Major Processes in Feed Manufacturing

Question 1

Major processes in feed manufacturing:

Answer 1

-ingredients receiving
-grinding
-batching and mixing
-conditioning and pelleting

Question 2

Receiving center ingredients terms:

Answer 2

-unprocessed grains
-processed bulk ingredients
-soft feed ingredients
-heavy feed ingredients
-liquids
-micro-ingredients

Question 3

Receiving center equipment:

Answer 3

-scales
-unloading mechanisms (truck dumper, hopper bottom trailers or RR cars, mechanical scoops, front end loader for barges)
-receiving hopper and conveyors
-cleaning/screening devices (magnets, grain scalpers, grain cleaners)
-elevator legs

Question 4

Grinding operation

Answer 4

-increases surface area
-enhances energy and nutrient digestibility

Question 5

Functions of grinding:

Answer 5

-to achieve proper and uniform particle size
-to improve the efficiency of pelleting operations as well as pelleted feed quality
-to maintain desired physical characteristics of the feed such as flowability and limiting dust

Question 6

Warehouse

Answer 6

-ingredients and totes are stored on racks
-First in first out ingredient rotation

Question 7

Factors to consider with grinding equiptment:

Answer 7

-target particle size
-grinding capacity requirement (depends on particle size)
-energy consumption (roller mill more efficient at larger particle size)
-maintenance cost
-environmental safety

Question 8

Target particle sizes

Answer 8

-fine (less than 400 microns)
-medium (400-700 microns)
-coarse (greater than 700 microns)

Question 9

Maintenance cost for roller mills

Answer 9

-re-corrugation
-freight cost (location of corrugation shop vs. feed mill)
-routine gap adjustment higher maintenance time (daily particle size samples)

Question 10

Maintenance cost for hammermill

Answer 10

-screen replacement
-hammer replacement
-minimal maintenance time

Question 11

Roller mill environmental safety

Answer 11

-less dust
-lower noise levels

Question 12

Hammermill environmental safety

Answer 12

-require dust control (bag house air permit)
-high noise levels
-risk of fire or explosion

Question 13

Particle size is controlled by what in hammermill operations?

Answer 13

-screen size
-hammer tip speed
-air assist system
-hammer setting
-hammer pattern

Question 14

Grind size is controlled by what in roller mills?

Answer 14

-number of roll pairs
-roll gap
-roll speed
-corrugations
-corrugation numbers

Question 15

When might roller mill technology not be feasible?

Answer 15

-when the product is not friable, fragile, or breakable (high fiber and moisture ingredients)
-no value from maintaining a uniform particle size with minimal fines

Question 16

Hammermill advantages:

Answer 16

-can produce a wide range of particle sizes
-can handle friable materials and fibers
-cost of purchase is low compared to roller mills
-low maintenance cost
-easy to operate

Question 17

Hammermill disadvantages:

Answer 17

-particle size could vary greatly (less uniform)
-high energy usage compared to the roller mill
-generates lots of heat (high energy wastage)
-is noisy with high potential for dust pollution

Question 18

Roller mill advantages:

Answer 18

-relatively low energy consumption
-relatively less noisy
-relatively less heat production and thus less moisture loss
-uniformity of particle size of milled product

Question 19

Roller mill disadvantages:

Answer 19

-investment costs are high
-complicated operation
-high maintenance cost
-problems with fibrous material (grinding issue)
-strict cleaning requirement before grindind

Question 20

Batching and mixing objective

Answer 20

-accurate weighing of ingredient
-minimum batching time
-production of feed with uniform distribution

Question 21

What is the last thing to add during batching and mixing?

Answer 21

oil

Question 22

What should be added close to the end during batching and mixing?

Answer 22

feed additives

Question 23

What size particles are mixed first?

Answer 23

largest

Question 24

Batching equipment

Answer 24

-micro bin systems
-tote bag systems
-scales (major and minor)
-weigh buggy

Question 25

Mixer uniformity analysis

Answer 25

calculation of mixer CV (mean of samples, standard deviation of samples)

Question 26

CV calculation

Answer 26

CV% = (standard deviation/mean) x 100

Question 27

What rating is a CV <10%

Answer 27

excellent

Question 28

What remedy/corrective action is taken with CV <10%

Answer 28

non

Question 29

What rating is a CV of 10-15%

Answer 29

good

Question 30

What remedy/corrective action is taken with CV 10-15%

Answer 30

increase mixing time by 25-30%

Question 31

What rating is a CV of 15-20%

Answer 31

fair

Question 32

What remedy/correction action is taken CV 15-20%

Answer 32

increase mixing time by 50%, look for worn equipment, overfilling, or sequence of ingredient addition

Question 33

What rating is CV of 20% +

Answer 33

poor

Question 34

What remedy/corrective action is taken for CV 20%+

Answer 34

possible combination of all the other corrective actions and to consult the extension personnel or feed equipment manufacturer

Question 35

Recommended mixing time for a paddle

Answer 35

Dry mix: 3 min
Wet mix: 3 min

Question 36

Recommended mixing time for a twin shift paddle

Answer 36

Dry mix: 0.5 min
Wet mix: 1 min

Question 37

Recommended mixing time for a double ribbon mixer

Answer 37

Dry mix: 1-2 min
Wet mix: 2-3 min

Question 38

Recommended mixing time for a twin shaft ribbon mixer

Answer 38

Dry mix: 0.75-1 min
Wet mix: 2 min

Question 39

Recommended mixing time for a vertical mixer?

Answer 39

Dry mix: 5-10 min
Wet mix: 5-10 min

Question 40

Causes of weighing variation

Answer 40

-hand-weighing ingredients
-micro-ingredients and premix dose errors
-discrepancies between call size and scale resolution

Question 41

What scale should always discharge first?

Answer 41

the major scale

Question 42

What must be serviced and checked regularly for accuracy?

Answer 42

weighing scales