STEPS INVOLVED IN AUTOMATED FEED MILL
- 1. BY, N.ESHWAR. STEPS INVOLVED IN OPERATION OF AUTOMATED FEED MILL
- 2. Automation of feed mill is done by more sophisticated control devices, equipment and systems. Various type of control systems used are Host computers Distributed control systems Industrial computers Personal computer based systems Operator interfaces
- 3. Host computers ◦ Function at or near the top of the feed mill control system hierarchy. ◦ Usually perform or coordinate supervisory manufacturing activities. Distributed control systems Single failure will not shut down the entire manufacturing operation.
- 4. Industrial computers With proper software makes a superb operator interface Alarm and diagnostics messages can be presented in the operators own language and become increasingly insistent.
- 5. Personal computer based systems PC can adapt to a wide variety of applications ranging from word processing, to structural analysis, to accounting and data acquisition Operator interfaces Multiple equipment that are linked by a host control system is controlled Put together advanced control functions, complex mathematics and optimized control strategies that were previously often impractical
- 6. Electric Control System Features and Benefits for Feed Pellet Production 1. Accurate and simple operation, high efficiency, reduced cost. 2. More compact device, circuit integration and functionality. 3. Equipment fault warning and fault location functions are helpful to maintainer; they can debug the faults and recover manufacture rapidly. 4. The steady and reliable system can provide advantages for the automation degree and management level of the enterprise.
- 7. BATCH EQUIPMENT OPERATION Starting/Stopping - the batching equipment is started and stopped from the graphical screen via the industrial PLC. Override - on screen override to test motor or valve operation. High level bin indication Surge bin sensor Scales – monitoring of hopper, belt and truck scales.
- 8. AUTOMATED RECEIVING MODULE User enters the receiving product name or number and amount through a pc interface. The electric distributor is automatically set for the appropriate destination bin, which references ingredient to bin location. Once the product is delivered to the appropriate bin the database is updated with the amount of the new product. Alarming - if any problems. Activity report can be printed on the main PC.
- 9. Every feed mill has a “white board” to show what materials are in the bins. White board will accurately display the materials and the amount for any bin. This provides instant access and maximum convenience. All displays are instantly refreshed and accurate within seconds of a bin change.
- 11. AUTOMATIC MILLING MODULE The electrical current draw of the roller mill is monitored by the PLC( programmed logical controller) Feed screw speed and operation is controlled by the PLC for control of product through the roller mill. Clean out time is allocated for the stopping of the process. Alarming - if any problems Reports of activity and hours of use can be printed.
- 12. AUTOMATIC MIXING MAJOR, MACRO, & MICRO INGREDIENTS A personal computer with a large colour monitor and printer is used as the interface for this stage of production. Scale heads will be interfaced to the PLC Liquid ingredient meter inputs will be interfaced to the PLC. The database can accept multiple formulas (products - operations).
- 13. Recipes are created from the PC. Number of batches needed to mix the recipe is automatically determined. The PLC will query the user for hand adds, with the acceptance by the user when added. Alarming - on problem arise.
- 14. Report on recipe completion Inventory check on available products before recipe production begins. Graphical displays on the screen showing recipe in the scales, recipe in the mixer and upcoming recipe in batch queue, etc. User will be able to monitor receiving, grinding, mixing, pelleting and shipping from different graphical screens from the PC.
- 17. AUTOMATIC DESTINATION Destination of the product is entered when the order is created; therefore the destination distributor is automatically set by the PLC when that order reaches the surge bin. This destination bin is recorded with this order for shipping module.
- 18. SHIPPING MODULE A truck scale is interfaced to the PLC. Positions of the gates on the overhead shipping bins are monitored. Once a bin is opened and button pressed for acceptance, the truck weight is recorded back to the original order.
- 19. Intelligent Scale Controllers This controller record, store and display scale weights along with truck ID, vendor ID, commodity ID, tare, net and gross weights. This information can be transferred to other devices for future storage and processing
- 20. Future growth and applications There will be increase in processing power, advanced programming languages and user configurable or programmable software Most powerful and faster computers coupled with abundant memory and creative software will create tremendous capabilities for feed mill control systems. The most dramatic increases come when plant floor operational information is coordinated with production planning and scheduling system.
- 21. Flow Chart of Animal Feed Pellet Line
- 22. Feed pellet line process: Silos for raw materials storage, Raw materials receiving system, First batching system, Mixing system, Second batching, Crushing system, Pelletizing system, Cooling system, Bagging system.
- 24. •The hammer mill is an important equipment for the raw material grinding process. •The hammer mill can grind the raw materials ingredients into the required size. • It is suitable for small or medium sized feedstuff pellet mill plant. •While if you manage a large scale feedstuff pelletizing factory, the water drop hammer mill is an ideal choice.
- 25. •Mixing is one of necessary processing in animal feed pellet line. • Proper mixing will lead to increase diet uniformity and improve the feedstuff quality. Two kinds of high efficiency feed mixers: twin shaft mixer for particle materials and screw belt mixer for powdered materials. •Both of them are equipped with atomizing spraying system to add needed liquids which can improve feed pellets quality
- 26. •Feed pelletizing machine is the key feed equipment for the animal feed pellet line. • The feed pelletizing machine is the ring die design which is broadly used to large capacity feed pellets production.
- 27. •Getting out of the feed pelletizing machine, the feed pellets with high temperature and large moist need cooling by counterflow cooler. •The these feed pellets can be crushed, screened or packed. Through the cooler, the feed pellets are decreased the temperature and moisture for next processing
- 28. •Because different animal such as poultry, cattle and pig feed pellets are with different sizes. Some big feed pellets should be crushed into small particles. •The feed pellet crumbler is the right equipment for the feed pellets crushing. The double roll feed pellet crumbler is suitable for crushing animal feeds like poultry, pig and cattle feed etc..
- 29. •By feed pellet crumbler, there may be some powder in the pellet feed. •The rotary grading sieve is used to screen and grade the feed pellets. • After this processing, you can get qualified feedstuff pellets without powder
- 30. •In order to pack for storing, transporting and selling, •automatic packing machine can weigh and pack the feedstuff pellets automatically with high accuracy.
- 31. Advantages of feed pellet line 1. Gelatinisation of starch 2. Animal will have feed with balanced nutrition. Feed wastage is reduced 3. The material of feed will get ripe during pelletizing. This gives feed a better tasty and digestibility that will accelerate animal growing faster and healthier 4. Processing feed to pellets can make the storage and transportation conveniently. Pellets can be sealed to avoid damp and degeneration so that keep the nutrition well 5. Destruction of pathogenic organisms