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-mix grind

Post-pellet blend
Post-batch grind
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
 Remove weights
2/3  Fill scale to 1/3 capacity
 Add test weights
 Record weight
 Remove weights
1/3  Fill scale to 2/3 capacity
 Add test weights
 Record weight
200 lb
 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 Major Scale:
Batching System
Computer draws multiple
bins to the major scale.
Micro Scale Computer switches to one
Major Minor bin and jogs at the end of
Scale Scale the each ingredient.

Major Ingredients
Corn/Wheat
SBM
Midds
DDGS
Batching Sequence
Batching System Minor Scale Fill:
Computer draws single
bins to the minor scale
Major Minor Micro Scale and jogs at the end of the
Scale
Scale each ingredient.

Minor Ingredients
Dical
Limestone
Salt
Lysine
Batching Sequence
Batching System Micro Scale Fill:
Computer draws single
Micro bins to the micro scale and
Scale jogs at the end of the each
Major Minor
Scale
Scale
ingredient.

Micro Ingredients
Vitamins
Trace Minerals
Medications
Amino Acids
Batching Sequence
Batching System

Scale Considerations:
Micro Scale

Major Minor Major Scale 80-90%

Scale
Scale
Minor Scale 10-15%
Micro Scale < 5%
Batching Sequence
Batching System
Major Scale
Discharges First
Micro Scale Fills the dead space
Major Minor between the ribbons
Scale
Scale
and tub.
Batching Sequence
Batching System
Minor Scale Discharges
after a 5-10 second
Micro Scale delay
Major Minor Minor ingredients mix
Scale
Scale
with the major
ingredients
Batching Sequence
Batching System
Micro Scale Discharges
after a 0-5 second delay
Micro Scale
Micro tub or scales open
Major Minor and the material is
Scale
Scale
transferred with a drag
conveyor
 Mixing Time
Batching
Batching System Horizontal Double Ribbon
30-60 second Dry Mix
Micro Scale 120-180 second Wet Mix
Major Minor Liquid Addition
Scale
Scale
Volumetric (meter)
Gravimetric (weighed)
Liquid Ingredients: Spray Here

Fat
Molasses
Choline
Amino acids
Batching Sequence Discharge Process
Batching/Mixing System
Mixer opens and
material drops to a
surge hopper
Micro Scale

Major Minor
Scale
Scale
 Batch Cycle

Weighing 2 min
Batch Cycle – 4 mins

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
Motor Starter

VFD
Batch Production Report
Recommended mix times

Mixer Dry Mix Wet Mix

Paddle 3 3
Twin Shaft Paddle 0.5 1
Double Ribbon 1-2 2-3
Twin Shaft Ribbon 0.75-1 2
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

Some Main Mixing

Main Mixing
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 Fat lumps created by poor

shaft 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  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
Sample surge 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: DATE:
ADDRESS:
SAMPLE:

QUANTAB READINGS

1 0.20
2 0.21
3 0.22
4 0.17
5 0.17
6 0.18
7 0.20
8 0.17
9 0.18
10 0.18

STANDARD DEVIA 0.02

MEAN 0.19

COEFFICIENT OF VARIATION (CV) 9.65

Micro Tracer Rotary Detector Method
 Materials
 Rotary Detector.
 Scale.
 Demagnetizer.
 Heating plate.
 Developing Solution.
 Filter paper 7.5 mm
 Grinder for pelleted feed
 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.
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%

15‐20% Fair Increase mixing time by 50%, look for worn

equipment, overfilling, or sequence of
ingredient addition
20% + Poor Possible combination of all the above
Consults extension personnel or feed
equipment manufacturer
Double Ribbon Mixer – RPM’s
Double Ribbon Mixer – Worn Ribbons
Double Ribbon Mixer – Wrong Rotation
Double Ribbon Mixer – Build-Up
Questions