Premix Feed Production Line in Brazil

RICHI MACHINERY

Project Overview

10-12T/H premix feed production line in Brazil was developed as a capacity expansion inside an already operating feed mill, where the client needed to move beyond conventional compound feed and enter the premix segment with stable quality and higher margin products. Instead of building a completely new factory, the project focused on optimizing the existing layout and integrating two dedicated premix lines within the current workshop.

The final setup includes two parallel premix feed production lines with identical process flow, designed for livestock and ruminant premix products. The total annual output reaches 30,000 tons, operating under a single-shift system. What made this project slightly tricky was not the capacity itself, but the need to maintain strict mixing uniformity while handling multiple fine powder raw materials with different bulk densities.

10-12T/H

capacity

$420,000

investment

Brazil

location

Feed

project type

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How the Project Actually Started

The first inquiry came in March 2025. The client didn’t start by asking about equipment. Instead, the question was very direct:

“We already produce compound feed. Can we add premix without rebuilding everything?”

That’s usually where these projects become interesting.

The client operates a mid-sized animal feed mill plant in central Brazil, mainly producing poultry and livestock feed. Existing production capacity:

120,000 tons/year compound feed
80,000 tons/year concentrated feed

But they were facing two issues:

Increasing demand for premix from local farms
Lower margins on traditional feed products

By May 2025, after several rounds of technical discussions and layout adjustments, the project was confirmed. Contract signing was completed in June 2025, with equipment manufacturing starting immediately.

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Existing Plant Snapshot (Before Expansion)

The animal feed processing plant was already functional, which meant every modification had to fit into real constraints — not just drawings.

Production Capacity

Product Type	Packaging	Annual Output
Compound Feed	40 kg bags	120,000 tons
Concentrated Feed	40 kg bags	80,000 tons

Basic Plant Information

Total site area: 6,172 m²
Workforce: 20 employees
Working schedule:
- 1 shift/day
- 8 hours/shift
- 300 days/year

Existing Facilities

Area	Size
Office Area	500 m²
Living Area	100 m²
Production Workshop	11,400 m²
Raw Material Warehouse	2,040 m²
Finished Product Warehouse	992 m²

One thing noticed during the first visit — dust accumulation in certain corners of the workshop. Not a major issue, but something that always needs attention when adding premix systems.

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Why Premix? (Real Business Reasoning)

The decision wasn’t random.

Brazil’s livestock sector, especially poultry and cattle, has been shifting toward more precise nutrition management. Farms prefer:

Customized premix
Stable trace element dosing
Consistent vitamin distribution

The client had access to downstream customers already. What they lacked was:

Controlled micro-ingredient handling
High-precision mixing
Clean packaging environment

That’s exactly what this 10-12t/h premix feed production line in Brazil was designed to solve.

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Raw Materials (Premix Formulation)

Premix production is not about large volume ingredients. It’s about accuracy.

In this premix feed mill project, the material system includes fine powders and liquid additives.

Raw Material Consumption

Material Name	Form	Annual Consumption
Trace Elements	Powder	0.0192 ×10⁴ t
Minerals	Powder	0.12 ×10⁴ t
Dicalcium Phosphate	Powder	0.296 ×10⁴ t
Limestone Powder	Powder	0.616 ×10⁴ t
Rice Husk Powder	Powder	0.63 ×10⁴ t
Lysine	Liquid	0.144 ×10⁴ t
Zeolite Powder	Powder	0.8 ×10⁴ t
Vitamin Premix	Powder	0.38004 ×10⁴ t

A small but practical observation:
Rice husk powder and zeolite act as carriers. Without proper mixing sequence, segregation happens fast — especially during conveying.

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Production Process — What Actually Happens Inside

This is a non-pelletizing premix system, which is quite different from standard feed pellet production lines. No conditioning, no pelleting, no cooling. Everything revolves around precision and cleanliness.

Process Flow (Simplified but Real)

Dosing & Weighing
- Micro and macro ingredients weighed separately
- Accuracy is critical (especially for trace elements)
Batching
- Powder materials combined in batching bins
- Controlled feeding to avoid bridging
Mixing
- Double-shaft premix mixer machines used
- Mixing time adjusted based on bulk density differences
Liquid Addition
- Lysine added during mixing phase
- Spray system ensures uniform distribution
Discharge to Finished Bin
- No intermediate processing
- Direct transfer to finished product silo
Packaging
- Automatic weighing
- Bagging + sewing
- Storage ready for dispatch

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Equipment Configuration (Expansion Section)

Two identical lines were installed.

Main Equipment List

Equipment Name	Quantity
Feeding Hopper & Grid	2
Pulse Dust Collector	4
Double Shaft Mixer	2
Bucket Elevator	2
Mixing Bins	2
Finished Product Bins	2
Automatic Packing Scale	2

One important choice:
Two mixers instead of one large unit. This gives flexibility — one line can run while the other is cleaned or adjusted.

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Power & Utilities

Power supply integrated into existing system
Annual electricity consumption: ~3.3 million kWh
No steam or thermal system required

This is one reason premix projects are attractive — lower utility complexity compared to pellet plants.

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Layout Adjustment — Real Engineering Work

Since no new land was added, everything had to fit into the existing workshop.

Key adjustments:

Reorganized material flow direction
Separated premix area from compound feed area
Added enclosed conveying points to reduce contamination

Not everything worked perfectly on paper. During installation, one conveyor path had to be modified because of height limitations. That happens often in retrofit projects

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Investment & Cost

Equipment cost: ~$420,000
Total project investment: ~$650,000

For a 10-12t/h premix feed production line in Brazil, this falls within a reasonable range.

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Delivery & Shipping

Shipping port: Qingdao Port, China
Destination port: Santos Port, Brazil

Delivery time: ~45 days at sea

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Commissioning Notes (What Usually Doesn’t Show in Brochures)

First test run:

Mixing uniformity slightly off
Moisture imbalance due to liquid addition

After adjustment:

Mixing time extended
Liquid spray pressure reduced

Final result:

Uniformity reached industry standard
Stable operation achieved within 3 days

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Market Outlook in Brazil

Premix demand in Brazil is growing steadily, especially in:

Poultry farming
Cattle breeding
Large-scale integrated farms

Reasons:

Farmers shifting toward precision feeding
Feed companies moving upstream into additives
Increasing export-driven livestock production

Compared to traditional feed mills, premix plants:

Require lower energy
Have higher product value
Offer faster return cycles

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Final Thoughts from This Project

This 10-12t/h premix feed production line in Brazil is a good example of how existing feed mill engineerings can upgrade without massive reinvestment.

Not every project needs a new factory. Sometimes, optimizing what already exists is the smarter move.

From early consultation to final commissioning, the key wasn’t just equipment — it was understanding:

Material behavior
Mixing precision
Space limitations

For companies considering similar upgrades, the first step is usually simple:

Check your current plant.
Look at your raw materials.
Then decide what you really need to add — not rebuild.

And that’s where proper planning makes the difference.

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RICHI Service

● Consulting

Customer Consultation

We want to have a deep understanding of your industrial process, to know your exact needs of feed, wood, biomass, fertilizer or other pellet processing.

● Design

Animal feed Plant Design

Based on your unique situation and industrial process, we will tailor complete pellet plant you need, and inform you of every additional detail that could facilitate operation, minimize total cost.

● Manufacturing

Equipment Manufacturing

The critical components of the of the complete pellet production line equipment are built in our own workshops in Asia. Additional equipment is manufactured by our worldwide network of reliable partners.

● Testing

Quality Inspection & Testing

Before leaving the factory, all equipment will be inspected by the quality inspection department. We can also provide customers with testing services from a single machine to a complete pellet plant system, and provide you with real actual data for “worry-free use.”

● Delivery

Equipment Delivery

In equipment boxing and packaging, we adopt professional packaging and modular solutions to ensure the safe and non-destructive delivery of pellet plant equipment.

● Installation

Installation & Commissioning

Whether you choose your own subcontractor for the erection phase or you want to install everything together with us, a Richi supervisor will be around to make sure everything is mounted in a safe and thorough way.

● Training

Staff Training

We provide comprehensive training for the technicians of each project. We can also continue to provide support for the technicians during latter project operation.

● After-sales

Project Follow-Up

When everything is up and running our Richiers will help you further whenever needed. We are ready to answer your call 24/7.We’ll also visit you regularly to learn about your needs.

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Who we are

RICHI Machinery is one of the world’s leading suppliers of technology and services for the animal feed, aqua feed and pet food industries, also the largest pellet production line manufacturer in China.

Since 1995, RICHI’s vision to build a first-class enterprise, to foster first-class employees, and to make first-class contributions to society has never wavered.

In the past three decades, we have expanded our business to a wide range of areas, including animal feed mill equipment, aqua feed equipment, pet feed equipment, biomass pellet equipment, fertilizer equipment, cat litter equipment, municipal solid waste pellets equipment, etc.