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In this second installment of our three-part guide focusing on energy efficiency and low-cost manufacturing in feed mills, we examine the pelleting and conditioning processes, which account for the largest share of total energy consumption. Through empirical case studies, we analyze how technical parameters ranging from efficient steam conditioning and direct-drive presses to die-roller optimization and ration pelletability can yield improvements of 10–25% in electrical consumption and 5–25% in press throughput capacity.

Energy consumption, which constitutes the largest operating expense in compound feed production after raw material costs, has become the most critical agenda item for feed mills in line with narrowing profit margins and carbon emission targets. In these facilities where electrical and thermal processes are intensively carried out, correct engineering optimizations to be implemented in grinding and pelleting lines, which hold the vast majority of total energy consumption, both unlock the door to sustainable production and radically reduce operating costs.

EU greenhouse gas emissions climbed to 900 million tonnes of CO2-equivalents in early 2025, up 3.4% from the same period last year. Electricity production and household consumption were the main drivers, while agriculture, forestry, and fishing saw a slight decline.