Industry Innovations in Feed Mill Design 2018 - Hennie...Industry Innovations in Feed Mill Design ... Vitamin Mineral Dosing Plant. Conceptual Aquatic Feed Plant Site Layout. On-Farm

Hennie PieterseOttevanger Milling Engineers

Australian Milling Conference 2018Gold Coast Convention & Exhibition CentreBroadbeachAustralia

Industry Innovations in Feed Mill Design

Industry Innovations in Feed Mill DesignWhy is Innovative Design necessary?

Flexibility to adjust to Market Trends & Changes producing a range of Final Products that have market demand

Flexibility to cope with a wide range of Raw Materials in a cost effective way

Flexibility to expand in a logical way with minimum impact on Operations

Innovative Feed Plant design should lead to lowest cost producing high quality Fish, Meat, Milk & Eggs

Industry Innovations in Feed Mill DesignCharacteristics of good or Innovative “Design” :

• Functionality - most important design goal. Failure to properly meet required functionality and the rest means little

• Engineering Integrity - meeting Engineering design criteria in terms of material Choice; Structural Strength; Workmanship; Durability, etc

• Cost - Capital & Operational Costs clear. The Hidden Costs of inferior design might be surprising

• Ergonomics - User-friendliness; Health & Safety and its effect on End-Product Quality

• Aesthetics - no reason why a good design should not look good

Hammermill with Automatic Screen Change (Courtesy Ottevanger Milling Engineers)

Industry Innovations in Feed Mill DesignInvesting in Innovative Engineering Design of Processing Plant has at least following effects:

Functionality- Designed to fulfil Specific Function- Meet & Exceed plant Customer’s Expectations

(Physical & Nutritional Final Product Characteristics)- Failure to meet above makes low cost design

expensiveDowntime

- Inferior Design & Equipment results in unnecessary Operational Constraints, Failure & Downtime

- This may disappoint Processing Plant Customers and has potential to drive them to Competitors

Cost- Initial Engineering Investment Cost small with big

effect when neglected- Other Costs continuous and affected by Design

1%15%

49%

35%

Costs over Feed Mill Lifetime

Planning & EngineeringEquipment & InstallationOperations & ManagementInterest

Courtesy American Council of Engineering Companies

Why Innovative Feed Mill Design?• Increase in Feed demand no surprise :

7.5 Billion people on earthNet Growth = 2 people per secondAlltech Report confirms 2,57% annual growth (2016 - 2017)Total volume 1.07 Billion tonTotal Value = US$ 430 Billion

• Challenge :To keep up with growthwith decreasing natural resourcesin an Innovative Feed & Food Manufacturing Regime

Table 1. Percentage and Growth of Global Feed Production by Species (Alltech)

Feed by Species % of Total Annual Growth [%]

Broiler Feed 28% 3%

Aquatic Feed 4% 1% as result of China down

Petfood * 3% 5% to 12%

Horse Feed 1% all regions up, EU 24%

Pig Feed 27% 5.5%

Dairy Feed 11% 3%

Beef 7% -1%

Layer Feed 13% 1%

Other 6%

* up to 12% growth in Metropolitan China (Petfood Industry)

• EQUIPMENT & PROCESS INNOVATIONSEquipment innovations

Hygienic Equipment DesignSquare SilosVacuum Coating & Liquid Layering

Process Innovations

• DESIGN PROCESS INNOVATIONS

• RAW MATERIAL FLEXIBILITY DESIGN INNOVATIONS

• SAFE FEED MANUFACTURING INNOVATIONS


Steam Preconditioner with Thermal Retention Time Barrel (Courtesy Ottevanger Milling Engineers)

9. Increases capacity of Pellet Press / Expander / Extruder

Hygienic Equipment Design

Horizontal spaces and surfaces in Equipment design could collect Fines & Dust

Feedstock staying behind inside equipment (Product Hang-up) could go off over time and cause contamination

Feedstock staying behind inside equipment (Product Hang-up) could lead to cross-contamination between different formulations

Equipment Innovations

Extruder and Preconditioner Chassis or Frame design that leaves no horizontal space for dust collection or product hang-up during cleaning or barrel change-over. (Courtesy Wenger manufacturing Inc.)

Square Silos in general

Maximised Storage Capacity compared to Round

Structurally and Functionally integrates with Plant

Flexibility & Traceability simplified

Could be custom designed meeting specific Requirements


Fig 1. Extruder and Preconditioner Chassis or Frame design that leaves no horizontal space for dust collection or product hang-up during cleaning or barrel change-over. (Courtesy Wenger manufacturing Inc.)

Square Silo Block (Courtesy TSC Silo)

Square Silos with Smooth Cell Walls

Constructed with Double Wall System

Optimal Product Outlet

No Weld Seems in Silo Walls

Hygienic Dust-Free Work Environment

Modular Construction means logical expansion

Bin Coatings as requiredStainless Steel as required


Square Silos with Profiled Cell Walls

Lightweight Single Wall System

Profile provides Structural Strength

Hygienic & Dust Free Silo Environment

Modular Construction

Bin Coatings as required

Stainless Steel as required

Equipment InnovationsProfiled Panels for specific

Products / Economy

Hopper Design meeting Raw Material Characteristics &

Behaviour

Purlins for attaching Cladding directly to Square Silo Block

Square Silos : Bin Hoppers

Different Bin Hopper Designs to meet specific Raw Material Flow Characteristics

Bin Hopper Outlet Design round or Square as required

Accommodates Loading Bellows when Bins are used as Final Product Bins

Seamless transition from Bin to subsequent Process

Equipment InnovationsSquare or round Hoppers to

match any Raw material Type

Smooth Double Walled Panels for specific

applications

Purlins accommodate Cladding directly to Silo Block

Square Silos : Bin Roof Top Design & Function

Bin Roof Top becomes Service Floor for easy Maintenance

A Closed & Safe Work Environment


Square Silos : Integration with Process & Superstructure


Vacuum Coating & Liquid Layering

Higher fat levels compared with Atmospheric Coaters

Liquid Layering of several Liquids & Micro Ingredients possible

Liquid with lowest palatability pulled to centre of Pellets

Liquid with highest palatability applied to surface of pellets

Several other liquids could be layered concentrically between centre and surface of pellets

above achieved by sequencing liquids (through Process Control) at varying negative pressures.


Typical examples of Vacuum Coater used in Petfood / Aquatic Feed processing (Courtesy

Ottevanger Milling Engineers / Forberg / Dinnissen)

Extruded / Pelleted Product

Product Voids @

Atmosphere

Application of Vacuum

Application of Coating

Vacuum Release

Surface / Attractant Coating

Optimised Coating

Several Concentric

Layers possible

Online Process ControlQuality & Feed Safety requires Critical Control Point (HACCP) Analysis and ControlHistorically we attempted to do this manually with challenges :

not TimelyHuman Error

Innovations in Process Control and Sensing Technology led to Online Process Control with little to no maintenance calibration requiredOnline Process Control consisting of Hardware & Software :

• Sensor sensing Operating Parameter• PLC to Process Control Software• Process Control Software to Device

rectifying Operational Condition Typical examples of Sensing Technology for specific Operational Parameter Sensing (Courtesy Source Technology / Tovalia / TEWS Elektronik)

Process Innovations

Containerised Plant Design

Modular approach based and standard 20ft Container Frames

Meets International Shipping Requirements

Process Flow Design like Conventional Plant Design

Suits any Process - in some cases Partially Containerised

Designed to meet Structural Process, Maintenance and OHSA requirements


Containerised Plant Design

Manufactured and Mechanically & Electrically installed at Point of Manufacture

Dry Testing at Point of Manufacture

Superstructure housing the Plant a Shell-type Structure only accommodating and protecting Plant & Equipment

Sidewalks, safety Railing and Stairs bolted to individual Container Modules on ground level = Installation and OHSA cost reduction in Australia


Equipment InnovationsContainerised Plant Design - Sizing

Small to Large Plant

For any Application in Feed Manufacturing

Full & Partial Containerised Plant Design

Certain Zones of plant could be Full Containerised [Size Reduction & Mixing / Micro Ingredient Batching / etc]

Other Zones could be Conventional for reasons of Function Size [Pellet Pressing / Extrusion / Drying & Cooling / etc]

Results in Partially Containerised Plant Design


Containerised Design Conventional Design

Partially Containerised Design

Equipment InnovationsContainerised Plant Design Timeline

• EQUIPMENT & PROCESS INNOVATIONS

• DESIGN PROCESS INNOVATIONSHistorical Design ApproachIntegrated Design Approach



Design Process Innovations

Design Process InnovationsHistorical Design Approach

2D Design Software

Costly and Time Consuming

Challenging to Interpret & Present

Majority of Design Flow was Manual (and open to Human Error) :

Process Flow DiagramsStructural Analysis and DesignPlan Views and ElevationsManufacturing & Fabrication Detail DrawingsBills of Materialetc

Design Process InnovationsIntegrated Design Approach

3D Design Software

An integral part of Project Development

More economical over Project Development lifetime

Easy to Present to Decision Makers, Investors; Other Designers part of the Project, etc

3D Design great for studying potential Equipment & Process Interference

3D Design Work Flow integrates all aspects of Project Development

Design Process InnovationsIntegrated Design Approach

Modelling & Presentation as Project is developedKeeps design costs low Accelerates Decision-makingDetailing as required and as Project develops“Plug-in” software integrates with 3D design software to incorporate :

BIM (Building Information Modelling)MEP (Mechanical, Electrical & Plumbing)HVAC (Heating, Ventilation & Air Conditioning)Heat Transfer ModellingTraffic Flow Patternsetc

Modular Steam Generation Plant

Conceptual Aquatic Feed Plant Site LayoutVitamin Mineral Dosing Plant

On-Farm Liquid Addition System

Images Courtesy hp dezign Pty Ltd

Design Process InnovationsIntegrated Design Approach Workflow

Process Flow Design

3D Modelling & Layout

Generate Plans / Section Cuts / Elevations / Perspectives

Iteration Process with Customer Input

Detail Drawings for Manufacturing and Fabrication Raw Model (Perspective) Rendered Views (Isometric)

Interference

Design Process Innovations

Plan Views(& Horizontal Sections)

Elevation 1(& Vertical Sections)







Conventional Raw IngredientsEngineered Raw IngredientsValue-Added or Enhanced Raw IngredientsFresh Meat or Fish as Raw Ingredients



Raw Material Flexibility Design InnovationsEngineered Raw Ingredients

“New” Ingredients could be developed from by-products and products with limited value :

By mixing in specific ratio By-Product with a locally available Product and then co-extrude Product Pasteurised after ExtrusionFinal Product could be in Pellet, Granule or Meal formFinal Product Nutritional Profile could be tailored for specific applicationsBy-Products could consist of:• Meat or Fish / proteins• Plant / Fruit / Vegetable Processing by-products• Animal Processing By-product• Spent Hens• etc

Fish By-Product co-extruded with Soybean Meal (Courtesy Food Protein R&D Centre Texas A&M University)

Fresh Fish Processing By-Product Ground & mixed with Soybean Meal

High Shear Extrusion Dried & Milled Fish By-Product Meal

Raw Material Flexibility Design InnovationsValue-added / Enhanced Raw Ingredients

Many Ingredients in un-processed state has limitations in terms of Nutrition / Functionality and Application :

• Some Pulses and Oilseeds contain Anti-Nutritional Factors we have to deal with effective and safe application as feed ingredient is possible.

• Raw Starch in Cereals could be gelatinised thereby making it effective in nutrition of young animals and animals sensitive to raw starch.

Effective Heat Treatment under correct processing conditions plays an important role in Raw Material Enhancement

Raw Oilseed Full Fat Oilseed Partially Defatted Oilseed

Gelatinised Starch Soluble Starch

Raw Material Flexibility Design InnovationsFresh Meat / Fish as Raw Ingredients

Humanisation of Pets & demands of Pet Owners led to major advances in utilising novelty ingredients / Fresh Meat / Fresh Fish as :

Emulsified Meat / Fish SlurryMeat / Fish Hydrolysate

Innovations in Thermal Processing led to Technologies

Emulsified Slurry

Hydrolysed Liquid





Plant Design & ZoningLimiting Cross-ContaminationImportance of Thermal Processing


Plant Design & Zoning

The Plant, whether of Horizontal or Vertical design, is zoned in order to isolate Operational Processing Activities thereby managing, controlling & limiting :

Cross-contamination

Noise

Odour

Dust

Safe Feed Manufacturing Innovations

Non Thermal Plasma Odour Control System with UV Sterilisation Unit (Courtesy Schenck)

Online Dust Control & Fire Suppression (Courtesy Ottevanger Milling Engineers)

Typical zoned Vertical Plant Layout (Courtesy hp dezign Pty Ltd)

Typical zoned Horizontal Plant Layout (Courtesy Wenger

Manufacturing Inc.)

Safe Feed Manufacturing InnovationsLimiting Cross-Contamination

How does Cross-Contamination occur?

Hang-up of Product in Transitional Equipment

Hang-up of Product in poorly designed Equipment

Spillage / Leakage in poorly designed & constructed Plant

Poor Process Flow Design

Poor or limited Operating Procedures followed by Workers

Cross Contamination between formulations minimised through proper Process Control and Sequencing

Poorly designed Equipment, poor Process Flow Design, poor construction and Fabrication all lead to cross-contamination and potentially Unsafe Feed

Safe Feed Manufacturing InnovationsLimiting Cross-Contamination Before Thermal Processing

Separate Intake, Preparation, Storage for Dry and Wet Ingredients (Fresh Meat & Fish)

Wet Product does not enter Process before Heat Treatment

Process design should limit unnecessary Transitional Equipment

Processing Equipment should be of “clean” design with minimum to no Product Hang-up

Transitional Equipment selection to consider physical Product Characteristics & potential Cross-contamination

Purge Options at Critical Control Points before Extrusion / Pellet Pressing

Picture please

Fresh / Wet Product Flow

Dry

Feed

stock

Flo

wFin

al Pr

oduc

t Flo

w

Thermal Processing

Limiting Cross-contamination between Dry and Wet Products in a Petfood Plant (Courtesy hp design Pty Ltd)

Safe Feed Manufacturing InnovationsLimiting Cross-Contamination During Thermal Processing

Thermal Processing Operation first point of Fresh Product meeting Dry feedstock thanks to innovations in Fresh Meat & Fish Handling & Preparation techniques

Thermal Processing with proven Start-up and Shut-down procedures helps controlling Water Activity challenges

A well designed Plant facilitates Wash-Down and Steam-Cleaning

Advanced Suppliers offer Start-up Waste Recovery Systems (Cost Recovery)

CIP & COP limit potential of Cross-Contamination

Fresh Product enters Plant without crossing paths with Dry Feedstock

Fresh Product meets Dry Feedstock first

time at Thermal Processing

Images Courtesy Wenger Manufacturing Inc.

Safe Feed Manufacturing InnovationsLimiting Cross-Contamination After Thermal Processing

Conveying down-stream from Extruder carefully selected to meet specific Product Requirements

Options may include Pneumatic Conveying, Belt Conveying, Pendulum Conveying

CIP (Clean-in-Place) Solutions available for Pendulum Conveying

Vacuum Coating could include a CIP Cycle

Purge Options at CCP’s between Extrusion and Final Product Bins / Packaging / Bagging

Purged Product could be re-used in Budget Formulations Negative Pressure Dilute Phase Pneumatic Conveying Pre-Drying to Drying-Cooling (Courtesy Wenger Manufacturing Inc.)

Safe Feed Manufacturing InnovationsConveying Options for Pet & Aquatic Feeds INTAKE

EXTRUSION

PRE-DRYER

DRYER-COOLER

STD DRY EXPANDED >50% FRESH MEAT PET SEMI-MOIST PET SHRIMP / MICRO

COATER

COOLER

PACKAGING

By-Pass Pre-Dryer Flat Belt Conveyor max 10 deg incline By-Pass Pre-Dryer By-Pass Pre-Dryer

Negative Dilute Phase PneumaticPendulum Conveyor

Cleated Incline Belt Conveyor

Negative Dilute Phase PneumaticCleated Incline Belt Conveyor Cleated Incline Belt Conveyor Negative Dilute Phase Pneumatic

Positive Dense Phase PneumaticPendulum Conveyor




Pendulum ConveyorCleated Incline Belt Conveyor

Pendulum ConveyorNegative Dilute Phase Pneumatic






Pendulum ConveyorCleated Incline Belt Conveyor By-Pass Coater





Pendulum ConveyorCleated Incline Belt Conveyor By-Pass Cooler

Drag ConveyingScrew Conveying

Positive Dilute Phase Pneumatic

in Cooperation with Wenger Manufacturing Inc.

Safe Feed Manufacturing InnovationsImportance of Thermal Processing (Technology Dependant)

Producing Safe FeedCooking of Feed IngredientsStarch GelatinisationControlling Density (Aquatic Feeds)Sterilising (By-Product) / Stabilising (Rice Bran) / Sanitising (Layer Feed)Minimising the effect of Anti-Nutritional FactorsMaximising Digestibility of Protein, Fat & FibreProduction of new Textures (TVP’s / TSP’s)Enhancing Solvent ExtractionEnhancing Mechanical Oil Expelling

Extrusion Capability varies from Technology to Technology and should be specified with care (Courtesy Wenger Manufacturing Inc., Extru-Tech Inc. & ALMEX)

Safe Feed Manufacturing Innovations

Thermal Processing Opportunity Preconditioner Thermal Compactor Thermal Sanitiser Expander Oil Press Extruder

Oilseeds X X X X

Raw Material Enhancement X X X X X

By-Product Processing X X X

General Animal Feeds X X X X X X

Solvent Extraction X

Aquatic Feeds X X X

Petfoods X X

Human Foods X X X

Thermal Processing Potential

Australia / New Zealand Contact Details

Hennie PieterseTel : +61 (0)410 950 746e-mail : [email protected] Box 4536Springfield LakesBrisbane, QLD 4300AUSTRALIA

Head Office Contact Details

Paul EijmbertsTel : +31 (0)79 760 05 06

e-mail : [email protected] 32

PO Box 32750 AA Moerkapelle

The NETHERLANDS

mailto:[email protected]

mailto:[email protected]

Industry Innovations in Feed Mill Design 2018 - Hennie...Industry Innovations in Feed Mill Design ... Vitamin Mineral Dosing Plant. Conceptual Aquatic Feed Plant Site Layout. On-Farm

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