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Internship Report Presentation

Kamalia Feed Mill

Presented By:
Nazim Abbas Shah (2013-ag-3276)
BSC (Hons) Animal Sciences

University of Agriculture,
Faislabad
Contents:
• Introduction
• Organizational Set-up
• Inventory
• Poultry Feed Ingredient Analysis
• Production Tower
• Vitamin Mineral Premix and Feed Additives
• Boiler
• Summary
• List of Figures
Introduction:
• The poultry industry is the second largest industry of the Pakistan after textile. It has
the major contribution in country’s GDP.
• Feed contributes 70-75% in the poultry production. A feed is formulated according to
the requirements of poultry birds at different stages.
• Kamalia feed mill is situated at 7km from Rajana road Kamalia.
• It is a growing feed mill with the production capacity of 10 tons/hour. Feed raw
materials are purchased from different dealers.
• Production system is pre grinding system.
 Organizational Set-up:

Designation Name
Managing Director Mian Sajid Hussain

General Manager Mian Khalid Hussian

Production Manager Dr. Hafiz Tayyab Aziz

Admin Officer M. Waseem Abbas

Accounts Officer M. Farooq

1- Inventory:
Commercial feed is formulated with different feed ingredient to fulfill the required nutrient composition.
To analyze the ingredients, samples are taken from the vehicles.

1.1- Sampling:
Two samples are taken from each vehicle.
‘A’ is from the backside of the vehicle.
‘B’ is taken from the top of the vehicle.
 1.1.1- Corn:
Corn is observed for the fungal growth.
Angoori fungus, dot like fungus and green fungus.
During the season 1%. Percentage is determined by the rough estimation that is one
probe will contain 200 corn seeds.
During off season they have to accept 1-2 % fungus.
Reduction of price by 1% or 2%.

1.1.2- Rice Tips:

There is no test on the rice tips except percentage of husk. Sample is taken as in case of
corn.
Sample is sent to the lab for estimation of husk. 100 gm. sample is sieved by fine sieve.
If husk is more than 6%, material is rejected and if it is less than 6% it is accepted but on
the basis of Kat system.
 1.1.3- Animal Protein Sources:
Fish meal and Feather meal
Analyze the sample for it oil, CP, TP, ash, moisture and chromium in case of fish meal.
On the basis of these results, material is selected and rejected.

1.1.4- Plant Protein Sources:

• Samples are taken from the vehicles and sent to the laboratory.
• These samples are tested for Moisture, ash, cp and KOH.
• There is one godown in the mill.
• Godown no 1 is attached with the tower.
2- Poultry Feed Ingredient Analysis:
2.1. Proximate Analysis:
In 1864, Hennberg and Stohmann developed a method of forage analysis at
Weende Experiment Station of Germany. It is called proximate analysis or
weende analysis scheme of feed or fodder. This scheme separates the
feedstuff into different fractions as follows:
Crude protein (%)
Crude fat (Ether Extract) (%)
Crude Fiber (%)
Ash (%)
Moisture (%)
Nitrogen Free Extract
 2.1.1- Crude Protein Estimation
(kjeldhal Method):
Principle:
The basis for the crude protein estimation is the estimation of Nitrogen. For this
purpose, sample is digested using sulphuric acid in the presence of catalyst to convert
the nitrogen present in the sample into ammonium sulphate. Acidic solution is made
basic with sodium hydroxide solution. The ammonia is distilled and trapped in the boric
acid solution and titrated against 0.1N H2So4.
Apparatus:
Weighing balance, volumetric flask (250 ml), Pipette, Kjeldhal Flask, Kjeldhal apparatus
and Heater
  Reagents Used:

5 gm Digestion mixture, 25 ml concentrated H2So4, 10 ml 40% NaOH, 10 ml 2%

Boric Acid, 0.1 N H2So4.
Digestion:
 Take 1.5g ingredient sample in a paper and wrap it to make a thimble that will be easily
pass through the narrow neck of the digestion flask
 Add 5g Digestion mixture in the digestion flask
 Add 30 ml sulphuric acid in flask
 Heat it on 2000 watt heater for 3 hours
 Mix the sample after every 10 min for first 3-4 times and then mix after every 30 min
 Cool it for 30 min
 Dilution:
• Add distilled water in the flask to make 250 ml volume of solution. Care should be taken
while adding distilled water. Flask should be constantly shaken under the running tab water
so that during adding water should not heat up.
• Mix it gently and make the accurate 250 ml volume
Distillation:
• Take 10 ml of digested sample and add into the Kjeldahl apparatus
• Add 10 ml of 40% NaOH in the apparatus
• Distill it against 2% Boric acid solution for 3 min
• Start to count the time when color of the boric acid changes
• At the end of distillation, volume become about 40 ml in the flask containing boric acid
solution
• Make sure that during distillation, water should be constantly running through the Kjeldahl
apparatus.
Titration:
• Note the initial reading of the acid in the burette
• Titrate it against 0.1 N H2So4 till color changes to light Pink
• Note the final reading on burette
 Calculation
𝐹𝑖𝑛𝑎𝑙𝑅𝑒𝑎𝑑𝑖𝑛𝑔−𝐼𝑛𝑖𝑡𝑖𝑎𝑙𝑅𝑒𝑎𝑑𝑖𝑛𝑔 𝐴𝑐𝑖𝑑𝑈𝑠𝑒𝑑𝑖𝑛𝑚𝑙 𝑋𝐹𝑎𝑐𝑡𝑜𝑟
• %CP =
𝑆𝑎𝑚𝑝𝑙𝑒𝑊𝑒𝑖𝑔ℎ𝑡 (𝑔𝑚)
• Factor = Normality of H2So4 used in titration X 0.0014 X volume of the diluted sample
X 100 X 6.25
• Factor = 0.1 X 0.0014 X 250 X 100 X 6.25
= 21.875
OR
𝑉𝑜𝑙𝑢𝑚𝑒𝑜𝑓𝑎𝑐𝑖𝑑𝑢𝑠𝑒𝑑𝑋 0.0014 𝑋 250 𝑋 100
• % Nitrogen =
𝑤𝑒𝑖𝑔ℎ𝑡𝑜𝑓𝑠𝑎𝑚𝑝𝑙𝑒𝑋 10
• % CP = %N X 6.25
 Results interpretation:
The protein sources are tested for their protein content through kjeldahlmethod. This method determines the
percent nitrogen in the sample, from which we can easily calculate the CP content. Normally cereals are not
tested for their CP content. This test is mostly performed on the plant and animal protein sources.

Following are the range of CP values of different ingredients:

Ingredient Min CP% Max CP%

SBM 44.21 46.74

SFM 23.62 30.73

GM 37.31 40.67

Gluten 30% 23.62 24.69

Gluten 60% 49.59 57.59

Maize 7.13 8.55

Wheat bran 13.29 13.90

Rice tips 8.77 9.96

Peas 21.50 21.69

Canola meal 35.98 36.48

Rice Polish 10.18 14.18

2.1.2- Crude Fat Estimated (Soxhlet
Extraction Method):
Principle:
Crude Fat is extracted with an organic solvent like hexane. Solvent is heated and
volatilized and then is condensed over the sample. Hexane drips on the sample and
soaks it to extract the fat. After 15-20 min hexane siphoned to the heating flask placed
in water bath and this process starts again. Fat content is measured by weight of the fat
removed.
Apparatus:
Soxhlet’s Apparatus, thimble Or Filter paper, water Bath, weighing balance, oven,
desicator, Round Bottom Flask.
 Reagents:
Hexane

Procedure:
• Weigh the empty flask that will collect the fat during extraction
• Make the thimble of the filter paper with the help of staple pins
• Add 3.5 gm sample in the thimble
• Adjust the pre weighed flask under the siphon tube
• Put the thimble in the siphon tube and fill the ¾ volume of the siphon
tube with hexane
• Heat the hexane in water bath for 2-3 hours
• After 3 hours remove the extra hexane from the siphon tube
• Remove the flask from the siphon tube and place in the oven for 1:30
hours
• Take the flask out of the oven and cool it and weigh it.
 Calculation:
𝐹𝑖𝑛𝑎𝑙𝑤𝑒𝑖𝑔ℎ𝑡𝑜𝑓𝑡ℎ𝑒𝑓𝑙𝑎𝑠𝑘−𝑖𝑛𝑖𝑡𝑖𝑎𝑙𝑤𝑒𝑖𝑔ℎ𝑡𝑜𝑓𝑡ℎ𝑒𝑓𝑙𝑎𝑠𝑘
% Crude Fat = X 100
𝑊𝑒𝑖𝑔ℎ𝑡𝑜𝑓𝑡ℎ𝑒𝑠𝑎𝑚𝑝𝑙𝑒𝑢𝑠𝑒𝑑

Result Interpretation:
Fish meal, feather meal and rice polish are mainly tested for the oil content. Following
are some results of the oil content in the feed ingredients:
Ingredient Min Oil Content Max Oil Content

Rice Polish 14.12 15.64

SBM 0.70 2.50

SFM 0.52 1.75

GM 4.27 6.13

Gluten 2.19 2.63

Maize 3.35 4.39

Wheat bran 4.18 5.37

2.1.3- Crude Fiber Estimation:
Principle:
Crude fiber is determined by sequential extraction of oil free sample with 1.25% H2So4
and 1.25% NaOH. The insoluble residue is collected by filtration, dried, weighed and
burnt in the furnace to avoid mineral contamination of fiber residue.
Apparatus:
Weighing balance, beaker (500ml), hot plate, filter cloth, vacuum pump for filter,
crucible, desicator, hot air oven and furnace.
 Reagents:

1.25% H2So4 and 1.25% NaOH

Procedure:
• Take 2g ground feed sample in beaker of 500ml capacity
• Add 200ml of 1.25% H2So4
• Heat it on hot plate for 30 min
• Note the time when boiling starts
• After heating filter it with cloth
• Add 200ml of 1.25% NaOH in a beaker and add residue of filter in this beaker
• Heat again for 30 min on hot plate
• Filter it with cloth
• Put the residue in the crucible and put in the oven for 2 hours
• Put the crucible in the descicator and after it weigh it
• Put the crucible in the furnace for 30 min
• Take out the crucible from furnace and cool it in desicator and weigh it
 Calculation:
𝐹𝑖𝑛𝑎𝑙𝑤𝑒𝑖𝑔ℎ𝑡−𝐼𝑛𝑖𝑡𝑖𝑎𝑙𝑤𝑒𝑖𝑔ℎ𝑡
Crude Fiber (%) = X 100
𝑆𝑎𝑚𝑝𝑙𝑒𝑊𝑒𝑖𝑔ℎ𝑡

Result Interpretation:
On the basis of fiber content material can also be rejected. Following are the acceptable
values of fiber content. Greater than these values of fiber is not accepted.
Ingredient Min. Fiber Max. Fiber

SBM 3.05 6.65

SFM 22.90 24.75

GM 10.95 12.25

Gluten 30% 6.70 7.15

Gluten 60% 0.75 0.90

2.1.4. Ash Estimation (%):
 Principle:
The feed or feed ingredients contain both organic and inorganic matter. When this
sample is burnt on 750o C for 1.5 hours, organic matter is oxidized as Co2 and remaining
material is the inorganic.
Apparatus:
Weighing balance, crucible, muffle furnace, Oven, Desiccator and forceps
 Procedure:
• Note the weight of empty crucible
• Add 2g ground sample in the pre weighed crucible
• Put the crucible on heater for 30 min
• Put the crucible with forceps in the furnace for 1.5 hour
• Take the crucible out from the furnace and put in the oven at 105o C for 30 min
• Put the crucible in the Desiccator to cool down
• Weigh the cool crucible and calculate the ash %
 Calculation:
𝐹𝑖𝑛𝑎𝑙𝑊𝑒𝑖𝑔ℎ𝑡−𝐼𝑛𝑖𝑡𝑖𝑎𝑙𝑊𝑒𝑖𝑔ℎ𝑡
Ash (%) = X 100
𝑆𝑎𝑚𝑝𝑙𝑒𝑊𝑒𝑖𝑔ℎ𝑡

Result Interpretation:
Ash content represent the inorganic part of the ingredients. If there is more ash content
than normal values, Acid insoluble ash is determined. AIA represent the sand or dust
mixed in the ingredient. Rice Polish is mostly analyzed for AIA. If AIA is more than 3 in
case of polish, vehicle is rejected.
Ingredient Min .Ash Max. Ash

SBM 5.80 8.95

SFM 7.35 7.90

GM 4.95 5.90

Gluten 30% 7.72 8.58

Gluten 60% 0.90 1.52

4- Production Tower:
Batching in the mill was manual. Batching was pre grinding. Ingredients were first grinded and then weighed
according to the formulation. There are two grinders, one was large and other was small depending upon their
capacity.

Elevator of Grinder:
The elevator which supplies the ingredients to the small grinder has following
characteristics.

Parameter Value Parameter Value

Elevator height (foot) 35 Bucket dimension (inch) 7x5x3

Elevator motor HP 5 Bucket to bucket space(inch) 10

Motor RPM 1400 Elevator capacity

4.2- Grinder:
The grinder is the hammer grinder. It contains the 4 set of blades, each containing 12 blades. Hammers strike with the
ingredients and break them into pieces. There is advantage of the hammer mill over roller mill that it consumes less
energy than roller mill but disadvantage is that it produces heavy noise. There are following characteristics that we
noted during our work.

Parameter Value Parameter Value

No of blades 48 (12 x 4) Motor HP 50

Blade Dimension (inches) 8’’x2’’x1.66’’ Motor RPM 1400

Blade hole size (mm) 25’’ Sieve dimension (inch) 40’’ X 12.5’’

Rod length(inch) 12’’ No of holes in sieve 2884, 1805

Rod diameter (inch) 1’’ Weight of the one set of blades

Weighing Hopper capacity(ton) 1.5

4.5- Drum Cleaner:
• Drum cleaner is the machine that has a rotating sieve. It screens out the larger
unwanted particles that can seriously harm the grinder.
• Elevator sends the ingredient in the drum cleaner through inlet.
• Clean material goes to the grinder and larger particles are come out from a separate
outlet. It has a motor attached with the chain that rotates the sieve.
• Despite of the drum cleaner, some material like bag tying threads pass to the grinder
and it started to produce striking sound. Then, gate of the grinder is opened and
mesh is clean out.
4.6- Batching Elevator:
• Despite of the drum cleaner, some material like bag tying threads pass to
the grinder and it started to produce striking sound. Then, gate of the
grinder is opened and mesh is clean out.
• Then, gate of the grinder is opened and mesh is clean out
• Batching elevator has following main parts and their description:
Parameter Value Parameter Value

Height(Foot) 56 Bucket dimension(inch) 8x5x4

Belt Width(inches) 9.5 Bucket to bucket distance(inch) 7

Motor HP 5 Elevator Puli RPM 77

Large garrari teeth 33 Small garrari teeth 17

Motor Gear RPM 150

4.7- Batching Hopper:
• The material that is elevated from the batching elevator is dropped in the
batching hopper.
• Batching hopper has the capacity of 2 tons. A complete batch of 1.5 ton is
elevated and dropped in the batching hopper.
• Material stays for about 1 or 2 min until the previous batch is completely
mixed and dropped in the surge hopper.
• On the base of the hopper, there is a pneumatic gate that controls the
ingredient movement to downward in the mixer.
Hopper Length 6.5ft

Hopper Width 4.91ft

Hopper Height 6.66ft

4.8- Mixer:
• The mixer is the horizontal mixer of 2 ton capacity. There is a main shaft in
the mixer attached with the motor.
• 2 pairs of ribbons are installed, outer and inner. Outer is the large wide
blades and inner pair is narrow than outer. They move the ingredient
from left to right and right to left.
• The mixer mixes the ingredient in approximately 3.5 minutes. Premix, oil,
molasses, amino acids and antibiotics are added in the batch from the
mixer.
• There are two pneumatic gates installed on the bottom of the mixer.
When batch completely mixed, operator opens the pneumatic gates and
ingredients are dropped
Mixer length(ft) 9.66 in the surge
Motor hopper.
Gear Puli Teeth 24

Mixer Width (ft) 4.91 Mixer Puli teeth 45

Motor HP 50 Mixer RPM 26.66

Motor Gear RPM 50 Feed stay time(min) 3.5

4.9- Surge Hopper:
• Surge hopper receive the mixed feed from the mixer and gives to the elevator
through worm conveyer that is installed on the bottom of the surge hopper.

Length (ft) 9.6

Width (ft) 4.91

Height (ft) 5.91

4.10- Cooler:
• Cooler receive the pellet feed from the pellet machine that is heat up due to the
steam addition.
• Feed stays about 5-6 minutes in the cooler.
4.11- Cyclone:
• Cyclone is a round cone shape structured that is attached with the blower fan.
• Blower fan from the other side, attached with the cooler
4.15- Crumbler:
• There are two rolls that rotate in the opposite direction to each other.
• There is a slight distance between these rolls.
• Distance is adjustable according to the size of the pellet.

Length of the rolls(ft) 5

Diameter of the rolls(inch)

Life of the rolls(months) 5

Motor HP 20

Motor RPM 1400

6- Boiler:
• There are different types of boiler that are being used in different industries that
may be water tubes boiler or fire tube boiler.
• The boiler that is installed in this feed mill is the fire tube and has the capacity of 1.5
ton of steam production per hour.
• They are mainly divided in following three types depending upon their capacity of
the per hour steam production:
• A-Class (>5ton/hour)
• B-Class (3-5ton/hour)
• C-Class (1-2ton/hour)
In kamalia feeds, C-Class boiler is installed.
There are following main parts of the boiler.
• Furnace
• Flu and fire sides
• Water sides
• Cyclone and air lock
• Blower fans
• Economizer
• Water tanks
• Water feed pumps
• Water feed check valve
Some other main parts of the boiler

• Water gauges
• Temperature gauges
• Pressure gauges
• Blow down valve
• Safety valve
• Stop valve
• Steam storage tank
• Distributor tank
Summary:
kamalia feed mill one of the growing feed mills
of Pakistan.
• Its production capacity is 10tons/hour.
• Batching is manually done here. It works on the pre grinding batching system.
• There is one gowdon.
• Grinded material is weighed according to the formulation. One complete batch is
dumped in the dumping pi and is provided to the mixer.
• It provides the material to the surge hopper and from here elevated to the pellet bin.
Pellet bin provide the material to the pellet machine which forms the feed in pellet
form
Summary:
• Feed falls into the cooler, crushed into the small pieces with the help of
crumbler. This feed elevated to the magnetic siever and sieved to 3
fractions.
• Normal size of the feed goes to the packing hopper. Small powder form
again falls in the pellet bin.
• Extra large particles are separated out in the bag and again added in the
batching cutting pit.