From Raw Materials to Finished Feed: Inside a 20t/h Turnkey Plant

In order to keep the plant compact and maintain a relatively low footprint, structural steel towers were used. Additionally, a number of chain conveyors and bucket elevators were incorporated for the majority of the conveying within the plant.

A raw material intake system was required to cater for up to thirteen different products, with maize being the bulk ingredient. This maize is conveyed from bulk silos adjacent to the plant and fed into a hammer mill to be converted into meal.

Once processed, the meal, along with other raw materials, all in granular or powdered form, is conveyed into large holding bins. Below each bin is a feed screw conveyor system that allows for the extraction of any product to be fed into a weigh hopper strategically positioned below the bins. This process enables precise percentage proportions and feed rates to be achieved in fulfilling pre-programmed recipes.

The combined products are then conveyed up into a ribbon blender positioned atop one of the structural towers. This crucial stage blends all the ingredients into a homogeneous mix within minutes, ensuring consistency in the final product.

Once mixed, bomber doors below the ribbon blender discharge the product into further conveyors leading to the pelletizing system located on another structural tower. This system incorporates a buffer bin and pre-conditioner augers. Through heat and pressure, the perfect pellet is formed.

An important stage of the process is cooling down the hot pellets to ambient temperature. This is essential to prevent breakage and is accomplished using a counter-flow air chamber cooler positioned below the pelletizer, utilizing a high-pressure extraction fan. The now-cooled pellets are conveyed into the finished product bin.

The same product can be diverted and conveyed into a crumbler as needed, where it is converted into a coarse powdered product referred to as mash. This mash is also conveyed to a second finished product bin. From the two finished product bins, the final product is fed into a packer-weigher system, where it is measured and filled into 50kg polypropylene bags, sewn closed, and prepared for dispatch.

This turnkey animal feed plant project showcases our commitment to innovation and excellence in material handling solutions. By employing advanced engineering techniques and automated processes, we ensure that our clients receive high-quality products that meet their specific needs. Our focus on efficiency and reliability positions us as a leader in the industry, ready to tackle the complex challenges of material handling in the agri-food sector.

For more information about our solutions, please visit our website.