Feed Machinery and Processing

24/04/2026

28/01/2026

The Process of Premix

(I) Pretratamiento de Materias Primas

Las materias primas para las premezclas de aditivos son diversas, con propiedades físicas y químicas variables. Por lo tanto, el pretratamiento necesario es esencial, y el nivel de tecnología de pretratamiento afecta directamente la calidad del producto. Si las materias primas para la producción de premezclas son productos de grado alimenticio que cumplen con los requisitos de producción, no se requiere ningún tratamiento adicional. Sin embargo, si los productos adquiridos no cumplen con los requisitos de producción (por ejemplo, alto contenido de humedad, gran tamaño de partícula, higroscopicidad, aglutinación), se requiere pretratamiento.

1. Pretratamiento de Vehículos y Diluyentes. Existen muchos tipos de vehículos y diluyentes. Para garantizar la calidad de las premezclas de aditivos, los vehículos y diluyentes seleccionados deben pretratarse, principalmente mediante secado y pulverización. Generalmente, el contenido de humedad de los vehículos y diluyentes no debe superar el 10%, con un máximo del 12%. Si el contenido de humedad supera el 12%, es obligatorio secarlos antes de su uso. Para reducir costos, se puede utilizar el secado al sol. Si este no cumple con los requisitos de calidad, se debe emplear el secado mecánico. El tamaño de partícula de los portadores y diluyentes afectará su capacidad para transportar los ingredientes activos del aditivo y la calidad de la mezcla. El tamaño de partícula del portador debe controlarse entre 0,18 y 0,6 mm. Generalmente, se requiere que el tamaño de partícula del diluyente sea más fino que el del portador, entre 0,13 y 0,6 mm. Sin embargo, las partículas demasiado finas pueden generar más polvo, por lo que se debe seleccionar el tamaño de partícula adecuado en función del tamaño de partícula del aditivo.

2. Pretratamiento de las materias primas de aditivos de oligoelementos. Los aditivos de oligoelementos se refieren principalmente a sales minerales y óxidos de cobre, hierro, manganeso, zinc, etc. Algunos de estos aditivos presentan baja solubilidad en agua y son fáciles de procesar; otros son muy susceptibles a la higroscopicidad y la aglomeración, lo que afecta directamente al procesamiento, la vida útil del equipo y la calidad del pienso. Por lo tanto, es necesario un tratamiento adecuado antes de la aplicación, como el secado, la granulación, la adición de antiaglomerantes y la preparación de premezclas, para modificar ciertas propiedades físicas y garantizar el cumplimiento de los requisitos de procesamiento y la calidad del producto.

(1) Secado. Los compuestos de oligoelementos, como sulfatos como el sulfato ferroso, el sulfato de cobre, el sulfato de cobalto, el sulfato de manganeso y el sulfato de zinc, suelen contener de 5 a 7 moléculas de agua de cristalización. Absorben fácilmente la humedad del aire y se aglomeran, adhiriéndose a las paredes del equipo durante el procesamiento, causando corrosión, afectando la uniformidad de la mezcla y perjudicando la bioactividad de otros componentes durante el almacenamiento del producto. Por lo tanto, es necesario el secado forzado para reducir la cantidad de agua de cristalización a una molécula.

(2) Granulación. La granulación consiste en moler finamente los aditivos de oligoelementos para mejorar la uniformidad de la mezcla y garantizar la misma probabilidad de consumo animal. Cuanto menor sea la proporción de oligoelemento añadido, más fino debe ser el tamaño de partícula. Sin embargo, una finura excesiva también puede tener efectos adversos, como mala fluidez y aumento de los efectos electrostáticos. Por lo tanto, es recomendable seleccionar el tamaño de partícula óptimo. Los aditivos de oligoelementos generales deben alcanzar un tamaño de partícula de 0,1 mm, mientras que los oligoelementos extremadamente finos, como el yodo, el selenio y el cobalto, deben pulverizarse a 0,03 mm. Si no es posible pulverizarlos a 0,03 mm, pueden disolverse en agua en una proporción de 1:(15-20) en masa, pulverizarse uniformemente sobre un soporte de 10 veces su volumen, secarse rápidamente y pulverizarse.

(3) Adición de antiaglomerantes. Para ciertas materias primas de sulfatos con tendencia al aglomerado higroscópico, se puede añadir una pequeña cantidad de antiaglomerantes con baja absorción de agua, buena fluidez y no perjudiciales para el ganado ni las aves de corral, como la sílice y el silicato de calcio, para solucionar los problemas de aglomeración y fluidez de los sulfatos. Sin embargo, la cantidad de antiaglomerante no debe superar el 2 %.

(4) Premezcla. La premezcla consiste en mezclar previamente los aditivos de oligoelementos con diluyentes o portadores para garantizar una mezcla uniforme, lo que aumenta la eficacia y la seguridad. Por ejemplo, el selenito de sodio y el cloruro de cobalto deben premezclarse antes de su uso.

(5) Preparación de complejos o quelatos de polisacáridos. Los compuestos de polisacáridos son complejos metálicos especiales formados por sales solubles y soluciones de polisacáridos. Por ejemplo, los compuestos de polisacáridos de cobre pueden prevenir la interacción entre minerales, vitaminas y otros elementos minerales. El uso de ácido dietilaminotetraacético (DEA) como agente quelante para preparar quelatos de cobre, zinc, hierro, etc., puede eliminar las desventajas de las sales solubles y mejorar la tasa de utilización de oligoelementos por los animales. Los productos quelatos de un solo aminoácido que se utilizan actualmente, como la metionina de zinc y la metionina de hierro, tienen buenos resultados.

(6) Recubrimiento. Este recubrimiento establece una barrera de agua para el material, logrando así su protección. Los métodos principales son:

① Recubrimiento con aceite mineral: La adición de aceite mineral directamente al mezclador en una proporción no superior al 0,06 % de la dieta total para participar en la mezcla de oligoelementos garantiza que los oligoelementos secos no absorban humedad ni se humedezcan. Además, la adición de aceite mineral puede prevenir la formación de polvo y eliminar la electricidad estática.

② Recubrimiento con parafina: Se utiliza principalmente cera de abejas y cera de carnauba. Estos son ésteres formados a partir de ácidos grasos y alcoholes monohídricos alifáticos de alto peso molecular. Su función es la misma que la del aceite mineral.

(7) Trituración. Los oligoelementos tratados como se describe anteriormente deben pulverizarse para cumplir con los requisitos de tamaño de partícula. Cuanto menor sea la proporción añadida, más fino será el tamaño de partícula requerido. Las proporciones de los diversos elementos minerales varían considerablemente, por lo que los requisitos de tamaño de partícula también difieren. Por ejemplo, los oligoelementos generales requieren una finura de 0,1 mm, mientras que los oligoelementos extremadamente finos, como el yodo, el cobalto y el selenio, deben pulverizarse a un diámetro de 0,03 mm. Las normas chinas sobre piensos estipulan que todas las premezclas de oligoelementos deben pasar por un tamiz analítico de 0,425 mm de diámetro, y el residuo en un tamiz de 0,177 mm de diámetro no debe superar el 20 %.

3. Pretratamiento de vitaminas. Las vitaminas se ven fácilmente afectadas por factores como el oxígeno, la humedad, el calor, la luz y los iones metálicos, lo que puede reducir su actividad. Para cumplir con los requisitos del proceso de producción, casi todos los aditivos vitamínicos requieren un procesamiento especial, como recubrimiento, emulsificación, adsorción, preparación de derivados o preparación de premezclas, para mantener la estabilidad y la actividad de las vitaminas.

20/01/2026

Impact of Conditioning Temperature and Cooling Time on the Hardness of Pellet Feed The competition in the feed market has become increasingly fierce, and pelleting has become a strictly defined processing procedure. User requirements for feed quality are also rising: pellets must have a smooth appearance, uniform length, moderate hardness, and low fine content. However, the factors determining feed quality are multifaceted, including the selection of nutritional formulas, characteristics of raw materials, and differences in processing technology and equipment. Therefore, finding the optimal balance between high quality, high yield, and low cost—while improving pellet quality, production efficiency, and reducing costs—is one of the most urgent problems for feed production enterprises. Numerous studies have shown that during the production process, the conditioning temperature and the cooling time after pelleting have a certain impact on the hardness and quality of the feed pellets. This study primarily investigates the effects of different conditioning temperatures and post-pelleting cooling times on feed pellet hardness under identical steam pressure and feeding speeds. 1. Materials and Methods 1.1 Pelleting ProcessA conventional pelleting process was adopted: raw materials passed through a permanent magnet cylinder for magnetic separation before entering the raw material bins. After grinding, the materials were mixed and transferred to two pre-pelleting bins. An electromagnetic speed-regulating auger was used for feeding. Conditioning was performed using saturated steam in a single-stage long conditioner. Pelleting was executed by a ring-die pellet mill, followed by cooling in a counter-flow cooling tower and grading via a vibrating screen. Qualified products entered the finished product bin. 1.2 SamplingThe main components of the pellet feed were: wheat (58.39%), corn gluten (3%), palm kernel meal (22%), high-oil protein (12%), and bentonite (2%). Ring-die parameters: 3.0 mm diameter with a compression ratio of 12.The conditioning steam pressure was 4 kg, and the feeding auger operated at a frequency of 40 Hz. Test variables included cooling times of 5, 8, 12, and 15 minutes, and conditioning temperatures of 75°C, 85°C, 95°C, and 105°C. A 1 kg sample of pellet feed was collected at the exit of the finished product bin. After preparation, pellet hardness was measured using a pellet hardness tester. 1.3 Measurement of Pellet HardnessHardness was measured using an impact-type hardness tester. Radial pressure was applied to a single pellet until it broke; the pressure at the point of fracture was recorded as the hardness of that pellet. The average hardness of multiple pellets represented the final hardness value. Twenty pellets of approximately the same size and length (above 6 mm) were selected from the 1 kg sample. After zeroing the pressure pointer, each pellet was placed horizontally on the stage directly under the pressure rod using tweezers. The handwheel was turned at a moderate and uniform speed to raise the plunger. The pressure value was read upon fracture.The mean hardness (N) was calculated as: \((X_{1}+X_{2}+X_{3}\dots +X_{20})/20\), where \(X\) represents the hardness value of an individual pellet. 1.4 Statistical AnalysisExperimental results were analyzed using SPSS 13.0 software. 2. Results and Analysis As shown in Table 1, feed hardness increased significantly with the extension of cooling time and the rise in conditioning temperature. In the interval of 5 to 12 minutes of cooling, pellet hardness increased significantly, whereas the increase was marginal after 12 minutes. Similarly, hardness increased significantly as the conditioning temperature rose, but the increase became less pronounced once the temperature reached 105°C.Conversely, when the cooling time was too short and the conditioning temperature too high, the pellets maintained high moisture content, resulting in insufficient hardness and excessive fines in the finished product. Pellets that are not sufficiently cooled are prone to spoilage and mold. Furthermore, conditioning temperatures that are either too low or too high can easily cause blockages in the pellet mill, which not only hinders production efficiency but also compromises product quality. 3. Conclusion This study demonstrates that feed hardness increases significantly with longer cooling times and higher conditioning temperatures. The increase is most prominent when the cooling time is between 8 and 12 minutes and the conditioning temperature is between 75°C and 95°C. The formula used in this experiment was for large duck feed, which has high hardness requirements. In production practice, insufficient hardness in duck feed leads to waste. Since many factors—such as moisture, starch, protein, fat, crude fiber content, particle size of raw materials, as well as storage and transportation—affect pellet quality, greater attention must be paid to the hardness index when producing pellet feed for large ducks.

07/01/2026

An In-depth Analysis of Electricity Consumption per Ton of Feed Production: From Process Differences to Energy-Saving Keys
In the feed processing industry, electricity cost is one of the most significant production expenses second only to raw materials. As the manufacturing sector's requirements for "green and low-carbon" operations further intensify in 2026, precise control of electricity consumption per ton (kWh/t) has become a core indicator for measuring a feed mill's management level and competitiveness. This article provides a deep dive into the energy consumption distribution of different feed types and the key factors affecting power usage.
I. Process Determines Consumption: A Comparison of Three Major Feed Types
The physical form of the feed directly determines the complexity and power requirements of the production line. According to the latest industry standards, electricity consumption per ton across different feed types shows a significant gradient:
Mash Feed (Ordinary Powdered Feed)
Consumption Level: 8–15 kWh/ton.
Process Characteristics: This is the simplest production process, primarily consisting of cleaning, grinding, and mixing. Since it bypasses high-temperature conditioning and physical extrusion, energy consumption remains at the lowest level.
Pelleted Feed (Common for Livestock and Poultry)
Consumption Level: 25–40 kWh/ton.
Process Characteristics: Building on grinding and mixing, this process adds conditioning (steam treatment) and pelleting stages. The pellet mill consumes substantial mechanical energy when extruding material through the ring die holes, causing energy consumption to double.
Extruded Feed (Aquatic Feed and Pet Food)
Consumption Level: 60–100 kWh/ton.
Process Characteristics: This is currently the most complex and energy-intensive variety. Materials are subjected to high temperature, high pressure, and intense shearing within the extruder, followed by a lengthy drying process. Energy consumption for some high-standard pet foods can even exceed 100 kWh/ton.
II. Production Line Breakdown: Where is the Most Power Consumed?
Taking a typical pelleted feed production line as an example, the distribution of electricity consumption exhibits a clear "head effect":
Pelleting Stage (40%–50%): The absolute "power hog." The pellet mill's motor power is usually the largest in the entire production line. The frictional resistance between the press rollers and the ring die is the primary cause of energy loss.
Grinding Stage (25%–30%): Second only to pelleting. The energy consumption of the grinder is directly influenced by the hardness of raw materials (such as the difference between corn and soybean meal) and the required grinding fineness.
Mixing and Conveying (15%–20%): This includes bucket elevators, drag conveyors, and mixers. Although the power of individual machines is moderate, their cumulative energy consumption is significant as they operate throughout the entire process.
III. Three Core Variables Affecting Electricity Consumption
In actual production, even when producing the same type of feed, the electricity consumption per ton varies across different factories, primarily depending on the following factors:
Grinding Fineness:
Experiments prove that the relationship between grinding fineness and energy consumption is not linear but exponential. The finer the grind, the longer the material stays in the grinding chamber, leading to a sharp increase in power consumption per unit of output.
Pelleting Specifications (Die Hole Diameter):
The smaller the die hole diameter, the greater the frictional resistance. Producing small-diameter pellets (e.g., 2.0mm for fry feed) consumes far more electricity than large-diameter pellets (e.g., 4.0mm for pig feed).
Equipment Sophistication and Automation:
Modern factories in 2026 commonly utilize frequency conversion technology and high-efficiency energy-saving motors. Compared to older, smaller workshops, highly automated plants can achieve 15%–20% energy savings by optimizing load operations.
IV. Management Recommendations
To effectively reduce electricity consumption per ton, feed enterprises should focus on:
Regular Replacement of Wear Parts: Heavily worn hammers and ring dies significantly reduce efficiency and increase idling energy loss.
Optimization of Conditioning Parameters: Appropriate steam moisture and temperature can act as a "lubricant," reducing the pelleting current.
Off-Peak Production: While meeting capacity requirements, utilize peak-valley electricity price differentials to reduce overall integrated power costs.
Summary: Understanding and monitoring electricity consumption per ton is not only about cost reduction; it is a necessary path for feed enterprises toward refined management and sustainable development

05/01/2026

Hammer Mill Blockage‌
During the use of hammer mills, blockage issues frequently occur. The causes of blockage can vary, including insufficient component fit during assembly, high viscosity of agricultural materials adhering to inner walls, or most commonly, improper operator handling.

1.1 Overloading Leading to Blockage‌
During operation, excessive material input during feeding can cause overloading, resulting in blockage. To prevent this, operators must monitor the ammeter needle. When the current exceeds the high-range threshold, feeding should immediately cease. Prolonged overloading can damage the motor. Hammer mills typically operate at high speeds to maximize feed output, with dynamic load capacity. Current limits are usually kept within 20% of the rated value, depending on feed input volume. Feeders are categorized into manual (for small-power mills) and automatic (for industrial-scale equipment), with selection based on mill specifications.

1.2 Material Discharge Channel or Airflow Network Blockage‌
Extended use may wear down screw blades or cause them to detach, leading to discharge obstruction. Similarly, severe wear on elevator belts can cause slippage or misalignment, exacerbating blockages. Immediate repairs—such as tightening belts or replacing damaged parts—are required.
Hammer mills rely on auxiliary airflow networks for operation. Blockages in these networks reduce airflow, causing material accumulation. For certain materials with limited diameters, small sieve apertures may further restrict airflow, necessitating regular cleaning of channels and air ducts.

1.3 Other Blockage Causes‌
Additional factors include hammer wear, sieve clogging, or excessive material moisture (above 20%). High moisture content reduces output and accelerates mechanical wear. Regular inspections and maintenance are critical to address these issues.

1.4 Material Variety Influencing Blockage‌
Material properties vary significantly—some are high in moisture, others contain fibrous or oily components. Certain materials cannot be processed alone due to their texture or composition. Small sieve apertures exacerbate blockages when processing high-fiber materials. To mitigate this, select materials compatible with mill specifications, ensure low moisture content, and pre-process materials (e.g., shelling or blending with other ingredients). Avoid excessively small sieve apertures to enhance efficiency.

Excessive Noise and Vibration‌
During installation, ensure the hammer mill is level and stable. Test the frame rigidity; if insufficient, reinforce it. Direct drive systems are commonly used for their simplicity and ease of maintenance. However, misaligned components can cause severe vibration and noise. Proper alignment tailored to mill models is essential.
Eccentricity between the motor and hammer mill rotor can also induce vibration. Adjustments—such as repositioning the motor or altering its height—can restore concentricity. Unbalanced hammer weights (with errors exceeding 5g) contribute to vibration. Regular rotor inspections and replacements are necessary to maintain consistent speed.

Bearing Overheating‌
Bearings are critical components whose performance directly impacts operational efficiency. Overheating accelerates wear and reduces lifespan. Upon detecting excessive heat, immediately halt operations and diagnose the issue. Causes include improper bearing height, excessive lubrication, or tight installation between bearing housing and components. Bearing failure often necessitates complete shutdowns; prompt repairs are vital.

Conclusion‌
Hammer mills, as essential industrial equipment, are widely used in feed production and other sectors. However, installation and operational faults are inevitable. Operators must possess analytical and troubleshooting skills to ensure efficiency and prolong equipment longevity. Only through proficient knowledge can production stability and asset durability be maintained.

23/10/2025

Deliver goods to a large feed factory named YangXiang in China

08/08/2025

The Difference of the flat die pellet mill and ring die pellet mill
I. Deep Analysis of Equipment Structure and Working Principles‌
Ring Die Pellet Mill‌
Structural Design‌: A ring-shaped die is vertically mounted on the main shaft. Press rollers form a compression zone with the inner wall of the die via hydraulic/mechanical pressure systems. Material passes uniformly through die holes under centrifugal force.
Power System‌: Utilizes gear/belt transmission with adjustable speed (200-600 r/min) and power range (15-315 kW), accommodating diverse formulations.
Conditioning Process‌: Equipped with multi-layer conditioners (steam addition: 3%-6%), achieving >85% material gelatinization and significant starch (gelatinization).
Flat Die Pellet Mill‌
Structural Limitations‌: Horizontal die enables static pressing, relying on gravity for discharge. This causes uneven material distribution, especially for lightweight raw materials (e.g., bran).
Power Constraints‌: Typically uses small motors (7.5-55 kW) with low speed (50-200 r/min), resulting in unstable extrusion pressure (20-80 MPa).
II. Six Core Advantages of Ring Die Mills in Livestock Feed Production‌
Production Capacity & Efficiency‌
Output: Up to 30 tons/hour for ring die mills (e.g., SZLH420 model), 5-8× higher than flat die mills, meeting large-scale feed plant demands.
Reliability: Continuous operation downtime rate