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Digital Re-print September | October 2013
The holistic approach to avoid
losses in the feed mill
Grain & Feed Milling Tech...
FEATURE

The holistic approach to avoid
losses in the feed mill
by Yiannis Christodoulou, president, Agentis Innovations, ...
FEATURE
tiple batch-weigh scales and digital PLC
controls should provide an accuracy of 0.5
percent or less.

Hand additio...
FEATURE

QUICK CONNECT ®

installation friendly
perfect fitting
shock explosion proof
tight
solid
easy to clean
easy expand...
FEATURE

Optimize your feed formulation

Staying ahead of the competition requires smart feed formulations. You – as formu...
Six eyes strive for top quality. Increase consistent product quality of flour and
semolina with the latest NIR technology....
LINKS
September - October 2013

This digital Re-print is part of the September | October 2013 edition of Grain & Feed
Mill...
The holistic approach to avoid losses in the feed mill
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The holistic approach to avoid losses in the feed mill

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In the past five years the cost of ingredients and many feed additives has risen significantly.
However, many feed companies within the Asia Pacific region still do not maintain tight control on stock inventory, scale tolerances and the volume of recycled fines and rework arising from inefficient production processes and equipment.

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The holistic approach to avoid losses in the feed mill

  1. 1. Digital Re-print September | October 2013 The holistic approach to avoid losses in the feed mill Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 2013 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872 www.gfmt.co.uk
  2. 2. FEATURE The holistic approach to avoid losses in the feed mill by Yiannis Christodoulou, president, Agentis Innovations, Thailand I n the past five years the cost of ingredients and many feed additives has risen significantly. However, many feed companies within the Asia Pacific region still do not maintain tight control on stock inventory, scale tolerances and the volume of recycled fines and rework arising from inefficient production processes and equipment. This lack of control should be considered unsustainable and the aim of this paper is to highlight some of the common areas where waste and losses occur and what steps can be taken to improve so that feed companies remain competitive. For the purpose of this paper, we are going to consider a typical feed mill from the region, that receives bag and bulk tip raw materials and ingredients, stores corn in silos before transfer to the feed mill for grinding and blending and has a meal and pelleting line for production of final feeds in either packing silos or bulk silos. Raw material receiving In the Asia Pacific region, many companies still rely heavily on bags and less in bulk for the receiving of ingredients. In either case it is common to see numerous trucks lined up either inside or outside the mill waiting to unload. This creates a number of challenges in terms of maintaining control of trucks and personnel while on site and ensuring the correct quantity and type of product are unloaded. Manual systems that rely on paperwork are prone to human errors. To counter this, automation systems can be installed that replace the paperwork and ensure the movement of trucks and ingredients to the 10 | September - october 2013 correct location for discharge as well as provide for accurate stock inventory and traceability. Raw material unloading Control of the unloading of raw materials is important to avoid waste. Waste can occur from a number of errors for both bags and bulk. For bulk intakes, errors can result in expensive losses due to incorrect manual silo selection or failure to recognise a silo is full. This represents both financial loss as well as nutritional loss due to mixing of different ingredients. Programmable Logic Control Units (PLC) in conjunction with adequate and appropriate instrumentation and software can eliminate this type of error through automatic route control and high level silo indicators to show when silos are full. Technology also provides sophisticated bag counters on the unloading conveyors which provide accurate real time stock inventory. Bag unloading can be inaccurate in terms of ensuring the correct number of bags are unloaded at the correct point. Technology now provides sophisticated bag counters on the unloading conveyors which are difficult to de-fraud and again provide real-time stock inventory. Grain silos and drying Often the quantity of grains discharged into and out of silos is not known accurately due to the lack of a weigh scale hopper or in-flight conveyor weighing systems resulting in inaccurate stock reconciliation when transferred to the mill. The most common causes of loss are either wastage due to poor silo management or losses due to moisture shrinkage. Silo management to prevent grain dete- rioration is a subject in itself and is a particular challenge in Asia Pacific region because of the need to take in grains at harvest and store for long periods of time. It is not uncommon to hear of significant volumes of grains being disposed of because they are unfit for purpose when emptying the silos. The other risk is the deterioration due to mycotoxin/bacterial contamination that often occurs due to long-term storage and which can result in significant nutritional losses. New in-line microwave moisture sensor technology is being utilised to provide real time information as grains either enter or leave the storage silos and are transferred into the feed mill, thereby providing valuable information to assess the total moisture loss from intake through to the mill storage phase. This will allow the operators to make adjustments based on the real moisture content of the formulated mixture or additional moisture addition, at the mixer or conditioning phase. Grinding Losses occur at this process step due to the physical effect of grinding on moisture levels. Automating the control of the grinders is one method to optimise throughput and reduce energy costs as well as reduce the moisture loss associated with excessive grinding. Batch control The weigh scale system is often associated with losses due to excessive tolerances and lack of in-flight material control. Clearly these losses are significant when you consider microscale weighers and the value of the products that are being weighed. Modern, appropriately sized, mul- &feed millinG technoloGy Grain
  3. 3. FEATURE tiple batch-weigh scales and digital PLC controls should provide an accuracy of 0.5 percent or less. Hand additions and premix addition The losses that can occur at this stage are significant because of the impact of putting the wrong additive into the wrong feed type, or the impact of under or over dosing. The most effective method to reduce the risk of errors is to automate the process using either barcoding or weigh stations or a combination of both. This has the advantage of providing complete traceability which can also limit losses if an error does occur. Flush batching In many feed mills there is a requirement to flush or purge the mixer and pelleting lines to avoid carryover of specific materials or feed additives, coccidiostats and medicines. The method of how the mixer and pellet lines are flushed will impact how much loss is associated with this process. Mixer flushing is usually done using a defined quantity of raw material such as corn, which is then re-routed back to a nominated silo for inclusion into specified feed types. Each flush batch represents cost in terms of mixer time, energy consumption and potential losses associated with the re-circulation system. Therefore, it is important to optimise the scheduling/production planning to ensure the flush process is only used where there is no alternative. This can be achieved most effectively through PLC control which can prevent cross contamination scheduling and programme the flush batch automatically before a sensitive feed type. The pelleting lines may also require flushing and this again will impact significantly on production cost. Some feed mills run the same feed material used for the mixer flush through to bulk or packing silos. This is certainly wasteful because of the time involved and the manpower required to pack or transport the rework back to the raw material silos or intake. Some feed companies use a specified quantity of the first batch of feed, following the coccidiostat or medicine, and run this through the line and recirculate as rework. Once again this is wasteful not only for the reasons already listed, but because each time you reprocess feed there will be some deterioration in some of the heat sensitive OUR OUTPUT COMES IN ALL SHAPES AND SIZES 2.0 mm floating fish feed vitamins as well as the risk of over-gelatinisation of starch leading to poorer nutritional performance. A more efficient flush procedure is to be able to use the flush batch as final feed. This can be done by either removing the coccidiostat or medicine in the final batch but adding this to the existing feed on the basis that when mixed with the original batches it will only represent a minor dilution. Once again the PLC pelleting control can control the routing of different feed types to each pellet line and ensure a flush is created before the next sensitive feed type. Pelleting crumbling and conditioning Of all the process points in the feed mill, BIN LEVELS without climbing! smartBob and eBob software dog food 14mm affordable. reliable. safe. Insta-Pro’s new medium shear extruder answers the market’s demand for a low cost extrusion solution that effectively produces pet and fish feeds of high quality, equal to that of higher cost extrusion systems. Inventory management systems and bin level indicators • Ease of operation • Ability to make pellets of different shapes • Low cost of production and a variety of sizes, down to 2mm • Thru capacities up to 1.5 TPH Don’t pay more than you have to, to get the quality & quantity you need. Contact us at +515-254-1260 or visit us at insta-pro.com/medium to learn more. Rotary Pressure Switch Vibrating Rod Capacitance Probe Binmaster level controls info@binmaster.com • www.binmaster.com +515-254-1260 | Insta-Pro.com | info@insta-pro.com &feed millinG technoloGy Grain © 2013 BinMaster, Lincoln, Nebraska uSa September - october 2013 | 11
  4. 4. FEATURE QUICK CONNECT ® installation friendly perfect fitting shock explosion proof tight solid easy to clean easy expandable QUICK CONNECT ® pull-ring more timeefficient during assembly. INSTALLATION FRIENDLY and easy to dismantle. PERFECT FITTING in long durability with top quality – that is our pipework and distribution system. pelleting and conditioning represent one of the most wasteful areas in terms of energy, blockage downtime and reprocessed feeds. The major limiting factors are manual control and poor conditioning. Automated pelleting can reduce the power consumption by more than 40 percent in some cases as well as improve the productive life of pellet die and rolls and prevent blockage and cleanout times. Automation removes the manual variability that leads to suboptimal steam conditioning and power settings resulting in variable pellet quality, which in turn results in a higher level of returns from the sieves. This is particularly important when producing crumbs because in some feed mills sieve return levels of 30 percent are not uncommon which is extremely wasteful as well as resulting in feed being reprocessed three or four times. Automated pellet control therefore results in a significantly lower level of returns from the sieves, reduced down time and blockages and efficient scheduling of flush batches. Batching or post pelleting liquid addition systems SOLID and precise in case of retrofitting. Batching, pelleting or post pelleting liquid application systems require very a specific set up, nozzle type and accurate dosing due to the high cost of either over or under-application. Lack of automation control linked to the central batching system frequently leads to variable analysis or performance and variable pellet quality leading to further rework and waste. EASY TO CLEAN and easy replaceable. Cooling SHOCK EXPLOSION PROOF safely JACOB pipework system. TIGHT connection for our pipework systems. EASY EXPANDABLE by variability of our modular system. Visit us at POWTECH 2013 April 23 rd-25 th, Germany, hall 5, booth 5-348, powtech.de EUROPE’S NO. 1 IN PIPEWORK SYSTEMS The QUICK CONNECT ® pull-ring makes the acclaimed Jacob modular pipe system even more economical for installation. In new plants for animal feed, pharmaceuticals, chemicals, food, glass, semiconductors or environmental technology as well as for upgrading existing layouts user-friendly system installation becomes precise and easy due to the great versatility of mass-produced pipe components. ORIGINAL QUALITY TO A MODULAR DESIGN  Straight welded, lipped-end pipes and components.  ø 60 mm to ø 800 mm in a standard range.  Up to ø 400 mm normally dispatched immediately from stock.  Larger than ø 350 mm also available with flange connection.  Powder coated steel or hot-dipped galvanised steel as well as stainless steel.  1-3 mm wall thicknesses.  Larger diameters / special requirements upon request.  Shock-explosion certified pipes and components available. Fr. Jacob Söhne GmbH & Co. KG, Germany Tel. + 49 (0)571 95580 | jacob-pipesystems.eu 12 | September - october 2013 513459_GrainFeed_47x270_gb_4c_RZ.indd 126.03.13 11:19 There are two losses associated with the cooling process. One is the dust and fines that can be lost from the air ducting due to incorrect set up and fan speeds, and the second are the losses associated with moisture loss. New technology to reduce moisture loss during the cooling process is now available to the industry. This technology is specifically developed to provide vital information to a PLC in order to perform real-time control of a number of parameters that influence moisture loss. Sieving Poor pellet quality leads to an increase in fines and dust for rework which incurs losses. The ‘throughs’ of the sieves, at all settings, should wherever possible be routed back to the pelleting process for immediate reprocessing without the need for any intermediate storage or manual handling. Mills that have particularly long conveyor or elevator handling systems, or fall from the highest point (usually distributor head) also result in greater damage to pellets (or segregation of coarse and fine material in mash feeds) and hence dust. Sieves can be programmed to switch off when producing medicated feeds to avoid recirculation of medicated dust back to the pellet silos. Bulk finished feed storage and packing Errors arising from placing the wrong product in the wrong silo or placing the product in a silo which is not empty can be avoided by implementing automated route control, fixed silos and high/low level indicators to provide accurate record of how much feed is in each silo. The other challenge is accurate data about the number of bags packed and sent to the warehouse. Weighing systems and bag counting technology can provide the necessary solution so that management personel are able to log the productivity of each packing line. Bulk truck loading The control of trucks entering the mill and loading procedure can be automated to avoid human errors and provide real time stock inventory and traceability. Modern bar coding technology or computer input screens can remove the element of human errors and avoid having drivers operate the loading system. Bag loading In Asia Pacific this represents a real challenge because of the confusion that can occur from having multi loading belts and different products to load. The primary concern is inventory control to ensure the correct product type and quantity has been loaded. This can be most achieved by utilising scanning and bag counting technology. Plant maintenance How many feed mills measure the amount of waste each month? An effective automated preventative plant maintenance plan can significantly impact the level of waste from leaks and blockages. Summary A lack of adequate waste control should be considered unsustainable if feed companies wish to remain competitive. Losses through moisture loss, inadequate waste control, accuracy of production or time management are not acceptable. Technology is available that can improve all of these factors and also provide valuable real-time stock control from intake to loading and full traceability from supplier to farm. Agentis Innovations is a specialist in providing and developing technologies that automate manufacturing processes and integrate data collection for the global agricultural industry which include animal feed, aquafeed, pet food, and premixes. More inforMation: Website: www.agentisinnovations.com &feed millinG technoloGy Grain
  5. 5. FEATURE Optimize your feed formulation Staying ahead of the competition requires smart feed formulations. You – as formulation manager – are key in this strategy. But how do you create the best quality and lowest cost recipes – under any conditions and at any time? BESTMIX® provides the answer. This user-friendly software makes it easy to manage accurate nutritional values, production parameters and recipe specifications. You can adapt instantly to volatile material costs, ingredient stocks and purchasing positions. The results are perfect recipes that can be translated directly into practical products and synchronized automatically with labelling and safety data. Want the least cost recipe, no matter how challenging the requirements? Call us today on +32 50 30 32 11 and get BESTMIX®. The smartest way to beat the competition. Adifo develops and services sector-specific software tools for the international nutrition industry. We enable you to gain maximum control over your core processes and guarantee the protection of critical business knowledge. www.adifo.com &feed millinG technoloGy Grain September - october 2013 | 13
  6. 6. Six eyes strive for top quality. Increase consistent product quality of flour and semolina with the latest NIR technology. The Bühler NIR Multi Online Analyzer MYRG continuously monitors the quality of your raw material and finished products – only one spectrometer is needed to evaluate up to six different measuring points at the same time. The system not only offers a seamless analysis, but also locates any quality change in real-time, initiating adjustments without delay. We would be pleased to present you the various options and applications. www.buhlergroup.com Bühler AG, Grain Milling, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 66 11 milling@buhlergroup.com, www.buhlergroup.com NIR Multi Online Analyzer MYRG. Multifunctional Monitoring of protein, moisture, ash and other ingredients in whole grain, semolina and flour. Real-time monitoring Corrective actions can be implemented in the ongoing production process, without waiting for laboratory analysis. Consistent product quality Supplies decisive information for smart control of the gluten, moisture, or ash contents. High efficiency One spectrometer evaluates up to six different measuring points simultaneously. Innovations for a better world.
  7. 7. LINKS September - October 2013 This digital Re-print is part of the September | October 2013 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on www.docstoc.com. first published in 1891 • The holistic approach to avoid losses in the feed mill In this issue: • • Sieving technology in feed pellet production • Mixed integer optimization: Traceability a new risk in maize production? • See the full issue • Visit the GFMT website • Contact the GFMT Team • Subscribe to GFMT a new step in formulation software • Weighbridges the workhorses of industrial weighing • High-precision sensors: the ideal solution for measuring grain humidity INCORPORATING PORTS, DISTRIBUTION AND FORMULATION A subscription magazine for the global flour & feed milling industries - first published in 1891 To purchase a paper copy of the magazine, or to subscribe to the paper edition please contact our Circulation and Subscriptions Manager on the link adove. INFORMATION FOR ADVERTISERS - CLICK HERE Article reprints All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these have been used as point of sale materials, promotional materials for shows and exhibitions etc). If you are interested in getting this article re-printed please contact the GFMT team for more information on - Tel: +44 1242 267707 - Email: jamest@gfmt.co.uk or visit www.gfmt.co.uk/reprints www.gfmt.co.uk

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