RU2469624C1 - Granulated fodders production line - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: granulated fodders production line includes three process lines, installed in parallel: the first line (for components subject to extrusion), the second line (for components unsubject to extrusion), the third line (for extrusion of wastes with a grain filler) as well as a belt-type conveyor connected to the main mixer via the first line extrudate miller. Additionally, the main mixer has a loading bin for delivery into the paste preparation device with the prepared paste delivered into the main mixer on the recurrent circulation principle.

EFFECT: invention usage will enable combination of component subject and unsubject to extrusion during granulated fodders production.

2 dwg

Description

The invention relates to the processing of food raw materials and can be used in a production line for the production of animal feed by simultaneously granulating and extruding the feedstock.

In the conditions of modern agricultural production, the organization of the cultivation of livestock products, poultry farming, as well as the development of industrial fish farming is associated with the organization of feed production based on in-depth processing of feed components.

More advanced processing technologies for raw materials include extrusion and expansion. The expansion technology is based on a moisture-barothermic method of processing feed mixtures and is a very complex process. Therefore, the realization of the advantages of expansion technology is possible at large factories producing high-quality compound feeds.

A more efficient way of technological processing of grain in conditions of small production is extrusion (see, for example, RF patent No. 23228171, from 10.07.2008). In the process of extrusion, the raw material is subjected to the simultaneous effect of elevated temperature, pressure and moisture. The extrusion process is conventionally divided into technological stages:

- loading;

- compression;

- homogenization;

- actually extrusion.

As a result of this technological process, the cellular structure of the components is destroyed, and the product acquires a viscous flow state. Upon the transfer of raw materials from the high pressure zone to the atmospheric region, an “explosion”, “decompression shock” occurs, while the granules swell, acquire porosity, and buoyancy. During the extrusion process, the product undergoes significant structural changes that do not occur during conventional granulation. It was found that hydrobarothermic treatment of raw materials contributes to the rupture of cell membranes, the death of microflora, inactivation of toxins, and a change in the structure of starch. At the same time, the mechanical and physicochemical properties of the raw material change, the adhesion strength of the particles increases, the specific gravity decreases, and the feed acquires buoyancy. Thus, extrusion is the heat treatment of feeds, which contributes to the breakdown of complex nutrients contained in feeds, thereby reducing the energy costs of their digestibility in animals and fish. Heat treatment improves taste and sterilizes feed. The inclusion in the diet of animals, fish components without this treatment is ineffective.

There are two types of extrusion. There is a “dry” extrusion - this is when the extrusion takes place with the help of heat, which is generated during the passage of the extrudable product through several limiters in the extruder barrel. Wet extrusion is most effective. In the process of such processing, the extruder is equipped with a chamber for preliminary processing of raw materials with steam. If moisture is introduced into the pre-treatment chamber and into the extruder chamber, then it serves as a source of additional energy, which is then used during steaming. Moisture also promotes gelatinization of starch and changes in the properties of proteins. With wet extrusion, you can lay up to fifty percent of the wet material and mix it with the dry, thereby reducing costs.

Dry extruders and pellet mills operating at low humidity (16 to 20%) cannot process more wet waste. The extrusion process takes less than thirty seconds. During this time, the raw material manages to go through several stages of processing.

The closest line for the production of granular feed is the line for the production of extruded products (RF patent No. 2302337, July 10, 2007). This line includes a mixer, a device for preliminary hydrothermal processing of feedstock made in the form of a screw conveyor, an extruder, a degasser-steam sorber, a dryer and a sifter.

The disadvantage of this line is the inability to introduce components that are not subject to extrusion or components without extrusion.

The technical result provided by the proposed line for the production of granular feed is the ability to:

- reconfiguration of the production line operator feed lines in a few minutes to release feed for animals, birds or aquaculture;

- ensuring the uniformity of the feed mass of not less than 95% for any version of the manufacture of feed for animals, birds or aquaculture;

- introduce components that are not subject to extrusion (premixes, medicinal additives, chalk, etc.);

- introduce waste from animal husbandry, poultry farming using extrusion technology, as well as waste from processing aquaculture, weed fish without extrusion, but using semi-dry pressing, depending on the availability of waste;

- dosing when introducing components to obtain a balanced compound feed for protein, metabolic energy, fat;

- in the manufacture of compound feeds, fully ensure the fulfillment of the compiled formulation for balancing compound feeds for vitamins, phosphorus-calcium balance, amino acid balance.

The granular feed production line includes three parallel installed production lines and then sequentially installed: the main mixer, the screw conveyor, the main hopper-agitator, a semi-dry press granulator using steam from a steam generator, belt conveyors, a cooler and a finished product hopper, with the first line - the line of components to be extruded contains sequentially installed: the first crusher with pneumatic conveying, flapper valve in the pneumatic piping de, vertical screw mixer mounted on a mechanical balance, a second flap valve in this line, a screw conveyor, agitator hopper, extruder, belt conveyor, extrudate crusher, main mixer.

The line according to the notation in the diagram (1, 3, 4 (10), 47, 7, 9, 8, 13, 16)

The second line - the line of components not subject to extrusion, contains sequentially installed: a second crusher with pneumatic conveying, a vertical screw mixer mounted on a mechanical balance, the main mixer complete with an unloading screw, a pasta machine loading auger, a pasta machine with the prepared paste fed to the main mixer according to the principle multiple circulation loader of weed fish or fish waste. This scheme includes a freestanding small mixer for premixes. This line is intended both for producing fish-protein granular concentrate, which is subsequently used in the manufacture of compound feed, and for preparing a complete, complete feed with the input of all necessary components according to a given formulation using the first and third processing lines.

The line according to the notation on the diagram (2, 11, 43, 16, 48, 15, 14, 45)

The third line is designed for processing slaughterhouse waste, case, incubation waste using grain and grain mixtures as a filler. Contains: a mixer (32), into which a grain filler or grain mixture is fed from a first-line crusher through a flap valve, a vertical screw mixer mounted on a mechanical balance, and waste from the grinder through a screw conveyor, pasta machine, and a screw conveyor. From the general mixer the prepared mass arrives: screw conveyor, horizontal hopper-agitator, screw conveyor, waste extruder, belt conveyor, extrudate crusher, main mixer.

The line according to the symbols on the diagram

(1, 3, 5, 6, 38, 39, 40, 37, 32, 31, 36, 33, 35, 34, 12, 16)

This line includes scales (41), refrigerators (49), rooms II.

The feed mill scheme provides for the production of feed without an extrudate according to a simplified scheme with the introduction of the necessary additives (meat and bone meal, fish meal, etc.) using a flap valve (47) and a screw conveyor (46). Through the main mixer (16), the flap valve (44), the prepared mass, for any combination of the lines, is fed to the pellet mill (20) through the screw conveyor and the main agitator. Granular feed enters through a small conveyor belt, a belt conveyor, a cooler, a belt conveyor into the finished product bin, followed by loading into a container using a dispenser. From the cooler, the technological screening as a result of the operation of the fan (26), the cyclone of the cooler (25) and the vibration sieve of the cooler, screw conveyors (42/21) is sent to the hopper of the cultivator-accumulator for repeated pressing.

The line according to the symbols on the diagram

(44, 17, 18, 19, 20, 22, 23, 24, 27, 28, 29, 26, 25, 42, 21)

The combination of the production line of granulation and extrusion can significantly reduce capital costs for the purchase of equipment, operating costs, energy costs:

1. The savings on the purchase of equipment consists in the fact that there is no need to install a feed line for conveying components, transporting, mixing, dosing, cooling, packaging and warehousing. A feed granulation line is used.

2. The reduction in operating costs consists in the absence of the need to procure the extruded components in a warehouse with the exception of soybean extrudate, which is planned to be harvested on the proposed line in one working day for seven to ten working days of the full operation of the feed mill. If desired, it is possible to harvest the soybean extrudate in the second shift, as well as to prepare the protein concentrate, depending on what biological waste is available.

3. Energy costs are reduced by combining technological processes and reducing the number of equipment involved. In practice, the exception is one technological line, which was supposed to work in a warehouse. But a significant saving in energy costs lies in the fact that uncooled extruded components enter the granulation. This provides a significant reduction in steam consumption during feed granulation.

As for humidity, it should be controlled at all technological stages of preparation of compound feeds and is regulated empirically. It is very important.

Depending on the fed animals, a granulator can be removed from the technological process, or work in a mode of weak pressing.

Figure 1 shows the proposed scheme for the production line of granular feed from feed components, subject and not subject to extrusion.

Figure 2 shows a 3-dimensional view of the production line of granular feed.

Where the positions indicated:

1. The first crusher

2. Second crusher

3. First changeover valve

4. Screw mixer

5. Screw mixer

6. Mechanical balance

7. Screw conveyor

8. Extruder

9. Hopper agitator

10. Mechanical balance

11. Screw mixer

12. Crusher

13. Belt conveyor

14. Hopper loader

15. Pastor

16. The main mixer

17. Screw conveyor

18. Steam generator

19. The main hopper-agitator

20. Press granulator

21. Screw conveyor

22. Conveyor belt

23. Belt conveyor

24. Cooler

25. Cooler cyclone

26. Fan

27. Belt conveyor

28. Filler dispenser

29. Hopper of finished products

30. Injector pneumatic transport

31. Screw conveyor

32. Mixer

33. Screw conveyor

34. Belt conveyor

35. Extruder

36. Hopper agitator drive

37. Screw conveyor

38. Waste shredder

39. Screw conveyor

40. Pastor

41. Scales

42. Screw conveyor

43. Mechanical balance

44. Flap valve

45. Small mixer for premixes

46. Screw conveyor

47. Flapper valve

48. Screw conveyor

49. Cold stores

I. Feed room

II. Waste paste cooking room

III. Warehousing of feed components

The operation of the claimed line for the production of granular feed, shown in Figure 1, is as follows.

To compile the full composition of the feed mixture, three production lines are provided:

The first line, the line of components to be extruded.

The second line, the line of components not subject to extrusion.

The third line, the line used in the presence of slaughterhouse waste, case, incubation waste.

The first line - through the first crusher (1) by pneumatic transport through the first flap valve (3), the grain components are fed into a screw mixer (4) mounted on a mechanical balance (10). From the screw mixer (4), through the overflow valve (47), the grain mixture is fed to the screw conveyors (7) into the agitator hopper (9). From the agitator hopper, the grain mixture is fed to the extruder (8), the extruded grain mixture is fed by a belt conveyor (13) through the crusher (12) to the main mixer (16). At the same time:

In the second line, through the second crusher (2) by pneumatic transport, components that are not subject to extrusion are fed into a screw mixer (11) mounted on a mechanical balance (43). From the screw mixer (11), the mixture enters the main mixer (16).

Weed fish or fish processing waste is fed into the main mixer (16) with a hopper loader (14). The unloading auger of the main mixer (16) through a flap valve (44) by a screw conveyor (48) delivers the prepared mixture of weed fish or fish waste with a protein filler of sunflower meal or cake to the pasta cooker (15) with the prepared paste in the main mixer 16. In the mode Repeated recirculation of the mixture is brought to the required humidity by introducing a filler. As a result, through the first and second lines, two predetermined weights of the feed components from the screw mixers (4) (11) enter the main mixer (16). After the final mixing in the main mixer (16) by means of a screw conveyor (17) through a flap valve (44), a complete uncooled mixture enters the main hopper-agitator (19), followed by semi-dry pressing with a steam granulator (20) using steam from the steam generator (18). Then, the granulated feed is fed according to the known scheme using belt conveyors (22) (23) to a cooler (24). Using a conveyor belt (27), the cooled granules are fed into the finished product hopper (29), followed by packaging in bags using a filling dispenser (28). Technological screening from the cooler cyclone (25) and the cooler vibration sieve is returned to pressing by screw conveyors (42) (21).

The third line is used in the presence of slaughterhouse waste, mortality, incubation waste, etc. To process this raw material, a second special-purpose extruder (35) is installed. A grain filler is required to ensure extrusion. The third line includes: the first crusher of the first line (1) with pneumatic conveying, through the first flap valve (3) the filler is fed into a screw mixer (5) mounted on a mechanical balance (6). From the screw mixer (5), the mixture enters the mixer (32). From the waste grinder (38) with a screw conveyor (39) through a pasta machine (40), with a screw conveyor (37), the paste is fed into the mixer (32).

After the necessary mixing, the mixture is fed by means of a screw conveyor (31) to the agitator hopper (36), by a screw conveyor (33) to the extruder (35). The extruded mass without cooling by means of a conveyor belt (34) through a crusher (12) enters the main mixer (16). Thanks to the weight control in vertical screw mixers and floor scales (41), you can fully maintain the given compounding formula. To ensure short-term storage of waste for the preparation of meat and bone, fish additives refrigerators 49 are provided (room II).

The combination of the production line of granulation and extrusion can significantly reduce capital costs for the purchase of equipment, operating costs, energy costs. The proposed technology allows to obtain finished products without preliminary preparation of extrudable components. An exception is the need for extrusion of soybeans, since it cannot be extruded in a mixture. It is also possible to pre-harvest protein concentrate based on sunflower meal and fish waste, weed fish, slaughterhouse waste, case, incubation. It is planned to produce flattened wheat grain used at the end of the aquaculture age period, as well as in the absence of the ability to produce complete feed. The feed mill scheme allows using the three lines at the same time to use the maximum capacity of a semi-dry press to 3 t / h. The scheme also allows when shutting down for some reason the extrusion line to produce granular feed of high quality with a capacity of up to 2 t / h.

Claims (1)

The granular feed production line includes three parallel installed production lines and then sequentially installed: the main mixer, the screw conveyor, the main hopper-agitator, a semi-dry press granulator using steam from a steam generator, a belt conveyor, a cooler, a belt conveyor and a finished product bin with a batcher for packaging finished products in bags, the first line being the line of components to be extruded, it contains sequentially installed: a crusher, a pneumatic conveyor with a first flap valve, a vertical screw mixer mounted on a mechanical scale, a second flap valve, a screw conveyor, a hopper-agitator, an extruder, a conveyor belt and an extrudate crusher connected to the main mixer, while the second flap valve is auger the conveyor is connected to the main mixer, the second line is the line of components not subject to extrusion, contains sequentially installed: the second crusher, pneumatic conveyor, mixer l vertical screw mounted on a mechanical balance connected to the main mixer, the third line of extrusion of waste with grain filling contains sequentially installed: flap valve connected through a pneumatic conveyor to the first crusher of the first line, vertical screw mixer mounted on a mechanical balance, mixer, screw conveyor , an extruder, a conveyor belt connected through a crusher of an extrudate of the first line to the main mixer, in addition, the main mixer also has a hopper -zagruzchik for supplying feed pastoprigotovitel cooked pasta into the main mixer on the principle of repeated circulation.

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