Feed mill production; is hard to define as it is a combination of so many factors. Few Factors are as mentioned:

a. Fiber
b. Fat
c. Starch
d. Moisture
e. Protein  & Density
Ingredients with high natural protein will plasticize under heat, which will cause good quality pellets. Ingredients or feeds with high density have high production rates. If an ingredient or feed is high in natural protein as well as density, the high production rates and good pellet quality can be expected.

At low oil & hard formulations project will give around 80 % of the stated production.

1.1.2) Particle size:
If there are bigger granules of maize or other grains the pellet will tend to break at that point after the pellet is formed, resulting in more fines. It is important to maintain uniformity of grinding.

1.1.3) Pellet Durability:
Pellet quality is usually expressed as the pellet durability index(PDI) and measured by using a tumbling can device, in which the pellet sample to be tested is first sieved to remove fines, then tumbled in the tumbling can device for a defined period of time. Then after tumbling, we compare the fines produced during tumbling with actual weight.

PDI = weigh of the pellet after tumbling / weight of Pellet before tumbling x 100
At PDI lower than 88 pellet tends to break during crumbling; producing more fines which rresultin more recycling of feed and low final output.

1.1.4) Die configuration:
And using low compression dies in soft broiler formulation may lead to poor PDI (Pellet Durability Index – Pellet Strength). Considering all the above factors using a separate die for both layer & broiler feed is a better and cost-effective solution. Die selections govern approx. 10-15 % in pellet quality & output.
a) Operators skill:
The operator should regularly check the:
1.1.5)2. The state of wear of the conditioner paddles: To ensure efficient pre-conditioning.
1.1.5)3. Steam traps and filters: To ensure that no condensate is being passed into the conditioner.
1.1.5)4. Press Roll slippage due to increased moisture content, it leads to die roll over.
1.1.5)5. Observing wearing pattern of die; it is recommended to change the side of the die (front side – Back side) for more uniform wear.
1.1.5)6. Setting optimum parameters for different formulations and ingredient qualities.

b) Using spare parts more than their optimum life.

Sometimes we use the consumable parts more than their standard life but loose much more in feed quality and life of other parts which directly are related to them. Like for an average die life cycle it is recommended to use 5 pieces (2.5 sets) of roll shells for a better die life and uniform PDI feed quality. Hence using the roll shells & beaters more than recommended life results in great losses in terms of grinding texture, conditioning & pelleting which directly affects pellet strength and PDI; and productivity and above all pellet quality.

c)Steam quality and quantity:
Proper steam of good quality is required for better performance of machines and production of quality feed. Steam parameters required are:

1. Dry Saturated Steam Minimum 9-10 kg/cm2 at the boiler.
2. 2-2.5 Kg/Cm2 after PRV
3. Good & reputed make boiler, Water softener.
4. Proper Steam traps, insulation of steam line and supporting valves.

d) Recipe Management:
It will take around 30-40 minutes to change the recipe. It’s better if we run one recipe a shift as it saves lots of time.

e) Manpower:
Good results certainly cannot be achieved without the adequate availability of qualified & skilled manpower. The timely response of labor & supervisors to automation controls, overfilling / under filling bins - alarms, etc. helps in smooth production.

f) Power Failure/ Trips / jamming:

The above information is based on data collected from our existing customers & internet sources and is only for your reference. As expertise in feed mill engineering only, lark engineering will not be responsible for any type of loss occur due to above stated information.