Agricultural business: feed production. Feed production business plan: technology and necessary equipment. Overview of equipment for the production of animal feed

Today, this industry Agriculture how animal husbandry intensively uses animal feed in its activities. Compound feed is a product for feeding animals, which includes a variety of herbal and grain components, salt, fish and bone meal, vitamins and other trace elements necessary for the normal life of birds and livestock.

The quality of the final product depends on the quality of the animal diet. Therefore, farmers and individuals who are engaged in breeding farm animals are interested in obtaining cheap but nutritious feed.

1 Feed production technology

The production of combined feeds is a complex of processes that make it possible to obtain the final product from the feedstock with different characteristics. The resulting feed may vary according to chemical composition, nutritional value, shape, etc. Each type of compound feed has an exact recipe. When making them, it is necessary to take into account the type, gender, age and food purpose of the animal (milk, meat, wool, eggs, skin, etc.).

Types of combined feeds according to the content of nutritional value:

Concentrated: minimum water and fiber content with a high concentration of cereal grains, which makes this feed nutritious.
Balanced supplements: contain certain trace elements, proteins, vitamins, etc.
Complete ration feed: used for complete nutrition.

Feed production is organized in the following forms:

Granules: dense rounded, oblong lumps.
Loose compound feed: a product obtained by grinding granular compound feed. Grinding can be coarse, medium and fine.
Briquettes: Rectangular or square tiles of high density feed.

1.1 Feed production technology (video)

1.2 Production of pelleted feed

I would like to elaborate on this topic as pelleted feed is considered to be more effective than other forms of compound feed in some respects. Each granule is a collection of those nutrients that are necessary for the diet of farm animals.

Eating granules, the animal receives the whole complex of necessary nutritional elements. At the same time, the opportunity to choose the “tastier” parts of the feed, leaving those that you didn’t like, is excluded. Granular compound feed is also well suited for feeding fish. Granules can stay in water for a long time without dissolving without losing their nutritional value.

The granule is generally cylindrical in shape. Its size depends on the type of animal. The granule diameter for young poultry is 2-3 mm, for adult poultry and fish - up to 5 mm, for piglets - 8 mm, for adult pigs - up to 10 mm.

There are two types of granulation of compound feeds: dry and wet. In dry production, loose mixed fodder is exposed to steam, pressed and binders are added, such as fat, molasses, etc. Wet production is characterized by adding to the mass warm water. In this case, it is necessary to achieve a humidity of 30-35%. Granules are made from the resulting mass, which are then dried.

So, we can distinguish the main stages of the production of granulated feed:

grinding of primary raw materials;
division into doses and addition of appropriate trace elements;
mixing and obtaining a homogeneous mass;
granule formation;
cooling;
packing.

2 How to set up a feed business?

Today we can say with confidence about the constantly growing demand for feed for the livestock sector. Therefore, enterprising people can consider the production of animal feed as a business. What do you need to know to set up a feed production line?

2.1 Raw materials

The main components for the production of combined feed for farm animals are:

hay, straw, cake;
cereals and legumes;
herbal, fish, bone, limestone flour;
starch and treacle raw materials;
minerals: salt, chalk;
chemical raw materials: vitamins, antibiotics;
protein and vitamin supplements.

More than 100 types of raw materials are used for the production of animal feed. The use of certain components and additives directly depends on the type of animals and their special characteristics.

2.2 Production room

The production of combined feed requires the availability of premises for the placement of equipment and storage of finished products.

The production facility must meet the following requirements:

height not less than 4.5 m;
temperature at least 5 degrees Celsius;
availability of sufficient space for placement of equipment and finished products;
workers - 1-2 people.

2.3 Special equipment

For the manufacture of compound feed are used different technologies. They depend on the type of raw material, composition and type of the final product.

There are two types of equipment for the production of compound feed:

Multifunctional machines.

Extruder - a device for processing raw materials into a homogeneous mass. At the same time, the final product is given certain form by passing the raw material through a special calibrating device, the cross section of which corresponds to the shape of the finished product.

2.5 Feed production at home

If you do not have sufficient space or in cash, which are necessary to establish a line large-scale production combined feed, you can organize a mini plant at home.

Owner of a private house or suburban area there will certainly be a room (or area for construction) to accommodate a mini-factory for the production of animal feed. Such equipment is characterized by smaller dimensions and, consequently, lower cost.

The productivity of such feed equipment is 250-3000 kg per hour. It has a small weight, which makes it possible to move the unit without special efforts. For such a mini-factory no need to build a special platform.It needs to be placed on a flat, stable surface. Then install the embedded elements, assemble the installation and connect to the power source.

The mini-factory includes an electronic scale that is used to measure the exact weight of raw materials. Also, the feed production line can be equipped with an MKD control panel, which will make the work process fully automated.

Characteristics of products, raw materials and semi-finished products. Compound feed is a complex homogeneous mixture of various feed components and additives cleaned and crushed to the required size, compiled in accordance with the requirements for the full feeding of animals and birds, taking into account their species, age, sex, health status and purpose of feeding. The production of compound feeds implies their balance in terms of energy, protein, macro- and micro-additives, vitamins and biologically active substances.

Depending on the purpose, there are complete mixed feeds, mixed feed concentrates, feed mixtures, protein-vitamin-mineral (PVMD), protein-vitamin (BVD) and mineral additives, premixes.

Complete mixed feeds fully satisfy the needs of animals for energy, nutritional and biologically active substances ah, without additional feeding of other feeds and micro-additives. They must contain all the nutrients necessary to ensure high productivity and product quality, good animal health and low nutrient costs per unit of production.

Compound feed concentrates are intended for cattle, pigs, rabbits and other animals. They have a high content of protein, mineral and biologically active substances. These compound feeds are fed to animals in limited quantities, exclusively as an addition to grain, coarse and succulent feeds. Compound feed-concentrates in their composition should correspond to the quality of roughage and succulent feed, providing the necessary nutritional indicators of the diet. As a variety, it is sometimes customary to single out a separate group of starter feeds, i.e. feed for young animals in the first periods of his life.

Feed mixtures are intended mainly for cattle. They can be made from the waste of flour milling and cereal production, for example, from barley husks, flour with the addition of molasses, urea, and other additives, preferably in granular form. If compound feeds produced for one reason or another with significant deviations from regulatory and technical documentation do not meet zootechnical requirements, they can be classified as feed mixtures. The Ministry of Agriculture and Food of the Republic of Belarus does not recommend the use of this type of feed.

Protein-vitamin additives (BVD) and superconcentrates are balancing feed additives, which are homogeneous mixtures of high-protein feed products, micro- and macro-additions, vitamins and other biologically active substances crushed to the required size. They are produced according to scientifically based recipes and used for the preparation of feed based on grain fodder. This type of feed additive is intended for supply to collective farms, state farms, inter-farm feed enterprises, farmers for the production of so-called "secondary compound feed" on the basis of feed grains available on farms, herbal vitamin flour and other feed products. These mixed feeds must fully correspond in quality to complete mixed feeds or compound feeds-concentrates.

Premixes are special concentrated feed additives, which are a homogeneous mixture of pre-prepared biologically active substances, crushed to the required particle size, and in some cases microadditives with filler, used to enrich animal feed and protein and vitamin supplements. The basis of premixes are vitamins, microelements, amino acids. In addition, the composition of premixes may include substances with a stimulating effect (antibiotics, etc.); substances that have a protective effect on feed, prevent the deterioration of their quality, contribute to best use feed (antioxidants, emulsifiers, enzymes, flavorings, etc.); having a therapeutic and prophylactic effect (furazalidon, sulfadimisin, etc.); sedatives (tranquilizers); surface active (detergents).

Features of production and consumption of finished products. The technology for the production of compound feed is a set of operations, the sequential execution of which makes it possible to obtain from various feedstocks that differ from each other in terms of physical and mechanical properties and chemical composition, feed with specified parameters depending on the recipe. The main requirements for the technology are to obtain high quality products, which, in turn, is due to the observance of all stages of the technological process and the introduction of automation of machine operation and product quality control. The final products are produced at feed mills in loose and granular form. Compound feed is an important component of animal and poultry diets. In feeding rations, its share can be up to 27 ... 36% for cattle, 38 ... 90% for pigs and 60 ... 100% for poultry.

It is customary to evaluate the technology of compound feed production according to the flow diagrams that graphically show the sequence of operations, as well as the place of each of them in the overall structure of the preparation of the final product from different types of feedstock. Each technological scheme consists of a number of preparatory and main lines, which are a system of interconnected machines and mechanisms arranged in the order of sequential operations.

The process flow diagram is usually depicted graphically and denotes: the quantity and place of unloading of raw materials from vehicles, types and sizes of mechanisms, and their performance; number of warehouses; their capacity, and for silo warehouses - the number of silos, places for loading and unloading warehouses, types and standard sizes of transport mechanisms and their productivity; the number of lines for supplying raw materials to production; the number and carrying capacity of scales for raw materials when entering production; the number of production lines of the technological process and the equipment used with the main characteristics and technical data; the number of warehouses for finished products, their capacity; places for unloading and loading finished products into vehicles; directions of flows of raw materials, components, products and wastes* at all stages of the technological process; the number and length of magnetic barriers, the place of their installation along the lines, the number of aspiration equipment and its distribution over aspiration networks with reference to aspiration machines.

Stages of the technological process. Feed preparation includes the following main operations:

Reception, weighing and storage of raw materials;

Purification of raw materials from impurities;

Peeling of oats and barley; crushing of grain and other components;

Drying and grinding of mineral raw materials;

Preparation of a mixture of microadditives with a filler;

Introduction of liquid additives into animal feed;

Dosing of components according to recipes;

Mixing of components;

Granulation or briquetting of mixtures;

Accounting and issuance of compound feed.

Characteristics of equipment sets. The structure of compound feed production provides for the main and auxiliary processes. The main ones include processes directly related to the conversion of feedstock into animal feed. Auxiliary processes are not directly related to the production of feed. These include: transportation, reception, placement and storage of raw materials; storage and release of finished products; recycling of waste from the main production, etc.

The organization of production should ensure the minimum duration of the technological cycle, complete mechanization and flow of the process, timely quality control in the main sections of the line, uninterrupted operation of inter-shop and intra-factory transport, accounting for raw materials and products, efficient use of technological and power equipment, operational dispatch control, favorable working conditions and etc. The flow of production and the continuity of the process are ensured by: the maximum use of the properties of the flowability of products; introduction of operational bunkers (over-crushing, over-dosing, etc.) into production lines; dividing the total flow into separate lines, specializing depending on the properties of the components; rational choice of productivity and line rhythm, as well as the percentage of components in accordance with the recipe.

Technological operations are usually carried out on specialized production lines, due to the range of recipes and possible changes in their composition. Such lines are part of feed mills or workshops. At the same time, their number, depending on the purpose of the plant, can be different both in quantity and in composition. Compound feed enterprises include the following main technological lines: 1) reception and processing of grain raw materials (there may be several parallel lines equal to the number of grain types); 2) separation of films from oats and barley; 3) mealy raw materials (bran, flour); 4) vitamin herbal flour (loose or granulated separately); 5) feed products of food production; 6) meals; 7) pressed and lumpy raw materials; 8) processing of raw materials in containers; 9) preparation of table salt; 10) preparation of fodder chalk and other raw materials of mineral origin; 11) input of molasses (hydrol, liquid concentrate, fodder lysine); 12) input of feed fat, MEK (multi-enzyme formulations) or vegetable oil, fish oil; 13) input of premixes (preparation and input of enrichment mixtures); 14) input of urea (in dry form, in the form of a solution of molasses with urea, urea concentrate); 15) dosing and mixing; 16) granulation; 17) expansion, extrusion of grain raw materials or compound feed; 18) placement, storage and distribution of finished products; 19) preliminary mixtures of protein difficult-to-flow components; 20) preliminary mixtures of grain, granular and other raw materials.

In addition to the lines listed above, modern factories such as the line of thermodextrinization of grain raw materials, preparation of a preliminary mixture of common salt with a filler can also be included; a line for the introduction of table salt in the form of saturated solutions, a line for the reception and introduction of mineral premixes (MPR) or vitamin-amino acid preparations (VAP) and others.

The device and principle of operation of the line. There are several principles for constructing a technological process at a feed mill.

Series-parallel preparation of all components and single dosing is the most common. This is a classic, common in many countries, principle of completing feed mills. The components for dosing are prepared separately. On some lines - in series, and on others - in parallel. They are placed in dosing hoppers (Fig. 5.1). Such acquisition is distinguished by a large number of over-dosing bins capable of containing a stock of components for 8 ... 36 hours of operation of the main dosing unit. The number of preparatory lines in this case ranges from 10 to 12.

The basic algorithm for the operation of such plants and their lines can be formulated as follows:

Striving for the constant filling of all dosing bins with the initial components necessary for the current production, according to the recipe;

Parallel preparation of additional components for the next batch (recipe) of compound feed, in order to minimize the loss of time when switching from one recipe to another.

Figure 1- Classical technological scheme for completing a feed mill

Feed grain from the corresponding silo or hopper 1 enters when the outlet window of the bottom is opened with the help of flow valves 2 through the downpipes to the conveyor 3. The silos are equipped with upper and lower level sensors that are connected to the central control center of the plant. With the help of valves-regulators 2, a batch of grain is formed, which is fed for processing into mixed fodder. Electropneumatic valves are used as flow control valves. Each flow of grain passes through magnetic separators 4, and then enters the crusher 5. Separators 4 are cleaned from metal impurities. The crushed product is then fed by crusher pneumatic transport to the cyclone unloader 6, and from it to the screening machine 7. Large impurities are fed back to the conveyor 3, and the product fraction of the required degree of grinding is fed to the conveyor-distributors in the dosing bins 8 of the component mixing section. Shredded protein raw materials and mineral additives enter other dosing bins. From the 8 bunkers, the raw material enters the 9 multi-component weight dispensers, which, according to the recipe, form the feed component flow of a certain intensity. The dosed flow of the corresponding raw material enters by gravity or with the help of special conveyors 10 into the batch mixer 11.

The disadvantages of the classical principle of constructing a technological scheme include the large time spent on preparatory operations at the beginning of the shift, if the dosing bins were empty. In addition, when carrying out replaceable (ten-day) stripping, it is very difficult to take into account the mass of raw material residues in the bunkers, and therefore the stripping of the production building is carried out once a year.

Due to numerous parallel technological lines, classical schemes are saturated with main, transport and auxiliary equipment, including aspiration equipment, the operation of which requires large amounts of energy. It is difficult to manage the work of production due to the need to obtain and process a huge amount of information.

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1. Characteristics of raw materials and compound feed formulations

The feed industry presents high requirements for the production of high-quality feed, balanced in nutrition, protein, carbohydrates, minerals and vitamins. The raw material composition of compound feed is extensive and includes a wide variety of raw materials of plant microbiological, biochemical, chemical, synthetic and animal origin. Up to 16 types of raw materials are introduced into compound feed. This feature of feed production makes it difficult to provide existing enterprises with raw materials, since raw materials in such a variety can only be supplied by a large number of suppliers from various industries. Features of the raw material base of the feed industry lead to the search for optimal technological options; schemes and techniques that could improve production and improve the quality of products. Grain components: corn, wheat, barley, oats, millet, sorghum, etc. are contained in larger quantities in the recipe. This is due to the fact that they are the most concentrated in terms of nutritional value and regulate the carbohydrate composition of the feed (the content of starch, sugar, fiber, etc.), provide the energy content of the diet. Barley is the oldest - along with wheat - cereal on earth: its grains were eaten 10 thousand years ago. It was distributed almost everywhere, since it takes root well in the cold polar lands, and in the steppes and semi-deserts, and in the highlands of Tibet, the Pamirs, the Caucasus (for example, in the Indian state of Punjab, barley is grown at an altitude of 5000 meters - no one grows so high another cereal). In the East, and sometimes in Europe, barley grains are added to animal feed.

In Buryatia, a feed mill processing barley.

Norma To ensure the food security of the republic, the government of the Republic of Belarus plans to increase the sowing of grain crops. It is also a rich source of amino acids. Recently, a functional product has been developed on the basis of grain crops. A functional product is a special food product intended for systematic use as part of food. To organize the production of a nutrient mixture functional purpose in the Republic of Buryatia, the development of technology with the use of modern equipment used in small enterprises is required. The power justification should be made taking into account the needs not only for local purposes, but also for the sale of the mixture as one of the national food products in the zones. Since there is no such production in the Republic of Buryatia, taking into account the above, in order to meet the demand at the initial stage, it is necessary to organize the production of a nutrient mixture in the amount of 300 kg / day, which is equal to 14,980 sachets of 20 grams each. With an increase in demand, it will not be difficult to increase the volume of production.

Feed products of food production (meat and bone, fish meal, yeast, reverse, etc.) are distinguished by a high content of complete protein and minerals that are easily digestible by the animal body. Their content is relatively small.

The group of flour components is bran and flour. Bran for dairy cows and calves is introduced in large quantities, sometimes more than half of the feed composition. For broilers, bran is not administered. In the production of feed for sheep (goats), as well as for fattening cattle and dairy cows, a significant part of the recipe is meal.

Of the minerals in the composition of compound feeds, they include table salt, chalk, feed phosphates, flour and grits from shellfish shells, limestone flour, etc.

When choosing technological methods of production, the formula (composition) of feed is decisive.

When choosing a compound feed formula for cows, sheep and other ruminants, you can pay attention to the fact that, along with components common to other animal species, urea or carbamide concentrate is used for ruminants. Therefore, in the production of compound feed for cows, sheep, it is necessary to provide urea lines or the introduction of carbamide concentrate. In addition, the line of bran and other farinaceous components should be designed for input, up to 60%. Molasses is necessarily introduced into such compound feeds on the line of liquid components.

Complete loose feed produced for poultry farms should fully meet the need for nutrients, minerals and biologically active substances, since it is impossible to develop technological lines at feed mills without knowledge of these issues. For example, when considering recipes for complete feed for laying hens, it is necessary to develop a technological scheme for the production of feed in accordance with the rules with the following lines: grain, feed products for food production, chalk and other raw materials of mineral origin (fluorine-free phosphate, limestone flour), salt, premixes or preparation and input enrichment mixtures.

Table 1 - Distribution of components in recipes

Components
	broilers	meat fattening pigs

Grain raw materials
Mealy raw materials

Feed products of food production
Raw materials of mineral origin
Premixes

2. Technological lines for the production of animal feed

The technological process of compound feed production begins with the preparation of raw materials, which includes its purification from impurities, and, if necessary, grinding, peeling, drying, and heating of liquid components.

Under the preparatory line is understood a set of machines and mechanisms on which components with similar technological properties are processed, therefore, similar requirements for processing modes.

In the production of mixed fodder, the technology can provide for preparatory lines for grain raw materials, separation of films, heat treatment of grain, farinaceous raw materials, loose grass flour, fodder food products, meal, pressed and lumpy raw materials, raw materials of mineral origin.

Line of grain raw materials. Serves for cleaning grain and leguminous raw materials from foreign, harmful and metal-magnetic impurities, as well as grinding grain raw materials to the required size. When designing, it is possible to apply two technological lines of grain raw materials, which can be at feed mills: a variant with separate preparation of grain raw materials, a variant of preparing a preliminary mixture of grain and granulated raw materials. According to the first option, grain crops come from the granary through transport lines to an air-sieve separator installed in the production workshop, where impurities that differ from grain in size and aerodynamic properties are separated. The cleaned grain is sent to a magnetic separator or a magnetic column to separate the metal-magnetic impurities, and then it enters the crushing hopper. From it, the grain is fed into the crusher, crushed and sent to the screening machine to separate the under-grinded fraction of the product, which again enters the crusher. The prepared product is sent to the bunkers of the main dosing-mixing line. A large feed mill usually has two or three such lines running in parallel on each crop. It is more economical if the separator is installed in a silo working building and the grain enters the production building after cleaning.

Film separation line. A significant fiber content in oats and barley makes it difficult to use them for the early young of farm animals and birds.

Therefore, when preparing starter compound feeds, it is necessary to separate the films from the kernel of oats and barley.

Preparation of oats or barley is carried out as follows. After weighing on the scales, oats or barley enters the separator for cleaning from impurities and separating the fine grain fraction. The grain that has passed through a sieve with holes of 2.2x20 mm and descended from the undersowing sieve is sent for peeling, the passage of fine grain enters the raw material warehouse. A large fraction of grain, having passed the magnetic protection, is fed through the bunker to the shelling machine and then to the aspirator. The cleaned core is sent for storage or to a crushing hopper and then for grinding in a hammer crusher. The prepared product is fed into dosing bins.

Line of farinaceous raw materials. It is designed to separate waste from bran, flour and other farinaceous products that do not require grinding. Mealy raw materials in the production building are cleaned in screening machines, where large impurities are separated, and in magnetic separators to separate metal-magnetic impurities. Then the product enters the bunker to the main dosing - mixing line. In a sieving machine for separating impurities, sieves with holes of 0.8 ... 10 mm or with cells measuring 8x8 mm are installed.

Line of feed products for food production. The line is used for processing meat and bone, blood, fish meal, fodder yeast, etc. Raw materials supplied in bags, after unpacking by mechanical or pneumatic transport, are sent to a sifting machine to separate large impurities and a large fraction of the product. Then the coarse fraction enters the hammer crusher, passing through a magnetic separator. The standard size product is fed into the magnetic separator and then into the dosing hopper. In a screening machine for separating impurities, sieves with holes of 015 ... 20 mm or with cells measuring 14 x 14 mm are installed. In the descent from this sieve should not be more than 2% of the feedstock. To separate the large fraction of the product, sieves with a hole size are installed based on the requirements for the size of the finished product. Usually these are sieves with holes 0 3 ... 5 mm.

The line of cuts. It is designed for cleaning from large foreign and metal-magnetic impurities, as well as for grinding meal. Meal from the silo building is transported by elevators and conveyors to the production building. After passing through the magnetic separator, the meal enters the screening machine, where large impurities and a large fraction of the meal are separated, which, after passing through the magnetic protection, is crushed in a hammer crusher. The standard size product from the screening machine and after the crusher is sent to over-dosing bins. In the sifting machine, to separate large impurities, sieves with cells of 015 ... It is possible to clean the meal only from coarse foreign impurities, followed by grinding the entire product in a crusher. In the hammer crusher, sieves are installed with the size of the holes that provide the fineness of the finished product required by the standard.

Line of raw materials of mineral origin. It is used for drying, grinding and screening such raw materials. There are two preparation options. According to the first option, the raw material, which has pieces of the product, is sent to a crusher for grinding them to a particle size of less than 10 mm. Salt, if its moisture content is more than 10.5%, chalk with a moisture content of more than 10%, and lime powder with a moisture content of more than 1.5%, enter the dryer. If the raw material of mineral origin has a standard moisture content, then it is fed into a crusher for fine grinding. The crushed product is sent to the screening machine to control the under-crushed fraction. A large part of the product again enters the crusher, and the product of standard size, having passed the magnetic protection, enters the dosing bin. In the sifting machine, to control the fineness of the crushed raw materials, sieves are installed with openings of size: for salt 0.8x0.8 mm or 1.0x1.0 mm, for chalk and lime flour - 1.6x1.6 mm or 0 2.0 mm.

The second option for salt preparation is also used. It is served in a vertical pneumatic pipeline. Here, as a result of the action of gravitational forces, the salt moves down, and the air stream of hot air moves up. In the vertical pipeline, the salt is dried and the salt of standard size is selected; for this, the required air flow rate is set. In the unloader, air is separated from salt, and the prepared product is sent to the dosing bin. Coarse salt particles enter the hammer crusher, are crushed and again sent by the elevator to the vertical pipeline.

Premix input line. The line is intended for unpacking and feeding the premix into the dosing bin. Usually the premix is fed in a separate line by mechanical and aerosol transport.

Dosing line - mixing. The line is used to prepare products according to the recipe. Feed components prepared separately for introduction into compound feed enter the over-dosing bins of the dosing-mixing line. Depending on their percentage input into the compound feed, the components are sent to weight dispensers and then to a batch mixer, where they are evenly distributed throughout the mass. Loose compound feed after the mixer passes through magnetic protection and is sent to the finished product body or to granulation.

When preparing the components separately, to ensure the required dosing accuracy, three or two multicomponent weighing batchers of different load capacities are most often installed. If the technology provides for the preparation of preliminary mixtures, then one or two batchers can be installed on the main dosing-mixing line.

3. Designing a technological scheme of a feed mill

When developing a process flow diagram, a student should strive to solve the main problem of organizing production process- ensuring the minimum duration of the technological cycle, timely accounting of raw materials and products, quality control of the operation on the main sections of the line, uninterrupted operation of inter-shop transport, efficient use of technological and power equipment, etc.

The technological scheme, using conditional images, graphically displays the essence and sequence of production, operations and processes provided for in the project. The correct construction of the technological process scheme ensures the release of finished products required quality and high technical and economic performance of the enterprise. The scheme of the technological process of a modern feed mill should be based on the introduction of the achievements of science, technology, and the experience of advanced plants. When drawing up the scheme, it is necessary to fulfill the main requirement, which is that the technological equipment, silos and bunkers are loaded to the maximum, and the number of transport equipment (bucket elevators, conveyors) is minimal. When developing a flow diagram, special attention should be paid to the grinding process, since the efficiency of feeding compound feeds in terms of digestibility is directly proportional to the particle size.

Depending on the goals and purpose of the enterprise, its technical equipment, the technological process of production can be complex or simple. All the existing variety of building technology at feed mills and workshops can be reduced to three types of feed production: with separate preparation of raw materials, with preliminary preparation of a mixture close in physical properties raw materials, with the preparation of raw materials in the overall product mix.

The scheme of a feed mill with separate preparation of raw materials provides for the following lines: for the preparation of grain raw materials with separate processing of certain types of grain and leguminous crops, separation of the film from oats and barley, heat treatment of grain, farinaceous raw materials, fodder food products, meal, loose herbal flour, pressed and lumpy raw materials, finely divided components and premixes, raw materials of mineral origin, mixing dosing, preparation of liquid components, granulation, packaging - after bunkers. Then, on the plans and sections, over-dosing bins are drawn, since they occupy a significant volume of the room, and then weighing batchers and mixers.

Over-dosing hoppers and single hoppers (over crushers, presses) can be made with rectangular or round sections. The latter are better for product outflow, but when placed in a block, they occupy a larger volume of the building than rectangular bins of the same capacity. Therefore, it is better to use round-section bunkers for difficult-to-flow components, and for grain raw materials, granules, rectangular-section bunkers with a side size of 1.5x1.5 m and a height of 1 floor can be used.

The technological scheme is depicted graphically indicating:

Points of acceptance of raw materials, performance points and methods of unloading raw materials from road and rail transport;

Numbers and capacities of all silos, bunkers in warehouses;

All technological lines for preparing components and obtaining products;

Number of technological and auxiliary equipment, its brands, characteristics of working bodies;

Directions of all flows of raw materials, products and waste from individual machines;

Numbers and lengths of magnetic barriers along the lines;

The number of aspiration equipment and its distribution among aspiration installations with reference to aspirated machines and an indication of the direction of drift (small particles);

The number of loading points, their performance and ways of loading finished products.

The process flow diagram can be complex and simplified. A complex scheme includes all processes and possible options. For example, the introduction of all liquid components into loose feed during production and dispensing, the introduction into granulators and the coating of granules with fat. The simplified diagram contains the main processes for obtaining finished products without including some technological lines and techniques. For example, without a peeling line for hulled crops, without the introduction of liquid components or with the introduction of only granular feed, etc.

If floors are indicated on the diagram, then such a diagram is called floor-by-floor. The stages and operations of product development are subject to requirements that are reflected in the Rules for the Organization and Conduct of the Technological Process for the Production of Feed, Protein and Vitamin Supplements, Premixes and Carbamide Concentrate.

In order for the feed production process to be continuous, it is necessary to ensure the simultaneous entry into the filling hoppers above the dispensers of all the components that make up this type of feed. This can be achieved by increasing the number of parallel streams, which eliminates the time losses associated with the supply and processing of raw materials.

When designing, the scheme of the technological process is drawn up depending on the range of feed produced and the productivity of the plant. The scheme from the "Rules for the organization and conduct of the technological process at feed mills" or from other sources, taking into account the latest achievements of domestic and foreign science and practice, can be taken as a basis.

The technological process for the production of compound feeds and protein-vitamin supplements (BVD) in structure consists of the following separate stages:

Acceptance of raw materials and their storage;

Preparation of components for dosing;

Dosing and mixing of components to obtain loose (powdery) finished products;

Granulation;

Packing;

Release of finished products.

In the production of premixes, granulation is not used.

The technology for the production of feed for pigs has a number of features. In the production of loose mixed fodder, to ensure fineness, it is necessary: such grinding to prevent residue on a sieve with holes Ø 3 mm, and on a sieve with holes 02 no more than 5%.

The technological scheme for the production of feed for weaned piglets (SC recipes) provides for additional operations in the preparation of certain types of raw materials. The scheme must include a line for separating films from barley with peeling in special machines. Heat treatment is also envisaged to increase its nutritional value and thermal disinfection. ,

In the technological scheme for the production of feed for cattle, the following technological lines are required: grain components; farinaceous raw materials; meal; lumpy raw materials; carbamide or carbamide concentrate; liquid components; salt and other raw materials of mineral origin (monocalcium phosphate, feed phosphate); premixes. The number of lines, their saturation with technological, aspiration equipment are determined by the purpose of compound feed or BVD, their recipe, species composition, as well as the need to bring the input components to the requirements of standards and other regulatory documents.

For dairy cows and calves, bran is introduced in large quantities (sometimes more than half of the composition of the feed), and for broilers, roughage is not introduced at all. In the production of feed for sheep (goats), as well as for fattening cattle and dairy cows, a significant part of the recipe is meal. Of the minerals in the composition of compound feeds, they include table salt, chalk, feed phosphates, flour and grits from shellfish shells, limestone flour, etc.

In the technological scheme for the production of feed for broilers, the input of fat is mandatory, so it is necessary to provide a line for the input of liquid components (fat). This is due to the fact that a complete feed in terms of chemical composition, nutritional value (diet energy), and specific properties should meet the needs of the body of this group of animals and ensure their high productivity, as well as good product quality at low nutrient costs. Particular attention should be paid to the quality of complete feed intended for young animals of early ages. In this case, it is necessary to take into account the norms for the introduction of each type of raw material.

The technology for the production of feed for pigs has a number of features. In the production of loose mixed fodder, to ensure fineness, such grinding is necessary to prevent residue on a sieve with 03 mm holes, and on a sieve with 02 mm holes - no more than 5%.

The technological scheme for the production of feed for weaned piglets (SC recipes) provides for additional operations in the preparation of certain types of raw materials. The scheme must include a line for separating films from barley with peeling in special machines. There is also a heat treatment (roasting) of barley to increase its nutritional value and thermal disinfection.

When considering the composition of feed for cows, sheep and other ruminants, one can pay attention to the fact that, along with the components common to other animal species, urea or carbamide concentrate is used in recipes for ruminants. Therefore, in the production of feed for cows, sheep (deer), it is necessary to provide lines for urea, urea concentrate or BVD based on it. In addition, the line of bran and other farinaceous components should be designed for their input up to 60%. In such recipes, the introduction of molasses along the line of liquid components is mandatory. This especially contains food, the more easily digestible carbohydrates and trace elements in the diet: phosphorus, sulfur, manganese, iron, etc.

In the technological scheme for the production of feed for cattle, the following technological lines are required: grain components, mealy raw materials, meal, lumpy raw materials, urea or carbamide concentrate, liquid components, salt and other raw materials of mineral origin (monocalcium phosphate, feed phosphate), premix input or preparation and input of enrichment mixtures.

4. Calculation of storage capacity

4.1 Calculation of storage capacity of silos

When calculating the capacity of storage facilities, the storage period for raw materials should be taken within 28 days. For bran, if the feed mill is built at the mill, 2-3 days.

Required storage capacity for various kinds raw materials are calculated based on the average consumption of raw materials for the production of compound feed or according to current recipes in accordance with the table

Table 2 - Average consumption of raw materials,%

	name of raw materials	For production compound feed
	Grain and leguminous raw materials
	Mealy raw materials


	Mineral raw materials
	Premixes

The required number of silos is determined by the formula:

where Qz is the productivity of the feed mill, in tons / day;

C - capacity reserve in days = 28;

Y is the amount of raw materials to be stored, Y = 60 - for grain raw materials;

L width of a silo of square section, m;

H - silo height, m;

Bulk weight of this type of raw material; in g/m3;

Silo utilization factor, 0.9.

For grain raw materials:

We take 24 silos

For mealy raw materials:

We take 7 silos

For meals:

We take 5 silos

4.2 Calculation of floor storage area

The amount of raw materials to be stored is determined by the formula:

where Qz is the productivity of the plant, g/s;

The amount of raw materials to be stored, % of the daily productivity of the plant;

С - terms of storage of raw materials, days, 28 days for grain raw materials.

For feed waste:

For chalk:

For salt:

For premixes:

4.3 Calculation of the storage area in the warehouse

The calculation of the area is determined by the formula:

where Ks - the amount of raw materials to be stored in a warehouse, t;

H is the height of the product layer, m;

Bulk weight, t/m3;

Warehouse area utilization ratio.

For feed waste;

For salt;

For chalk;

4.4 Calculation of the area and warehouse for storing raw materials in bags

Calculation of the warehouse area for storing raw materials in bags according to the formula:

where Ks - the amount of raw materials to be stored in bags;

f - area occupied by one bag, 0.45 m2;

g - weight of one bag, kg - 50 kg;

h is the number of bags in the stack

Warehouse area utilization factor equal to 0.6.

For premixes:

For salt:

5. Calculation and selection technological equipment

5.1 Characteristics of the equipment used

At feed mills, machines and mechanisms for unloading railway cars, cars, transport, grain cleaning and weighing equipment are used common to grain processing enterprises. On the lines for the preparation of raw materials, crushing, dosing - mixing, granulating and introducing liquid components, specialized equipment, which is not used at other enterprises for the storage and processing of grain.

When designing, it is necessary to know the performance and characteristics of the working bodies of all types of equipment, their main dimensions, the area of inlet and outlet openings. Brands of equipment and their technical specifications presented in Appendix 3.

To clean grain raw materials from impurities that differ from it in width, thickness and aerodynamic properties, air-sieve separators are used. For calculation, the passport performance of separators with a reduction factor of 0.8 is taken. To control the fineness of crushed types of raw materials and finished products, the A1-DSM screening machine and its modernized version, the A1-DMK, A1-DMP screening machines are used. The performance of these machines depends on the requirements for the size of the finished product.

To separate metal-magnetic impurities from raw materials and finished products, an A1-DES electromagnetic separator is installed with a capacity of 20 t / h on grain, -9 ... 12 t / h on loose feed, magnetic columns BKMZ-7, BKM4-5, BKMA2-500A, BKMA2-300A, BKMA2-15A, BKMASH-3. Magnetic columns are selected based on the required front length magnetic field.

For peeling the grain of filmy crops, machines L1-ZSHN-3 are used, scouring machines with an emery cylinder. For grinding grain raw materials, hammer mills of the reversible type A1-DMR-6, A1-DMR-12, A1-DMR-20, A1-DDR, A1-DDP, DM, DM-440-U are used. For coarse grinding of a lumpy product, mineral raw materials, hammer crushers SMD-Sh are used.

Almost all cereals and leguminous crops are introduced into compound feed in crushed form. They also crush granulated, lumpy and coarse-grained feed raw materials. The variety of raw materials with different grinding-ability when bringing its particles to the required size makes it difficult to calculate the productivity of hammer mills. In addition, their performance is affected by humidity, initial and final particle size of the product. The passport performance of grain crushers is given for the processing of barley with a moisture content of 13%. Sometimes the performance of the crusher is given for the main types of grain raw materials and depending on the size of the sieve openings.

In order to obtain a product of a standard size in the line of grain raw materials, many plants have screening machines after crushers. In this case, a stamped sieve with holes of 05 ... 6 mm is installed in the working chamber of hammer crushers, and sieves with holes of a certain size are selected in the screening machine.

For dosing, automatic multicomponent dispensers 6DK-100, 5DK-200, 16DK-1000, YuDK-2500, dual-range AD-500-Zh, AD-2000-2K, horizontal AD-3000-GK are installed. The productivity of batchers, depending on their carrying capacity and the duration of the weighing cycle, can be from 1 to 36 t/h. Components from the hoppers are fed by two-speed: screw or rotary feeders. Moreover, depending on the performance, various screw feeders are used. Feeders of short length and for components with a small percentage in the mixture, it is advisable to install not horizontally, but with an upward slope of 8.. 10 degrees towards the outlet. For compound feed production, horizontal batch mixers with a capacity of 1 ... 36 t / h are used: A9-DSG-0.1; A9-DSG-0.2; A9-DSG-0.5; A9-DSG-1.5; A9-DSG-2D); A9-DSG-3 SGK-2.5M; SGK-1.

To enter liquid components, B6-DAB units are used for molasses of compound feed with a capacity of 30 t/h, installations for introducing B6-DSZh fat into loose compound feed with a capacity of 10 t/h. The composition of the units for introducing molasses includes a molasses heater, a molasses mixer, a pump, filters and the necessary fittings. The B6-DSZH installation includes a mixer, supply and storage tanks, a pumping unit with filters, a grease trap, a fat melter, an electric hoist with a gripper and the necessary fittings.

For loose mixed fodder, DG, B6-DGV, B6-DGE installations are used. The kit includes a cooler, grinder, separator, fan, control panel with electrical equipment, pipelines with fittings for steam and liquid components. The performance mainly depends on the diameter of the holes (filters) in the matrix. Usually, the calculated performance is taken when installing a matrix with holes of 0-4.7 mm. For unpacking fabric and paper bags, dust collectors A1-BPU are used. The dust collector ensures the normal sanitary condition of the room as a result of creating a vacuum above the receiving grate.

For packing finished loose products, a weight semi-automatic dispenser DVK-50P is used, complete with a ZZE-M bag sewing machine, which is currently being replaced by K4-BUA.

5. 2 Selection and calculation of technological equipment

To calculate the productivity of the equipment of technological lines, it is necessary to know the capacity of the plant, the maximum amount of raw materials sent to this production line as a percentage of the daily productivity of the plant (Table 3), the utilization rate of the equipment and its operation time.

The performance of technological lines for the preparation of raw materials is determined by the formula:

where gi is the productivity of the i-th production line, t/h;

Q - plant productivity, t/h;

ai - the maximum amount of raw materials,%;

i - operating time of the i-line, h.

Knowing the characteristics of the manufactured equipment (see Table 3), the number of machines performing this operation is determined.

Table 3 - The maximum amount of raw materials (as a percentage of daily productivity)

	name of raw materials	For production compound feed
	Grain and leguminous raw materials
	Mealy raw materials
	Feed waste from food production, grass meal

	Mineral raw materials
	Premixes

Note:

The capacity of lines of filmy crops for grinding oats and barley should be taken according to the design assignment.

When producing compound feed for poultry over 50%, the amount of mineral raw materials should be taken equal to 7%.

Grain preparation line

Powdery raw material preparation line

Meal preparation line

Feed Waste Preparation Line

Mineral preparation line

Premix line

The required number of equipment for cleaning, grinding, peeling and is found by the formula:

where Km - equipment utilization factor (for crushers 0.7, for other equipment 1);

Qm - passport productivity of the selected equipment on this line, t / h.

Line of grain raw materials

Separator calculation

We accept 1 air-sieve separator brand A-BIS-12

Selection of an electromagnetic separator.

We accept 1 separator brand A1-DES

Crusher calculation

We accept 1 crusher A1-DMR-12 and 1 more reserve

Calculation of the peeling and grinding machine

We accept 1 car brand A1-ZSHN-3

Meal line

Screening machine calculation

Crusher calculation

We accept 1 crusher brand RI-BDK-M

Feed food line

Screening machine calculation

Crusher calculation

We accept 2 crushers PI-BDK-M

Line of mineral raw materials

Screening machine calculation

Crusher calculation

We accept 1 crusher brand A1-DDL

Grain peeling line

Calculation for a screening machine

We accept 1 screening machine brand A1-BTsP-10.

Calculation of the weigher:

Taking into account the productivity of the plant for dosing components, it is necessary to install 2 batchers - 1 for components introduced into compound feed in an amount of more than 30% and for salt, chalk, premixes the second batcher.

We accept a weight batcher brand 10DK-2500 Q= 12 t/h

We accept a weight batcher brand 5DK-200 with a capacity of 2.4 t / h

Mixer calculation:

We accept a batch mixer brand SKG-1M with a capacity of 12 t/h

5.3 Calculation of the coefficient of equipment used

You can check the actual use of equipment b i (%) by the productivity of the received machine using the formula:

For the line of grain raw materials

Air-sieve separator brand A1-BIS 12

Electromagnetic separator brand A1-DES

Peeling grinder brand A1-ZSHN 3

Crusher brand A1-DMR 12

For a meal line

Screening machine brand A1-BTsP-10

Crusher brand PI-BDK M

For Mineral Line

Crusher brand A1-DDL

5.4 Calculation of the dosing and mixing line

The dosing-mixing line completes the process of production of loose mixed fodder, here the finished product is formed in accordance with the given recipe. The capacity of the hoppers above the dispensers is taken from 4 to 8 hours of plant productivity.

The capacity and number of dosing hoppers for individual components depend on the content of components in each recipe in (%), its volumetric weight, the utilization factor of the hopper capacity and the time (h) during which the dosing line is provided. When using preliminary dosing and mixing of feed components, the time (t) is taken equal to 4 hours; without the use of preliminary dosing, the capacity of the dosing hoppers is calculated for 8 hours of plant productivity.

The one-story arrangement of bunkers is accepted for feed mills with a capacity of up to 300 t / s, and above - two-story. This allows them to reduce their production area and ensures the minimum length of the feeders that supply components to the multi-component scales. The required number of dosing hoppers II is determined by the formula:

where Q is the performance of the feed mill,

T - capacity reserve in hours; v. 4 Y - the amount of raw materials to be stored,%;

a - the size of the side of the square-section bunker, m 0.5x1.5);

H is the height of the bunker in m, (4.8 m);

j - volumetric weight of this type of raw material in t/m2;

K n - coefficient of use of the volume of silos, is taken equal to 0.9.

Dosing and mixing line for grain 30%;

We accept 12 grain bins.

Powdery raw material line 40%;

We accept 6 bunkers for flour raw materials.

Meal line 20%;

We accept 4 bunkers for meal.

Line of mineral raw materials 5%;

We accept 1 bunker for mineral raw materials.

Premix line 1%;

We accept 1 bunker for premixes.

Calculation of the total number of dosing bins

We accept 24 bunkers

5.5 Calculation of the capacity of the over-dosers of bunkers

Total number of dosing bins

When determining the number and brand of weight batchers, the number of bins under which the batchers are installed and the total productivity of the batching line are taken into account.

The performance of the dosing-mixing line is calculated by the capacity of the mixer E (t), which is determined by the formula:

where Q - plant capacity, t / day;

fi; - operating time of the dosing line - mixing, h;

Km - equipment utilization factor, Km = 0.9;

n is the number of cycles per hour, n = 10.

Dosing line productivity.

When installing two or three dispensers, it must be taken into account that the sum of the largest weighing limit must be greater than the capacity of the mixer. This is due to the fact that certain components are dosed in each dispenser and their total amount in different compound feeds is different. Usually dispensers do not fill up to the maximum weighing limit.

When designing a dosing line - mixing, the time of one dosing cycle is 6 minutes. It consists of the time of filling the mixer, mixing and unloading the mixer.

Within 1 hour, a mixer of any capacity mixes ten metered portions (performs ten cycles). Thus, the performance of the mixer is equal to its capacity multiplied by the number of cycles:

mixer performance.

We choose 2 multicomponent weight batchers of brands 10DK-2500 Q=12t.h. and 5DK-200 Q=2.4t.h. and 1 more mixer brand SGK-1M Q=12t.h.

For example, if the capacity of the mixer is 1.2 t (SGK-1M), then with ten cycles its productivity is 12 t/h.

In practice, the total time for filling mixers and unloading (emptying) does not exceed 1 min. Therefore, the total mixer cycle is 5 minutes. This time corresponds to the passport data for the operation of multi-component dispensers, i.e. the total filling and emptying time.

Multi-component weight batchers are selected based on the following conditions: the amount of any component must not be less than the minimum allowable weighed portion of the batcher. However, the mass of the sum of the components sent to the dispenser should not exceed its weighing limit; components with a low percentage in compound feed should be sent to dispensers with a lower weighing limit, since they have a small dosing error.

6. Selection of magnetic speakers

To clean grain from metal-magnetic impurities, magnetic columns or electromagnetic separators are used. Metal. impurities are dangerous not only for animals, but also adversely affect the service life of equipment - sieves, crushers, screening machines. If metal enters the equipment, it may spark and ignite the product or dust and cause an explosion. Magnetic columns are selected according to the length of the magnetic field (see Table 4).

Table 4 - Norms of magnetic barriers installed at enterprises for the production of animal feed, BVD, premixes and carbamide concentrate

Technological	Places for installation of magnetic barriers	Norms of the length of the front of the magnetic field, m
		Line productivity, t/h

Grain raw materials	After cleaning before grinding
Film compartments	After cleaning before peeling
Mealy raw materials and herbal flour	After cleaning
Feed food production	After screening before peeling
Raw materials of mineral origin	Before grinding
Carbamide concentrate	Before grain grinding and extrusion
finished products	After mixing before granulation

For example, for a line of grain raw materials with a capacity of 8 t / h, the length of the magnetic line should be 300 m (see Table 4). This length is close to the length of the magnetic line of the magnetic column for grain BKMA-2-3, in which it is equal to 0.3 m.

7. Principles of placement of technological equipment in the production workshop

Before proceeding with the placement of equipment on the plans and floors, it is necessary to determine the basic principles of placement, to outline the installation sites for elevators and pneumatic risers. They should be placed near the walls, and if the building is two-span - in the middle of the building.

The placement of equipment for preparatory production lines should begin with those lines that, in terms of composition, have more pieces of equipment or equipment of large dimensions. Since most of the equipment is on the line for the preparation of grain raw materials, it is recommended to start the layout from this line. In addition, the possibility of using separators installed in the working tower of the elevator for grain cleaning should be considered. technological feed equipment

The creation of mixtures of grain and granulated raw materials in silo-type buildings leads to a significant reduction in transport equipment, a decrease in the required area for placing technological equipment and operational bunkers of a loose mixed fodder workshop. If the grain cleaning equipment is located in the production building, then at the same stage it is necessary to provide a place for the installation of aspiration equipment serving the separators.

Depending on the technological scheme, one bunker or a group of bunkers is installed above the crushers. Having outlined the location of them and the crushers on the floor plans, it is necessary to check from the sections whether there are the necessary angles of inclination of the gravity pipes above the crusher, since the explosion chambers above the crusher are large. If the product is moved from under the crushers by mechanical transport, then bunkers are installed under them, the main purpose of which is to ensure the aspiration of the crushers. To ensure that the air duct does not interfere with maintenance, the hopper located under the crushers should be larger in plan than the crusher body.

Similarly, other preparatory lines are drawn, placing the equipment according to the scheme one under the other.

The multi-storey building allows to place the equipment of each line without additional horizontal transport - conveyors, screws. Therefore, the correct layout can be assessed by the number of conveyors and screws. However, in some cases, such transport is needed, for example, when taking the product from groups of machines (from crushers) and feeding a group of machines (to presses), a bunker. The use of conveyors under the mixer hoppers makes it possible to eliminate the cyclical and uneven loading of bucket elevators.

When laying out feeders and multi-component weighers, it is necessary to draw options in sections, which makes it possible to determine the required floor height.

Granulation lines are equipped with presses, a cooler and a grinder, which must be strictly placed one below the other. In addition, coolers are connected by larger diameter air ducts to cyclone stacks and fans. It is expedient to place all this equipment - next to it on the same floor with the cooler or on the floor located below.

The equipment of feed mills with mixed transport is placed according to the feed production scheme. Simultaneously with the development of the scheme, the required equipment and the capacity of the bins are calculated. The floor plan of the feed mill is designed in such a way that the number of vertical lifts is minimal. Therefore, it is necessary to carefully arrange the cars on the floors, comparing various options to choose the most rational option.

The number of floors of the feed mill is determined by the height of the part of the building where the silos are located. At the same time, they consider that manufacturing facility according to architectural requirements, it must have the same height as the silos.

Single separators. screening machines are located on the same floor - to improve the maintenance of the equipment and create a good appearance.

Hammer crushers, turboblowers, roller mills are located on the first and second floors.

The equipment of the line for the preparation of liquid components is located on the first and second floors, multi-component dispensers are placed under the dosing hoppers with the installation of batch mixers on the lower floor.

In general, it is desirable to arrange the equipment of the main production lines vertically with a single rise of products.

Weighing equipment is installed on the upper floors. If necessary, part of the scales can be installed on the lower floors.

When placing equipment and bins, it is necessary to observe the required passages to the method by machines. Safety regulations establish minimum standards for passage between rows of machines and between machines. The general passage from the wall to the row of cars must be at least 1.25 m.

On floors where presses for granulation or briquetting are installed, free areas with an area of at least 1.5x1.5 m should be left for replacing matrices. The same areas should be provided for hammer crushers.

For multi-component scales and scale control panels, it is also necessary to leave an area of at least 1.2x1.5 m.38

The requirements relating to the natural light conditions of the main technological equipment relate to the provision of conditions for monitoring the operation of machines with control devices (automatic scale meters, flow meter dials, etc.). These appliances must be located in the immediate vicinity of windows.

Machines that do not require systematic monitoring can be placed on long distance from windows, as filters and cyclones with a height of more than 3.5 m, when located near windows, will reduce the illumination of the room.

Automatic balances should not be installed near suction filters, as vibrations that occur during the operation of the shaking mechanism increase the error of the balance. The same applies to high-pressure fans and turboblowers, which, if the rotors are not properly balanced, can cause ceiling vibrations.

Pneumatic separators, unloaders and elevator heads can be placed on the platforms of the upper floor. With a height of the upper floor of 6 m, the site is located at a level of no more than 3 m from the floor, which makes it possible to use this floor for the installation of pneumatic separators, unloaders, elevator heads and other equipment.

When designing feed mills, it is planned to install explosion-discharge pipelines on elevator heads (with the exception of bucket elevators for transporting mineral raw materials and urea), on the outlet cones of hammer crushers, air ducts after the fan along the way to direct air to air conditioners.

8. Design of intrashop communication

The intrashop mode of transport at grain processing enterprises is designed in accordance with the Technological Design Standards.

At feed mills, gravity, mechanical, pneumatic and aerosol transport are used for intrashop movement of raw materials and finished products.

To perform communication, the following design materials are required: a) a flow diagram; b) transverse and longitudinal sections of the building; c) regulatory and reference materials (plans of inlet and outlet openings of machines, standard allowable angles of inclination of gravity pipes for various products, equipment options, a nomogram for determining the angle of inclination of a gravity pipe, etc.); d) statement of the movement of products.

Under intrashop communication is understood the interconnection of technological equipment among themselves by means of transport mechanisms in accordance with the scheme of the technological process. The task of communication includes the most rational placement of equipment on floors and systems with a minimum number of horizontal and vertical transport mechanisms. In the process of communication, the option of the most appropriate placement of technological, transport equipment is determined to minimize the length of movement of raw materials, intermediate products and finished products in accordance with the process flow diagram. When developing communications, they specify the location of machines, receivers and cyclones of pneumatic transport unloaders, bucket elevators for mechanical transport, and also determine the number of transport mechanisms (product pipelines, screws, bucket elevators, etc.). Correct selection communication helps to reduce the cost of purchasing and installing transport mechanisms, reducing the power supply of the enterprise and the cost of finished products. Communication is drawn in transverse and longitudinal sections, and in the settlement and explanatory note a statement of the movement of products is given in the prescribed form.

At enterprises, it is necessary to provide automatic systems that ensure the shutdown of communications by high-speed valves U2-BZB, provided that the excess pressure of the explosion is released into the atmosphere.

The vertical principle of constructing a technological scheme makes it possible to widely use gravity transport for transferring products, intermediate products and finished products from one machine to another, to and from bunkers. This connection is called communication. The unhindered movement of products through gravity pipes depends on the fulfillment of a number of conditions for conducting communications.

For product communication, gravity pipes are installed, as well as transport equipment. The angle of inclination of gravity pipes must be greater than the angle of repose of the transported product (see Appendix 2). However, this does not mean that one should strive for vertical laying of gravity pipes. A significant increase in the angle of inclination leads to a high falling speed, at which the product hits the working parts of the machine (sieve, feeder) or the product located in it. This causes an increased release of dust particles.

The higher the product speed, the more air is captured (electrified) in the gravity pipes and more air is required to aspirate the equipment or hopper. An increase in product velocity occurs in gravity pipes passing through the floors, even if the angle of inclination does not exceed the standard value. To reduce the speed, the direction of gravity pipes is changed by installing bends (sectors) or tees, one section of which is closed. Their advantage lies in the fact that the dead end of the tee is filled with the product and the impact occurs on it, and not on the metal. In this case, the tees practically do not wear out, while the sectors need to be replaced often.

By changing the direction of the gravity pipes, the product speed is partially reduced. In this case, the speed loss can be determined by calculation or experimentally. The true speed loss will be slightly higher than the calculated loss, since it is impossible to take into account additional losses in the calculations, depending on the turbulence of the product when changing the direction of movement, the nature of the impact of the product particles against each other and at the point of change in the angle of the gravity pipe.

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The technological methods discussed above are combined into a general technological process for the production of animal feed. For the organization of continuous in-line production of compound feed, technological lines for the preparation of raw materials are created. Under the technological line understand the sequence of machines and apparatus designed to perform any operation. The number of preparatory lines depends on the performance of the feed mill, the range of products produced. The total number of technological lines can reach 16 ... 20, however, there are usually 7 ... .10 mandatory lines. Some of the lines can be used to prepare different products with similar properties. For example, lines for the preparation of farinaceous raw materials, meal, loose herbal flour can be combined. One line can be used to prepare salt and chalk, a grain line can be used for granular components, etc.

At the feed mill, the following lines can be distinguished: grain raw materials; farinaceous raw materials; separation of films from oats and barley; loose herbal flour; fodder products of food production; meal; pressed and lumpy raw materials; salt preparation; raw materials of mineral origin; input of liquid types of raw materials (molasses and fat); preparation and input of enrichment mixtures (premixes); processing of packaged raw materials; preliminary mixtures of difficult-to-flow components; pre-dosing - mixing grain, granular raw materials; heat treatment of grain raw materials; dosing - mixing; granulation.

The number of mandatory lines for the preparation of raw materials includes lines: grain raw materials, farinaceous raw materials, pressed and lumpy raw materials, fodder products for food production, raw materials of mineral origin. The plant, operating according to the simplest technology, should have five lines for the preparation of raw materials and a dosing-mixing line.

Line of grain raw materials . Designed for cleaning and grinding corn, wheat, barley, oats, etc. Therefore, the line includes grain cleaning and grinding machines. Air-sieve and magnetic separators are used to clean grain from impurities.

In the production of animal feed, large impurities, sand, and metal-magnetic impurities are subject to mandatory separation.

The grain is crushed to a fineness, which is due to the requirements of regulatory and technical documentation for the produced feed. The required degree of grinding of raw materials is obtained by selecting sieves in crushers.

At feed mills, various grain grinding schemes are used. At factories of high productivity, several grain lines can be allocated, which work in parallel, each line prepares the grain of a particular crop. In plants of small productivity, the processing of different crops is usually carried out sequentially.

Line of farinaceous raw materials . It serves to clean bran, flour from broken ropes, packaging materials, etc., as well as to separate metal-magnetic impurities. Large impurities are isolated in sieve separators.

Metal-magnetic impurities are isolated in electromagnetic separators or separators with static magnets.

Film separation line for oats and barley . In a number of compound feed recipes, in particular, young poultry, fur-bearing animals, piglets, shelled oats and barley are introduced.

Films from grain are separated in two ways: by grinding grain, followed by screening of films; peeling of grain in peeling machines. Before the separation of the films, oats and barley are cleaned of impurities and fine grain is separated by a passage of sieves with openings of 2.2x20 mm. A large fraction is sent to the film separation line, since such grain is better peeled, less non-shelled grains remain. By first way a large fraction of grain is subjected to a single grinding in hammer crushers or double consecutive grinding in roller mills.

When grinding the grain, the core and shells are crushed differently - the core to smaller sizes, and the shells remain mostly large. During the subsequent sifting of the grinding product, finer particles of the core are obtained by the passage of sieves, and the shells are obtained by gathering. The quality of shelled oats and barley is checked for fiber content.

Second way provides for the peeling of oat and barley grains in special peeling machines. Scouring machines are usually used for peeling oats. For better peeling, a double successive passage of grain through scouring machines is used with the separation of the husk after each system, as well as with the selection of the kernel after the first peeling. Instead of scouring machines, centrifugal peelers can be used.

Loose Grass Flour Line . Herbal flour usually comes in containers - fabric or paper bags. Therefore, the line of herbal loose flour is designed for unpacking, cleaning from impurities and feeding raw materials into dosing bins. Unpacking is carried out in dust collectors or bagging machines. Herbal flour is cleaned from random impurities in sieving machines. Metal-magnetic impurities are isolated in electromagnetic separators or magnetic columns. Due to the fact that grass flour belongs to highly dusty products, it is desirable to use suction pneumatic installations for its transportation.

Line of feed products for food production. Designed for processing various products of animal origin: meat and bone, meat, blood, fish meal, fodder yeast and other products. Such products are highly hygroscopic, cake, form lumps, which, when cleaned, can end up in waste. In addition, many products have an increased fat content, which impairs their flowability. Feed products most often come in containers - bags, containers. In screening machines, two sieves are installed, of which the upper one is designed to separate random impurities, the lower one separates large particles of clumped products. The passage of sieves is sent to over-dosing hoppers, the descent is crushed in hammer mills. After grinding, the descent is attached to the passage of the lower sieve. Metal-magnetic impurities are isolated in magnetic separators.

Meal line . Designed for cleaning from impurities and grinding meal. The line has approximately the same scheme as the line of feed products for food production. The upper sieve is used to separate large impurities, the lower sieve is used to separate fine and coarse meal. Coarse meal is crushed in hammer mills.

Technological schemes allow the processing of meal on the line of grain raw materials.

Line of pressed and lumpy raw materials. Many types of raw materials are supplied to feed mills in the form of granules, briquettes, pieces (corn on the cob). Products are crushed in two stages: first, in special machines - stone crushers, oil cakes, etc. Lumpy products are crushed to a fineness characterized by a particle size of 20 ... 30 mm, and only then to the required fineness - in a hammer crusher. The second stage: the grinding products are sieved in screening machines, returning the descent from the sieves for re-grinding in a hammer mill.

Salt preparation line . Salt is introduced into compound feed in a small amount, therefore, for its uniform distribution, fine grinding of raw materials is required. Since salt is very hygroscopic, and at a moisture content of more than 0.5% it becomes raw, poorly free-flowing, during crushing it smears the openings of crusher sieves, sticks to the walls and working bodies of machines, etc., the salt preparation line must include a dryer, crusher.

Salt is dried in drum or screw dryers. After drying and control in magnetic separators, the salt is crushed in hammer mills. The products of grinding are sieved on a sieve with a mesh size of 1 mm.

One of the ways to add salt to mixed fodder is to add its saturated solution in water.

Line of raw materials of mineral origin . It is intended for the preparation of chalk, limestone, shells, etc. Like the salt preparation line, it includes a dryer, since the processing of raw materials of mineral origin with a moisture content of more than 10% causes great difficulties.

If limestone containing large pieces enters the processing, they are first crushed in stone crushers to pieces no larger than
10 mm. Preliminarily ground limestone, chalk is ground in hammer mills to a fineness characterized by the passage of sieves with holes with a diameter of 2 mm or a wire mesh with holes with a size of 1.6x1.6 mm. The descent from the sieves is re-crushed in the same crushers.

Liquid Injection Line . A number of liquid components are introduced into the compound feed - molasses, fat, phosphatide concentrate, etc. Some components become liquid only at a temperature
50 ... 70 ° C. Therefore, the line of liquid components must have heating devices, and the lines - good thermal insulation. Liquid components are delivered to feed mills in railway and truck tanks (molasses), barrels, flasks (fats, phosphatide concentrate), etc. Sometimes solid fat is obtained in boxes or cardboard boxes. Both separate lines for molasses and fat, as well as a combined line for the periodic preparation and supply of these components, can be installed at the plants.

Line for introducing molasses into animal feed. Molasses is introduced into animal feed at different stages of their production. It can be introduced into the main mixer, into the mixer of the pellet press, when it is released to the consumer. When entering the main mixer or pellet press, the molasses is usually heated. When molasses is introduced during the feed dispensing process, molasses can also be in a cold state. In feed mills, molasses is stored in large tanks equipped with local heating devices in the form of hot water coils or electric heating. Typical settings B6-DAB or B6-DAK have storage tanks with heating, from where the molasses is pumped into the heater tank.

Molasses is dosed using dosing pumps. For weight dosing, measuring tanks can be used, in which molasses is weighed or measured. Molasses is pumped by plunger, centrifugal, gear and other pumps. Molasses has the lowest viscosity at a temperature of about 50 ° C, at more high temperature the process of caramelization of sugar begins, particles of the solid phase appear, which clog filters, pipelines, etc.

Fat entry line . Fats have a high energy value, their introduction into mixed feed for animals and especially poultry significantly increases the value of the finished product. Most often, animal fats are used, the melting point of which exceeds 30 ° C. In addition, phosphatide concentrates, vegetable fats, etc. are introduced. The fat injection line is equipped with a device for rendering from barrels, which is a vertical or inclined coil heated by steam.

If fat is introduced into loose feed directly in the main mixer, then its amount does not exceed 2%, since the input more fat sharply reduces the flowability of the feed, leads to its caking, as well as sticking of the mixer.

Line for the preparation of enrichment mixtures . To enrich animal feed with microadditives (vitamins, microelement salts, etc.), either ready-made premixes are used, which are produced at specialized enterprises, or enrichment mixtures are made locally. Since the enrichment mixture is introduced into the compound feed in an amount not exceeding 1% (0.1 ... 1%), fine grinding of the components and their thorough mixing are necessary.

Enrichment mixture (as well as premixes) consists of a filler and biologically active substances. Bran, ground grain, meal, etc. are used as a filler. The preparation of the filler includes its grinding and sieving.

In the first mixer, microelement salts (mainly sulfate and chloride) are mixed with the filler; in the second - vitamins added in small doses, potassium iodide, carbonic salts. Enzymes, amino acids, vitamin B 2 are feed preparations, and they are introduced in a relatively large amount. Therefore, they are immediately served for the final mixing. For better mixing, destruction of lumps of hygroscopic sulfate and chloride salts, as well as their additional grinding, the products are ground a second time and sieved on a sieve with holes of 1.2 mm. The final mixing of all components and filler is carried out in the last mixer.

Processing line for packaged raw materials . Many types of raw materials (milk powder, bone meal, fodder amino acids, fodder yeast, etc.) are delivered to feed mills in packaged form, most often in paper bags. These products, as a rule, do not require grinding, so the main operations on the line are raw material unloading, cleaning from large and metallic impurities.

Line of preliminary mixtures of difficult-to-flow components . At a number of enterprises, to improve the technological properties of difficult-to-flow types of protein and mineral raw materials, to increase the accuracy of its dosing, preliminary dosing is used - mixing these components. All components of animal and mineral origin, yeast, herbal flour, meals, premixes are prepared on lines similar to the line of farinaceous raw materials, packaged products, feed products for food production, etc. After preparation, dosing - mixing of the components, the resulting mixture is subsequently used as one component.

Pre-dosing line - mixing grain, granular raw materials. The principle of construction of this line is similar to that described above with the difference that preliminary dosing - mixing is carried out for components that require grinding. The preparation of components is carried out along lines designed for the preparation of grain, granular products, etc. After cleaning the components from impurities, they are dosed in the desired ratio in weight batchers.

The components are mixed and ground in one or two steps. The exit from the sieves is returned to the same or to a separate crusher for re-grinding. The resulting mixture is then used as a single component in the main dosing/mixing line.

Line of heat treatment of grain raw materials . As a result of heat treatment of grain, taste properties are improved, nutritional value is increased, and raw materials are disinfected. The grain processing line includes devices for steaming grain, its extrusion and expansion. After processing, the grain is crushed and sent to over-dosing bins.

Dosing and mixing line . The components are dosed in volumetric and weight batchers of continuous and intermittent action. Volumetric dosing is carried out continuously, and simultaneously in all dispensers. Each dispenser is assigned to a specific component and is adjusted to the desired performance. After dosing, all components are sent to a continuous mixer.

For weight dosing, single-component and multi-component batch dispensers are used.

All dispensers are filled with the product in parallel, the dosing cycle ends after the dose has been taken by the last dispenser. According to a given program, all dispensers are emptied simultaneously; the supply of the product also begins in them. Since the dispensers are intermittent, the mixers installed after them must also be batch mixers. The dosing cycle in such dispensers is about 1 minute, while the mixing cycle is 5...6 minutes.

The most common method is dosing with multi-component weighers. Such dispensers are more compact, accurate enough, it is relatively easy to switch to another recipe in them.

Granulation line . As a result of dosing - mixing, loose compound feeds are obtained, which are not always convenient for feeding poultry and fish. Compound feed is also produced in the form of granules, the size of which depends on the type, age of the animals, and the way they are fed.

The bulk of the granular feed is produced in a dry way. Domestic factories use DG-type granulation plants, including press granulators and a cooler-grinder. In the mixer of the granulator press, the compound feed is steamed with dry steam, which is supplied under pressure up to 0.5 MPa. Liquid binders can also be fed into the mixer.

The resulting granules are then cooled in a cooling column, since they are fragile and easily destroyed when hot. After cooling, the granules are sent either to a grinder or to a control screening on sieves to separate fine particles sent for re-granulation.

It is unprofitable to produce small granules for young birds, since when they are obtained, the productivity of the press decreases significantly and the specific power consumption increases. Therefore, it is advisable to obtain larger granules and then grind them into grits, the size of which corresponds to the type and age of the bird. The grinding products are sieved on sieves, the size of the holes of which depends on the required fineness of the granular feed.

Granulated fish feed must have high water resistance, i.e., retain its shape in water for a long time. The granules obtained by the wet method are more water resistant, but their production process is more labor-intensive compared to the dry method. Therefore, fish pellets are mainly produced in a dry way, but measures are taken to increase their water resistance. Water-repellent compositions are applied to the surface of the granules or special processing of the granules is carried out. Increases the water resistance of granules and the use of high protein components, as well as granular raw materials. This can be achieved by treating the granules with steam, which creates a protective film on their surface.

The capacity of individual technological lines should ensure the continuous operation of the plant as a whole with a minimum of maintenance personnel.

feed mills

The feed industry is represented by factories, workshops with varying degrees of technical equipment. There are plants built according to standard designs with a capacity of 315, 320, 400, 420, 525, 630, 1000 tons / day. There are also feed mills of the old (pre-war) construction, which exceed their design capacity by 2...6 times, and plants built according to the so-called local projects with a capacity of 150...200 t/day. The latter have a simplified technology.

For large livestock complexes and poultry farms, specialized plants produce compound feed in a certain range. Such plants have lines for separating films from oats and barley, roasting, heat treatment of components, and granulation. Large feed mills have specialized workshops for the production of premixes, carbamide concentrate, BVD.

Modern feed mills use automatic means and automated process control systems. Dispatch automated control (DAU) of individual major operations or the entire technological process is carried out remotely from the control panel. Process control and management tools include the ability to control the consumption of raw materials and finished products, filling and emptying bins, product temperature, steam pressure, etc. Most high level automated systems– direct control of the process by computers and microprocessors. Large (with a capacity of over 1000 tons/day) feed mills have already been put into operation, which are controlled by computers.

In addition to industrial enterprises, a significant number of inter-farm feed mills operate in our country, as well as factories and workshops belonging to various associations and enterprises of other forms of management that use their own grain feed and ready-made industrial BIA and premixes.

On-farm enterprises produce complete feed mixtures for ruminants on a large scale. In the composition of such mixtures, 50 ... 70% of crushed roughage is introduced (straw, corn cobs, sunflower baskets and other crop waste). Such feed mixtures are produced in the form of granules, briquettes and are used as an addition to the main feed or as a complete feed, mainly for fattening cattle. Often, carbamide concentrate or carbamide is introduced into feed mixtures.