This is a large TMR beef feed production line project, which is built in three phases. The project mainly uses forage, grains and distiller's grains as the main raw materials, and will produce 180,000 tons of TMR feed and distiller's grains feed annually. The final products of the project are pellet feed and briquette feed.
TMR feed has broad application prospects in Brazil. TMR (total mixed ration) is a feed that evenly mixes coarse feed, fine feed, concentrate, minerals, vitamins and water, which can meet the comprehensive nutritional needs of ruminants such as cattle and sheep.
As the world's major supplier of grain and meat, the development of Brazil's feed industry has an important impact on the global feed market. The promotion and application of TMR feed can not only improve the utilization rate of feed, but also help farmers better manage feeding costs, thereby improving overall production efficiency and economic benefits.
The customer of 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project is an agricultural company from Brazil. Through long-term market research, based on Brazil's rich agricultural resources and developed animal husbandry, the customer invested 1.5 million US dollars to build this large TMR beef feed plant project.
The Brazi cattle feed plant project has a total of 7 staff members, and 10 more workers in the production workshop need to be added each phase. After the completion of the third phase, the total number of workers in the factory will be 37. This project operates 300 days a year, three shifts a day, 8 hours a shift, and 24 hours a day.
Name:
Hay grass pellet feed plant
Country:
Brazil
Date:
2023.11.19
Capacity:
25T/H
Pellet Size:
4-8mm
The install period:
100 days
Control Mode:
Automatic
Guiding Price:
1,500,000 USD
This 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project mainly includes production plants, office buildings, dormitory areas, power distribution rooms, laboratories, etc. It is planned to build 3 production lines, and a single production line can simultaneously produce TMR beef cattle complete mixed rations and grain wet alcohol grains feed. It will be built in three phases. The composition of this cattle grass pellet plant project is shown in the table below.
| Category | Project | Project Content | Remarks |
| Main Project | Production Plant | Content of Phase I construction: 1 production plant with an area of about 6,100m2 will be built in the middle and eastern part of the factory area. The internal divisions of the plant include production area, dregs raw material/unloading/mixing stacking area, feeding area, concentrated feed/corn storage area, finished product warehouse, etc. 1 production line will be built inside the production plant, with an annual production capacity of 120,000 tons of feed (including 60,000 tons of TMR beef cattle complete mixed ration and 60,000 tons of grain wet alcohol dregs feed). | New Construction |
| Contents of Phase II Construction: 1 additional production line will be built in the production plant, with an annual production capacity of 120,000 tons of feed (including 60,000 tons of TMR beef cattle complete mixed ration and 60,000 tons of grain wet alcohol grain feed). | New Construction | ||
| Contents of Phase III Construction: 1 additional production line will be built in the production plant, with an annual production capacity of 120,000 tons of feed (including 60,000 tons of TMR beef cattle complete mixed ration and 60,000 tons of grain wet alcohol grain feed). | Newly built | ||
| Auxiliary engineering | Life support | The office building and dormitory area are located in the northwest of the factory area, with a light steel plate structure and a single floor; the laboratory is located in the northeast of the factory area, with a light steel plate structure and a single floor. The total area ofthe office building, dormitory area and laboratory is about 1143m2. | Newly built, all in the first phase of construction |
| Storage and transportation engineering | Liquid material storage tank area | Contents of the first phase of construction: On the east side of the production plant, set up a corn slurry storage tank, a honey storage tank, and a water storage tank, each of which has a capacity of 50m3 for the corn slurry storage tank and the honey storage tank, and a capacity of 2m3 for the water storage tank. | New Construction |
| Contents of Phase II Construction: On the east side of the production plant, set up a corn slurry storage tank, a honey storage tank, and a water storage tank, each with a capacity of 50m3 for the corn slurry storage tank and the honey storage tank, and a capacity of 2m3 for the water storage tank. | New Construction | ||
| Contents of Phase III Construction: On the east side of the production plant, set up a corn slurry storage tank, a honey storage tank, and a water storage tank, each with a capacity of 50m3 for the corn slurry storage tank and the honey storage tank, and a capacity of 2m3 for the water storage tank. | New Construction |
The 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project production scale and product plan are shown in the table below.
| Product Name | Phase I | Phase II | Phase III | Whole Factory | |
| TMR Beef Cattle Complete Mixed Ration | TMR200 | 1 | 1 | 1 | 3 |
| TMR400 | 2 | 2 | 2 | 6 | |
| TMR600 | 2 | 2 | 2 | 6 | |
| TMR999 | 1 | 1 | 1 | 3 | |
| Total | 6 | 6 | 6 | 18 | |
| Grain wet distiller's grain feed | 6 | 6 | 6 | 18 | |
| Product raw and auxiliary materials | Phase I t/a | Phase II t/a | Phase III t/a | Whole plant t/a |
| Alfalfa, straw, hay | 1.48 | 1.48 | 1.48 | 4.44 |
| Corn | 1.36 | 1.36 | 1.36 | 4.08 |
| Molasses | 0.23 | 0.23 | 0.23 | 0.69 |
| Corn syrup | 0.3 | 0.3 | 0.3 | 0.9 |
| Cassava starch residue | 2.52 | 2.52 | 2.52 | 7.56 |
| Wet brewer's grains | 4.38 | 4.38 | 4.38 | 13.14 |
| Dried distillers grains (DDGS) | 1.07 | 1.07 | 1.07 | 3.21 |
| Stone powder | 0.071 | 0.071 | 0.071 | 0.213 |
| Soybean meal (43%) | 0.1172 | 0 .1172 | 0.1172 | 0.3516 |
| Water | 0.18 | 0.18 | 0.18 | 0.54 |
| TMR core materials (vitamins, minerals, amino acids, etc.) | 0.333 | 0.333 | 0.333 | 0.999 |
The cattle grass feed production equipment used in this 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project is shown in the table below.
| Equipment name | QTY | Specification model | ||||
| Phase I | Phase II | Phase III | Whole plant | |||
| 1. Raw material feeding system, crushing system | ||||||
| Customized car unloading hopper | 1 | 1 | 3 | 2m*3m*1.5m | ||
| Spiral elevator | 1 | 1 | 3 | SSL220 | ||
| Raw material primary screening | 1 | 1 | 1 | 3 | TCQY63 | |
| Bucket Elevator | 1 | 1 | 3 | TDTG48/28 | ||
| Raw Grain Grid Silo | 1 | 1 | 3 | 100m³ | ||
| Horizontal Screw Elevator | 1 | 1 | 3 | S SL160 | ||
| Spiral elevator | 1 | 1 | 3 | SSL220 | ||
| Z type iron remover | 1 | 1 | 3 | ZX101 | ||
| Water drop crusher | 1 | 1 | 3 | SFSP66*60 | ||
| Pulse dust collector | 1 | 1 | 1 | 3 | TBLMF12 | |
| Fan | 1 | 1 | 1 | 3 | 4-72-4A | |
| Closed wind auger | 1 | 1 | 1 | 3 | SBGL20 | |
| 2. Batching and mixing system | ||||||
| Bucket elevator | 1 | 1 | 3 | TDTG26*23 | ||
| Bucket elevator | 1 | 1 | 3 | TDTG26*23 | ||
| Bucket elevator | 1 | 1 | 3 | TDTG26*23 | ||
| Rotary distributor | 1 | 1 | 3 | TFPX4 | ||
| 10T Silo | 3 | 3 | 3 | 9 | 20m³ | / |
| Loading position | 8 | 8 | 24 | / | ||
| Self-cleaning scraper conveyor | 2 | 2 | 2 | 6 | TWLL20 | |
| Spiral elevator | 3 | d>3 | 3 | 9 | SSL160 | |
| Warehouse Discharging Machine | 1 | 1 | 3 | TWLL20 | ||
| Batching Scale + Pneumatic Gate | 1 | 1 | 1 | td> | 3 | 2m³ |
| Spiral Elevator | 1 | 1 | 3 | SSL220 | ||
| Horizontal Double Screw Mixer | 1 | 1 | 3 | 9HWP-1000 | ||
| Pneumatic gate | 1 | 1 | 3 | TZMQ40*40 | ||
| Bucket elevator | 1 | 1 | 3 | TDTG26*23< /td> | ||
| 5T silo | 2 | 2 | 2 | 6 | 10m³ | |
| Output machine | 1 | 1 | 1 | TWLL20 | ||
| 3. TMR mixing system | ||||||
| Grass pellet machine | 1 | 1 | 1 | 10T/H | ||
| Grass feed briquetting machine | 1 | 1 | 1 | 1 | 4T/H | |
| Fixed TMR equipment | 3 | 3 | 3 | 9 | 36M3, 110KW | |
| Discharging machine | 3 | 3 | 3 | 9 | 11.5 meters long, 11KW | |
| Temporary warehouse | 3 | 3 | 3 | 9 | 36M 3 | |
| Uninstall Material discharging machine | 3 | 3 | 3 | 9 | Length 15 meters, 22KW | |
| Hay storage warehouse | 1 | 1 | 1 | 3 | 30M³11KW | |
| Slag storage warehouse | 1 | 1 | 1 | 3 | 30M³ , 11KW | |
| Main scraper for roughage | 1 | 1 | 3 | Length 20 meters, 22KW | ||
| Automatic packaging machine | 1 | 1 | 3 | Customized | ||
| Electrical control system | 1 | 1 | 1 | 3 | Frequency conversion control cabinet, local cabinet, main power cabinet, PLC cabinet | |
| 4. Liquid material system | ||||||
| Corn slurry storage tank | 1 | 1 | 3 | 50m3 , 304 stainless steel | ||
| Molasses storage tank | 1 | 1 | 3 | 50m3 , 304 stainless steel | ||
| Water storage tank | 1 | 1 | 1 | 3 | 2m3 , 304 stainless steel | |
| screw pump | 2 | 2 | 2 | 6 | 15m3/h , 7.5KW | |
| centrifugal pump | 1 | 1 | 3 | 15m3/h , 5.5KW | ||
| 5 Auxiliary system | ||||||
| Compressed air system | 1 | 1 | 3 | / | ||
| Electronic control system | 1 | 1 | 3 | / | ||
| Steel frame platform | 1 | 1 | 3 | / | ||
In this 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project, a single production line can produce TMR beef cattle complete mixed ration and grain wet alcohol grain feed at the same time.
The production process of TMR beef cattle complete mixed ration and grain wet alcohol grain feed is the same. The raw materials of grain wet alcohol grain feed are less than those of TMR beef cattle complete mixed ration, such as straw, alfalfa, liquid feed (honey, corn syrup, water), etc. The computer-controlled automatic batching system can produce different products.
Brief description of the production process of TMR beef cattle complete mixed ration and grain wet alcohol grain feed:
The raw materials for this 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project include bulk raw materials, bagged raw materials and liquid raw materials. The bulk raw materials are corn, and the bagged raw materials are alfalfa, straw (purchased cut alfalfa and straw), cassava starch residue, wet brewer's grains (sealed with plastic wrap), dry corn brewer's grains (sealed with plastic wrap), soybean meal (sealed with plastic wrap), stone powder, and TMR core material. Liquid materials are molasses, corn syrup and water.
Bulk corn particles are stored in the raw grain grid bin through the discharge port and the elevator. The unloading process of corn particles will generate unloading dust. Bags of raw materials are stacked in the temporary storage bin for standby use. Wet beer grains and dry corn grains will generate a small amount of odor during the storage process. The unpacking process of bagged raw materials will generate waste raw material packaging bags.
This process is mainly for pellets (corn particles) that need to be crushed. The pellets need to be screened and magnetically separated before crushing. The corn enters the primary screening machine and iron remover through the elevator. After removing impurities, it enters the crusher through the bucket elevator for crushing. The corn powder enters the batching bin through the elevator.
The production of TMR 200 and TMR 999 products does not require the use of corn raw materials. Therefore, there is no corn particle cleaning and crushing process when producing TMR 200 and TMR 999 products.
Raw materials that do not require crushing, such as cassava starch residue, soybean meal, stone powder and TMR core materials, are manually unpacked and then fed from the feeding port by manual feeding.
The raw materials enter the next process through the elevator; alfalfa and straw are directly fed into the TMR equipment through a scraper; wet beer grains and dry corn distiller's grains are directly fed into the TMR equipment through manual unpacking. Liquid materials such as corn syrup, molasses and water are transported to the TMR equipment through a metering pump.
The products of this 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project can be divided into TMR beef cattle complete mixed ration and grain wet alcohol grain feed.
Among them, grain wet alcohol grain feed is produced every day, and TMR beef cattle complete mixed ration is subdivided into TMR 200, TMR 400, TMR 600 and TMR 999 feed. The production time ratio is 1:2:2:1, and only one of them is produced every day. The types of raw materials fed are adjusted according to the types of products produced every day and the production formula requirements.
According to the proportion of the formula, the powder materials in the batching bin, such as cassava starch residue, soybean meal, and corn flour, are transported to the batching scale by a rotary distributor for measurement and then enter the horizontal double-screw mixer for premixing. The mixed powder materials enter the powder storage bin for temporary storage.
The products that need to be prepared as premixes for this alfalfa pellet production line in Brazil project are TMR400, TMR600 and grain wet alcohol grain feed. There is no premixing process when producing TMR200 and TMR999.
According to the feed formula requirements, the raw materials involved in the batching enter the TMR equipment for mixing. After being mixed evenly, they enter the next process.
The evenly mixed materials are compressed and formed by the grass cattle feed pellet machine and grass briquetting machine and then packaged for sale. Because the product contains a certain amount of water, no dust is generated during the packaging process.
The power supply for this 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project is supplied by the local power grid.
The living and production water of this project is taken from the local tap water pipe. The water used in this alfalfa pellet machine plant project is mainly for employees' living water, production water and laboratory water.
There are 17 workers in the first phase of this project, 10 more in the second phase (all of them are workers in the production workshop, not living in the factory), and 10 more in the third phase (all of them are workers in the production workshop, not living in the factory).
The living water quota for employees who do not live in the factory is 50L/person·d, and the living water quota for employees who live in the factory is 100L/person·d. Therefore, the living water consumption in the first phase is 0.95m3/d (285m3/a), the living water consumption in the second phase is 0.5m3/d (150m3/a), and the living water consumption in the third phase is 0.5m3/d (150m3/a).
After the completion of the third phase, the total domestic water consumption of the plant = 285m3/a + 150m3/a + 150m3/a = 585m3/a.
According to the TMR beef cattle complete mixed ration ingredient list and grain wet alcohol grain feed ingredient list, the water consumption for producing 1 ton of TMR 200 and TMR 600 beef cattle complete mixed ration is 60kg, that is, 0.06m3/ton·product.
The production scale of TMR 200 and TMR 600 beef cattle complete mixed ration is 30,000 t/a in the first phase, 30,000 t/a in the second phase, and 30,000 t/a in the third phase. The production water consumption in the first phase is 1800m3/a (6m3/d), the production water consumption in the second phase is 1800m3/a (6m3/d), and the production water consumption in the third phase is 1800m3/a (6m3/d).
After the completion of Phase III, the total water consumption of the plant = 1800m3/a + 1800m3/a + 1800m3/a = 5400m3/a.
The laboratory of this 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project mainly conducts product inspections. The inspection frequency is random sampling of batch products.
The factory inspection items are conventional physical and chemical indicators: moisture, crude protein, total phosphorus, crude ash, calcium, crude fiber, crude fat, sodium chloride, fatty acids, various amino acids; heavy metal and harmful substance indicators: heavy metals, melamine, aflatoxin; feed enzyme preparations: cellulase, phytase, pectinase, amylase, acid protease, heavy protease, saccharification enzyme, lipase, etc.; microbial indicators: total colony count, Escherichia coli, pathogenic bacteria, mold and yeast, etc.
The laboratory water is mainly used for cleaning laboratory instruments and preparing reagents. The project's laboratory water consumption is not large. The laboratory water consumption for each phase is about 0.007m3/d (2.1m3/a).
After the completion of the third phase, the laboratory water consumption of the entire plant is 0.021m3/d (6.3m3/a). Laboratory wastewater is disposed of in strict accordance with the requirements of hazardous waste management. It is collected in waste liquid barrels and regularly entrusted to qualified units for disposal.
The drainage system adopts a rainwater and sewage diversion system. Rainwater is collected through drainage ditches around the plant area and discharged outside the plant after treatment in sedimentation tanks.
The wastewater generated by this 25t/h TMR cattle alfalfa grass pellet production line in Brazil project is mainly domestic sewage, which is treated in a three-level septic tank and used for fertilization in surrounding agriculture and forestry.
According to the general layout design of the factory area we provide for customers:
The factory area is divided into office buildings, dormitory areas, laboratories, and production plants. The office buildings and dormitory areas are located on the northwest side of the factory area, the laboratory is located on the east side of the factory area, and the production plant is located in the middle and eastern part of the factory area.
The internal divisions are clear: from south to north, they are the raw materials/unloading/mixed stacking area in the dregs → feeding area → fine feed/corn storage area, and finished product warehouse.
The temporary storage room for hazardous waste is located in the laboratory, close to the entrance and exit of the factory area, which is convenient for transportation. The layout of each area of the 25t/h TMR grass beef cattle feed production line in Brazil project is reasonable and smooth, the divisions are obvious, and the general layout is basically reasonable.
The environmental protection measures adopted by this 25t/h TMR beef cattle grass alfalfa pellet production line in Brazil project are as follows:
| Item | Pollution source | Pollutant item | Environmental protection measures | Implementation standard |
| Atmospheric environment | DA001 | Particulate matter | Pulse bag dust collector | Comprehensive emission standard of air pollutants |
| Wine lees storage | Ammonia, hydrogen sulfide, odor | 15m high exhaust pipe diluted by atmosphere, absorbed by vegetation | Emission standard of odor pollutants | |
| Canteen | Oil smoke | Oil fume purifier | Emission standard of oil fume for catering industry | |
| Surface water environment | Domestic sewage | CODcr, ammonia nitrogen, BOD5, SS, etc. | Third-level septic tank | Used for fertilization of surrounding agriculture and forestry, no external discharge |
| Acoustic environment | Production equipment | Equivalent continuous A Level | Foundation shock absorption, factory building sound insulation | Factory boundary "Environmental noise emission standards for industrial enterprises" |
| Solid waste | Office and living area | Set up domestic garbage bins, and domestic garbage will be regularly handed over to the sanitation department for disposal | ||
| Waste raw material packaging bags, waste product packaging bags | Collected and sold to waste recycling stations | "General Industrial Solid Waste Storage and Landfill Pollution Control Standards" | ||
| Dust collected by pulse bag dust collector | Returned to production process after regular cleaning | / | ||
| Impurities | The iron impurities that can be recycled are sold to the scrap recycling station, and the stones are entrusted to the sanitation department for disposal | "Pollution Control Standards for Storage and Landfill of General Industrial Solid Waste" | ||
| Laboratory waste liquid, waste disposable laboratory supplies, reagent waste packaging materials, waste lubricating oil | Classified and temporarily stored in the hazardous waste room, and regularly entrusted to qualified units for disposal | "Pollution Control Standards for Storage of Hazardous Waste" | ||
| Soil and groundwater pollution prevention and control measures | District anti-seepage: Hazardous waste rooms and laboratories are key anti-seepage areas, and the anti-seepage technical requirements for key pollution prevention and control areas are: equivalent clay anti-seepage layer Mb≥6.0m, K≤1×10-7cm/s; simple anti-seepage areas are production plants, office buildings, dormitory areas and other office and living areas, requiring the use of general ground hardening | |||
| Environmental risk prevention measures | ① Smoking is prohibited in the factory area, and the factory circuit should be inspected regularly to strictly control the power load; ② In the preliminary design, construction and commissioning of the project, fire and explosion prevention measures in the factory area should be implemented in accordance with relevant specifications, and lightning protection measures should be taken for buildings; ③A gas collection system should be set up in the dust-producing link, and pulse bag dust collectors should be used for dust removal; ④The hoist and scraper are precisely installed to prevent abnormal friction; ⑤Strengthen production management and prohibit open flames; ⑥Regularly inspect and maintain the pulse bag dust collector to ensure its effective and normal operation; ⑦Focus on anti-seepage in hazardous waste rooms. | |||
TMR is the abbreviation of Total Mixed Ration. The so-called total mixed ration (TMR) is a feeding technology that fully mixes roughage, concentrate, minerals, vitamins and other additives to provide sufficient nutrition to meet the needs of dairy cows.
TMR feeding technology, based on supporting technical measures and excellent TMR machinery, can ensure that every bite of ration taken by cows is a complete ration with a stable ratio of concentrate to roughage and consistent nutrient concentration.
This mature cattle feeding technology has has been widely used in Israel, the United States, Italy, Canada and other countries. A total mixed ration (TMR) is a relatively balanced ration obtained by fully mixing and granulating/pressing roughage, concentrate and various nutritional additives chopped (kneaded) to appropriate lengths according to the nutritional needs of ruminants at different physiological stages.
The outlook for TMR feed processing is generally positive. TMR feed, as a nutritionally balanced feed form, can meet the nutritional needs of ruminants, improve feed utilization and animal health, and therefore has broad application prospects in animal husbandry.
The development prospects of TMR feed processing are mainly reflected in the following aspects Aspects:
However, TMR feed processing also faces some challenges:
In summary, the prospects for TMR feed processing are promising, but the cost and Popularization and other challenges to achieve wider application and promotion.
RCIHI Machinery is a professional feed equipment processor. The cattle feed mill equipment we can provide covers grass feed, concentrated feed, roughage, complete feed, premix , fermented feed, etc., and our equipment has been exported to the United States, Australia, New Zealand, Argentina, South Africa, Ghana, Indonesia, India, Tunisia and other countries.
If you are interested in building a cattle feed production line to process TMR feed, feel free to contact us customized professional production line design solutions and equipment quotations.
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