GB2225921A - Method and apparatus for making a feedstuff - Google Patents

Abstract

In a method and apparatus for making animal feedstuff comprising germinated grain, a water source material, such as a cross-linked acrylamide polymer, may be pretreated with relatively warm water mixed with dry seed or other plant material then rotated in a drum while the seed or plant material obtains its water supply for germination or growth from the solid water source material, the mixture then being deposited in a stack or pile in which germination/growth proceeds. The drum 12 comprises means for effecting movement of the feed or other plant material within the rotating drum, this means comprising for example member 56 having a roof-shaped structure with flat sloping side faces 74, 76 and also flat plates 58 generally in the form of chords with respect to the drum. The drum may be polygonal with member 56 mounted on one of the flat peripheral faces (Fig. 6 not shown). <IMAGE>

Description

METHOD AND APPARATUS FOR MAKING FEEDSTUFFS This invention relates to a method and apparatus for making feed stuffs. Particularly, but not exclusively, the invention relates to the production of animal feed stuffs based on germinated grain. The invention may also be applicable to the germination of other seeds and the treatment and growth of other plant or crop material.

In our prior published application GB 2 176 386A we have disclosed a method and apparatus for making animal feedstuffs in which grain is mixed with a water absorbent polymeric material. Preferably, the grain and polymer are soaked in water before mixing. The grain and polymer mixture is formed into a layer on a conveyor having perforations to admit air to the layer of plant material.

Germination conditions are maintained on the conveyor. The conveyor is driven continously or stepwise to provide a suitable residence time of eg four days for the plant material to form into a mat. The mat is discharged continuously or batchwise at an unloading station, cut up, and fed directly to animals such as cattle.

We incorporate herein, by reference, the entire disclosure of our prior application GB 2 176 386A.

While the invention disclosed in our prior application represents a considerable advance in the art, based upon the discovery that the polymeric water source material can be used as a growing medium which supplies the water requirements of the germinating seeds, nevertheless there is significant scope for improvements in the manner in which such treatment of plant material is effected.

Specifically, further simplification of the method and apparatus is desirable together with improvements in efficiency, and an object of the present invention is to provide improvements in one or more of these respects, or generally.

According to the invention there is provided a method and apparatus for making feed stuffs as defined in the accompanying claims.

In a preferred embodiment, the conveyor apparatus employed throughout in the method and apparatus of our prior application has been eliminated. The water for the process is initially heated and then used to treat the solid gel or crystal, constituting the water source material, before mixing with the seed. This ensures that the water when combined with the gel is relatively warm and the difficulty of warming the gel subsequently is avoided.

Also in a preferred embodiment, the quantities of materials employed are precisely controlled in a batchwise process. The initial treatment of the gel with the water may extend up to about eight hours. a non-emulsifying central stirrer or spoon operates to effect axial mixing within a mixer drum as the latter rotates, simultaneously with the circumferential or radial mixing.

In the preferred embodiment, the use of warm water in the gel, for example in the range 35 degrees centigrade to 50 degrees centigrade and preferably 40 degrees centigrade to 45 degrees centigrade has the result that germination is triggered far more rapidly than is normal. Moreover, by mixing the relatively dry seed with the pre-expanded and warm gel, the seed then takes from the gel only the water which it requires for germination and/or growth. Once such germination and/or growth has started, we have discovered that the subsequent continuation of it is relatively independent of the ambient conditions and will proceed even if the material is simply dumped in a heap.

Also in the preferred embodiment, the mixture of expanded solid water source material or polymer and germinating seed stays in the mixer means or drum for up to about two days. The mixer drum may be provided with perforations. During the latter stages of the process, rotation of the drum may cease for significant periods.

The arrangement may be such that the drum stops with the perforated region or regions below the mixture in a lower portion of the drum. The mixture may then be discharged from the drum onto conveyor means for a relatively short time, or may be simply stacked. We have ascertained that after treatment in the mixer means or drum, germination proceeds without the need for provision of carefully controlled supplies of air and precisely controlled temperature conditions. Once germination has started, surprisingly, we have found that it is very readily maintained and continued. We have further ascertained that during this process of continued germination and growth there is an expansion in volume of the mixture. In some cases, the volume may approximately double. There is accordingly a need to provide sufficient room for such expansion to occur.Accordingly, according to a further preferred feature of the invention, the mixture is discharged from the mixing apparatus to form a mass or stack having room around it for expansion. Temperature monitoring means is provided to ensure that, although exact temperature maintenance is not critical, the core of the mass or stack is not permitted to rise to damaging temperature levels.

Also in a preferred embodiment of the invention, there is provided within the mixing means or drum, the drum being rotatable, a material mixing or exchange member. This is mounted on an internal surface of the drum for rotation therewith. In the embodiment, the mixing member is of generally rectangular configuration. It is arranged so that, during a certain portion of the rotation of the drum, it engages and lifts a significant proportion of the content of the drum (for example 30 per cent to 50 per cent by volume) and lifts this material and holds same for an appreciable time interval during rotation of the drum.

During this interval, guide members in the form of side plates or panels likewise mounted within the drum for rotation therewith, engage at least some of the remainder of the material therein and guide it axially inwards into the region from which the mixing member has removed the material. In this way, a lateral or axial mixing action is achieved which would otherwise not occur. For example, the mixing member or spoon may remove material from a central region of the drum and the side panel members may guide material towards the centre from the lateral sides of t-he drum. It is believed that these features of the construction of the mixing means are a major contributor to the improved technical effect of the mixing drum as part of the overall germination and/or plant growth process.

In the preferred embodiment, the gel or polymer, after expansion by treatment with water at a suitable temperature, is mixed with the dry grain in the abovedescribed mixing drum or means without causing problems of homogenisation of the mixture, and in this way a much more rapid onset of germination is achieved. A contributory factor in relation to the performance of the drum is the fact that the spoon structure is not flat but tapers at both ends whereby the mixed material runs off as the drum rotates. While the presence of the spoon in the drum may reduce the volume capacity of the latter for the mixture by, perhaps, up to 15 per cent, the performance improvement achieved thereby very substantially offsets this effect.

Moreover, the presence of the spoon is significantly different from any prior proposals which may be found relating to the use of paddles for mixing materials. In the present environment, the use of a paddle would undoubtedly produce a 'pudding' of material, thereby damaging the crop and probably preventing germination as a result of the homogenisation which would be produced.

In the embodiment, the rate of rotation of the mixer drum is relatively slow. For example one rotation of the drum may take up to 6, 8 or even 10 minutes and preferably about 3 to 4 minutes.

An embodiment of the invention will now be described by way of example with reference to the accompanying drawings in which: Fig 1 shows a front elevation view of a mixer drum and its drive; Fig 2 shows, likewise somewhat diagrammatically, an elevation view, partly sectioned, showing the apparatus for weighing grain prior to transfer to the mixer drum of Fig 1; Fig 3 shows, diagrammatically, a liquid feed control system for the mixer drum of Fig 1; Fig 4 shows, in an elevation view similar to that of Fig 1, but cut away to show the internal structure, the mixer drum of Fig 1; Figs 5 and 6 show sections through the drum of Fig 4 on the lines V-V and VI-VI in Fig 4 respectively; Fig 7 shows an end view of a mixing member or spoon mounted in the drum of Figs 1, 4, 5 and 6, the direction of viewing being indicated by arrow VII in Fig 6; and Fig 8 shows a section through the mixing member of Fig 7, on the line VIII-VIII in Fig 7.

Referring to Figs 1 to 3, apparatus 10 for making animal feedstuffs comprises a mixer drum 12, a liquid reservoir 14 and a weigh hopper 16. Broadly speaking, liquid from reservoir 14 is caused to treat a solid water source material in drum 12. Thenl weighed grain from hopper 16 is mixed therewith, again in drum 12, germination commences, and after a mixing interval the germinating material is deposited to complete germination and growth.

Referring to Fig 3, water is held in reservoir 14 for preliminary treatment. Inlet and outlet valves 18, 20 respectively together with a water level detection system 22 determine the water volume in reservoir 14. The temperature is raised by a heat exchanger 24 under the control of a temperature sensor 26 acting via a solenoid valve 28. The temperature of the water is raised to the range 40 degrees centigrade to 50 degrees centigrade and transferred from reservoir 14 to mixer drum.l2 via a transfer pump 30 and a control valve 32 connected to a series of such drums by conduits 34, 36 etc. Reservoir 14 is automatically replenished after discharge.

Referring now to Fig 2, grain from a silo (not shown) is delivered to a receiving hopper 48 of an elevating auger 40 which delivers grain into the weigh hopper 16 whereby measured quantity of grain in tonnes is temporarily stored prior to being transferred to the mixer drum 12 of Fig 1.

A weigh balance lever 42 is preset to measure the required quantity of grain deposited in the hopper and auger 40 is stopped when the required quantity of grain has been delivered. A hopper condition monitor 44 determines that the hopper is empty before auger 40 can deliver grain.

Thus, further operation of the auger is inhibited until the weigh hopper has been fully discharged and the grain transferred to mixer drum 12 via a horizontal auger 46.

Referring now to Fig 1 and Figs 4, 5 and 6, the horizontally mounted process mixer drum 12 is mounted on bearings 48 and rotated by an electric motor 50 via a chain drive 52.

A measured quantity of the crystalline water source material (not shown) is manually deposited in drum 12 and the latter is automatically positioned with its filler port at top dead centre. On command, a measured quantity of water is transferred from reservoir 14 into drum 12 via conduit 34. After a prescribed soaking period for the crystals, the process grain is transferred from weigh hopper 16 via horizontal auger 46 to a transfer chute 54, and into drum 12. The filler port is closed and locked, and rotation of the drum commences.

During rotation, a central mixer member 46 effects transfer of material axially outwards, and two outer mixer members effect corresponding transfer of material axially inwards of the drum, thereby ensuring a homogeneous mix of expanded crystals and grain.

When mixing is complete, the mixer ventilation ports (not shown) are positioned about bottom dead centre for a prescribed degassing period. Under manual control, the mixer drum is rotated to permit access to the filler ports which then have their covers removed. The drum is then electrically rotated under manual control to deposit its contents for ongoing germination and/or growth, or use.

Turning now to the details of the drum structure shown in Figs 4, 5 and 6, it will be seen first that drum 12 is a regular dodecagon, but other polygons having more or less sides than 12 may be employed. At each angle of the polygon, an axially extending generally roof-shaped feed element 60 is provided, consisting of a pair of flat plates suitably inclined and mounted. The radial height of the feed element is approximately one sixth of the radius of the drum, but may be in the range of one half to one tenth thereof, and preferably one fifth to one seventh.

Rectangular openings 62 are provided in the end plates of the drum for mounting of the feed elements.

Generally radial stiffeners 64 are provided internally of drum 12 to enhance the strength thereof. These are in the form of tie rods or other tension members which do not significantly interfere with axial movment of material within the drum.

To effect axial movement of material within the drum, the central mixer member 56 is mounted on one of the flat faces 66 of the drum by means of an angled end plate 68, and generally radial supports 70 (shown in Fig 4 only).

Mixer member 56 has a corresponding inner end plate 72 seen in Figs 7 and 8.

Mixer member 56 has the profile seen in Fig 7, namely that of a rather flattened roof-shaped structure having flat sloping side faces 74, 76 which serve to assist free flow of material axially outwards (direction O in Fig 7) towards the side faces of the drum, an apex 73 and a bottom plate 75.

Thus, as drum 12 rotates, mixer member 56 enters the crop material therein. Fig 6 shows at 78 the approximate position of the surface of the material in the drum as the latter rotates in direction R. It will be understood that as mixer member 56 emerges from the material in the drum, it will carry on it a significant amount of that material which will progressively slide off the faces 74, 76 in-an axially outward direction.

To effect a corresponding axially inward movement of the material within the drum, there are provided two inclined outer mixer members 58 (see Figs 4 and 5).

As shown in Figs 4 and 5, the outer mixer members 58 are in the form of generally flat plates inclined at an angle 78 of about 45 degrees with respect to a pure radius as seen in Fig 4. The plates are generally in the form of chords with respect to the drum, suitably shaped at their outer periphery to fit the flat faces thereof and extending from, at one end, the drum side faces 80, 82, to a location 84 somewhat inward of the centre point 86 between the side faces 80, 82. Thus the outer mixer members exert a generally axially inwardly directed effect on the material in the drum as the latter rotates in direction R, thereby complementing the effect of mixer member 56.

Interestingly, in the above embodiment, we have provided a simple means for preparing animal feed stuff.

The rotary mixing drum with its axial mixing action promotes effective germination while pretreatment of the water source material with warm water promotes rapid initial germination, after mixing in the drum, with the dry grain material. After germination has started, it continues readily without scrupulous monitoring and control of ambient conditions.

Claims (25)

1 A method of making a feedstuff comprising: a) charging a rotatable container with seeds or other plant material; b) providing a source of water and air for growth and/or germination of said seeds or other plant material; and c) rotating said container to effect movement of said plant material therein; characterised by the step of d) causing movement of said plant material axially with respect to rotation of said container as well as circumferentially or radially thereof.

2 A method according to claim 1 characterised by the step of removing said plant material from a central region of said container and causing it to move axially outwards.

3 A method according to claim 1 or claim 2 characterised by the step of removing said plant material from an axially outer region of said container and causing it to move axially inwards.

4 A method according to claim 3 characterised by the step of causing plant material in said container to move both axially inwards and axially outwards as rotation proceeds.

5 A method according to any one of the preceding claims characterised by the step of causing said movement of said plant material axially outwards by means of a lifting member mounted within said container for rotation therewith to remove said plant material from a central region thereof.

6 A method according to any one of the preceding claims characterised by said movement of said plant material in said container from an axially outer region thereof inwards towards a central region thereof being effected by an inclined guide member to guide material axially inwards of the container.

7 A method according to any of the preceding claims characterised by the step of rotating said container at a rate of between one revolution per ten minutes and one revolution per minute.

8 A method of making a feed stuff substantially as described herein with reference to the accompanying drawings.

9 Apparatus for making a feedstuff comprising: a) a rotatable container to be charged with seeds or other plant material; b) means for supplying a source of water and air for growth and/or germination of said plant material; c) Means for rotating said container to effect movement of plant material therein; characterised by d) means for effecting movement of plant material axially with respect to rotation of said container as well as circumferentially and/or radially thereof.

10 Apparatus according to claim 9 characterised in that said means for causing said movement of said plant material comprises means for removing said plant material from a central region of said container and causing it to move axially outwards thereof.

11 Apparatus according to claim 9 or claim 10 characterised in that said means for causing said movement of said plant material comprises means for removing said plant material from an axially outer region of said container and causing it to move axially inwards thereof.

12 Apparatus according to claim 11 characterised by means for effecting movement of said plant material both axially inwards and axially outwards with respect to said container.

13 Apparatus according to any one of claims 9 to 12 characterised in that said means for causing said movement of said plant material axially with respect to said container comprises a lifting member mounted within the container for rotation therewith to remove a part of said plant material from a central region thereof and to cause it to move axially outwards.

14 Apparatus according to claim 13 characterised in that said means for causing axial movement of said plant material comprises an inclined guide member to guide said plant material axially inwards of the container.

15 Apparatus according to any one of claims 9 to 14 characterised by means for rotating said container at a rate of between one revolution per ten minutes and one revolution per minute.

16 Apparatus for making a feed stuff substantially as described herein with reference to the accompanying drawings.

17 A method of making a feedstuff comprising: a) mixing seed material with a solid water source material; b) providing said mixture with conditions such as to allow germination of said seeds to commence; and c) subsequently providing conditions to allow said germination and/or growth of said seeds to continue for a period; characterised in that d) said subsequent step of providing conditions to allow said germination and/or growth is provided by merely forming a stationary stack or pile of the plant material on a support, and allowing said germination and/or growth to continue under ambient conditions.

18 A method according to claim 17 characterised in that said subsequent step is performed without provision of a special internal air supply for said stack or pile of plant material.

19 A method according to claim 17 or claim 18 characterised in that said method is carried out batchwise with said steps of mixing said seed material with a solid water source material, and of providing said mixture with conditions such as to allow germination of the seeds to commence being effected in a rotary mixer, and said subsequent step being effected by discharging the material from the mixer in a suitable location where germination and/or growth can continue.

20 A method according to claim 17 substantially as described herein with reference to the accompanying drawings.

21 A method of making a feedstuff comprising: a) mixing seed or other plant material with a solid water source material; b) providing a supply of water for said water source material and effecting treatment of the latter with the former for absorption of the former by the latter; and c) providing said mixture with conditions to allow germination to commence; characterised in that d) said treatment with said water is effected by treating the water source material with the water prior to mixing the water source material with said plant material, whereby said plant material obtains substantially all its water requirements for growth indirectly from said water supply via said water source material.

22 A method according to claim 21 characterised in that said plant material is substantially dry when mixed with said water source material.

23 A method according to claim 21 or claim 22 characterised by said step of providing a supply of water for said water source material being effected with a preheated supply of water at a temperature of between 25 degrees centigrade and 50 degrees centigrade.

24 A method according to any one of claims 21 to 23 characterised by being carried out batchwise, said step of mixing said seed or other plant material with a solid water source material being effected in a rotary mixer, said plant material being added to said water source material in said rotary mixer after treatment therein of said water source material with said water supply.

25 A method according to claim 21 substantially as described herein with reference to the accompanying drawings.