The continuous need for superior pellet quality in animal feed has propelled advancements in pelleting technology. Critical phases in pellet production, particularly conditioning and pelleting, significantly influence the physical quality of pellets. This article traces the evolution of pelleting technology from historical milestones to more recent innovations, highlighting significant advancements and their impact on pellet quality control. Future trends and desired innovations in pelleting technology are also discussed.
Territory Manager
CPM Industrial Solutions
The production of high-quality animal feed pellets is vital for efficient animal nutrition and health. Over the past century, equipment manufacturers have strived to develop technologies that ensure consistent pellet quality. The conditioning and pelleting phases are central to achieving the desired pellet durability and hardness. This article reviews the historical developments and recent innovations in pelleting technology, and outlines future directions for improved pellet quality control.
HISTORICAL DEVELOPMENTS IN PELLETING TECHNOLOGY
Early 20th Century: California Pellet Mill
Flat Die Pellet Mill
The inception of modern pelleting technology can be traced back to the early 20th century with the development of the flat die pellet mill by California Pellet Mill (CPM). This innovation marked the beginning of mechanized pellet production, enabling more efficient and consistent feed processing.
Ring Die Pellet Mill Innovation
Following the flat die, California Pellet Mill introduced the ring die pellet mill which significantly improved the uniformity and durability of pellets. This advancement was a crucial step forward in enhancing the overall quality of feed pellets.
Integrating Steam Conditioning
with the CPM Master Pellet Mill
The integration of steam conditioning with the CPM Master Pellet Mill was another significant development. The addition of steam made the feed mixture more pliable, enhancing pellet formation and durability. This technique also improved nutrient preservation and digestibility in the final product.
PELLET QUALITY AND MEASUREMENT
Durability and Hardness
Pellet quality is primarily assessed based on durability and hardness. Durability indicates the pellet’s ability to withstand handling and transportation without disintegration, while hardness measures its resistance to mechanical forces. These parameters are critical for ensuring that the feed remains intact and effective until consumption.
Different Requirements for Different Feeds
The nutritional and physical requirements of different animal species necessitate tailored pellet quality parameters. For example, broiler feed might require softer pellets compared to cattle feed, which demands harder pellets for optimal rumination. Therefore, understanding and meeting the specific needs of each type of feed is essential for effective pellet production.
CORRELATION OF STEAM ADDITION, PELLETING CAPACITY, DIE SPECIFICATION, AND PELLET QUALITY
Data and Analysis
Graphs illustrating the correlation between steam addition, pelleting capacity, die specifications, and resulting pellet quality are instrumental in optimizing the pelleting process. This data helps identify the optimal conditions for producing high-quality pellets.
BENEFITS OF NEW PRODUCT FORMULATIONS
CPM Double Pelleting Innovation
The double pelleting innovation by CPM was developed in response to new feed formulations. This method involves passing the feed mixture through the pellet mill twice, enhancing pellet durability and uniformity, particularly for complex feed compositions.
Pre-Compactor Innovation
The pre-compactor innovation involves super conditioning the feed mixture by expanders, for example, before it enters the pellet mill. This process improves pellet durability, making it particularly effective for high-fiber or coarse feeds.
INCREASED PELLET MILL DIE SURFACES
Maintaining Pellet Quality at Increased Capacities and Reduced Pellet Diameters
Advancements in die design have led to increased pellet mill die surfaces which help maintain pellet quality at higher production capacities and with reduced pellet diameters. This ensures efficient production without compromising pellet integrity.
AUTOMATIC ROLLER ADJUST INNOVATION
Pre-Compression in the Pellet Mill Die
Automatic roller adjust systems optimize pre-compression in the pellet mill die, ensuring consistent pressure application. This results in uniform pellet quality and reduced wear on the equipment.
ROLL SPEED MEASUREMENT INNOVATION
Anti-Blocking System
Innovations in roll speed measurement include anti-blocking systems that prevent feed mixture buildup while optimizing steam conditioning and pre-compression. This results in smoother operation and higher quality pellets.
DIE SPECIFICATION AND PRODUCT DISTRIBUTION
Pellet Flow Measuring Plate Innovation
The pellet flow measuring plate innovation ensures even distribution of the feed mixture across the die surface. This technology enhances pellet uniformity and consistency, which is crucial for maintainin
g high-quality standards.
PELLETING ROLLS LUBRICATED FOR LIFE
Reduced Pelleting Roll Rotation
Resistance Innovation
Oil lubrication for life technology reduces the rotation resistance of pelleting rolls, leading to more efficient operation and extended equipment lifespan. This innovation minimizes maintenance requirements and enhances production efficiency.
NEW TECHNOLOGY CONDITIONING INNOVATION
Increased Steam and Liquid Addition
New conditioning technologies incorporate double retention times and advanced blending techniques to increase steam and liquid addition. This improves pellet quality by ensuring thorough mixing and optimal moisture content.
CURRENT INNOVATIONS IN THE PELLETING PROCESS
Smart Sensor Installation for Data Acquisition
The integration of smart sensors in pelleting technology represents a significant advancement in optimizing pellet quality and production efficiency. Smart sensors enable real-time data acquisition, monitoring, and control, ensuring consistent quality and operational efficiency.
Inline Pellet Quality and Pellet Temperature
Measurement at the Die
Inline measurement of pellet quality and pellet temperature at the die is a great asset for ensuring consistent production of high-quality animal feed pellets. These measurements enable real-time adjustments to the pelleting process, leading to improved efficiency and product uniformity, thereby reducing waste and rework.
FUTURE DIRECTIONS IN PELLETING TECHNOLOGY
Increasing flexibility towards raw materials in the pelleting process is crucial for optimizing production efficiency and product quality. The current state-of-the-art pelleting technology faces constraints in roll slip management and the necessity for frequent die changes to accommodate different pellet diameters and varying pelleting resistance. Future developments could focus on overcoming these limitations, enabling more adaptable and efficient pelleting processes.
CONCLUSION
Pelleting technology has evolved significantly, with numerous innovations enhancing pellet quality control. From early pellet mill die designs to advanced conditioning systems, each development has contributed to better feed pellet production. As the industry continues to innovate, future advancements will further refine and optimize the pelleting process, ensuring improved animal feed quality and efficiency.
About Paul Alderliefste
With over 30 years of experience at CPM Industrial Solutions, Paul Alderliefste has observed firsthand the critical role of innovations in the commercial success of animal feed mill customers. Notably, he has recognized the significant impact of pelleting roll slip management in collaboration with one of the leading feed companies in Western Europe. He is a member of the animal feed segment group within CPM Industrial Solutions. This group is in contact with all stakeholders, ensuring that the latest industry requirements are consistently met.
