Animal Feed Plant In South Africa

RICHI MACHINERY

overview

After the technical transformation is completed, a microcomputer batching animal feed plant in South Africa with an annual output of 60,000 tons will be built, and production and auxiliary equipment such as hammer mills, bucket elevators, screw conveyors, feed hoppers, batching bins, buffer bins, finished product bins, quantitative packaging scales, and pulse dust collectors will be purchased.

The customer originally processed chicken feed and pig feed, and this animal feed mill plant technical transformation project will be used to process ruminant feed, that is, cattle, sheep, and horse feed.

RICHI MACHINERY

Overview of existing projects

The product plan of the existing animal feed plant in South Africa project is to produce 12,000 tons of chicken feed and 12,000 tons of pig feed annually. Next, let’s first introduce the customer’s existing feed plant.

Occupancy area	5000m2
Main products	Chicken feed, pig feed
Production scale	Annual processing of 24,000 tons of livestock and poultry feed
Number of employees	24 people
Main project	One ​​production workshop, with a construction area of ​​1000m2, and one feed production line
Auxiliary Engineering	Raw Material Warehouse	2, building area 1530m2, used to store raw materials
	Finished Product Warehouse	1, building area 260m2, used to store finished feed
	Office	1, building area 500m2, two floors
	Grain Warehouse	1, building area 70m2, used to store corn kernels
		1 computer room, with a construction area of ​​45m2, used for feed ingredient automatic control system
		1 boiler room, with a construction area of ​​30m2, used for production and heating
		1 weighing room, with a construction area of ​​90m2, used for weighing purchased raw materials and sold feed
		1 small material warehouse, with a construction area of 135m2, used for storing small materials

The main animal feed processing machines of the existing animal feed plant in South Africa project is shown in the table below.

No.	Equipment Name	Model	QTY
1	Pulse Pulse Dust Collector	TBLMb-6	1
2	Pulse Pulse Dust Collector	TBLMb-4	2
3	Main material auger	LSS.20	1
4	Auxiliary material auger	LSS.16	1
5	Main material crusher	FSP60×36	1
6	Auxiliary material crusher	FSP56×30	1
7	Elevator	TDG36/23	2
8	Batching auger	LSS.16	1
9	Finished product auger	LSS.20	1
10	Premixer	——	1
11	Dual-shaft paddle mixer	SJHJ1	1
12	Crusher	FSP80×80	1
13	ring die feed pellet machine	TYPE	1
14	Cooling fan	4-72N04A	1
15	Grading screen	SFJH130×2	1
16	Ingredients bin	——	18
17	Finished product warehouse	——	1
18	Electronic batching scale	FSDPD.500	1
19	Automatic packaging scale	LCS50A	2
20	Computer control system	——	1
21	Alcohol-based fuel boiler	WNS0.5-0.7-YO	1
22	Alcohol-based fuel storage tank	2m3	2
23	Vegetable oil storage tank	10m3	2

The consumption of main raw and auxiliary materials for existing animal feed plant in South Africa project is shown in the table below.

No.	Name	Consumption	Remarks
1	Corn	13714.3t/a	Stored in the raw material warehouse
2	Bran	1142.9t/a	Stored in the raw material warehouse
3	Soybean meal	3428.6t/a	Stored in the raw material warehouse
4	Corn germ meal	1142.9t/a	Stored in the raw material warehouse
5	Calcium stone powder	274.3t/a	Stored in the raw material warehouse
6		Peanut cake	Stored in the raw material warehouse
7		Vitamins	Stored in the raw material warehouse
8		Salt	Stored in the raw material warehouse
9		Trace elements	Stored in the raw material warehouse
10		Vegetable oil	Stored in oil tank
11		Feed bag Bags	Stored in the raw material warehouse
12	Fresh water	1638m3/a	Provided by the local water supply network
13	Electricity	100,000 kWh/a	Provided by the local power supply station
14	Alcohol-based fuel	40t/a	Provided locally

① Power supply

The electricity for the existing animal feed plant in South Africa project is provided by the local power supply station. A 200KVA transformer is built in the plant area, with an annual power consumption of 100,000 kW·h, which can meet the power demand for production and living of the project.

② Steam supply

The heat for production of the existing project is provided by a 0.5t/h boiler built in the plant area, which works 300 days a year and uses alcohol-based fuel.

The plant area of the animal feed plant in South Africa project is a rectangular site that is long from east to west and wide from north to south, covering an area of 5,000m2 and a construction area of 3,660m2.

The main buildings in the plant area are distributed as follows:

• the plant gate is located in the middle of the west side, the office area is on the north side of the gate, the weighing room is on the south side of the gate, and the carport is adjacent to the south side of the plant building;
• the production workshop is directly opposite the gate to the east, the granary is on the north side of the production workshop, the finished product warehouse is on the south side, and the boiler room is adjacent to the northwest side of the workshop;
• the raw material warehouse is on the east side of the production workshop, and the raw material warehouse is on the easternmost side of the plant area.

The main process flow of the existing animal feed plant in South Africa project is briefly described as follows:

1) Raw material reception: After the raw materials arrive at the factory, the warehouse department notifies the quality control personnel to conduct sensory inspection. The raw materials can be unloaded only after they pass the inspection. The quality control personnel take samples and send them to the laboratory. The laboratory conducts physical and chemical inspections and then notifies the procurement department and the warehouse department of the inspection results. If the physical and chemical indicators are qualified, they will be hung with identification tags for standby use. If they are unqualified, they will be directly returned.

2) Feeding: After receiving the feeding task from the central control room, confirm the raw material stack to be used, and then start feeding. During the feeding process, if the raw materials are found to be lumpy and moldy, they should be picked out in time and notified to the relevant personnel. After one raw material is fed, clean the screen and the area around the feeding port.

3) Crushing: After the raw materials in the powder bin enter the crusher, select the screen according to the processing requirements, check the wear of the hammer and screen every day, and replace them in time if problems are found to ensure uniform crushing particle size. After crushing, they enter the batching bin through the elevator. The feed port of the crusher is connected to the feeding pit, that is, the feed port of the crusher is the feeding port.

4) Batching: The raw materials in each batching bin are fed to the batching scale by the feeder under each batching bin controlled by the computer automatic batching control system, and each raw material is weighed by the batching scale. The dosage of each raw material is controlled by the batching scale control system according to the production formula. After the batching is completed, the batching scale hopper discharge door opens, and the batch of materials is discharged into the mixer. The batching scale discharge door is closed, and the batching scale can weigh and batch the next batch of materials. Each batch of materials is 2t.

5) Mixing: The material falls into the mixer and sends a small material addition prompt signal. The small material worker introduces the pre-mixed small material into the mixer and then starts timing. The mixing time is 120s. While mixing, grease is added to the mixer through the grease system as needed to increase the energy of the feed. The mixed powder will be sent to the animal feed granulator.

6) Granulation: In the granulation chamber, the powder is squeezed into the designed cylindrical particles by the high-speed rotating ring die and pressure roller.

7) Cooling: The pellets pressed by the animal feed pellet mill have high temperature and humidity, and need to enter the cooler for cooling and dehydration. There is a continuous reverse natural wind blowing through the feed in the cooler, reducing the feed temperature to about 5°C different from the room temperature and the moisture content below 14%.

8) Screening: Since it is difficult for the animal feed pellet making machine to press all the powder into shape, the material must be graded with a grading screen after cooling. The upper layer is to screen out the agglomerated materials formed during the pelletizing process and collect them into the waste pipe for manual removal and enter the crushing process as recycled materials; the middle layer is the standard granular finished material, which is collected in the silo and waits for packaging; the lower layer is powder, crushed material or semi-granules, which are directly sent to the pellet mill through the chute for re-granulation.

9) Packaging: The finished product is weighed, bagged and sealed by an automatic packaging scale, and a double-line sewing bagging machine is used to effectively avoid the occurrence of opening. The bagging specifications can be changed by adjusting the packaging scale.

RICHI MACHINERY

Overview of the technical transformation project

The following is an introduction to the technical upgrading and transformation project of the 60,000-ton microcomputer-blended animal feed plant in South Africa in which RICHI participated. The technical transformation project added 10 new laborers, working in the day shift system, 8 hours a day, and 300 working days per year.

After the completion of the animal feed plant in South Africa technical transformation project, the annual processing and production of ruminant feed will be 60,000 tons.

No.	Product	Output (10,000 t/a)
1	Ruminant feed	6

This animal feed plant in South Africa technical transformation project uses the company’s existing factory buildings, purchases 24 sets of production and auxiliary equipment such as hammer mills, bucket elevators, screw conveyors, feed hoppers, batching bins, buffer bins, finished product bins, quantitative packaging scales, and pulse dust collectors, and builds a 60,000-ton microcomputer batching feed production line without increasing land occupation.

This technical transformation project is located in the existing production workshop of the factory area, which can make full use of public engineering facilities such as water and electricity, and the overall layout has reasonable functional zoning.

Project composition		Construction content	Remarks
Main project	Production workshop	1, steel structure, building area 1000m2, one original livestock and poultry feed production line, and one new annual production line of 60,000 tons of microcomputer-mixed feed on the original basis;	Reuse of old equipment
Auxiliary Engineering	Raw Material Warehouse	2, building area 1530m2, used to store raw materials	Reuse
	Finished Product Warehouse	1, building area 260m2, used to store finished feed	Reuse
	Office	1, building area 500m2, two floors	Reuse
	Grain Warehouse	1, building area 70m2, used to store corn kernels	Reuse
		1 computer room, with a construction area of ​​45m2, used for automatic control system of feed ingredients	reuse
		1 boiler room, with a construction area of ​​30m2, used for production and heating	reuse
		1 weighing room, with a construction area of ​​90m2, used for weighing purchased raw materials and sold feed	reuse
		1 small material warehouse, with a construction area of ​​135m2, used for storing small materials	reuse

The consumption of raw and auxiliary materials and energy for this new animal feed plant in South Africa project is shown in the following table:

No.	Raw Materials	Consumption	Remarks
1	Corn	37636.1t/a	Purchased from outside, stored in the raw material warehouse
2	Soybean Meal	7525t/a	Purchased from outside, stored in the raw material warehouse
3	Cottonseed Meal	6841t/a	Purchased from outside, stored in the raw material warehouse
4	Rapeseed meal	3421t/a	Purchased from outside, stored in the raw material warehouse
5	DDGS	3421t/a	Purchased from outside, stored in the raw material warehouse
6	Calcium hydrogen phosphate	1026t/a	Purchased from outside, stored in the raw material warehouse
7	Trace elements	20.5t/a	Purchased from outside, stored in the raw material warehouse
8	Vitamins	3.4t/a	Purchased from outside, stored in the raw material warehouse
9	Methionine	37.6t/a	Purchased from outside, stored In the raw material warehouse
10	Lysine	68.4t/a	Purchased from outside and stored in the raw material warehouse
11	Fresh water	120m3/a	Provided by the local water supply network
12	Electricity	200,000 kWh/a	Provided by the local power supply station

The main ruminant feed production equipment newly added to this animal feed plant in South Africa project is as follows:

No.	Equipment Name	Specification Model	QTY	Remarks
1	Pulse Dust Collector	TBLMY18	2	Newly Added
2	Pulse Dust Collector	TBLMY24	1	Newly Added
3	Pulse Dust Collector	TB LMY6	2	New
4	Feed hopper and screen	1.2*0.8	1	New
5	Screw conveyor	–	1	New
6	Hammer mill	FSP60*50	1	New
7	Bucket elevator	DTG36/23	4	Newly added
8	Batching bin	3m3	4	Newly added, including batcher
9	Batching bin	4m3	4	Newly added, including batcher
10	Buffer bin	1m3	1	Newly added
11	Single-shaft ribbon mixer	HJJ100	1	Newly added
12	Finished product warehouse	2m3	1	Newly added
13	Quantitative packaging scale	Auger with bucket	1	Newly added
Total			24

After the technical transformation, the production process flow of the animal feed plant in South Africa project is analyzed as follows:

1. Raw material reception

After the raw materials arrive at the factory, the storage department notifies the quality control personnel to conduct sensory inspection, and the raw materials can be unloaded only after the inspection is qualified. The quality control personnel take samples and send them to the laboratory. The laboratory technician conducts physical and chemical inspections according to the standards, and then informs the purchasing department and the storage department of the inspection results. Strengthen the indicators and hang the identification plate for standby use, and directly return the unqualified products.

2. Feeding

After receiving the feeding task from the central control room, confirm the raw material stack used, and then start manual feeding. During the feeding process, if the raw materials are found to be agglomerated and moldy, they should be picked out in time and notified to the relevant personnel. After one raw material is put into the machine, clean the screen and the feeding port.

3. Crushing

After the raw materials enter the crusher, select the screen according to the processing requirements, check the wear of the hammer and screen every day, and replace them in time if problems are found to ensure uniform crushing particle size. After crushing, they enter the batching bin through the elevator. The feed port of the crusher is connected to the feeding pit, that is, the feed port of the crusher is the feeding port.

4. Batching

The raw materials in each batching bin are fed to the batcher by the feeder under each batching bin controlled by the computer automatic batching control system, and each raw material is weighed by the batching scale. The dosage of each raw material is controlled by the batching scale control system according to the production formula. After the batching is completed, the batching scale hopper discharge door opens, and the batch of materials is discharged into the mixer. The batching scale discharge door closes, and the batching scale can weigh and batch the next batch of materials.

5. Feed mixing

The material falls into the mixer and sends a small material addition prompt signal. The small material worker introduces the pre-mixed small material into the mixer and starts timing. When the mixing time is up, the mixing is completed.

6. Packaging

The products are weighed, bagged, and sealed, all with double-seam packaging to effectively avoid the mouth-testing phenomenon. The bagging specifications can be adjusted and changed as needed.

In addition to this animal feed plant in South Africa project, we have built many pellet production line projects in South Africa, such as alfalfa pellet production line, animal feed production line, straw pellet plant, wood pellet production line, organic fertilizer production line, etc. If you also want to invest in a pellet production line project, please feel free to contact RICHI MACHINERY to obtain information such as full plant design, equipment layout, civil engineering, production line 3D design, equipment quotation, delivery plan, etc.