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PELLETING
Myths vs Facts
The “BIG” Pellet
Mill at K-State
ISSUES IN PELLETING?
PELLET QUALITY
VS
PRODUCTION RATE
PELLET QUALITY
IS:
…the ability of pellets to take handling
without generating excessive fines.
PELLET THROUGHPUT
IS:
… the ability to feed the birds!!!
PELLET QUALITY FACTORS
40%
15%
5%
20%
20%
Formulation
Grind
Die
Conditioning
Dry/Cool
Pellet Quality Issues
Durability
Fines
Segregation
Selective Feeding
Animal Performance
PELLET QUALITY
FORMATION
Pellet Quality is Primarily
Established in the
Conditioner,
Not in the Pellet Die.
6. principles of steam conditioning
PELLET PRODUCTION
FACTORS
40%
25% 25%
10%
Formulation
Grind
Die Conditioning
PELLET THROUGHPUT
ISSUES
Production Rate
Man-hr./ton
Labor cost
Over Time
Roll & Die Cost Energy Cost
Maintenance
Delivery
Steam?
Electrical
DIE RESISTIVE FORCE
6. principles of steam conditioning
6. principles of steam conditioning
MAJOR FACTORS AFFECTING
PRODUCTION RATE
Formulation
-Fat/Oil content
-Animal Protein
-Grain Type
-Grain Moisture
-Phosphate Source
FORMULATION
Diet formulation is based on meeting the nutrient
requirements of the animal at the least possible
cost per ton.
Little consideration for:
-Pellet Quality
-Production Rate
CONDITIONING:
....any modification or addition made to the mash
after it leaves the mixer and before it reaches the
pellet die chamber...
MAJOR FACTORS AFFECTING
PRODUCTION RATE
Steam Conditioning
The level of steam conditioning possible
depends on the:
-Formula moisture content
-Formula fat/oil content
-Steam quality
-Die resistance and condition
-Roll surface and condition
MAJOR FACTORS AFFECTING
PRODUCTION RATE
Steam Conditioning
As a rule, the higher the level of conditioning,
the higher the throughput and pellet quality.
Condensed steam acts as a lubricant
(up to a point!!)
STEAM CONDITIONING
Steam has the ability to carry and
transfer
both heat and moisture efficiently
through
the process of “CONDENSATION”.
STEAM
CONSIDERATIONS!!
-Quality?
*Insulation
*Traps
*Valves
-Pressure?
*Constant not Fluctuating
*Makes little difference in heat
content.
CONDITIONING
ALTERNATIVES
• Steam Addition-----Atmospheric.
• -----Pressure.
• Water Addition.
• Expanding.
• Compacting.
• Re-Pelleting.
• Ripening.
70 F
212 F
D T=142 F
STEAM CONDENSATION
Grain
Particle
HEAT/MOISTURE DIFUSION
TIME!!!!
Starch at the surface of
The particle is gelatinizes
And becomes soluble
Starch Granules
Amylopectin
Molecule
PARTICLE ADHESION
HOT/MOIST
CONDITIONING
COOL/DRY
CONDITIONING
6. principles of steam conditioning
6. principles of steam conditioning
6. principles of steam conditioning
MASH
CONDITIONED
MASH
STEAM
TYPICAL CONDITIONING
6. principles of steam conditioning
6. principles of steam conditioning
CONDITIONER OPTIONS
RENTENTION TIME
1.Conditioner Volume- L x W
2. Pick (paddle) Angle.
3. Shaft Speed.
0 15 45 75 90
Pick Angle (degrees)
PADDLE ANGLE
ADJUSTMENT
6. principles of steam conditioning
6. principles of steam conditioning
CONDITIONER VOLUME
VS
Large Length to Diameter Ratio
Small Length to
Diameter Ratio
In-Line Moisture
Control
The Effect of Precise Moisture
Control on Pelleting Operations
OBJECTIVE:
To determine if precise moisture control at the
Mixer would affect pellet mill operations and
pellet quality.
PROCEEDURE:
1. Corn was low-temp. dried and ground through a
8/64” HM screen.
2. Feed Type- corn-soy pig finishing ration.
3. Feed mixed in a 1,000 lb (454 Kg) ribbon mixer.
4. Pelleting done w/ a CPM Master model pellet mill
equipped w/ a 3/16”X1.5” die.
5. Water was applied to the mash in the mixer using
a “Grain Prep” auto delivery system.
Incoming Target Actual Conditioned
(%) (%) (%) (%)
11.4 12.0 12.2 15.1
11.0 13.0 13.0 15.9
10.9 14.0 14.0 16.8
10.7 14.5 14.7 17.0
11.1 15.0 15.1 18.5
Moisture and Conditioning Results
6. principles of steam conditioning
72
74
76
78
80
82
84
86
88
90
12 13 14 14.5 15
Effect of Added Moisture on Pellet Quality
PDI
%
Starting Mash Moisture (%)
Moisture Management
Summary
1. The automated system provided very accurate
and precise control of cold mash moisture.
2. Finished feed pellet quality increased with each
increase in cold mash moisture over the range
studied
Pelleting?
THE FUTURE!
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
Pelleting Will Not Go
Away!!!
THE FUTURE!
PELLETING-CONDITIONING
Conditioning Time Control
-Variable Shaft Speed
-Pick Angle Control
-Steam Block Panels
-Conditioner Angle
THE FUTURE!
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
EXPANDERS
6. principles of steam conditioning
THE FUTURE!
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
Compactors
6. principles of steam conditioning
6. principles of steam conditioning
Compactor
Roll
Assembly
THE FUTURE!
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
UNIVERSAL PELLET COOKER
The “UPC”
from
Wenger Manufacturing
6. principles of steam conditioning
6. principles of steam conditioning
THE FUTURE!
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
Pressure Pelleting
PRESSURIZED CONDITIONING
PCI, Inc. Wichita, Ks.
6. principles of steam conditioning
THE FUTURE!
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
“ON-LINE”
ROLLADJUSTMENT
Remote Roll Adjust
THE FUTURE!
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
Formulating for Pellet
Quality !!
Is It Possible??
THE FUTURE!
COOLERS AND COOLER DESIGN
Counter Flow Coolers
Are Here To Stay!
Bliss
Counter Flow
Pellet
Cooler
THE FUTURE!
COOLERS AND COOLER DESIGN
Future Designs Will
Include Drying Capability
THE FUTURE!
Post Pellet Additive Application
*Low Inclusion Liquids
-Enzymes
-Drugs
-Vitamins
-Biologicals
Source: AMANDUS KAHL
Source: Hayes & Stolz Mfg. Co.
SUMMARY
(ADVICE!!)
Stay Informed!!!
* Consider the Economics
* Consider the Alternatives
*Make Logical, Rational Decisions
*Watch Related Developments

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