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Page 1

Feed Mill Design

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By
Fred J. Fairchild, P. E.
Department of Grain Science and
Industry
Kansas State University

Page 3
2

Planning

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Determine Needs
Determine Purpose
Design to
Requirements

Page 4

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Product Mix

Bulk Feeds
Mash
Pellets & Crumbles
Textured Feeds
Miscellaneous

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Page 5

Product Mix

Bagged Feeds
Mash
Pellets & Crumbles
Textured Feeds
Whole/Processed Grains
Premixes
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Scratch Feed

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Product Mix

Bulk Feeds
Mash 8.1%
Pellets & Crumbles 20.3%
Textured Feeds 48.6%
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Miscellaneous 1.4%
78.4%

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Product Mix

Bagged Feeds
Mash 1.4%
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Pellets & Crumbles 5.4%
Textured Feeds 8.1%
Whole/Processed Grains 2.7%
Premixes 1.4%
Scratch Feed 2.7%
21.6%

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Product Mix

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Bulk Feeds 78.4%
Bagged Feeds 21.6%
100.0%

Page 9

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Cost Centers

Receiving
Sizing
Flaking/Crimping
Batching/Mixing
Pelleting
Continuous Proportioning Mixing
Bagging
Warehousing
Bulk Loadout

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Page 10

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Process Flow Diagram
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Production Capacity

Initial:
2000 MTPW / 40 Hr./Wk. = 50.0 MTPH
(1 Shift @ 5 days per week)
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Page 12

Production Capacity

Intermediate:
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3000 MTPW / 50 Hr./Wk. = 60.0 MTPH
(1 Shift + @ 5 days per week)

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Production Capacity

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Final:
5500 MTPW / 96 Hr./Wk. = 57.3 MTPH
(2 Shifts @ 6 days per week)

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Design Production
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Capacity

Required Capacity = 60 MTPH Average

Design Capacity = 60 MTPH/0.80*


Design Capacity = 75 MTPH

* 80% Efficiency Factor

Page 15

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System Capacities

Individual processing systems in the


total production process must be able
to support the plant production
requirements to avoid restricting
production rates.

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Page 16

System Capacities
Equipment sizing is based on the
production rate(s) required.
As an example:
If the majority of the formulas made
use a maximum of 65% ground grains,
the grinding equipment should
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operate at no less than 70% of the
plant production capacity.

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Bin Types

Round, Square, Rectangular


Metal or Steel

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Page 18

Bulk Ingredient Bin Sizing

Based on Delivery Unit Capacity


(Tons/Load)
Minimum of 1.5 times smallest delivery unit.
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Sufficient capacity to store needed amount
between deliveries.
Sufficient capacity to receive and store total
shipment. (ie, unit train)
Sufficient capacity to meet variations in
delivery schedules
Sufficient capacity to meet daily production
needs.
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Bulk Liquid Storage

Tank size based on


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size of shipment
plus reserve.
Liquid and tank
construction must
be compatible.
Locate bulk tank for
easy access by
supply truck or rail
car.

Page 20

Tote Bags
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Use for micro or low
use ingredients.
Can be used to
directly refill micro
batching system
bins.
Reduces labor and
disposal of paper
bags.

Page 21

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Receiving System

Minimum receiving capacity should be 2


times the plant production capacity.

Other factors affecting receiving capacity


include:
Receiving operating hours
Availability of shipments
Size of shipment
Permitted unloading times

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Page 22

Receiving System

Large pit openings and deep pits can


accommodate full truck or rail car loads,
but require dust control systems to keep
free falling ingredient dust within the pit.
Dust control system requires 45 cm/m of
air per 1 square meter of grate area.
3M x 3M grate requires 406 cm/m of air for
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dust control.

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Receiving System

Alternate receiving system uses high


speed unloading equipment and
shallow or no pit.

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Trucks and cars are dumped into
conveyors and form choke feed
stream that produces little dust.

Page 24

Ingredient Processing
Hammermill
Hammermill capacity should be
designed to operate near full motor
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capacity.
The addition of an air assist system on
the hammermill will increase capacirty
by 10-15% while narrowing the particle
size distribution band.

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Ingredient Processing
Hammermill
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Magnet

Feeder

Grinding
Chamber

Ingredient Processing
Page 26

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Hammermill
Air Assist System
Air required is .007-
.009 cubic meters of
air per square
centimeter of
hammermill screen
area.
Air assist forms
negative pressure
inside hammermill.
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Page 27

Ingredient Processing
Roller Mill
Requires less
energy than
hammermill.
Use 2 or 3 pairs of
rolls to grind in steps
for better particle
size control.
Does not grind
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fiberous materials.

Page 28

Ingredient Processing
Steam Flaking
Pre-conditioning by
adding water prior to
steam chest.

Steam chest should


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have a minimum of
1 hour capacity at
processing rate.

Page 29

Proportioning Systems

Batching System (scale hopper


individual ingredient addition)
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Continuous System (continuous feed
simultaneous ingredient addition)

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Proportioning
Batching System
Capacity must be
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fast enough to keep
up with mixer cycle
times
Multiple scale
hoppers shorten
batching time
requirements.

Page 31

Proportioning
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Continuous System
Ingredient addition
rates must be
closely monitored to
assure accuracy.
Individual
continuous scale
feeders for each
ingredient best.

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Page 32

Mixing
Batch System
Cycle time must be long enough to fully mix
dry ingredients and added liquids.
Cycle time must allow time for filling and
discharging the mixer.
Size of mixer based on required mixing time.
Standard ribbon mixer requires 3-5 minutes
for mixing.
Twin rotor and special agitator mixers can
fully mix in 1-1 minutes.
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Page 33

Mixing
Batch System
Cycle time example:
Design capacity = 75 MTPH
Assume 4 metric ton capacity mixer
Batches per hour = 75/4 = 18.75
Cycle time = 60/18.75 = 3.2 minutes
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Cycle time = 3.2 x 60 = 192 seconds

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Mixing
Batch System
Cycle time = 3.2 x 60 = 192 seconds
Assumptions
Mxer fill time = 15 seconds
Mixer discharge time = 15 seconds
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Mixing time = 192-30 = 162 seconds

Mixer must be able to fully mix in 2.7 minutes

Page 35

Batching Scale & Mixer

Scale Hopper

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Liquid Manifold

Mixer

Inter-vent

Surge Bin

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Twin Rotor Mixer

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Mixer

Inter-vent

Surge Bin

Page 37

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Pelleting System

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Page 38

Pelleting System

Capacity is dependent on drive


horsepower.
Capacity varies by ingredients used,
liquid added, and pellet size.
A minimum of 2 mash bins should be
located above mill.
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Page 39

Pelleting System
Horizontal Cooler
18-21 cubic meters per
minute of air per metric
ton of capacity.
High maintenance.

Conterflow Cooler
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12-16 cubic meters per
minute of air per metric
ton of capacity
Low maintenance .

Page 40

Bagging System

Manual bag
placement and
sealing.

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Requires 1-2 people
to operate at
capacity.
Manual System
6-8 bags per minute

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Bagging System

Automatic bag
placement, filling
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and sealing.

Requires restocking
of new bags in bag
hanger.
Automated System
18-20 bags per minute

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Bagging System
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Bagging system capacity based on
amount to be bagged and time allowed
to do it.
A minimum of 2 supply bins should be
placed above packing system.
Supply bin capacity based on batch or
lot size to be bagged.

Page 43

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Warehousing

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Page 44

Warehousing

Allow adequate space for storage of


individual bagged products and
supplies.
Products should be arranged so oldest
products are used first (FIFO).
Products should be located in
warehouse to minimize travel distances
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to and fvrom storage area.

Page 45

Bulk Feed Loadout

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Page 46

Bulk Feed Loadout

Scaled weight
required for selling
product.
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1. Truck scale
2. Weigh Lorry
3. Batch weight

Page 47

Bulk Feed Loadout Bins

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Number of bulk product bins based on
amount of feed made, number of
products made, truck capacity, available
loading time, scheduling.
Capacity of bulk product bins based on
lot size, batch size or use requirements.

Page 48

Summary
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The product mix for the facility must be clearly
identified and understood.

Production requirements for each type of


product must be determined to identify
equipment needed.

Plant capacities both current and future must


be determined to make sure key systems will
handle all capacity levels.

Page 49

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Summary

The process flow of the mill must be


defined and drawn before any physical
layout of the mill is started.

Provision for future equipment and


systems must be included in initial mill
design.

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