[Mrs. Mopelola O. Omotoso]

There must be in addition to the points raised, the development of Standard Operating procedures (SOPS) for all the operations in the feedmill and the SOPs must be strictly adhered to. Very importantly is the restriction of movements of outsiders and the use of recycled feed sacks which are ready sources of disease spread.

[Michael]

Unavailability of nutrients supply

[Bello Bashir]

Variability in maize quality significantly impacts pellet mill operation, primarily affecting pellet quality, mill efficiency, and overall feed production. Maize’s moisture content, particle size, starch content, and fiber content all influence how well it can be processed into durable pellets. Inconsistent maize quality can lead to issues like decreased production rates, increased fines (dust), and reduced pellet durability, ultimately affecting animal performance.

[India]

Maize Quality Impact on Pellet Mill Operation

1. Moisture Content

Ø Low Moisture (<11%) → Difficult starch gelatinization, poor binding, high fines, brittle pellets.

Ø High Moisture (>14%) → Risk of mold growth, storage issues, variable steam absorption in conditioning.

Impact: Directly affects pellet durability, energy use, and storage stability.

2. Starch Quality & Gelatinization

Ø Well-formed starch granules → Good gelatinization → higher pellet durability.

Ø Immature / weather-damaged maize → Poor gelatinization → weak pellets.

Ø Impact: Limits degree of cook and binding in pellets.

3. Foreign Material & Impurities

Ø Stones, husks, dust → cause die/roller wear, fire risk in hammer mill, unstable pellet quality.

Ø Impact: Maintenance downtime, reduced die life, variable product quality.

4. Grain Hardness

Hard maize → Produces uniform grind, good starch gelatinization, stronger pellets.

Soft/floury maize → Excess fines, poor binding, high dust levels.

Impact: Influences particle size distribution and pellet durability.

5. Grinding Performance

Poor maize quality → Uneven grind, variable particle size.

Impacts steam penetration and starch cooking in conditioner.

Impact: Directly influences pellet PDI (Pellet Durability Index).

8. Consistency of Supply

Variation in maize lots (from different suppliers or regions) → Different grinding, conditioning, and pelleting responses.

Leads to unstable pellet quality and mill adjustments.

✅ Summary:

Maize quality directly influences pellet durability, energy consumption, die life, and throughput. Uniform, clean, hard maize with 13–14% moisture and good starch quality is ideal for pellet mill operations.

Sakthivel V P

[India]

Energy costs are one of the largest operating expenses in a feed mill, often accounting for 20–30% of production cost. Below are practical, field-proven tips to reduce energy consumption without compromising feed quality:

1. Raw Material Handling & Storage

Ø Use gravity flow wherever possible instead of conveyors/elevators.

Ø Schedule bulk unloading at off-peak hours to reduce power load spikes.

Ø Keep silos clean → less bridging/blockage → reduced re-handling.

2. Grinding / Hammer Mill

Ø Select optimal particle size (not too fine → saves energy, reduces wear).

Ø Maintain sharp hammers and correct screen size (worn hammers ↑ energy use 10–15%).

Ø Use post-grinding system (grind only ingredients that need grinding).

Ø Consider roller mills for cereals → up to 20–30% energy savings vs hammer mills.

3. Batching & Mixing

Ø Optimize batch sizes → avoid under-loading mixers.

Ø Maintain mixer paddles and clearances → worn mixers consume more energy.

Ø Reduce unnecessary re-mixing (good sequencing + accurate weighing).

4. Steam Generation & Conditioning

Ø Boiler efficiency: Use economizers, good water treatment, insulate steam lines.

Ø Maintain correct steam pressure (avoid over/under-pressurization).

Ø Prevent steam leaks in valves, traps, and joints.

Ø Optimize conditioning time → uniform cook with minimal energy loss.

5. Pelleting

Ø Die selection: Use thinner dies with larger effective hole area for easy flow.

Ø Keep rolls & dies well maintained → worn dies ↑ kWh/t drastically.

Ø Lubricate rollers regularly → reduces drag power.

Ø Control feed particle size → uniform particles improve pellet mill efficiency.

6. Cooling & Drying

Ø Optimize airflow in coolers (clean fans, ducts, avoid blockages).

7. Utilities & Support Systems

Ø Replace old motors with energy-efficient (IE3/IE4) motors.

Ø Use variable frequency drives (VFDs) on conveyors, fans, pellet mills, coolers.

Ø Monitor compressed air leaks (common hidden energy loss).

Ø Schedule preventive maintenance to avoid energy wastage due to friction/overload.

8. Process Optimization & Management

Ø Optimize production planning → fewer recipe changeovers (less downtime/cleaning).

Ø Run machines at optimal load, not at partial load for long periods.

Ø Install energy meters by section (grinding, pelleting, etc.) → track kWh/ton.

Ø Train operators on energy-conscious practices (steam use, air leaks, machine loading).

Sakthivel V P

[India]

Key Batching Parameters in Feed Mills

1. Weighing Accuracy

Ø Micro-ingredients: ±1 g to ±5 g

Ø Premixes / Minerals: ±10 g to ±50 g

Ø Macro-ingredients (Maize, Soy, etc.): ±0.1% of batch weight

Ø Target: Maintain within 0.5% of total batch weight

________________________________________

2. Batch Size

Ø Typically, 1–5 tons depending on mixer capacity.

Ø Should match mixer’s working volume (70–80% of rated capacity).

________________________________________

3. Mixing Time

Ø Dry Mix: 60–120 seconds (depending on mixer type)

Ø Liquid Addition: Additional 30–90 seconds

Ø Coefficient of Variation (CV): ≤10% (ideally 5%)

________________________________________

4. Ingredient Addition Sequence

Ø Macro-ingredients (maize, soya, wheat bran)

Ø Minerals & premixes

Ø Micro-ingredients (amino acids, enzymes, vitamins)

Ø Liquids (oil, molasses, fat, enzymes in liquid form)

________________________________________

5. Batching Speed & Cycle Time

Ø Cycle time per batch: 5–10 minutes (weighing → mixing → discharge)

Ø Target: Minimize idle time between batches.

________________________________________

6. Tolerance Settings in Batching Software

Ø Macro tolerance: ±0.5%

Ø Micro tolerance: ±0.1%

Ø Premix tolerance: ±0.05%

Ø Reject/alert if out of tolerance.

________________________________________

7. Moisture Control

Ø Raw material moisture: 10–12% (cereals), 10–12% (soymeal)

Ø Batching water/oil addition: Controlled for pellet quality

Ø Monitor with NIR or moisture analyzers.

________________________________________

8. Traceability Parameters

Ø Raw material lot tracking

Ø Batch ID / Recipe ID

Ø Operator ID & time stamp

Ø Automatic log for audits (HACCP / GMP+ compliance).

________________________________________

9. Software & Automation Parameters

Ø Recipe management

Ø Real-time inventory update

Ø Auto-correction for over/under weighing

Ø Interlocks for sequencing (avoid cross-contamination).

Sakthivel V P

• This reply was modified 5 months, 3 weeks ago by  India.

[AHMED]

manufacturer specification.

different in expected and actual.

manual dosing or weighing.

observation of over dosage.

[AHMED]

if there are variance in expected and actual .this will determine if it need calibrication daily/weekly.

[Md.Rejuan Hossain]

By leveraging IoT and AI to monitor equipment in real time, feed mills can transition from reactive maintenance models to a data-driven approach that maximizes efficiency, reduces costs, and supports sustainability.

[Muhammad Ahmad]

Yes true

[Amir]

The biggest obstacles to maximum production are – lack of raw materials, lack of technical knowledge and skills, inadequate infrastructure, lack of finance, and marketing problems. In addition, lack of skilled labor, limitations in the use of modern technology, and management problems also hinder production.

[India]

Good one and also you may include the following :

1. Raw Material Handling & Storage

Ø Inward logistics delays (trucks waiting for unloading).

Ø Limited silo/storage capacity → leads to congestion.

Ø Variation in maize/soy quality (moisture, impurities) slows batching.

2. Grinding / Hammer Mill Section

Ø Hammer mill screen clogging or wear → reduced capacity.

Ø Insufficient grinding capacity vs. batching demand.

Ø Energy spikes during peak load (motors overheating/tripping).

3. Batching & Mixing

Ø Weighing system slowdowns (overloads, inaccurate dosing).

Ø Long cycle times in mixers (especially when liquids are added).

Ø Cross-contamination risk → extra cleaning between formulations.

4. Conditioning & Pelleting

Ø Steam supply limitations (boiler undersized or pressure drop).

Ø Conditioner residence time not adequate for degree of cook.

Ø Pellet mill die choking / wear → lower throughput.

Ø Frequent recipe changes → more downtime for adjustments.

5. Cooling & Drying

Ø Cooler capacity insufficient at high throughput.

Ø High ambient humidity → poor cooling, high moisture in pellets.

Ø Fines & breakage during handling due to insufficient cooling.

6. Finished Product Handling

Ø Bagging machines not matching pellet mill capacity.

Ø Conveyor / elevator bottlenecks (spillage, breakdown).

Ø Dispatch delays due to truck availability or weighing bridge congestion.

7. Utilities & Support Systems

Ø Boiler unable to meet steam demand during peak pelleting.

Ø Compressed air pressure drops affecting automation.

Ø Power fluctuations leading to equipment stoppage.

8. Human Resource & Management

Ø Inadequate skilled operators to run multiple shifts.

Ø Delays in decision-making (quality hold-ups for approvals).

Ø Manual record-keeping slowing traceability.

✅ Summary:

The most common choke points are hammer mills, steam supply/pellet mills, and coolers, followed by bagging and dispatch delays.

Sakthivel V P

[Md]

Excellent presentation

[Md]

Biosecurity

[India]

In addition to your observation , the following points are to be noted as well :

Why Micro Dosing is Critical in Feed Mills

Ø Many additives are high-cost, low-inclusion → overdosing leads to quality deterioration in addition to the cost escalation

Ø Some (e.g., coccidiostats, mycotoxin binders) are safety-sensitive → under dosing compromises feed safety & performance.

Ø Ensures nutritional precision in line with formulation specs.

Micro Dosing System Components

Ø Micro-bins / Hoppers (each dedicated to one additive).

Ø Load cells / Weigh hopper → precision weighing (accuracy ±1–5 g).

Ø Automation Software → recipe-controlled dosing, traceability.

Ø Discharge System → micro-ingredients emptied into the mixer or pre-batch hopper.

Best Practices in Batching & Micro Dosing

Ø Segregated bins for micro ingredients to avoid cross-contamination.

Ø Calibrate load cells & dosing augers regularly.

Ø Use automation with interlocks → prevents wrong ingredient addition.

Ø Sequence addition properly: macros → premixes/minerals → micros → liquids.

Ø Maintain clean dosing units (powder bridging and clogging are common).

Ø Implement traceability system (batch ID, operator ID, lot number).

KPIs to Monitor

Ø Batching accuracy (% deviation).

Ø Micro dosing accuracy (g deviation per dose).

Ø Number of batching/micro dosing errors per month.

Ø Rework batches (%) due to dosing errors.

Ø Cost impact of over/under dosing (₹ per ton).

Sakthivel V P