Large Poultry Feed Factory in Brazil

RICHI MACHINERY

Flock Placements Determine the Production Week

The customer behind the Large Poultry Feed Factory in Brazil manages different ages of birds across its integrated supply network. A new broiler placement calls for starter feed while older flocks need grower and finisher products. Layer sites add a different formulation and physical feed requirement to the weekly order schedule.

That demand pattern makes product routing as important as total hourly capacity. The factory programme allocates 40 t/h to pellets and crumbles, plus 20 t/h to mash on a combined production basis. The shared front end is sized for both, and finished bins keep each product identified through truck loading.

Brazil’s corn and soybean processing industries provide a strong ingredient base for poultry feed. For a plant in Minas Gerais, purchasing still needs to manage harvest timing, storage condition and transport from approved supply regions. The mill’s stock policy is built around that delivery programme rather than an assumption of uninterrupted fresh grain.

The poultry feed production line in Brazil has a finished-feed plan of 288,000 tonnes per year. At 60 t/h over 16 net production hours per day and 300 days, daily output is 960 tonnes. The split is 192,000 tonnes of pellet products and 96,000 tonnes of mash over the planned year.

For the Large Poultry Feed Factory in Brazil, those figures define the main process duties. They also determine ingredient receiving, steam demand and loadout. The customer can compare weekly flock orders with the available production hours and finished-bin stock before confirming the next feed schedule.

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A Process Tower with a Clear Ground Footprint

The layout for the Large Poultry Feed Factory in Brazil uses a 26,667 m² industrial property. Covered ground allocations total 6,550 m². A four-level process structure adds 2,700 m² above its 900 m² ground footprint, bringing the total allocated floor area to 9,250 m².

Structure or function	Ground allocation	Layout purpose
Main process structure	900 m²	Vertical batching and processing arrangement
Raw-material warehouse	3,050 m²	Meals, premixes and controlled bagged stocks
Finished-feed staging	1,200 m²	Held lots and bagged dispatch
Utilities and maintenance	450 m²	Steam, compressed air and workshop
Offices, laboratory and staff space	450 m²	Planning, quality and personnel facilities
Covered receiving	500 m²	Ingredient unloading and inspection
Total covered ground allocation	6,550 m²	Floor area counted separately above

The remaining property area accommodates outdoor bins, internal roads, truck staging, drainage and required separation. The arrangement keeps ingredient vehicles away from the finished-feed loading route where practical. It also leaves access to bin foundations, inspection points and extraction equipment.

This commercial poultry feed mill in Brazil uses the vertical process structure to shorten transfers between batching, mixing and the assigned product route. Supporting steelwork is checked against operating bin loads and machinery forces, with maintenance lifting included in the local structural design.

Raw storage is arranged by ingredient turnover. Corn, soybean meal and lower-volume ingredients have separate stock controls. The warehouse retains access for sampling and inspection, allowing held deliveries to remain physically and electronically separated from ingredients released for feed production.

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Corn and Soybean Meal Lead the Formulation

The Large Poultry Feed Factory in Brazil is based on corn-and-soybean-meal diets for its broiler programme. The following one-tonne batch illustrates the equipment duty for a grower formula. The customer’s nutritionist approves the actual nutrient specification, ingredient matrix and inclusion limits for each product.

Illustrative broiler grower batch	Quantity per 1,000 kg	Process consideration
Corn	600 kg	Controlled particle distribution
Soybean meal	300 kg	Protein quality and flowability
Wheat bran	30 kg	Fibre and bin discharge condition
Vegetable oil	30 kg	Accurate addition and uniform spraying
Limestone	11 kg	Separate mineral scale
Monocalcium phosphate	12 kg	Formula-specific dosing
Salt	3 kg	Minor-ingredient accuracy
Premix and amino acids	14 kg	Controlled hand-add or automatic micro-dosing

The layer-mash programme uses its own formulas and calcium arrangement. The Large Poultry Feed Factory in Brazil keeps these recipe versions and finished-bin assignments distinct. Product scheduling considers residual material in conveyors and bins before a different formula enters the same equipment.

The Large Poultry Feed Factory in Brazil also schedules limestone grades around the layer programme. A suitable coarse fraction can follow its assigned dosing route when required by the nutritionist, while the broiler recipe uses its own mineral preparation. Receiving labels, bin assignments and the batch instruction identify which grade belongs in each feed. The customer can maintain that distinction through mixing and bulk dispatch.

Corn acceptance includes moisture, damage, foreign material and risk-based mycotoxin testing. Soybean meal is checked for its agreed chemistry and processing quality. A delivery is assigned to a usable bin only after the receiving and release checks have been completed.

The poultry feed manufacturing plant in Brazil plans gross annual ingredient procurement at approximately 294,000 tonnes for its finished-feed programme. On an average 12% intake-moisture basis, this contains 258,720 tonnes of dry matter. Finished feed at an 11% planning moisture contains 256,320 tonnes, leaving a 2,400-tonne dry-matter allowance for material outside saleable product.

That allowance includes cleaning rejects and unrecoverable production losses. Clean internal returns are counted within the process, and steam addition is handled in the water balance. The customer can therefore compare ingredient use with released feed weight without treating circulating fines as new output.

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Shared Batching, One Full-Size Pellet Mill

One SZLH768 with a 315 kW main motor serves the 40 t/h pellet design duty in the Large Poultry Feed Factory in Brazil. The mash programme bypasses the pelleting section. This arrangement gives the customer a single matched pellet route rather than adding presses for feed that does not need densification.

The Poultry Feed Pellet Making Machine receives mash through its own surge and conditioning system. Feed distribution, steam condition and die selection are developed around the agreed broiler recipes and pellet size. The test programme measures useful finished output alongside durability and fines.

Main processing duty	Equipment arrangement	Design basis
Ingredient receiving	Separate grain and meal intake routes	About 120 t/h bulk receiving duty
Corn grinding	One 400 kW hammer mill	About 42 t/h on the agreed grind
Batching and mixing	One 4-tonne paddle mixer with overhead weighing	Complete batch cycle within 3 minutes
Pellet formation	One SZLH768, 315 kW	40 t/h specified pellet duty
Cooling and screening	One matched main route	Full pellet flow and controlled returns
Crumble production	One adjustable crumbler in a selectable route	Starter-feed programme
Mash delivery	Dedicated bypass to assigned bins	20 t/h average programme
Bulk dispatch	Two controlled loading positions	Serve the day’s scheduled farm loads

At a three-minute complete cycle, the four-tonne mixer has a theoretical 80 t/h batch capacity. This provides working margin above the combined programme. Filling, mixing and discharge are included in that cycle, with scale accuracy and uniformity checked using the intended recipes.

A feed mill pellet machine must be supported by reliable steam. The selected boiler duty is 2.5 t/h, compared with an approximately 1.6 t/h conditioning allowance at 40 kg of steam per tonne of pellets. The margin covers control and distribution needs within the defined operating basis.

Grinding is selected for the actual corn fraction. With about 36 t/h of corn in the example combined programme, a single appropriately sized grinder can supply the required duty. Its test includes the specified particle distribution, allowing the customer to assess capacity and feed preparation together.

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Different Feed Forms Leave Through Different Routes

The Large Poultry Feed Factory in Brazil groups recipes into production campaigns that suit bird age, physical form and the available finished-bin stock. The process control system links each batch to its approved formula version and destination, helping the loading team serve farms with different feeding schedules.

Clean and grind for the broiler recipe

Incoming grain passes through cleaning and magnetic protection before the hammer mill feed grinder. A working broiler-grain target is approximately 800–1,200 microns, checked by a defined sieve method. The setting is selected for the customer’s diet and equipment, with grind distribution reviewed when a new grain lot changes milling behaviour.

Weigh, mix and select the route

Major ingredients enter the batch through their assigned scales. Minor ingredients are checked through the micro-dosing or supervised hand-add system. Oil addition follows the approved sequence. The mixed batch then enters the pellet buffer or its designated mash path according to the production order.

Condition and form the pellet product

The main pellet programme uses a 4 mm die, with conditioning developed around the formula. A typical trial temperature window is 75–85°C, alongside defined retention and moisture checks. Any claim for a microbial reduction step requires validation of the full time-and-temperature process.

Cool before crumbling or screening

Hot pellets enter the pellet cooler machine, where bed depth and airflow follow the production rate and ambient conditions. Product temperature is checked before further handling. Starter-feed runs can pass through the crumbler to produce an approximately 1–2 mm screened crumble fraction; other pellet runs bypass that machine.

Release by batch and load by order

Screens separate the agreed product fraction and measure fines. Finished bins receive only their assigned feed. The dispatch operator checks farm order, vehicle compartment and bin identity before loading. A retained sample links the delivered feed with its production and ingredient records.

The Large Poultry Feed Factory in Brazil uses these checks to maintain a useful distinction between process throughput and delivered product. Crumbling returns, screen fines and held batches are visible in the production report. The customer can assess the available saleable tonnes before accepting another order.

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Utilities Sized Around the Product Split

Electrical planning for the Large Poultry Feed Factory in Brazil allows approximately 1,400 kW connected load. The machinery design basis is a 380 V, 60 Hz, three-phase distribution system. The final transformer and service arrangement are coordinated with the site’s local electrical designer and utility conditions.

Annual electricity is budgeted at about 5,760,000 kWh, equivalent to 20 kWh per tonne of combined feed. Across 4,800 net production hours, this is an average working load of approximately 1,200 kW. The figure covers the defined mix of mash, pellets and crumbles.

Conditioning steam is planned at approximately 7,680 tonnes per year for the pellet programme. Fresh-water planning is about 9,300 m³ per year, including boiler make-up, blowdown allowance and staff facilities. Heat and electricity are recorded separately, allowing the customer to see how a change in the pellet-to-mash split affects utility use.

Dust collection is arranged at receiving, grinding, dosing, transfer and loading points. The protection and isolation design follows the machinery and facility assessments. Clean recovered material has a defined return point, while rejected grain, floor-cleaning material and maintenance waste have separate handling routes.

For a broiler feed factory in Brazil, housekeeping and maintenance access remain production issues. The customer needs to reach conveyor covers, elevator boots and bin outlets on a routine schedule. The arrangement supports those tasks while keeping product identity and released stock under control.

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Commissioning Around Feed the Farms Need

The Large Poultry Feed Factory in Brazil is handed over through staged checks. Empty-machine testing confirms directions, interlocks, bin selection and emergency stops. Scales and liquid dosing are then checked before the team begins trials using the customer’s selected feed ingredients.

The poultry feed mill project acceptance programme includes one representative mash formula, one main broiler pellet formula and the intended starter crumble. Each test follows the material through its complete route to released product. This shows the customer what the line can deliver for its actual product programme.

Trial records include the formula, grain moisture, grind distribution, mixer cycle, steam condition, output, electricity and screened yield. The customer can use those records when training further operators or investigating a later change in production behaviour.

Equipment transport can use Santos as a sea-freight gateway, with inland delivery planned against the Minas Gerais site and the packed dimensions. Lifting and access checks are completed before unloading. Installation follows the defined interface between machinery, local structural work, utilities and controls.

Staffing is planned at 48 people: 32 in operations and relief coverage, six in maintenance, four in quality and six in planning, stores, dispatch and management. The shift arrangement provides trained coverage for receiving, processing and loadout, with handover records identifying held lots and current equipment condition.

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Where the Capital Goes in This Scope

The equipment budget for the Large Poultry Feed Factory in Brazil is USD 1,180,000. The total installed project budget is USD 2,150,000. The basis uses an existing industrial property and the defined process structures, with receiving, ingredient storage, one pellet route, mash bypass, utilities and dispatch equipment included in the scope.

The installed budget allows for the specified freight, erection, electrical infrastructure and building adaptations. Storage capacity, local structural conditions and the chosen control system are reviewed before a final project quotation. The customer can compare competing proposals against the same processing and storage duties.

Poultry feed plant cost in Brazil has to reflect the daily supply business. A large press has little commercial value if raw intake or finished loading restricts the delivery schedule. This project therefore assesses the complete route, including how batches reach the correct bin and trucks reach the intended farms.

RICHI’s contribution is equipment manufacture, process coordination, installation documentation and operating instruction. The poultry business retains control of feed formulation, ingredient purchasing and farm delivery. The supplier and customer can work against clear responsibilities and a defined acceptance programme.

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Match the Mill to Your Flocks

Your weekly flock placements and feed forms provide the starting point for machinery selection. RICHI can turn that schedule into a Large Poultry Feed Factory in Brazil with the required pellet, crumble and mash routes. Storage targets, delivery vehicles and available utilities complete the working brief. Contact our team with those details to develop the equipment package around the feed your farms need.

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