How to start 20t/h animal feed production factory? Today Richi Machinery will give you a very detailed 20t/h commercial animal feed making plant business plan. This business plan comes from a 20t/h livestock animal feed pellet production plant we completed in 2019.
1. Project Overview
The project with 20 tons per hour animal livestock feed and expanded corn is a new project. The plant is located in Linyi City, Shandong Province, China. The main construction content is feed and expanded corn production facilities, auxiliary facilities and public works. The total investment of this project is 4.8 million yuan, including environmental protection investment of 400,000 yuan, with a total area of 3564m2 and a total construction area of 3762m2. The project was completed and put into production in April 2019. It has an annual output of 50,000 tons of feed and extruded corn (full price feed 45,000 t/a, expanded corn 5 million t/a), and an annual sales income of 8,000 The annual average profit is RMB 2 million; the number of employees is 15; the annual production time is 300 days, 4800 hours, and the investment payback period is 2 years.
2. 20T/H full automatic animal feed making plant project engineering content
|Engineering category||Engineering name||Engineering Content||Remarks|
|Structural work||Production workshop||Construction area of 1386m2, steel frame structure, inside is divided into boiler room, raw material storage area, production area, etc. Among them, the previous process and equipment of corn crushing (including) are shared by full-price feed and extruded corn.||An annual output of 45,000 tons of full-price feed and 5,000 tons of expanded corn.|
|Storage and Transportation Engineering||Warehouse||Building area of 1980m2, steel frame structure, the interior is divided into additive production area, finished product storage area, additive preparation room, etc.Mainly used for storage of finished products and additives.|
|Supporting Engineering||Office building||Building area of 396m2, mainly used for office and business management.|
|Public works||Water supply||The water source for this project is groundwater, which is supplied by a 20m deep self-provided well in the plant area. The water used is mainly domestic water and boiler water.||The primary water consumption is 6180m3/a.|
|Drain||The plant area implements rain and sewage diversion, and newly builds a rainwater pipe network and a sewage pipe network. Rainwater is finally discharged to Lubu River through nearby drainage ditches; sewage is mainly domestic sewage is treated in a septic tank and then transported to compost without being discharged.|
|Powered by||It is powered by the local power supply and has a 400kVA transformer.||Annual electricity consumption 500,000 kW·h.|
|Heating||The heat supply for this project is provided by a 1t/h natural gas steam boiler with fuel
It is natural gas, provided by the local gas company.
|Environmental Engineering||Exhaust||Boiler exhaust gas: 1 15m exhaust tube (8#).||Discharge|
|Corn unloading dust: air collecting hood (collection efficiency 90%) + bag filter (1 set, dust removal efficiency 99%) + 1 15m exhaust tube (1#)||Discharge|
|Corn crushing dust 1. Puffed corn cooling dust 1. Puffed corn crushing dust 1: Negative pressure collection + bag filter (1 set, dust removal efficiency 99%) + 1 15m exhaust tube (2#)||Discharge|
|Complete animal feed dust: air collecting hood (collection efficiency 90%) + bag filter (2 units, dust removal efficiency 99%) + 1 15m exhaust tube (3#)||Discharge|
|Corn crushing dust 2, expanded corn crushing dust 2, full-price feed crushing dust, complete compound feed ingredient mixed dust: negative pressure collection + bag filter (4 units, dust removal efficiency 99%) + 1 15m exhaust tube (4 #)||Discharge|
|Expanded corn cooling dust 2: negative pressure collection + cyclone dust collector (1 set, dust removal efficiency 85%) + 1 15m exhaust tube (5#)||Discharge|
|Complete feed pelleting cooling dust: negative pressure collection + cyclone dust collector (1 set, dust removal efficiency 85%) + 1 15m exhaust tube (6#)||Discharge|
|Additive feeding dust, mixed dust of small material ingredients: air collecting hood (collection efficiency 90%) + bag filter (2 sets, dust removal efficiency 99%) + 1 15m exhaust tube (7#)||Discharge|
|Waste water||The domestic sewage is treated in a septic tank and then transported for compost without being discharged.||Resource utilization|
|Noise||Measures such as shock absorption, sound insulation, and noise reduction.||Discharge|
|Solid waste||Raw material sieve residue: Sanitation and transportation;||Zero emission|
|Raw material waste packaging: takeaway waste recycling station;|
|Non-conforming product: reused in production;|
|Dust collected by dust collector: reused in production;|
|Domestic waste: The sanitation department collects and bury the waste in a unified manner.|
|Waste reverse osmosis membrane: Sanitation and transportation.|
3. The main raw and auxiliary materials and power consumption of the 20t/h animal feed production factory project
|1||Consumption of main raw materials and auxiliary materials|
|(3)||Corn germ meal||t/a||5000|
|Serial number||Animal feed making machine name||QTY||Remarks|
|1||Corn grinder||2||Corn crush|
|2||Expanded Corn Crusher||2||Expanded corn crush|
|3||Animal feed hammer mill grinder machine||1||Crushing of complete feed ingredients|
|4||Animal feed pellet milling machine||1||Granulation|
|7||Air compressor||1||Gas source|
|9||Animal feed mixer machine||2||Mixing|
|12||Oil storage tank||1||Oil storage (capacity 1t)|
|15||Fan||Several||Draw the wind|
|16||1T/H natural gas steam boiler heating||1||Heat|
|17||Soft water preparation system||1||Soft water preparation|
This 20t/h animal feed making project is a feed and expanded corn production project. The products are complete compound animal feed and expanded corn. The raw material of expanded corn is corn; the raw material of compound feed is corn, soybean meal, corn germ meal, stone powder, calcium hydrogen phosphate, methionine, salt, soybean oil, DDJS etc;The production process of this 20t/h animal feed mill factory is divided into three: extruded corn production line, feed additive production line and complete feed pellet production line for livestock.
(1) Production process of expanded corn
①Receipt of raw materials
Bulk corn and other raw materials are mainly received by automobile, and the raw materials are unloaded to the unloading pit after being weighed by a dump truck with a loadometer.
Impurities in feed ingredients such as corn not only affect the quality of feed products, but also directly affect feed processing equipment and personal safety. In severe cases, the entire equipment can be damaged and affect the smooth progress of feed production, so it should be removed in time. The cleaning equipment is mainly screening. According to the difference in particle size, width, thickness, etc. of the material particles, one part of them will pass through the sieve surface to become the under-sieve, and the other part will remain on the sieve surface as the over-sieve, thereby making feed and impurities separation, to achieve the purpose of removing impurities, or to separate feeds of different sizes and shapes for classification processing. The screening equipment removes large and long sundries such as straw, straw, hemp rope, paper pieces, soil blocks, corn leaves, corn cobs and other sundries in the raw materials. The screening process is completely airtight, and the screening materials are lifted into the silo.
The screened raw materials are lifted by a hoist into the silo, and a dust filter device is installed on the top of the silo, and the dust generated by the falling of the material during the lifting process is filtered by the filter device.
The corn kernels in the warehouse to be crushed enter the crusher through the impeller feeder. This process is equipped with two crushers. The grain size of the corn after crushing in this process is about 01-3 mm. Work efficiency: part of the crushed corn enters the extruder to produce expanded corn, and part of the corn and soybean meal and other materials enter the large crusher to be further crushed to produce compound animal feed.
The method of corn puffing in this project is wet puffing. Corn puffing is a starch gelatinization process under the combined effects of moisture, heat, mechanical shear, friction, kneading and pressure difference. The corn puffing heat source of this project is the steam produced by the natural gas steam boiler. When the corn flour is mixed with the steam, the starch particles begin to absorb water and expand. When passing through the puffing cavity, the rapidly rising temperature and the kneading of the spiral blades accelerate the absorption of water by the mesh bag starch particles.
The crystal structure begins to disintegrate, the hydrogen bond breaks, and the expanded starch grains begin to rupture and become a viscous melt. Due to the instantaneous pressure drop at the exit of the extruder, the instantaneous loss of steam (moisture) makes a large amount of expanded starch The granules disintegrate and the starch gelatinizes. High temperature, high pressure and mechanical shearing make the starch gelatinization more thorough than the starch produced by other processing methods. Generally, the gelatinization degree can reach 80%-100%. Compared with the conventional cooking process, the plant cell wall can be broken. The starch chain is shorter, which improves digestibility more effectively. There are many factors affecting corn puffing, mainly moisture, puffing temperature, puffing pressure difference and mechanical shearing force in the cavity.
⑥ Cooling of extruded material
In the puffing process, the high temperature and high humidity steam is introduced and the material is extruded to generate a lot of heat, which makes the temperature and humidity of the puffed particles higher. Under such conditions, adhesion and mildew will occur during temporary storage. The moisture must be reduced to below 14%, and the temperature must be lowered to below 8°C higher than the air temperature. Air cooling is used for project cooling. The extruded material is cooled by the air sent by the fan. The moisture and dust generated during the cooling process are passed through cyclone. Dust collector is discharged outside after treatment.
The extruded material in the warehouse to be crushed enters the crusher through the impeller feeder, and the crushed pellets are conveyed by the screw conveyor and lifted to the temporary storage warehouse by the bucket elevator. This process is equipped with 2 pulverizers, and the particle size after pulverization is about 2-3mm. The purpose of pulverization is to increase the specific surface area of the feed, increase the utilization rate of the animal to the feed, increase the contact area of digestive enzymes to the raw material, and reduce the animal's intake The energy consumption of mastication in the process is beneficial to increase the feed reward; the material is crushed with a pulverizer and then sieved, and the sieved material is returned to the original pulverizer to be crushed again.
Stone powder, calcium hydrogen phosphate, methionine, salt and other small materials are transported to the next step through the feeding port through the scraper.
② Ingredients and mixing
Ingredients refer to the various ingredients of the animal livestock feed formula, which are mixed according to the specified weight ratio, and processed so that every small part of the whole, even a feed, has the same ingredient ratio as the formula requires. This project uses a high-efficiency mixer with a short mixing cycle, and the coefficient of variation of mixing uniformity is less than or equal to 5%. The materials enter the mixer after being accurately configured by weighing according to the scientific formula, and after a reasonable and scientific mixing time, they enter the baler after being evenly mixed
In order to facilitate the subsequent production of ingredients, the evenly mixed small materials are measured and packaged by the baler.
•Soybean meal, crushed corn, corn germ meal, DDJS and other raw materials are input through the feeding port, and then conveyed by a screw conveyor, and the bucket elevator is lifted into the next step.
• After the small materials are put in through the powder feeding port, they are conveyed by a screw conveyor and lifted by a bucket elevator to the next step.
• Soybean oil, etc. are directly transported from the storage tank to the batching process;
The pellets in the silo to be crushed enter the animal feed pulverizer through the impeller feeder, and the crushed pellets are conveyed by the screw conveyor and lifted to the batching silo by the bucket elevator.
The purpose of pulverization is to increase the specific surface area of the feed, increase the utilization rate of the animal’s feed, and increase the contact area of the digestive enzymes with the raw materials; reduce the energy consumption of the animal's chewing during the feeding process, which is conducive to increasing the feed return; improving the quality of the subsequent processes, Improve work efficiency.
③ Ingredients and mixing
Ingredients refer to the various ingredients of the feed formula, which are mixed according to the specified weight ratio, and processed so that every small part of the whole, even a feed, has the same ingredient ratio as the formula requires. When batching, the materials and small materials are mixed in a certain proportion, and the batching accuracy is less than 0.3%. Using a high-efficiency mixer, the mixing cycle is short, and the mixing uniformity variation coefficient is less than or equal to 5%. According to the scientific formula, the materials enter the mixer through a microcomputer and weighing accurately. After a reasonable and scientific mixing time, the microcomputer controls the discharge into the silo to be granulated through the buffer hopper, scraper, elevator, and distributor.
Before entering the animal feed pelletizer machine, it needs to be tempered. The tempering must be steamed into the material to directly contact and mix and moisten the material. After the tempering is uniform, it will fall to the granulator for granulation by extrusion. The pellet feed formed by compacting and extruding a single raw material or compound mixture through mechanical action is called pelleting.
The purpose of pelleting is to make finely divided, dust-prone, poorly palatable and difficult-to-ship feed into pellets using the heat, moisture and pressure during the pelleting process. Compared with powdered feed, pelleted feed has the following advantages: improve feed digestibility; reduce animal picky eaters; make storage and transportation more economical; pelletizing generally increases the bulk density of powdered feed by 40% to 100%; avoids feed ingredients Automatic grading, reducing environmental pollution; killing Salmonella in animal feed. The steam is provided by a natural gas-fired boiler.
In the animal feed pelleting process, the high temperature and high humidity steam is introduced and the material is extruded to generate a lot of heat, so that when the pellet feed comes out of the pelletizer, the water content reaches 16%-18%, and the temperature is as high as 75℃ -85. ℃, under this condition, the pellet feed is easy to deform and break, and it will also cause adhesion and mildew during storage. The moisture must be reduced to below 14%, and the temperature must be lowered to 8℃ higher than the air temperature. The project is cooled by wind Cold, the dust generated during the cooling process is discharged outside after being processed by the Shakron dust collector.
After the pellet feed is processed by the crushing process, a part of powder clots and other unqualified materials will be produced. Therefore, the crushed pellet feed needs to be sieved into products with neat particles and uniform sizes. The finished granular material is conveyed to the grading screen by the elevator, and the grading screen is a two-layer screen. Large debris, primary products and other large particles on the sieve are collected through the trash discharge port and recycled to the cooling process. The intermediate sieve is the qualified product through the flow tube to the finished product warehouse, and the powder and other small particles under the sieve Reflux directly to the granulation process. This process is all airtight. After being concentrated and mixed, the finished powdered material enters the powder sieve for screening, the over-screen material returns to the crushing process, and the under-screen material enters the finished product warehouse as qualified products. This process is all airtight.
The finished product is transported to the finished product temporary storage warehouse, and then is packaged and metered and packaged. The finished product warehouse is airtight. Because the powder and fine materials have been screened during the screening process, the amount of dust generated during the packaging process of the pellets is small.
6. The main pollution process:
(1) Waste gas: The waste gas generated during the production process of this project is mainly corn unloading dust, silo blanking dust, cooling dust, crushing dust, feeding dust, ingredient mixing dust, packaging dust, production process (puffing, manufacturing) Odor and boiler exhaust gas generated by granulation, cooling, screening, packaging).
(2) Wastewater: The wastewater from the boiler soft water treatment equipment of this project is directly discharged as clean sewage, and the wastewater is mainly domestic sewage from employees.
(3) Noise: The noise sources generated in the production process of this project are mainly grinders, screeners, granulators, extruders, air compressors, mixers, balers, palletizers, forklifts, fans, boilers, Operation noise of equipment such as soft water preparation system.
(4) Solid waste: The solid waste generated in the production process of this project mainly includes dust collected by the dust collector, raw material sieve residue, raw material waste packaging, unqualified products, waste reverse osmosis membranes generated by replacement of soft water treatment equipment, and employee domestic waste.
7. Public works
(1) Power supply: The power for this project is provided by the local power supply bureau. A 400kVA transformer is transformed into 380V/220V from an external 10kV power supply branch line into the factory area for use by the power consumption units of the project. The average power load is 104.17kW, and the annual power consumption is about 500,000 kW·h.
(2) Water supply: The water source of this project is self-provided well water. The water used in this project is mainly boiler soft water treatment equipment and staff domestic water. The total primary water consumption is about 6180m3/a.
(3) Heat supply: The heat supply for this project is provided by a 1t/h steam boiler in the plant area, the fuel is natural gas, and the local gas company is provided with a consumption of 455,000 m3/a.
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