Pig Feed Mill In United States

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overview

The pig feed mill in United States project was undertaken by a large livestock company in the United States. The customer began to invest in the construction of three modern pig farms in 2020. Considering that the pig farming project is located in a remote area and the feed consumption in the pig farming process is large, purchasing directly from the market may result in high feed costs, long transportation cycles, and feed quality cannot be guaranteed. Therefore, the customer company invested in the construction of a pig farm supporting feed workshop, which is this project.

This project is divided into two phases, with a production scale of 100,000 t/a in the first phase and 180,000 t/a in the second phase, with a total production scale of 280,000 t/a. The feed processed by this project will be used in the customer’s pig farm and will not be sold to the outside.

The overall design, civil engineering plan and production line layout of the project are all provided by the engineering team of RICHI MACHINERY, and the first phase project that has been built is also undertaken by us, and the full set of equipment is designed and manufactured by us. The second phase project has not yet started construction.

The labor quota for the first phase of the pig feed mill in United States project is 25 people, and the labor quota for the second phase is 15 people, all of whom are provided with food and accommodation in the site. The employee work system adopts a two-shift system, with each shift working 8 hours and 300 working days per year.

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Construction content

The construction period of the pig feed mill in United States project includes site leveling, main and auxiliary engineering construction, equipment installation, site cleaning, acceptance, etc. The construction site of the project is a forest land, which is full of weeds. Trees and weeds need to be cleared at the beginning of construction.

The main engineering of the USA pig feed mill plant project is the construction of the production workshop, and the auxiliary projects include the raw material workshop, finished product workshop, silo area, boiler room, etc., all of which are constructed with steel frame structure. The project equipment includes bucket elevator, permanent magnet drum, screening machine, crusher, granulator, cooling tower, pulse dust collector, cyclone dust collector, etc.

The main construction content of this project is shown in the following table.

Engineering category	Production unit	Engineering content and function
		Phase I	Phase II
Main engineering	Main workshop	1 building, 6 floors, frame structure, covering an area of ​​629m2	Shared with Phase I
	Raw material and finished product workshop	1 building, 1 floor, frame structure, covering an area of ​​947m2	1 building, 1 floor, frame structure, covering an area of ​​947m2
	Bulk workshop	1 building, 5 floors, frame structure, covering an area of 263m2	1 building, 5 floors, frame structure, covers an area of ​​190m2
Auxiliary engineering	Unloading shed	2 buildings, one of which is 2 floors, 12.3m high, color steel tile sealed frame structure, covers an area of ​​276m2; another 1 building is 1 floor, 13.3m high, frame structure, covers an area of ​​247m2	2 buildings, 13.3m high, frame structure, single building covers an area of ​​247m2;
	Comprehensive building	1 building, 4 floors, brick-concrete structure, covers an area of ​​473m2	Shared with the first phase
	Gate guard	1 building, 1 floor, brick-concrete structure, covers an area of 150m2	Shared with Phase I
	Washing and disinfection room	1 building, 1 floor, brick-concrete structure, covering an area of ​​147m2	Shared with Phase I
	Raw material washing and disinfection room	1 building, 1 floor, brick-concrete structure, covering an area of ​​155m2	Shared with Phase I
	Boiler room	1 building, 1 floor, covering an area of ​​164m2	Shared with Phase I
Storage and transportation engineering	Silos	5, including 2 corn silos with a single tank volume of 2170m3/unit×2, soybean meal: 590m3/silo×3	8, including 3 corn silos with a single tank volume of 2170m3/unit×3, soybean meal: 590m3/silo×5
	Fuel yard	100m2	Shared with Phase I
	Ash yard	20m2	Shared with Phase I
	Hazardous waste temporary storage room	5m2	Shared with Phase I

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Product plan

The product plan for this pig feed mill in United States project is shown in the following table.

No.	Product Name	Status	Scale (10,000 tons)		Remarks
			Phase I	Phase II
1	Pig Feed	Granular	10	18	The feed products comply with the US “Compound Feed for Piglets and Growing and Finishing Pigs” standard. The annual output of pig feed products for this project is 280,000 tons.

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Main raw and auxiliary materials

The main raw and auxiliary materials for this pig feed mill in United States project are shown in the table below.

No.	Category	Raw material name	Annual consumption (t)		Maximum storage (t)	Storage location	Source
			Phase I	Phase II
1	Main raw and auxiliary materials	Corn	66833	120299	18713	Silo	Purchased, steam Transport, bulk
3		Soybean meal	6056	10900	1696	Silo	Purchased, truck transport, bulk
4		Premix	398	717	112	Raw material workshop	Purchased, truck transport, bagged
5		Stone powder	847	1524	237	Raw material workshop	Purchased, truck transport Transport, bagged
6		Calcium hydrogen phosphate	637	1147	178	Raw material finished product workshop	Purchased from outside, transported by truck, bagged
7		Vegetable oils and fats	1195	2151	335	Storage tank	Purchased from outside, transported by truck
8		Feed additives	24034	43261	6729	Raw material finished product Workshop	Purchased, transported by truck, packed in bags
Total			100000	180000	28000	/	/
1	Energy	Biomass Molded Fuel	1239	2222	346	Boiler Room Fuel Storage Yard	Purchased, transported by truck Transport
2		Water	8616	13256	/	/	Municipal water supply network
3		Electricity	300,000 kW·h/a	500,000 kW·h/a	/	/	Municipal power supply
1	Others	Lubricating oil	0.2	0.3	0. 1	Main workshop	Purchased from outside, transported by truck, in barrels

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List of physical and chemical properties of main raw and auxiliary materials

Physical and chemical properties of raw and auxiliary materials for this pig feed mill in United States project are shown in the table:

Name	Physical and Chemical Properties
Corn	Corn is also called corn, corn, and pearl rice. It is rich in nutrients, protein, and cellulose; moisture ≤14.5%, crude protein ≥8.0%, and bulk density ≥680g/L. It is mainly used for food, feed, and industrial raw materials.
Soybean meal	The main components of soybean meal are: protein 40%~48%, lysine 2.5%~3.0%, tryptophan 0.6%~0.7%, and methionine 0.5%~0.7%. The biggest use of soybean meal is as the main raw material for making livestock and poultry feed. It can also be used to make pastry food, health food, and raw materials for cosmetics and antibiotics.
Premix	Premix is ​​a homogeneous mixture made of multiple additives of the same type or multiple additives of different types in a certain ratio. Since the proportion of additives in the premix is ​​very small, it is a mixture of multivitamins, trace elements, constant mineral elements, some protein feed non-nutritional additives and carriers.
Stone powder	Stone powder is commonly known as limestone and calcium powder. It contains 32% calcium and is heavy calcium carbonate. It is a commonly used powdered inorganic filler with the advantages of high chemical purity, high inertness, low chemical reaction, and good thermal stability.
Calcium hydrogen phosphate	Calcium hydrogen phosphate, white monoclinic crystalline powder, odorless and tasteless. It is stable in the air and begins to lose crystal water when heated to 75°C to become anhydrous. It becomes pyrophosphate at high temperature.
Plant oils and fats	Plant oils and fats are extracted from plant seeds, pulp and other parts. They are natural high molecular weight compounds composed of fatty acids and glycerol. They are collectively referred to as plant oils and fats. They include peanut oil, rapeseed oil, sesame oil, corn oil, etc.
Feed additives	Feed additives refer to small or trace substances added during the production, processing and use of feed. The amount used in the feed is very small but the effect is significant. The additives used in this project mainly contain lysine, methionine, trace elements (ferrous sulfate, copper sulfate, zinc sulfate and calcium carbonate, etc.)

Calculation of boiler fuel usage:

Phase I: Set up a 2 tons/hour biomass boiler with a thermal efficiency of 84%. The heat required to produce 1 ton of steam is calculated as 600,000 kcal (2508MJ). The combustion rate of biomass molding fuel is calculated as 95%. The low calorific value of biomass molding fuel is conservatively calculated as the lowest 16.74MJ/kg. The amount of steam required for the first phase of production is 6600m3/a. The amount of biomass molding fuel used in the first phase is about 6600×2508÷84%÷95%÷16.74÷1000=1239t/a.

Phase II: Set up a 4 tons/hour biomass boiler with a thermal efficiency of 84.3%. The steam required for the first phase of production is 11880m3/a, so the amount of biomass molding fuel used in the first phase is about 11880×2508÷84.3%÷95%÷16.74÷1000=2222t/a.

Therefore, the total amount of biomass molding fuel used in this pig feed mill in United States project is 3461t/a.

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Main production equipment for pig feed mill in United States

The main production equipment of this pig feed mill in United States project is shown in the table below.

Main production units	Main processes	Production facilities	QTY		Facility parameters
			Phase I	Phase II
Feed processing	Raw material handling	Feed hopper	5	6	Volume: Steam Car unloading + manual feeding port 3-5m3
		Magnetic separator	1	1	Processing capacity: 30-50t/h (single unit)
		Cleaning screen	1	2	Removal rate: ≥80-90%
		Permanent magnetic cylinder	1	1	Processing capacity: 40t/h (single unit)
	Crushing	Crusher	2	2	Production capacity: 70-80t/h (single unit)
	Mixing	Mixer	1	1	Production capacity: 80t/h (single unit)
		Conditioner	2	2	Production capacity: 20t/h (single unit)
	Pelletizing	Pelletizing machine	1	3	Processing capacity: pelletizing machine export capacity calculation particle diameter 3.8mm, compression ratio 1:7 pig feed capacity 72T-80T
		Grading screen	1	3	Removal rate: 90-95%
Boiler room	Storage system	Fuel silo	1	0	Volume: 0.7m3
		Fuel yard	1	0	Area: 100m2
		Ash yard	1	0	Area: 20m2
	Conveying system	Fuel loading device	1	1	Conveying capacity: 800t/h
		Belt conveyor	1	1	Conveying capacity: 800t/h
	Softened water preparation system	Ion exchange resin tank	2	0	Volume: 0.5m3
		Desalted water tank	1	0	Volume: 6m3

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Process flow design of the American pig feed plant project

The production process flow of this pig feed mill in United States project is as follows:

1. Raw material unloading, receiving and initial cleaning section

This pig feed mill in United States project is divided into three receiving and cleaning production lines: granular material line, powder material line and auxiliary material powder material line. Granular raw materials such as corn are transported by car to the unloading shed (enclosed workshop) and poured into the unloading port. At the unloading port, they are lifted by scrapers and bucket elevators.

The rear end of the bucket elevator is designed with a pneumatic tee, which controls the corn to enter the cleaning room for cleaning and impurities to ensure that subsequent equipment is free from failure or damage. After corn is lifted to the double-layer cylinder primary cleaning screen, it is then removed by a permanent magnetic cylinder for iron removal.

After impurities are removed, corn is transported to the silo for temporary storage by a bucket elevator and conveyor, and barley is transported to the barley silo for temporary storage by a bucket elevator and conveyor. Soybean meal is transported to the raw material warehouse by an elevator after passing through the feeding port and the scraper. Stone powder, calcium hydrogen phosphate (powdery auxiliary material), premix, additives, etc. are packaged in bags and unloaded manually to the raw material finished product workshop for temporary storage.

2. Granular raw material crushing section

The corn after primary cleaning is transported from the corn silo to the feeder through a scraper and bucket elevator and enters the rotary distributor, and then transported to the crusher by a conveyor for crushing. After crushing, the raw materials are sent to different batching bins by the distributor for storage.

3. Batching and mixing section

The batching and mixing section is the core process of feed processing. It is fully automated. The batching system automatically controls the amount of raw materials added in the batching bin according to the formula pre-entered into the computer. After the batching is completed, the scale door automatically opens and the materials are unloaded into the mixer through the conveying pipeline.

Soybean meal and other materials are automatically fed by the feeding system and enter the premix batching auger through the elevator and scraper. Stone powder and calcium dihydrogen phosphate are manually unpacked and fed into the feeding system through the elevator and scraper to enter the premix batching auger.

The purpose of the premixing stage is to mix the trace raw materials and carriers required by the animals, distribute the trace raw materials well, and shorten the mixing cycle of the full-price batched feed. The premixed raw materials and crushed corn enter the batching auger through the elevator.

After all the raw materials are batched, they are mixed together through the bucket elevator and conveyor into the mixer. The uniformity of the mixture is adjusted by reasonably utilizing the mixing time and feeding sequence of the mixer.

4. Granulation Section

The granulation section of this pig feed mill in United States project is the process of processing the mixed powder feed into granular feed. The whole process includes: conditioning and quality preservation, extrusion, granulation, cooling, screening, and killing the toxins in the raw materials by high temperature.

The pellets are squeezed out through the ring membrane to make the feed density higher, thereby improving the storage capacity of the silo. The pellets are easy to transport and suitable for automatic feeding systems.

Conditioning and quality preservation: Before the powder leaves the mixer and enters the granulator, it is necessary to adjust and process the powder, mainly by introducing steam into the conditioner, so that the feed and steam are mixed and stirred, and the heat and moisture exchange is carried out (conditioning is the key link in the production of pellets, and the effect of conditioning directly determines the quality of the product and the capacity of the pellet machine).

Before pelleting, the high-temperature and high-humidity steam generated by the boiler is introduced (the steam is in direct contact with the material), and the steam temperature is about 150℃; the steam will reduce the pressure and temperature when it enters the conditioner, and the steam temperature is about 110℃.

After contacting the material, the material temperature rises to about 60~85℃, and the conditioner needs to stay for 30~45s; the temperature of the conditioner is maintained at 60~85℃, and the residence time is about 60s; the feed after conditioning has a certain degree of adhesion, which is conducive to particle formation, starch gelatinization, and improves the digestibility of the feed. In order to ensure the effect of feed conditioning, the project is equipped with a quality preserver to stabilize the quality of the feed.

• Extrusion and granulation:
  The granules just squeezed out of the pig feed pellet machine have a moisture content of 15.5~17% and a temperature between 60~85℃. The granules in this state are fragile and not suitable for storage and transportation. They also need to be quickly cooled to near room temperature (generally 6~8℃ higher than room temperature) by a cooler, and the moisture content is reduced to 14%, making the granules hard.
• Cooling:
  During the whole working process of the countercurrent cooler, the fan is always on. Since the material flows from top to bottom, and the wind is opposite to the flow direction of the material, flowing from bottom to top, and the cold wind contacts the cold material, and the hot wind contacts the hot material, this cooler is called a countercurrent cooler.
  Since the temperature and moisture of the particles in the silo are high, the material stays in the silo for a period of time. Through the suction of the fan, natural air enters from the bottom and passes through the material layer in the silo for heat exchange.
  At the same time, the fan exhausts the heat and moisture of the material, which plays a role in cooling the material and reducing the moisture. The countercurrent cooler is used to cool the material, ensuring that the feed temperature is 3-5℃ higher than the room temperature, the moisture is below 12%, the pellets become hard, and the feed products meet the requirements of the customer company.
• Screening:
  The cooled pig feed pellets are screened by the fool grading screen and then enter the finished product warehouse through the conveyor. A small amount of fine powder is screened out and returned to the mixing warehouse for mixing.

⑤ Measuring bulk

After screening, the finished feed particles are conveyed into the bulk workshop for temporary storage through a conveyor and transported to the pig farm by truck or scraper trestle.

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Plant layout

The pig feed mill in United States project has clear functional divisions, smooth process flow, compact layout, and smooth flow of people and goods. The overall layout of this project satisfies the smoothness of the process flow, reflects the convenience of material transportation, simplifies the transportation of materials, facilitates production, and the general layout is relatively reasonable.

This project has two entrances and exits. The main entrance and exit is located on the southwest side of the plant. A raw material washing and disinfection room is set up at the entrance and exit. The other entrance and exit is connected to the second field to facilitate feed transportation.

The project sets the living and office area on the southwest side of the plant, which belongs to the side wind direction. The main workshop is arranged in the center of the plant. The southwest side of the main workshop is the silo area and unloading peng, the north side is the raw material finished product workshop, and the northeast side is the bulk workshop. This workshop mainly stores finished feed temporarily and is close to the entrance and exit, which is convenient for feed transportation.

In addition, the boiler room is set on the north side of the pig feed plant, which belongs to the downwind direction, which can reduce the harm of exhaust gas to employees. The roads in the project plant are arranged along the production area and silo area.

On the basis of ensuring the clear flow of vehicles and people, and different internal and external flow lines in the plant area, the traffic lines between the closely connected parts in the area are as short as possible, shortening the transportation routes of raw materials and finished products.

The animal feed factory project plant area has a reasonable plane layout, clear functional division, and convenient transportation in the plant area.

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Public works

1. Water supply

(1) Domestic water

The labor quota for the first phase of the pig feed mill in United States project is 25 people, and the labor quota for the second phase is 15 people. All of them are accommodated and fed in the factory. The domestic water consumption is calculated as 130L/person·d. The water consumption for the first phase of the project is 3.25m3/d. (975m3/a), and the water consumption for the second phase is 1.95m3/d. (585m3/a).

When the daily domestic water consumption per capita is ≤150 liters/person·day, the pollution reduction coefficient is 0.8, then the domestic sewage generation in the first phase is 2.6m3/d (780m3/a), and the domestic sewage generation in the second phase is 1.56m3/d (468m3/a).

After pre-treatment in a tertiary septic tank, the domestic sewage is treated in the self-built sewage treatment facilities of the second phase of the pig farm project and reused for agricultural and forestry irrigation after meeting the standards, and is not discharged.

(2) Production water

The production water of this project is mainly used for boiler replenishment.

① Steam consumption of pelleting process

A 2-ton steam/hour biomass boiler is set up in the first phase, and a 4-ton steam/hour biomass boiler is set up in the second phase. The pelleting process requires 60kg of dry saturated steam for each ton of feed conditioning. Therefore, the steam consumption of the pelleting process in the first phase is 20m3/d (6000m3/a), and the steam consumption of the pelleting process in the second phase is 36m3/d (10800m3/a).

During the steam transportation process, some steam will be lost in the process of cylinder separation and pressure relief. Calculated at 1% of the steam consumption, the steam loss in the first phase is 600m3/a, and the steam loss in the second phase is 1080m3/a. Therefore, the total steam consumption in the first phase is 22m3/d (6600m3/a), and the total steam consumption in the second phase is 39.6m3/d (11880m3/a).

② Boiler sewage and softening wastewater

Fresh water needs to be softened before entering the boiler. The boiler is equipped with soft water preparation equipment. During the soft water preparation process, the saturated ion exchange resin needs to be regularly rinsed and regenerated, which will produce a certain amount of softening wastewater.

During the operation of the boiler, as the boiler water continues to evaporate, the impurity concentration in the water gradually increases. In order to control the quality of boiler water, it is necessary to discharge sewage regularly, so a certain amount of boiler sewage will be produced.

The consumption of biomass molding fuel in the first phase is about 1239t/a, and the consumption of biomass molding fuel in the second phase is about 2222t/a. Therefore, the total amount of boiler sewage and softening treatment wastewater in the first phase is about 441m3/a (1.47m3/d), and the total amount of boiler sewage and softening treatment wastewater in the second phase is about 791m3/a (2.64m3/d).

Therefore, the total amount of production water in the first phase is about 6600+441=7041m3/a

(23.47m3/d), and the production water in the second phase is about 11880+791+468=13256m3/a (44.19m3/d).

③ Disinfection water

The disinfectant used in this pig feed mill in United States project is a mixture of chemicals and water in a certain proportion, and the disinfection method adopts atomization disinfection.

Disinfection time nodes When the main employees go to and from get off work and when external vehicles enter the factory, the annual consumption of the project disinfectant is 60kg, which needs to be diluted to a concentration of 100mg/L disinfectant before use, so the annual water consumption is 600m3/a, 2m3/d. After the disinfectant is atomized, it evaporates naturally.

2. Drainage

The factory implements rainwater and sewage diversion. Rainwater is collected in the collection ditch and discharged outside the factory after sedimentation in the sand settling tank; domestic sewage is pre-treated in the three-level septic tank, and then sent to the self-built sewage treatment facilities of the pig farm phase II project through pipelines with boiler sewage and soft water treatment wastewater.

3. Power supply

After the completion of the construction of this pig feed mill in United States project, the total power consumption of the first phase is about 300,000 kW·h/a, and the total power consumption of the second phase is about 500,000 kW·h/a, which will be supplied by the municipal power grid and can meet the power demand of the project.

If you are interested in this project and want to build your own pig feed production line, feel free to contact RICHI MACHINERY to get a free pig feed production line construction plan, equipment quotation, process design and layout.