25T/H Cattle Feed Manufacturing Plant In Ecuador

Construction scale

The cattle feed manufacturing plant in Ecuador project covers an area of 39,632.40m2, which is industrial land. The project will build a ruminant feed (feed for animals with ruminant stomach) production line. After completion, it will produce 180,000 tons of ruminant feed annually. The product plan of the whole plant is shown in the table below.

Construction Content

This cattle feed manufacturing plant in Ecuador project mainly constructs feed workshop and raw material warehouse complex, corn silo, grain unloading room, finished product warehouse, auxiliary rooms, office complex, gatehouse, sampling room, production workshop, public facilities, electricity, water supply and drainage, building fire protection, greening and other supporting facilities. The main construction contents of the project are detailed in the table below.

List of main structures of the Ecuador cattle feed plant project

Raw and auxiliary materials and energy consumption

The main raw and auxiliary materials used in this cattle feed manufacturing plant in Ecuador project and their physical and chemical properties are shown in the table below.

List of main raw and auxiliary materials and energy consumption

List of physical and chemical properties of raw and auxiliary materials

Main equipment

The main equipment of this cattle feed manufacturing plant in Ecuador project is shown in the table below.

Process design of Ecuador cattle feed project

The cattle feed manufacturing plant in Ecuador project mainly uses corn, meal and other raw materials to produce ruminant feed after crushing, mixing, granulation and other processes. After completion, the annual output of ruminant feed is 180,000 tons, including 54,000 tons/a of granular feed and 126,000 tons/a of powdered feed.

Except for the addition of the granulation section, the other process flow of granular feed is the same as that of powdered feed, and the two feeds are not produced at the same time.

In order to reduce the emission of pollutants, the material unloading pit of the project is equipped with a downdraft device and a closed air device; the material transfer, crushing, mixing, granulation and other process nodes are fully enclosed.

Raw material receiving section

The raw material receiving section mainly includes raw material receiving, classified storage, raw material pretreatment, etc.

Raw material reception and storage

Reception of bulk raw materials: bulk raw materials such as corn and soybean meal are transported by bulk trucks, and are transported to bulk bins by scrapers after pretreatment; Reception of packaged raw materials: bagged raw materials such as pulped corn husks, germ meal, and wheat bran, and barreled or canned raw materials such as trace elements and molasses are directly stored in the raw material warehouse after acceptance.

Raw material pretreatment

Bulk raw materials such as corn and soybean meal are transported to the unloading room by transport vehicles. After the vehicle enters the unloading room, the door of the unloading room is closed, and the raw materials are unloaded to the unloading pit through the rear hydraulic flap.

The unloading pit is equipped with a lowering screen bucket to remove general impurities contained in the raw materials, and then the raw materials are transported to the pellet barrel screen by the scraper to further remove impurities.

After removing general impurities, the raw materials are automatically ironed by an iron remover to remove iron impurities, and then lifted to the silo by a bucket elevator for storage. Corn is transported to the corn silo by the elevator for storage, and soybean meal is transported to the meal silo by the elevator for storage.

Crushing section

Corn, soybean meal, etc. in the bulk bin are transported by scraper conveyor to the feed workshop, and then to the crushing buffer bucket for measurement by bucket elevator, and then to the closed crusher through the feeder.

The bagged raw materials that need to be crushed, such as germ meal, cotton meal, sunflower seed meal, rapeseed meal, sesame meal, and beet granule meal, are lifted by bucket elevator through the feeding port to the cylindrical primary cleaning screen, magnetic separation drum machine for impurity removal, and then to the crushing buffer bucket for measurement by flow scale, and then to the closed crusher through the feeder.

This cattle feed manufacturing plant in Ecuador project is equipped with two hammer mills, which can achieve coarse and fine crushing by adjusting the gap between the hammer and the screen. Hammer mill is the most widely used type of crusher at present.

Mixing Section

Raw materials that do not need to be crushed, such as bran, wheat bran, corn husk, corn (DGS), etc., are transported to the batching bin via a scraper conveyor and a bucket elevator. Corn, soybean meal, germ meal, cottonseed meal, sunflower meal, rapeseed meal, sesame meal, beet granules, etc. are crushed and then enter the batching bin.

The raw materials in the batching bin are controlled by the computer in the central control room according to the proportion of each raw material, and the batcher is discharged to the batching scale.

After weighing, the materials flow through the pipeline to the double-shaft paddle high-efficiency mixer. The trace element small silo is weighed from the batching hopper scale and then mixed evenly in the single-shaft mixer before entering the double-shaft paddle high-efficiency mixer to mix with the raw materials.

Molasses are mixed evenly from the buffer bin to the molasses mixer via the screw conveyor, and then enter the double-shaft paddle high-efficiency mixer to mix with the raw materials. After all materials are fully mixed in the closed mixer, powdered feed is produced and then sent to the finished product warehouse for packaging via a scraper conveyor and a bucket elevator; granular feed is produced and sent to the granulation warehouse via a scraper conveyor and a bucket elevator.

Granulation section

The granulation section in this cattle feed manufacturing plant in Ecuador project mainly includes conditioning, granulation, cooling, screening, etc.

Conditioning

The mixed materials are firstly removed by a safety magnet to remove iron and impurities and then conditioned. Conditioning is mainly to mature the feed so that it becomes a powdered feed with a certain amount of moisture and humidity that is conducive to granulation. The conditioning of this project mainly adopts a conditioner + retainer.

In the conditioner, the material and steam are fully gelatinized under the strong action of shearing and stirring. This process produces a full-structure matrix in the particles containing soluble sugar and fiber, increases the volume of the particles, becomes a porous structure, and fully matures the compound.

The main function of the retainer is to extend the maturation time of the material and further improve the maturation degree of the material. After the feed is matured, not only the physical state such as the appearance changes, but also the molecular structure of the internal organic matter changes, making starch easier to digest and protein easier to use.

Granulation and cooling

The matured feed is granulated in the ring die pelletizer, and the feed pellets are transported to the countercurrent cooler by the scraper conveyor and bucket elevator for cooling and drying.

During the granulation process, due to the introduction of high-temperature and high-humidity steam and the extrusion of the material to generate a large amount of heat, the pellet feed has a moisture content of 15% and a temperature of up to 98°C when it just comes out of the feed pellet machine.

Under such conditions, the pellet feed is easy to deform and break, and it will also produce adhesion and mildew during storage. The moisture content must be reduced to below 12.5% and the temperature must be reduced to below 8°C higher than the air temperature, which requires cooling. The countercurrent cooler uses an air compressor to generate compressed cooling air to cool the pellet feed to a suitable temperature.

Screening

The cooled cattle feed pellets are crushed into pellets by the crusher, and the crushed feed is graded by the rotary grading screen. The qualified pellets are stored in the finished product warehouse. The pellets with too large pellets are crushed by the pelletizer, and the pellets with too small pellets are sent to the pelletizer for pelleting again.

Finished product packaging section

The products are packaged from the finished product warehouse through a computer-controlled quantitative packaging scale to the packaging bag, and are inspected and put into storage for sale.

Plan layout

The cattle feed manufacturing plant in Ecuador project combines functional requirements and site conditions, takes process logistics as the main line, and divides the factory area into three functional areas, namely processing and production area, auxiliary facilities area, and office and living area.

The processing and production area is the core area of the plant, located in the middle and north of the plant, with one feed workshop, one raw material warehouse, one finished product warehouse, one grain unloading room, four corn silos and six meal silos.

The auxiliary facilities area is distributed at the west and south entrances of the plant according to the site characteristics and functional requirements, and is mainly equipped with one auxiliary facility room, one gatehouse and one sampling room.

The office and living area is located in the southwest of the plant, mainly with one office complex building, which is separated from the processing and production area by a green belt and a hollow wall.

The office entrance and exit and the logistics entrance and exit are located on the south side of the plant, and the fire entrance and exit are located on the north side of the plant. The cargo transportation in the plant is smooth and pedestrians are convenient.

Public works

Power supply

The power supply for this cattle feed manufacturing plant in Ecuador project is provided by the power supply network. There is a 1250KVA transformer in the plant to supply power for production and life, and a 250KVA transformer to supply power for the fire protection system. The annual power consumption is about 3.5235 million kW·h, which can meet the power demand of the project.

Heating and cooling

The production heat of this project is steam heating, which is provided by the steam pipeline network, and the annual steam consumption is 3560t.

Water supply and drainage

(1) Water supply

The water used in this cattle feed manufacturing plant in Ecuador project is supplied by the water supply pipeline network, mainly including water for staff life, canteen, equipment cleaning, greening, and road dust suppression. The total water consumption of the project is 20.30m3/d (3470m3/a), of which fresh water consumption is 15.32m3/d (3454m3/a) and recycled water consumption is 0.08m3/d (16m3/a).

The living water of employees is mainly for washing. The cattle feed mill project has a labor quota of 60 people. The living water consumption is calculated at 45L/person·d, so the living water consumption is 2.70m3/d (810m3/a);

The canteen water consumption is calculated at 20L/person·d. There are 60 people eating, and the fresh water consumption is 1.20m3/d (360m3/a).

The company conducts equipment cleaning four times a year, mainly in seasons with suitable temperatures. Each equipment cleaning uses 5m3 of water (20m3/a, 0.1m3/d, calculated based on 200 days), all of which is fresh water; the greening water consumption is 1.0L/m2·d, the greening area is 3000m2, and the number of greening days is 200 days, so the greening water consumption is 3m3/d (600m3/a), all of which is fresh water; the road dust suppression water consumption is 0.2L/(m2·times), the road area is 21000m2, and it is swept twice a day.

The number of wet sweeping days is 200 days, so the road dust suppression water consumption is 8.4m3/d (1680m3/a), of which 0.08m3/d is recycled water and 8.32m3/d is fresh water.

(2) Drainage:

The cattle feed manufacturing plant in Ecuador project drainage is mainly employee domestic sewage and canteen wastewater. The amount of domestic sewage, canteen wastewater, and equipment washing wastewater are all calculated based on 80% of the water consumption, that is, the amount of domestic sewage is 2.16m3/d, the amount of canteen wastewater is 0.96m3/d, and the amount of equipment washing wastewater is 0.08m3/d.

After the canteen wastewater is treated in the grease trap, it is discharged into the factory septic tank together with the domestic sewage, and then enters the water treatment center through the sewage pipe network for treatment; the equipment washing wastewater is used for road cleaning and dust suppression in the field, and is not discharged.

If you are interested in this cattle feed manufacturing plant in Ecuador project and want to build your own cattle feed production line, feel free to contact RICHI MACHINERY to obtain free ruminant feed production line construction plan, equipment quotation, process design and layout.