ISSUE FOCUS FEED & ADDITIVE MAGAZINE April 2025 59 means that the retention time in the conditioner needs to be increased. To help solve this problem, California Pellet Mill (CPM) brought a new conditioning technology to the market when they introduced a revolutionary shaft and paddle design in combination with shaft speed regulation. This innovation makes it possible to fill the conditioner up to 70% while providing full contact mixing of product particles with liquids and steam. The improved conditioning allows for the higher temperatures that achieve better quality pellets with lower energy and operational costs. This conditioner also provides excellent blending with molasses and other added liquids. The design principle is based on the fact that the material is moving forwards and backwards through the conditioner, and is “rubbing” itself what is increasing liquid and steam absorption. LESS DENSITY The lower density of some exotic ingredients also negatively affects processing. Conditioners can hold less mass of the product, while generally a longer retention time is required due to the ingredient’s lower absorption capabilities. Since the pelleting process is volumetric, less density means fewer tons can be produced. LESS BINDING Another characteristic of alternative ingredients is that they have weaker binding properties. This means that the pellet needs to be produced more mechanically. With traditional ingredients, pellet binding is enhanced by the heat and moisture from the added steam, but pellets made from alternative ingredients must be formed with brute force in a thicker pellet mill die. Thick dies are the pellet mill operator’s curse. They make the pellet mill more sensitive to roll slip and the surface of the die is more easily damaged, which adds to the instability of the overall process. Sometimes it is so difficult to add the required energy in the pelleting process that capacity is reduced just to maintain pellet quality. Even when quality is not negatively affected by the higher capacity, using more mechanical energy still reduces capacity because the pellet mill motor becomes a limiting factor. Variations in raw materials also means variation in how they influence the pelleting process. One day a “good” formulation can make the pellet mill operate smoothly while on the next day it won’t move at all. This creates a headache for the planner because the output demand on the factory doesn’t take into account the pellet mill behavior. DOUBLE PELLETING If pelleting is harder to do in one big step, a simple solution is breaking it into two smaller ones that allow for thinner dies, increased flexibility, lower-cost raw materials and lower production costs. This pelleting principle is extremely successful with cheaper high-fiber formulations that have replaced grains and soya. DOUBLE PELLETING SINGLE PELLETING PELLETS MEAL
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