Compound Feed Mill Expansion in Uzbekistan

RICHI MACHINERY

Expansion Built on an Existing Customer Base

The mill serves agricultural customers from a Jizzakh production base linked to regional grain and byproduct supplies. Increasing preparation capacity helps the business handle ingredient deliveries and organise production batches while retaining its established sales channels.

Commercial feed must provide consistent formulation, safe raw materials and timely dispatch. These requirements determine receiving, testing, storage and packing capacity before an annual sales target is assigned.

Twelve years in feed production gave the customer practical experience with ingredient purchasing, formula changes and customer delivery patterns. The expansion connected that operating experience with additional machinery rather than requiring a separate factory organisation.

The customer’s production cost depends strongly on ingredient selection and batch consistency. Controlled weighing, reliable grinding and orderly changeovers help keep the purchased nutrients in the intended formula and reduce avoidable handling losses.

For an existing commercial mill, expansion value comes from relieving the stages that interrupt production. RICHI connected the new preparation equipment with retained assets so that capital served the material route from intake to dispatch.

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East and West Workshops Within One Feed Site

The 18,020 m² Jizzakh property includes a 2,000 m² east production area and a 570 m² west production area. Existing silos, buildings and services formed the base for the expansion. Keeping the new equipment within this site preserved the customer’s established receiving and dispatch arrangements.

The retained asset schedule includes:

Item	Details
Total land	18,020 m² (about 4.45 acres)
East plant production area	2,000 m²
West plant production area	570 m²
Raw material warehouse (east)	Bagged ingredients and receiving stock
Raw material warehouse (west)	Separated ingredients for the west workshop
Finished product warehouse (east)	Bagged feed staging and dispatch
Finished product warehouse (west)	Product storage serving the west workshop
Corn silos	2 units
Gas boilers	2 units (2 t/h each)
Staff	90 people
Existing annual output	Approximately 100,000 tonnes/year baseline
Operating schedule	Two shifts, 8 hours per shift, 300 days/year

The retained animal feed plant machinery includes steam supply for the pellet route and handling assets serving the existing buildings. Mash production leaves the mixed feed route before pelleting, allowing the mill to use the same ingredient preparation base for different finished forms.

The product routes accommodate the following feed categories:

Product	Form	Production arrangement
Duck feed (pellet)	Pellet	Conditioning and pelleting
Duck feed (mash)	Powder	Mixing and direct packing
Chicken feed (pellet)	Pellet	Conditioning and pelleting
Chicken feed (mash)	Powder	Mixing and direct packing
Pig feed (pellet)	Pellet	Separate formula batches
Pig feed (mash)	Powder	Separate formula batches
Product forms		Mash and pellets

The mill schedules species-specific formulas in separate batches. Ingredient selection, addition rates and changeover routines follow the nutritional requirements of each product. That flexibility is useful in a commercial compound feed production line in Uzbekistan serving more than one farm segment.

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Grain and Byproducts Enter Separate Preparation Routes

Maize provides the main grain stream, with protein meals, wheat bran, minerals, vitamin ingredients and oil entering through their appropriate handling points. Separate preparation and controlled dosing allow each material to reach the mixer in the required condition.

Ingredient handling within the expanded route:

Raw Material	Preparation and use	Form	Source
Corn (maize)	Cleaning, grinding and major-ingredient dosing	Grain (bulk)	Local farms, Syr Darya region
Soybean meal	Protein meal dosing	Powder (bagged)	Imported via Kazakhstan
Cottonseed meal	Controlled species-specific inclusion	Powder (bagged)	Cottonseed oil processors
Wheat bran	Byproduct receiving and dosing	Flaky (bagged)	Local flour mills
Vitamins	Small-quantity addition	Vitamin or premix ingredients	Imported
Minerals	Controlled mineral addition	Feed-grade mineral ingredients	Qualified feed ingredient suppliers
Vegetable oil	Metered liquid addition	Liquid (tank)	Local processor

Incoming ingredients are managed by identity, moisture and nutritional quality. Cottonseed meal requires formula-specific control of free gossypol, while minerals must be suitable for feed use. These acceptance rules protect the value of the batch before it reaches the automated weighing route.

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Equipment Added From Intake to Bagging

The new equipment package connects grain receiving, byproduct preparation, batching, mixing and finished-feed handling. Conveyors, bins, gates and extraction components support the main machines so that material moves through a controlled sequence.

Section	Equipment Added	Quantity
Intake & cleaning	Dust control fan	2 units
	Pulse bag filter	2 units
	Receiving pit screen	1 unit
	Drag chain conveyor	1 unit
	Bucket elevator	2 units
	Rotary pre-cleaner	1 unit
	Magnetic drum	1 unit
	Electric gate valve	5 units
Grinding	Discharge conveyor	1 unit
	Bucket elevator	1 unit
	Permanent magnet	1 unit
	Level sensor	4 units
	Grinding bin	1 unit
	Screw feeder	1 unit
	Hammer mill feed grinder	1 unit
	Suction hood	1 unit
	Bucket elevator	1 unit
	Air distributor	1 unit
	Dust fan (3.6A)	1 unit
	Pulse filter (21 bags)	1 unit
Byproduct handling	Receiving pit	1 unit
	Screw conveyor	1 unit
	Bucket elevator	1 unit
	Air distributor	1 unit
	Rotary pre-cleaner	1 unit
	Air distributor	1 unit
	Permanent magnet	1 unit
	Grinding bin	1 unit
	Screw feeder	1 unit
	Hammer mill (56×40)	1 unit
	Suction hood	1 unit
	Bucket elevator	1 unit
	Air distributor (8-way)	1 unit
Dust collection (byproduct line)	Cyclone	3 units
	Airlock	3 units
	Dust fan (4A)	1 unit
	Combined pulse filter (28 bags)	1 unit
Batching & mixing	Level sensor	9 units
	Batching bins (1×1.5x4m)	12 units
	Screw feeder (LSS.25)	5 units
	Screw feeder (LSS.20)	7 units
	Batch scale (1,000 kg)	1 unit
	Pneumatic discharge gate	1 unit
	Dust fan (2.8A)	1 unit
	Pulse filter (15 bags)	1 unit
	Additive hopper	1 unit
	Batch mixer	1 unit
	Oil spray system	1 unit
Post-mixing	Surge bin	1 unit
	Screw conveyor (LSS.25)	1 unit
	Bucket elevator	1 unit
	Vibrating screen (powder)	1 unit
	Screw conveyor (LSS.25)	1 unit
	Air diverter (3-way)	1 unit
	Screw conveyor (LSS.25)	1 unit
Packaging	Level sensor	2 units
	Finished product bin	1 unit
	Bagging scale (50 kg)	1 unit
	Dust fan (2.8A)	1 unit
	Pulse filter (15 bags)	1 unit
Scope		Integrated preparation and handling equipment

Grinding sits between cleaned grain storage and the batching bins. Controlled feeder speed, screen selection and aspiration determine the prepared meal supplied to the mixer. The separate byproduct route keeps material already suited to dosing from unnecessarily passing through the grain grinder.

Local work included boiler additions and steam piping for the production site. Steam distribution follows the pellet route, while mash feed bypasses conditioning and pelleting. This keeps thermal services connected to the products that use them.

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Equipment Arranged Around the East Workshop

The main additions occupy the east production area, with conveyors and elevators connecting preparation, batching and post-mixing handling. Platform access and machine clearance preserve room for screen changes, lubrication and cleaning within the building.

The working zones are arranged as follows:

East production area: 2,000 m².

• North side (600 m²): New intake pit and pre-cleaning. Corn and wheat arrive by truck, dump into the pit, get cleaned, then go to the existing silos or the new grinding bins.
• Central 800 m²: grinding, batching and operating access.
• South 600 m²: mixing, packing and transfer towards finished-stock handling.

West production area: 570 m².

• Separate production tasks and product batches within the retained workshop.

Ingredient storage and replenishment:

• Bagged materials, additives and stock aisles organised around the receiving and batching routes.

Connections between the buildings carry material without repeated manual unloading. Accessible supports and transfer points allow the maintenance team to inspect drives and clean out residual feed during product changes.

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Controlled Weighing Links Preparation to Finished Feed

The expanded poultry feed production line in Uzbekistan brings receiving, ingredient preparation, batching and dispatch into one coordinated route. Each material reaches the mixer through a controlled addition point.

Grain Intake
Receiving screens and magnetic protection remove foreign matter before grain moves towards storage and grinding. Conveyors and elevators transfer the cleaned material to the next stage.

Dust extraction at receiving keeps displaced air and fines out of the operator’s working area. Accessible hoods and filters support cleaning between deliveries.

Grain Grinding
The feeder controls the load entering the hammer mill. Screen selection follows the feed formula and target particle distribution, with aspiration carrying prepared meal towards the next handling stage.

Byproduct Preparation: A separate route handles meals and bran. Materials needing further size reduction pass through the byproduct grinder; suitable powders move to dosing with their ingredient identity preserved.

Batch Weighing
Twelve bins, controlled screw feeders and a batch scale supply the principal dry ingredients. The additive hopper provides a separate point for small inclusions, keeping recipe changes traceable.

Coordinating bin discharge, weighing and mixer availability reduces interruptions between batches. The operator follows the complete cycle, including filling and discharge, so the next weighed batch is ready when the mixer clears.

Mixing
The mixer distributes the weighed ingredients through a controlled batch. Mixing time and working fill follow the recipe, while accessible discharge and cleanout support changeovers between products.

The oil system adds liquid according to the selected formula. Controlled addition and suitable spraying help distribute the oil through the dry ingredients without creating concentrated wet patches.

Mash Feed Handling
Mixed feed passes through screening and finished-product handling before packing or bulk dispatch. The route serves formulas sold in mash form while preserving the same weighing and mixing controls.

Pellet Feed Handling
The retained ring die feed pellet machine route receives conditioned mixed feed. Steam prepares the mash for pressing, followed by cooling and screening to produce stable pellets for storage and delivery.

Steam use follows the quantity sent to pelleting and the formula’s conditioning requirements. Insulated piping and controlled supply help keep conditions steady at the press feed.

Pellet Cooling
Controlled airflow lowers product temperature before storage. Operators follow the bed condition and discharge temperature as the recipe and production rate change.

Screening: The screen separates saleable product from oversize material and fines. Compatible rework returns in controlled quantities, preserving formula identity and product consistency.

Packing
The 50 kg bagging station weighs and fills product for distribution. Sealing, stacking and finished-stock movement are organised around dispatch, keeping bags clear of the material receiving route.

Surge storage connects continuous processing with intermittent vehicle loading. This gives the team flexibility to prepare feed batches while trucks are being positioned or loaded.

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Site Services for Feed Processing and Staff Facilities

The animal feed processing plant operates two eight-hour shifts over 300 days. Electrical services support the machines and handling routes, while water serves steam generation, staff facilities and laboratory work. The daily water allocation is shown below.

Utility	Daily allocation	Annual (300 days)	Notes
Fresh water	26.2 m³	7,860 m³	Combined site water allowance
– Boiler makeup	16 m³/day	4,800 m³	Steam retained in feed is not returned condensate
– Staff (90 people)	9 m³/day	2,700 m³	Toilets, showers, canteen
– Lab	0.2 m³/day	60 m³	Glassware washing
– Landscape	1 m³/day	300 m³	Landscape maintenance
Electricity	Production motors and handling equipment	Consumption follows running hours	Grinding, conveying, mixing and packing
Natural gas	Steam generation	Consumption follows pellet production	Boilers and steam distribution

The shift plan coordinates new preparation equipment with the retained mill. The operating team schedules formula changes, cleaning and maintenance around customer dispatch, with mash and pellet batches using the services needed by their respective routes.

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Keep Feed Safety Separate From Dust Recovery

Collection equipment serves dusty handling points across the expansion. Feed safety also depends on keeping incoming contaminants separate from clean product and managing drainage around staff and service areas.

We installed:

• Bag filters at identified receiving, preparation, bin venting, mixing and packing points.
• Cyclones where appropriate ahead of final filtration, with guarded and sealed dust discharge.
• Combustion controls serving the boiler installation.
• Domestic and boiler wastewater handled through locally approved routes with relevant treatment.

Intake dust may contain mould, soil and rejected material. It must not automatically be returned as feed filler. Rework acceptance requires composition and hygiene controls.

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Commissioning Connected the Added and Retained Equipment

Commissioning followed material through receiving, preparation, weighing, mixing and packing. The work addressed the interfaces where a new route joined existing machinery and where changes in feed formula affected handling.

Electrical operation
motors, protective devices and start sequencing were coordinated with the process sections.

Elevator operation
belt alignment, take-up and discharge condition supported reliable material transfer.

Liquid addition
the oil system was set around formula quantities and distribution through the batch.

Bagging accuracy
weight checks and filling adjustment connected the packing station with the required 50 kg product format.

The operator’s routine combines batch weights, machine loading and finished-product checks. This keeps the effect of a process adjustment visible through to the feed leaving the mill.

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Training the Retained Team for the New Route

Ninety staff support the wider site across production, maintenance, quality, warehousing and administration. Training for the added equipment concentrated on the people using and servicing each section.

• Mill operators (4 people): How to adjust the new hammer mill (screen changes, hammer replacement, bearing lubrication). How to set the feed rate using the screw feeder speed control.
• Batch operators: recipe selection, weighing controls, alarms and changeover procedures.
• Maintenance: safe isolation, lubrication, condition checks and electrical protection awareness.
• Quality staff: material moisture, particle preparation and pellet quality checks.

Practical instruction at the equipment linked recipe control with the material route. Operators learned how feeding, screen condition and batch timing affect downstream production.

The retained team’s experience helped connect the new controls and maintenance routines with day-to-day mill operation.

RICHI MACHINERY

Machinery Delivery to the Jizzakh Site

The equipment shipment travelled through Bandar Abbas and onward to Jizzakh. The transport arrangement connected the sea leg with inland delivery for installation at the existing feed site.

Equipment unloading and placement followed the installation sequence so that the customer could keep working areas accessible during the expansion.

Six 20-foot containers and two 40-foot flat racks carried the machinery. The mix of enclosed and flat-rack transport accommodated components with different packing dimensions.

The project budget separated sea freight, inland transport and customs expenditure. That gives a buyer a clearer view of the delivered equipment cost alongside the local installation work.

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Capital Directed Towards the Added Production Route

The expansion expenditure remained separate from the retained feed preparation plant assets. The project cost schedule covers machinery, transport and local works:

Item	Cost (USD)	Notes
Equipment (FOB Qingdao)	$520,000	Preparation and handling package
Sea freight + insurance (Qingdao → Bandar Abbas)	$32,000	8 containers
Overland transport (Bandar Abbas → Jizzakh)	$18,000	Inland delivery
Customs budget	$26,000	Import-related allowance
Local civil works (platforms, pits, conveyor bridge)	$65,000	Concrete, steel, labor
Electrical installation	$45,000	Panels, wiring and site connections
Boiler addition (2 units, 2 t/h each)	$60,000	Locally sourced
Steam piping + insulation	$22,000	Boilers to pellet mills
Installation supervision (our team, 25 days)	$35,000	Flights, hotel, per diem (2 engineers)
Operator training	Included in supervision	Equipment operation and handover
Contingency reserve	$35,000	Budget provision for additional local work
Fixed-work cost schedule	US$923,000 including customs allowance	Excludes the US$35,000 contingency reserve

Equipment accounts for US$520,000 of the expansion. Freight, local civil and electrical work, boiler additions, steam piping and supervision make up the other cost categories. The fixed-work schedule totals US$923,000 including the customs allowance; the US$35,000 reserve remains separate. This places capital against the added route while preserving the value of buildings and machines already in use.

RICHI MACHINERY

Expansion Options Follow the Next Bottleneck

For a customer planning another stage of growth, RICHI begins with the operations that limit dispatch:

• Receiving and storage capacity during concentrated grain deliveries.
• Grinder loading and the supply of prepared ingredients to batching.
• Complete batch cycles, mixer occupancy and finished-feed handling.

A higher factory output depends on the full route. Adding a press or grinder is most useful when the connected weighing, mixing and dispatch equipment can absorb the additional material. RICHI can compare those interfaces before specifying the next purchase.

RICHI MACHINERY

Feed Products Matched to Regional Farm Customers

The Jizzakh business builds its product range around the farms and distributors it serves. Ingredient availability and formula requirements guide the choice between mash and pellets for each customer segment.

Maize, wheat byproducts and protein meals provide the main purchasing base, with separate quality controls for different supplier lots.

An established site team supports production, warehousing and customer deliveries across the two-shift operation.

The complete feed mill plant accommodates separate poultry and livestock formulas, with batch control and changeover routines supporting a varied order book.

Bagging and bulk handling can be matched to customer storage and delivery equipment.

The commercial priority is consistent feed delivered on schedule from a production route that uses the existing site effectively.

RICHI MACHINERY

Plan an Expansion Around Your Operating Mill

For a compound feed mill expansion in Uzbekistan, supply the actual current output, accepted product mix and hourly records at each stage.

Describe the equipment that already works well and the stages that interrupt output.

Include a surveyed site plan, equipment nameplates and the batch and mixer working-volume records.

Provide grid capacity, measured demand, boiler steam use and water balance.

List installation windows and the production that must continue while new equipment is connected.

RICHI can stage installation around your production windows and set out the new machinery, connection work and operator training required for the expansion.

RICHI can assess the feed mill factory expansion from intake through dispatch and identify which bottlenecks require new machinery.

The proposal can show the added processing functions, expected production schedule and separate machinery and local-work costs.