The technical equipment and installations at compound feed plants can and often have to remain in service for decades. And they must do this reliably, precisely, and with only short down and maintenance times. Despite this there are many occasions for renewing individual components or entire assemblies. These can include signs of wear, but are due far more frequently to rises in the demands made of efficiency and precision of the work performed, or changes in the requirements concerning feed quality.

» Increasing the energy efficiency
Measures of UFA feed mills in Switzerland

UFA is Switzerland’s largest animal feed producer, with sites in Herzogenbuchsee (300,000 t/a), St.Margrethen (90,000 t/a), Sursee (85,000 t/a), and Puidoux (70,000 t/a). The finished product is marketed in the form of either expanded or pelleted feed. The average electrical energy requirement was cut within ten years by about 4 per cent, while thermal energy consumption was reduced by 10 kWh/t. And this was accomplished while increasing the upgrading degree from 60 to currently 100 per cent. All feed produced in the UFA facilities is thermally hygienized.

» Carry-over and cross contamination of critical macro-ingredients
Prevention strategies for industrial compound feed production

Compound feedstuffs are produced almost exclusively in multi-product facilities. The high number of different formulations, tailor-made to customer specifications and with short production deadlines, lead to production methods characterised by small batches and frequent formulation changes. This makes optimising the production sequence and so minimising the risk of contaminating subsequent batches by unavoidable carry-over considerably more difficult.

» Staying on schedule for an equipment upgrade
KSE doubled weighing and dosing capacity

When modifying and switching equipment in a plant, which runs six days a week producing animal feed to customer specifications, minimizing the downtime is essential. The old machines had to be removed, the new equipment and infrastructure installed and all services reconnected as well as the control software upgraded- all within a few days. The new installation then has to be tested and ramped up to full production speed, so it needs very detailed planning for the multi-disciplinary teams who often work in parallel.

» Conditioning of feed with the crown expander
Background, facts and use in livestock nutrition

The performance of livestock is constantly improving due to consistent genetic progress. This goes hand in hand with changing demands on the part of farm animals regarding the composition of feed, and especially as regards feed structure. Feed which is finely ground and pelleted, usually with a hammer mill, is becoming increasingly problematic, especially for broilers and pigs. Stomach ulcers and gastric erosion are now encountered more frequently familiar in pigs. Broilers respond to very fine feed structure with changed development of the gastroenteral tract, for example abnormal enlargement of the proventriculus and an underdeveloped gizzard. Digestive mechanisms are compromised and the animals are much more susceptible to Salmonella infection (Kamphues et al., 2007). Abdominal dropsy (ascites) is widespread among broilers, especially in unfavourable environmental conditions like summer heat or locations at high altitude.

» Maximum oil yield increases profits
The Bunge oil mill monitors production with NIR-Online industrial spectrometers

The basic rule for processing rapeseed is: the higher the oil yield, the higher the profit. Bunge Deutschland GmbH belongs to one of the world’s leading oil seed and grain trading and refining groups, where this principle is implemented via prompt process controls with industrial spectrometers from NIR-Online GmbH.