global milling advances august 2013 -

Power inMotionNew Kubex™

Pellet Mill

Issu

e 4

Aug

ust

2013

In this issue:

Feed Pellet Press Productivity

Alapala Product Line

2013 Events

By Buhler

Contents

BuhlerPower in motion –New KubexTM pellet mill

MuyangPractical ways to improve feed conditioning efficiency

Allance Pellet Mil

AlapalaProduct Line

Events 2013Upcoming events

EditorialWelcome to the summer issue of Global Milling Advances. In this issue we take a look at pellet press technology, with articles from Jiangsu Muyang Group and Allance Machinery.

Jiangsu Muyang Group focus on the practical ways to improve feed conditions efficiency and Allance Machinery talk us through influencing factors of feed pellet press productivity.

Global Milling will be exhibiting at UK Grain in November, if you are visiting this event please call by our stand No. 14 and pick up your free copies of our magazines.

Keep up to date with events happening in your industry! Download your copy of our 2014 wall planner today at www.globalmilling.com

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The new Kubex™ T pellet mill takes the successful foundation of the popular Kubex™ to a new dimension, continuing the tradition of robustness, reliability and ease of operation of the previous model, but driving it to an even more efficient and powerful level. Up to 30 %1 less energy consumption, high production capacities of up to 80 t/h2 and a customer driven design are the result of extensive research and development by Bühler in cooperation with leading feed millers.

Direct drive sets new standard in energy efficiency

A for a long time awaited drive concept has now become reality: without gearbox and transmission belts, the machine’s direct drive significantly reduces maintenance requirements and increases the pellet mill’s uptime. Thanks to efficient power transmission, the new Kubex™ T saves up to 30 % 1 energy per ton of produced pellets compared to conventional drive systems. Another advantage is the variable die speed that is adjustable during operation. The flexibility provided by this feature enables on- ‐going optimization of the production process and the pellet quality based on the feed formulation, and also extends the lifetime of the die.

High performance, small footprint

The new Kubex™ T pellet mill is available in two versions, with Kubex™ T12 being the most powerful model with power of up to 585 kW and 1200 mm die diameter, delivering high pelleting performance of up to 80 tons/hour 2. The smaller version Kubex™ T9 comes with motor power of up to 410 kW and a 900 mm die,

suitable for production capacities of up to 50 t/h 2. Characterized by its very compact design, the new Kubex™ T pellet mill fits the exact space requirements of every feed mill due to its small footprint in length, width and especially height. In existing feed mills, line capacity expansion is made possible without costly building and process modification works.

Customer driven design

Bühler innovators have worked closely with leading feed producers to ensure the Kubex™ T pellet mill fulfils the aspirations of feed millers for hygienic, ergonomic and robust machine design. Wide- opening, smooth- running sliding doors on both sides provide full access to the machine for fast and easy maintenance, while the slightly pressurized machine housing efficiently prevents dust settlements in critical areas. An improved die change concept with access to the screws and fittings from the clean motor chamber significantly reduces the time needed for the die change, maximizing machine uptime. Another new development is the ABS control for the press rolls, preventing roll slippage and thus protecting the machine against blockages and equipment damage.

Power forward

Quite simply, selecting Bühler as a partner means gaining access to the best technology and process expertise in the feed milling industry. Close collaboration with customers is always aimed at increasing their productivity and competitiveness. Bühler is continually empowering feed

Global Milling Advances

Power in motion –New KubexTM pellet mill

More information:Michael Tremp,Produktmanager Grain MillingBuhler AG CH- 9240Uzwil, SwitzerlandEmail: [email protected]: www.buhlergroup.com

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The primary purpose of conditioning is to improve pellet quality and pellet mill throughput. If being correctly operated and controlled, a given conditioner could be optimized to achieve the best quality at the best production rate possible for a pelleting system.

According to the report of Energy Intensity of Agriculture and Food System published on July 29, 2011, feed provision contributes, on average, 75% of energy inputs to livestock production in U.K, about 86% for feedlot beef production in the United States, and about 90% of cradle- to- farm gate energy use for salmon produced globally. Sourcing energy-efficient feed inputs therefore offers considerable opportunity to decrease energy use in farming industries.

Under this trend, only processes, systems and equipment that saving energy in feed production can help feed manufacturers keep competitive in the market.

Conditioning is one of the most important processing steps in pellet feed production. How to cut energy usage and improve processing efficiency of a conditioner has been the question that feed manufacturers always concerned.

We at Muyang have studied the possible ways to solve this question for years. In this article, we will introduced some practical ways to improve feed conditioning efficiency through carefully controls on conditioning temperature, retention time and water addition in production.

Conditioning temperature Moisture, heat, and pressure combine to gelatinize or break down protein components in the feed ingredients during conditioning, which permits better digestibility and durability for feed pellets.

Table 1 shows the effects of conditioning temperature on pelleting performance. As feed mash temperature increased in conditioning stage, the durability of pellet products is improved while the energy used for producing per ton of feed is reduced. A great deal of heat contributes to easy penetration of steam into feed mash molecules, forming hydration water, which binding with ingredients will make feed mash more pelletable.

However, not all materials are adapted to the above mentioned “feed mash temperature and pelleting performance” rule. For feed mash of heat sensitive ingredients such as whey, milk, urea, etc., conditioning temperature that higher than their gelatinization temperature or solution temperature (usually is about 60°c) will cause over- gelatinized or too much water in feed mash, resulting in blockage in die holes. While for cereals

Table 1: Effects of conditioning temperature on palleting

Mash Temp/°CEnergy Consumptoion/

(kW-h/t)Pellet Durability/%

21 30.7 69.5

65 17.3 90.6

80 11.9 96

and materials of high protein content, a conditioning temperature that higher than 85°c can be able to increase the plasticity, cohesiveness and pellet ability of feed mash. Therefore, conditioning temperature is formulation dependent. It should be controlled properly to achieve good conditioning.

Retention time The time available for heat and moisture to penetrate into the core of each particle before pelleting is referred to as “retention time”. It is limited and supposed to be less than the time needed for a given particle to move through the conditioning chamber, because feed mash doesn’t contact with steam in the distance between feeding inlet and steam inlet. However, retention time cannot be measured precisely and, in reality, it represents the average amount of time mash retaining in the chamber. To optimize conditioning operations, retention time must be optimized.

Trails were carried out in a feed mill in Guangdong Province of China to study the impacting factors and find out practical methods to optimize conditioning retention time.

The first trail was set up to evaluate the influence of paddle angle on conditioning performance. It was subjected to 4 paddle settings giving:

• Setting 1: all paddles are forward ones (retained at ex- works setting) (Fig.1- a)

• Setting 2: with 4 backward paddles (Fig.1- b);


Practical ways to improvefeed conditioning efficiencyBy Zhou Xiang, Ye Zhen, Jiangsu Muyang Group Co., Ltd, China

More information:Jiangsu Muyang Group Co., LtdNo.1 Muyang Road,Yangzhou, ChinaPostcode 225127Tel: +86 514 87848880Fax: +86 514 87848686Email contacts: [email protected] [email protected]


Setting 3: with 8 backward paddles (Fig.1- c); Setting 4: with 12 backward paddles (Fig.1- d); Setting 3: with 8 backward paddles (Fig.1-‐c);

Setting 4: with 12 backward paddles (Fig.1-‐d); The results showed in Fig.2 tell that retention time is adjustable by changing the angle of paddles. As the number of backward paddles increased, it achieves better conditioning and pelleting results. The filling level of a conditioner is increased too, and fewer fines are generated from pellet products.

The second trail was designed to evaluate the effects of shaft speed on conditioning and pelleting performance. It was set up base on paddles installed with Setting 4. The shaft speed was changed by a variable-‐frequency controller on the drive motor.

See Fig.3, a slower shaft speed (37Hz) allows feed mash to settle to the bottom of the conditioner and be pushed gently along the barrel. This obviously allows for a longer retention time and a high filling level. However, too slow a shaft speed will lead to a steady state, namely a state of steady filling level and

retention time. There is not enough linear velocity and centrifugal force to lift up the feed mash. In Fig.3, the longer retention time and higher filling level in a frequency of 30Hz are the results of feed mash accumulation. In this case, feed mash cannot mix with steam sufficiently. To guarantee satisfactory result, the conditioner usually should be designed with a linear velocity of 6-‐8m/s.

By comparing with the results shown in Fig.2, we also can find out that shaft speed contributes little to fines generation of pellet products if under the same conditioning effect. Therefore, it is suggested to optimize retention time and improve conditioning effect by carefully controlling the shaft speed, and to lower

power consumption in mash pelleting by reducing the compression ratio of die holes. Water addition Different moisture contents are required to feed in different processes, the moisture content usually are: 1) 11.5~12.5% after grinding and mixing; 2) 15~16.5% after conditioning and before pelleting; 3) 14~15% after pelleting; and 4) 11~13% after cooling to be finished product.

A well understanding of the effects and functions of moisture content in different processing steps can bring

more profits to feed production. Feed mash to be pelletized if with a moisture level less than 15% may cause poor pelletability and problems such as die blockage, pellets with bad durability, burned surface, cracks, brokens, etc. While finished pellet products if with a moisture content that higher than a safety level

will result in mould in transport and storage, which will degrade feed quality and shorten the shelf life. Therefore, the moisture content should be strictly controlled to achieve qualified and profitable feed pellets. Fig.4 shows the result of a 2×5 factorial arrangement of conditioning processes that set up to evaluate the effects of two steam introducing manners (multiple entry ports and single entry port) on the moisture-‐rise (∆H) of feed mash before and after conditioning with five samples. An optimum steam introducing manner can improve the effect of steam contacting and mixing with feed mash. Compared to the single entry port manner, steam introduced into the conditioning through multiple entry ports achieves conditioned mash with a more steady and higher average moisture content. Namely, water adding to feed mash is more uniform. Conclusion Studies on conditioning temperature, retention time and water addition in conditioning production provide efficiently practical ways to improve pellet quality, maximize energy usage and minimize feed and energy losses during production: 1) Temperature and moisture required for conditioning depends on the characteristics of ingredients used in feed. The processing of different types of feeds should follow different guidelines. Generally, more heat can achieve better pellet durability and reduced power consumption for pelleting process. 2) Retention time can be optimized by adjusting paddle angle and shaft speed. Increasing the number of backward paddles can prolong the retention time and improve the filling level of feed mash in a conditioner. Slow shaft speed also allows for longer retention time and higher filling level. However, the speed should be great enough to provide good agitation and movement down the conditioner. An appropriate linear speed for shaft is 6~8m/s. 3) Steam introduced into conditioner through multiple entry ports is benefit for getting conditioned feed mash uniform moisture content. In a word, well know the conditioning process and optimize the operation with available methods are the feasible ways to add value to a given pellet mill.

The results showed in Fig.2 tell that retention time is adjustable by changing the angle of paddles. As the number of backward paddles increased, it achieves better conditioning and pelleting results. The filling level of a conditioner is increased too, and fewer fines are generated from pellet products.

The second trail was designed to evaluate the effects of shaft speed on conditioning and pelleting performance. It was set up base on paddles installed with Setting 4. The shaft speed was changed by a variable- frequency controller on the drive motor.

Setting 3: with 8 backward paddles (Fig.1-‐c); Setting 4: with 12 backward paddles (Fig.1-‐d);










See Fig.3, a slower shaft speed (37Hz) allows feed mash to settle to the bottom of the conditioner and be pushed gently along the barrel. This obviously allows for a longer retention time and a high filling level.

However, too slow a shaft speed will lead to a steady state, namely a state of steady filling

level and retention time. There is not enough linear velocity and centrifugal force to lift up the feed mash. In Fig.3, the longer retention time and higher filling level in a frequency of 30Hz are the results of feed mash accumulation. In this case, feed mash cannot mix with steam sufficiently. To guarantee satisfactory result, the conditioner usually should be designed with a linear velocity of 6- 8m/s.











By comparing with the results shown in Fig.2, we also can find out that shaft speed contributes little to fines generation of pellet products if under the same conditioning effect.

Therefore, it is suggested to optimize retention time and improve conditioning effect by carefully controlling the shaft speed, and to lower

power consumption in mash pelleting by reducing the compression ratio of die holes.

Water addition Different moisture contents are required to feed in different processes, the moisture content usually are: 1) 11.5~12.5% after grinding and mixing; 2) 15~16.5% after conditioning and before pelleting; 3) 14~15% after pelleting; and 4) 11~13% after cooling to be finished product.

A well understanding of the effects and functions of











moisture content in different processing steps can bring more profits to feed production. Feed mash to be pelletized if with a moisture level less than 15% may cause poor pelletability and problems such as die blockage, pellets with bad durability, burned surface, cracks, brokens, etc. While finished

pellet products if with a moisture content that higher than a safety level will result in mould in transport and storage, which will degrade feed quality and shorten the shelf life. Therefore, the moisture content should be strictly controlled to achieve qualified and profitable feed pellets.

Fig.4 shows the result of a 2×5 factorial arrangement of conditioning processes that set up to evaluate the effects of two steam introducing manners (multiple entry ports and single entry port) on the moisture- rise (ΔH) of feed mash before and after conditioning with five samples. An optimum steam introducing manner can improve the effect of steam contacting and mixing with feed mash. Compared to the single entry port manner, steam introduced into the conditioning through multiple entry ports achieves conditioned mash with a more steady and higher average moisture content. Namely, water adding to feed mash is more uniform.

Conclusion Studies on conditioning temperature, retention time and water addition in conditioning production provide efficiently practical ways to improve pellet quality, maximize energy usage and minimize feed and energy losses during production:

1) Temperature and moisture required for conditioning depends on the characteristics of ingredients used in feed. The processing of different types of feeds should follow different guidelines. Generally, more heat can achieve better pellet durability and reduced power consumption for pelleting process.

2) Retention time can be optimized by adjusting paddle angle and shaft speed. Increasing the number of backward paddles can prolong the retention time and improve the filling level of feed mash in a conditioner. Slow shaft speed also allows for longer retention time and higher filling level. However, the speed should be great enough to provide good agitation and movement down the conditioner. An appropriate linear speed for shaft is 6~8m/s.

3) Steam introduced into conditioner through multiple entry ports is benefit for getting conditioned feed mash uniform moisture content.

In a word, well know the conditioning process and optimize the operation with available methods are the feasible ways to add value to a given pellet mill.


Feed pellet press is to produce pellets for poultry, livestock and aquacultural animals. The main raw materials for feed pellet press are crushed or milled corn, bean cakes, straw, grass, rice husk, etc. Feed pellet press can be divided into three types which are ring die feed pellet press, flat die pellet mill and double roller feed pellet press. However, due to pellet press manufacturing technology and missoperation, feed pellets productivity can hardly satisfy the expected requirement; besides, the feed pellets surface is rough, fragile and high powder rate. We will analyze the factors, which influence feed pellet press productivity.

1. Raw materials Raw materials play the direct role in feed pellet production. Different raw material component, milling condition and the mixing rate can exert great influence on feed pellets.

1.1 Material components Materials with high starch content are easy to be gelatinized and sticky enough to form feed pellets after conditioning. For those materials with high crude fiber content, a certain amount of fat addition can reduce friction between raw materials and ring die during pelletizing, and is good to form smooth feed pellets. The common fat addition amount is about 1% for more addition will make pellet loose. If more fat is needed, we can consider spraying fat after pelletizing, which is especially suitable to, high standard feed pellets production.

1.2 Milling granularity Grain material milling granularity decides feed pellet surface area which means the finer granularity, the larger size, the faster speed of moisture absorption; then it is easy for feed material conditioning and pelletizing. From the perspective of pelletizing, the finer material, the higher pelletizing strength; but more steam will block pellet press. Besides, the finer material will consume more powder. If the materials are too crude, the wear

of ring die and roller will be increased and make it hard to pelletizing. For pellet press with little die holes, it is harder to form pellets; what’s more, the material will have

bad gelatinization, low productivity and high powder rate in feed pellets. Therefore, for the common poultry and livestock feed pellets, corn milling should adopt 2.5- 3.0mm sieving plates which can avoid too finess and ensure feed granularity for conditioning for less powder content.

1.3 Grain material mixing The evenness of grain material mixing should be paid attention as well. Because of the complexity of feed formula, the huge differences of different materials, we should choose the right mixing time according to the formulas with the aim of controlling the variable coefficient of evenness to 5% and laying a good foundation for pelletizing.

Feed Pellet Press Productivity Influencing FactorsBy Amanda Zhou, Allance Machinery, China, Email: [email protected]

More information:Allance Pellet MillWeiyi Road,Zhengzhou,China, 450000Web: www.pellet- machine.net

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2. Steam quality control Using steam for feed pellets can improve pellet press production and pellet quality. Steam is the source of both moisture addition for conditioning and starch gelatinization. Adding a certain amount of steam in conditioner can kill some bacteria and also dilute the natural binder in feed materials; in this way, the particles surface forms a layer of thin water-bearing stratum which is in favor of gelatinization and pelletizing. The correct design of steam pipe should ensure not only pressure and flow but also prevent condensate water entering conditioner.

Generally, raw material moisture content is about 12% before conditioning, steam pressure is high and moisture content is low; while after conditioning, moisture content is above 16.5% and pellets are difficult to store. The conditioning temperature is 85°c for common animal feed pellets; but change it lower or higher in winter and summer respectively.

3. Feeding flow control Feeding flow control is to ensure pellet press work continuously and uniformly and thus quite important. Feeder part should be unobstructed for smooth feeding. Take SZLH series 400 as an example, the feeding flow should be no less than 10t/h. In order to make the even feeding flow, it is wise to install a surge bunker on top offeed press. It is difficult to ensure even feed flow without a surge bunker or other connecting pipes (longer than 0.5m). In a general way, when feed pellet press works stably, steam supplies adequately, all feeding gates open, feeding speed is the rated value but the main motor can never achieve the rated power value, we can judge that the feeding flow is insufficient.

4.Pelletizing operation 4.1 Adjust the space between roller and die. Too small space between roller and die will make easier to create wear and loud noise; too big space will influence material pressing; thus the space is about 0.05- 0.30mm. Sometimes a feeler gauge is good to help.

4.2 Industrial butter is needed Butter is needed on roller so that bearings can be protected safely from high temperature.

4.3 Feeding knives adjustment Adjust feeding knives in case materials can’t enter the space between roller and die. Part of raw materials will go out of die holes and form more powder; thus the adjustment should make sure the space between the curves on the upper edge and die is 2-3mm.

4.4 Feed pelletizing Start pellet press, conditioner and feeder successively; at this time, feeder should be in the smallest feeding amount. In order to avoid sundries enter to the die, the operator should open the discharge door outside pellet press for removing impure materials. When the materials are clean, we can lead them to ring die. The important thing is that we should feed part of the material to see ifthere are feed pellets formed. If everything works


well, we can increase raw material and steam to the rated current. If the materials enter pressing chamber but no feed pellets forming, with the electric current increasing; we should open discharge door outside pellet press and watch if the electric current lowers down. Mechanically, the pelletizing process involves forcing soft feed through holes in a metal ring die or flat die. The holes may be round or square, tapered or nontapered. This is done either by using locally fabricated pelleting machine, which is operated by diesel engine, electricity powered machine or manually, or by using automatic highly sophisticated machines with hot air or water conditioning. It consists basically of cylindrical dies of different diameters to pelletize varying sizes of feed, which depends on the age, size and species of animals involved. Most feed produced is a compressed pellet.

Pelleted feed has numerous advantages which include less feed wastage, uniform feed intake, and destruction of growth inhibitors.

It is noteworthy that at the beginning stage of feeding, we should not add steam anxiously. Because at this time, raw materials are in small amount and the steam amount is hard to control. More steam and less material is easy to block pellet press. Besides, before close down pellet press, we should add some oil material to ring die holes to prevent materials becoming hard.

Feed pellet production is simple but good feed pellet isnot so easy because it needs not only pelletizing technology but also rich experience. We hope this analysis will assist you in improving feed pelletproductivity to some extent. For both domestic and commercial feed pellet production, we can customize the most cost-effective pelletizing solutions.

SIMILAGO II The new Similago has been studied and developed by Alapala to provide the utmost technology in roller mill design with elegance and durability. This new roller mill satisfies the most

stringent hygiene standards together with milling precision and simple maintenance making it the most versatile roller mill for any new or existing plant design. The new state of the art electronics make the Similago II making it user friendly and flexible The quick roll change module cartridge has been updated by using the latest state of the art components The Similago II roller mill is also available in the 8 roll superimposed version with option for either 250 mm or 300 mm roll diameters. PURIFIER

This machine is an evolution of our highly successful model DISA giving higher efficiency, integrated with optimal illumination of the screen. A new generation of

vibration mountings and maintenance free motors ensure low energy consumption and low maintenance with

minimum of downtimes. QUADRO PLANSIFTER

Ingeniously designed to comply with the highest hygiene standards, easy to operate, minimum maintenance, modular design constructed in stainless steel and with a large sifting area. An important part of this plansifter is that on the basic main frame with a redesigned oscillating mechanism, it is possible to attach from 2 to 8 sections. These sections are insulated with ABS for anti condensation properties. With great consideration all the components have been designed and developed with the use of rounded recesses and profiles to stop product build up leading to infestation

More information: ALAPALA Machine Industry & Trade Inc. Flour and Feed Technology Istanbul Division World Trade Center A-‐1 No: 15/453 Yesilkoy Istanbul Turkey Tel: +90 212 465 6040-‐41 Fax: +90 212 465 6042 Web: www.alapala.com



















More information:ALAPALA Machine Industry & Trade Inc.Flour and Feed TechnologyIstanbul DivisionWorld Trade Center A- 1 No: 15/453YesilkoyIstanbulTurkey

Tel: +90 212 465 6040- 41Fax: +90 212 465 6042Web: www.alapala.com

The new Similago has been studied and developed by Alapala to provide the utmost technology in roller mill design with elegance and durability. This new roller mill satisfies the most stringent hygiene standards together with milling precision and simple maintenance making it the most versatile roller mill for any new or existing plant design. The new state of the art electronics make the Similago II making it user friendly and flexible The quick roll change module cartridge has been updated by using the latest state of the art components The Similago II roller mill is also available in the 8 roll superimposed version with option for either 250 mm or 300 mm roll diameters.

This machine is an evolution of our highly successful model DISA giving higher efficiency, integrated with optimal illumination of the screen. A new generation of vibration mountings and maintenance free motors ensure low energy consumption and low maintenance with minimum of downtimes.

PU

RIF

IER

SIM

ILA

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II

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Ingeniously designed to comply with the highest hygiene standards, easy to operate, minimum maintenance, modular design constructed in stainless steel and with a large sifting area.

An important part of this plansifter is that on the basic main frame with a redesigned oscillating mechanism, it is possible to attach from 2 to 8 sections. These sections are insulated with ABS for anti condensation properties.

With great consideration all the components have been designed and developed with the use of rounded recesses and profiles to stop product build up leading to infestation


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6th November UK Grain Peterborough, UKWeb: www.farm-smart.co.uk/ukgrain/

10th-16th November Agritechnica, Hannover, GermanyWeb: www.agritechnica.com

13th-14th November64th JTIC Milling & Cereals Meeting Reims, FranceWeb: www.jtic.eu

December8th-10th December NGFA Country Elevator Conference & Tradeshow St Louis, Missouri, USAWeb: www.ngfa.org

2013 Events List



G R A I N

2013THE GRAIN BUSINESS EVENT

Post Harvest Technology

Storage

Drying

Handling

Marketing

Organised by FarmSmart Events in association with the HGCA as Grain Quality partner

www.farm-smart.co.uk • 0845 4900 142 • [email protected]

Wednesday 6th NovemberEast of England Showground,

Peterborough PE2 6XE

Tickets £15 on the day Save £5 by pre-booking

FarmSmart-UKGrain ad-210x297_Layout 1 14/12/2012 10:07 Page 1

Global Milling 2013 Annual - Page 10

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Bringing you the latest up-to-date relevant news, upcoming industry events, Universities and worldwide company contact information – Everything you need in one place!

Keep up-to-date with Global Milling

www.globalmilling.com

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global milling advances august 2013 -

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