1000 Tons/Day Large-scale Cattle Sheep and Chicken Feed Pellet Mill Production and Processing Project

Date: 01/04/2021 08:44:30 From: feed-pellet-plant.com Clicks:

With the change of people's dietary structure and the improvement of living standards, the demand for meat products of pigs, cattle, sheep, chickens, ducks and goose will increase greatly, and the demand for livestock and poultry aquatic feed products will increase accordingly. 1000 tons/day large-scale cattle sheep and chicken feed pellet mill production and processing project. The design scale of this project is the production and processing project of an annual output of 300,000 tons of cattle, mutton and chicken feed pellets. It operates 300 days a year and operates 16 hours a day. It produces 62.5 tons of livestock and poultry aquatic feed pellets per hour, and the daily output of feed pellets is as high as 1000 tons.

1000 Tons/Day Large-scale Cattle Sheep and Chicken Feed Pellet Mill Production and Processing Project

1. Construction Content

The main project of the project includes production equipment for livestock and poultry feed products (designed to produce 300,000 tons of compound feed per year) and workshops, and auxiliary projects include comprehensive office buildings, feed product testing laboratories, etc. The storage and transportation projects include raw material warehouses, vertical silos, and Finished product warehouses, etc., and public works include water and electricity supply facilities and fire-fighting facilities. 

The total area of ​​the project is 33471m2, the total building area is 12923m2, and the vertical silo covers an area of ​​4484m2. The building covers an area of ​​11153m2, the green area rate is 8.6%, and 35 parking spaces (including 10 large truck parking spaces). The traditional and advanced compound feed processing and production technology adopted in the project does not involve material extraction technology, fermentation technology, and feed additive production. The project composition details are shown in Table 1-1:

Table 1-1 List of contents of this project

2. Main Raw Materials and Energy Consumption

The main raw materials used in the project are grain crops and their by-products (wheat, corn, soybean meal), which are common raw materials. The project is supporting the construction of a raw material warehouse of 3,024 square meters. On the north side of the raw material warehouse, 6 vertical silos with a volume of 1500 cubic meters and 5 bulk warehouses with a volume of 300 cubic meters are used for stacking the raw materials (wheat, corn) used in the project. The evaluation requires raw materials They shall not be piled up randomly in the factory area, and shall not be piled up in the open air. They shall be piled up to the designated place according to relevant storage requirements. This evaluation requires the owner not to use raw materials with peculiar smell, and the purchase of raw materials should meet the requirements of the compound feed process. The raw and auxiliary materials and energy consumption of the project are listed in Table 1-2.

Table 1-2 List of main raw and auxiliary materials and energy consumption

3. Main Raw and Auxiliary Cooking Properties

• Corn and wheat: These are common grains, and the project uses imported raw materials. These raw materials are stable under normal temperature and pressure, and there is no special gas during storage. Corn and wheat are the bulk raw materials used in the project. They are purchased through international trade and purchased from the river-sea combined transport to the Yueyang Chenglingji foreign trade port. They are then transported to the project plant by vehicles and stored in bulk in raw material silos.
• Soybean meal: is a by-product of soybean oil extracted from soybeans. Generally, it is in the shape of irregular fragments, the color is light yellow to light brown, and the taste has a roasted soybean aroma. The main components of soybean meal are protein 40%～48%, lysine 2.5%～3.0%, tryptophan 0.6%～0.7%, and methionine 0.5%～0.7%. As a kind of high protein, soybean meal is the main raw material for making livestock and poultry feed. For soybean meal, there are two steel silos with a volume of 435 cubic meters in the raw material warehouse, and the steel silo for bulk storage of raw materials.
• Compound pre-mixed feed: a homogeneous mixture made by mixing various feed additives and carriers or diluents according to the formula and actual requirements. For example, the premix of trace elements, vitamins and other ingredients is a kind of feed additive. The additive is in powder form. Vitamins include vitamins A, D2, E, K3, D3, B6, and multiple vitamins, choline , Pig premix additives, 20-25 kg/bag, stored in the raw material warehouse of this project. The project prohibits the use of product additives that restrict the construction of vitamin B1/B2/B12/C additives in the industrial policy.
• Zeolite powder: It is made by grinding natural zeolite rock, the color is light green and white. It has various basic conditions as a carrier and diluent for additive premix. Zeolite has a neutral pH between 7 and 7.5, and when it contains water, it is only 3.4 to 3.9%, and it is not easily affected by moisture and contains mineral salt trace components of crystal water. Mixing can absorb the water in it and enhance the fluidity of the feed. At the same time, it can appropriately extend the release time of trace components and is more conducive to animal absorption. Zeolite powder has no special smell and is stored in the raw material warehouse in 50kg/bag.
• Antifungal agent: a feed additive that can reduce the number of microorganisms in the feed, control the metabolism and growth of microorganisms, inhibit the production of mycotoxins, prevent the loss of nutrients during the feed storage period, prevent the feed from becoming moldy and prolong the storage time.

4. Main Production Equipment Configuration

The main equipment of the project includes raw material receiving system, crushing system, batching and mixing system, granulating system, finished product packaging system and related auxiliary systems. The main production equipment configuration list is shown in Table 1-3.

Table 1-3 List of main production equipment configuration of this project

The maximum design capacity of the equipment introduced in this project is 65t/h. The production working time of the project is reasonably allocated according to the customer’s order requirements. In general, the production time is calculated based on 300 working hours per year (day working time is 8h/shift, two shifts per day). It has the ability to meet the annual production capacity of 300,000 tons of compound feed.

5. LAbor Quota and Production System

The overall labor quota of the project is 45, including 30 production personnel, 4 management personnel, 8 purchasing and sales personnel, 1 customs declaration and commodity inspection personnel, and 2 financial and auxiliary personnel. The production management is an 8-hour work system, and the production and processing is a two-shift system a day, one shift is 8 hours, and the annual working day is 300 days. The entire main production workshop implements an eight-hour work system. There is a canteen and no dormitories for employees.

6. Investment Scale and Economic Benefits

The total investment of the project is 120 million yuan. After the project is completed and put into operation, it will produce 300,000 tons of combined livestock and poultry feed products. According to market analysis and production cost analysis, with reference to the current market sales, the annual sales revenue (including tax) of the project after reaching production capacity is 610 million yuan, the total profit in normal operating years is 39.71 million yuan, and the annual main business tax and additional expenses are about 79.3 million yuan.

7. Process Flow

The traditional and advanced compound feed processing and production technology adopted in this project does not involve the extraction process and fermentation process, and does not produce feed additives.

Brief description of process principle:

(1) Receiving and cleaning of raw materials

Raw material reception is divided into main raw material reception and side raw material reception. The main raw material reception refers to wheat and corn, and the side raw material reception refers to other raw materials except wheat and corn. The raw materials needed for production are directly sent to the warehouse for storage after being weighed and inspected by a truck scale; wheat and corn need to be processed in a vertical silo.

Receiving and cleaning of raw materials

When transported by bulk cars, trains and ships, the materials are unloaded to the unloading pit after being weighed by a dump truck with a loadometer; the reception of packaging materials: manual handling and mechanical reception. During the handling and loading and unloading of raw materials, a small amount of fugitive dust will be generated. Therefore, the evaluation requires the owner to specify a unified raw material handling and loading and unloading location, and install dust suction at the floor discharge port, discharge port, bucket elevator, and scraper. Cover, collect the fugitive dust and enter it into the dust removal air net system for processing; the bagged raw materials in the factory are specially used for forklifts, combined with a small amount of manual handling, and through strengthening production management, limiting the speed of the control area of ​​the unorganized fugitive dust. Workers wear labor protection equipment and dust masks during the process of raw material receiving, transfer, loading and unloading, and concentrated water spraying around the loading and unloading points to prevent the dust from spreading. Through the establishment of green dust barriers around the warehouse, the dust can be controlled within the scope of the workshop and avoid the surrounding air. environmental impact.

Impurities in feed ingredients not only affect the quality of feed products, but also directly affect feed processing equipment and personal safety. In severe cases, the entire equipment may be destroyed and affect the smooth progress of feed production, so it should be removed in time. The cleaning equipment of the feed factory is mainly screening and magnetic separation equipment. The screening equipment removes large and long debris such as stones, mud and sack pieces in the raw materials. The magnetic separation equipment mainly removes iron impurities. In this project, the raw materials that need to be crushed will enter the production workshop through the conveying equipment, and then enter the warehouse to be crushed after the impurities are removed by the primary cleaning screen and the iron impurities are removed by the magnetic separator. The raw materials that do not need to be crushed enter the production workshop through the conveying equipment, and are sent to different batching bins by the distributor after the impurities are removed by the primary cleaning screen and the iron impurities are removed by the magnetic separator.

(2) Crushing of raw materials

The raw materials in the bin to be crushed are crushed to the qualified particle size requirements by a crusher, and then distributed to the batching bin for storage by the conveying equipment. The feed crushing process used in this project is a cyclic secondary crushing process. In the single-cycle pulverization process, a pulverizer is used to pulverize the material and then be sieved, and the screened material is returned to the original pulverizer for pulverization.

(3) Ingredient mixing process

According to the requirements of the formula, various raw materials participating in the ingredients enter the mixer in turn through the computer-controlled ingredient scale. In the batching process, a computerized automatic batching system is used for batching weighing to ensure the accuracy of the batching and shorten the batching time. This project uses the commonly used multi-warehouse counting scale ingredients, and the measured materials are grouped according to their physical characteristics or weighing range, and each group is equipped with a corresponding measuring device. The mixing process is continuous mixing. The continuous mixing process is to measure the various feed components simultaneously and separately and continuously to form a stream containing various components in proportion. When this stream enters the continuous mixer, Continuous mixing to form a uniform stream. The advantage of this process is that it can be carried out continuously and is easily connected with continuous operations such as pulverization and granulation, and does not require frequent operations during production.

Additives and other auxiliary materials with less dosage are weighed by the automatic batching weighing system and then put into the mixer. Various raw materials are mixed in the mixer, and various powdered or liquid raw materials (grease, etc.) are added during the mixing process. The mixed finished powder can be refined and granulated according to needs, or directly enter the finished product warehouse for packing and storage, or enter the bulk finished product warehouse for loading with a bulk truck.

(4) Tempering

Quenching and tempering is the most important link in the pelleting process. The quality of conditioning directly determines the quality of pellet feed. The purpose of tempering is to adjust the mixed dry powder material into a powdered feed with a certain moisture and humidity, which is beneficial to granulation. This project uses steam to complete the tempering process. The modulator is a double-layer stainless steel structure and belongs to the granulator. The ancillary equipment of the modulator is insulated with fresh steam after pressure adjustment by steam distribution in the plant area (the tempering temperature is controlled at about 80 ℃), and the inside of the modulator uses fresh steam to directly contact the material. The feed formed in the modulator absorbs the heat and moisture in the water vapor to make itself soft, which is beneficial to the process of pellet formation.

This project is located in the Comprehensive Bonded Zone of Xingang District, Chenglingji, and belongs to the central heating area of ​​Huaneng Power Plant. The steam is supplied from the central heating pipe network and is uniformly transmitted and distributed to the quenching and tempering section through the distribution and regulation of the pressure in the plant.

(5) Granulation

The uniformly tempered material is first removed by the security magnet, and then evenly distributed between the pressing and mixing and the pressing die, so that the material enters the pressing area from the pressing area of ​​the feeding area, and is clamped into the die hole by the pressing roller to continuously squeeze open. It is divided into a columnar feed, which is cut into pellet-like feed by a cutter fixed on the outside of the die as the die rotates.

Feed Pellet Machine

(6) Cooling

In the pelleting process, the high temperature and high humidity steam is introduced and the material is extruded to generate a lot of heat, so that when the pellet feed comes out of the pelletizer, the water content reaches 16%~18%, and the temperature is as high as 75℃-85. ℃, under this condition, the pellet feed is easy to deform and break, and it will also cause adhesion and mildew during storage. The engineering cooling uses a countercurrent cooling system. The moisture of the material is reduced to below 14%, and the temperature is reduced to below 8°C higher than the air temperature.

(7) Packaging

The cooled materials enter the packaging section. The project adopts two packaging methods, bulk and bagged, and different packaging methods are used according to the needs of downstream customers. The finished bagged products enter the finished product warehouse, and the bulk materials are directly transported by cars.

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