global milling advances august 2013 -
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Power inMotionNew Kubex™
Pellet Mill
Issu
e 4
Aug
ust
2013
In this issue:
Feed Pellet Press Productivity
Alapala Product Line
2013 Events
By Buhler
Contents
BuhlerPower in motion –New KubexTM pellet mill
MuyangPractical ways to improve feed conditioning efficiency
Allance Pellet Mil
AlapalaProduct Line
Events 2013Upcoming events
EditorialWelcome to the summer issue of Global Milling Advances. In this issue we take a look at pellet press technology, with articles from Jiangsu Muyang Group and Allance Machinery.
Jiangsu Muyang Group focus on the practical ways to improve feed conditions efficiency and Allance Machinery talk us through influencing factors of feed pellet press productivity.
Global Milling will be exhibiting at UK Grain in November, if you are visiting this event please call by our stand No. 14 and pick up your free copies of our magazines.
Keep up to date with events happening in your industry! Download your copy of our 2014 wall planner today at www.globalmilling.com
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NISA Media Ltd14 Clarke WayCheltenhamGL50 4AXUnited Kingdom
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International Marketing ManagerSabby MajorTel: +44 117 2306493Email: smajor@globalmilling.com
News EditorMartin LittleEmail: mlittle@globalmilling.com
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Events 2013Upcoming events
04
06
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The new Kubex™ T pellet mill takes the successful foundation of the popular Kubex™ to a new dimension, continuing the tradition of robustness, reliability and ease of operation of the previous model, but driving it to an even more efficient and powerful level. Up to 30 %1 less energy consumption, high production capacities of up to 80 t/h2 and a customer driven design are the result of extensive research and development by Bühler in cooperation with leading feed millers.
Direct drive sets new standard in energy efficiency
A for a long time awaited drive concept has now become reality: without gearbox and transmission belts, the machine’s direct drive significantly reduces maintenance requirements and increases the pellet mill’s uptime. Thanks to efficient power transmission, the new Kubex™ T saves up to 30 % 1 energy per ton of produced pellets compared to conventional drive systems. Another advantage is the variable die speed that is adjustable during operation. The flexibility provided by this feature enables on- ‐going optimization of the production process and the pellet quality based on the feed formulation, and also extends the lifetime of the die.
High performance, small footprint
The new Kubex™ T pellet mill is available in two versions, with Kubex™ T12 being the most powerful model with power of up to 585 kW and 1200 mm die diameter, delivering high pelleting performance of up to 80 tons/hour 2. The smaller version Kubex™ T9 comes with motor power of up to 410 kW and a 900 mm die,
suitable for production capacities of up to 50 t/h 2. Characterized by its very compact design, the new Kubex™ T pellet mill fits the exact space requirements of every feed mill due to its small footprint in length, width and especially height. In existing feed mills, line capacity expansion is made possible without costly building and process modification works.
Customer driven design
Bühler innovators have worked closely with leading feed producers to ensure the Kubex™ T pellet mill fulfils the aspirations of feed millers for hygienic, ergonomic and robust machine design. Wide- opening, smooth- running sliding doors on both sides provide full access to the machine for fast and easy maintenance, while the slightly pressurized machine housing efficiently prevents dust settlements in critical areas. An improved die change concept with access to the screws and fittings from the clean motor chamber significantly reduces the time needed for the die change, maximizing machine uptime. Another new development is the ABS control for the press rolls, preventing roll slippage and thus protecting the machine against blockages and equipment damage.
Power forward
Quite simply, selecting Bühler as a partner means gaining access to the best technology and process expertise in the feed milling industry. Close collaboration with customers is always aimed at increasing their productivity and competitiveness. Bühler is continually empowering feed
Global Milling Advances Page 4
Power in motion –New KubexTM pellet mill
More information:Michael Tremp,Produktmanager Grain MillingBuhler AG CH- 9240Uzwil, SwitzerlandEmail: michael.tremp@buhlergroup.comWeb: www.buhlergroup.com
ONE SHOW
•Over26,000industryleadersfromover110countries•Over1,100exhibitorsrangingfromproductiontopointofsale•Over24+acresofexhibitspace•Exceptionaleducationalprogramsscheduledfortheentireweek•Oneofthemostaffordableattendeeregistrationfeesintheworld
INDUSTRIESMEATFEEDPOULTRY
THRE
EThe World’s Largest Annual Poultry, Feed, and Meat Technology Exposition
January 28 - 30, 2014GeorgiaWorldCongressCenterAtlanta,GeorgiaUSAwww.ippexpo.org
The primary purpose of conditioning is to improve pellet quality and pellet mill throughput. If being correctly operated and controlled, a given conditioner could be optimized to achieve the best quality at the best production rate possible for a pelleting system.
According to the report of Energy Intensity of Agriculture and Food System published on July 29, 2011, feed provision contributes, on average, 75% of energy inputs to livestock production in U.K, about 86% for feedlot beef production in the United States, and about 90% of cradle- to- farm gate energy use for salmon produced globally. Sourcing energy-efficient feed inputs therefore offers considerable opportunity to decrease energy use in farming industries.
Under this trend, only processes, systems and equipment that saving energy in feed production can help feed manufacturers keep competitive in the market.
Conditioning is one of the most important processing steps in pellet feed production. How to cut energy usage and improve processing efficiency of a conditioner has been the question that feed manufacturers always concerned.
We at Muyang have studied the possible ways to solve this question for years. In this article, we will introduced some practical ways to improve feed conditioning efficiency through carefully controls on conditioning temperature, retention time and water addition in production.
Conditioning temperature Moisture, heat, and pressure combine to gelatinize or break down protein components in the feed ingredients during conditioning, which permits better digestibility and durability for feed pellets.
Table 1 shows the effects of conditioning temperature on pelleting performance. As feed mash temperature increased in conditioning stage, the durability of pellet products is improved while the energy used for producing per ton of feed is reduced. A great deal of heat contributes to easy penetration of steam into feed mash molecules, forming hydration water, which binding with ingredients will make feed mash more pelletable.
However, not all materials are adapted to the above mentioned “feed mash temperature and pelleting performance” rule. For feed mash of heat sensitive ingredients such as whey, milk, urea, etc., conditioning temperature that higher than their gelatinization temperature or solution temperature (usually is about 60°c) will cause over- gelatinized or too much water in feed mash, resulting in blockage in die holes. While for cereals
Table 1: Effects of conditioning temperature on palleting
Mash Temp/°CEnergy Consumptoion/
(kW-h/t)Pellet Durability/%
21 30.7 69.5
65 17.3 90.6
80 11.9 96
and materials of high protein content, a conditioning temperature that higher than 85°c can be able to increase the plasticity, cohesiveness and pellet ability of feed mash. Therefore, conditioning temperature is formulation dependent. It should be controlled properly to achieve good conditioning.
Retention time The time available for heat and moisture to penetrate into the core of each particle before pelleting is referred to as “retention time”. It is limited and supposed to be less than the time needed for a given particle to move through the conditioning chamber, because feed mash doesn’t contact with steam in the distance between feeding inlet and steam inlet. However, retention time cannot be measured precisely and, in reality, it represents the average amount of time mash retaining in the chamber. To optimize conditioning operations, retention time must be optimized.
Trails were carried out in a feed mill in Guangdong Province of China to study the impacting factors and find out practical methods to optimize conditioning retention time.
The first trail was set up to evaluate the influence of paddle angle on conditioning performance. It was subjected to 4 paddle settings giving:
• Setting 1: all paddles are forward ones (retained at ex- works setting) (Fig.1- a)
• Setting 2: with 4 backward paddles (Fig.1- b);
Global Milling Advances Page 6
Practical ways to improvefeed conditioning efficiencyBy Zhou Xiang, Ye Zhen, Jiangsu Muyang Group Co., Ltd, China
More information:Jiangsu Muyang Group Co., LtdNo.1 Muyang Road,Yangzhou, ChinaPostcode 225127Tel: +86 514 87848880Fax: +86 514 87848686Email contacts: zx@muyang.com yezhen@muyang.cn
Global Milling Advances Page 8
Setting 3: with 8 backward paddles (Fig.1- c); Setting 4: with 12 backward paddles (Fig.1- d); Setting 3: with 8 backward paddles (Fig.1-‐c);
Setting 4: with 12 backward paddles (Fig.1-‐d); The results showed in Fig.2 tell that retention time is adjustable by changing the angle of paddles. As the number of backward paddles increased, it achieves better conditioning and pelleting results. The filling level of a conditioner is increased too, and fewer fines are generated from pellet products.
The second trail was designed to evaluate the effects of shaft speed on conditioning and pelleting performance. It was set up base on paddles installed with Setting 4. The shaft speed was changed by a variable-‐frequency controller on the drive motor.
See Fig.3, a slower shaft speed (37Hz) allows feed mash to settle to the bottom of the conditioner and be pushed gently along the barrel. This obviously allows for a longer retention time and a high filling level. However, too slow a shaft speed will lead to a steady state, namely a state of steady filling level and
retention time. There is not enough linear velocity and centrifugal force to lift up the feed mash. In Fig.3, the longer retention time and higher filling level in a frequency of 30Hz are the results of feed mash accumulation. In this case, feed mash cannot mix with steam sufficiently. To guarantee satisfactory result, the conditioner usually should be designed with a linear velocity of 6-‐8m/s.
By comparing with the results shown in Fig.2, we also can find out that shaft speed contributes little to fines generation of pellet products if under the same conditioning effect. Therefore, it is suggested to optimize retention time and improve conditioning effect by carefully controlling the shaft speed, and to lower
power consumption in mash pelleting by reducing the compression ratio of die holes. Water addition Different moisture contents are required to feed in different processes, the moisture content usually are: 1) 11.5~12.5% after grinding and mixing; 2) 15~16.5% after conditioning and before pelleting; 3) 14~15% after pelleting; and 4) 11~13% after cooling to be finished product.
A well understanding of the effects and functions of moisture content in different processing steps can bring
more profits to feed production. Feed mash to be pelletized if with a moisture level less than 15% may cause poor pelletability and problems such as die blockage, pellets with bad durability, burned surface, cracks, brokens, etc. While finished pellet products if with a moisture content that higher than a safety level
will result in mould in transport and storage, which will degrade feed quality and shorten the shelf life. Therefore, the moisture content should be strictly controlled to achieve qualified and profitable feed pellets. Fig.4 shows the result of a 2×5 factorial arrangement of conditioning processes that set up to evaluate the effects of two steam introducing manners (multiple entry ports and single entry port) on the moisture-‐rise (∆H) of feed mash before and after conditioning with five samples. An optimum steam introducing manner can improve the effect of steam contacting and mixing with feed mash. Compared to the single entry port manner, steam introduced into the conditioning through multiple entry ports achieves conditioned mash with a more steady and higher average moisture content. Namely, water adding to feed mash is more uniform. Conclusion Studies on conditioning temperature, retention time and water addition in conditioning production provide efficiently practical ways to improve pellet quality, maximize energy usage and minimize feed and energy losses during production: 1) Temperature and moisture required for conditioning depends on the characteristics of ingredients used in feed. The processing of different types of feeds should follow different guidelines. Generally, more heat can achieve better pellet durability and reduced power consumption for pelleting process. 2) Retention time can be optimized by adjusting paddle angle and shaft speed. Increasing the number of backward paddles can prolong the retention time and improve the filling level of feed mash in a conditioner. Slow shaft speed also allows for longer retention time and higher filling level. However, the speed should be great enough to provide good agitation and movement down the conditioner. An appropriate linear speed for shaft is 6~8m/s. 3) Steam introduced into conditioner through multiple entry ports is benefit for getting conditioned feed mash uniform moisture content. In a word, well know the conditioning process and optimize the operation with available methods are the feasible ways to add value to a given pellet mill.
The results showed in Fig.2 tell that retention time is adjustable by changing the angle of paddles. As the number of backward paddles increased, it achieves better conditioning and pelleting results. The filling level of a conditioner is increased too, and fewer fines are generated from pellet products.
The second trail was designed to evaluate the effects of shaft speed on conditioning and pelleting performance. It was set up base on paddles installed with Setting 4. The shaft speed was changed by a variable- frequency controller on the drive motor.
Setting 3: with 8 backward paddles (Fig.1-‐c); Setting 4: with 12 backward paddles (Fig.1-‐d);
The results showed in Fig.2 tell that retention time is adjustable by changing the angle of paddles. As the number of backward paddles increased, it achieves better conditioning and pelleting results. The filling level of a conditioner is increased too, and fewer fines are generated from pellet products.
The second trail was designed to evaluate the effects of shaft speed on conditioning and pelleting performance. It was set up base on paddles installed with Setting 4. The shaft speed was changed by a variable-‐frequency controller on the drive motor.
See Fig.3, a slower shaft speed (37Hz) allows feed mash to settle to the bottom of the conditioner and be pushed gently along the barrel. This obviously allows for a longer retention time and a high filling level. However, too slow a shaft speed will lead to a steady state, namely a state of steady filling level and
retention time. There is not enough linear velocity and centrifugal force to lift up the feed mash. In Fig.3, the longer retention time and higher filling level in a frequency of 30Hz are the results of feed mash accumulation. In this case, feed mash cannot mix with steam sufficiently. To guarantee satisfactory result, the conditioner usually should be designed with a linear velocity of 6-‐8m/s.
By comparing with the results shown in Fig.2, we also can find out that shaft speed contributes little to fines generation of pellet products if under the same conditioning effect. Therefore, it is suggested to optimize retention time and improve conditioning effect by carefully controlling the shaft speed, and to lower
power consumption in mash pelleting by reducing the compression ratio of die holes. Water addition Different moisture contents are required to feed in different processes, the moisture content usually are: 1) 11.5~12.5% after grinding and mixing; 2) 15~16.5% after conditioning and before pelleting; 3) 14~15% after pelleting; and 4) 11~13% after cooling to be finished product.
A well understanding of the effects and functions of moisture content in different processing steps can bring
more profits to feed production. Feed mash to be pelletized if with a moisture level less than 15% may cause poor pelletability and problems such as die blockage, pellets with bad durability, burned surface, cracks, brokens, etc. While finished pellet products if with a moisture content that higher than a safety level
will result in mould in transport and storage, which will degrade feed quality and shorten the shelf life. Therefore, the moisture content should be strictly controlled to achieve qualified and profitable feed pellets. Fig.4 shows the result of a 2×5 factorial arrangement of conditioning processes that set up to evaluate the effects of two steam introducing manners (multiple entry ports and single entry port) on the moisture-‐rise (∆H) of feed mash before and after conditioning with five samples. An optimum steam introducing manner can improve the effect of steam contacting and mixing with feed mash. Compared to the single entry port manner, steam introduced into the conditioning through multiple entry ports achieves conditioned mash with a more steady and higher average moisture content. Namely, water adding to feed mash is more uniform. Conclusion Studies on conditioning temperature, retention time and water addition in conditioning production provide efficiently practical ways to improve pellet quality, maximize energy usage and minimize feed and energy losses during production: 1) Temperature and moisture required for conditioning depends on the characteristics of ingredients used in feed. The processing of different types of feeds should follow different guidelines. Generally, more heat can achieve better pellet durability and reduced power consumption for pelleting process. 2) Retention time can be optimized by adjusting paddle angle and shaft speed. Increasing the number of backward paddles can prolong the retention time and improve the filling level of feed mash in a conditioner. Slow shaft speed also allows for longer retention time and higher filling level. However, the speed should be great enough to provide good agitation and movement down the conditioner. An appropriate linear speed for shaft is 6~8m/s. 3) Steam introduced into conditioner through multiple entry ports is benefit for getting conditioned feed mash uniform moisture content. In a word, well know the conditioning process and optimize the operation with available methods are the feasible ways to add value to a given pellet mill.
See Fig.3, a slower shaft speed (37Hz) allows feed mash to settle to the bottom of the conditioner and be pushed gently along the barrel. This obviously allows for a longer retention time and a high filling level.
However, too slow a shaft speed will lead to a steady state, namely a state of steady filling
level and retention time. There is not enough linear velocity and centrifugal force to lift up the feed mash. In Fig.3, the longer retention time and higher filling level in a frequency of 30Hz are the results of feed mash accumulation. In this case, feed mash cannot mix with steam sufficiently. To guarantee satisfactory result, the conditioner usually should be designed with a linear velocity of 6- 8m/s.
Setting 3: with 8 backward paddles (Fig.1-‐c); Setting 4: with 12 backward paddles (Fig.1-‐d);
The results showed in Fig.2 tell that retention time is adjustable by changing the angle of paddles. As the number of backward paddles increased, it achieves better conditioning and pelleting results. The filling level of a conditioner is increased too, and fewer fines are generated from pellet products.
The second trail was designed to evaluate the effects of shaft speed on conditioning and pelleting performance. It was set up base on paddles installed with Setting 4. The shaft speed was changed by a variable-‐frequency controller on the drive motor.
See Fig.3, a slower shaft speed (37Hz) allows feed mash to settle to the bottom of the conditioner and be pushed gently along the barrel. This obviously allows for a longer retention time and a high filling level. However, too slow a shaft speed will lead to a steady state, namely a state of steady filling level and
retention time. There is not enough linear velocity and centrifugal force to lift up the feed mash. In Fig.3, the longer retention time and higher filling level in a frequency of 30Hz are the results of feed mash accumulation. In this case, feed mash cannot mix with steam sufficiently. To guarantee satisfactory result, the conditioner usually should be designed with a linear velocity of 6-‐8m/s.
By comparing with the results shown in Fig.2, we also can find out that shaft speed contributes little to fines generation of pellet products if under the same conditioning effect. Therefore, it is suggested to optimize retention time and improve conditioning effect by carefully controlling the shaft speed, and to lower
power consumption in mash pelleting by reducing the compression ratio of die holes. Water addition Different moisture contents are required to feed in different processes, the moisture content usually are: 1) 11.5~12.5% after grinding and mixing; 2) 15~16.5% after conditioning and before pelleting; 3) 14~15% after pelleting; and 4) 11~13% after cooling to be finished product.
A well understanding of the effects and functions of moisture content in different processing steps can bring
more profits to feed production. Feed mash to be pelletized if with a moisture level less than 15% may cause poor pelletability and problems such as die blockage, pellets with bad durability, burned surface, cracks, brokens, etc. While finished pellet products if with a moisture content that higher than a safety level
will result in mould in transport and storage, which will degrade feed quality and shorten the shelf life. Therefore, the moisture content should be strictly controlled to achieve qualified and profitable feed pellets. Fig.4 shows the result of a 2×5 factorial arrangement of conditioning processes that set up to evaluate the effects of two steam introducing manners (multiple entry ports and single entry port) on the moisture-‐rise (∆H) of feed mash before and after conditioning with five samples. An optimum steam introducing manner can improve the effect of steam contacting and mixing with feed mash. Compared to the single entry port manner, steam introduced into the conditioning through multiple entry ports achieves conditioned mash with a more steady and higher average moisture content. Namely, water adding to feed mash is more uniform. Conclusion Studies on conditioning temperature, retention time and water addition in conditioning production provide efficiently practical ways to improve pellet quality, maximize energy usage and minimize feed and energy losses during production: 1) Temperature and moisture required for conditioning depends on the characteristics of ingredients used in feed. The processing of different types of feeds should follow different guidelines. Generally, more heat can achieve better pellet durability and reduced power consumption for pelleting process. 2) Retention time can be optimized by adjusting paddle angle and shaft speed. Increasing the number of backward paddles can prolong the retention time and improve the filling level of feed mash in a conditioner. Slow shaft speed also allows for longer retention time and higher filling level. However, the speed should be great enough to provide good agitation and movement down the conditioner. An appropriate linear speed for shaft is 6~8m/s. 3) Steam introduced into conditioner through multiple entry ports is benefit for getting conditioned feed mash uniform moisture content. In a word, well know the conditioning process and optimize the operation with available methods are the feasible ways to add value to a given pellet mill.
By comparing with the results shown in Fig.2, we also can find out that shaft speed contributes little to fines generation of pellet products if under the same conditioning effect.
Therefore, it is suggested to optimize retention time and improve conditioning effect by carefully controlling the shaft speed, and to lower
power consumption in mash pelleting by reducing the compression ratio of die holes.
Water addition Different moisture contents are required to feed in different processes, the moisture content usually are: 1) 11.5~12.5% after grinding and mixing; 2) 15~16.5% after conditioning and before pelleting; 3) 14~15% after pelleting; and 4) 11~13% after cooling to be finished product.
A well understanding of the effects and functions of
Setting 3: with 8 backward paddles (Fig.1-‐c); Setting 4: with 12 backward paddles (Fig.1-‐d);
The results showed in Fig.2 tell that retention time is adjustable by changing the angle of paddles. As the number of backward paddles increased, it achieves better conditioning and pelleting results. The filling level of a conditioner is increased too, and fewer fines are generated from pellet products.
The second trail was designed to evaluate the effects of shaft speed on conditioning and pelleting performance. It was set up base on paddles installed with Setting 4. The shaft speed was changed by a variable-‐frequency controller on the drive motor.
See Fig.3, a slower shaft speed (37Hz) allows feed mash to settle to the bottom of the conditioner and be pushed gently along the barrel. This obviously allows for a longer retention time and a high filling level. However, too slow a shaft speed will lead to a steady state, namely a state of steady filling level and
retention time. There is not enough linear velocity and centrifugal force to lift up the feed mash. In Fig.3, the longer retention time and higher filling level in a frequency of 30Hz are the results of feed mash accumulation. In this case, feed mash cannot mix with steam sufficiently. To guarantee satisfactory result, the conditioner usually should be designed with a linear velocity of 6-‐8m/s.
By comparing with the results shown in Fig.2, we also can find out that shaft speed contributes little to fines generation of pellet products if under the same conditioning effect. Therefore, it is suggested to optimize retention time and improve conditioning effect by carefully controlling the shaft speed, and to lower
power consumption in mash pelleting by reducing the compression ratio of die holes. Water addition Different moisture contents are required to feed in different processes, the moisture content usually are: 1) 11.5~12.5% after grinding and mixing; 2) 15~16.5% after conditioning and before pelleting; 3) 14~15% after pelleting; and 4) 11~13% after cooling to be finished product.
A well understanding of the effects and functions of moisture content in different processing steps can bring
more profits to feed production. Feed mash to be pelletized if with a moisture level less than 15% may cause poor pelletability and problems such as die blockage, pellets with bad durability, burned surface, cracks, brokens, etc. While finished pellet products if with a moisture content that higher than a safety level
will result in mould in transport and storage, which will degrade feed quality and shorten the shelf life. Therefore, the moisture content should be strictly controlled to achieve qualified and profitable feed pellets. Fig.4 shows the result of a 2×5 factorial arrangement of conditioning processes that set up to evaluate the effects of two steam introducing manners (multiple entry ports and single entry port) on the moisture-‐rise (∆H) of feed mash before and after conditioning with five samples. An optimum steam introducing manner can improve the effect of steam contacting and mixing with feed mash. Compared to the single entry port manner, steam introduced into the conditioning through multiple entry ports achieves conditioned mash with a more steady and higher average moisture content. Namely, water adding to feed mash is more uniform. Conclusion Studies on conditioning temperature, retention time and water addition in conditioning production provide efficiently practical ways to improve pellet quality, maximize energy usage and minimize feed and energy losses during production: 1) Temperature and moisture required for conditioning depends on the characteristics of ingredients used in feed. The processing of different types of feeds should follow different guidelines. Generally, more heat can achieve better pellet durability and reduced power consumption for pelleting process. 2) Retention time can be optimized by adjusting paddle angle and shaft speed. Increasing the number of backward paddles can prolong the retention time and improve the filling level of feed mash in a conditioner. Slow shaft speed also allows for longer retention time and higher filling level. However, the speed should be great enough to provide good agitation and movement down the conditioner. An appropriate linear speed for shaft is 6~8m/s. 3) Steam introduced into conditioner through multiple entry ports is benefit for getting conditioned feed mash uniform moisture content. In a word, well know the conditioning process and optimize the operation with available methods are the feasible ways to add value to a given pellet mill.
moisture content in different processing steps can bring more profits to feed production. Feed mash to be pelletized if with a moisture level less than 15% may cause poor pelletability and problems such as die blockage, pellets with bad durability, burned surface, cracks, brokens, etc. While finished
pellet products if with a moisture content that higher than a safety level will result in mould in transport and storage, which will degrade feed quality and shorten the shelf life. Therefore, the moisture content should be strictly controlled to achieve qualified and profitable feed pellets.
Fig.4 shows the result of a 2×5 factorial arrangement of conditioning processes that set up to evaluate the effects of two steam introducing manners (multiple entry ports and single entry port) on the moisture- rise (ΔH) of feed mash before and after conditioning with five samples. An optimum steam introducing manner can improve the effect of steam contacting and mixing with feed mash. Compared to the single entry port manner, steam introduced into the conditioning through multiple entry ports achieves conditioned mash with a more steady and higher average moisture content. Namely, water adding to feed mash is more uniform.
Conclusion Studies on conditioning temperature, retention time and water addition in conditioning production provide efficiently practical ways to improve pellet quality, maximize energy usage and minimize feed and energy losses during production:
1) Temperature and moisture required for conditioning depends on the characteristics of ingredients used in feed. The processing of different types of feeds should follow different guidelines. Generally, more heat can achieve better pellet durability and reduced power consumption for pelleting process.
2) Retention time can be optimized by adjusting paddle angle and shaft speed. Increasing the number of backward paddles can prolong the retention time and improve the filling level of feed mash in a conditioner. Slow shaft speed also allows for longer retention time and higher filling level. However, the speed should be great enough to provide good agitation and movement down the conditioner. An appropriate linear speed for shaft is 6~8m/s.
3) Steam introduced into conditioner through multiple entry ports is benefit for getting conditioned feed mash uniform moisture content.
In a word, well know the conditioning process and optimize the operation with available methods are the feasible ways to add value to a given pellet mill.
Global Milling Advances Page 10
Feed pellet press is to produce pellets for poultry, livestock and aquacultural animals. The main raw materials for feed pellet press are crushed or milled corn, bean cakes, straw, grass, rice husk, etc. Feed pellet press can be divided into three types which are ring die feed pellet press, flat die pellet mill and double roller feed pellet press. However, due to pellet press manufacturing technology and missoperation, feed pellets productivity can hardly satisfy the expected requirement; besides, the feed pellets surface is rough, fragile and high powder rate. We will analyze the factors, which influence feed pellet press productivity.
1. Raw materials Raw materials play the direct role in feed pellet production. Different raw material component, milling condition and the mixing rate can exert great influence on feed pellets.
1.1 Material components Materials with high starch content are easy to be gelatinized and sticky enough to form feed pellets after conditioning. For those materials with high crude fiber content, a certain amount of fat addition can reduce friction between raw materials and ring die during pelletizing, and is good to form smooth feed pellets. The common fat addition amount is about 1% for more addition will make pellet loose. If more fat is needed, we can consider spraying fat after pelletizing, which is especially suitable to, high standard feed pellets production.
1.2 Milling granularity Grain material milling granularity decides feed pellet surface area which means the finer granularity, the larger size, the faster speed of moisture absorption; then it is easy for feed material conditioning and pelletizing. From the perspective of pelletizing, the finer material, the higher pelletizing strength; but more steam will block pellet press. Besides, the finer material will consume more powder. If the materials are too crude, the wear
of ring die and roller will be increased and make it hard to pelletizing. For pellet press with little die holes, it is harder to form pellets; what’s more, the material will have
bad gelatinization, low productivity and high powder rate in feed pellets. Therefore, for the common poultry and livestock feed pellets, corn milling should adopt 2.5- 3.0mm sieving plates which can avoid too finess and ensure feed granularity for conditioning for less powder content.
1.3 Grain material mixing The evenness of grain material mixing should be paid attention as well. Because of the complexity of feed formula, the huge differences of different materials, we should choose the right mixing time according to the formulas with the aim of controlling the variable coefficient of evenness to 5% and laying a good foundation for pelletizing.
Feed Pellet Press Productivity Influencing FactorsBy Amanda Zhou, Allance Machinery, China, Email: info@pellet-machine.net
More information:Allance Pellet MillWeiyi Road,Zhengzhou,China, 450000Web: www.pellet- machine.net
THE
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ISRMAX DELHI
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Global Milling Advances Page 12
2. Steam quality control Using steam for feed pellets can improve pellet press production and pellet quality. Steam is the source of both moisture addition for conditioning and starch gelatinization. Adding a certain amount of steam in conditioner can kill some bacteria and also dilute the natural binder in feed materials; in this way, the particles surface forms a layer of thin water-bearing stratum which is in favor of gelatinization and pelletizing. The correct design of steam pipe should ensure not only pressure and flow but also prevent condensate water entering conditioner.
Generally, raw material moisture content is about 12% before conditioning, steam pressure is high and moisture content is low; while after conditioning, moisture content is above 16.5% and pellets are difficult to store. The conditioning temperature is 85°c for common animal feed pellets; but change it lower or higher in winter and summer respectively.
3. Feeding flow control Feeding flow control is to ensure pellet press work continuously and uniformly and thus quite important. Feeder part should be unobstructed for smooth feeding. Take SZLH series 400 as an example, the feeding flow should be no less than 10t/h. In order to make the even feeding flow, it is wise to install a surge bunker on top offeed press. It is difficult to ensure even feed flow without a surge bunker or other connecting pipes (longer than 0.5m). In a general way, when feed pellet press works stably, steam supplies adequately, all feeding gates open, feeding speed is the rated value but the main motor can never achieve the rated power value, we can judge that the feeding flow is insufficient.
4.Pelletizing operation 4.1 Adjust the space between roller and die. Too small space between roller and die will make easier to create wear and loud noise; too big space will influence material pressing; thus the space is about 0.05- 0.30mm. Sometimes a feeler gauge is good to help.
4.2 Industrial butter is needed Butter is needed on roller so that bearings can be protected safely from high temperature.
4.3 Feeding knives adjustment Adjust feeding knives in case materials can’t enter the space between roller and die. Part of raw materials will go out of die holes and form more powder; thus the adjustment should make sure the space between the curves on the upper edge and die is 2-3mm.
4.4 Feed pelletizing Start pellet press, conditioner and feeder successively; at this time, feeder should be in the smallest feeding amount. In order to avoid sundries enter to the die, the operator should open the discharge door outside pellet press for removing impure materials. When the materials are clean, we can lead them to ring die. The important thing is that we should feed part of the material to see ifthere are feed pellets formed. If everything works
Global Milling Advances Page 13
well, we can increase raw material and steam to the rated current. If the materials enter pressing chamber but no feed pellets forming, with the electric current increasing; we should open discharge door outside pellet press and watch if the electric current lowers down. Mechanically, the pelletizing process involves forcing soft feed through holes in a metal ring die or flat die. The holes may be round or square, tapered or nontapered. This is done either by using locally fabricated pelleting machine, which is operated by diesel engine, electricity powered machine or manually, or by using automatic highly sophisticated machines with hot air or water conditioning. It consists basically of cylindrical dies of different diameters to pelletize varying sizes of feed, which depends on the age, size and species of animals involved. Most feed produced is a compressed pellet.
Pelleted feed has numerous advantages which include less feed wastage, uniform feed intake, and destruction of growth inhibitors.
It is noteworthy that at the beginning stage of feeding, we should not add steam anxiously. Because at this time, raw materials are in small amount and the steam amount is hard to control. More steam and less material is easy to block pellet press. Besides, before close down pellet press, we should add some oil material to ring die holes to prevent materials becoming hard.
Feed pellet production is simple but good feed pellet isnot so easy because it needs not only pelletizing technology but also rich experience. We hope this analysis will assist you in improving feed pelletproductivity to some extent. For both domestic and commercial feed pellet production, we can customize the most cost-effective pelletizing solutions.
SIMILAGO II The new Similago has been studied and developed by Alapala to provide the utmost technology in roller mill design with elegance and durability. This new roller mill satisfies the most
stringent hygiene standards together with milling precision and simple maintenance making it the most versatile roller mill for any new or existing plant design. The new state of the art electronics make the Similago II making it user friendly and flexible The quick roll change module cartridge has been updated by using the latest state of the art components The Similago II roller mill is also available in the 8 roll superimposed version with option for either 250 mm or 300 mm roll diameters. PURIFIER
This machine is an evolution of our highly successful model DISA giving higher efficiency, integrated with optimal illumination of the screen. A new generation of
vibration mountings and maintenance free motors ensure low energy consumption and low maintenance with
minimum of downtimes. QUADRO PLANSIFTER
Ingeniously designed to comply with the highest hygiene standards, easy to operate, minimum maintenance, modular design constructed in stainless steel and with a large sifting area. An important part of this plansifter is that on the basic main frame with a redesigned oscillating mechanism, it is possible to attach from 2 to 8 sections. These sections are insulated with ABS for anti condensation properties. With great consideration all the components have been designed and developed with the use of rounded recesses and profiles to stop product build up leading to infestation
More information: ALAPALA Machine Industry & Trade Inc. Flour and Feed Technology Istanbul Division World Trade Center A-‐1 No: 15/453 Yesilkoy Istanbul Turkey Tel: +90 212 465 6040-‐41 Fax: +90 212 465 6042 Web: www.alapala.com
Alapala Product Line
SIMILAGO II The new Similago has been studied and developed by Alapala to provide the utmost technology in roller mill design with elegance and durability. This new roller mill satisfies the most
stringent hygiene standards together with milling precision and simple maintenance making it the most versatile roller mill for any new or existing plant design. The new state of the art electronics make the Similago II making it user friendly and flexible The quick roll change module cartridge has been updated by using the latest state of the art components The Similago II roller mill is also available in the 8 roll superimposed version with option for either 250 mm or 300 mm roll diameters. PURIFIER
This machine is an evolution of our highly successful model DISA giving higher efficiency, integrated with optimal illumination of the screen. A new generation of
vibration mountings and maintenance free motors ensure low energy consumption and low maintenance with
minimum of downtimes. QUADRO PLANSIFTER
Ingeniously designed to comply with the highest hygiene standards, easy to operate, minimum maintenance, modular design constructed in stainless steel and with a large sifting area. An important part of this plansifter is that on the basic main frame with a redesigned oscillating mechanism, it is possible to attach from 2 to 8 sections. These sections are insulated with ABS for anti condensation properties. With great consideration all the components have been designed and developed with the use of rounded recesses and profiles to stop product build up leading to infestation
More information: ALAPALA Machine Industry & Trade Inc. Flour and Feed Technology Istanbul Division World Trade Center A-‐1 No: 15/453 Yesilkoy Istanbul Turkey Tel: +90 212 465 6040-‐41 Fax: +90 212 465 6042 Web: www.alapala.com
Alapala Product Line
SIMILAGO II The new Similago has been studied and developed by Alapala to provide the utmost technology in roller mill design with elegance and durability. This new roller mill satisfies the most
stringent hygiene standards together with milling precision and simple maintenance making it the most versatile roller mill for any new or existing plant design. The new state of the art electronics make the Similago II making it user friendly and flexible The quick roll change module cartridge has been updated by using the latest state of the art components The Similago II roller mill is also available in the 8 roll superimposed version with option for either 250 mm or 300 mm roll diameters. PURIFIER
This machine is an evolution of our highly successful model DISA giving higher efficiency, integrated with optimal illumination of the screen. A new generation of
vibration mountings and maintenance free motors ensure low energy consumption and low maintenance with
minimum of downtimes. QUADRO PLANSIFTER
Ingeniously designed to comply with the highest hygiene standards, easy to operate, minimum maintenance, modular design constructed in stainless steel and with a large sifting area. An important part of this plansifter is that on the basic main frame with a redesigned oscillating mechanism, it is possible to attach from 2 to 8 sections. These sections are insulated with ABS for anti condensation properties. With great consideration all the components have been designed and developed with the use of rounded recesses and profiles to stop product build up leading to infestation
More information: ALAPALA Machine Industry & Trade Inc. Flour and Feed Technology Istanbul Division World Trade Center A-‐1 No: 15/453 Yesilkoy Istanbul Turkey Tel: +90 212 465 6040-‐41 Fax: +90 212 465 6042 Web: www.alapala.com
Alapala Product Line
Alapala Product Line
More information:ALAPALA Machine Industry & Trade Inc.Flour and Feed TechnologyIstanbul DivisionWorld Trade Center A- 1 No: 15/453YesilkoyIstanbulTurkey
Tel: +90 212 465 6040- 41Fax: +90 212 465 6042Web: www.alapala.com
The new Similago has been studied and developed by Alapala to provide the utmost technology in roller mill design with elegance and durability. This new roller mill satisfies the most stringent hygiene standards together with milling precision and simple maintenance making it the most versatile roller mill for any new or existing plant design. The new state of the art electronics make the Similago II making it user friendly and flexible The quick roll change module cartridge has been updated by using the latest state of the art components The Similago II roller mill is also available in the 8 roll superimposed version with option for either 250 mm or 300 mm roll diameters.
This machine is an evolution of our highly successful model DISA giving higher efficiency, integrated with optimal illumination of the screen. A new generation of vibration mountings and maintenance free motors ensure low energy consumption and low maintenance with minimum of downtimes.
PU
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SIM
ILA
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II
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Ingeniously designed to comply with the highest hygiene standards, easy to operate, minimum maintenance, modular design constructed in stainless steel and with a large sifting area.
An important part of this plansifter is that on the basic main frame with a redesigned oscillating mechanism, it is possible to attach from 2 to 8 sections. These sections are insulated with ABS for anti condensation properties.
With great consideration all the components have been designed and developed with the use of rounded recesses and profiles to stop product build up leading to infestation
Global Milling Advances Page 14
THE
RICE & GRAIN INDUSTRYFOR
ISRMAX AsiaIMPACT Exhibition and Convention Center
Bangkok, Thailand
29-31 August 2014
Mr. Vishal GuptaChairman, PCSLMob: +91 9812082121vishal@pixie.co.inOrganizer
Pixie Consulting Solutions Ltd. MUYANG THONG THANI
EXHIBITOR PROFILE
�
�Boilers
�Color sorters
�DG Sets
�Dryers
�Elevators and conveyors
�Material Handling
Systems
�Packaging machinery
�Rice Machinery
�Rubber rolls
�Silos
�Steam Turbines
�Weighing Scales Bridges
Mfrs.
Abrasive wheels
VISITOR PROFILE �Rice millers�Rice Departments�Certifying agencies �Hoteliers/caterers �Research
scientists/universities/Students
�Retailers�Ministeries and chamber
of Commerce �Goverment Bodies/selling
Agents/Institutional Buyers
�Technical Consultants,Supply Chain Executives
�Equipments Disrtibutors
www.isrmaxasia.net
Mr. Sirapat Kettarn Project Manager, IMPACTTel: +66 2833 5208sirapatk@impact.co.th
THE
RICE & GRAIN INDUSTRYFO
R
ISRMAX AsiaIMPACT Exhibition and Convention Center
Bangkok, Thailand
29-31 August 2014
Mr. Vishal GuptaChairman, PCSLMob: +91 9812082121vishal@pixie.co.inOrganizer
Pixie Consulting Solutions Ltd. MUYANG THONG THANI
EXHIBITOR PROFILE
�
�Boilers
�Color sorters
�DG Sets
�Dryers
�Elevators and conveyors
�Material Handling
Systems
�Packaging machinery
�Rice Machinery
�Rubber rolls
�Silos
�Steam Turbines
�Weighing Scales Bridges
Mfrs.
Abrasive wheels
VISITOR PROFILE �Rice millers�Rice Departments�Certifying agencies �Hoteliers/caterers �Research
scientists/universities/Students
�Retailers�Ministeries and chamber
of Commerce �Goverment Bodies/selling
Agents/Institutional Buyers
�Technical Consultants,Supply Chain Executives
�Equipments Disrtibutors
www.isrmaxasia.net
Mr. Sirapat Kettarn Project Manager, IMPACTTel: +66 2833 5208sirapatk@impact.co.th
THE
RICE & GRAIN INDUSTRYFO
R
ISRMAX AsiaIMPACT Exhibition and Convention Center
Bangkok, Thailand
29-31 August 2014
Mr. Vishal GuptaChairman, PCSLMob: +91 9812082121vishal@pixie.co.inOrganizer
Pixie Consulting Solutions Ltd. MUYANG THONG THANI
EXHIBITOR PROFILE
�
�Boilers
�Color sorters
�DG Sets
�Dryers
�Elevators and conveyors
�Material Handling
Systems
�Packaging machinery
�Rice Machinery
�Rubber rolls
�Silos
�Steam Turbines
�Weighing Scales Bridges
Mfrs.
Abrasive wheels
VISITOR PROFILE �Rice millers�Rice Departments�Certifying agencies �Hoteliers/caterers �Research
scientists/universities/Students
�Retailers�Ministeries and chamber
of Commerce �Goverment Bodies/selling
Agents/Institutional Buyers
�Technical Consultants,Supply Chain Executives
�Equipments Disrtibutors
www.isrmaxasia.net
Mr. Sirapat Kettarn Project Manager, IMPACTTel: +66 2833 5208sirapatk@impact.co.th
Global Milling Advances Page 16
Milling WorldMilling World, a new blog from NISA Media
Ltd, bringing together agriculture news stories from around the world.
As well as looking at events and shows we look at companies involved in agriculture, food production and animal production as
well as the feed industry and veterinary aspects of farming and agriculture.
The blog runs side by side with our online resource Global Milling Annual. Publishing press releases from key companies and key figures in the agriculture world, books releases and information
from global sources. As well as looking at the ever-changing face of agriculture, through GMO’s, research and other innovative
approaches to agriculture.
Another aspect of the agriculture world is the ever-changing effect of climate change on the industry, and as natural disasters occur,
such as droughts, floods, hurricanes we keep you updated.
Contact Martin (mlittle@globalmilling.com) with your latest news!
Global Milling 2013 Annual - Page 4
Global Milling Advances is a new online only supplement to complement our annual
Published quarterly, Global Milling Advances focuses on the technologies used within the milling industry.
To view our online issues or for more information visit:
www.globalmillingadvances.com
2013 International Modern Agriculture Exhibition
Shanghai World Expo Exhibiton&Convention Center·China
Cocurrent Events
2013 China International Protected Agricultural Equipment&Garden Materials Exhibition
2013 China International Seed Industry&Technology Exhibition
2013 China International New Fertilizer&Biopesticide Exhibition
2013 China International Water-Saving Irrigation Equipment&Technology Exhibition
2013 Global Digital Agriculture Development Summit&Exhibition
2013 Asia Fruit&Vegetable Trade Fair
The Most Influential Modern Agricultural Event in Asia
Global Milling
Global Milling Directory
Global Milling has become a brand new reference source for the Grain, Feed, Flour, Cereals, Rice, and Pasta industries. Covering all aspects from equipment to raw materials and including all suppliers and manufacturers working within the industry.
Bringing you the latest up-to-date relevant news, upcoming industry events, Universities and worldwide company contact information – Everything you need in one place!
Keep up-to-date with Global Milling
www.globalmilling.com
A new online directory
Available Now!
August7th-9th AugustLivestock Philippines 2013Manila, PhilippinesWeb: www.livestockphilippines.com
15th-17th AugustISRMAX Asia 2013Bangkok, ThailandWeb:www.isrmaxasia.net
15th-17th AugustLogiware Asia 2013Bangkok, ThailandWeb: www.logiwareasia.com
23rd-25th August GrainTech IndiaBangalore, IndiaWeb: www.graintechindia.com
25th-28th AugustICC Conference 2013Perth, AustraliaWeb: www.icc.or.at
September10th-12th September Liquid Feed SymposiumSt Louis, Missouri, USAWeb: www.afia.org
17th-19th September2013 International Modern Agriculture ExhibitionShanghai World Expo Exhibition& Convention Center, ChinaWeb: www.modernagri.cn
24th-26th September7th International Conference‘Flour Mill – 2013′International Industrial Academy, Moscow, RussiaEmail: dashevsky@grainfood.ru
24th-26th September Livestock Asia 2013, Kuala Lumpur, MalaysiaWeb: www.livestockasia.com
October1st-3rd October The 6th Scientific Conference of Animal Wealth ResearchCairo, EqyptWeb: www.facebook.com/groups/animalconf/
6th-9th October International Baking Industry Exposition, IBIE 2013,Las Vegas, USAWeb: www.ibie2013.org
November5th-8th NovemberIAOM MEA Tunisia 2013Sousse, TunisiaWeb: www.iaom-mea.com/tunisia2013
6th November UK Grain Peterborough, UKWeb: www.farm-smart.co.uk/ukgrain/
10th-16th November Agritechnica, Hannover, GermanyWeb: www.agritechnica.com
13th-14th November64th JTIC Milling & Cereals Meeting Reims, FranceWeb: www.jtic.eu
December8th-10th December NGFA Country Elevator Conference & Tradeshow St Louis, Missouri, USAWeb: www.ngfa.org
2013 Events List
Global Milling Advances Page 18
Global Milling Advances Page 19
G R A I N
2013THE GRAIN BUSINESS EVENT
Post Harvest Technology
Storage
Drying
Handling
Marketing
Organised by FarmSmart Events in association with the HGCA as Grain Quality partner
www.farm-smart.co.uk • 0845 4900 142 • admin@farm-smart.co.uk
Wednesday 6th NovemberEast of England Showground,
Peterborough PE2 6XE
Tickets £15 on the day Save £5 by pre-booking
FarmSmart-UKGrain ad-210x297_Layout 1 14/12/2012 10:07 Page 1
Global Milling 2013 Annual - Page 10
Global Milling
Global Milling Directory
Global Milling has become a brand new reference source for the Grain, Feed, Flour, Cereals, Rice, and Pasta industries. Covering all aspects from equipment to raw materials and including all suppliers and manufacturers working within the industry.
Bringing you the latest up-to-date relevant news, upcoming industry events, Universities and worldwide company contact information – Everything you need in one place!
Keep up-to-date with Global Milling
www.globalmilling.com
A new online directory
Available Now!
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