Alapala has been one of the global leaders in machinery production and turnkey solution providers since 1954. With its 1.000+ references in 4 continents over 120 countries and expertise in integrated plants for the grain, feed, and pasta processing industries, Alapala aims to be one of the leaders of the feed milling industry with its focus on research and development on feed milling technologies with Alapala Feed Tech brand.
Gopal URANGAPULI
Alapala Feed Tech
Feed Technologies Manager
Navigating the complexities of the feed milling process poses significant hurdles. Achieving exceptional, nourishing animal feed demands the precise management of a range of critical factors.
Within the domain of the feed milling sector, several pivotal issues take center stage: upholding the utmost purity, guaranteeing accuracy and safety in plant activities, cultivating adaptability and efficiency, applying efficient heat treatment and hygiene techniques, and establishing flawless traceability. The fundamental technology that forms the bedrock of feed milling procedures holds the key to addressing these urgent challenges.
Let us have a look into Thermal Conditioning, Pelletizing/Compactizing, Pellet Cooling, Pellet Crumbling, De-dusting/Sifting, and Post Pelletting processes.
THERMAL CONDITIONING / HYGIENIZING PROCESS
Thermal conditioning serves the primary purpose of modifying feed ingredients and destroying pathogenic microorganisms. The gelatinization process involves inactivation and sterilization, with influencing factors such as particle sizes, humidity, steam quality, conditioner speed, retention time, and thermal loss during the process. Adhering to a “First in first out” method for material conveying ensures optimal results.
PELLETIZING/COMPACTIZING PROCESS
The pelletizing process involves converting thermally treated mash into solid pellets through mechanical pressing. This crucial step results in the gelatinization of starch and deactivation of harmful microorganisms like salmonella. The selection and operation of pellet mills are essential considerations, with factors such as die opening area, effective thickness, total thickness, roll shell type, main drive power, die speed, and steam line fittings playing a pivotal role. The physical and chemical properties of ingredients are also critical in determining the performance of the pellet mill.
PELLET COOLING PROCESS
Pellet coolers play a vital role in removing excess moisture and temperature from the pellets to prevent microbiological growth, enhance shelf life, and prevent breakages. Various factors, including moisture content, bulk density, surface area, specific heat capacity, compactness, and components like starches and fats, influence the drying and cooling activities.
PELLET CRUMBLING / SIZE REDUCTION PROCESS
Crumblers or crushers are employed to break down pellets into smaller, digestible sizes. Factors influencing this process include pellet diameter, moisture content, roller diameter, roller speed, roller gap, and the number of teeth on the roller.
DE-DUSTING/SIFTING PROCESS
The sifting process segregates fines and lumps/longer products from the final products. The inclination of the sieve, sieve area, oscillation frequency, product moisture, and fines level are key influencing factors.
POST PELLETING APPLICATION PROCESS
The post-pelleting application process involves adding liquid to the final products to enhance pellet quality and reduce fines. Factors such as rotor speed, paddles angle, nozzle type, drum/batch mixer volume, and retention time are crucial considerations in this process.
CONCLUSION
Understanding and optimizing each stage of the feed pellet production process, from thermal conditioning to post-pelleting applications, is essential for producing high-quality, safe, and nutritionally balanced feed pellets. Feed producers must carefully consider the influencing factors at each stage to ensure efficiency, product quality, and animal health.