Today, when the price of raw material is soaring and the market competition is very fierce, feed enterprises are required to comprehensively control various factors, according to different situations in the whole process of production, so that the final moisture content of the product can reach the expected goal of the producer, and ensure the quality of pellet feed.
Product manager – Feed Process Optimization
Adiveter
The moisture content of the final pelleted feed is closely related to the moisture change during the feed production. The total loss of moisture in the feed production process can reach up to 1.5%. Moisture loss not only seriously affects the economic benefits, but also affects the quality and palatability of the pellets. Understanding this moisture changes in the production process and comprehensively regulating it, can help feed enterprises achieve the purpose of controlling the moisture content of the finished pellets.
It will be analyzed the factors affecting in the content of moisture during the process and how ADIVETER 4.0, is a very innovative and unique technology in the market, developed to prevent losses during entire process due to moisture variation of raw materials and controlling cooler operating process to increase feed quality.
Moisture changes at the grinding process
During the grinding process of the raw materials, heat is generated by the impact and friction between the high-speed rotating hammer and the raw material. The temperature inside the crushing chamber is higher than the outer temperature generally around 45 ºC to 50 ºC. The moisture loss in that process is generally between 0.5% and 1.5%. The loss degree is related to the particle size¹, type of hammer mill² and temperature³.
The moisture lost in this process, will need to be added later in the process to ensure good moisture and quality pellets.
Moisture changes and control measures in the mixing process with Adiveter 4.0 (Pellet Plus Online)
After the grinding process, the raw materials are mixed to get and homogenous meal in the mixer.
When the moisture content of the mixed powder is much lower than 12.5%, it is recommended to add atomized free water during the mixing. But there are many problems in this aspect:
1. The retention performance is poor.
2. Free water increases the water activity and makes to increase the risk of mildew.
3. Need to pay attention for:
a. The mixing time,
b. Free water adding time,
c. The position, angle and spray effect of the nozzle,
d. The accuracy of the addition.
Not to have the problems described before, Pellet Plus Online is the solution, the real time moisture control during the mixing of each batch, together with an optimized dosing equipment of the hydrating solution (water + Re-Hydra Pro (Surfactant & mildew-proofing agent)).
The Re-Hydra Pro, can reduce the surface tension of water, helping the water to improve the fixation to the particles of the feed and a better homogenous moisture dispersion, and thanks to the small molecules organic acids providing an effectively control of the water activity.
Moisture changes during the conditioning process
Conditioning and tempering of feed refers to the hydrothermal treatment of the materials by introducing steam before it enters the granulator, thereby improving the physical and chemical properties of the powdery material.
The moisture content of the material after conditioning is reasonable between 14% and 15.5% in terms of moisture, because the processing quality of the pellet feed produced and processed under this condition is good; the moisture content of the finished product is easy to meet the standards requirements. However, in dry and hot seasons, it is difficult to archive 14% moisture content after conditioner. The conditioning moisture can be increased by adjusting the conditioning time and the amount of steam, where Adiveter’s technicians have a lot of experience on it.
Moisture changes and control measures in the granulation process
During pelleting, the temperature feed increases by 8 ºC to 15 ºC, these values could consider reasonable, due the friction and extrusion, and the moisture decrees around 0.5%.
Reasonable compression ratio is important, having more compression you have more friction resistance during the granulation process, and that affects negatively for pellet quality and moisture content.
Moisture change and control measures in cooling process with Adiveter 4.0 (Cooler Plus)
The function of the cooler is to cool the hot pellets from the pellet granulator, generally no more than 5 ºC of ambient temperature. Studies have shown that in the cooler, the temperature of the pellets generally decreases by 11 ºC, and the moisture of the pellets decreases by 1%. The key parameter for particle cooling control is the Cooler Plus. With Cooler Plus we have a real time monitoring, with the control of some parameters, that helps not to lose between 0,15 pp to 0,4 pp, depending on the season.
Having an excessive cooling air volume and long cooling time will cause excessive moisture loss in the product, which will affect the efficiency of the enterprise, and in the quality of final feed, having less PDI also.
Today, when the price of raw material is soaring and the market competition is very fierce, feed enterprises are required to comprehensively control various factors, according to different situations in the whole process of production, so that the final moisture content of the product can reach the expected goal of the producer, and ensure the quality of pellet feed. The economic benefits of the enterprise make it occupy a favorable position in the fierce market competition.
Footnotes
¹The smaller the particle size we want the higher moisture loss will be. A smaller particle size will allow the flour to take a higher temperature and better absorb moisture, key points to accelerate gelatinization of the starch.
²In a roller mill and counter-hob mill, the moisture loss is significantly lower than a hammer mill.
³Reasonable preparation of the suction air volumen during the grinding.
