Chapter No: 2 Raw Material Inspection before Purchasing

2.1 Introduction to Raw Material Inspection

Before purchasing raw materials for feed production, it is essential to conduct a thorough
inspection to ensure they meet the required quality standards. This step helps avoid costly
mistakes, ensures feed quality, and protects the feed mill’s processing equipment. Inspecting raw
materials before buying guarantees that only suitable materials are used in the production
process, preventing issues like contamination, inconsistent nutrient profiles, and potential harm
to animal health.

2.2 Objectives of Raw Material Inspection

 Ensure quality and safety: To confirm that raw materials are free from contaminants
(e.g., mold, toxins, foreign matter) that could affect the final feed product.
 Verify nutritional value: To ensure that the raw materials meet the required nutritional
standards, which are crucial for formulating balanced and nutritious animal feed.
 Prevent equipment damage: To ensure that the materials do not contain harmful
elements (e.g., stones or metals) that could damage processing equipment.
 Ensure consistency: To verify that the raw materials are uniform and consistent in
quality, which is critical for producing a high-quality feed product.
2.3 Key Aspects of Raw Material Inspection
2.3.1 Physical Inspection:
 Appearance: Checking for any visible signs of damage, mold, or contamination. The
raw material should be free of debris, insects, or foreign objects.
 Moisture Content: Measuring moisture content is crucial since high moisture levels can
lead to mold growth and spoilage. A moisture meter or oven drying method can be used.
 Foreign Matter: Inspecting the raw material for any unwanted substances, such as
stones, metals, plastics, or dirt, that could cause damage to equipment and affect feed
quality.
2.3.2 Chemical and Nutritional Analysis:
 Nutrient Composition: Laboratory testing of raw materials to check for protein, fat,
fiber, and other nutrients, ensuring they meet the required specifications for the feed
formulation.
 Contaminant Testing: Testing for harmful substances such as pesticides, mycotoxins,
and heavy metals. These contaminants can have serious health implications for animals
and humans consuming the feed.
 Aflatoxin or Mold Testing: Aflatoxins are toxic compounds that can be present in
certain feed ingredients, especially grains like corn. Ensuring that the levels of aflatoxins
are within the acceptable limits is crucial for animal health.
2.3.3 Microbiological Testing:
 Pathogen Testing: Testing for harmful bacteria such as Salmonella, E. coli, and other
pathogens that can affect both animal health and the safety of the final feed product.
 Fungal Contamination: Inspecting for mold and fungi, which can lead to spoilage and
the production of mycotoxins in raw ingredients.

2.4 Importance of Raw Material Inspection

 Minimizes Risk: Early detection of poor-quality or contaminated raw materials prevents
costly mistakes in production, such as producing inferior feed products that might harm
animals.
 Ensures Consistent Product Quality: By ensuring the raw materials meet all the quality
and nutritional requirements, you can guarantee the final feed product is of consistent
high quality.
 Reduces Costs: Preventing poor-quality raw materials from being purchased can save
the feed mill from expensive rework or disposal costs. Additionally, it helps avoid
equipment damage caused by contaminants.

2.5 Methods of Raw Material Inspection

2.5.1 Visual Inspection
 Conducting a simple, yet effective, visual check to spot any obvious contaminants or
signs of poor-quality materials.
2.5.2 Sampling
 A sample of the raw material is taken and sent for laboratory testing to assess its
nutritional content, contaminants, and moisture level.
2.5.3 On-site Testing
 Perform on-site tests using moisture meters, protein analyzers, or other equipment to
assess raw material quality before purchase.
 Chapter No: 3 Pre-Cleaning Process
3.1 Introduction to Pre-Cleaning
Pre-cleaning is the first stage in the feed milling process, where raw materials (grains, seeds, or
other ingredients) are cleaned to remove contaminants, dirt, and foreign materials before further
processing. This step is crucial for ensuring the quality of the final feed product, improving
efficiency, and preventing damage to milling equipment.

3.2 Objectives of Pre-Cleaning

 Remove impurities: To eliminate dirt, stones, dust, and other foreign materials that may
damage machinery or affect the quality of the feed.
 Improve efficiency: By cleaning the raw materials, it reduces wear and tear on
equipment in subsequent processing stages.
 Enhance product quality: Helps in ensuring the feed is pure and safe for animals by
reducing the chances of contaminants.
 Prepare raw materials for further processing: Ensures a smoother grinding or mixing
process, leading to a better-quality final product.

3.3 Equipment Used in Pre-Cleaning

The pre-cleaning process typically involves a combination of mechanical equipment designed to
perform various tasks.
3.3.1 Sifters
Used to separate small particles, dust, and other fine impurities.
3.3.2 Drum Cleaners
The drum cleaner is a rotating cylindrical device used to remove large debris and foreign objects
from raw materials. The material is fed into the drum, which rotates and separates larger
contaminants (such as stones, sticks, and larger particles) using screens or sieves. This is
particularly useful for cleaning grains and seeds before further processing.
3.3.3 Rotary Magnets
Rotary magnets are used to remove any ferrous (metal) contaminants from the raw materials.
These magnets are typically installed in-line and consist of rotating magnetic drums that attract
and remove metal pieces such as nails, screws, or wire, which could damage equipment or
compromise feed safety. These magnets help ensure that no metal particles contaminate the raw
materials, making the final feed product safer and more reliable.
3.4 Steps in the Pre-Cleaning Process
 Initial Inspection: Raw materials are visually inspected for any obvious contaminants or
issues before entering the cleaning process.
 Screening: Raw materials are passed through vibrating screens with different mesh sizes
to remove larger debris.
 Air Cleaning: Air currents are used to remove dust and lighter particles from the raw
material.

3.5 Importance of Pre-Cleaning

 Minimizes contamination: By removing foreign materials, pre-cleaning reduces the risk
of contamination that could affect the feed quality and the health of animals.
 Protects downstream equipment: It helps to protect costly equipment like grinders,
mixers, and pellet mills from wear and tear caused by hard foreign materials.
 Increases feed quality: Ensures that the final product is pure, consistent, and free of any
harmful substances.
 Chapter No: 4 Silo Storage at Asia Feed Mill
4.1 Introduction
At Asia Feed Mill, silo storage is a crucial component of our feed production process. We utilize
concrete silos to store key raw materials such as maize, wheat, and rice. These silos ensure that
our grains are stored safely and maintain their quality until they are ready for processing. By
using concrete silos, we can optimize storage efficiency, maintain product integrity, and ensure
continuous production at the mill.

4.2 Types of Silos

At our facility, we use reinforced concrete silos for the storage of bulk grains. While both
concrete and steel silos are common in the feed milling industry, we specifically use concrete
silos for several practical reasons that suit the needs of our operations.
 Construction and Design: Concrete silos are constructed with reinforced concrete to
withstand the heavy weight of bulk grains. They are cylindrical in shape, providing an
efficient storage solution that minimizes space and maximizes storage capacity. This
robust design ensures long-term durability and structural integrity under heavy loads.
4.2.1Why Concrete over Steel?
 Cost-Effectiveness: Concrete silos are more cost-effective in the long run. While the
initial construction of concrete silos may take longer and may appear more expensive
upfront, they typically require less maintenance over time compared to steel silos,
offering greater long-term value.
 Durability and Longevity: Concrete silos provide exceptional durability and longevity
compared to steel silos, particularly in environments where moisture, temperature
fluctuations, and grain storage challenges are present.
 Thermal Insulation: Concrete provides better natural insulation compared to steel. This
helps maintain a stable internal temperature within the silo, preventing heat buildup or
rapid temperature fluctuations that could negatively affect the stored grains.
 Higher Capacity: Concrete silos can typically handle larger volumes of grain, making
them ideal for our high-capacity storage needs. The thicker walls of concrete silos
provide additional strength, allowing them to store greater quantities without
compromising stability.

4.3 Grains Stored in Our Silos

At Asia Feed Mill, we store a variety of grains that are essential for animal feed production:
 Maize (Corn): Maize is a primary ingredient in feed for poultry, livestock, and swine,
due to its high energy content.
 Wheat: Wheat is another essential grain, contributing carbohydrates and protein to
animal feed formulations.
  Rice: Rice is stored in specific silos for use in particular feed formulations, offering a
source of energy for poultry.
Each grain type is stored separately in dedicated silos to avoid contamination and maintain the
quality of the raw materials.

4.4 Storage Process

Grains are stored in the silos following a structured process to ensure optimal quality:
 Receiving and Loading: Grains are delivered by truck or rail and transferred into the
silos using pneumatic conveyors or bucket elevators. This ensures efficient and safe
handling during the transfer process.
 Segregation: Different types of grains are stored in separate silos to maintain their
individual characteristics and prevent cross-contamination.
 Sealing and Protection: Our silos are tightly sealed to create an airtight environment,
protecting the grains from external contaminants, moisture, and pests.

4.5 Silo Management and Monitoring

To maintain the integrity of the grains, we employ a range of silo management practices:
 Temperature and Humidity Control: We utilize aeration systems to regulate
temperature and humidity inside the silos. This helps prevent spoilage and mold growth,
ensuring that the grains remain in good condition.
 Inventory Monitoring: Automated systems are used to monitor grain levels within the
silos, ensuring that inventory is managed efficiently and that raw materials are available
when needed.
 Quality Control: Regular checks are conducted on the grains stored in the silos. These
include moisture content analysis, contaminant testing, and ensuring that the grains meet
the quality standards required for feed production.
 Chapter No: 5 Receiving Materials
At Asia Feed Mill, receiving raw materials from the silos and godown is an essential step to
ensure the smooth flow of the production process. We carefully manage the transfer of grains
like maize, wheat, and rice, along with other materials such as meals, bone crush, and additives
from the godown, to begin the feed manufacturing process.

5.1 Receiving Grains from Silos

The first step in the production process is the transfer of grains stored in the silos to the milling
area.
 Conveyors for Grain Transfer: The grains (maize, wheat, and rice) are moved from the
concrete silos to the production area via automated conveyors. These conveyors ensure
that the grains are efficiently transported without causing contamination.
 Segregation by Grain Type: Each type of grain is kept separate during transport to
prevent mixing and maintain consistency in the feed formulation.

5.2 Receiving Additional Materials from Godown

In addition to grains, we receive other critical materials like meals, bone crush, and additives
from the godown (storage warehouse) for feed production.
 Conveyors for Material Transfer: These materials are transferred from the godown to
the production area using conveyors, ensuring the safe and efficient delivery of
ingredients.
 Proper Material Handling: Each material is carefully handled and kept separate to
prevent contamination, ensuring that the raw materials maintain their integrity.

5.3 Grinding of Grains in the Hammer Mill

Once the grains are received from the silos, they are sent to the hammer mill for grinding.
 Hammer Mill Operation: The grains (maize, wheat, rice) are ground in the hammer mill
to achieve a finer particle size. This makes the grains easier to mix and enhances
digestibility for the animals. The hammer mill uses high-speed rotating hammers to break
down the grains into fine powder or meal.
 Optimized Grinding: The grinding process is carefully monitored to ensure a consistent
and uniform particle size, which is essential for producing high-quality feed.

5.4 Inspection after Grinding

After the grains are ground, they undergo an inspection process to ensure that the material meets
the necessary quality standards before moving further down the production line.
 Quality Checks: A quality control team conducts inspections on the ground materials to
check for consistency, quality, and compliance with nutritional standards. This includes
 examining the particle size and ensuring that the ground material meets the desired
specifications.
 Moisture Content and Contaminant Testing: The ground materials are also tested for
moisture content and checked for any potential contaminants. This is crucial to avoid
issues such as mold growth or the presence of foreign particles that could affect the
quality of the feed.
 Rejection or Reprocessing: If any issues are found during inspection, the materials are
either rejected or sent for reprocessing to correct the problem. This helps maintain the
high standards of the final feed products.

5.5 Dust Control in Hammer Mill

During the grinding process, it is crucial to control dust generated by the grains to ensure a safe
and efficient working environment.
 Dust Filters on Hammer Mill: Dust filters are attached to the hammer mill to capture
and remove any air and dust generated during the grinding process. These filters help
prevent the spread of grain dust, maintaining a cleaner environment around the mill and
minimizing the risk of dust-related issues such as respiratory concerns or fire hazards.
 Efficient Air Removal: The filters are designed to effectively remove air and dust
particles, ensuring that the hammer mill operates efficiently while reducing the presence
of airborne particles in the production area.