Poultry Mash Feed Plant In Malaysia

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overview

This is a 3-5 tons/hour poultry mash feed plant in Malaysia project.

Against the backdrop of the booming poultry and egg industry in Malaysia, a local agricultural enterprise with 20 years of breeding experience decided to invest in the construction of a professional layer chicken poultry feed plant.

This decision stems from several key factors:

• First, Malaysia’s egg self-sufficiency rate reaches 115%, and it is one of the few countries in Southeast Asia that has achieved net export of poultry eggs. It exports more than 500 million eggs to Singapore and Brunei each year, and the demand for high-quality feed continues to grow;
• second, the traditional family-style feed mixing method is nutritionally uneven, resulting in egg production rates of laying hens fluctuating by as much as 15%;
• finally, the Malaysian Ministry of Agriculture launched the “Smart Breeding Plan” to provide 10-15% tax relief for companies that use automated feed equipment.

Based on these market opportunities, the customer began research in early 2023 and eventually introduced this modern poultry mash feed plant in Malaysia with an output of 3-5 tons per hour for US$43,000, aiming to improve feed quality while reducing overall production costs.

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Raw material formula and localized innovation

The customer made full use of Malaysia’s agricultural resources and designed a set of laying hen feed formulas with tropical characteristics:

• Main energy raw materials: local palm meal (accounting for 25-30%, the cost is 40% lower than corn), imported broken rice (10%)
• Protein source: Indonesian fish meal (18% protein), soybean meal (44% protein) mixed
• Functional additives: coconut oil residue (natural antioxidant), chili powder (natural appetite-stimulating ingredient)
• Mineral formula: Specially added selenium (to cope with the problem of selenium deficiency in Malaysian soil)

The highlights of this formula are:

The use of palm meal to replace part of the grain not only reduces the cost, but also its high fiber characteristics ( 12-14%) and significantly improves the intestinal health of laying hens;

Innovatively add 3% fermented pineapple residue (Malaysian specialty), the bromelain in it helps to improve protein digestibility by 8-10%;

According to the characteristics of tropical climate, add 0.5% garlic powder to prevent common digestive tract diseases in hot and humid environments.

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the core process of poultry mash feed plant in Malaysia

This poultry mash feed plant in Malaysia adopts the process of “precise ingredients + efficient mixing + sterilization treatment”, which is specially designed for the characteristics of raw materials in tropical areas:

Raw material pretreatment stage

All raw materials must undergo three quality inspections after entering the site: moisture detection (required ≤12%), mycotoxin screening (aflatoxin ≤20ppb), and protein content verification.

Fiber raw materials such as palm meal must first pass through a 2mm sieve to remove crude fiber, and fish meal must be sterilized at 60℃. The unique raw material pretreatment system includes:

• Magnetic separation iron removal device (processing capacity 5 tons/hour)
• Gravimetric stone remover (removes impurities such as sand and gravel)
• Pulse dust removal system (controls the dust concentration in the workshop ≤5mg/m³)

Core mixing process

Use “three-level progressive mixing” technology to ensure uniformity:

• Premixing: trace components such as vitamins and minerals are first diluted and mixed with the carrier (usually rice bran) at 1:10
• Main mixing: The twin-shaft paddle mixer runs at 32rpm for 180 seconds, and the mixing uniformity CV≤5%
• Post-ripening: The mixed feed is left to stand in the temporary storage bin for 30 minutes to fully integrate the nutrients

The specially equipped tropical cooling system can quickly reduce the material temperature from 45℃ to below 30℃ after mixing to prevent the degradation of nutrients in high temperature and high humidity environments.

Sterilization and packaging stage

After the powder passes through the ultraviolet sterilization tunnel (killing pathogens such as Salmonella), it is packaged by a fully automatic packaging machine at a specification of 25kg/bag.

The packaging line is specially designed with moisture-proof lining to adapt to the average relative humidity environment of 85% in Malaysia.

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Key equipment configuration for poultry mash feed plant in Malaysia

This poultry mash feed plant in Malaysia worth $43,000 includes the following core equipment:

• SWFP-660 poultry feed hammer mill: equipped with corrosion-resistant stainless steel screen, suitable for high-fiber raw materials
• SLHSJ-2 double-shaft high-efficiency mixer: 2 tons per batch, mixing uniformity CV≤3%
• Automatic batching system: 8-bin design, weighing accuracy ±0.1%
• Pulse dust removal unit: dust removal efficiency ≥99%, automatic reuse of recycled powder
• Fully automatic packaging line: supports multiple packaging specifications of 5-50kg, error ±0.2%

It is particularly worth mentioning its “tropical” design highlights:

• All motors are equipped with IP65 protection level to prevent corrosion in high humidity environments
• The poultry feed mixer has built-in cooling coils to control the material temperature below 40°C
• Use mildew-proof circuit boards to adapt to high temperature environments all year round

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Multifunctional expansion of poultry mash feed plant in Malaysia

In addition to laying hen powder, the poultry mash feed plant in Malaysia only needs to adjust the formula and process parameters to produce:

• Early starter feed for broilers (finely crushed to less than 0.8mm)
• Aquatic seedling powder feed (add fish oil spray system)
• Special economic animal feed (such as quail, guinea fowl, etc.)
• Premix carrier (can be processed to 80 mesh fineness)

What customers value most is its flexible formula switching ability – during the surge in corn prices in the fourth quarter of 2023, they completed the conversion from corn-soybean meal type formula to palm meal-cassava powder type formula in just 3 days, saving 23% of raw material costs.

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Analysis of Malaysia’s market prospects

The successful implementation of this poultry mash feed plant in Malaysia project reflects three important trends in Malaysia’s feed industry:

Industry integration is accelerating:

Among the more than 800 feed factories in the country, the top 10 companies have occupied 75% of the market share, and small and medium-sized manufacturers must improve their competitiveness through equipment upgrades.

Compared with traditional equipment, this poultry mash feed plant in Malaysia can reduce the production cost of a ton of feed by about US$12, and the investment recovery period is only 18 months.

Precise nutritional needs:

With the increase in the density of laying hens (now an average of 8-10 per square meter), the price premium of special feed for different egg-laying stages has reached 15-20%.

Halal certification value-added:

Feeds that have obtained JAKIM halal certification can be exported to the Middle East market, and customers are planning to develop feed formulas that comply with Islamic teachings.

According to customer feedback, since the production line was put into operation in July 2023, the laying hen feed produced has achieved three major improvements in the farm:

• Egg production rate increased from 82% to 87%
• Feed-egg ratio decreased from 2.3:1 to 2.1:1
• Egg breakage rate reduced by 40% (thanks to the balanced calcium-phosphorus ratio)

In the future, as the Malaysian government promotes the “Egg Industry 2030 Plan” (targeting an annual output of 18 billion eggs), this type of automated hen feed plant will become the industry standard.

It is particularly noteworthy that Malaysia’s unique geographical location makes it a distribution center for feed raw materials in ASEAN. In the future, the production line can also undertake OEM business and provide customized feed production services for neighboring countries.

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Localized innovation practice

The poultry mash feed plant in Malaysia developed two special applications in operation:

• Using the abundant seaweed resources in Malaysia, the customer tried to add 2% spirulina powder to improve the yolk color (reaching DSM yolkfan level 12).
• Cooperated with local research institutes to develop an “anti-heat stress formula” and added 0.3% moringa leaf powder to help laying hens cope with high temperature weather.

These innovations have made the poultry feed production line not only realize the value of the equipment, but also become an important case for promoting the upgrading of Malaysia’s poultry and egg industry.

Compared with European equipment with the same configuration (usually quoted at US$60,000 to US$80,000), this production line has obvious cost-effectiveness and is particularly suitable for the modernization of small and medium-sized feed companies in Southeast Asia.

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Highlights of operational data

Actual production capacity is stable at 4.2 tons/hour (reaching 105% of the nominal capacity)

• Electricity consumption per ton is only 18 degrees (25% lower than traditional equipment)
• The number of operators on the production line has been reduced from 6 to 3
• The product has been certified by the Malaysian Veterinary Department (DVS)

This case fully proves that the animal feed production line tailored to the characteristics of tropical regions can not only solve the pain points of the local breeding industry, but also create a unique market competitive advantage.

With the consumption of poultry eggs in the ASEAN region growing at an annual rate of 6-8%, this type of efficient and flexible poultry mash feed plant in Malaysia will surely usher in a broader development space.