Title of Invention : Process of Powder and Pellet Feed production using processing machine with an oblique tank with potential to preserve additives properties

Technical Field

[0001] The technical field of this invention relates to the livestock and poultry feed production line.

Background Art

[0002] A device to thermally condition animal feedstuffs, oil seeds, oil fruits or similar (EP 0664087). The feed passes through a series of helical drive shafts and paddles within a cylindrical housing before arriving at a stopper surrounded by a circular exit at the end of the housing. The spaces between the paddles in the final stage of the helix accommodate projecting inserts which may be raised or lowered. The novelty is that the mixer paddles and the inserts can be adjusted whilst the unit is in operation. The invention differs from the claimed one in feed processing mechanism, processing time, humidity, form, structure and in particular output materials, device capacity and control among others.

Technical Problem

[0003] Within all domestic and international production units, the common configuration and structure based on the arrangement of machinery for livestock and poultry feed production line is as follows: 1 - Raw material silos 2- Mill 3- Conveyors 4- Storage silos for milled material along with vitamins and medicines reservoirs and liquids-containing hoppers 5- Weighing system 6- Mixer 7- Conditioner or curing machine 8- Pellet machine 9- Cooler dryer 10- transporter 11 - Bag filling machine and conveyor for leaving the production line.

[0004] The main limitation in the production of livestock and poultry feed in the current arrangement is as follow:

[0005] A. Arrangement and configuration of feed production machines

[0006] B- High cost and high depreciation rate of pellet machine accessories as the most important part of the feed production line [0007] C- The high cost of supplying additives (vitamins, supplements, and micronutrients) and the loss of their properties in the current arrangement of machinery

[0008] Another major issue, and perhaps more important than the costs of the pellet processing mills, is related to the cost that must be spent on the preparation and purchase (additives) drugs, micronutrients, vitamins in the production unit, these additives as an integral part of the feed-in each production unit are expensive on the one hand, and on the other hand, due to the high sensitivity of these materials to heat, moisture, abrasion, and compression, they practically lose their properties and despite spending a lot of money, they have no effect on the quality of the produced feeds.

[0009] In each production unit, a conditioner machine is usually used to produce mesh or pellet feed. As mentioned, in the arrangement of conventional machines, the process of mixing all feed ingredients, including additives (medicine, vitamins, supplements ...) takes place in the mixer, located before the conditioner machine.

[0010] In the existing process, the materials, after being mixed by the conveyors for curing and eliminating anti-nutritional substances and harmful bacteria (Salmonella), enter the curing machine or conditioner, in this machine to achieve the above goal and better efficiency of the pellet machine, located after curing machine, steam is injected into the machine and the temperature is raised to 95 to 100 C for curing the ingredients. It is at this point that many additives lose their properties due to the high injection temperature, humidity, as well as wear and pressure due to the operation of the curing machine. In addition, mechanical pressure and heat due to the operation of the pellet machine exacerbate the above process.

[0011] Vitamin stability under various circumstances

[0012] Generally, the four factors of abrasion, heat, pressure, and humidity degrade vitamins. High temperatures in the pelleting process or conditioning time increase chemical reactions between ingredients and eliminate vitamins. Vitamins of C, K3, D3, A, and thiamine also have problems in the pelleting process. Feed manufacturers usually point out that the main reason to rise pellet temperature is controlling Salmonella and increasing digestibility while using steam in pellets or expanders plays a major role in vitamin degradation. Using feeds with high levels of energy (fat) causes less consumption of feed and hence reduces the concentration of vitamins in the feed.

Solution to Problem

[0013] In order to obviate the issues mentioned in the claimed invention, some changes have been made in some devices and as a result, changes in the layout of the production process. In fact, the use of new machines allows us to change the production line process and achieve much better results in the quality and quantity of products. On the other hand, products are obtained at a much lower cost in this new process.

[0014] In this process, the materials are stored in larger silos and transferred to smaller silos after milling. In smaller silos, materials will be weighed, which during the production process, their composition and additives will be produced in a standard manner. In this process, the weighed ingredients will no longer enter the mixer because at this stage micronutrients will not be added to them.

[0015] Once weighted, the raw materials enter the feed processing machine with an oblique tank. In this machine, the curing time and temperature are defined by the user for the machine. Given the lack of micronutrients, it is possible to adjust the curing temperature to 110 C in 6 minutes. Temperature and time can be changed according to the capacity of the machine. The output of the feed processing machine with an oblique tank is a processed and bulk material in which all microbes and its anti-nutritional materials are eliminated and gelatinized.

[0016] After this step, the material enters the dryer cooler device. This device consists of two floors, on the upper floor of which the materials are desiccated and dried due to heat generation, and on the lower floor the dried materials are cooled. The drying and dehumidification rate of this device can be adjusted according to the type of inputs.

[0017] In this production process, the product enters the mixer after passing through the dryer cooler to add micronutrients and other additives. Given the low temperature of the material at this stage, the added micronutrients will not be lost and there is no limit to adding them. The output of this mixer is processed mesh feed.

[0018] In the next step, if the product needs to be pelleted, the materials will enter the pellet milling machine. In order to pelletize the product, there is no need for high temperature. The required temperature is about 30 to 40 C. considering the molecular shape of the materials obtained in the previous steps, materials are pelletized with high speed and low energy consumption (compared to previous models).

[0019] But the most important factor that makes this transfer possible in the production line is the use of animal, poultry, and aquatic feed processing machine with an oblique tank. The main body of the device has an oblique angle. The direction of rotation of the shaft or mixing paddles of the material in the machine is inversed to flow of passing materials, i.e. the paddles that in the previous generations had the task of moving and transferring materials to the outlet, in this machine, the shaft or axle paddles only have the task of mixing and homogenizing the materials so that material transferring is done cyclically. To put it more clearly, materials that flow to the output of the device due to slope under gravitational force, the movement of the paddles, and the rotation of the device shaft in the opposite direction of the slope, flow material upwards or inlet. This will cause the ingredients to be overturned and homogenized and increase the curing time.

[0020] This machine consists of 6 parts, which are as follows: a. 1 . Chassis b. 2. Body and steam transmission system and valves c. 3. Machine shaft with material mixing and transfer paddles d. 4. Inlet and outlet system e. 5. Sensors f. 6. Automation and software

[0021 ] Machine Chassis [0022] The chassis is designed so that it can be placed on a pellet or extruder. The built-in bases for holding and maintaining the machine have an angle of 35 degrees, which makes the chassis completely resistant to torsional and compressional stresses applied by the rotor or shaft.

[0023] Body and steam transmission system and valves

[0024] The body of the processing machine is made of double walls. The main reason for using a double-wall device is to heat materials both directly and indirectly. The direct mode is to maintain the humidity and temperature of livestock and poultry feed, in this case, the water vapor from the boiler enters directly into the chamber of the device after opening the steam inlet valves or proportional valve. In indirect mode, instead of moisture, heat is used to process the feed. To apply heat to the material, indirect steam water is used, so that the flexible tubes are located between the first and second walls of the device and steam water passes indirectly through these pipes and transfers heat to the material.

[0025] Machine shaft with material mixing and transfer paddles

[0026] Shaft rotation is supplied by an electromotor with a belt attached to a gearbox. The shaft uses blades that can be adjusted in 3 modes and 3 degrees of freedom on the shaft.

[0027] The first mode: the ability to adjust the distance between the blades, on the axis, which by the default mode of the device is at a distance of 80 mm from each other.

[0028] The second mode: the ability to adjust the distance of the blades from the inner wall of the device, which in the default mode is 20 mm away from the inner wall of the device.

[0029] Third mode: the ability to adjust the angle of the blades on the shaft, which is adjusted to guide and apply pressure to the material.

[0030] Inlet and outlet system:

[0031 ] The inlet consists of a spiral feeder with an electric gearbox and a small feeder with an electric gearbox in the outlet to feed the next machine on the production line, which can be a pellet press or another machine. Given that the curing time ranges 2 to 6 minutes, the issue of interest when operating the machine is materials inflow and outflow to the machine, so coordination between the machine feeder and loader is a very important issue that is solved by PLC. The loader has a damper that opens or closes the load outlet path with a pneumatic rotating jack.

[0032] Sensors:

[0033] The number of seven PT100 sensors is installed in the device, 1 at the inlet, 5 at the wall, and 1 at the outlet, and this set of sensors is responsible for measuring the temperature in each part of the machine.

[0034] Automation and software:

[0035] One of the most important parts of this machine is automation and software. PLC controls this machine by and the monitoring system is operated with HMI and it also connects to a computer wirelessly for better data entry by the production line operator. Another feature of this system is the online troubleshooting and updating system so that if the system troubleshooting operator is not present in the factory, it can connect to the control system via the internet and troubleshoot the problem and or it can change the data this way.

Advantageous Effects of Invention

[0036] 1 . The high feed conversion ratio

[0037] 2. Gelatinization of starch in cereals

[0038] 3. Increased digestion and absorption coefficient in the living digestive system

[0039] 4. Eliminating Salmonella and harmful bacteria

[0040] 5. Preservation of micronutrients in the production process

[0041 ] 6. Cost-effective production

[0042] 7. Reduction and optimal consumption of raw material resources

[0043] 8. Low energy consumption in the production process

[0044] 9. Low depreciation of production line devices

[0045] 10. The prolonged shelf life of materials [0046] 11 . In the processing machine, steam material enters the machine directly from several nozzles and the curing process is homogeneous and uniform.

[0047] 12. In the material processing machine, the axis rotates in the opposite direction to the exit of the material, which causes the material to be completely mixed.

Brief Description of Drawings

Fig.1

[0048] Fig 1 : Overview of the production process

[0049] Fig 2: Raw material inlet

[0050] Fig 3: Raw material milling system

[0051] Fig 4: Material weighing system

[0052] Fig 5: Materials curing process, dryer cooler and mixing system

[0053] Fig 6: Material pelleting system

[0054] Fig 7: Material loading system

Description of Embodiments

[0055] Part 1 , Raw material inlet

[0056] In this part, raw materials (cereals: corn, barley, wheat, soybeans, etc.) enter the raw material silos 101 for storage at high capacity and given the capacity of the production line, silos with different volumes are designed. This part includes a load control hopper and feeder 102 for unloading the load from the truck and moving it to the conveyor.

[0057] This part also has a conveyor 103 to transfer materials vertically at different elevations and different capacities for feeding and unloading inside silos. Screw feeder 104 is used to transfer materials horizontally on silos in different capacities. Pneumatic valves 105 are used to control the entry and exit of materials in the silo to the desired number and capacity. Finally, the material on the screw feeder 106 moved to the conveyer 107 for transfer to the next stage.

[0058] Part 2, raw material milling system [0059] This part, also called the material crushing part, transports the grains by a screw conveyor 201 to bucket 202 mounted on the mill. Then the amount of input materials to the mill is controlled by an input feeder. Also, a magnet is installed in the inlet to prevent the entry of metal objects.

[0060] In the milling, process materials are crushed in different sizes in the mill 203. To prevent and control the dust caused by the milling process, a filter bag with a 204 centrifugal fan is installed, which is used according to the production capacity of different types. In order to transfer the milled material to the screw 205, it is installed under the mill, the function of which is defined in proportion to the capacity of the mill. The conveyor 206 is used to transport the milled material to the milled silos and weighing system.

[0061] Part 3: Material weighting system

[0062] In this part, 6 tanks 301 have been installed to store milled raw materials such as corn and soybeans, as well as bag materials such as calcium carbonate, etc., each of which is fed by elevator 302. After storing the material in these tanks, the material is weighed into the system by 303 feeders installed under the storage tanks according to the formula registered by the operator. After weighing the materials according to the formula defined as a batch, they enter the screw machine 304 and then enter the lift and are transferred to the next section.

[0063] Part 4 Materials curing process, dryer cooler and mixing system

[0064] In this part, the milled materials are transferred to the feed processing part according to the desired formula after passing through the weighing system for processing. The materials are transferred by an elevator to a silo 401 on top of a feed processing machine 402 and then fed into a processing machine by a feeder 403 for curing.

[0065] The materials are subjected to mechanical pressure of high humidity and temperature between 95 to 110 ° C and 4 to 6 minutes processing and curing. After curing the materials for drying and cooling, they enter the dryer cooler 404 or mesh cooler. This two-floor machine with a special and exclusive mechanism dries the processed materials first and then cools them. In fact, the performance of the components of this machine completes the processing process. [0066] Then, after drying and cooling the materials that come out of the cooler dryer in the form of mesh (powder), the micronutrients that are mixed through a 205 mixer pedal and then in the buckets 406 for the final mix with the mesh materials through a screw feeder 407 enter ribbon mixers 408. Liquids also enter the ribbon mixer through the static weighing system 409 to be added to the processed material. The final mixed material is transferred to the pelleting section through the bucket 410 and 411 screw bin located under the mixer.

[0067] Part 5: Material pelleting system

[0068] Once dried and cooled, the processed materials through an elevator enter the silo 501 , which is installed on top of the pellets. Below the silo is the conditioner502, where a little temperature and humidity are applied to the material for better pelleting. These mesh materials are granulated in a pelleting machine 503.

[0069] Once pelletized, for drying purposes, the pelleted material enters the ordinary cooler 505 through a feeder 504. Next to the air conditioner, a cyclone 506 with a centrifugal fan 507 and an airlock 508 have been installed to transfer hot air by the fan and bypass the materials through the airlock. After this process, the pelleted materials are ready and enter the loading section to be transported to the next section by elevator.

[0070] Part 6: Material loading system

[0071] In the loading section, after leaving the mixer, the material is entered into the silos 602 to be loaded by a screw 601 , and given the capacity of the pneumatic valves to open or close the material, it is poured into the filling bag device 603 for packing and loading.

Industrial Applicability

[0072] In the livestock industry, the preparation of a balanced and healthy feed that contains all the necessary additive for livestock and poultry is of particular importance, so that any deficiency in terms of percentage of protein, minerals, vitamins, and energy required, causes inefficiency and it will cause diseases in livestock and poultry. Given the sensitivity of the matter and also considering the development and expansion of various fields of livestock and poultry feed production, it has become a separate industry and a number of people have established such facilities at great expense.

[0073] In the case of using this technology, the existing factories will increase the conversion rate of livestock and poultry feed to livestock products and approach the standard, while reducing and optimal consumption of raw materials, more products will be produced.