Optimizing Feed Production Tips by a Feed Milling Industry Veteran

• Batching: It has seen a shift from manual batching systems to fully automatic, highly precise ones. This minimizes human error and ensures a more reliable production process. Process Automation: Automation has become a major driver of efficiency. Central control rooms now enable the operation of entire plants with minimal manpower.
• Material Storage and Handling: Improvements in this area haven’t received as much attention as core production processes, but they’re still important. Well-designed storage facilities and advancements in handling systems contribute to overall efficiency.
• Quality Systems: A strong emphasis on quality control systems ensures consistent production of high-quality feed.
• Energy Conservation: Energy-efficient equipment and processes are becoming increasingly important for both economic and environmental reasons.
• Particle Size Reduction: Variable speed hammer mills with diverse sieve and beater options allow for precise control over particle size, leading to a more consistent product. These mills are energy efficient with better capacity utilization.
• Mixing: High-capacity mixers with multi-liquid addition capabilities and reduced mixing times with better coefficient of variation (CV) values have significantly enhanced efficiency and consistency.
• Conditioning: Long-term conditioning techniques ensure optimal starch gelatinization and proper moisture content in the final feed product.
• Safety Measures: Multi-level safety measures have been implemented throughout the feed processing stages, prioritizing worker safety within the mills.

Despite our progress in batching, mixing, and pelleting, material handling systems are an area where we lag. What improvements would you recommend for feed millers in this regard? Absolutely. While advancements in core production processes like batching, mixing, and pelleting have been impressive, material handling systems haven’t received the same level of attention. Many feed millers prioritize the selection of feed mill equipment itself, often overlooking the crucial role that proper feed storage and handling play in overall efficiency. Here, I would recommend a focus on well-designed storage facilities for both raw materials and finished goods for feed safety. These facilities should be spacious and well-ventilated to maintain optimal product quality during storage. Today, most feed mills utilize grain storage silos. However, it’s important to ensure these silos have proper aeration systems and online mold inhibitor application systems to prevent spoilage.

For larger operations, establishing corn silos near corn production areas along with dryers can significantly improve the shelf life of this key ingredient. On the finished product side, progressive poultry operators are increasingly looking towards automation solutions like bulk feed handling systems and even farm-level feeding automation. These advancements not only reduce labor costs, packing costs, and the risk of human error but also help maintain the integrity of the feed itself.

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