3T/H Pet Food Factory In Kyrgyzstan

Construction content

The pet food factory in Kyrgyzstan project makes use of the already built 1# and 3# plants. The 1# plant is arranged from west to east with freeze-drying pre-treatment area, pet staple food production area, finished product warehouse, packaging area, pet feed production area, and flavoring material production line.

The 3# workshop is arranged from west to east with finished product warehouse, freeze-drying and freezing workshop, material department, equipment management department, etc. The hazardous waste temporary storage room is located on the northwest side of the 1# workshop, the sewage treatment station is located in the north of the 3#, and the boiler room is located on the east side of the 3# workshop.

The plant area of this project is based on the production process and the actual terrain. In line with the principles of saving funds, land, compact layout and reasonable utilization, it not only meets the dominant position of the production process, but also complements each other with the auxiliary production units to improve the construction and operation efficiency.

The plane layout of the entire plant area reflects the convenience of production, taking into account the principles of fire protection, safety, and environmental protection, and the plane layout of the plant area is reasonable.

The main construction content of the pet food factory in Kyrgyzstan project is shown in the table below:

Product plan

The product plan for this pet food factory in Kyrgyzstan project is as follows:

Main raw and auxiliary materials

The main raw and auxiliary materials of this pet food factory in Kyrgyzstan project are shown in the table below.

Main pet food manufacturing equipment list

The main production equipment of this pet food factory in Kyrgyzstan project is shown in the table below:

The laboratory of this pet food factory in Kyrgyzstan project only conducts simple physical and chemical analysis tests, mainly to detect trace elements such as protein in each product. The raw material component test is provided by the raw material supplier, and no test is conducted in the factory. The test of heavy metals and other substances is outsourced. The project laboratory does not provide third-party services to the outside world.

Staff quota and work system

The labor quota and work system adopted by this pet food factory in Kyrgyzstan project are shown in the table below:

Public works

Water supply and drainage engineering

The water source of the pet food factory in Kyrgyzstan project relies on the local municipal water supply network and is directly connected to the factory area. The water supply pipes in the factory area are arranged in a ring shape, and the outdoor production, living and fire-fighting water supply system is shared.

A certain number of outdoor ground-type fire hydrants are set according to fire protection regulations. After the change, the project water is mainly used for domestic water, alkali spraying water, equipment cleaning water, floor mopping water, and boiler water.

① Domestic water

The local project labor quota is 32 people, working 260 days a year, and the domestic water consumption is 34.05m3/d (8854m3/a). The emission coefficient is 0.8, and the domestic sewage generation is about 27.24m3/d (7083.2m3/a). The domestic sewage is discharged into the sewage treatment plant for deep treatment and then discharged into the local river after meeting the standards.

② Equipment cleaning water

The equipment cleaning water consumption of this pet food factory in Kyrgyzstan project is about 3m3/d (780m3/a), and the wastewater generation is about 80% of the water consumption, so the equipment cleaning wastewater generation is 2.4m3/d (624m3/a). The cleaning wastewater is treated at the sewage treatment station and discharged into the sewage treatment plant through the municipal sewage pipe network.

③ Alkali spraying water

The alkali spraying water consumption of this project is about 10m3/d (2600m3/a). Most of the spraying water is recycled, and the wastewater discharge accounts for about 20% of the water volume, so the wastewater discharge is 2.0m3/d (520m3/a). The alkali spraying wastewater is treated at the sewage treatment station and discharged into the sewage treatment plant through the municipal sewage pipe network for deep treatment.

④ Floor mopping wastewater

The floor mopping water consumption of this project is about 2m3/d (520m3/a), and the wastewater generation is about 80% of the water consumption, so the mopping wastewater discharge is 1.6m3/d (416m3/a). The floor mopping wastewater is treated in the sewage treatment station and discharged into the sewage treatment plant through the municipal sewage pipe network for deep treatment.

⑤ Boiler water

• Boiler steam water: This project sets up a steam boiler to produce the required steam of 28454.4t/a, so the boiler needs 30124.8t/a of soft water, and the boiler steam condensate water collection is about 90% of the steam volume, so the boiler steam water collection is 104.28m3/d (27112.32m3/a), and the steam condensate is discharged into the rainwater pipe network.
• Soft water use: Boiler water is soft water, and the generation coefficient of natural gas fuel boiler wastewater (external water treatment: boiler wastewater + softening wastewater) is 13.56t/10,000 cubic meters-raw materials.
  The annual natural gas consumption of the boiler is about 1.26 million cubic meters, so the boiler wastewater generation is 1708.56m3/a (6.57m3/d). The total boiler water consumption of this project is 31833.36m3/a (122.44m3/d), and the wastewater discharge is 28820.88m3/a (110.85m3/d). The boiler drainage is discharged into the rainwater pipe network as clean sewage.

Transportation

The transportation of this pet food factory in Kyrgyzstan project is mainly automobile transportation, which is entrusted to a professional logistics company.

Steam supply

The project is equipped with an 8t/h natural gas boiler to supply steam and heating for the office area in winter. The production of one ton of pet feed requires 0.7t of steam, one ton of pet freeze-dried food requires 1t of steam, one ton of flavoring material requires 0.8t of steam, and one ton of pet staple food requires 0.8t of steam. It takes about 896,000 kcal of heat (including 30% loss) to produce one ton of low-pressure steam.

After the change, the annual output of the project is 20,000 tons of pet feed, 3,000 tons of pet freeze-dried food, 2,100 tons of pet staple food, and 500 tons of flavoring material. The supply and demand steam volume is about 6.84t/h. The boiler reserves 1.16t/h for heating the office building in winter. The heating of the office building is calculated based on 90 days of heating per year.

Kyrgyzstan project pet food and cat litter production process design

The process of this pet food factory in Kyrgyzstan project includes multiple processes, corresponding to different products. The following will describe the process flow of the project for you:

Pet freeze-dried production process

1. Thaw:
   Thaw the frozen meat raw materials.
2. Seasoning:
   Add seasoning to the pre-made product.
3. Steaming:
   Steam the seasoned meat.
4. Freezing and slow freezing:
   Freeze the steamed meat pre-made product.
5. Vacuum freeze drying:
   Use a vacuum freeze dryer to process the frozen meat raw materials, and the water is directly converted from solid to gas, which can remove 99% of the water in the raw materials.

Pet staple food production process

1. Raw materials:
   Mix various meat products according to the proportion of ingredients.
2. Grinding:
   Grind the meat raw materials into meat paste.
3. Extrusion molding:
   The ground meat paste is passed through a mold with a certain shape and extruded into a corresponding shape according to its rules.
4. Drying:
   Bake at a certain temperature (<50℃) to dry the product.
5. Oil spraying and seasoning:
   The dried product is transported to the sprayer and sprayed with oil and flavoring materials.
6. Manual inspection:
   After the product is naturally cooled, it is manually visually inspected. After the inspection, the qualified materials are sold as products.
7. Packaging:
   The finished product is weighed and packaged.

Pet extrusion feed production process

1. Crushing:
   Raw materials such as fish meal, chicken meal, beef meal, soybean meal and corn are lifted into the crusher by the elevator to crush the raw materials.
2. Batching and mixing:
   The crushed raw materials are sent to different silos through the rotary distributor. According to the design of pet food factory in Kyrgyzstan, different materials are automatically weighed and batched by the PLC batching scale and batching system, and added to the mixer for mixing according to the ratio requirements.
3. Extrusion:
   The mixed materials enter the pet extruder equipment, and the tempered materials are heated and matured by steam, and then extruded and puffed into granules.
4. Drying:
   The formed materials are dried by the dryer. In this process, steam is used to indirectly provide heat for the belt dryer.
5. Oil spraying:
   The dried products are transported to the sprayer and sprayed with oil and flavoring materials.
6. Cooling and screening:
   The sprayed materials are cooled. This project uses cold air to cool the materials. The cooled materials are screened through the screen. The materials that do not meet the product requirements are transported to the crusher through the bucket elevator and crushed for reuse.
7. Finished product packaging:
   The finished products are packaged by the fully automatic packaging system, and the packaged products are stored in the finished product warehouse waiting for sale.

Production process of flavoring materials

1. Raw material crushing:
   Chicken liver, duck liver, marine fish and other raw materials are crushed for production.
2. Raw material emulsification:
   The crushed raw materials are mixed with water and heated by steam jacket to achieve full emulsification.
3. Enzyme hydrolysis:
   The emulsified liquid and protease are fully mixed in a closed system and heated by steam jacket to degrade the high molecular weight protein.
4. CIP cleaning:
   The corresponding emulsification tank, enzymolysis tank, etc. are cleaned to meet the cleaning requirements. Commonly known as the cleaning-in-place system, it is widely used in food production enterprises with a high degree of mechanization, such as beverages, dairy products, juices, and jams.
   Cleaning-in-place is referred to as CIP, also known as cleaning positioning or positioning cleaning. Cleaning-in-place means that the contact surface with food is cleaned by using hot water without disassembling or moving the device, that is, the cleaning and purification of production equipment with strict hygiene requirements.

In addition to this pet food factory in Kyrgyzstan project, we have built many poultry feed production lines, livestock feed production lines, fish feed production lines, biomass pellet production lines, organic fertilizer production lines, and cat litter production line projects in Kyrgyzstan.

If you also want to invest in a pellet plant project, feel free to contact RICHI MACHINERY to obtain information such as the whole plant design, equipment layout, civil engineering, production line 3D design, equipment quotation, and delivery plan.