The process flow of the complete pellet feed machine set
The process flow of the complete pellet feed machine set consists of three main parts: preprocessing (such as conditioning), pelletizing, and post-processing. These three parts are interdependent, and they determine the quality and economic efficiency of the pellet feed.
Pellet Feed Production Process and Key Points
The pellet feed production system is mainly divided into three stages: preprocessing, pelleting, and post-processing. These stages are closely interconnected and interdependent, determining the quality and economic efficiency of the pellet feed. While the process may vary depending on factory size and product requirements, it is essential to follow basic principles to ensure the improvement of both production efficiency and feed quality.
Raw Material Preprocessing
Raw material preprocessing is a critical step in the feed production process, typically involving conditioning and grinding. The conditioning process adjusts the raw materials through heating and moisture addition to prepare them for pelleting. Grinding is done by feed grinders to reduce the material size to the appropriate fineness. Common grinding equipment includes hammer mills and self-priming grinders, which help improve the grinding effect and ensure smooth operation in subsequent steps.
Mixing and Pelletizing
After preprocessing, the next steps are mixing and pelletizing. A mixer is used to blend different raw materials uniformly. Common mixers include vertical mixers and horizontal screw mixers. Mixing ensures the even distribution of nutrients throughout the feed, providing uniform raw material for pelleting.
Pelletizing is the core process in feed production. Pellet mills convert mixed powder into pellet feed under high temperature and pressure. Common pellet mills include ring die pellet mills and flat die pellet mills, with the main difference being the configuration of the die. Ring die pellet mills are available in both vertical and horizontal configurations, and selecting the appropriate pellet mill is crucial for achieving the desired results.
Post-Processing and Cooling
Pellets that emerge from the pellet mill are typically hot and have a high moisture content. Therefore, they must undergo cooling to prevent breakage or quality degradation. Cooling is a vital step in maintaining pellet integrity and quality. Common cooling devices include counter-flow coolers and simple coolers (air dryers), which quickly reduce the temperature and moisture content of the pellets, ensuring the final product’s quality and stability.
After cooling, the pellets undergo further processing in a crusher for sieving and grading. Broken pellets and fine powders are separated and sent via an elevator to the product bin or returned to the mixing stage to maintain product consistency.
Packaging and Storage
Once the pellets are cooled and graded, they move to the packaging stage. Packaging helps preserve the feed’s quality and safety while making it easier for users to handle and store. Proper packaging not only extends the shelf life of the feed but also enhances its brand value. Packaging equipment should not be placed immediately after the pellet mill or sieving equipment. This arrangement helps to avoid disruptions caused by fluctuations in the pellet mill’s output.
Design Principles for the Production Process
When designing the pellet production process, certain fundamental principles should be followed to ensure smooth and efficient production:
- Storage System Setup: At least two ingredient bins should be prepared for pelleting to allow for recipe changes without stopping the machine, ensuring continuous production.
- Iron Removal Device: An efficient iron removal device should be installed before the pellet mill to protect the equipment from metal impurities.
- Equipment Layout: The pellet mill should be placed directly above the cooler, preventing pellet breakage during transport and saving additional conveying equipment.
- Product Bin and Packaging: A well-designed product bin, such as one with a vertical spiral chute, will protect pellets from damage. Packaging equipment should be placed after the product bin. This placement prevents fluctuations in the pellet mill output from affecting packaging stability.
Conclusion
By carefully designing the pelleting process, feed producers can maximize both quality and efficiency. Each step in the process, from initial cleaning and grinding to mixing, pelleting, cooling, crushing, and packaging, requires precise control. This ensures the consistency and quality of the final product.
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