Addis Ababa University
College of Veterinary Medicine and
Agriculture
Department of Animal Production Studies
By Sisay W. (MSc in Animal Production)
Topics: Introduction to compound feed
production
Operation in Feed mill
Compound Feeds
Compound feed is a mixture of raw materials
and supplements fed to the livestock, sourced
from either plant, animal, organic or inorganic
substances, or industrial processing, whether
or not containing additives.
Compound cattle feed is an economical source
of concentrate supplements and it could be in
the form of mash, pellets, crumbles, cubes, etc
Compound Feeds Cont…
Compound feed refers to the feed that produced
on the basis of animals’ different growth stages,
different physiological requirements and different
production uses, as well as the experiment and
Research on the evaluation of feed nutrition
value, and according to the scientific formula that
mix feed of various different sources uniformly in
a certain proportion and processed by prescribed
technology
Raw materials for compound feed
Processing
Cereal grains and cereal grain by-products
Maize Maize By-Products
Wheat Wheat By-Products
Barley, Rye, Triticale, Oats, Sorghum
Millet, Rice and By-Products Of Rice
Oil seeds and their by-products
Soy Beans and By-Products
Linseed and By-Products
Groundnuts and By-Products
Cotton Seed and By-Products
Sunflower Seeds and By-Products
Sesame seeds and by-products
Coconuts and by-products
Palm kernels and by-products
Rape seed and by-products
Products of animal origin
Dried skimmed milk powder
Dried whey powder
Fish meal
Blood meal
Tankage
Meat and bone meal
Bone meal
Feather meal and Animal fat
Different Compound Feeds Produced by
Feed processing Feed mill
1.Layer compound feeds
2. Broiler Compound feeds
3. Dairy Compound feeds
4. Beef Compound Feeds
Layer compound feed
• CHICKEN STARTER CRUMBLE
(21% CRUDE PROTEIN, 3050 KCAL)
Unique crumble feed gives a powerful start of the layer.
• REARING FEED
(18,5% CRUDE PROTEIN, 2950 KCAL)
Rearing feed for a perfect body and organ development
• PULLET DEVELOPER FEED
(15% CRUDE PROTEIN, 2750 KCAL)
To prepare the chicken to become a great egg laying chicken
• LAYER PHASE 1
(16% PROTEIN, 2750 KCAL)
To achieve a high peak production and persistent high production.
• LAYER PHASE 2
(15,5% CRUDE PROTEIN, 2700 KCAL)
Broiler compound feeds
• CHICKEN STARTER CRUMBLE
(21% CRUDE PROTEIN, 3050 KCAL)
• BROILER GROWER CRUMBLE
(19% CRUDE PROTEIN, 3150 KCAL)
• BROILER FINISHER FEED
18% CRUDE PROTEIN, 3250 KCAL)
Dairy Feed
Heifer feed
Your calf becomes a heifer, and should give birth around 24 months
of age. To assure a proper growth, and a good fertility you feed
heifer feed to your heifer. Always in combination with good
quality roughage.
Dairy Feeds
• Depending on your strategy and cow breed, there is choice
between 3 different dairy feeds for lactating cows;
Dairy Basic
For local and low blood level crossbreeds. For economic
production, not aiming for the highest milk yield
Dairy feed cont…
Dairy Excellent
For commercial farmers, having high bloodlevel cross
breed cows, focusing on production and health.
Dairy Super
Top of the bill. If you are a commercial farmer, having a
bloodlevel cows (Holstein) and ready to invest in a
high production, health and fertility.
Energy, protein, vitamins and minerals increase starting
from Dairy Basic to Dairy Excellent and Dairy Super.
Beef Feed
Beef Fattening Feed Basic.
Beef Fattening Feed Basic is the ideal feed for small scale
beef farmers looking for an economical way to fatten their
animals.
Beef Fattening Feed Super
For professional farmers, looking to fatten their animal is
the shortest time possible in combination with high quality,
tender beef meat.
Many large beef farmers, including exporters, are
experiencing the advantage of Beef Fattening Feed
SUPER.
Feed mill operations
General outline of feed mill operation four main functions production
1. collecting of raw materials
operations as transporting, receiving, cleaning, drying and storage;
2. modifying of raw materials
operations like grinding in a hammer mill but also flaking in a roller mill;
3. blending and mixing of the ingredients
• includes the operations weighing or volumetric dosing, and mixing;
4. delivering the compound feeds produced.
operations like weighing, bagging, storage and transportation to the farm.
modification of the mixed products by pelleting may
be part of the production process.
Block flow chart for compound
feed production
Flow diagram of a small scale feed mill
• While a block flow-chart shows the sequence
of operations and the flow of the product, it
does not indicate the scale of production and
the type of equipment used.
• This information which is also specific for
every feed mill is usually shown in a so-called
Flow Diagram.
Flow diagram of a larger feed mill
Buildings
• Capable of being kept clean
• Dust level as low as possible.
• Required space for storage of raw materials and feeds
• Equipment totally enclosed in a light structure;
• A concrete floor, which can be swept, is usual.
• A supply of electricity is always necessary
• Where there is no reliable public supply a (stand-by)
generating plant will be required.
• Water is required only for direct addition and/or raising
of steam in pelleting.
Reception of raw materials
There are three categories of raw materials used in feed
production:
1. Dry macro-ingredients (e.g. grains and oilseeds);
2. Dry micro-ingredients (e.g. premixes, minerals);
3. Liquid ingredients (in particular molasses).
The reception of raw materials includes:
Unloading from the transport;
Weighing to check the incoming weight;
Sampling to check the condition;
Conveying the materials to the storage.
Bulk handling
Types of conveying systems
Type
Different types of screw conveyers
Storage of raw materials
No losses in quality and quantity of raw material
–Good storages facilities
–Proper storage conditions (temp, RH)
–Cleaning and drying of products
Important factors
–Required length of storage period
–Value of products to be stored –The prevailing climate
conditions
–System of transport to the feed mill
–Cost and availibility of labour
–Cost and availibility of sacks
–Cost of buildings and silobins –Availibility of space
Bag handling and storage
Bag Storage Cont…
• The site should be above possible flood level during
the wet season;
• Walls should be smooth and waterproof;
• Floors should also be smooth and waterproof;
• The roof should be reflecting solar radiation and
preferably have top ventilation openings;
• The building should (if possible) be oriented with the
shortest wall
• facing east/west, while the roof should have sufficient
awning to shade the walls;
Bag Storage Cont…
• Windows should be small and preferably not
be placed in east or west walls;
• The building should have controllable
ventilation and large doors opposite each
other;
• A bag warehouse should preferably have a
loading-ramp and be surrounded by drain
ditches.
For short term storage
bags can be stacked directly on the floor with a
maximum of about 8 to 10 layers
Between stacks sufficient space should be left
for handling with trucks and/or for ventilation.
In stock management the rule "first in, first
out" should be adhered to (i.e. the material
first stocked should also be utilised first in
production).
For long term storage
Bags are best stacked on pallets or otherwise
on plastic sheets.
When pallets (with about 1 tonne each) are used
a maximum of 3 loaded pallets can be placed on
top of each other. This results in storage of
about 2 t/m 2
When stacked on the floor a maximum of 30
layers of bags with a height of 6-7meters is
usual. This results in storage of about 3 t/m 2
bags - warehouse
floor storage
Bulk storage
Bulk storage in floor compartments
Advantages of this type of storage are:
Relatively low investment;
Flexibility in the use of warehouse space;
Can use the warehouse also for storage of bags.
No working capital needed for bags.
Disadvantages are, however:
Relatively high labour cost for loading and unloading
(as compared to bulk storage in bins);
Dust production;
Difficult to avoid losses by rodents and insects
Silo’s and bins
Bulk storage in silo’s and bins
Bins may be round, square or hexagonal in
shape and have a flat bottom or a hopper-
shaped bottom with an outlet spout .
Flat-bottomed bins are more suitable for
longer-term storage, while hopper bins are
particularly suitable for short-term storage.
Hopper bins are also used as buffer- or
intermediate storage between the machines
in the processing line.
Blending / dosing
Weighing is
accurate and can be used for all types of materials;
however, the equipment used is relatively expensive and
sensitive to damages.
Volumetric dosing
has the advantages that the equipment used is relatively
inexpensive, simple and robust.
However the flow properties of materials and variations
in bulk density may present problems.
So regular calibration of the equipment demands more
attention from operators.
Scale types
For blending by weighing different types of
equipment are available:
Platform scales;
Hopper scales (movable, fixed, long bin);
Belt scales
During operation we have to know the influence
of temperature differences, vibrations and air
movement on the accuracy of a scale. Regularly
scales need to be calibrated to be reliable.
Platform scale
Long-bin scale Mixer on weigher
Belt weigher
Grinding
Why grinding?
improvement digestibility (maize)
improvement of mixing (size/mass)
improvement pelleting (size)
Important:
1. Reduce particle size
2. uniformity in size
(pigs 0,5-0,7mm; broiler 0,7-0,9mm; layers 0,9-
1,5mm; cattle 0,8-1,0mm)
Particle size
Modern Feed mill
Equipment
Grinding equipment
Mixing
Mixing is the combining of different
components into a more or less homogeneous
mass that cannot easily be separated again.
In compound feed production we deal with
mixing of:
Dry ingredients only;
Dry ingredients with a relatively small
proportion of liquid (e.g. meal with less than
10 % molasses);
Mixing equipment: vertical mixers
A vertical mixer consists of a cylindrical bin
with a conical (or hopper) shaped bottom.
Inside the vessel is a vertical screw-
conveyor which moves the material upward
centrally;
the material subsequently flows downward at
the wall of the vessel.
Vertical mixers
Horizontal mixer
Comparing mixers
Delivery of finished product: bags
The materials of which the bags are made.
Bags can be made of jute, paper, sheet or woven
plastic.
Woven jute or plastic bags are very strong and
often used for 50 kg and can be used several times.
Disadvantages are:-
costs of recollection
repair
the risk of contamination. (Diseases)
The shape of the bags
Usual filling weights are 50 kg and 25 kg.
Bags that are too thinly filled are less stable in
piles and damage easily.
Tied bags that are too long give difficulties in
piling.
The method of closing.
Bags can be closed by tying with a string, by
sewing or by heat-sealing
Bag filling and closing units
Bulk delivery
Bulk delivery has as advantages over delivery and transport in
bags:
Lower labour requirements;
Higher capacity in loading and unloading;
Lower storage space requirements;
No packaging required. This may result in lower delivery costs
per tonne of product.
Disadvantages, however, are:
Higher investments in storage facilities are required;
Specialised transport trucks may be necessary;
Unloading requires energy supply;
Farms must be equipped with bulk storage facilities.
Bulk delivering systems
Bulk trucks
Pelleting
Pelleting Cont…
• Disadvantages of pelleting are, however:
Pelleting installation requires considerable
additional investment;
Operation requires skilled labour;
Maintenance and replacement of wearing
parts entails high costs;
Energy consumption is high.
bag sampler
Storage possibilities
Storage possibilities (losses)
Storage possibilities
Storage possibilities
