed direct transfer into shipping containers for export.

Core Equipment Supplied by RICHI Machinery

The full set of equipment for this high-capacity alfalfa hay bale pellet plant in Mexico included:

• Hydraulic bale breaker with chain conveyor
• Twin 132 kW hammer mills with cyclone dust collection
• Double-shaft paddle mixer (used only for pre-homogenization of chopped alfalfa)
• 2× RICHI CZLH678 alfalfa pellet making machines with custom dies for alfalfa
• Counterflow cooler with automatic temperature sensors
• Vibrating rotary screener
• Fully automatic bagging system (25–50 kg, export-certified)
• Bulk silo system with container loading conveyors
• Centralized PLC control system with data logging

Investment Breakdown and Economics

The total investment of USD 370,000 covered alfalfa pellet production line equipment, installation, automation, and training.

At a capacity of 10t/h, the plant can produce 80 tons of pellets per 8-hour shift. With international prices averaging USD 280 per ton, the potential daily revenue is USD 22,400.

Even accounting for raw alfalfa production, labor, energy, and logistics, the client projected a payback period of 12–16 months.

Market Outlook: Export-Driven Growth

This alfalfa hay bale pellet plant in Mexico project's success hinged on global demand, and the timing could not have been better:

• China has steadily increased alfalfa imports to support its dairy expansion.
• Saudi Arabia and UAE, facing strict water limitations, have banned or reduced domestic alfalfa cultivation and rely heavily on imports.
• Japan and South Korea also purchase forage pellets for their livestock industries.
• By producing high-density, durable pellets, this Mexican plant positioned itself as a competitive supplier in these markets.

Challenges Addressed by RICHI Machinery

Pure alfalfa pelletization poses unique challenges:

• Fibrous Material Resistance: Alfalfa fibers are tough on pellet mill dies. RICHI supplied special wear-resistant dies to extend lifespan.
• Dust Management: Grinding alfalfa generates fine dust. RICHI included cyclone dust collectors and negative-pressure systems to ensure a clean, safe plant.
• Consistency Across Shifts: Export buyers demand uniform pellets. Automation and real-time monitoring guaranteed stable production quality.

RICHI's Value-Added Services

Beyond equipment, RICHI provided a suite of services:

• Pre-Project Feasibility Study: Analyzed export pellet market prices and raw material costs.
• Custom Engineering: Designed the facility layout to integrate with the client’s existing warehouse space.
• International Compliance: Ensured the bagging system and labeling met standards required for shipments to China and the Middle East.
• Operator Training in Spanish: Delivered intensive training to ensure local staff could run the facility efficiently from day one.
• After-Sales Support: A remote monitoring system enabled RICHI technicians in China to support the plant without costly travel delays.

Impact on Mexican Agriculture

This alfalfa hay bale pellet plant in Mexico project represented more than just a new feed mill—it marked Mexico’s entry into a higher-value forage export chain. Instead of shipping bulky, low-density hay bales, Mexico could now deliver:

• Three times higher product density per shipping container.
• Improved shelf life and durability, ensuring pellets arrived intact after long sea voyages.
• New income streams for farmers, who could sell raw alfalfa to the pelletizing company rather than exporting bales themselves.

Customer Testimonial

The client's general manager offered this perspective after the plant’s successful commissioning:

“We had been exporting vegetables for years, but margins were shrinking. Alfalfa gave us a new horizon. With RICHI Machinery's biomass pellet plant, we not only serve the domestic dairy market but have opened a door to Asia and the Middle East. The scale, efficiency, and quality of this facility exceeded our expectations. We see this as the foundation of our company’s future.”

The 10t/h pure alfalfa hay bale pellet plant in Mexico is a model of how local agricultural strengths can be transformed into globally competitive products. With an investment of USD 370,000, the client gained not just a production line but a gateway into international forage markets.

RICHI Machinery’s role went far beyond delivering machines—it involved strategic planning, engineering customization, compliance expertise, and long-term support. This biomass pellet project demonstrated how a partnership with RICHI can enable Mexican agribusinesses to step confidently into the global stage.