Industry Innovations in Feed Mill Design

Transcription

1 Industry Innovations in Feed Mill Design Hennie Pieterse Ottevanger Milling Engineers Australian Milling Conference 2018 Gold Coast Convention & Exhibition Centre Broadbeach Australia

2 Industry Innovations in Feed Mill Design Why is Innovative Design necessary? Flexibility to adjust to Market Trends & Changes producing a range of Final Products that have market demand Flexibility to cope with a wide range of Raw Materials in a cost effective way Flexibility to expand in a logical way with minimum impact on Operations Innovative Feed Plant design should lead to lowest cost producing high quality Fish, Meat, Milk & Eggs

3 Industry Innovations in Feed Mill Design Characteristics of good or Innovative Design : Functionality - most important design goal. Failure to properly meet required functionality and the rest means little Engineering Integrity - meeting Engineering design criteria in terms of material Choice; Structural Strength; Workmanship; Durability, etc Cost - Capital & Operational Costs clear. The Hidden Costs of inferior design might be surprising Ergonomics - User-friendliness; Health & Safety and its effect on End-Product Quality Aesthetics - no reason why a good design should not look good Hammermill with Automatic Screen Change (Courtesy Ottevanger Milling Engineers)

4 Industry Innovations in Feed Mill Design Investing in Innovative Engineering Design of Processing Plant has at least following effects: Costs over Feed Mill Lifetime 1% 15% Functionality - Designed to fulfil Specific Function - Meet & Exceed plant Customer s Expectations (Physical & Nutritional Final Product Characteristics) - Failure to meet above makes low cost design expensive Downtime - Inferior Design & Equipment results in unnecessary Operational Constraints, Failure & Downtime - This may disappoint Processing Plant Customers and has potential to drive them to Competitors Cost - Initial Engineering Investment Cost small with big effect when neglected - Other Costs continuous and affected by Design 35% Planning & Engineering Equipment & Installation Operations & Management Interest Courtesy American Council of Engineering Companies 49%

5 Why Innovative Feed Mill Design? Increase in Feed demand no surprise : 7.5 Billion people on earth Net Growth = 2 people per second Alltech Report confirms 2,57% annual growth ( ) Total volume 1.07 Billion ton Total Value = US$ 430 Billion Challenge : To keep up with growth with decreasing natural resources in an Innovative Feed & Food Manufacturing Regime Table 1. Percentage and Growth of Global Feed Production by Species (Alltech) Feed by Species % of Total Annual Growth [%] Broiler Feed 28% 3% Aquatic Feed 4% 1% as result of China down Petfood * 3% 5% to 12% Horse Feed 1% all regions up, EU 24% Pig Feed 27% 5.5% Dairy Feed 11% 3% Beef 7% -1% Layer Feed 13% 1% Other 6% * up to 12% growth in Metropolitan China (Petfood Industry)

6 9. Increases capacity of Pellet Press / Expander / Extruder Industry Innovations in Feed Mill Design EQUIPMENT & PROCESS INNOVATIONS Equipment innovations Hygienic Equipment Design Square Silos Vacuum Coating & Liquid Layering Process Innovations DESIGN PROCESS INNOVATIONS RAW MATERIAL FLEXIBILITY DESIGN INNOVATIONS SAFE FEED MANUFACTURING INNOVATIONS Steam Preconditioner with Thermal Retention Time Barrel (Courtesy Ottevanger Milling Engineers)

7 Equipment Innovations Hygienic Equipment Design Horizontal spaces and surfaces in Equipment design could collect Fines & Dust Feedstock staying behind inside equipment (Product Hang-up) could go off over time and cause contamination Feedstock staying behind inside equipment (Product Hang-up) could lead to crosscontamination between different formulations Extruder and Preconditioner Chassis or Frame design that leaves no horizontal space for dust collection or product hang-up during cleaning or barrel change-over. (Courtesy Wenger manufacturing Inc.)

8 Equipment Innovations Square Silos in general Maximised Storage Capacity compared to Round Structurally and Functionally integrates with Plant Flexibility & Traceability simplified Could be custom designed meeting specific Requirements Fig 1. Extruder and Preconditioner Chassis or Frame design that leaves no horizontal space for dust collection or product hang-up during cleaning or barrel change-over. (Courtesy Wenger manufacturing Inc.) Square Silo Block (Courtesy TSC Silo)

9 Equipment Innovations Square Silos with Smooth Cell Walls Constructed with Double Wall System Optimal Product Outlet No Weld Seems in Silo Walls Hygienic Dust-Free Work Environment Modular Construction means logical expansion Bin Coatings as required Stainless Steel as required

10 Equipment Innovations Square Silos with Profiled Cell Walls Profiled Panels for specific Products / Economy Lightweight Single Wall System Profile provides Structural Strength Hygienic & Dust Free Silo Environment Modular Construction Bin Coatings as required Stainless Steel as required Hopper Design meeting Raw Material Characteristics & Behaviour Purlins for attaching Cladding directly to Square Silo Block

11 Equipment Innovations Square Silos : Bin Hoppers Square or round Hoppers to match any Raw material Type Different Bin Hopper Designs to meet specific Raw Material Flow Characteristics Purlins accommodate Cladding directly to Silo Block Bin Hopper Outlet Design round or Square as required Accommodates Loading Bellows when Bins are used as Final Product Bins Seamless transition from Bin to subsequent Process Smooth Double Walled Panels for specific applications

12 Equipment Innovations Square Silos : Bin Roof Top Design & Function Bin Roof Top becomes Service Floor for easy Maintenance A Closed & Safe Work Environment

13 Equipment Innovations Square Silos : Integration with Process & Superstructure

14 Equipment Innovations Vacuum Coating & Liquid Layering Higher fat levels compared with Atmospheric Coaters Liquid Layering of several Liquids & Micro Ingredients possible Liquid with lowest palatability pulled to centre of Pellets Liquid with highest palatability applied to surface of pellets Several other liquids could be layered concentrically between centre and surface of pellets above achieved by sequencing liquids (through Process Control) at varying negative pressures. Extruded / Pelleted Product Product Atmosphere Application of Vacuum Application of Coating Vacuum Release Surface / Attractant Coating Optimised Coating Several Concentric Layers possible Typical examples of Vacuum Coater used in Petfood / Aquatic Feed processing (Courtesy Ottevanger Milling Engineers / Forberg / Dinnissen)

15 Process Innovations Online Process Control Quality & Feed Safety requires Critical Control Point (HACCP) Analysis and Control Historically we attempted to do this manually with challenges : not Timely Human Error Innovations in Process Control and Sensing Technology led to Online Process Control with little to no maintenance calibration required Online Process Control consisting of Hardware & Software : Sensor sensing Operating Parameter PLC to Process Control Software Process Control Software to Device rectifying Operational Condition Typical examples of Sensing Technology for specific Operational Parameter Sensing (Courtesy Source Technology / Tovalia / TEWS Elektronik)

16 Equipment Innovations Containerised Plant Design Modular approach based and standard 20ft Container Frames Meets International Shipping Requirements Process Flow Design like Conventional Plant Design Suits any Process - in some cases Partially Containerised Designed to meet Structural Process, Maintenance and OHSA requirements

17 Equipment Innovations Containerised Plant Design Manufactured and Mechanically & Electrically installed at Point of Manufacture Dry Testing at Point of Manufacture Superstructure housing the Plant a Shelltype Structure only accommodating and protecting Plant & Equipment Sidewalks, safety Railing and Stairs bolted to individual Container Modules on ground level = Installation and OHSA cost reduction in Australia

18 Equipment Innovations Containerised Plant Design - Sizing Small to Large Plant For any Application in Feed Manufacturing

19 Equipment Innovations Full & Partial Containerised Plant Design Partially Containerised Design Certain Zones of plant could be Full Containerised [Size Reduction & Mixing / Micro Ingredient Batching / etc] Other Zones could be Conventional for reasons of Function Size [Pellet Pressing / Extrusion / Drying & Cooling / etc] Results in Partially Containerised Plant Design Containerised Design Conventional Design

20 Equipment Innovations Containerised Plant Design Timeline

21 Design Process Innovations EQUIPMENT & PROCESS INNOVATIONS DESIGN PROCESS INNOVATIONS Historical Design Approach Integrated Design Approach RAW MATERIAL FLEXIBILITY DESIGN INNOVATIONS SAFE FEED MANUFACTURING INNOVATIONS

22 Design Process Innovations Historical Design Approach 2D Design Software Costly and Time Consuming Challenging to Interpret & Present Majority of Design Flow was Manual (and open to Human Error) : Process Flow Diagrams Structural Analysis and Design Plan Views and Elevations Manufacturing & Fabrication Detail Drawings Bills of Material etc

23 Design Process Innovations Integrated Design Approach 3D Design Software An integral part of Project Development More economical over Project Development lifetime Easy to Present to Decision Makers, Investors; Other Designers part of the Project, etc 3D Design great for studying potential Equipment & Process Interference 3D Design Work Flow integrates all aspects of Project Development

24 Design Process Innovations Integrated Design Approach Modelling & Presentation as Project is developed Keeps design costs low Accelerates Decision-making Detailing as required and as Project develops Plug-in software integrates with 3D design software to incorporate : BIM (Building Information Modelling) MEP (Mechanical, Electrical & Plumbing) HVAC (Heating, Ventilation & Air Conditioning) Heat Transfer Modelling Traffic Flow Patterns etc On-Farm Liquid Addition System Vitamin Mineral Dosing Plant Images Courtesy hp dezign Pty Ltd Modular Steam Generation Plant Conceptual Aquatic Feed Plant Site Layout

25 Design Process Innovations Integrated Design Approach Workflow Process Flow Design 3D Modelling & Layout Generate Plans / Section Cuts / Elevations / Perspectives Iteration Process with Customer Input Detail Drawings for Manufacturing and Fabrication Raw Model (Perspective) Rendered Views (Isometric) Interference

26 Design Process Innovations Plan Views (& Horizontal Sections) Elevation 1 (& Vertical Sections) Elevation 2 (& Vertical Sections) Elevation 3 (& Vertical Sections) Elevation 4 (& Vertical Sections)

27 Industry Innovations in Feed Mill Design EQUIPMENT & PROCESS INNOVATIONS DESIGN PROCESS INNOVATIONS RAW MATERIAL FLEXIBILITY DESIGN INNOVATIONS Conventional Raw Ingredients Engineered Raw Ingredients Value-Added or Enhanced Raw Ingredients Fresh Meat or Fish as Raw Ingredients SAFE FEED MANUFACTURING INNOVATIONS

28 Raw Material Flexibility Design Innovations Engineered Raw Ingredients New Ingredients could be developed from by-products and products with limited value : By mixing in specific ratio By-Product with a locally available Product and then co-extrude Product Pasteurised after Extrusion Final Product could be in Pellet, Granule or Meal form Final Product Nutritional Profile could be tailored for specific applications By-Products could consist of: Meat or Fish / proteins Plant / Fruit / Vegetable Processing by-products Animal Processing By-product Spent Hens etc Fresh Fish Processing By-Product High Shear Extrusion Ground & mixed with Soybean Meal Dried & Milled Fish By-Product Meal Fish By-Product co-extruded with Soybean Meal (Courtesy Food Protein R&D Centre Texas A&M University)

29 Raw Material Flexibility Design Innovations Value-added / Enhanced Raw Ingredients Many Ingredients in un-processed state has limitations in terms of Nutrition / Functionality and Application : Some Pulses and Oilseeds contain Anti-Nutritional Factors we have to deal with effective and safe application as feed ingredient is possible. Raw Starch in Cereals could be gelatinised thereby making it effective in nutrition of young animals and animals sensitive to raw starch. Effective Heat Treatment under correct processing conditions plays an important role in Raw Material Enhancement Raw Oilseed Full Fat Oilseed Partially Defatted Oilseed Gelatinised Starch Soluble Starch

30 Raw Material Flexibility Design Innovations Fresh Meat / Fish as Raw Ingredients Humanisation of Pets & demands of Pet Owners led to major advances in utilising novelty ingredients / Fresh Meat / Fresh Fish as : Emulsified Meat / Fish Slurry Meat / Fish Hydrolysate Innovations in Thermal Processing led to Technologies Emulsified Slurry Hydrolysed Liquid

31 Industry Innovations in Feed Mill Design EQUIPMENT & PROCESS INNOVATIONS DESIGN PROCESS INNOVATIONS RAW MATERIAL FLEXIBILITY DESIGN INNOVATIONS SAFE FEED MANUFACTURING INNOVATIONS Plant Design & Zoning Limiting Cross-Contamination Importance of Thermal Processing

32 Safe Feed Manufacturing Innovations Plant Design & Zoning Typical zoned Horizontal Plant Layout (Courtesy Wenger Manufacturing Inc.) The Plant, whether of Horizontal or Vertical design, is zoned in order to isolate Operational Processing Activities thereby managing, controlling & limiting : Cross-contamination Typical zoned Vertical Plant Layout (Courtesy hp dezign Pty Ltd) Noise Odour Dust Non Thermal Plasma Odour Control System with UV Sterilisation Unit (Courtesy Schenck) Online Dust Control & Fire Suppression (Courtesy Ottevanger Milling Engineers)

33 Safe Feed Manufacturing Innovations Limiting Cross-Contamination How does Cross-Contamination occur? Hang-up of Product in Transitional Equipment Hang-up of Product in poorly designed Equipment Spillage / Leakage in poorly designed & constructed Plant Poor Process Flow Design Poor or limited Operating Procedures followed by Workers Cross Contamination between formulations minimised through proper Process Control and Sequencing Poorly designed Equipment, poor Process Flow Design, poor construction and Fabrication all lead to cross-contamination and potentially Unsafe Feed

34 Safe Feed Manufacturing Innovations Limiting Cross-Contamination Before Thermal Processing Separate Intake, Preparation, Storage for Dry and Wet Ingredients (Fresh Meat & Fish) Wet Product does not enter Process before Heat Treatment Process design should limit unnecessary Transitional Equipment Processing Equipment should be of clean design with minimum to no Product Hang-up Transitional Equipment selection to consider physical Product Characteristics & potential Cross-contamination Purge Options at Critical Control Points before Extrusion / Pellet Pressing Fresh / Wet Product Flow Picture please Dry Feedstock Flow Final Product Flow Thermal Processing Limiting Cross-contamination between Dry and Wet Products in a Petfood Plant (Courtesy hp design Pty Ltd)

35 Safe Feed Manufacturing Innovations Limiting Cross-Contamination During Thermal Processing Thermal Processing Operation first point of Fresh Product meeting Dry feedstock thanks to innovations in Fresh Meat & Fish Handling & Preparation techniques Thermal Processing with proven Start-up and Shut-down procedures helps controlling Water Activity challenges Fresh Product enters Plant without crossing paths with Dry Feedstock Fresh Product meets Dry Feedstock first time at Thermal Processing A well designed Plant facilitates Wash-Down and Steam- Cleaning Advanced Suppliers offer Start-up Waste Recovery Systems (Cost Recovery) CIP & COP limit potential of Cross-Contamination Images Courtesy Wenger Manufacturing Inc.

36 Safe Feed Manufacturing Innovations Limiting Cross-Contamination After Thermal Processing Conveying down-stream from Extruder carefully selected to meet specific Product Requirements Options may include Pneumatic Conveying, Belt Conveying, Pendulum Conveying CIP (Clean-in-Place) Solutions available for Pendulum Conveying Vacuum Coating could include a CIP Cycle Purge Options at CCP s between Extrusion and Final Product Bins / Packaging / Bagging Purged Product could be re-used in Budget Formulations Negative Pressure Dilute Phase Pneumatic Conveying Pre-Drying to Drying- Cooling (Courtesy Wenger Manufacturing Inc.)

37 Safe Feed Manufacturing Innovations Conveying Options for Pet & Aquatic Feeds INTAKE EXTRUSION Drag Conveying Screw Conveying Positive Dilute Phase Pneumatic STD DRY EXPANDED >50% FRESH MEAT PET SEMI-MOIST PET SHRIMP / MICRO By-Pass Pre-Dryer Flat Belt Conveyor max 10 deg incline By-Pass Pre-Dryer By-Pass Pre-Dryer PRE-DRYER DRYER-COOLER COATER COOLER PACKAGING Negative Dilute Phase Pneumatic Pendulum Conveyor Cleated Incline Belt Conveyor Positive Dense Phase Pneumatic Pendulum Conveyor Cleated Incline Belt Conveyor Positive Dense Phase Pneumatic Pendulum Conveyor Cleated Incline Belt Conveyor Positive Dense Phase Pneumatic Pendulum Conveyor Cleated Incline Belt Conveyor Negative Dilute Phase Pneumatic Cleated Incline Belt Conveyor Positive Dense Phase Pneumatic Pendulum Conveyor Cleated Incline Belt Conveyor Positive Dense Phase Pneumatic Pendulum Conveyor Cleated Incline Belt Conveyor Positive Dense Phase Pneumatic Pendulum Conveyor Cleated Incline Belt Conveyor Cleated Incline Belt Conveyor Pendulum Conveyor Cleated Incline Belt Conveyor Pendulum Conveyor Cleated Incline Belt Conveyor Pendulum Conveyor Cleated Incline Belt Conveyor Negative Dilute Phase Pneumatic Pendulum Conveyor Negative Dilute Phase Pneumatic Cleated Incline Belt Conveyor By-Pass Coater By-Pass Cooler in Cooperation with Wenger Manufacturing Inc.

38 Safe Feed Manufacturing Innovations Importance of Thermal Processing (Technology Dependant) Producing Safe Feed Cooking of Feed Ingredients Starch Gelatinisation Controlling Density (Aquatic Feeds) Sterilising (By-Product) / Stabilising (Rice Bran) / Sanitising (Layer Feed) Minimising the effect of Anti-Nutritional Factors Maximising Digestibility of Protein, Fat & Fibre Production of new Textures (TVP s / TSP s) Enhancing Solvent Extraction Enhancing Mechanical Oil Expelling Extrusion Capability varies from Technology to Technology and should be specified with care (Courtesy Wenger Manufacturing Inc., Extru-Tech Inc. & ALMEX)

39 Safe Feed Manufacturing Innovations Thermal Processing Potential Thermal Processing Opportunity Preconditioner Thermal Compactor Thermal Sanitiser Expander Oil Press Extruder Oilseeds X X X X Raw Material Enhancement X X X X X By-Product Processing X X X General Animal Feeds X X X X X X Solvent Extraction X Aquatic Feeds X X X Petfoods X X Human Foods X X X

40 Australia / New Zealand Contact Details Head Office Contact Details Hennie Pieterse Tel : +61 (0) h.pieterse@ottevanger.com PO Box 4536 Springfield Lakes Brisbane, QLD 4300 AUSTRALIA Paul Eijmberts Tel : +31 (0) p.eijmberts@ottevanger.com Moerkapelsezijde 32 PO Box AA Moerkapelle The NETHERLANDS