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Batching and Mixing

Charles Stark
North Carolina State University

Batching & Mixing Objective


Accurately weigh each ingredient
Minimize batching time
Produce a feed that has a uniform distribution
of nutrients and medications

Ingredient Factors
Particle size and shape
Density
Electrostatic charge
Hygroscopicity
Flowability
Source: IMC 1995

Particle Size Specification


Ingredients & Minerals
Supplier specifications
Customer specifications
Example SBM, DDGS (600 1200 microns)

Specifications based on screen size


Thru a US # _____

Premixes
Carrier
Particles per gram

Source: IMC 1995

Feed Segregation
Segregation occurs primarily as a result of
differences in particle size, the difficulty of
mixing multiple components can be reduced
by making the sizes of the components as
close as possible and also by reducing the
absolute size of the particles.

Source: IMC 1995

Ingredient Characteristics
Particle size
Shape
Flat
Round

Density
Wheat Midds
Ground Corn
SBM
Limestone
Source: IMC 1995

Particle Differences
Large Particles - For coarse particles, the
attractive force between two particles in contact
is small compared with the weight of a particle,
leading to a free flowing material.
Small Particles - If the particle size is reduced,
the weight of a particle falls more rapidly than
the attractive force between the particles, and
eventually the stage is reached where the
particles stick together. Segregation is then
prevented, because particles are no longer free
to move relative to each other.
Source: IMC 1995

Feed Mill Designs

Pre-batch grind

Post-batch grind

Post-mix grind

Post-pellet blend

Batching Equipment
Micro Bin Systems
Tote Bag Systems
Scales
Major
Minor

Weigh Buggy
Liquid Pumps & Meters

Scales

Batching Scale Fill Test


Major & Minor Scales
Fill test evaluates full
range of load cells
Add test weights
Record weight

2/3

Remove weights
Fill scale to 1/3 capacity
Add test weights
Record weight

1/3
200 lb

Remove weights
Fill scale to 2/3 capacity
Add test weights
Record weight

Document results

Batching Micro System


Multiple Hopper Scale

Single Hopper Scale

Batching - Totes
Totes & Scales

Tote Transfer

Liquid Ingredients
Self Contained System

Tank & Dike System

Liquid Addition Layout

Liquid Addition Equipment


Meters

Pumps

Mass Flow System Liquid Component


Coriolis Meter

Mass Flow System Coriolis Meter

Batching Sequence
Batching System

Computer draws multiple


bins to the major scale.
Micro Scale

Major
Scale

Minor
Scale

Major Scale:

Computer switches to one


bin and jogs at the end of
the each ingredient.
Major Ingredients
Corn/Wheat
SBM
Midds
DDGS

Batching Sequence
Batching System

Major
Scale

Minor
Scale

Minor Scale Fill:

Micro Scale

Computer draws single


bins to the minor scale
and jogs at the end of the
each ingredient.
Minor Ingredients
Dical
Limestone
Salt
Lysine

Batching Sequence
Batching System

Micro Scale Fill:

Micro
Scale
Major
Scale

Minor
Scale

Computer draws single


bins to the micro scale and
jogs at the end of the each
ingredient.
Micro Ingredients
Vitamins
Trace Minerals
Medications
Amino Acids

Batching Sequence
Batching System

Scale Considerations:
Micro Scale
Major
Scale

Minor
Scale

Major Scale 80-90%


Minor Scale 10-15%
Micro Scale < 5%

Batching Sequence
Batching System

Major Scale
Discharges First
Micro Scale
Major
Scale

Minor
Scale

Fills the dead space


between the ribbons
and tub.

Batching Sequence
Batching System

Micro Scale
Major
Scale

Minor
Scale

Minor Scale Discharges


after a 5-10 second
delay
Minor ingredients mix
with the major
ingredients

Batching Sequence
Batching System

Micro Scale Discharges


after a 0-5 second delay
Micro Scale
Major
Scale

Minor
Scale

Micro tub or scales open


and the material is
transferred with a drag
conveyor

Mixing Time

Batching

Horizontal Double Ribbon

Batching System

30-60 second Dry Mix


Micro Scale
Major
Scale

Minor

120-180 second Wet Mix


Liquid Addition

Scale

Volumetric (meter)
Gravimetric (weighed)
Liquid Ingredients:
Fat
Molasses
Choline
Amino acids

Spray Here

Batching Sequence
Batching/Mixing System

Mixer opens and


material drops to a
surge hopper
Micro Scale

Major
Scale

Minor
Scale

Discharge Process

Batch Cycle
Batch Cycle 4 mins

Weighing 2 min
Discharge
1 min

Mixing 3 min

Weighing 2 min
Discharge
1 min

Mixing 3 min

MIXING EQUIPMENT

Automation System

Automation Hardware
PC

Server
PLC

PLC
PLC Cards/Modules

PLC

PLC Computer Inputs

Theromcouple
Micro Switch

Hand Add Buttons

Scale Indicator

PLC Outputs

VFD

Motor Starter

Batch Production Report

Recommended mix times


Mixer

Dry Mix

Wet Mix

Paddle

Twin Shaft Paddle

0.5

Double Ribbon

1-2

2-3

Twin Shaft Ribbon

0.75-1

Vertical

5-10

5-10

Source: Froetschner, 2007

Mixer Design Factors


Dimensions
Short x Wide
Long x Narrow

Ribbon/Paddle Angle
Ribbon Width(s)
Ribbon Tip Speed
Total Surface Area

Mixer Sizes

200 CF Mixer
Feed (lbs/cft)
35 - 7000 lbs
40 8000 lbs
45 9000 lbs

Horizontal Ribbon Mixer

Ribbon mixer Multiple ribbons

Double ribbon Single shaft

Double Ribbon Mixer Mixing Zones

Feed Flow
Main Mixing Zone

Main Mixing Zone

Typical mix time = 3-4 min

Double Ribbon Horizontal Mixer

Paddle Mixer

Paddle mixer

Paddle Mixer Mixing Zones

Feed Flow
Main Mixing

Some

Main Mixing

Mixing

Main Mixing

Some
Mixing

Main Mixing

Horizontal Paddle Mixer

Rotating Drum Mixer Mixing Zones

Drum Mixer

Ribbon Mixer - Counterpoise

Ribbon Mixer Counterpoise Mixing Zone

http://www.hayes-stolz.com/

Forberg Fluid Bed Mixer

Forberg Mixer

Vertical Mixer

Vertical Mixer Mixing Zones


Main

Main

Mixing

Mixing

Zone

Zone

Main
Mixing
Zone

Vertical Mixer

Mixer-Problems
Liquid Spray Nozzle

Material Build up

Mixer Problems
Material on ribbons

Material on paddles

Batching & Mixing Problems


Fat sprayed on ribbon and
shaft

Fat lumps created by poor


liquid application and mixing

MIXER UNIFORMITY ANALYSIS

Factors Affecting Uniformity


Particle Shape
Spherical, square, flat

Particle Size
Different particle size can separate during the handling
process

Density
Heavy particles may settle out during conveying and
discharge to a bin

Static Charge
Particles will adhere to equipment if not properly grounded

Hydroscopicity
Vitamins or Feed Additives may absorb water

Adhesiveness
Fats or molasses may adhere to equipment

What Represents the Goal of Mixing?

Segregated
Mix

Perfect Mix
Random Mix

Distribution of weighing errors

Are You Weighing Ingredients Correctly?

Weighing Precision
Variation in weighing within ingredients, expressed
as Coefficient of Variation (CV)
Weighing CV ranges on average of about 5% (0.6 11% CV)

Causes of Weighing Variation


Hand-weighing ingredients
People tend to overdose by about 1% when ingredients are weighed by hand

Micro-ingredients and premix dose errors


Micro-ingredients scales seem to be more variable than macro-ingredient scales
because of the size of the call

Descrepancies between call size and scale resolution


Average weighing discrepancies in feed mill is about 2% but can range up to 20%
For example, requesting 11.3 lbs of an ingredient when the scale has a resolution
of only 2 lbs.

Ratio of call size to scale resolution


Weighing errors and CV decreases as the call size to scale resolution increases.
For example, a call for 100 lbs to be weighed on a scale with a resolution of 5 lbs
gives a call/scale resolution of 20, where as a call for the same 100 lbs on a scale
with a resolution of 2 lbs gives a ratio of 50.

Mixer Uniformity Analysis


Mixer Markers
Single nutrient/ingredient
Salt
Synthetic Amino Acids (Lysine or Methonine) Dry Mix Uniformity

Economical
Accurate and precise at inclusion level

Test twice per year


Ten samples from the same batch of feed
Sample mixer or a point closest to the
discharge

Feed Quality Assurance Mixer Test


Sample mixer

Sample surge

Mixer or Surge samples


provides information on dead
spots in the mixer or mixer
maintenance issues
Sampling during the discharge
process provides
representative samples of the
feed as it moves through the
system.
Sample discharge conveyor

Mixer Uniformity Analysis - Quantab

Mixer Uniformity Analysis - Quantab


Weigh 10 gram
sample of feed into
a dish
Scale +/- 0.1 g

Mixer Uniformity Analysis - Quantab


Fold filter paper to create a cone

Mixer Uniformity Analysis - Quantab


Measure out 90 ml
of HOT distilled
water
SAFETY
Hot Water Burns!!

Mixer Uniformity Analysis


Mix sample and water
for 30 sec wait and
re-mix for 30 sec.
Place filter paper
cone in cup
Place Quantab strip
into the filter cone
Indicator strip at the
top will turn black
when complete

Mixer Uniformity Analysis - Quantab


Read highest point
on the strip
Determine NaCl
level based on the
calibration chart on
the bottle.
Multiple by 10
(10:1 dilution)

Mixer Uniformity Analysis Calculations


Calculation of Mixer CV
Mean of samples
Standard deviation of samples
CV % = standard deviation x 100
mean

Mixer Uniformity Analysis Calculations


NAME:
ADDRESS:
SAMPLE:

DATE:

QUANTAB READINGS
1
2
3
4
5
6
7
8
9
10

0.20
0.21
0.22
0.17
0.17
0.18
0.20
0.17
0.18
0.18

STANDARD DEVIA
MEAN

0.02
0.19

COEFFICIENT OF VARIATION (CV)

9.65

Micro Tracer Rotary Detector Method


Materials

Test Method

Weigh 100 g sample


Place filter paper on the spindle
of the rotary magnet.
Transfer the sample of feed to
the top hopper of the Rotary
Transfer the Microtracer to a
scoop, demagnetize, then
disperse over a large wetted
filter paper on an aluminium
plate. Then dry on hot plate to
develop spots. Count the spots.

Rotary Detector.
Scale.
Demagnetizer.
Heating plate.
Developing Solution.
Filter paper 7.5 mm
Grinder for pelleted feed

Source: www.microtracers.com

MicroTracter Rotary Detector

Source: www.microtracers.com

FS-Red/ Natural Yellow


Spots Developed with 50% Water and Alcohol

Source: www.microtracers.com

Mixer Uniformity Evaluation


CV

RATING

CORRECTIVE ACTION

< 10%

Excellent

None

10-15%

Good

Increase mixing time by 25-30%

1520%

Fair

20%+

Poor

Increase mixing time by 50%, look for worn


equipment, overfilling, or sequence of
ingredient addition
Possible combination of all the above
Consults extension personnel or feed
equipment manufacturer

Double Ribbon Mixer RPMs

Double Ribbon Mixer Worn Ribbons

Double Ribbon Mixer Wrong Rotation

Double Ribbon Mixer Build-Up

Questions

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