6-8 T/H Alfalfa Pellet Production Line in Türkiye

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overview

With the development of Turkey’s animal husbandry and feed processing industry, the demand for forage feed is increasing, and there are higher requirements for the palatability, utilization, nutritional value, storage, processing and other aspects of forage feed.

In this context, ordinary grass products (hay, bales, grass blocks, grass powder) can no longer meet the market demand. Forage pellet products with good palatability and effective improvement of forage utilization and digestibility are widely favored by the market, and are also the main development direction of grass product processing in the future.

Based on the application prospects of alfalfa pellets and grass feed pellets, the customer of this project invested 360,000 US dollars to build a 6-8 tons per hour alfalfa pellet production line.

After the project is completed, it can achieve an annual production capacity of 20,000 tons of ruminant and livestock feed. The actual labor quota of this project is 15 people, including 5 management personnel, with an annual working time of 330 days and 8 hours a day.

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Engineering Composition

This 6-8t/h alfalfa pellet production line in Türkiye project produces 20,000 tons of ruminant and livestock feed annually. The engineering composition mainly includes main engineering, auxiliary engineering, environmental protection engineering, and public engineering. The project has an existing production plant for production.

This project only needs to install equipment in the plant, transform the plant into a closed plant, set up exhaust pipes, install environmental protection facilities, etc., without excavation, site clearance, land preparation and other projects. See the table below for a list of project engineering composition.

Type	Item	Construction Content
Main Project	Production Workshop No. 1	It has one ruminant feed production line, and one set of feeding, lifting and dust removal systems are added to the production line
	Production Workshop No. 2	It has one livestock and poultry feed production line, and one set of feeding, lifting and dust removal systems are added
Storage and Transportation Engineering	1# Raw Material Stacking Area	Located in the north and middle of Workshop 1, it is mainly used for classified stacking of raw materials and small materials
	1# Finished Product Stacking Area	Located in the southwest of Workshop 1, it is mainly used for classified stacking of finished products
	Dangerous Chemicals Warehouse	Located in the northwest corner of Workshop 1, it is mainly used for dangerous chemicals (sulfuric acid, hydrochloric acid) used in the inspection room ) and storage of sulfuric acid and hydrochloric acid bottles (temporary storage area for hazardous waste)
	2# Raw material stacking area	Located in the north and west of Workshop No. 2, it is mainly used for the classified stacking of ruminant raw materials, livestock and poultry raw materials and small materials
	2# Finished product stacking area	Located in the north and west of Workshop No. 2, it is mainly used for the classified stacking of ruminant raw materials, livestock and poultry raw materials and small materials
Auxiliary Engineering	Office Area	Located on the second floor in the southeast of Workshop No. 1, it has a steel frame structure and is mainly used for office and conference affairs
	Administrative Office	Located in the south of Workshop No. 2, it has a steel frame structure and is mainly used for office and conference affairs
	Test Room 2	The newly built Test Room 2 is located in the southwest of Workshop No. 2 and is mainly used for product testing and research. The ground is hardened with cement and generally waterproof (anti-seepage concrete paving, with a 2mm thick high-density polyethylene film underneath, and a comprehensive anti-seepage coefficient of ≤10-10cm/s)

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Project product plan

The main products of this 6-8t/h alfalfa pellet production line in Türkiye project are ruminants and livestock and poultry feed, with an actual output of 20,000t/a. The product plan is shown in the table below.

Number	Product name	Output
1	Ruminant, livestock and poultry feed	20000t/a

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Consumption of raw and auxiliary materials

The 6-8t/h alfalfa pellet production line in Türkiye project mainly uses alfalfa meal, corn, soybean meal and other raw materials, and its consumption is as follows: (This customer already has equipment such as forage crushers, so the alfalfa is already in a powder state when it enters the feed production line.)

Name	Consumption	Storage Location	Source
Corn	10000t/a	Production Area	Purchase
Alfalfa Meal	1000t/a	Production Area	Purchase
Sesame Meal	600t/a	Production Area	Purchase
Soybean Meal	3000t/a	Raw Production area	Purchase
Cottonseed meal	1200t/a	Production area	Purchase
Corn DDGS	2000t/a	Production area	Purchase
Sprayed corn husk	1600t/a	Production area	Purchase
Rice husk powder	1500t/a	Production area	Purchase

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Main equipment needed in alfalfa pellet production line in Turkey

The main production equipment of this project is shown in the table below.

Number	Equipment name	QTY
1	Full set of feed production line equipment (including all crushers, mixers, pelletizers, coolers, screeners, packaging scales, bucket elevators, screw conveyors, dust removal equipment, cleaning equipment, etc.)	1
2	Steam generator	1
3	Inspection instrument	/
4	Forklift	1
5	Scale	1

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Project energy consumption

The main energy consumption during the operation of this project is: water and electricity. The actual energy consumption of this project is shown in the following table:

Number	Item	Name	Annual consumption	Remarks
1	Energy consumption	Fresh water	1531.2m3/a	Provided by local water supply network
2		Electricity	20,000 kwh/a	Provided by local power supply network
3		Natural gas	105,000 m3/a	Provided by local natural gas network

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Türkiye alfalfa pellet Process design

The feed production process adopted in this 6-8t/h alfalfa pellet production line in Türkiye project is as follows:

Bagged corn is manually transferred to the feeding hopper (the feeding hopper is equipped with a pulse bag dust collector), and then transported to the head of the primary cleaning screen by a closed bucket elevator to complete the subsequent process.

In addition, raw materials such as soybean meal and cottonseed meal are powdery materials, which are manually transferred to the feeding hopper (the feeding hopper is equipped with a pulse bag dust collector), and then transported to the batching section by a screw conveyor and a bucket elevator. The feeding section is carried out in the production area.

After the corn is lifted to the head of the coarse cleaning screen by a closed bucket elevator, it is separated from impurities by a circular absorption separator. The fine and light impurities in the raw materials are processed by the corn cleaning system along the air duct and then discharged.

The corn enters the coarse cleaning screen to remove corn husks, large particles, etc., and then enters the permanent magnetic cylinder to further remove impurities (such as iron filings and other magnetic impurities).

The corn in the crushing bin enters the crusher through the frequency conversion feeder, and the crusher (equipped with a pulse bag dust collector) crushes the corn raw material into corn powder with a particle size less than 0.5mm, and then lifts it to the scraper powder feeder through the closed screw conveyor and bucket elevator, and then enters the batching bin through the pneumatic valve and pneumatic tee.

Corn powder, alfalfa powder, soybean meal, cottonseed meal, etc. are conveyed to the batching scale for automatic batching through the computer-controlled batching screw conveyor. After the materials are batched, they automatically enter the mixer, and then the electric bell automatically rings to remind the manual addition of additives to the feeding hopper (the feeding hopper is equipped with a pulse bag dust collector).

After the batching is completed, the mixer is manually started to automatically time the closed mixing, and the material is automatically discharged to the buffer bin after mixing for 2 minutes, and then the powder is lifted by the scraper conveyor and the bucket elevator to screen the powder for screening.

After removing impurities, it enters the permanent magnetic cylinder to further remove magnetic impurities such as iron filings.

The mixer uses a double-shaft paddle mixer with a mixing uniformity variation coefficient of 2.8%. The batching and mixing process uses a computer automatic control system. The dynamic accuracy of the batching is 0.2% and the static accuracy is 0.1%.

The moisture content of the material in the granulation bin is about 13%. After passing through the alfalfa pellet machine, steam modulation and granulation, the moisture content of the pellets is about 18%. The pellets enter the cooler, which cools the material through the cooling air net.

After cooling, the pellets are lifted to the rotary grading screen by a bucket elevator for screening; the powder is collected and sent to the granulation bin for re-granulation.

This 6-8t/h alfalfa pellet production line in Türkiye project adopts hot granulation for granulation, using steam modulation. The steam is prepared by a 0.5t/h natural gas steam generator.

The temperature during the granulation process is controlled at 60~90℃. The main function of granulation is that under the action of heat and moisture, the starch in the feed is gelatinized, the protein is denatured, the material is softened, the viscosity is increased, the palatability of the feed is improved, the digestibility of the feed is improved, and harmful bacteria are killed.

After pelleting, the moisture content of the material is 18%. In order to improve the shelf life of the product, this project uses rapid cooling to control the moisture content within an appropriate range. The cooling system consists of a countercurrent cooler, a fan and a cyclone dust collector.

The pellets flow from the top of the pellet cooler machine to the bottom, and the fan provides cold air to flow from the bottom to the top of the cooler. During the stay in the silo, the pellets exchange heat with the incoming cold air and take away the heat and moisture of the material, playing a role in cooling and reducing moisture. After cooling, the moisture content of the pellets is 13%.

The alfalfa feed pellets in the finished product silo are weighed by the automatic bagging machine through the buffer hopper and then packaged by the sewing machine combination unit. The process of finished feed packaging mainly consists of automatic quantitative weighing, bagging and packaging, and conveying and sealing.

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How to build an alfalfa pellet production line in Turkey?

The following aspects need to be considered when building an alfalfa pellet production line in Turkey:

• Market demand and raw material supply:
  First, it is necessary to investigate the market demand in Turkey and determine the type and scale of forage feed pellet production. At the same time, understand the local raw material supply situation and ensure the stable supply of raw materials.
• ‌Production line design‌:
  When designing alfalfa pellet production line in Türkiye, it is necessary to follow the principles of high efficiency, environmental protection, safety and economy.
  High efficiency requires that the production line can achieve high production efficiency, ensure the rapid conversion of raw materials and the stable output of products; environmental protection requires reducing the emission of pollutants and achieving green production; safety requires that the equipment and operation process ensure the safety of operators; economy requires that on the premise of meeting production needs, full consideration be given to cost control to improve the economic benefits of the production line.
• ‌Key equipment and technology‌:
  Choosing suitable equipment and technology is the key to the success of the production line. For example, high-efficiency crushing equipment can quickly refine alfalfa raw materials; cleaning equipment can remove impurities from forage raw materials and improve the purity of the product; granulation equipment can shape the raw materials and increase palatability; automated control systems can monitor and regulate the production process in real time to ensure stability and safety.
• ‌Environmental protection requirements‌:
  Turkey attaches great importance to environmental protection, and the environmental protection performance of the production line must meet the standards. The pelletizer in Turkey’s alfalfa pellet production line meets environmental assessment standards, is green and energy-saving, and has high intelligence. The alfalfa produced is of good color, uniform particle size, full particles, and purity.
• Market prospects:
  With the development of Turkey’s economy and the acceleration of industrialization, the market demand for alfalfa pellets continues to grow, providing a broad market prospect for the production line.

Through the comprehensive consideration and implementation of the above aspects, an alfalfa pellet production line can be successfully established in Türkiye.