RAW MATERIAL INTAKE
All the solid ingredients which are packed in bags for feed production would be received in plant by road. Their materials will be stored in store godown. According to the requirement, these materials will be dumped manually in dumping hopper and conveyed to the pre-cleaner through the mechanical conveyor system.
Pre-cleaning is a process of removing unwanted material from the ingredients. As we received the material, there will be possibility of having unwanted material such as jute threads, iron pieces, oversize pieces which can jam our silos\ system. So for cleaning we use a pre-cleaning machine. Then these materials are transpired to silos through mechanical conveyors and elevators.
Batching is process of combining each and every material in a proportioning ratio known as feed formula which is a very important process of every feed plant. The better and accurate ration of material will give is a better quality and a fully nutrients feed. The batching process may be a computerized controlled or may have manual control room to cut the cost of the plant.
Granding is a process of bracking solid ingredients to a required size. The finer the material higher will be the surface area exposure to heat and moisture to accomplish the gelatinization in conditioning. A fine granding material can transfer his maximum energy to the animal as compare to a course grinded material. It is a very energy consuming process.
As the name implies "Mixing" is a process of combining \ blending of micro ingredients. A proper mixing can be defined with a unit known as co-efficient of variation. Smaller the co-efficient of variation higher will be the quality of mixing. Our well designed mixer machine has such a great quality. Beyond this is a mixer machine which mix liquid to it as we need oil or molasses addition to the feed.
Conditioning is a checking process. We decide whether our material is ready to pellet or not. When the material will be ready, only then it will be allowed to transfer to the pellet mill. It is a process of adding heat & moisture in the mixed feed to achieve gelatinization and making the product more pliable for palleting. Heating is done to roast the mixed feed which will increase its digestibility quality. And moisture is increased to easy palleting of feed good conditioning should have a desired retention time.
Palleting is a main step of any pelleting plant. It is a process of changing any powder to solid shape called pallet. In this process, the powder material is created through a well designed die with the help of rollers to convert it in to pallets. The quality & production of pallet mill depends on so many parameters.
1. Qualityof conditioning
2. Feed formula
3. Quality of Granding
4. Die configuration
No doubt every material can be converted into pallets weather it may be a wood.
Cooling is a process of removing heat. As we know during conditioning we add heat and moisture and also through palleting process heat generates by extrusion process. But the pallet should have a standard moisture and heat to attain its life of storage and make it safe from fungus. So we have to remove extra heat and moisture from the pallet. All this is done with the help of a well designed counter flow cooler. Here we use atmosphere air to cool the pallet.
Crumbling is a process in which pallets after cooling is broken in to small pieces to make it ideal for small chicks or hens. When there is no need of crumbling, we by-pass the feed directly to the screen with the help of By-pass mechanism. A well designed crumbier should have capability to break the pellets without making much finer.
Product coming out of crumbier is or in pallets form (if we use by-pass) or in crumbs form. They are required to screen, to remove fines and oversize particle. A double deck screeners are used to remove both fine and oversize particles. The fine and directed to pallet mill for repalleting while oversize particles are directed to crumbier for reprocessing. A well desired screener should have capability to remove fine and oversize to a desired percentages, And it should not be clog frequently.
The end of process in every plant is bagging also known as packing. After screening the finished products are filled into bags. In small and medium plants, bagging can be carried out manually but for higher production it is batter to go for electronic bagging machine.