Dairy Cow Feed Production Line in Egypt

RICHI MACHINERY

Project Background

Livestock Sector in Egypt

Egypt holds one of the largest dairy cattle populations in North Africa, with millions of smallholder farms and emerging commercial dairies. The dairy sector is a critical part of the Egyptian economy, providing both nutrition security and employment. However, the sector faces structural challenges:

• Low feed conversion efficiency due to poor-quality roughages.
• Dependence on imported feed ingredients such as soybean meal.
• High volatility of international commodity prices.
• Fragmented feed production, with most feed mills being small-scale and outdated.

To address these challenges, the Egyptian government has been encouraging private-sector investment in modern feed processing facilities to support dairy development under its agricultural modernization agenda.

Motivation for the Project

The investor cooperative had long relied on a mixture of imported feed concentrates and small-scale local feed mills, which led to inconsistent feed quality and high costs. Rising dairy herd sizes and increasing demand for high-quality milk products necessitated an integrated feed production solution.

The decision was made to establish a state-of-the-art feed mill capable of producing both complete feed and concentrates, enabling farmers to either use fully formulated rations or blend concentrates with their own forage resources.

RICHI MACHINERY

Investor Profile

The investor is a large dairy cooperative headquartered near Cairo, with operations extending across the fertile Nile Delta. The cooperative manages:

• 30,000+ head of dairy cattle across multiple farms.
• A distribution network supplying milk to processors and retailers.
• Long-term partnerships with maize, wheat, and soybean producers.

The cooperative’s primary objectives for this fully automatic cattle feed plant are:

1. Reduce dependency on imported feed by maximizing the use of local raw materials such as maize, wheat bran, alfalfa, and cottonseed cake.
2. Ensure consistent feed quality with precise formulations designed by animal nutritionists.
3. Lower feed costs per liter of milk produced.
4. Support member farmers with affordable, high-quality feed supplements.
5. Strengthen market competitiveness by supplying surplus feed to surrounding dairy farms.

RICHI MACHINERY

Production Capacity

• Total Annual Capacity: 150,000 tons.
• Complete Feed for Dairy Cows: 125,000 tons.
• Concentrated Supplements: 25,000 tons.
• Daily Output: Approximately 500 tons (assuming 300 working days per year).
• Shift Arrangement: 3 shifts, 8 hours per shift.

The dairy cow feed production line in Egypt is designed with flexibility in mind, enabling the cooperative to adjust production ratios between complete feed and concentrates depending on market demand and raw material availability.

RICHI MACHINERY

Raw Materials

The cattle feed plant project prioritizes the use of locally sourced agricultural by-products and crops to minimize import dependence. Main feed ingredients include:

• Maize (corn) – primary energy source, widely grown in Egypt.
• Soybean meal – key protein ingredient, partially imported but also processed domestically.
• Wheat bran – abundant by-product from Egypt’s flour industry.
• Alfalfa hay – locally cultivated in Upper Egypt, crucial for fiber and protein.
• Cottonseed cake – by-product of Egypt’s cotton industry.
• Molasses – locally available from sugarcane and sugar beet processing.
• Premixes and vitamins – imported but used in small proportions.

By combining these ingredients in carefully formulated rations, the cattle feed production line ensures optimal nutrient balance, enhancing both milk yield and cow health.

RICHI MACHINERY

Process Flow

The plant’s fully automated feed processing line follows these steps:

1. Raw Material Receiving & Cleaning
   • Bulk grains, cakes, and by-products are received in silos or warehouses.
   • Magnetic separators and sieves remove impurities.
2. Crushing (Hammer Mill)
   • Grains such as maize are ground to 1–3 mm particles.
   • Ensures uniform digestibility for dairy cows.
3. Batching & Weighing
   • Ingredients are automatically weighed using computer-controlled batching systems.
   • High precision reduces formulation errors.
4. Mixing (Twin-Shaft Paddle Mixer)
   • Homogeneous blending of ingredients, ensuring CV ≤ 5%.
   • Liquids such as molasses can be added during mixing.
5. Conditioning & Pelleting
   • Steam conditioning improves starch digestibility and pellet durability.
   • Ring-die cattle feed pellet machines compress feed into 6–8 mm pellets, ideal for cows.
6. Cooling & Screening
   • Counterflow cooler reduces pellet temperature.
   • Vibrating screens separate fines and improve product quality.
7. Packaging & Storage
   • Bagging machines pack feed into 25–50 kg bags.
   • Bulk storage silos available for cooperative farms.

RICHI MACHINERY

Major Equipment Configuration

This cattle feed mill equipment configuration balances efficiency, durability, and cost-effectiveness, making it highly suitable for Egypt’s industrial feed production needs.

RICHI MACHINERY

Environmental & Safety Measures

• Dust Control: Pulse jet dust collectors reduce airborne particles.
• Noise Control: Acoustic enclosures for hammer mills.
• Waste Management: No wastewater; minimal solid waste reused as low-value feed.
• Energy Efficiency: High-efficiency motors and automated control systems.
• Worker Safety: Safety interlocks, fire extinguishing systems, PPE protocols.

RICHI MACHINERY

Plant Layout

The layout of this dairy cow feed production line in Egypt was designed for efficiency and safety:

• Raw material warehouse near intake area.
• Grinding & mixing section located centrally.
• Pelleting, cooling, and packaging line arranged in linear flow.
• Finished goods warehouse near loading bays for distribution.
• Administrative & laboratory building attached to the main workshop.

RICHI MACHINERY

Workforce and Management

Total Staff: ~45 people.

Skilled Technicians: 15.

Operators: 20.

Administration & Sales: 10.

Training: Operators trained on feed formulation, equipment handling, and safety.

RICHI MACHINERY

Market Outlook in Egypt

Egypt’s dairy industry is rapidly modernizing, with demand for processed milk products growing domestically and regionally. Key trends include:

• Rising demand for high-quality cattle feed to boost milk yields.
• Government push to reduce imports of feed concentrates.
• Expanding dairy farms and cooperatives, creating stable demand.
• Potential to export surplus feed to neighboring countries like Sudan and Libya.

This project positions the cooperative as a strategic supplier in Egypt’s feed sector, ensuring long-term growth and competitiveness.

RICHI MACHINERY

Conclusion

The 150,000 tons/year dairy cow feed production line in Egypt represents a milestone in the country’s livestock development strategy. By integrating modern equipment, local raw materials, and scientific nutrition, the project ensures:

• Stable, affordable feed supply.
• Improved productivity for dairy farmers.
• Reduced dependence on imports.
• Long-term profitability and sustainability.

This project demonstrates how realistic investment levels and practical technology choices can create a transformative impact on Egypt’s livestock economy, benefiting both the cooperative and the wider farming community.