Feed production process
Automation and modernization of feed production processes
Feed production is a multi-stage process, in which each step is crucial to achieving high quality and efficiency. Implementation of modern technological solutions in the field of automation and modernization allows for significant increase in precision, efficiency and safety at every stage of production.
What does the feed production process look like?
For a better understanding, we present the feed production process from an automation perspective. Each area has its own unique automation requirements.
Stage 1: Raw Material Receipt Point
The raw material acceptance system is based on a "basket" equipped with an aspiration system and transport to the silo storage or directly to the macro-dosing tanks. At this stage, the raw materials are initially cleaned using screens and magnetic catchers. In more advanced systems, operator panels with barcode scanners are used, which allow for the automation of the raw material acceptance process.
Processes supported by modernization and automation
- Raw material identification (barcode scanning)
- Raw material purification
- Transport to warehouses
Benefits
Better raw material management: Automation of receipt and identification minimizes errors and streamlines the process.
Improvement of product quality: Pre-cleaning reduces the risk of contamination.
Increased occupational safety: Automation of hopper operation reduces the risk of accidents.
Stage 2: Silo storage
Raw materials are stored in flat-bottomed or conical silos. Modern installations use multi-point temperature measurement systems and air circulation, which maintain optimal storage conditions.
Processes supported by modernization and automation
Temperature control in silos.
Air circulation management.
Inventory monitoring.
Benefits
Better raw material management: Monitoring systems provide control over storage conditions.
Environmental protection: Reduction of raw material losses.
Reduction of operating costs: Minimization of losses related to improper storage.
Stage 3: Macro Dosing
The area of macro dosing involves weighing large quantities of raw materials (from 1000 kg to several thousand kg) that constitute the main part of recipes.
Processes supported by modernization and automation
- Precise weighing of large quantities of raw materials.
- Automation of the weighing process.
Benefits
Increase production efficiency: Quickly and accurately weigh large quantities of raw materials.
Improve product quality: Precise dosing eliminates recipe errors.
Meet regulatory requirements: Automatic process documentation.
Stage 4: Micro-dosing
The area of weighing raw materials and additives, although their share in the mixture is small, is crucial for the quality, purpose and safety of the feed. It is important to eliminate errors when filling the tanks of the micro station. This is achieved by locking the filling holes, which are unlocked after verifying the compliance of the product codes from the packaging and the raw material assigned to the tank. The codes can be entered manually on the operator panel (cheaper solution) or scanned using a scanner (recommended option).
Processes supported by modernization and automation
Verification of raw materials (code scanning).
Precise dosing of microelements.
Benefits
- Improved product quality: Precise dosing of trace elements and additives.
- Increased work and product safety: Code verification minimizes the risk of errors.
- Reduced operating costs: Reduced waste of additives.
Stage 5: Grinding
In the milling area, raw materials are crushed using vertical or horizontal hammer mills or multi-roll mills. It is important to maintain the appropriate level of crushing and eliminate impurities (e.g. stones).
Processes supported by modernization and automation
Crushing of raw materials.
Elimination of impurities.
Benefits
- Improved product quality: Proper grinding improves feed digestibility.
- Increased work safety: Elimination of objects harmful to mills.
- Reduction of operating costs: Optimization of energy consumption.
Stage 6: Mixing
The mixing installation carries out production orders, preparing mixtures that can be a finished product sent for dispatch or sent for further processing, e.g. granulation. The mixing line is often equipped with a manual hopper for precise addition of ingredients or premixes. Liquid ingredients such as fats, water or acidifiers are also added at this stage. Effective management of the weighing stages is crucial to optimize the time needed to prepare the mixture.
Processes supported by modernization and automation
- Precise mixing of ingredients.
- Automation of adding liquid ingredients.
Benefits
Increased production efficiency: Optimized mix preparation time.
Improved product quality: Precise mixing ensures uniform quality.
Environmental protection: Reduced fluid losses.
Stage 7: Dosing of liquid raw materials
Liquid ingredients are dosed on a mixing or granulation line, which requires precise quantity management. Our scope most often includes the integration of a production line with a liquid storage and dosing installation.
Processes supported by modernization and automation
- Precise dosing of liquid ingredients.
Benefits
Improved product quality: Precise dosing of liquids.
Reduced operating costs: Minimized losses of liquid raw materials.
Stage 8: Granulation
The granulation line is a key element of most feed plants, where bulk feed is transformed into granules. The conditioner plays an important role, preparing the mixture for processing, influencing the quality of the final product. The key challenge is to optimally set parameters such as temperature, humidity and time spent in the conditioner. After granulation, the product goes to a cooler, where time and air flow control allows to achieve the desired properties. The next stages include crushing the granules and enriching, e.g. by greasing or adding enzymes. The finished product is then sent for dispatch.
Processes supported by modernization and automation
- Preparation of the mixture (conditioning).
- Cooling and crushing of the granulate.
- Adding enriching ingredients.
Benefits
- Improving product quality: Control of granulation parameters (temperature, humidity).
- Increasing production efficiency: Automation of the granulation process.
- Fulfilling legal requirements:
- Documentation of process parameters.
Stage 9: Shipping of the finished product
The final stage of the process is dispatch, i.e. storage and delivery of the finished product. There are various loading methods, such as weighing on a truck scale, a scale under the dispatch tanks or a chain conveyor without weight control. In modern factories, operator panels with code scanners are used, which read transport orders and automate loading.
Processes supported by modernization and automation
- Loading automation.
- Batch tracking and logistics documentation.
Benefits
Improving logistics processes: Faster loading and issuing of products.
Improved raw material management: Precise tracking of product batches.
Building a competitive advantage: Higher customer satisfaction thanks to timeliness.
Modern tools for production optimization: Nutrilo® and SCADA systems
The introduction of Nutrilo® software and SCADA systems by iPS Control® is the key to achieving full automation and modernization of feed production.
- Nutrilo® is advanced software that allows for comprehensive management of feed production. Its modular structure allows for any customization, which allows for adapting the system to the specific needs of the customer and eliminating unnecessary costs. The open architecture provides the possibility of integration with other systems, such as ERP superior systems or existing technological solutions.
- SCADA (Supervisory Control and Data Acquisition) is a system that allows for monitoring and control of all stages of production in real time. Thanks to it, precise data analysis and immediate response to any deviations from the assumed parameters are possible.
With Nutrilo® and SCADA, customers can effectively increase production efficiency, minimize errors, and optimize management and logistics processes.
By investing in IPS Control®, you gain a solution that acts as a bridge between the SCADA system and the ERP system.
Do you need an experienced partner who will carry out processes in the area of automation and modernization of feed production?
Do not hesitate. Contact us.