Dairy Cow Food Factory In USA

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overview

The main product processed by this project is ruminant feed. Ruminant feed is feed suitable for feeding ruminants (cattle, sheep, etc.). Ruminant feed is characterized by adding specific ingredients to the microbial environment in the rumen of ruminants, which can change and improve the microbial environment in the rumen of ruminants, so as to achieve the purpose of efficient use of feed and promote animal growth.

The dairy cow food factory in USA project was invested and constructed in September 2023, with an annual output of 120,000 tons of dairy cow ruminant feed. The project purchased 66,000 square meters of industrial land and built 15,155 square meters of new production workshops, raw material warehouses, finished product warehouses, office buildings and auxiliary facilities.

The main products of this project are two categories: dairy cow concentrate and dairy cow concentrate, including powder, granular, molasses powder and bulk finished products. The project production line produces about 40 tons per hour, which mainly includes 1 automatic bagging and packaging conveyor line and 1 420 high-end granulation production line with automatic control function.

In addition, the production line is also equipped with supporting equipment and facilities such as automatic batching of small materials, online premixing, molasses addition, barcode recognition, automatic stacking, bulk meal silo, hydraulic flap, finished product bulk production line, and finished product automatic destacking.

The fully automatic cattle feed plant project was put into production in December 2024, and after it was put into production, it will produce 120,000 tons of dairy cow ruminant feed annually. The project has a fixed staff of 38 people, working 300 days a year, and implementing a one-shift work system of 10 hours per shift.

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Products and production scale

The product plan of this large scale dairy cow food factory in USA project is shown in the table below:

No.	Product	Output
1	Finished bagged ruminant meal 35%	36000t/a
2	Bulk finished ruminant meal 60%	78000t/a
3	Bagged ruminant pellets 5%	6000t/a
4	Total	120000t/a

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Main construction contents

The main construction contents of this dairy cow food factory in USA project are shown in the following table:

Category	Construction Content	Composition and Scale
Main Engineering	Feed Workshop	Ruminant feed production line, with a construction area of ​​4371㎡, mainly arranged with production processes: receiving, crushing, impurity removal, batching, conditioning, granulation, cooling, grading, crushing and packaging.
		Production Equipment: Elevator, granulator, primary cleaning screen, crusher, crusher, mixer, baler and various fans.
Storage and Transportation Engineering	Raw Material Warehouse	1 building, 1F, with a construction area of ​​2129m2, mainly used for storage of raw and auxiliary materials.
	Unloading shed	1 building, 1F, with a construction area of ​​135m2, mainly used for raw material unloading.
	Finished product workshop	1 building, 1F, with a construction area of ​​867m2, mainly used for product storage.
	Silos	Occupy an area of ​​422㎡. It includes 800T×2 corn silos, 250T×8 silos, and 100T×2 bulk silos, including 3 silos for soybean meal and cottonseed meal, 2 silos for DDGS (alcohol protein feed), and 1 silo for stone powder and 100 tons of calcium hydrogen phosphate.
	Standby warehouses	3 silos, with areas of 1040m2, 504m2, and 652m2 respectively.
Office and living facilities	Comprehensive building	1 building, 2F, with a construction area of ​​3390m2, mainly used for office.
	Restaurant and canteen	1 building, 1F, with a construction area of ​​290m2, mainly used for employees’ meals.
Auxiliary Engineering	Gate room, fire control room and smoking room	1 building, 1F, with a construction area of ​​40m2.
	Parts warehouse, machine repair workshop	1 building, 1F, with a construction area of ​​271m2, used for machine repair and machine repair parts storage.
	Weighing room, billing room, driver’s lounge and laboratory	1 building, 1F, with a construction area of ​​468m2, used for raw material weighing, driver rest and product quality control.
Public Engineering	Water supply	Supplied by the local municipal water supply network
	Drainage	The wastewater generated by this project is mainly domestic sewage, softening water equipment drainage and boiler drainage.
	Power supply	Provided by the local power supply network, a distribution room is set up in the factory area. Equipped with 800kw*2 transformers.
	Heating	The winter heating and steam production of this project are provided by a 2t/h gas steam boiler.
	Gas supply	The natural gas of this project is connected to the nearby natural gas pipeline network.
	Boiler room	1 building, 1F, with a construction area of ​​192m2, used to provide steam and heating.

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Equipment list for 40 t/h dairy cow food factory in USA

The main cattle feed mill equipment of this dairy cow food factory in USA project is shown in the table below.

Number	Equipment name	Specification, model	QTY
Raw material receiving system
1	Bucket elevator (self-cleaning)	T500	3
2	Permanent magnetic cylinder	TCXT30	3
3	Pellet feeding hopper and fence	2500mm×2500mm	1
4	Cone powder screen	SCQZ90×80×110	1
Crushing system
5	Crushing bin	——	6
6	Upper level device	——	6
7	Lower level device	——	6
8	Buffer bucket	1
9	Impeller feeder	TWLY25	2
10	Pulverizer	SWFP66×80	2
11	Material sealing screw conveyor	TLSGF32	2
Batching and mixing system
12	Batching bin group	——	24
13	Upper level device	——	24
14	Lower level device	——	24
15	Dual-shaft paddle mixer	SLHS7 (7 cubic meters)	1
16	Paddle-type molasses mixer	STHJ50×275_B_B	1
17	Special mixer for premix	SYHJ1	1
18	Pulverizer	SFSP56*40	1
19	Energy-saving elevator (self-cleaning)	T600	1
Pellet system
20	Cattle feed pellet machine	SZLH420×140	1
21	Cooling fan	4-72-6C	1
22	Pellet crumbler	SSLG24×110	1
23	Pelletizing bin	——	2
24	Double-layer extended jacket modulator	——	1
25	Positioning device	——	2
26	Downloader	——	2
27	Steam system	——	1
28	Bucket elevator (self-cleaning)	——	1
29	Rotary grading screen	——	1
Finished product packaging system
30	Finished product warehouse (powder)	——	8
31	Finished product warehouse (pellets)	——	2
32	Loading positioner	——	12
33	Unloading positioner	——	12
34	Fixed bag sewing machine unit	GA2 _GK35-6A _GP4900	2
35	Bag Sewing Conveyor		2
Other Auxiliary Facilities System
35	Pulse Dust Collector	——	Configuration on Demand
36	Gas Boiler	2t/h	1
37	Air Compressor	——	2

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Main raw and auxiliary materials

The main raw and auxiliary materials consumption of this dairy cow food factory in USA project are as follows:

No.	Raw and auxiliary material name	Amount	Packaging
1	Corn	45000t/a	Bulk
2	Soybean meal 43%	23000t/a	Bagged
3	Cottonseed meal	11340t/a	Bagged
4	DDGS	1990t/ a	Bag
5	High-fat DDGS	5520t/a	Bag
6	Sprayed corn husk	10800t/a	Bag
7	Corn gluten powder	609.84t/a	Bag
8	Corn husk	516t/a	Bag
9	Corn germ meal	1164t/a	Bagged
10	Fermented soybean meal	480t/a	Bagged
11	Puffed soybean powder	432t/a	Bagged
12	Bran	8640t/a	Bagged
13	Stone powder	1920t/a	Bags
14	Sodium bicarbonate	1440t/a	Bags
15	Calcium hydrogen phosphate	720t/a	Bags
16	Sodium chloride	1020t/a	Bags
17	Slow-release protein	312t/a	Bags
18	wheat middlings	1416t/a	Bags
19	Magnesium oxide	456t/a	Bags
20	Fat powder	420t/a	Bags
21	Palm meal	1656t/a	Bags
22	Milk powder	7.68t/a	Bag
23	Magnesium sulfate	20.04t/a	Bag
24	Ammonium chloride	7.32t/a	Bag
25	Antioxidant	18.12t/a	Bag
26	Tumor Gold	552t/a	Bagged
27	Rapeseed Meal	132t/a	Bagged
28	0.2% Lactation Premix	168t/a	Bagged
29	0.2% Growing Premix	30t/a	Bagged
30	1% Dry period compound premix-210	42t/a	Bagged
31	1% Perinatal compound premix-211	6t/a	Bagged
32	1% Calf premix	165t/a	Bagged

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Public facilities

There is no central heating facility in the area where this dairy cow food factory in USA project is located. The winter heating and steam production of this project are provided by a 2t/h gas steam boiler.

Water supply

The water supply of this cattle feed production line project is supplied by the tap water network, with a total water consumption of 14541m3/a. The project water mainly includes domestic water and water inlet of soft water equipment.

• Domestic water: The domestic water quota is calculated at 100L/person·d.
• Soft water equipment loss and gas boiler water replenishment: The water used by the boiler is softened water, which is mainly the water loss of steam used in the production process and the water loss of boiler equipment. According to the boiler parameters, the steam loss of a 2T steam boiler is 2.4m3/h, which means 24m3 is lost every day; the boiler displacement is calculated as 5% of the maximum gas production, and the maximum circulating steam production of a 2t/h boiler is 20m3/d, so the boiler displacement is 1m3/d, and the boiler drainage replenishment is 1m3/d; in summary, the boiler replenishment is 25m3/d, and the replenishment is provided by the water output of the soft water equipment. The soft water preparation rate of the soft water preparation facility is 60%, so the fresh water usage is 41.67m3/d, 12501m3/a.

Drainage

The drainage of the dairy cow food factory in USA project mainly includes domestic sewage, drainage of soft water equipment and boiler drainage.

1. Domestic sewage: The generation of domestic sewage generally accounts for 80% of its water consumption. The domestic sewage discharge of the project is 1632m3/a. After being treated in the septic tank in the factory area, it is cleaned and used as agricultural fertilizer by a dedicated person.
2. Soft water equipment drainage: The soft water equipment has a preparation efficiency of 1 ton of tap water, which can prepare 0.6 tons of softened water. The water intake of the soft water equipment is 41.67m3/d, so the soft water equipment discharges concentrated water of 16.67m3/d, 5001m3/a, which is mainly used for sprinkling water on the ground in the factory area to suppress dust;
3. Boiler drainage: The boiler drainage is calculated as 5% of the maximum gas production. The maximum production of circulating steam of a 2t/h boiler is 20m3/d, so the boiler drainage is 1m3/d, and the boiler drainage replenishment is 1m3/d, 300m3/a.

The electricity for this project is provided by the local municipal power supply network, and a distribution room is set up in the factory area. Equipped with 800kw*2 transformers, the project power consumption is about: 400,000 kW·h/a.

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Process design for 40 t/h dairy cow food factory in USA

Based on the customer’s product type, raw materials and factory conditions, the process designed by the RICHI engineering team for this project is as follows:

① Corn reception

Pour the purchased corn into the sieve, and send it to the double-drum cleaning screen through a scraper conveyor to clean out the large particles, ropes, stones, soil and other soft impurities in the raw corn (impurity removal rate 99%), and then send it to the corn silo for storage through a bucket elevator.

② Soybean meal reception

Pour the purchased soybean meal into the sieve, and send it to the drum cleaning screen through a scraper conveyor to clean out the large particles and soft impurities such as hemp rope in the soybean meal (impurity removal rate 99%), and then send it to the soybean meal steel silo for storage through a bucket elevator.

③ Feeding and cleaning of corn, soybean meal, and other powdered auxiliary materials

The corn and soybean meal stored in the raw material bin are lifted to the vibrating grading screen through the scraper conveyor and bucket elevator to remove fine impurities such as sand, and then the corn and soybean meal are sent to the powder storage bin through the rotary distributor for temporary storage; the powdered materials stored in the batching bin are sent to the batching bucket of the closed bin discharging machine for mixing.

④ Corn and soybean meal crushing

The corn and soybean meal temporarily stored in the powder storage bin are sent to the crusher for crushing. The crushing process is fully closed. The crushed materials enter the dust settling chamber and are sent to the batching bin for temporary storage through the material sealing screw conveyor and bucket elevator.

There is a ventilation port on the dust settling chamber of the crusher. Its main function is to balance the air pressure in the settling chamber. A pulse bag dust collector is set at the ventilation port. The crusher adopts a special “U”-shaped secondary crushing structure, which can achieve coarse and fine crushing by adjusting the gap between the hammer screen.

⑤ Weighing and mixing ingredients

The powdered raw materials temporarily stored in the batching bin are measured by the level meter, and the ingredients are batched according to the product requirements.

The measured materials are sent to the bin discharge machine through the material sealing screw conveyor, and mixed by the mixer and the double-shaft high-efficiency mixer. After sufficient mixing, they enter the buffer hopper and the scraper conveyor sends part of the materials to the packaging system, and the other part of the materials are sent to the pelleting section.

⑥ Conditioning and pelleting

The mixed powdered ruminant feed is sent to the conditioner. By adding steam, the fiber in the feed can be softened and the pelleting effect can be improved. The temperature is generally kept below 60℃, and the maximum moisture content is kept at 12%~13%.

The residence time in the conditioning room is more than 30~40S. The conditioned material enters the cattle feed pellet machine and is pressed into pellet feed with a larger diameter, generally with a particle diameter of 6mm.

⑦ Cooling and screening

The pelletized feed produced by the cow feed pellet mill is cooled through the cooling air net, and then the overlong pellets and powder produced during the pelletizing process are separated from the product through rotary grading screening. The overlong pellets are sent to the crusher to break the long pellets to meet the product specifications, and the separated powder is sent back to the re-granulation section for re-granulation.

⑧ Add molasses to part of the powdered material

Part of the powdered feed in the mixing section is directly transported out of the factory by special vehicles; the other part needs to be packaged (a small part of which needs to be added with molasses). Steam is used to heat the molasses, and special adding equipment is used to add molasses, with an addition ratio of about 5%.

⑨Packaging

The powdered feed in the mixing section (including the powdered feed with molasses added) and the pelletized feed in the pelletizing section are sent to the finished product warehouse, and the finished product is filled into the woven bag through the packaging system, and then sent to the bag sewing machine for sealing.

The packaging system adopts domestic advanced technology, and the woven bag opening and the discharge port are precisely combined, which effectively prevents the loss of materials during the beating process.

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What are the prospects and advantages of building a dairy feed mill in the United States?

The prospects and advantages of building a dairy cow food factory in USA can be analyzed from many aspects. Here are some key points:

Market demand:

Stable animal husbandry: The United States is one of the largest milk producers in the world, with a large dairy farming industry and a steady demand for high-quality feed.

Increasing health awareness: Consumers’ increased attention to the quality and safety of dairy products has driven the demand for high-quality feed.

Policy support:

• Agricultural subsidies: The US government encourages the development of animal husbandry and feed production through various agricultural subsidies and support policies.
• Environmental regulations: Strict environmental regulations have prompted feed mills to adopt more environmentally friendly production technologies and enhance market competitiveness.

Technological progress:

• R&D investment: The United States has invested heavily in agricultural technology and feed research and development. The application of new technologies and new formulas has improved the nutritional value and production efficiency of feed.
• Automated production: The application of automated technology has reduced production costs, improved production efficiency and product quality.

Abundant raw material supply:

• Corn and soybeans: The United States is the world’s leading producer of corn and soybeans, which are the main raw materials for dairy cow feed, with sufficient supply and relatively stable prices.
• Other raw materials: The United States also produces a variety of other feed raw materials, such as alfalfa, wheat bran, etc. The diversity of raw materials helps to produce high-quality feed.

Advanced logistics system:

• Transportation network: The United States has a developed road, rail and water transportation network, which facilitates the transportation of raw materials and finished products and reduces logistics costs.
• Storage facilities: Complete storage facilities ensure the safe storage of raw materials and feed and reduce losses.

Mature industrial chain:

• Upstream and downstream cooperation: There is a close cooperative relationship between the livestock industry and the feed production industry in the United States, forming a mature industrial chain, which is conducive to the stable operation of cattle feed plants.
• Market channels: A wide range of market channels and sales networks help to quickly promote and sell feed products.

High-quality labor force:

• Technical talents: The United States has high-quality agricultural and feed production technical talents who can effectively manage and operate dairy cow food factory in USA.
• Training system: A complete vocational training system ensures the continuous improvement of labor skills.

Market Competition:

• In-Industry Competition: The US feed market is highly competitive, and new entrants need to have a clear competitive advantage.
• Price Fluctuation: Fluctuations in raw material prices may affect production costs and profits.

Environmental Pressure:

• Environmental Regulations: Strict environmental regulations may increase production costs, and more resources need to be invested in environmental protection facilities and technology upgrades.

Technology Update:

• Fast Technology Update: Feed production technology is updated rapidly, and continuous investment in research and development and technology upgrades are required to maintain competitiveness.

Building a dairy cow food factory in USA has good prospects and obvious advantages, especially in terms of market demand, policy support, technological progress and raw material supply. However, it is also necessary to cope with challenges such as market competition, environmental pressure and technological updates. Through reasonable market positioning, technology investment and management optimization, feed mills can succeed in the US market.

• Market Research: Conduct detailed market research to understand market demand and competition.
• Technical Cooperation: Cooperate with scientific research institutions and technology companies to introduce advanced production technologies.
• Environmental Investment: Plan environmental protection facilities in advance to ensure compliance with environmental regulations and reduce operational risks.
• Supply chain management: Optimize supply chain management to ensure stable raw material supply and cost control.
• Brand building: Build brand reputation and enhance market competitiveness through high-quality products and services.

Through these measures, the advantages of building dairy cow food factory in USA can be maximized to achieve sustainable development.