Pet Food Processing Line In Ireland

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overview

Ireland has significant advantages in pet food production. Ireland is one of the world’s major pet food exporters, and its products are known for their high quality and innovation. Irish pet food manufacturers focus on research and development and innovation, and are able to provide high-quality products that meet international standards. In addition, Ireland’s geographical location and efficient logistics system also provide convenience for its pet food exports.

The pet food processing line in Ireland project uses the existing plant of 6000m2, purchases equipment such as elevators, feeders, grinders, three-way distributors, and puffing and drying systems, and builds a pet puffed feed production line.

The production line uses corn, corn protein powder, chicken meal, beef bone meal, soybean meal, chicken fat, etc. as raw materials, and processes 20,000 tons of pet food annually through batching, mixing, crushing, conditioning, puffing, drying, cooling, screening, packaging and other processes. The project has a very high degree of automation, with a staff of 44 people, working 350 days a year, three shifts, 24 hours a day.

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Engineering composition

The pet food processing line in Ireland project composition table is shown in the table below.

Engineering Type	Engineering Name	Engineering Content
Main engineering	Workshop	The project uses the existing plant of 6000m2, purchases equipment such as elevators, feeders, crushers, three-way distributors, and puffing and drying systems, and builds a puffed grain production line located in the south of the workshop.
Auxiliary engineering	Office Area	Located on the second floor of the office building, covering an area of ​​about 100m2.
	Raw Material Area	Raw and auxiliary materials are stored in bags and barrels, and the storage location is located in the northwest of the workshop, covering an area of ​​about 200m2.
	Finished product area	Finished products are stored in bags in the northeast of the workshop, with an area of ​​about 200m2.

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Main products and production capacity

The product plan for this pet food processing line in Ireland project is shown in the table below.

Product Name	Designed Annual Product Capacity
Cat Food	10,000 Tons
Dog Food	10,000 Tons

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Types and quantities of main raw and auxiliary materials and fuels

In this pet food processing line in Ireland project, the consumption of main raw and auxiliary materials is as follows:

No.	Classification	Raw Material Name	Amount (t/a)	Packing Specification, Storage Method, Storage Location
1	Cat food	Corn	2200	50kg bag, raw material area
2		Rice	360	50kg bag, raw material area
3		Corn gluten powder	880	40kg bag, raw material area
4		Flour	440	5 0kg bagged, raw material area
5		Chicken meal	1760	50kg bagged, raw material area
6		Beef bone meal	880	50kg bagged, raw material area
7		Beet pulp	250	50kg bagged, raw material area
8		wheat middlings	220	40kg bag, raw material area
9		Pea flour	220	25kg bag, raw material area
10		Soybean meal	730	50kg bag, raw material area
11		Beer yeast	75	25kg bag, raw material area
12		Montmorillonite	60	25kg bag, raw material area
13		Salt	20	50kg bag , Raw material area
14		Calcium hydrogen phosphate	75	20kg bag, Raw material area
15		Fish meal	440	50kg bag, Raw material area
16		Chicken oil	730	180kg barrels, raw material area
17		Fish oil	110	180kg barrels, raw material area
18		Butter	110	180kg barrels, raw material area
19	Dog food	Corn	2300	50kg bag, raw material area
20		Rice	380	50kg bag, raw material area
21		Corn protein powder	920	40kg  bag, raw material area
22		Flour	460	50kg bag, raw material area
23		Chicken meal	1830	50kg bag, raw material area
24		Beef bone meal	920	50kg bag, raw material area
25		Beet pulp	270	50kg bag, raw material area
26		wheat middlings	230	40kg bag, raw material area
27		Pea flour	230	25kg bag, raw material area
28		Soybean meal	770	50kg Bag, raw material area
2 9		Beer yeast	80	25kg bag, raw material area
30		Montmorillonite	60	25kg bag, raw material area
31		Salt	20	50kg bag, raw material area
32		Calcium hydrogen phosphate	80	20kg Bag, raw material area
33		Chicken oil	760	180kg barrel, raw material area
34		Fish oil	115	180kg barrel, raw material area
35		Butter	115	180kg barrel, raw material area
36	Auxiliary materials	Probiotics	20	Bag, raw material area
37	Equipment maintenance	Lubricating oil	0.005	Barrel

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Design of pet food processing process flow

Based on the customer’s raw material formula, the type of pet food to be processed, the plant structure and other objective factors, we designed the pet food production process flow for this pet food processing line in Ireland project.

The project production unit is an expanded grain production line. The process flow is first cleaning, feeding 1, first mixing, second cleaning, crushing, first screening, feeding 2, feeding 3, second mixing, third cleaning, third mixing, tempering and puffing, drying, second screening, oil mixing, cooling, third screening, feeding 4, fourth mixing, and packaging.

(1) First cleaning, feeding 1:

The raw and auxiliary materials of this pet food processing line in Ireland project are all bagged or barreled materials, which are directly bagged or barreled and sent to the raw material warehouse for storage. The materials that need to be crushed (corn, rice, chicken meal, beef bone meal, beet pulp, soybean meal) enter the feeding port through a scraper or manual feeding, and then the elevator sends the materials to the permanent magnetic cylinder to remove the iron impurities in the materials and then enter the batching bin for standby.

(2) Initial mixing and second cleaning:

The materials that need to be crushed in the batching bin are batched by computer control and transported to the electronic weighing bucket by the batching dragon. The amount of each material is determined according to the size of the formula. After the batching is completed, the pneumatic switch door opens and the materials are placed in the 1# mixer.

The mixed materials are lifted to the permanent magnetic cylinder by the bucket elevator for the second cleaning to clean the iron impurities in the materials. The materials after the second cleaning are temporarily stored in the buffer bin. The type and quantity of raw materials fed into this process are instructed by the central control room. This process adopts 14 bins and one scale, and is automatically controlled by the computer.

(3) Crushing and initial screening:

Crushing: The granular materials entering the buffer bin are evenly fed into the 1# crusher through the feeder for the first crushing. After the first crushing, the materials enter the waiting crushing bin for standby use. The materials entering the waiting crushing bin are evenly fed into the 2# crusher through the feeder for the second crushing. The particle size after the second crushing is about 0.7-0.8mm.

During the conveying process, under the joint action of the fan, cyclone dust collector and air lock, the material is spirally conveyed to the high square screen for screening under the action of negative pressure.

Primary screening: Under the joint action of the fan, cyclone dust collector and air lock, the material is spirally conveyed to the high square screen for screening under the action of negative pressure. After the second crushing, the material is screened by the high square screen and then conveyed to the mixing bin for temporary storage through the three-way distributor.

(4) Feeding 2 and Feeding 3:

Feeding 2: Unnecessary crushed large materials (corn protein powder, flour, wheat middlings, pea powder) are manually fed to the feeding port and then enter the buffer bin for standby.

Feeding 3: Small materials (beer yeast, montmorillonite, salt, calcium bicarbonate, fish meal) are manually added to the small material adding hopper.

(5) Second mixing:

The materials after the initial screening enter the mixing bin, and after the pneumatic switch door is opened, they enter the 2# mixer. The amount of materials added is determined according to the size of the formula; the large materials (corn protein powder, flour, wheat middlings, pea powder) that do not need to be crushed in the buffer bin are controlled by computer and transported to the electronic weighing bucket by the batching dragon.

The amount of each material is determined according to the size of the formula. After the batching is completed, the pneumatic switch door is opened and placed in the 2# mixer; small materials (beer yeast, montmorillonite, salt, calcium bicarbonate, fish meal) are manually added to the small material adding bucket and then enter the 2# mixer. After the single batch of various raw materials is added, the 2# mixer performs the second mixing. The mixing and stirring time is determined according to the feed requirements and mixing conditions.

(6) Third cleaning and third mixing:

The finished powder after the second mixing is lifted by the bucket elevator to the permanent magnetic cylinder for the third cleaning to remove iron impurities in the material. After the third cleaning, the finished powder enters the 3# mixer for the third mixing. After the mixing is completed, it is transported to the puffing system for conditioning and puffing.

(7) Conditioning and extrusion:

The purpose of conditioning in this pet food processing line in Ireland project is to condition the final mixed and prepared dry powder into a powdered feed with a certain moisture and humidity that is conducive to extrution. This process completes the conditioning process by adding steam. After the third mixing, the material enters the pet food extruder machine and is tempered by adding steam. The temperature of the steam is about 170℃.

When it contacts the material, the temperature and humidity of the material are increased to a certain extent. The material puffs after the temperature and humidity are increased, and it is easier to form when extruded by the mold. After the uniformly modulated material is removed of impurities by the safety magnet, it is evenly distributed between the spiral and the die. After continuous extrusion, it forms a columnar feed, which is cut into granular pet extruded feed by a cutter.

(8) Drying:

Under the combined action of the fan, cyclone dust collector and air lock, the material is spirally conveyed from the extrusion system to the pet food dryer for drying under the action of negative pressure. This process uses steam indirect heating and drying, and the drying temperature is about 170℃.

(9) Second screening:

The dried granular feed is conveyed to the 1# rotary vibrating screen by a conveyor belt for screening. After the second screening, the qualified particle size feed is lifted to the buffer bin by a bucket elevator for temporary storage, and the unqualified particle size feed is conveyed to the feeding port for reuse.

(10) Oil mixing and cooling:

Oil mixing: After the second screening, the qualified particle size feed is lifted to the buffer bin by an elevator, the pneumatic switch door is opened, the amount of granular feed is determined according to the size of the formula, and then enters the 4# mixer for oil mixing. The grease adding system sprays the measured grease evenly on the surface of the granular feed. After the color is evenly mixed, it is lifted to the three-way distributor by a bucket elevator to prepare for the cooling process.

Cooling: After mixing with oil, the pellet feed is cooled by suction through the cyclone dust collector to reduce the temperature and humidity. When high-temperature and high-humidity steam is introduced during the puffing and drying process, the material is squeezed to generate a large amount of heat, which makes the temperature and humidity of the pellet feed high.

Under such conditions, the pellet feed is easy to deform and break, and it will also cause sticking and mildew during storage, so it needs to be cooled.

(11) Third screening:

After the pet pellet feed is processed by the oil mixing process, a part of powder clots and other materials that do not meet the requirements will be produced, so it needs to be screened into products with neat particles and uniform size. The cooled pet pellet feed is lifted by a bucket elevator to the 2# rotary vibrating screen for the third screening.

The qualified finished pellet feed is mixed with probiotics and then lifted by the bucket elevator to the finished product warehouse for standby use; unqualified materials are transported to the feeding port and reused in production.

(12) Four-time mixing and feeding 4:

After the third screening, probiotics are added to the qualified finished pellet feed. The amount of probiotics added is determined according to the size of the formula. The probiotics and the qualified finished pellet feed are fully mixed in the mixer. After the mixing is completed, the finished product is lifted to the finished product warehouse by the elevator.

(13) Packaging:

After the mixing is completed, the finished product enters the packaging scale by opening the pneumatic switch door, and the automatic metering and feeding are completed. After the bag is sealed, it is put into storage.

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Main equipment for pet food processing line in Ireland

The pet food processing equipment used in this pet food processing line in Ireland project and its parameters and quantities are shown in the following table:

No.	Corresponding process	Name	Equipment parameters	QTY
1	Initial cleaning, feeding + initial mixing	Feeding port	/	1
2		Pulse dust collector	TBIMAF18	1
3		Horizontal screw conveyor	LSS22	1
4		Bucket elevator	DTG36/ 23	1
5		Horizontal screw conveyor	LSS22	1
6		Distribution plate	FP220X14	1
7		Batching bin group	/	14
8		Rotary level meter	/	28
9		Batching screw conveyor	PM1-PM8	14
10		Electronic weighing bucket	1000KG	1
11		Pneumatic discharge door	500*700	1
12		Pulse dust collector	TBLMa-4	1
13		Small material adding hopper	/	1
14		Horizontal screw conveyor	LSS22	1
15		Pet feed mixer	SHLY2.0	1
16	Second cleaning	Bucket elevator	DTG36/23	1
17		Permanent magnetic cylinder	TCXT20	1
18		Buffer bin	/	1
19		Rotary level meter	/	1
20		Feeder	TWLY20*60	1
21		Pet feed grinder	SFSP40X60	1
22		Crushing bin	1.5m³	1
23		Rotary level meter	/	2
24		Feeder	TWLY20*80	1
25< /td>		Pet feed grinder	SFSP66X100	1
26		Cyclone dust collector	φ90	1
27		Air blocker	9L	1
28	Crushing, primary screening	Blower	9–26	1
29		Circular pulse	TBLMaY-44	1
30		Air lock	7L	1
31		High square screen	SFJG110*170	1
32		Three-way distributor	FP220X2	1
33		Mixing bin	/	2
34		Rotary level meter	/	2
35		Pneumatic discharge door	500*700	2
36		Pulse dust collector	TBLMa-4	1
37	Second mixing	Buffer bin	/	6
38		Rotary level meter	/	12
39		Batching screw conveyor	PM1-PM8	6
40		Electronic weighing bucket	1000KG	1
41		Pneumatic switch door	500X700	1
42		Pulse dust collector	TBLM a-4	1
43		Small material adding hopper	/	1
44		Single shaft mixer	SHLY2.0	1
45		Horizontal screw conveyor	Lss16	1
46		Bucket elevator	DTG36/23	1
47		Permanent magnet tube	TCXT20	1
48	Third cleaning, third mixing	Puffing bin	/	1
49		Rotary level meter	/	1
50		Feeding screw conveyor	LSS22	1
51		Pet food mixer	SHLY2.0	1
52	Conditioning, puffing	Sensor	/	4
53		Pet food puffing machine	/	1
54		Fan	9–26	1
55		Cyclone dust collector	φ90	1
56		Air blocker	16L	1
57	Drying, second screening	Oven	/	1
58		Conveyor belt	SD50	1
59		Vortex screen	Φ1500	1
60		1#Z bucket elevator	ZD-5L	1
61		Buffer bin	/	1
62		Pneumatic swing door	300×400	1
63		Three-way distributor	FP220X2	1
64		Electronic scale bucket	1 000KG	2
65		Switch door	500X700	2
66		Double shaft mixer	SSHJ2.0	1
67		Buffer bin	/	1
68		Rotary level meter	/	1
69		2#Z bucket elevator	ZD-5L	1
70		Three-way distributor	FP220X2	1
71		Air lock	9L	1
72	Oil mixing, cooling	Flap cooler	SKLN2.5	1
73		Fan	4-72	1
74		Cyclone dust collector	￠90	1
75		Air blocker	5L	1
76		Air blocker	9L	1
7 7		Flap cooler	SKLN2.5	1
78		Blower	4-72	1
79		Cyclone dust collector	￠90	1
80		Air lock	5L	1
81		3#Z bucket elevator	ZD-5L	1
82	Third Screening	Vibrating Screen	Φ1500	1
83		Three-way Distributor	FP220X2	1
84		Electronic Scale Bucket	1000KG	1
85		Switch Door	500X700	1
86		Pulse Dust Collector	T BLMa-4	2
87		Small material weighing bucket	/	2
88		Feeding screw conveyor	LSS16	2
89		Single shaft mixer	SHLY2.0	1
90		4#Z type bucket elevator	/	1
91	Fourth mixing and packaging	Finished product warehouse	/	8
92		Rotary material level meter	/	16
93		Pneumatic swing door	300×400	8
94		Quantitative packaging scale	/	2
95		Power distribution cabinet	/	1
96		Micro control system	/	1
97		Gas supply system	/	1
98	Auxiliary system	Grease adding system	/	1
99		Lifting system	/	1
Total				215

The pet food processing line in Ireland project arranges each production process according to the process flow. Each production process, raw material area, and finished product area are closely connected, and the material transportation distance is short, which is convenient for energy saving and consumption reduction, and improves production efficiency.

The general solid waste temporary storage area and hazardous waste temporary storage area are close to the pollution-producing link, which is convenient for the collection and treatment of various general solid wastes and hazardous wastes. The workshop layout is very reasonable.

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Public works

(1) Water supply

The water consumption of this project is 2800t/a.

(2) Drainage

The annual steam consumption of this pet food processing line in Ireland project is 10,000 tons. The consumption in the production process is calculated as 18% of the product volume, so the product carry-away volume is 3600t/a, and the steam condensate production volume is 6400t/a, which is discharged into the sewage network. Domestic sewage is pre-treated in a septic tank and discharged into the local sewage network.

(3) Heating

The production heating of this pet feed mill project adopts steam heating, and the steam is provided by a natural gas steam boiler.

(4) Power supply

The annual power consumption of the project is 5.04 million kWh, which is provided by the local power supply system and can meet the power demand.

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What is the prospect of building a pet food processing line in Ireland?

The prospect of building a pet food production line in Ireland is relatively optimistic. The following is a detailed analysis:

1. Market potential

(1) Growth of pet market size

• Increase in the number of pets: Ireland has a high pet ownership rate, especially the number of cats and dogs continues to grow. Pets are regarded as family members, which has driven the demand for pet feed market.
• Humanization trend of pets: Pet owners are increasingly concerned about the health and nutrition of their pets and are willing to pay a premium for high-quality pet feed.

(2) Consumption upgrade

• Increase in demand for high-end feed: Consumer demand for high-end pet feed such as natural, organic, and grain-free has increased significantly.
• Demand for customized feed: Customized feed for different pet types, ages, and health conditions is becoming more and more popular.

2. Policy and regulatory environment

(1) EU standards

• Strict food safety regulations: As a member of the EU, Ireland’s pet feed production needs to meet the strict EU standards, which provides regulatory guarantees for the production of high-quality pet feed.
• Environmental protection requirements: The EU has high requirements for environmental protection. Pet feed factories need to focus on sustainable production and environmental protection measures.

(2) Government support

The Irish government provides a variety of support policies for agriculture and food industries, including subsidies, tax incentives and technical support, which may benefit the pet feed industry.

3. Raw material supply

(1) Abundant agricultural resources

• Sufficient supply of local raw materials: Ireland is an important agricultural producer in Europe, with abundant meat, fish and grain resources, which are the main raw materials for pet feed.
• Raw material cost advantage: Sufficient supply of local raw materials and low transportation costs help reduce production costs.

(2) Sustainable raw material trend

Consumers are increasingly concerned about the sustainability of pet feed, and feed produced using local, renewable raw materials is more popular.

4. Technology and innovation

(1) Advanced production technology

• Europe’s leading technological level: Ireland is a European leader in food processing and production technology. It can learn from and apply advanced production technology to improve the quality and efficiency of pet feed.
• Strong R&D capabilities: Ireland has many well-known agricultural and food science research institutions that can provide technical support for the R&D of pet feed.

(2) Innovative product development

• Functional feed: Functional feed that targets pet health needs (such as promoting digestion and enhancing immunity) has huge market potential.
• Environmentally friendly packaging: The use of environmentally friendly packaging materials meets consumers’ expectations for sustainable development.

The prospects for building a pet food processing line in Ireland are relatively optimistic. The huge pet market size, consumption upgrading trend, abundant raw material supply and advanced technology level provide favorable conditions for the development of the industry. However, companies need to face fierce market competition and strict regulatory requirements.

By focusing on the high-end market, strengthening R&D and innovation, and focusing on brand building and sustainable development, companies can occupy a place in the Irish pet feed market and achieve long-term growth.

The Irish pet food industry will continue to benefit from the growth of the global market. High-quality, natural, organic, and additive-free pet food will continue to be favored by consumers as consumers pay more and more attention to the health and nutrition of their pets. In addition, personalized and customized pet food will also become a trend to meet the specific needs of different pets. Irish pet food companies should continue to invest in R&D and innovation to remain competitive in the global market.

If you are interested in building a pet food processing line in Ireland, feel free to contact RICHI MACHINERY for a customized process solution and get a quote for pet food equipment!