industry innovations in feed mill design 2018 - hennie...industry innovations in feed mill design...
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Hennie PieterseOttevanger Milling Engineers
Australian Milling Conference 2018Gold Coast Convention & Exhibition CentreBroadbeachAustralia
Industry Innovations in Feed Mill Design
Industry Innovations in Feed Mill DesignWhy is Innovative Design necessary?
Flexibility to adjust to Market Trends & Changes producing a range of Final Products that have market demand
Flexibility to cope with a wide range of Raw Materials in a cost effective way
Flexibility to expand in a logical way with minimum impact on Operations
Innovative Feed Plant design should lead to lowest cost producing high quality Fish, Meat, Milk & Eggs
Industry Innovations in Feed Mill DesignCharacteristics of good or Innovative “Design” :
• Functionality - most important design goal. Failure to properly meet required functionality and the rest means little
• Engineering Integrity - meeting Engineering design criteria in terms of material Choice; Structural Strength; Workmanship; Durability, etc
• Cost - Capital & Operational Costs clear. The Hidden Costs of inferior design might be surprising
• Ergonomics - User-friendliness; Health & Safety and its effect on End-Product Quality
• Aesthetics - no reason why a good design should not look good
Hammermill with Automatic Screen Change (Courtesy Ottevanger Milling Engineers)
Industry Innovations in Feed Mill DesignInvesting in Innovative Engineering Design of Processing Plant has at least following effects:
Functionality- Designed to fulfil Specific Function- Meet & Exceed plant Customer’s Expectations
(Physical & Nutritional Final Product Characteristics)- Failure to meet above makes low cost design
expensiveDowntime
- Inferior Design & Equipment results in unnecessary Operational Constraints, Failure & Downtime
- This may disappoint Processing Plant Customers and has potential to drive them to Competitors
Cost- Initial Engineering Investment Cost small with big
effect when neglected- Other Costs continuous and affected by Design
1%15%
49%
35%
Costs over Feed Mill Lifetime
Planning & EngineeringEquipment & InstallationOperations & ManagementInterest
Courtesy American Council of Engineering Companies
Why Innovative Feed Mill Design?• Increase in Feed demand no surprise :
7.5 Billion people on earthNet Growth = 2 people per secondAlltech Report confirms 2,57% annual growth (2016 - 2017)Total volume 1.07 Billion tonTotal Value = US$ 430 Billion
• Challenge :To keep up with growthwith decreasing natural resourcesin an Innovative Feed & Food Manufacturing Regime
Table 1. Percentage and Growth of Global Feed Production by Species (Alltech)
Feed by Species % of Total Annual Growth [%]
Broiler Feed 28% 3%
Aquatic Feed 4% 1% as result of China down
Petfood * 3% 5% to 12%
Horse Feed 1% all regions up, EU 24%
Pig Feed 27% 5.5%
Dairy Feed 11% 3%
Beef 7% -1%
Layer Feed 13% 1%
Other 6%
* up to 12% growth in Metropolitan China (Petfood Industry)
• EQUIPMENT & PROCESS INNOVATIONSEquipment innovations
Hygienic Equipment DesignSquare SilosVacuum Coating & Liquid Layering
Process Innovations
• DESIGN PROCESS INNOVATIONS
• RAW MATERIAL FLEXIBILITY DESIGN INNOVATIONS
• SAFE FEED MANUFACTURING INNOVATIONS
Industry Innovations in Feed Mill Design
Steam Preconditioner with Thermal Retention Time Barrel (Courtesy Ottevanger Milling Engineers)
9. Increases capacity of Pellet Press / Expander / Extruder
Hygienic Equipment Design
Horizontal spaces and surfaces in Equipment design could collect Fines & Dust
Feedstock staying behind inside equipment (Product Hang-up) could go off over time and cause contamination
Feedstock staying behind inside equipment (Product Hang-up) could lead to cross-contamination between different formulations
Equipment Innovations
Extruder and Preconditioner Chassis or Frame design that leaves no horizontal space for dust collection or product hang-up during cleaning or barrel change-over. (Courtesy Wenger manufacturing Inc.)
Square Silos in general
Maximised Storage Capacity compared to Round
Structurally and Functionally integrates with Plant
Flexibility & Traceability simplified
Could be custom designed meeting specific Requirements
Equipment Innovations
Fig 1. Extruder and Preconditioner Chassis or Frame design that leaves no horizontal space for dust collection or product hang-up during cleaning or barrel change-over. (Courtesy Wenger manufacturing Inc.)
Square Silo Block (Courtesy TSC Silo)
Square Silos with Smooth Cell Walls
Constructed with Double Wall System
Optimal Product Outlet
No Weld Seems in Silo Walls
Hygienic Dust-Free Work Environment
Modular Construction means logical expansion
Bin Coatings as requiredStainless Steel as required
Equipment Innovations
Square Silos with Profiled Cell Walls
Lightweight Single Wall System
Profile provides Structural Strength
Hygienic & Dust Free Silo Environment
Modular Construction
Bin Coatings as required
Stainless Steel as required
Equipment InnovationsProfiled Panels for specific
Products / Economy
Hopper Design meeting Raw Material Characteristics &
Behaviour
Purlins for attaching Cladding directly to Square Silo Block
Square Silos : Bin Hoppers
Different Bin Hopper Designs to meet specific Raw Material Flow Characteristics
Bin Hopper Outlet Design round or Square as required
Accommodates Loading Bellows when Bins are used as Final Product Bins
Seamless transition from Bin to subsequent Process
Equipment InnovationsSquare or round Hoppers to
match any Raw material Type
Smooth Double Walled Panels for specific
applications
Purlins accommodate Cladding directly to Silo Block
Square Silos : Bin Roof Top Design & Function
Bin Roof Top becomes Service Floor for easy Maintenance
A Closed & Safe Work Environment
Equipment Innovations
Square Silos : Integration with Process & Superstructure
Equipment Innovations
Vacuum Coating & Liquid Layering
Higher fat levels compared with Atmospheric Coaters
Liquid Layering of several Liquids & Micro Ingredients possible
Liquid with lowest palatability pulled to centre of Pellets
Liquid with highest palatability applied to surface of pellets
Several other liquids could be layered concentrically between centre and surface of pellets
above achieved by sequencing liquids (through Process Control) at varying negative pressures.
Equipment Innovations
Typical examples of Vacuum Coater used in Petfood / Aquatic Feed processing (Courtesy
Ottevanger Milling Engineers / Forberg / Dinnissen)
Extruded / Pelleted Product
Product Voids @
Atmosphere
Application of Vacuum
Application of Coating
Vacuum Release
Surface / Attractant Coating
Optimised Coating
Several Concentric
Layers possible
Online Process ControlQuality & Feed Safety requires Critical Control Point (HACCP) Analysis and ControlHistorically we attempted to do this manually with challenges :
not TimelyHuman Error
Innovations in Process Control and Sensing Technology led to Online Process Control with little to no maintenance calibration requiredOnline Process Control consisting of Hardware & Software :
• Sensor sensing Operating Parameter• PLC to Process Control Software• Process Control Software to Device
rectifying Operational Condition Typical examples of Sensing Technology for specific Operational Parameter Sensing (Courtesy Source Technology / Tovalia / TEWS Elektronik)
Process Innovations
Containerised Plant Design
Modular approach based and standard 20ft Container Frames
Meets International Shipping Requirements
Process Flow Design like Conventional Plant Design
Suits any Process - in some cases Partially Containerised
Designed to meet Structural Process, Maintenance and OHSA requirements
Equipment Innovations
Containerised Plant Design
Manufactured and Mechanically & Electrically installed at Point of Manufacture
Dry Testing at Point of Manufacture
Superstructure housing the Plant a Shell-type Structure only accommodating and protecting Plant & Equipment
Sidewalks, safety Railing and Stairs bolted to individual Container Modules on ground level = Installation and OHSA cost reduction in Australia
Equipment Innovations
Equipment InnovationsContainerised Plant Design - Sizing
Small to Large Plant
For any Application in Feed Manufacturing
Full & Partial Containerised Plant Design
Certain Zones of plant could be Full Containerised [Size Reduction & Mixing / Micro Ingredient Batching / etc]
Other Zones could be Conventional for reasons of Function Size [Pellet Pressing / Extrusion / Drying & Cooling / etc]
Results in Partially Containerised Plant Design
Equipment Innovations
Containerised Design Conventional Design
Partially Containerised Design
Equipment InnovationsContainerised Plant Design Timeline
• EQUIPMENT & PROCESS INNOVATIONS
• DESIGN PROCESS INNOVATIONSHistorical Design ApproachIntegrated Design Approach
• RAW MATERIAL FLEXIBILITY DESIGN INNOVATIONS
• SAFE FEED MANUFACTURING INNOVATIONS
Design Process Innovations
Design Process InnovationsHistorical Design Approach
2D Design Software
Costly and Time Consuming
Challenging to Interpret & Present
Majority of Design Flow was Manual (and open to Human Error) :
Process Flow DiagramsStructural Analysis and DesignPlan Views and ElevationsManufacturing & Fabrication Detail DrawingsBills of Materialetc
Design Process InnovationsIntegrated Design Approach
3D Design Software
An integral part of Project Development
More economical over Project Development lifetime
Easy to Present to Decision Makers, Investors; Other Designers part of the Project, etc
3D Design great for studying potential Equipment & Process Interference
3D Design Work Flow integrates all aspects of Project Development
Design Process InnovationsIntegrated Design Approach
Modelling & Presentation as Project is developedKeeps design costs low Accelerates Decision-makingDetailing as required and as Project develops“Plug-in” software integrates with 3D design software to incorporate :
BIM (Building Information Modelling)MEP (Mechanical, Electrical & Plumbing)HVAC (Heating, Ventilation & Air Conditioning)Heat Transfer ModellingTraffic Flow Patternsetc
Modular Steam Generation Plant
Conceptual Aquatic Feed Plant Site LayoutVitamin Mineral Dosing Plant
On-Farm Liquid Addition System
Images Courtesy hp dezign Pty Ltd
Design Process InnovationsIntegrated Design Approach Workflow
Process Flow Design
3D Modelling & Layout
Generate Plans / Section Cuts / Elevations / Perspectives
Iteration Process with Customer Input
Detail Drawings for Manufacturing and Fabrication Raw Model (Perspective) Rendered Views (Isometric)
Interference
Design Process Innovations
Plan Views(& Horizontal Sections)
Elevation 1(& Vertical Sections)
Elevation 2(& Vertical Sections)
Elevation 3(& Vertical Sections)
Elevation 4(& Vertical Sections)
• EQUIPMENT & PROCESS INNOVATIONS
• DESIGN PROCESS INNOVATIONS
• RAW MATERIAL FLEXIBILITY DESIGN INNOVATIONS
Conventional Raw IngredientsEngineered Raw IngredientsValue-Added or Enhanced Raw IngredientsFresh Meat or Fish as Raw Ingredients
• SAFE FEED MANUFACTURING INNOVATIONS
Industry Innovations in Feed Mill Design
Raw Material Flexibility Design InnovationsEngineered Raw Ingredients
“New” Ingredients could be developed from by-products and products with limited value :
By mixing in specific ratio By-Product with a locally available Product and then co-extrude Product Pasteurised after ExtrusionFinal Product could be in Pellet, Granule or Meal formFinal Product Nutritional Profile could be tailored for specific applicationsBy-Products could consist of:• Meat or Fish / proteins• Plant / Fruit / Vegetable Processing by-products• Animal Processing By-product• Spent Hens• etc
Fish By-Product co-extruded with Soybean Meal (Courtesy Food Protein R&D Centre Texas A&M University)
Fresh Fish Processing By-Product Ground & mixed with Soybean Meal
High Shear Extrusion Dried & Milled Fish By-Product Meal
Raw Material Flexibility Design InnovationsValue-added / Enhanced Raw Ingredients
Many Ingredients in un-processed state has limitations in terms of Nutrition / Functionality and Application :
• Some Pulses and Oilseeds contain Anti-Nutritional Factors we have to deal with effective and safe application as feed ingredient is possible.
• Raw Starch in Cereals could be gelatinised thereby making it effective in nutrition of young animals and animals sensitive to raw starch.
Effective Heat Treatment under correct processing conditions plays an important role in Raw Material Enhancement
Raw Oilseed Full Fat Oilseed Partially Defatted Oilseed
Gelatinised Starch Soluble Starch
Raw Material Flexibility Design InnovationsFresh Meat / Fish as Raw Ingredients
Humanisation of Pets & demands of Pet Owners led to major advances in utilising novelty ingredients / Fresh Meat / Fresh Fish as :
Emulsified Meat / Fish SlurryMeat / Fish Hydrolysate
Innovations in Thermal Processing led to Technologies
Emulsified Slurry
Hydrolysed Liquid
• EQUIPMENT & PROCESS INNOVATIONS
• DESIGN PROCESS INNOVATIONS
• RAW MATERIAL FLEXIBILITY DESIGN INNOVATIONS
• SAFE FEED MANUFACTURING INNOVATIONS
Plant Design & ZoningLimiting Cross-ContaminationImportance of Thermal Processing
Industry Innovations in Feed Mill Design
Plant Design & Zoning
The Plant, whether of Horizontal or Vertical design, is zoned in order to isolate Operational Processing Activities thereby managing, controlling & limiting :
Cross-contamination
Noise
Odour
Dust
Safe Feed Manufacturing Innovations
Non Thermal Plasma Odour Control System with UV Sterilisation Unit (Courtesy Schenck)
Online Dust Control & Fire Suppression (Courtesy Ottevanger Milling Engineers)
Typical zoned Vertical Plant Layout (Courtesy hp dezign Pty Ltd)
Typical zoned Horizontal Plant Layout (Courtesy Wenger
Manufacturing Inc.)
Safe Feed Manufacturing InnovationsLimiting Cross-Contamination
How does Cross-Contamination occur?
Hang-up of Product in Transitional Equipment
Hang-up of Product in poorly designed Equipment
Spillage / Leakage in poorly designed & constructed Plant
Poor Process Flow Design
Poor or limited Operating Procedures followed by Workers
Cross Contamination between formulations minimised through proper Process Control and Sequencing
Poorly designed Equipment, poor Process Flow Design, poor construction and Fabrication all lead to cross-contamination and potentially Unsafe Feed
Safe Feed Manufacturing InnovationsLimiting Cross-Contamination Before Thermal Processing
Separate Intake, Preparation, Storage for Dry and Wet Ingredients (Fresh Meat & Fish)
Wet Product does not enter Process before Heat Treatment
Process design should limit unnecessary Transitional Equipment
Processing Equipment should be of “clean” design with minimum to no Product Hang-up
Transitional Equipment selection to consider physical Product Characteristics & potential Cross-contamination
Purge Options at Critical Control Points before Extrusion / Pellet Pressing
Picture please
Fresh / Wet Product Flow
Dry
Feed
stock
Flo
wFin
al Pr
oduc
t Flo
w
Thermal Processing
Limiting Cross-contamination between Dry and Wet Products in a Petfood Plant (Courtesy hp design Pty Ltd)
Safe Feed Manufacturing InnovationsLimiting Cross-Contamination During Thermal Processing
Thermal Processing Operation first point of Fresh Product meeting Dry feedstock thanks to innovations in Fresh Meat & Fish Handling & Preparation techniques
Thermal Processing with proven Start-up and Shut-down procedures helps controlling Water Activity challenges
A well designed Plant facilitates Wash-Down and Steam-Cleaning
Advanced Suppliers offer Start-up Waste Recovery Systems (Cost Recovery)
CIP & COP limit potential of Cross-Contamination
Fresh Product enters Plant without crossing paths with Dry Feedstock
Fresh Product meets Dry Feedstock first
time at Thermal Processing
Images Courtesy Wenger Manufacturing Inc.
Safe Feed Manufacturing InnovationsLimiting Cross-Contamination After Thermal Processing
Conveying down-stream from Extruder carefully selected to meet specific Product Requirements
Options may include Pneumatic Conveying, Belt Conveying, Pendulum Conveying
CIP (Clean-in-Place) Solutions available for Pendulum Conveying
Vacuum Coating could include a CIP Cycle
Purge Options at CCP’s between Extrusion and Final Product Bins / Packaging / Bagging
Purged Product could be re-used in Budget Formulations Negative Pressure Dilute Phase Pneumatic Conveying Pre-Drying to Drying-Cooling (Courtesy Wenger Manufacturing Inc.)
Safe Feed Manufacturing InnovationsConveying Options for Pet & Aquatic Feeds INTAKE
EXTRUSION
PRE-DRYER
DRYER-COOLER
STD DRY EXPANDED >50% FRESH MEAT PET SEMI-MOIST PET SHRIMP / MICRO
COATER
COOLER
PACKAGING
By-Pass Pre-Dryer Flat Belt Conveyor max 10 deg incline By-Pass Pre-Dryer By-Pass Pre-Dryer
Negative Dilute Phase PneumaticPendulum Conveyor
Cleated Incline Belt Conveyor
Negative Dilute Phase PneumaticCleated Incline Belt Conveyor Cleated Incline Belt Conveyor Negative Dilute Phase Pneumatic
Positive Dense Phase PneumaticPendulum Conveyor
Cleated Incline Belt Conveyor
Positive Dense Phase PneumaticPendulum Conveyor
Cleated Incline Belt Conveyor
Pendulum ConveyorCleated Incline Belt Conveyor
Pendulum ConveyorNegative Dilute Phase Pneumatic
Cleated Incline Belt Conveyor
Positive Dense Phase PneumaticPendulum Conveyor
Cleated Incline Belt Conveyor
Positive Dense Phase PneumaticPendulum Conveyor
Cleated Incline Belt Conveyor
Pendulum ConveyorCleated Incline Belt Conveyor By-Pass Coater
Positive Dense Phase PneumaticPendulum Conveyor
Cleated Incline Belt Conveyor
Positive Dense Phase PneumaticPendulum Conveyor
Cleated Incline Belt Conveyor
Pendulum ConveyorCleated Incline Belt Conveyor By-Pass Cooler
Drag ConveyingScrew Conveying
Positive Dilute Phase Pneumatic
in Cooperation with Wenger Manufacturing Inc.
Safe Feed Manufacturing InnovationsImportance of Thermal Processing (Technology Dependant)
Producing Safe FeedCooking of Feed IngredientsStarch GelatinisationControlling Density (Aquatic Feeds)Sterilising (By-Product) / Stabilising (Rice Bran) / Sanitising (Layer Feed)Minimising the effect of Anti-Nutritional FactorsMaximising Digestibility of Protein, Fat & FibreProduction of new Textures (TVP’s / TSP’s)Enhancing Solvent ExtractionEnhancing Mechanical Oil Expelling
Extrusion Capability varies from Technology to Technology and should be specified with care (Courtesy Wenger Manufacturing Inc., Extru-Tech Inc. & ALMEX)
Safe Feed Manufacturing Innovations
Thermal Processing Opportunity Preconditioner Thermal Compactor Thermal Sanitiser Expander Oil Press Extruder
Oilseeds X X X X
Raw Material Enhancement X X X X X
By-Product Processing X X X
General Animal Feeds X X X X X X
Solvent Extraction X
Aquatic Feeds X X X
Petfoods X X
Human Foods X X X
Thermal Processing Potential
Australia / New Zealand Contact Details
Hennie PieterseTel : +61 (0)410 950 746e-mail : [email protected] Box 4536Springfield LakesBrisbane, QLD 4300AUSTRALIA
Head Office Contact Details
Paul EijmbertsTel : +31 (0)79 760 05 06
e-mail : [email protected] 32
PO Box 32750 AA Moerkapelle
The NETHERLANDS