It’s no secret that the need for improved feed efficiency is driven by rising operating costs: today’s farmers know how crucial it is to extract maximum value from each unit of feed. That means leveraging advanced technologies that optimize ingredient usage and minimize waste, enabling them to sustain production without compromising quality.
Sales Director, Feed & Food Platforms, North America, AGI
Vice Chairman, Marketing & Communications Committee, AFIA
The USDA projects continued growth in broiler chicken production for 2024, driven by increased demand. And broiler-type egg production is expected to reach 46.9 billion pounds, up by 489 million pounds from 2023.1 As well as pork production in 2024 is expected to be about 28.1 billion pounds, 2.9 percent above production in 20232.
This growth reflects the rising need for more efficient feed production solutions on farms – especially for those farmers making do with feed mills that may have been in operation for 30 years or more. New investment – and new technology – is key. AGI’s broad range of feed products are designed to help farmers meet these growing needs. Our AGI FLEXmill system is just one example.
AGI FLEXmill SYSTEM
It’s no secret that the need for improved feed efficiency is driven by rising operating costs: today’s farmers know how crucial it is to extract maximum value from each unit of feed. That means leveraging advanced technologies that optimize ingredient usage and minimize waste, enabling them to sustain production without compromising quality. The AGI FLEXmill is designed to do just that, by offering farmers a flexible, modular solution that can be tailored precisely to the specific needs of their operation.
The AGI FLEXmill is a predesigned configurable batching, grinding, and mixing system for feed mills. It has all the advantages and flexibility of a custom-designed commercial feed mill at a cost that is economical for feed applications. Standing at just 18 feet in height and suitable for a wide range of applications, our AGI FLEXmill can easily be retrofitted into existing facilities. And enhancing the efficiency of those facilities is what this system is all about.
A key advantage of the AGI FLEXmill is its integrated hammer mill with built in air assist. The hammer mill was designed with versatility in mind, as many integrated operations require the ability to grind multiple whole grains within a single recipe. The industry has not typically seen air assists installed on hammer mills for on-farm applications. AGI believes there is added value to the operations and livestock, as the air assist aids in the movement of ground grain through the screens and to control dust in the operation. Without air assist, ground particles have difficulty exiting the grinding chamber and as a result, pulverization occurs and excessive fines are created, along with premature hammer wear. The hammer mill has an established ratio of cubic feet/minute of air to screen area equal to 1.25. This not only preserves the integrity of feed ingredients but also enhances overall quality, making it ideal for producers aiming to reduce waste and enhance grinding efficiency.
Other benefits of the AGI FLEXmill include:
• Precise ingredient dosing and faster batching times
• Combination of various micro and macro storage and dosing options
• Multiple ingredient scales and rapid batching capabilities allow for high throughput, enabling feed mills to achieve production capacities of up to 12 metric tonnes per hour
• Amalgamation of roller mill if desired
AUTOMATION AND DIGITAL TOOLS IN FEED PRODUCTION
Automation has become an integral part of modern feed mills, reducing the need for manual labor and minimizing the risk of human error. AGI offers a range of solutions for automation to help give farmers precise control over various stages of production, from input storage and ingredient dosing to final product packaging. Providing this level of control not only helps improve feed quality, but also enhances workflow efficiency and reduces operational costs.
AGI BINMANAGER
The ambient temperature and humidity can affect a hammer mill’s performance. As temperature and moisture increase, the energy required to grind the material also increases. When the material’s temperature decreases the material becomes easier to grind. This is why it is important to monitor the conditions in your feed mill. AGI BinManager is an advanced grain bin monitoring solution that intelligently monitors the moisture content and temperature of the commodities inside your bin, as well as the outside air. This enables the system to automatically choose the optimal times to run heaters and fans. Frequent condition readings ensure you can be on top of what’s going on in your bin at any time, from anywhere, making it easier for you to maintain crop quality and reach targets.
AGI BinManager offers conditioning management, automatic drying, cooling, and hydration, and can be operated with either manual or user-defined controls. It seamlessly integrates with AGI’s cloud-based software, AGI SureTrack. Accessible through the app or any internet-connected device, the software allows users to see data collected by AGI BinManager and make decisions that enable them to maintain the highest quality crop.
AGI CMC HAZARD MONITORING
AGI’s CMC Hazard Monitoring is another example of how digital tools are transforming feed production. Our solutions provide real-time monitoring of equipment such as conveyors and hammer mills, to help ensure seamless, efficient production. By leveraging data from sensors that monitor bearing temperatures, belt misalignment and vibration, producers can detect and address potential issues before they lead to costly breakdowns. This predictive maintenance approach reduces downtime and enhances safety in feed mills, particularly where combustible dust poses significant risks. By utilizing the AGI FLEXmill, AGI BinManager and AGI CMC Hazard Monitoring together, an operator can decrease the amount of labor overseeing the feed mill operations and have confidence that their system can operate safely with the least amount of intervention.
OVERHEAD STORAGE SOLUTIONS AND MATERIAL HANDLING
AGI’s intelligently designed, engineered overhead storage bins are intended to help producers optimize space and minimize losses during storage and transfer. These bins are engineered with smooth interior walls and chamfered corners to prevent bridging and ensure optimal product flow. AGI overhead bins are designed to integrate perfectly with other feed mill components such as screw feeders, conveyors, and gates, to help create a seamless material handling system from storage to delivery. Our solutions are fully customizable to help meet specific feed storage needs.
ENHANCING NUTRITIONAL QUALITY THROUGH PROCESSING TECHNOLOGIES
As the focus on feed efficiency grows, so does the importance of maintaining the nutritional quality of the feed. AGI’s product line includes advanced feed processing technologies that help preserve essential nutrients during production.
For example, AGI’s teardrop hammer mill, available as part of the AGI FLEXmill system, is designed to help ensure consistent particle size reduction – critical for improving feed digestibility and enhancing overall animal health.
In addition, AGI offers a range of batching and mixing equipment that can help maintain even distribution of nutrients in feed formulations. The AGI horizontal paddle mixer, for instance, significantly reduces mixing time while maintaining a high coefficient of variation (CV), ensuring that all ingredients are thoroughly and evenly blended. This is essential for producing high-quality feed that meets nutritional requirements.
AGI AND PRODUCERS: ENVISIONING THE FUTURE TOGETHER
We continue to work closely with producers, to ensure that we fully understand their needs – and are able to deliver feed solutions that precisely meet those needs. Maximizing efficiency, minimizing loss, and maintaining quality are always at the forefront of our efforts – because we know these objectives are of prime importance to our customers in the industry, as well.
References
1. Fairman, S. (2024, August 15). Rising trends suggest higher broiler chicken output in 2024. Poultry Producer. Retrieved from https://www.poultryproducer.com/rising-trends-suggest-higher-broiler-chicken-output-in-2024/.
2. Jim, E (2024, April 23). Analysis of 2024 Pork Market Trends: Increased Production and Export Forecasts. Swine Web. Retrieved from https://www.swineweb.com/ag-finance/analysis-of-2024-pork-market-trends-increased-production-and-export-forecasts/#:~:text=Total%20pork%20production%20in%202024,in%20a%20persistently%20inflationary%20environment
About André Magrini
André Magrini is a seasoned executive in the feed and food industries. As Sales Director at AGI, he drives innovation and growth in agribusiness. He also serves as Vice Chairman of the Marketing and Communications Committee at AFIA, where he promotes industry standards and best practices.
André holds a Master’s in Agribusiness, an MBA, and certifications from Wharton Business School and Kansas State University. He is a published author on corporate governance and sales strategies, and is passionate about animal feed, nutrition, and sustainability.
