10-12T/H Ruminant Livestock Feed Plant In Russia

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Project Overview

The Russian feed industry is in a period of rapid development, and the output of ruminant feed is growing rapidly. Dairy cow feed is the main product of ruminant feed and occupies a large market share.

With the development of animal husbandry, the demand for ruminant feed will continue to grow, providing a stable market demand for feed production lines. Based on this background, the project client, an agricultural company from Russia, invested 410,000 US dollars to build this 10-12 tons per hour ruminant livestock feed production line.

The ruminant livestock feed plant in Russia project includes two feed production lines, one 50,000 tons of ruminant feed production line, mainly producing dairy cow feed; the other is a livestock pig feed production line with an annual output of 10,000 tons, mainly processing pig feed.

The labor quota of this Russia animal feed factory project is 40 people, with an annual working time of 330 days, 16 hours a day, and no food and accommodation in the factory area.

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Product plan

This ruminant livestock feed plant in Russia project produces 60,000 tons of ruminant and livestock feed annually, as shown in the table below.

Number	Product name	Output	Specifications
1	Ruminant feed	50,000 tons	Pellet, 40kg/bag
2	Livestock and poultry feed	10,000 tons	Pellet, 40kg/bag

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Construction content and scale

This ruminant livestock feed mill plant in Russia project is located in a total area of 3817m2, with an annual output of 60,000 tons of ruminant and livestock feed. The existing factory building is leased for construction. The project mainly includes the main project, storage and transportation project, auxiliary project, public project and environmental protection project. The project content is detailed in the table below.

Type	Item	MainConstruction Content
Main Engineering	Production Workshop	Located in the northern part of the factory, with a construction area of ​​3200m2, it has two production lines, one for ruminant and one for livestock and poultry feed, with crushers, mixers, animal feed granulators, balers, microcomputer batching systems, etc.
Storage and Transportation Engineering	Raw Material Stacking Area	Located in the northern and central parts of Workshop No. 1, it is mainly used for the classified stacking of ruminant raw materials, livestock and poultry raw materials and small materials.
	Finished product stacking area	Located in the southwest of Workshop 1, it is mainly used for the classified stacking of ruminant feed and livestock and poultry feed finished products.
	Dangerous chemical warehouse	Located in the northwest corner of Workshop 1, it is mainly used for the storage of hazardous chemicals (sulfuric acid, hydrochloric acid) for inspection rooms and the storage of sulfuric acid and hydrochloric acid packaging bottles (hazardous waste temporary storage area).
	Raw material stacking area	Located in the north and west of Workshop 1, it is mainly used for the classified stacking of ruminant raw materials, livestock and poultry raw materials and small materials.
	Finished product stacking area	Located in the southeast of Workshop 1, it is mainly used for the classified stacking of ruminant feed and livestock and poultry feed finished products.
Auxiliary Engineering	Office area	Located on the second floor in the southeast of Workshop 1, it is a steel frame structure and is mainly used for office and meeting.
	Administrative office	Located on the south of Workshop 1, it is a steel frame structure and is mainly used for office and meeting.
	Inspection room	Located on the second floor in the northwest of Workshop 1, it is a steel frame structure and is mainly used for quality inspection of finished products.
	Bathroom	Located in the northeast of Workshop 1, a new 5m3 septic tank is built to treat domestic sewage.
	Boiler room	Located in the north of No. 1 production workshop, it has a built-in 0.5t/h steam generator
Public Engineering	Water supply	The water used in this project is mainly domestic water, steam generator water and inspection water. The domestic water consumption is 1000m3/a, the steam generator water consumption is 2745.6m3/a, and the inspection water consumption is about 6.6m3/a, all of which are provided by the local water supply network.
	Drainage	The drainage of this project is mainly domestic sewage, steam generator wastewater and instrument cleaning wastewater, with a production volume of 5942.72m3/a. After collecting the instrument cleaning wastewater, add acid or alkali solution to neutralize it and then discharge it into the sewage treatment plant together with the steam generator wastewater and domestic sewage treated in the septic tank.
	Power supply	It is provided by the power grid of the park.
	Heating	The office is heated by electricity, and the production workshop is not heated.
	Gas supply	The two steam generators in the project use natural gas, and the annual natural gas consumption is 210,000 m3/a, which is provided by the local natural gas pipeline network.

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Raw and auxiliary materials, energy consumption and characteristics

The raw and auxiliary materials and energy consumption of this ruminant livestock feed plant in Russia project are shown in the table below.

Item	Number	Raw material name	Consumption	Specification
Main raw materials	1	Corn	15400 tons	50kg/bag
	2	Bran	3344 tons	50kg/bag
	3	Beet pulp	1100 tons	50kg/bag
	4	Soybean meal	8140 tons	70kg/bag
	5	Cottonseed meal	3560 tons	50kg/bag
	6	Corn DDGS	4092 tons	50kg/bag
	7	Sprayed corn husk	4136 tons	50kg/bag
	8	Rice husk powder	4224 tons	40kg/bag
Small Ingredients	1	Sweetener	17.6 tons	20kg/bag
	2	L-Lysine Sulfate	83.6 tons	50kg/bag
	3	Complex Enzyme Preparation I	29.4 tons	20kg/bag
	4	Flavoring Agent	2.64 tons	20kg/bag
Fuel	1	Natural Gas	210,000 m³	Pipeline Transportation

Item	Number	Raw material name	Consumption	Source, storage method
Reagents	1	Sulfuric acid	30L	Purchased from a chemical company and stored in a hazardous chemical warehouse, with a concentration of 98%. It is mainly used to detect nutritional indicators such as crude protein, calcium, and phosphorus in feed products and raw materials
	2	Hydrochloric acid	10L	Purchased from a chemical company and stored in a hazardous chemical warehouse, with a concentration of 37%. It is mainly used to detect nutritional indicators such as crude protein, calcium, and phosphorus in feed products and raw materials
	3	Sodium hydroxide	30kg	Stored in a hazardous chemical warehouse, mainly used to detect nutritional indicators such as crude protein, calcium, and phosphorus in feed products and raw materials

All raw and auxiliary materials of this project are purchased from outside. Among them, corn, soybean meal, wheat, flour, etc. are purchased locally, and this project does not produce raw and auxiliary materials.

• L-Lysine sulfate: a food additive. White or nearly white free-flowing crystalline powder. It is a high-density, dust-free flowable particle with good processing performance. In addition to 51% lysine (equivalent to 65% feed-grade L-lysine sulfate), L-Lysine sulfate also contains no less than 15% of other amino acids, which can provide animals with more comprehensive and balanced nutrition.
• Compound enzyme preparation for feed: refers to a compound enzyme preparation produced by fermentation of Aspergillus niger and other strains and specifically formulated according to the differences in feed raw materials and animal digestive physiology, containing xylanase, pectinase, acid protease and other main functional enzyme components.
• Sulfuric acid: The most important oxygen-containing acid of sulfur. Anhydrous sulfuric acid is a colorless oily liquid that crystallizes at 10.36°C. It is usually prepared in various aqueous solutions of different concentrations by tower method and contact method.
• Hydrochloric acid: It is an aqueous solution of hydrogen chloride (HCl), a monobasic inorganic strong acid with a wide range of industrial uses. Hydrochloric acid is a colorless, transparent liquid with a strong pungent odor and high corrosiveness. Concentrated hydrochloric acid (mass fraction of about 37%) is extremely volatile, so when the container containing concentrated hydrochloric acid is opened, the hydrogen chloride gas will evaporate, combining with water vapor in the air to produce small droplets of hydrochloric acid, causing acid mist to appear above the bottle mouth. Hydrochloric acid is the main component of gastric acid, which can promote food digestion and resist microbial infection.
• Sodium hydroxide:  It is a strong alkali with strong corrosiveness. It is generally in the form of flakes or particles. It is easily soluble in water (exothermic when dissolved in water) and forms an alkaline solution. Industrial products contain a small amount of sodium chloride and sodium carbonate, which are white opaque crystals. There are blocks, flakes, granules and rods. Formula weight 40.01 Sodium hydroxide can be used as an alkaline cleaning agent in water treatment. It is soluble in ethanol and glycerol, but insoluble in propanol and ether. It also has a corrosive effect on sodium carbonate at high temperatures. It undergoes disproportionation reaction with halogens such as chlorine, bromine, and iodine, and neutralizes with acids to generate salt and water.

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Main livestock feed production equipment

This ruminant livestock feed plant in Russia project has 2 production lines for the production of ruminant feed and livestock and poultry feed. 2 steam generators, several sets of testing instruments, and 3 forklifts, with different service lives. The main production equipment is shown in the table below, and the equipment for a single production line is shown in the table below.

Number	Equipment name	QTY	Remarks
1	feed Production lines	2	1 set of ruminant feed production unit; 1 set of livestock and poultry feed production unit
2	Steam generator	2	Specifications of each steam generator 0.5/h, fuel is natural gas
3	Inspection instruments	14	/
4	Forklifts	3	/
5	Scales	1	/

Number	Equipment name	Equipment specification	QTY
（1） Dust removal and feeding section
1	Pulse dust collector	TBLM15*2M	2
2	Feed hopper bar	2500*1500	2
3	Scraper conveyor	TGSU25	2
4	Bucket elevator	TDTG48/28	1
5	Bucket elevator	TDTG48/28	1
6	Drum primary cleaning screen	SCY100	1
7	Pulse dust collector	TBLM4*0.8	1
8	Permanent magnetic tube	TCXT25	1
9	Rotary distributor	TFP4*20	1
10	Powder cleaning screen	QLS- 80	1
11	Permanent magnetic tube	TCXT25	1
12	Pulse dust collector	TBLM4*0.8	1
13	Rotary distributor	TFP10*20	1
（2）Crushing section
1	Upper level device	Rotary resistance type	4
2	Crushing bin	15m3	4
3	Lower level device	Rotary resistance type	4
4	Pneumatic gate	30 0×300	2
5	Collecting bucket	/	2
6	Impeller feeder	TWLY20*100	2
7	Water drop type crusher	SWFP66*100	2
8	Sedimentation box	/	2
9	Screw conveyor	25 type	2
10	Pulse dust collector	TBLM48*2M	2
11	Fan	4-72-5A	2
12	Bucket elevator Machine (30m)	TDTG48/28	2
13	Pulse dust collector	TBLM4*0.8	2
14	Buffer hopper	/	2
15	Rotary distributor	TFP8*20	2
（3）Batching and Mixing Section
1	Loader	Rotary Paddle Type	18
2	Batching Silo	15m3	18
3	Unloader	Rotary Paddle Type	18
4	Discharging Silo	SWLL32	6
5	Discharging Silo	SWLL25	8
6	Storage machine	SWLL20	4
7	Batching scale	1500kg	2
8	Arc pneumatic gate	500×500	2
9	Hopper	/	1
10	Pneumatic gate	400×400	1
11	Return air duct	￠220	1
12	Double-shaft mixer	SCHY4	1
13	Storage silo	2000kg	1
14	Lower level device	Rotary resistance type	1
15	Scraper conveyor	TGSS2 5	1
16	Bucket elevator (30m)	TDTG48/28	1
17	Permanent magnet tube	TCXT25	1
18	Rotary distributor	TFP6*20	1
19	Powder cleaning screen	QLS-80	1
（4）granulation and cooling section
1	Upper material level device	Rotary resistance type	4
2	Pelletizing bin	15m3	4
3	Lower material level device	Rotary resistance type	4
4	Pneumatic gate	400×400	4
5	Pressure reducing bucket	/	2
6	Livestock feed pellet machine	SZLH420	2
7	Single-layer Conditioner	420*3000	4
8	Feeder	25 type	2
9	Random Ring Die	Aperture Φ3.5	/
10	Granulator Field Control Box	/	/
11	Feed hopper	/	2
12	Air shut-off device	TGFY16	2
13	Cooler	2.2*2.2*1.6m	2
14	Cooling air net	/	2
15	Cooling fan	4-72№8C	2
16	Cyclone	￠1500	2
17	Air Shutoff	TGFY7	2
18	Bucket Elevator (30m)	TDTG48/28	2
19	Rotary Classifying Screen	SFJH130	2
20	Pulse Dust Collector	TBLM6*1.2	1
（5）Finished product packaging section
1	Loading level device	Rotary type	3
2	Finished product warehouse	15 m3	3
3	Under-loading level device	Rotary type	3
4	Pneumatic gate	300×300	3
5	Automatic double bucket packaging scale	20-50kg	2
6	Belt conveyor bag sewing machine	/	2
7	Pulse dust collector	TBLMy9*1.2M	1
8	Air shutoff	TGFY5	1
9	Dust suction pipeline	/	1
（6）Other auxiliary equipment
1	Electric reed	2 tons	1
2	Single batching system	/	1
3	Electric control cabinet	/	1
4	Grease addition	/	1
5	Cables, cable ducts, cable tubes	/	1
6	Slide pipe	φ220	1
7	Gas distribution pipe	/	1
8	Other installation materials	/	1
9	Machine maintenance platform	/	1

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Water balance

The new water used in this ruminant livestock feed plant in Russia project mainly includes domestic water, steam generator water and inspection water. The discharged wastewater mainly includes domestic sewage, steam generator wastewater and instrument cleaning wastewater. The fresh water used in this project is supplied by the local water supply network.

This project has a staff of 40 people and operates 330 days a year. The office and domestic water quota is calculated as 25m3/person/year, so the domestic water consumption is 3.03m3/d (1000m3/a). The sewage discharge coefficient is 0.8, so the sewage generation is 800m3/a, which is treated in the newly built septic tank and discharged into the sewage treatment plant for treatment.

This ruminant livestock feed plant in Russia project constructs 2 0.5t/h gas steam generators, which generate 1t/h of steam per hour. The steam generators operate for 8 hours a day. The water heat loss of the steam generator is 3% of the steam volume, which is 0.03m3/h (0.24m3/d). The regular sewage discharge of the steam generator is 1% of the steam volume, which is 0.01m3/h (0.08m3/d). All the steam from the steam generator is involved in the production and enters the product.

The water replenishment volume of the steam generator is the sum of the water heat loss of the steam generator, the regular sewage discharge of the steam generator and the steam loss, which is 1.04m3/h (8.32m3/d). The soft water preparation rate of this project is 90%, so the raw water volume required is 1.16m3/h (9.24m3/d), and the soft water preparation wastewater generation is 10% of the raw water volume, which is 0.12m3/h (0.92m3/d).

The steam generator wastewater is the regular wastewater of 0.08m3/d and the wastewater generated by the soft water preparation of 0.92m3/d, which is the clean sewage and is discharged to the sewage treatment plant together with the domestic sewage after the septic tank treatment.

The inspection items are mainly water, crude protein, crude fat, crude fiber, calcium ions, phosphorus, sodium ions, toxins, etc. In this process, a small amount of water is used for the preparation of reagents and instrument cleaning, and the amount is about 0.02m3/d. The evaporation loss in the inspection water is calculated as 20%, and 10% is used for the preparation of test reagents. Then the amount of instrument cleaning wastewater is about 0.014m3/d.

By setting up a wastewater collection tank in the ruminant livestock feed processing plant in Russia project inspection room, the instrument cleaning wastewater is collected, and then acid or alkali solution is added for neutralization, and then it is discharged to the sewage treatment plant together with the domestic sewage after the septic tank treatment.

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10-12T/H russia livestock ruminant feed Plant layout

This ruminant livestock feed plant in Russia project uses existing land and existing plant buildings. The layout of this project is to make full use of the existing site and plant terrain, try to meet the production requirements of process equipment and the logistics storage and transportation requirements of raw materials and finished products, and the layout is concentrated and compact.

The production area is located in the central, western and northern parts of the plant, the office area is located in the northeast and southwest of the plant, and the finished product stacking area and the raw material stacking area are both located in the workshop.

The connection relationship between the various devices in the production workshop is fully considered, and efforts are made to ensure smooth process lines, short process pipelines, compact and reasonable layout, and meet the requirements of fire prevention, explosion prevention, safety and other aspects.

From the perspective of the overall layout, it is basically arranged according to the smooth process, which can meet the requirements of the production process flow to shorten the material transportation route. The production equipment of this project is all placed in the plant.

The impact of the noise of the production equipment on the external environment is attenuated by the shielding of the plant wall, and the plant boundary can meet the emission standards. From the perspective of environmental protection, the overall layout of this project is reasonable.

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russia ruminant feed plant Process flow design

All raw and auxiliary materials of this ruminant livestock feed plant in Russia project are purchased from outside. Corn, soybean meal, wheat, flour, etc. are purchased locally in Ningxia. The local raw materials are of high quality and low price, which reduces the transportation links and production costs. Cottonseed meal is purchased locally, and cottonseed meal is of good quality and reasonable price.

The rest of the raw and auxiliary materials are purchased from outside, and this project does not produce raw and auxiliary materials. All raw materials of this project must undergo strict sampling inspection when entering the factory, and pass the quality inspection of the quality inspection department. Only after passing the inspection can they enter the production workshop. The production workshop arranges production teams to produce. After the product is manufactured, it must also be inspected by the quality inspection department. Only after passing the inspection can the product be put into storage.

Detailed introduction to the production process flow of ruminant and livestock feed:

• ① Receiving of packaging raw materials: divided into manual handling and mechanical reception.
• ② Receiving of liquid raw materials: Bottled and barreled can be directly transported into the warehouse by manual handling. Solid raw materials are all bagged and transported to the raw material warehouse for classification and stacking. They are randomly sampled for chemical inspection before entering the warehouse.

The cleaning equipment is mainly screening and magnetic separation. The screening equipment removes large and long debris such as stones, mud, sack pieces, etc. in the raw materials, and the magnetic separation equipment mainly removes iron impurities.

The process flow of feed crushing is determined according to the required particle size, feed variety and other conditions. Different product varieties have different processes. This project uses the first crushing process and the second crushing process for raw material crushing.

After crushing, various raw materials enter the batching bin separately, and then batch and mix.

The mixed materials are first tempered to make them into powdered feed with a certain moisture and humidity that is conducive to granulation. This project completes the tempering process by adding steam. The tempered materials are evenly transported to the animal feed pellet making machine for granulation.

The materials coming out of the ring die feed pellet machine are cooled by a stable cooler. During the pelleting process, high-temperature, high-humidity steam is introduced and the material is squeezed to generate a large amount of heat. As a result, the moisture content of the pellet feed reaches 16%~18% and the temperature is as high as 75°C~85°C when it just comes out of the animal feed pellet mill.

Under such conditions, the pellet feed is easy to deform and break, and it will also become sticky and moldy during storage. The moisture content must be reduced to below 14% and the temperature must be reduced to below 8°C higher than the air temperature, which requires cooling.

Qualified feed is selected by grading, and unqualified feed is returned to the feed mill pellet machine for re-pelleting.

The product is packaged by the packaging machine and inspected and stored.

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What is the prospect of building a ruminant livestock feed plant in Russia?

‌The prospect of building a livestock feed production line in Russia is very broad, mainly due to the development of Russia’s animal husbandry and policy support. ‌

Russia’s animal husbandry has always been one of the important pillars of its economic development. In recent years, with the continuous growth of domestic consumer demand, animal husbandry has shown a booming trend. Russia has more than 20 million cattle, of which about 7.5 million are dairy cows.

The cattle breeding technology is relatively high, and many farms use modern management methods and advanced technical equipment. In addition, although Russia’s dairy farming industry has developed rapidly, there are still a lot of market gaps in high-end dairy products, organic milk and other fields, which provides entrepreneurs with a broad space for development.

The Russian government has given strong support to the development of agriculture and animal husbandry, including a series of policies such as tax incentives and loan support, providing entrepreneurs with a good business environment2. These policy supports help reduce the cost of entrepreneurs and improve market competitiveness.

Russia has vast land and rich grassland resources, which provide sufficient raw material sources for livestock feed. In addition, Russia’s animal husbandry has a large demand for feed, especially in the dairy farming industry, where the demand for feed is more significant. Therefore, the construction of a ruminant livestock feed plant in Russia can meet the needs of local animal husbandry and has a high market potential.

The construction of a livestock feed plant in Russia can take advantage of local resource advantages and reduce production costs. Russia has a vast territory and a sparse population, and the logistics cost is relatively low, which helps to establish a stable supply chain, ensure the timely supply of products and meet market demand. At the same time, due to the strong demand and high prices of the Russian dairy market, the benefits of the feed production line will also be relatively high.

In summary, the construction of livestock feed processing plants in Russia has broad market prospects and policy support, with low costs and high benefits. Through reasonable management and risk control, high returns can be obtained.

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How to build a high-yield large-scale ruminant feed plant in Russia?

There are mainly the following steps to build a high-yield large-scale ruminant livestock feed manufacturing plant in Russia:

In-depth understanding of the needs of the Russian market, continuous improvement of products according to market demand, improve product adaptability, and meet customer needs.

Choose a place with superior geographical location and convenient transportation to establish a production line to facilitate the transportation of raw materials and the sale of products. At the same time, consider local labor costs and available resources to ensure that the operating costs of the animal feed production line are effectively controlled.

The first is the characteristics of the raw materials, including the source, type, moisture content and size of the raw materials, which directly affect the particle shape and output requirements of the feed. At the same time, the scale of the production site is also key, which limits the optional feed equipment and the layout design of the overall feed pellet production line.

Therefore, before deciding to build a livestock feed plant in Russia, manufacturers must comprehensively evaluate the characteristics of the raw materials, formulas, feed types and applications to ensure the efficient operation and cost-effectiveness of the production line.

After clarifying the source, moisture content, size of the raw materials, and the particle shape and output requirements of the finished feed products, the selection of feed equipment has a clear direction. If the raw materials do not contain grass, etc., ordinary livestock and poultry feed equipment can be used for processing.

At the same time, for raw materials containing grass, forage pellet machines are required for rumination and livestock feed processing. In this process, the selection of feed pellet machines must fully consider the characteristics of the raw materials and product requirements to achieve efficient and high-quality feed processing and production in Russia.

The design of the feed production line is a layout based on the production site and needs, and we need to respect the actual available space. In addition to the pellet mill, the layout of auxiliary equipment such as crushing equipment and mixing equipment also needs to be considered in a coordinated manner.

Generally speaking, engineers need to conduct on-site surveys and field investigations, and then combine production needs to provide a solution that satisfies customers – a high-yield ruminant livestock feed plant in Russia.

The smooth commissioning of a feed production line does not mean the completion of the production line construction. On the contrary, after operation, it is an important period for how to ensure the high yield and high quality of the production line.

Equipment selection affects the upper limit of the output and service life of the livestock ruminant feed mill, and the operation and maintenance of the production line affects the lower limit of the output and service life of the feed mill. If you do not pay attention to daily maintenance, the animal feed pellet press that could have been used for 10-15 years may be scrapped after only a few years due to problems such as excessive wear, which will increase the operating cost.

If you want to build a ruminant livestock feed plant in Russia, feel free to contact us to get factory construction plans, process equipment and equipment quotations!