20 T/H Multi Species Feed Mill in South Africa

RICHI MACHINERY

Serving Farms from the Free State

Broiler farms, pig producers and distributors require different campaign sizes and dispatch slots.

Buyer group	Product need	Scheduling issue	Quality focus
Broiler farms	Pellets and starter crumbles	Growth-stage campaigns	Particle distribution
Pig farms	Stage-specific feed	Bulk and bagged orders	Recipe consistency
Specialist poultry	Approved formulations	Smaller campaigns	Line clearance
Distributors	Identified packaged products	Dispatch slots	Labels and traceability

Competition centres on feed consistency and delivery reliability.

The customer portfolio is organized by delivery and production needs:

Customer route	Production planning	Delivery basis
Pig farms	Ration-specific campaigns	Bulk or bags
Specialist poultry	Orders matched to campaign size	Identified batches
Broiler farms	Starter and grower schedules	Pellets or crumbles
Complete portfolio	Within available line hours	Coordinated dispatch

Orders of about 160–240 tonnes per production day suit the regional customer brief. Two eight-hour shifts allow twelve net production hours; 20 T/H gives a 240-tonne upper planning figure on the main recipes. Starter crumble campaigns receive their own lower rates where preparation or screening limits output.

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Use Regional Grain without Losing Recipe Flexibility

Qualified milling by-products and protein meals complement maize.

Ingredient roles shape storage and dosing:

Ingredient	Role	Supply route	Storage	Acceptance
Yellow maize	Energy	Qualified grain suppliers	Monitored silo	Moisture and mycotoxins
Wheat bran	Fibre and nutrients	Flour mills	Dry store	Condition and composition
Soybean meal	Protein	Qualified processors and traders	Suitable silo	Protein quality
Middlings	Recipe component	Flour mills	Dry store	Nutrient specification
Sorghum	Alternative grain	Qualified suppliers	Separate storage	Recipe suitability
Other protein meals	Formulation-specific	Qualified processors	Separate lots	Nutritional constraints
Premixes and additives	Small-dose nutrients	Approved suppliers	Controlled store	Identity and shelf life
Complete batch	Approved ration	Recorded receipts	Traceable bins	Mass reconciliation

Batch records connect ingredient receipts with finished rations. The main product groups require different processing priorities:

Product	Campaign basis	Maize	Bran	Soybean meal	Middlings	Sorghum	Other meals	Additives
Pig feed	Growth stage	Energy base	Recipe-specific	Protein source	Qualified use	Qualified use	Nutritionist selection	Accurate dosing
Broiler feed	Starter or grower	Energy base	Limited by recipe	Protein source	Qualified use	Qualified use	Nutritionist selection	Accurate dosing
Specialist poultry	Confirmed order	Recipe-specific	Recipe-specific	Protein source	Qualified use	Qualified use	Nutritionist selection	Accurate dosing

Bulk storage provides 600 tonnes of usable maize capacity and 250 tonnes of usable soybean-meal capacity. At 240 tonnes/day with 60% maize and 25% meal, each covers about four production days. Supplier scheduling and bagged-ingredient stock support the approved formulations.

• Identified maize silos with monitored stock
• Protein-meal storage suited to its discharge behaviour
• Temperature observation and appropriate aeration
• An 800 m² warehouse for bagged meals and minor ingredients

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Keep Trucks Moving while the Mill Runs

Receiving trucks and customer vehicles use separate loading positions. The principal areas are:

Area	Size (m²)	Arrangement	Function
Production building	800 footprint	Multiple levels	Process equipment
Ingredient warehouse	800	Protected storage	Bagged and minor ingredients
Finished warehouse	900	Palletized storage	Released product
Silo area	600 allocation	Bulk storage	Grain and protein meal
Staff support	100	Separated facilities	Shift support
Office	100	Controlled space	Administration and quality
Gate and weighbridge	50 m² allocation	Vehicle control	Receipts and dispatch
Landscape and separation	1,150	Open area	Drainage and separation

Within the production building, equipment is grouped by function:

The 800 m² process footprint includes service access and a utility annex. Equipment platforms use vertical transfers where useful, but the project does not require a new high-rise production tower or duplicate pelleting floors.

Position	Design consideration	Function	Equipment group
Upper distribution	Structure and service access	Ingredient routing	Elevator heads and distributors
Preparation zone	Dynamic loads and access	Grinding	Mills and extraction
Batching zone	Gravity and maintenance	Weighing and mixing	Bins, scales and mixers
Pelleting and discharge	Cooling below presses	Product finishing	Presses, coolers and packing

The silo area connects to the process through:

• Maize receiving and cleaning
• A separate route appropriate to protein meals
• Accessible outlets, level information and stock monitoring

RICHI MACHINERY

RICHI Machinery Working to One Production Duty

RICHI coordinates preparation, pelleting, crumbling and dispatch. Installed feed factory machines and operating roles are:

Section	Equipment	Quantity	Drive basis	Function
Receiving and cleaning	Local extraction	2 groups	Airflow selection	Intake dust
	Cake breaker	1	15 kW	Break compacted meals
	Drag conveyors	2	Route selection	Horizontal transfer
	Bucket elevators	2	Lift selection	Vertical transfer
	Pre-cleaners	1	Ingredient duty	Remove foreign matter
	Magnets	2	Flow selection	Ferrous removal
	Distributors	2	Bin arrangement	Route ingredients
	Powder screens	1	Meal duty	Lump separation
Grinding	Hammer mills	2	110 kW each	Recipe preparation
	Grinding extraction	Coordinated groups	Airflow selection	Dust and aspiration
	Discharge conveyors	Matched set	Route selection	Controlled transfer
Batching and mixing	Ingredient bins	12	Usable volume basis	Separated ingredients
	Feeders	12	Material selection	Controlled dosing
	Weighing systems	1 main plus small-dose	2-tonne main batches	Recipe weighing
	Local filters	1 group	Airflow selection	Batching dust
	Batch mixers	1	2-tonne working batch	Homogeneous feed
Pelleting	RICHI SZLH678 press	1	250 kW	Single 20 T/H pelleting route
	Conditioners	1	Train duty	Steam preparation
	Counterflow coolers	1	Matched airflow	Pellet cooling
	Cooler collectors	1	Air circuit	Fines separation
	Crumblers	1	Product duty	Starter format
	Screens	2	Product specification	Classification
Dispatch	Finished bins	4	Short-term buffer	Product separation
	Weighing stations	2	25 kg and 50 kg bags	Bagging
	Closing conveyors	2	Packing duty	Secure closure
Utilities	Steam boiler package	1	2 T/H steam	Conditioning supply
	Air compressors	Duty arrangement	Demand study	Pneumatics
	Piping and controls	Coordinated scope	Utility design	Interlocked operation

One complete process line, moderate silo capacity and product-specific finishing define the equipment scope. Additional presses are not required to meet the selected customer brief.

The production arrangement combines five features:

One working press. A single SZLH678 animal feed pellet mill serves the nominal 20 T/H duty on the main 4 mm feeds. Product changes and die service use scheduled stops supported by finished-stock availability.

Separate ingredient storage. Grain, meals and small ingredients retain the handling and dosing arrangements appropriate to their physical form.

A compact steam package. One 2 T/H liquid-fuel boiler supplies the conditioner, with its treatment, fuel and steam-distribution equipment included in the utility scope.

Extraction at the working points. Intake, grinding, transfers and packing connect to accessible dust-handling circuits.

Product-specific finishing. The 250 kW press, one crumbler and two classification screens serve pig and poultry campaigns. The mash bypass provides a separate route for approved unpelleted products.

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Keep the Recipe Identifiable through the Whole Mill

Recipe identity continues through weighing, processing and destination selection.

Receive Grain and Meals into the Right Stream

Bulk receiving includes:

• Identifying the vehicle and ingredient lot
• Sampling and unloading at the assigned position
• Directing material to the selected silo

Bagged materials follow:

• An identified warehouse receipt
• Controlled tipping or small-dose weighing
• The preparation route appropriate to that ingredient

Grain unloading remains clear of finished-feed loadout.

Clean before Grinding and Batching

Accessible screens and magnets protect downstream machinery.

The arrangement combines:

Grain pre-cleaning:

• Screens selected for the grain
• Controlled distribution across the cleaner
• Separate collection of foreign matter

Ferrous-metal removal:

• Magnets at appropriate transfer points
• Accessible cleaning and recovered-metal collection

Meal preparation:

• A route suited to powder ingredients
• Separation of lumps and foreign material

Receiving rejects leave the process; only compatible clean fines return.

Prepare the Grain for the Product Campaign

Two 110 kW hammer mill feed grinders share grain preparation. A 60% grain formulation needs about 12 T/H of grinding at full line output, divided between the two mills. Screen and particle-profile checks establish the working rate for finer starter recipes.

Grinding selection connects machinery and formulation:

Item	Selection	Verification
Ingredient	Qualified grain	Incoming checks
Main motor	110 kW per mill	Load monitoring
Screen	Recipe-specific	Sieve test
Rotor operation	Machine specification	Vibration and bearings
Aspiration	Matched circuit	Filter condition
Production duty	Preparation demand	Measured tonnes and particle profile

Different products use their own preparation targets:

Product	Particle selection	Release check
Pig grower and finisher	Nutritionist-approved profile	Sieve analysis
Broiler starter	Suitable crumble and meal profile	Particle distribution
Specialist poultry starter	Product-specific profile	Sieve analysis

Matched aspiration supports grinding, with clear access for screens and bearing service.

Feed the Scales from Identified Bins

Twelve ingredient bins supply controlled recipe feeders. The bin groups accommodate:

• Ground maize for principal energy ingredients
• Bran in a separate fibrous-material route
• Soybean meal as an identified protein ingredient
• Middlings for approved formulations
• Qualified alternative grain such as sorghum
• Other meals retained by ingredient identity
• A dedicated route for small additions

Bin-level signals trigger replenishment before batching stops.

Use a Scale Suited to the Dose

Bulk ingredients and concentrated additives use appropriately sized scales. One main weighing system supplies the mixer, with a holding hopper and separate small additions:

• Main weighing matched to 2-tonne batches and holding hoppers
• Minor and micro dosing matched to the formulation

The batch sequence is:

Step	Control	Action
1	Recipe authorization	Confirm ingredients and route
2	Scale readiness	Tare and weigh major materials
3	Fine dosing	Complete small additions
4	Batch permission	Discharge to assigned mixer

Reliable weighing combines:

• Repeatable filling
• Complete discharge
• Recorded addition of the small ingredients

Mix, then Select the Product Route

One 2-tonne mixer on a five-minute complete cycle provides 24 T/H of batch capacity above the 20 T/H pelleting duty. The scale prepares the next batch while the mixer runs; homogeneity testing determines the approved mixing period.

Mixer item	Operating basis
Working batch	2 tonnes per batch
Complete batch cycle	5 minutes including fill and discharge
Homogeneity	Validated with suitable tracer
Combined batch duty	24 T/H from one mixer

The operating sequence brings together:

1. The weighed principal ingredients
2. Their distribution through the mixer
3. Verified minor additions
4. Liquids at the selected point
5. The identified premix or small ingredients
6. The established mixing period
7. Discharge to the assigned finishing route

Approved mash products bypass pelleting into an assigned finished-product route.

Condition the Mash and Form the Pellet

Stable steam delivery supports even press loading.

At 20 T/H, steam addition of 3–5% requires about 0.6–1.0 T/H before distribution losses. The 2 T/H boiler provides working margin and warm-up capacity. Conventional grower recipes start within a 75–85°C conditioning window, with each formulation validated separately.

The conditioning arrangement provides:

Conditioning item	Basis
Steam supply	Regulated with condensate control
Feed temperature	Recipe-specific validated setting
Steam addition	3–5% working range
Residence	Product and feed-safety programme

The installed press group is organized as follows:

Press item	Configuration	Operating role
Main motors	1 × 250 kW	One working press
Die holes	Product-specific	Pellets or crumble feedstock
Die geometry	Formulation trial	Quality and throughput
Controls	Load-regulated feeding	Stable operation
Nominal plant duty	20 T/H	Qualified product mix

A nominal 4 mm pig-feed product uses these physical controls:

Property	Control
Diameter	Nominal 4 mm die
Length	Product-specific cutter setting
Moisture	Storage release specification
Durability	Buyer and product test

Cool Before Crumbling or Storage

Each press feeds its own counterflow cooler before product classification.

Cooling item	Operating basis
Type	Counterflow
Air supply	Selected for the train
Residence	Adjusted to release condition
Outlet temperature	Close to actual ambient
Outlet moisture	Measured product specification

Fines return only to compatible recipes under the rework procedure.

Make Starter Crumbles without a Separate Feed Factory

Crumblers and screens produce the required starter-size distribution.

Screens then separate the saleable product from oversize and fine fractions:

Fraction	Setting	Destination
Oversize	Product-specific screen	Approved rework
Accepted product	Pellet or crumble range	Assigned finished bin
Fines	Product-specific lower cut	Compatible recipe return

Connect Finished Bins with the Dispatch Order

Four finished bins each hold 20 tonnes usable, giving 80 tonnes or four hours of buffer at nominal line output. Rations remain separated; larger dispatch stocks occupy the finished warehouse.

Bagging is arranged around:

Packing item	Basis
Bags	25 kg and 50 kg
Combined rate	Matched to bagged share of output
Weight control	Calibrated scale and routine checks

The packing sequence follows the order identity:

1. Present the specified bag
2. Fill to the selected net weight
3. Close and label the product
4. Transfer to the assigned pallet position
5. Stack within the warehouse handling arrangement

Bulk loading is selected for 30 T/H. For a fully bagged 20 T/H stream, the two weighing-and-closing stations jointly provide at least eight 50 kg bags/minute or sixteen 25 kg bags/minute. Pallet handling is arranged around the selected bag format.

RICHI MACHINERY

Utility Connections for the Working Combination

Utility	Main duty	Supply basis	Sizing check	Record
Electricity	Drives and auxiliaries	Actual site connection	Running and starting demand	Section meters
Steam	Conditioning	Site-compatible boiler fuel	About 0.6–1.0 T/H plus losses	Steam and fuel logs
Water	Boiler and staff	Qualified site supply	Treatment and demand	Water balance

The connected-load schedule follows this single-line arrangement:

Group	Connected kW	Installed role	Working basis	Operating check
Intake and cleaning	12	Receiving	Delivery windows	Ingredient routing
Elevators	15	Vertical transfers	Selected routes	Level interlocks
Two hammer mills	220	Grain preparation	Shared grinding load	Particle profile
Extraction	15	Dust and aspiration	With process equipment	Filter pressure
Batching and mixing	22	Recipe preparation	One mixer	Cycle and homogeneity
Pellet mill	250	Pressing	Single working train	Feeder and load
Cooling	12	Pellet cooling	With the press	Product condition
Crumbling, screens and conveyors	24	Product finishing	Pellet or crumble campaign	Size and fines
Packing	10	Two stations	Selected bag format	Weight and closure
Compressed air	10	Pneumatics	Demand controlled	Pressure and leaks
Conditioning, boiler auxiliaries and support	10	Services	Production and occupancy	Separate metering
Total	600	Connected-load basis	Demand and starting study	Meter actual use

The animal feed pellet press and two grinding motors account for 470 kW. Auxiliary and support allowances bring the installed connected load to about 600 kW. The three-phase 50 Hz connection is sized from simultaneous demand, power factor and controlled motor starts.

RICHI MACHINERY

Adapt the Mill to the Site and the Product Range

The South African operating brief combines ingredient flexibility with a manageable production routine:

Multiple species. Campaign organization keeps formulations and finishing settings distinct within one mill.

The equipment supports:

• Dies selected for the pellet product
• Crumbling for suitable starter feeds
• Authorized recipes and recorded changes
• Production sequences with time for line clearance

A defined operating team. Nine positions per shift cover production and material handling. Eight day-support staff cover quality, maintenance, order planning and administration, giving twenty-six people in total.

The workplace layout provides:

• Extraction near dusty operations
• Enclosed material transfers
• Clear emergency-stop and isolation access
• Appropriate separation around noisy equipment
• Staff facilities away from process exposure

Site-specific steam. The liquid-fuel boiler includes water treatment, a feed tank and steam-distribution equipment. It does not depend on an unconfirmed regional pipeline connection.

Treated-water provision allows up to 2 m³/h at the boiler. Staff and routine cleaning add about 2 m³/day; fire-water storage is a separate service. Dry housekeeping limits water use around finished feed.

Controlled restart. Controls have continuity for recording batches and stopping safely. A full-load standby generator is outside this project scope; the mill uses stock and delivery scheduling during extended interruptions.

The control arrangement includes:

• Central recipe and route management
• Sequenced machinery starts
• Clear indication of abnormal load or equipment condition
• Equipment-specific instruction:
  • Safe isolation, start-up and routine inspection
  • Screen and die service using the machine instructions
  • Scale, ingredient and recipe management
  • Fault finding and restart procedures

RICHI MACHINERY

Sell a Defined Feed Product

Species, growth stage and physical format remain visible in every product specification.

Product	Campaign	Format	Nutrition	Physical focus	Dispatch
Pig grower	Growth stage	4 mm pellets	Approved ration	Durability	Bulk or bags
Pig finisher	Growth stage	4 mm pellets	Approved ration	Fines	Bulk or bags
Broiler starter	Starter orders	1–3 mm crumbles	Approved ration	Distribution	Identified batch
Broiler grower	Grower orders	3–4 mm pellets	Approved ration	Strength	Identified batch
Specialist starter	Confirmed orders	1–3 mm crumbles	Species ration	Distribution	Separate order
Specialist finisher	Confirmed orders	Selected pellets	Species ration	Moisture	Separate order

Delivery formats support different buyers:

Route	Handling	Dispatch check
Pig feed in bulk	Clean compartment	Ration and destination
Pig feed in bags	Palletized	Label and weight
Broiler feed	Format-specific	Starter or grower identity
Specialist poultry	Separate campaign	Species and batch

RICHI MACHINERY

A Practical Position in an Established Feed Market

Buyers receive identified rations in the physical form and delivery quantity ordered.

• Poultry farms. Starter and grower products follow the farm’s production cycle, with crumble distribution and pellet fines controlled through handling.
• Pig producers. Growth-stage formulations are organized into bulk or bagged campaigns suited to farm demand.
• Specialist orders. Smaller products receive an appropriate campaign size rather than being forced into the same run length as a major ration.
• Grain procurement. Regional maize supply connects with monitored storage and the approved ingredient specification.

Campaign planning translates the sales mix into working hours and dispatch slots.

The arrangement addresses these recurring business constraints:

Constraint	Operating response
Grain supply variation	Qualified suppliers and controlled stocks
Power interruptions	Defined shutdown, backup and restart duties
Inland delivery distances	Route planning and customer storage coordination
Established competition	Consistent products and dependable service

One coordinated scope defines machinery and installation responsibilities.

RICHI MACHINERY

Discuss Your Multi Species Feed Mill in South Africa

RICHI Machinery can develop an animal feed production line around your product mix and site services. The proposal becomes more useful when it starts with the weekly orders rather than only a headline tonnes-per-hour request.

• Ingredients. Provide the grain, meals and additives together with their supplied form and moisture range.
• Utilities. Include the electrical connection, steam fuel route and required backup duty.
• Products. List species, growth stages, mash, pellets and crumbles with the quantities needed in each campaign.
• Deliveries. Identify bags, bulk vehicles and the farms or distributors the mill will serve.

Send that information with the site plan. RICHI can connect poultry feed plant requirements and livestock campaigns in one feed mill equipment layout, including the preparation and finishing differences between products.

Request a coordinated equipment scope and installation interface plan for your feed manufacturing plant. Those details make the quotation directly comparable with your production and delivery requirements.