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Digital Re-print - July | August 2010 Making Feed Pellets

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A feed mill needs to produce pellets in a hygienic way with the least costs and the highest

efficiency. This cannot be realised without the close relationship between the operators in the field and the engineers at the drawing table.

Through this cooperation equipment manufacturer CPM Europe, in Amsterdam, The Netherlands, has been able to launch many ‘firsts’ which have later been adopted and copied to become industry standards.

Plant operators working in the feed industry often consider the handling of their pelleting equip ment to be an art.

Manufacturers of these ma chines con-sider their businesses to be closely related to science. But this science can learn from the pelleting ‘artists’ by developing and implementing demands and views from practice.

The engineers at CPM Europe are the last ones to deny that practice is closely intertwined with their work on the compu-ter controlled drawing programs.

"Our close relationship between prac-tice and our ability to translate practical improvements into factual equip ment, has delivered us almost always a competitive advantage which is especially valuable in

our indus try - which is not specifically known for its innovative power," says the company.

Conditioning with hygieniserCPM is active in the grinding and pelleting

section of the feed manufac-turing process.

Before pel-leting the feed mash needs to be treated before it enters the pellet mill. This condi-tioning of the mash has sev-eral advan tages. Proper condi-tioning ensures a better pellet qual ity (hard-ness, durability) resulting in bet-ter conversion rates with the animals.

Conditioning improves pellet mill capacity,

reduces electrical power use and reduces wear of dies and rollers. Furthermore, with condition ing more difficult (cheaper and/or) ingredients can be used.

Conditioning is a combination of moisture addition (steam and/or water), mechanical

Feed PelletsTable 1: Comparison of expander and CPM hygieniser as a conditioner before pelleting

Expander CPM hygieniser

Maximum formulation flexibility Formulation fat level 8% max

250 kW drive installed 2.2 kW drive installed

12 kWh/tone average (expander + pellet mill)

8 kWh per tone average (hygieniser + pellet mill)

$0.75 per tone wearing items No wearing items

Increased parts wear with limestone or oyster shell

in formulationNo sensitivity for abrasive elements in

formulation

High skill required to operate Very simple to operate

Down time risk due to blocking No down time risk

High starch formulation increases blocking risk

No sensitivity for high starch formulations

Moisture content in pellets difficult to maintain

Moisture content in pellets simple to maintain

High temperatures effect sensitive elements like vitamins

Simple and accurate temperature control

Product retention time is not controlledControlled product retention time for

optimum salmonella destruction

Making

Grain&feed millinG technoloGy18 | July - august 2010

FeatureFeed Pellets

treatment (kneading and shearing) and ther-mal treatment (time/tempera ture).

Especially the last feature has become essential in feed manufacturing.

Through higher temperatures the feed is hygienised and bacteria are already killed in the conditioner. CPM was at the forefront of this development with the introduction of the hygieniser or super conditioner. This piece of equipment has shown to be an extremely efficient con-

ditioner before pelleting and it is much cheaper than an expander, which is also often used.

Table 1 shows die differences between an expander and die hygieniser.

Hot start mixerOne small thing was still a problem: when

starting the conditioning process the first approximate 100 kg of a new run did not reach the required temperature and would

have to be by-passed or discarded before pelleting.

CPM has overcome this problem by developing the ‘Hot Start Mixer’, which functions as a buffer in the start-up of the condition ing process.

The paddles and screw in the first section of the hygieniser at start-up turn in reversed direction until the mash has reached the required temperature and then the direction is changed and the mash can flow through the hygieniser.

There is no longer any need for a by-pass and the full batch of feed can

be used without chance of recontamination.

Specialist in pelletingAround 50 percent of all pellet mills

used in the world are made by CPM. So the company, indeed, can call itself a specialist in pelleting.

Pelleting is not just the use of a machine that turns ground and mixed ingredients into pellets, it is a process and begins after the grind ing process with conditioning, followed

“CPM was at the forefront of this

development with the

introduction of the hygieniser

or super conditioner”

Grain&feed millinG technoloGy July - august 2010 | 19

Feature Feed Pellets

CONTACT CPM/Europe BV Distelweg 89, 1031 HD Amsterdam, The Netherlands, Phone +31 20 494 61 11, Fax +31 20 636 42 94, info@cpmeurope.nl

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Replace your die in less then 20 minutes.Use the best die for each purpose• Easy• Safe• Quick• Mechanical• Cost saving- Quick die change clamp- Pneumatic operated

die hoist- Lineator

■ HIGH PERFORMANCES ■ LOW COST MAINTENANCE ■ MAXIMUM SAFETY ■ LONG LIFETIME ■ WWW.CPMEUROPE.NL

Since 1883 Quick die change

CONTACT CPM/Europe BV Distelweg 89, 1031 HD Amsterdam, The Netherlands, Phone +31 20 494 61 11, Fax +31 20 636 42 94, info@cpmeurope.nl

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Higher capacity & better quality withRoll Speed Measurement

• Enhanced control over pellet quality• Improved steam addition control• No more overloads• Cost effective

■ HIGH PERFORMANCES ■ LOW COST MAINTENANCE ■ MAXIMUM SAFETY ■ LONG LIFETIME ■ WWW.CPMEUROPE.NL

Since 1883 Roll Speed

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With this system two people can remove a die in less than four minutes and the same people can fit a new die in less than five minutes. The quick die change clamp can also be mounted on existing machines that have been supplied by CPM in the past 10 years.

Roll speed measurementThe latest innovation is the roll speed

measurement, which has been in opera-tion for testing over one year and is now mature to sell on the CPM Pellet mills.

The new integrated roll speed measure ment device works with very little maintenance and high accuracy.

It was observed that with clean die and rollers, the roll speed measurement allowed an automatic 'zero-positioning' of the Lineator. Until now this 'zero-posi-tioning' proved to be a rather subjective interpre tation by various operators.

Different operators can 'pre-load' the rollers differently against the die to set the zero-position. With the roll speed measurement the zero-position is set at the moment both rollers are rotating at nominal speed.

In practice, influencing the pellet qual-ity is reached by using a thicker die or BOA-compactor or expander.

Now CPM introduced another option with roll speed measurement system together with a Lineator. The operator can safely move the rollers from the die and creating a “variable die” and so influence the pellet quality, all this can be done due to the roll speed measurement.

The roll speed measurement continu-ously measures the roll speed so that it stays above a certain speed, so that the die doesn’t choke.

Due to this “variable die” specifications less die changes are needed and the dif-ferent batch are made with the optimal “variable die.”

ity without stopping the production.

Energy eff iciency is a lso depending on the method of power transmission in die pel let mi l l . For this reason CPM pel let mi l ls oper-ate with a gear box instead of double V-belt drive.

Gearbox trans-mission has a high efficient power trans-mission. For a 250kW with an operating time of 6000 hours per year and an ener-gy price of eight euro-cents per kWh this would mean an ener-gy cost of €120,000. At 11 percent higher efficiency this would mean a saving of

13,200 in the advantage of a gear box drive.

Quick die changeEvery pellet plant operator knows the

burden of chang ing a die. Not only is it a heavy and time consuming job, it also adds considerably to the down-time of the plant.

The CPM engi-neering group in Amsterdam has developed a quick die change system for its 32" and 36" pellet mills.

The objective was to have the pellet mill up and running with a new die only 30 minutes after the end of the pre-vious run. This

means that for the actual (hot) die change only 20 minutes are being reserved.

To meet this objective CPM installed a pneumatic die hoist, automatic knives positioning, automatic roller adjust type lineator, 18 segments die clamp type bear claw and pre-assembled die with stiffen-ing ring and rotary cone.

by die actual pelleting and then cooling of the hot pellets and where applicable the addition of fats.

Pelleting is also about energy consumption.

The way the die and the die rolls are positioned largely deter mine how much energy can be added to the prod-uct. There is a close relationship between energy consump tion and pellet quality.

The more ener-gy is put into the pellet the better its quality will be. At the pellet mill this is limited to maximum 20kWh/tonne.

The consump-tion of energy is also dependent on the roller distance to the die.

An increase in roller distance will result in higher energy consumption. To be able to manage this process CPM developed the lineator, which enables die operator to adjust the roller distanc-es while pelleting and thus give himself the opportunity to influence pellet qual-

More inforMation:CPM Europe B VDistelweg 89Amsterdam, NL-1031 HD The Netherlands

Tel: +31 20 4946111Fax: +31 20 6364294Email: info@cpmeurope.nlWebsite: www.cpmeurope.nl

Grain&feed millinG technoloGy20 | July - august 2010

FeatureFeed Pellets

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• Mycotoxintesting:

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