SPECIAL STORY FEED & ADDITIVE MAGAZINE July 2022 53 Where should a feed mill manager start when looking to improve efficiency? ANDRITZ recommends hiring a qualified third-party consultant with a global perspective to inspect, analyze, interview and report on the state of the plant, allowing even the most experienced plant manager to benefit from vast and varied processing experience. Improving efficiency starts with identifying the current situation and comparing it with both short- and long-term goals (2-5-10 years). The goals could include getting the plant back to its original design specifications. What should be taken into account when planning and choosing technology for efficient production? A careful study should be conducted to determine the best course of action: the introduction of new machines inside an existing building, the addition of an extension building, or an entirely new greenfield should be considered before updating existing equipment. Sometimes clearing out areas inside the feed mill can free up room for new pelleting lines, and grinders and mixers can be placed in an outside extension. This approach may be more cost-efficient and better suited for a limited time frame as unexpected or prolonged downtime is extremely costly. Carefully consider the options for renovation, extension, and remediation. Instead of simply selecting equipment, select a process and solution provider who understands which equipment is best for your process. Could you give information about other factors affecting efficiency? If we limit the efficiency concept to plant capacity and pellet quality, the following elements are important: 1. Good raw materials and appropriate storage. Good cleaning and aeration are necessary, as grains may quickly deteriorate without it. Impurities and foreign objects may also cause problems in both the hammer mill and the pellet mill for products which are bypassing the hammer mill. 2. Precise dosing. Systematic dosing deviations are, of course, costly. Still, random variations cause instability in hammer mills, mixers, conditioners, and pellet mills and may generate recalls due to declared specifications for the finished product. Instabilities can make operators reduce capacity to cope with erratic blockages. Carefully monitor your product reports, compare them with your inventory and perform regular chemical analysis of your finished feeds. 3. Precise grinding. Conditioning and pellet mill performance as well as capacity and pellet durability are heavily dependent on correct grinding. Maintained wear parts like hammers, screens and other internal wear parts are vitally important. Finally, don’t forget the filter, fan and air flow which are “invisible” but crucial elements of a hammer mill operation. Too much air or too little air flow have a critical impact on the grinding process. Keep a continuous eye on air flow, differential pressure, and adhere to your maintenance plan. An often-overlooked way of increasing hammer mill capacity is to mix ingredients prior to grinding. Many grinders have difficulty transitioning from soybean meal to oat/barley meal. Under the best circumstances, the feeder may adapt, but there is the potential for the control system to stop the feeder or the main motor may trip, blocking the entire grinding chamber. Premixing prior to grinding helps the control system obtain a stable amperage load which can be increased further later in the process. 4. Efficient mixing and liquid application. Mixing and introduction of liquids is vitally important to ensure constant product composition entering the conditioning and pelleting machines. Again, instabilities lead to erratic stops and/or blockages. As a result, operators will reduce capacity to a level where the machine can continue to run. Continuously monitor your mixing quality (CV). Restricted liquid flow and prolonged mixing cycles are not solved by removing the blocked nozzles. 5. Good, long steam conditioning. Just like the airflow in the hammer mill, steam is invisible, yet
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