ISSUE FOCUS 60 FEED & ADDITIVE MAGAZINE April 2025 The effect is shown in the next tables. In the first dairy formulation, beet pulp is replaced by coconut meal. This is a lower cost formulation, but pellet quality drops from 60 to 43. By using double pelleting, the low-cost formulation can be produced with a quality of 62, which is slightly higher than the original formulation. The second example shows the effect of a high-energy formulation on the pelleting process. When 3.2% of tapioca meal is replaced by fat, quality drops from 40 to 27. However, double pelleting enables the high-energy formulation to reach the same quality as the lower energy formulation produced with single pelleting. A major benefit of the double pelleting process is that the capacity is much more stable compared to the single pelleting process. This reduces headaches and ensures that the required quantities can be produced daily. EXPANDER PELLETING For very high fat and liquid formulations that make it harder to supply enough energy to produce good pellet quality the Expander can be a solution. It enables control over the energy consumption by adjusting the cone, pressure, kneading intensity and product heating. At high fat and liquid formulations where it is hard to get energy in, the Expander improves pellet quality. However, it uses a lot more energy. Running the expander on lower fat and liquid formulations results in much higher energy usage and wear costs, as well as a less controllable and user-friendly process. We see the same outcome if we compare the double pelleting process with Expander pelleting. This reinforces that there is no single solution that works in all cases. Finding the optimal process depends on the properties of the raw materials and the desired pellet DPI (%) 100 90 80 70 60 50 18 16 14 12 10 8 6 Test number 1 2 3 4 5 6 Correlation DPI (%) and Energy Consumption (KWH/TON) DPI (%) KWH/TON This figure shows the production of three different formulations. The odd-numbered tests are single pelleting tests and the even-numbered tests are produced on an expander pelleting set up. Dairy feed formulation Linseed Rapeseed meal Coconut meal Corn gluten fodder meal Citrus pulp Fat Linseed scales Beet pulp Molasses Additives Quality [HS] single Quality [HS] double Double pelleting Single 4 25 35 1 7 15 10 3 60 3 3 20 25 35 1 10 3 43 62 Dairy feed high energy Single Double pelleting Linseed meal Rapeseed meal Coconut meal Sunflower seed meal Corn gluten fodder meal Tapioca Meal Beet Pulp Fat Molasses Additives Quality [HS] single Quality [HS] double 1055 Fodder Units 950 Fodder Units 5 6 10 10 15 7 32 1.3 10 2.2 40 5 6 10 10 15 3.8 32 4.5 10 2.2 27 40
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