North Carolina State University
Animal Science Departmental Report
2004-2005
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Feed Milling Education Initiative

 

Academic Program

Feed Mill Educational Unit

Feed Milling Center

Capital Campaign

 

First Version, November, 2001

 

 

Introduction

Animal agriculture contributes more than 50% of the total annual agricultural income in North Carolina. The basis for all of animal agriculture is a dynamic feed milling industry that provides the nutrients essential for animal growth and reproduction. Sustainability of animal agriculture in North Carolina depends upon efficient feed utilization and minimization of environmental impact. The College of Agriculture and Life Sciences (CALS) at North Carolina State University (NC State) has embarked upon a Feed Milling Education Initiative to support this key industry. The College of Agriculture and Life Sciences Feed Milling Education Initiative is designed to develop well-educated men and women for leadership roles in the feed milling industry and to provide the underlying educational and research programs required to support a sustainable industry.

 

Structure

The College of Agriculture and Life Sciences Feed Milling Education Initiative is comprised of the following three components:

 

·         Academic Program.

·         Feed Mill Educational Unit.

·         Feed Milling Center.

·         Capital Campaign.

 

Present Status

The Academic Program has been initiated with the approval of a Minor in Feed Milling effective Fall Semester 2001. The basic structure that will house the Feed Mill Educational Unit is currently under construction at the Lake Wheeler Road Field Laboratory. The Feed Milling Center concept is currently under development.

 

Capital Campaign

To support the successful development of the Feed Milling Education Initiative a Capital Campaign with a goal of raising $2 million in cash and equipment will be conducted over the three-year period from 2002-2004.

 

General Perspective

Plans are well underway to convert the historic Yates Mill, pond, and wetlands adjacent to the Lake Wheeler Road Field Laboratory into a Wake County Ecological Park that has environmental education as its purpose.  The emphasis of this park will be on youth education with anticipated full involvement by the College of Agriculture and Life Sciences in this effort. The surrounding urban areas of Raleigh, Cary, Garner, and the Swift Creek-Middle Creek community continue to grow and create demands upon the undeveloped acreage of the Lake Wheeler Road Field Laboratory.  The Lake Wheeler Road Field Laboratory remains one of the few "open areas" in the Raleigh area.  Further, the fact that many educational programs dealing with agriculture are located there has provided the College of Agriculture and Life Sciences with a unique opportunity to develop a premiere educational program based upon the contributions of animal agriculture to the local environment and society. The educational outreach will extend to students, agriculturalists, the scientific community, and the general public as a whole.

The Feed Mill Educational Unit is being planned as an integral part of the environmentally sound "mini-integration" involving present animal production and crop production units at the Lake Wheeler Road Field Laboratory, the Waste Processing Facility of the Animal & Poultry Waste Management Center, and other facilities and programs within the College of Agriculture and Life Sciences as outlined below.  It will serve as an excellent teaching model of good natural resource stewardship practices and how they can be combined with efficient, integrated and sustainable animal agriculture.

 

The development of the Animal and Poultry Waste Management (A&PWM) Center has provided a number of opportunities to coordinate activities with the Feed Mill Educational Unit.  One of the primary missions of the A&PWM Center is to develop methods to convert byproducts (animal mortalities, offal, hatchery wastes, plant components not normally harvested, etc.) into value-added coproducts for the animal or plant industries. Since such animal byproducts represent approximately 30 percent of the total live weight of the animals produced, it is extremely important that recycling technologies be further developed. The extremely high temperatures produced during milling render the coproducts produced biologically safe for re-entry into the feed stream.

 

Development of an Academic Program in Feed Milling

Establishment of a new major degree program within the University of North Carolina system is a lengthy process. Due to monetary constraints any new major requires considerable justification regarding the need. Further, any new program, as well as continuing programs, must be constantly justified if the number of students graduating annually is low. This is presently the case for a number of degree programs in traditional agricultural areas. Therefore, a more logical way to proceed was to first develop a minor that could be used by students to receive academic training and certification in the specific topical area of feed milling. Development of the minor required the identification of courses that were presently being taught that could be applied to the topical area. In the case of feed milling there are a good number of courses currently available that have direct applicability. These are described in the text below. In addition, there has recently been developed a general survey course in feed milling that can serve as the initial core course. Collectively these courses will serve as the basic preparation for an actual feed milling work experience that can be structured within the External Learning Experience summer internship course. It is anticipated that a number of commercial feed mills will cooperate with the College of Agriculture and Life Sciences to provide these summer work experiences for our students. In the longer term, it is envisioned that interested feed milling enterprises may create full-time positions that can be filled on a rotating basis by Co-Op students.  This Co-Op model is used in other curricula at NC State.  The minor was approved effective Fall Semester 2001.

 

One weakness of the minor approach is the relatively low number of credit hours required. However, it is anticipated that this academic program will evolve rapidly in the direction of a feed milling “concentration” that will require a greater number of credit hours. This will ensure that students are exposed to a more complete program. A record of successful placement of graduates from the Feed Milling Minor in jobs with feed milling enterprises at competitive salaries will provide the necessary stimulus and justification for this evolution. A Feed Mill Management Concentration may be developed within any or all of the three present participating departments. Further, at least two more courses in Feed Milling will be needed along with a revision of the present core course to adequately cover required materials. This would create a core curriculum of three courses. This will require the addition of a new faculty member specifically educated in the feed milling area.

 

An Undergraduate Inter-Departmental Minor in Feed Milling in the College of Agriculture and Life Sciences 

The Inter-Departmental Feed Mill Minor is especially important to the North Carolina agricultural economy.  Currently, there are limited educational programs in the United States that specifically provide a balanced program in animal feed milling technology and animal and poultry management. Currently, North Carolina is a leading animal feed producer with over 11 million tons of animal feed manufactured each year.  Modern feed mills are complex and technologically advanced, requiring well-educated graduates to manage them.  There is presently an acute shortage of such graduates that could be met by an appropriate educational program. The Inter-Departmental minor will allow students an opportunity to acquire the knowledge they need to enter this field while providing employers with a supply of much needed people. The academic objectives of an Inter-Departmental Minor in Feed Milling are:

 

1.                  To acquire an understanding of the functions of a modern feed mill.

2.                  To learn the procedures to assist in operating a modern feed mill.

3.                  To learn to apply academic skills to the challenges of running a manufacturing facility.

 

Procedure for Admission to the Program

The student may consult the Departmental Teaching Coordinator in Animal Science, Biological and Agricultural Engineering or Poultry Science to initiate the minor program.  Students in this minor program, with the help of their primary faculty advisor, can also request advising assistance from a designated Departmental Feed Mill Minor advisor.  The student must submit an Application for a Minor to the Departmental Teaching Coordinator in Animal Science, Biological and Agricultural Engineering or Poultry Science.  These interdepartmental forms will be available in each departmental teaching coordinator’s offices. Students from other College of Agriculture and Life Sciences departments may submit the necessary written materials through any of the three departments listed above.

 

NCSU Undergraduate Catalog Description

The Inter-Departmental Minor in Feed Milling will provide knowledge needed for entry level in feed mill management and operation.  Students may select courses to emphasize nutrition, processing, management or engineering processes.

 

A minimum of 15 credit hours from the prescribed list and a grade of C- or better in these courses is required to receive an Inter-Departmental Minor in Feed Milling but the overall GPA of the minor must be a minimum of 2.0.  The intent is to make the initial program as flexible as possible.

 

1.      All students would be required to take one of the following introductory courses:

 

ANS 150  Introduction to Animal Science  4(3‑3) F,S

Fundamental principles of animal management including contributions of animals and animal products to humanity, application of science to animal production, and issues regarding animal production.

 

BAE 101  Introduction to Biological Engineering and Computing  3(2‑2) F

Preq: MA 141

Introduction to areas of concentration within Biological Engineering, and example engineering problems from each. Departmental and campus‑wide computing facilities will be examined.

 

PO 201  Poultry Science and Production  4(3‑3) F,S

Preq: BIO 125

Fundamental principles of broiler, turkey and egg production including poultry physiology, breeding, incubation, housing, nutrition, disease control, management and marketing.

 

2.      All students must take the following course:

 

PO (ANS) 425  Feed Mill Management and Feed Formulation  3(2‑3) S

Preq: PO (ANS, NTR) 415 or ANS 230; CH 220 or 221

Feed mill management, feed ingredient purchasing, inventory, storage, and quality evaluation, computerized feed formulation, feeding programs for poultry and swine, feed mill design, equipment, maintenance, operation, safety, state and federal regulations pertaining to feed manufacturing.

 

3.      A practical experience in a feed mill (summer job) is highly suggested. Faculty will assist

      interested students in making the necessary feed milling industry contacts.

 

ANS-BAE-PO 492  External Learning Experience  2-3 credit hours

 

4.   All students must take a minimum of two other courses from the following:

 

ARE 304  Agribusiness Management  3(3‑0) S

Preq: ARE 201 or EC 201

Management decision‑making by food, fiber, horticulture, and forestry firms. Emphasis on current agribusiness topics such as information utilization, strategic planning, organization structures, competitor intelligence, pricing, leadership, crisis management, ethics, and human resource management. Business communications, agribusiness case studies, and a computerized management simulation game.

 

ARE 311  Agricultural Markets  3(3‑0) F,S

Preq: ARE 201 or EC 201

Agricultural marketing system and economic forces affecting its structure and efficiency. Public policy issues affecting agricultural markets. Emphasis on the analysis of current sources of agricultural market information. Marketing and storage problems over time; futures markets and the management of risk; transportation and international trade; government agricultural programs.

 

BAE 201  Shop Processes and Management  3(2‑3) F,S

Safety practices, materials, equipment, processes, procedures, and management techniques related to operation and maintenance of a mechanized agricultural enterprise or agriculture‑related industry. Theory and practice through basic shop operations and procedures.

 

BAE 202  Intro to Bio and Ag Engineering Methods  3(1‑0) S

Preq: BAE 101

Basic design and problem solving methodology for Biological Engineering. Visualization skills, computer‑aided 3‑D solid modeling of parts, 3‑D assembly of solid part geometries, computation of mass properties, 2‑D engineering drawings, engineering design process, safety, tools, and fabrication processes and design, and hands‑on shop fabrication of semester project.

 

BAE 333  Processing Agricultural Products  4(3‑3) S

Preq: PY 212

Application of the principles of fluid flow, heat transfer, refrigeration, psychrometrics, and materials handling to the processing of agricultural products. Pump sizing, heat exchanger selection, refrigeration analyses, fan sizing, crop drying, and selection of materials handling equipment.

 

BAE 343  Agricultural Electrification  3(3‑0) F

Coreq: PY 212

Practical and efficient use of electrical energy for agricultural and home application. Energy conservation, electric rates, farm and house wiring, circuit design, single‑phase and three‑phase distribution systems, electric motors, lighting, space and water heating, electric controls, safety and protective devices.

 

BAE 344  Circuits and Controls  1(0‑3) F

Coreq: PY 212; BAE 343 or ECE 211

Applied laboratory covering energy conservation, farm and home wiring, circuit design, single‑phase and three‑phase distribution systems, electric motors, lighting, heating, electric controls, safety and protective devices, and home water systems.

 

BAE 432  Ag and Environmental Safety and Health  3(3‑0) F

Preq: Junior standing and 6 hrs CALS Group A, B or C Electives

Safety and health issues for agricultural and environmental occupations. Hazard recognition, injury and illness prevention, regulations, and safety and health management strategies for agricultural production, chemical handling, and waste management. Environmental factors which affect human health and safety.

 

BUS 330  Human Resource Management  3(3‑0) F,S

Preq: Sophomore standing

The systematic principles for managing the human resource component of organizations. Topics include: environmental influences on planning, recruitment, and selection; managing workforce diversity; developing effectiveness and enhancing productivity; compensation, benefits, and security; and strengthening employee‑management relations.

 

FS 495I  Special Topics – HACCP  2 credit hours

Examines issues related to the development of HACCP programs.

 

PO (ANS) (NTR) 415  Comparative Nutrition  3(3‑0) F

Preq: CH 220 or 221 and 223

Principles of nutrition, including the classification of nutrients and the nutrient requirements of and metabolism by different species for health, growth, maintenance and productive functions.

 

Feed Milling Education Initiative Faculty Impacts

A new faculty position to provide leadership to the College of Agriculture and Life Sciences Feed Milling Education Initiative will be requested from the North Carolina General Assembly through the University of North Carolina System. The scope of the responsibilities of the faculty position will depend upon the feed mill facilities that can be developed. Industry support for this initiative would facilitate the timely development of this program.

 

Feed Mill Educational Unit

 

Benefits and Educational Impacts

The Feed Mill Educational Unit will yield several benefits.  This facility will provide animal researchers with a state‑of‑the‑art facility within which to manufacture modern feeds for animals, thus positioning the College of Agriculture and Life Sciences as a leader in animal feed milling and nutrition research and education.  This will attract external grant opportunities and contracts.  It will also help attract the best undergraduate and graduate students, faculty, and industry collaborators to the College of Agriculture and Life Sciences educational programs.  The facility will provide the backbone of an educational program designed to produce college graduates that are competent in feed mill management.  Moreover, this facility will allow the College of Agriculture and Life Sciences to fully and efficiently utilize current animal research space and facilities and help maintain the diverse agricultural industry that has tremendous economic impact in all areas of our state.  During the harvest of the more than 60 agricultural commodities grown in North Carolina significant byproducts can be produced that have presently undeveloped economic use in animal feeds. The facility will also encourage the current industry trend towards precision animal nutrition that meets the nutritional requirements of animals while minimizing environmental impact.

 

Present Status

A comprehensive schematic plan has been developed that will allow the phased construction of a College of Agriculture and Life Sciences Feed Mill Educational Unit.  Approximately $2.4 million, appropriated by the 1997 legislative session of the North Carolina General Assembly and another $300,000 from the recent Bond Package, is available for construction of the basic structure. To maximize the effectiveness of these funds construction documents were developed for a basic mill structure and site work as a bid package separate from the milling facilities and equipment.  A general contractor was hired for construction of the buildings and site work.  After construction of these structures, local millwrights, electricians, tradesmen, etc. will be hired to install NC State purchased and/or industry-donated equipment. This strategy will require a longer period of construction than a turn-key job but will ensure that qualified contractors are responsible for the specialized as well as general requirements of this unique facility at the lowest possible cost. Further, direct purchasing of the milling infrastructure by NC State will hopefully maximize the possibilities for discounts, gifts-in-kind, and donations from vendors and supporters.  The North Carolina Agricultural Foundation will provide assistance to individuals or companies who would like to arrange a tax-advantaged contribution or gift-in-kind.

 

Construction Pictures

 
Figure 1. Site excavation
 

Figure 2. Concrete forms

 

Figure 3. Concrete forms removed
 

Figure 4. Steel frame construction
 

Figure 5. Steel frame with added sheet metal

Feed Mill Educational Unit Planning Priorities

The feed milling facility will be officially named the Feed Mill Educational Unit and as envisioned will meet a number of educational objectives for animal agriculture related programs.  These include:

 

·         On campus instructional programs at the undergraduate and graduate levels in relation to feed formulation; feed manufacturing; mill design; mill operation and maintenance; mill safety; ingredient and finished feed quality assurance programs; specialty feed production; mill regulatory programs, etc.

·         Production of relatively small batch precision feeds for research animals, as well as precision premixes and concentrates.

·         Extension education programs including workshops and short courses.

·         Educational programs for the general public.

·         Research on certain aspects of feed manufacturing per se for the livestock and poultry industries.

 

Feed Mill Educational Unit Facility Design and Features

·         The facility will include all of the normal components of a commercial mill.

·         Provisions for a video surveillance system will be incorporated throughout the mill to allow viewing in a remote location and discussion of remote and micro processes.

·         Quality assurance and quality control testing of ingredients and feeds produced will be an integral part of the overall mill arrangement.  Quality control procedures (i.e., ingredient and finished feed sampling, sample storage, sample testing) and regulatory compliance programs will need to be utilized in the day-to-day feed production processes, and demonstrated in the teaching programs.

·         The milling processes involved will be subject to either semi-automation or manual operation, so that the teaching and/or research programs can utilize or demonstrate the unique aspects of each part of the system or of the system as a whole.

·         Ruminants can utilize a number of coproduct feedstuffs developed from animal and other agricultural byproducts.  The basic feed mill, however, will not be designed to handle very bulky types of feed such as fodder, hay, silages, etc., but will be able to produce premixes and concentrates designed to be mixed with bulky or wet feeds in adjacent facilities.  Cottonseed hull based complete diets for ruminants will be made in the mill.

·         The mill design will incorporate both a small batch pilot facility and a main production facility.

·         The physical plant for the mill will provide enough flexibility and room to allow for upgrading of the equipment, and the testing of new and experimental equipment and processes.

·         Utility connections for the major equipment items will have usage monitoring incorporated into the design so that economic evaluations can be made for various processing techniques.

·         Safety will be a major consideration in design, operation, and instruction.

·         The facility will be capable of dispensing feeds into bags, bulk boxes, bulk bags, and bulk trucks.

·         A unique split-level design with an upper Ingredient Level and lower Process Pit will position access to most operations at or below a floor level to facilitate operations and instructional activities.

 

College of Agriculture and Life Sciences Feed Production Requirements

It has been estimated that a 150-ton per week capacity mill should meet the production needs of the College of Agriculture and Life Sciences animal units.  There will be nearly 100 unique feed formulas typically in use at any given time.  It is desired that the feed production needs be met in three working days per week, so as to allow two days per week for research, educational, and maintenance activities.

 

Feed Mill Educational Unit Schematic Design

At the rear of this document there is a list of required equipment, elevations and diagrams that detail the present Feed Mill Educational Unit plan.  A complete set of plans are available by request.

 

Feed Mill Educational Unit Planning Committee

The Feed Mill Educational Unit planning committee membership was developed from several constituencies that include the College of Agriculture and Life Sciences administration (CALS), Animal Science (ANS), Biological and Agricultural Engineering (BAE), Facilities Planning and Design (FPD), Poultry Science (PO), and University Field Laboratories (UFL).

 

Ken Anderson             PO                                           Walker "Mac" McNeill              UFL

Bob Bottcher               BAE                                         Jack Odle                                ANS

Richard Currin            UFL                                         Carm Parkhurst                       PO

Peter Ferket                PO                                           Matt Poore                               ANS

Jim Garlich                  PO                                           Jerry Spears                           ANS

Jesse Grimes             PO                                           Glenn Thomas                        FPD

Winston Hagler           PO                                           Eric van Heugten                    ANS

Bill Hedspeth               UFL                                         Lon Whitlow                            ANS

George Kriz                 CALS                                       John Brake                              PO, Chair

                              

Mill Design:                              Wagester and Lease, Pittsburgh, PA

Architect:                                 Brown and Jones Architects, Inc., Raleigh

Site Design:                            George Finch/Boney and Associates, Raleigh

Mechanical Design:                Atlantec Engineers, Raleigh

 

Several experienced commercial feed mill managers have advised the committee on an ad hoc basis.

 

Feed Milling Center

A Feed Milling Center concept is currently under development. A Center within the University of North Carolina (UNC) system is organized from dues-paying members that comprise the Board of Directors for the Center. There are full members and associate members of the Center based upon the level of dues that are contributed. The full members make the decisions as to where member fees are spent to support educational and research initiatives. Full members share in semi-exclusive licenses to any new intellectual property as well.  In the case of the Feed Milling Center it is envisioned that there will be Academic, Extension Education, and Research initiatives that will involve issues such as new coursework, Extension Educational Programs and Workshops, and investigations of optimum feed milling practices. 

 

Individuals and companies that make contributions qualifying for the Gold or Platinum recognition levels will be invited to participate as Charter Members for a limited time in the Feed Milling Center at no cost. The Charter Members will help guide the initial development of the Feed Milling Center.

 

Feed Milling Education Initiative Capital Campaign

A three-year capital campaign is planned to raise the additional funding necessary to acquire the necessary feed milling equipment for the Feed Mill Educational Unit. Companies and individuals may make three-year pledges of cash donations through the North Carolina Agricultural Foundation. Companies may also purchase or donate specific pieces of equipment and receive the necessary tax receipts documenting that donation. Companies who are interested in providing specific items of equipment may discuss the tax implications of that type of contribution with the North Carolina Agricultural Foundation.  Generally, such gifts are eligible for tax deductions at fair market (retail) value.  The necessary IRS documents will be provided by the North Carolina Agricultural Foundation.  Individuals and companies that make contributions qualifying for the Gold or Platinum recognition levels will be invited to participate in the Feed Milling Center without charge for a limited time.  This Charter Membership will become effective when the Center is approved by the UNC General Administration.

 

An appropriate plaque(s) recognizing all individuals and companies who contribute financially to this effort will be placed prominently in the facility.

 

There is a need for interested individuals to assist with this Capital Campaign effort. Individuals or company representatives that have such an interest may contact one of the three individuals listed below for more information.

 

Capital Campaign Co-Chairs:            Jack Odle (Animal Science)

Robert Bottcher (Biological and Agricultural Engineering)

John Brake (Poultry Science)

 

Three-Year Cumulative Contributor Recognition Levels

 

 

Naming Rights Level      $ 1-2 Million

 

Corporate Gifts

Individual Gifts

Platinum

$ 500,000

Platinum

$ 5,000

Gold

$ 100,000

Gold

$ 1,000

Silver

$   50,000

Silver

$    500

Bronze

$   10,000

Bronze

$    100

Friends

Other

Friends

Other

 

For further information please contact:   

                                                            Dr. John Brake, Co-Chair

                                                            Feed Milling Education Initiative Capital Campaign

                                                            Campus Box 7608

                                                            North Carolina State University

                                                            Raleigh, NC 27695-7608                               

                                                            Phone:   919-515-5060

                                                            Fax:       919-515-2625

                                                            Email:  john_brake@ncsu.edu

 

Feed Mill Major Equipment Requirements

The type of equipment listed below will need to be either purchased or donated in order to meet the projected educational mission of the Feed Mill Educational Unit. The following list is intended to provide a general overview of requirements without being exhaustive in detail. Individuals or companies interested in any of the items should make an inquiry for full details and specifications. Full bid-type specifications are available by request.

 

Feed Cleaner

            Rated at 1,500 CFH for mash feed (40 PCF) with 3/8” screen.

 

Gates/Diverters

Twenty-one (21) slide gates ranging from 10” to 20” that will be either manual or air-operated.

 

Four (4) diverters ranging from 10” to 13” that will be manually operated.

 

Hammermill

One (1) hammermill rated at 7 TPH on US #2 corn at a 600 micron mean particle size with air swept gravity discharge, vibration switch, door limits and inlet chute with double step permanent ceramic plate magnet.

 

Rollermill

One (1) rollermill rated at 7 TPH on US #2 corn at a 1200 micron mean particle size with air swept gravity discharge and manual roll adjust.

 

Level Indicators

Twenty-two (22) rotary level indicators, three (3) diaphragm level indicators, and one (1) capacitor level indicator.

 

Microingredient System

One (1) 20-bin electric microingredient system with stainless steel bins for in-floor installation.

 

Plant Control System

One (1) PC/PLC based control system including automated routing, receiving, grinding, batching and pelleting.

 

Liquid Coater

            Dry flow type               Animal feed @ 40 PCF

                                                Maximum flow rate @ 8 TPH

 

            Liquid materialLiquid fat to be applied at 2% to 12% of dry flow rate

                                                Enzymes to be applied at appropriate rates

 

Total installation will include pre-surge bin with high and low level, weigh feeder, spray chamber, 10’-0” long blending screw, and controls that will be supplied as part of plant control system.

 

Meters

One (1) mass flow meter rated at 35 GPM and one (1) mass flow meter rated at 5 GPM for liquid fat.

 

Mixers

One (1) 2-ton capacity horizontal twin shaft batch mixer with liquid manifold, full drop bottom discharge, 115 CF surge and discharge drag conveyor rated at 1,500 CFH. Designed for a 2-minute total mix time with a CV of 7 or less with animal mash feed (35 – 40 PCF).

 

One (1) 5-ton capacity horizontal single shaft batch mixer with liquid manifold, multiple slide gate discharge, partial surge with full length discharge screw conveyor (center discharge) rated at 1,500 CFH. Designed for a 2-minute total mix time with a CV of 7 or less with animal mash feed (35 – 40 PCF).

 

One (1) 500 pound capacity horizontal single shaft batch mixer with liquid manifold, single gate discharge. Designed for a 2-minute total mix time with a CV of 7 or less with animal mash feed (35 – 40 PCF) as well as premix materials.

 

Expander

One (1) expander rated at 8 TPH and 10 KW/Ton with controls, standard water injection and necessary temperature and level probes.

 

            One (1) crusher rated at 8 TPH.

 

Extruder

One (1) extruder line rated at 2 TPH with extruder, dryer/cooler and controls.

 

Pelleting System

Two (2) pelleting systems rated at 4 TPH and 8 TPH producing an 11/64” diameter pellet with a minimum PDI rating of 80 at the cooler discharge. Included with each system will be:

 

·                     Stainless steel feeder screw

·                     Variable speed stainless steel conditioner to achieve 210º F assuming a mash feed temperature of 75º F and mash feed moisture of 12%

·                     Steam harness with a gate valve, a pressure regulator, a pneumatically operated flow control valve and pneumatically operated shutoff valve

·                     Counterflow cooler to cool pellets within 10º F of ambient temperature complete with stainless steel construction, manual clean out, inlet spreader, automatic air damper and basic control panel

·                     Crumbler with manual roll adjustment and manual bypass as well as an inlet roll feed if required

 

Pumps

One (1) rotary gear pump rated at 35 GPM @ 40 PSI for and one (1) rotary gear pump rated at 3 GPM @ 75 PSI for animal fat.

 

Liquid Application Systems

Pumps and spray systems appropriate for typical liquid ingredient and enzyme applications.

 

Screw Conveyors

Eleven (11) feeder screw conveyors with variable pitch flared trough inlets and double pitch flighting at the discharge varying from 9” to 12”.

 

Six (6) transfer screw conveyors varying from 9” to 12”.

 

Drag Conveyors

Six (6) transfer drag conveyors both horizontal and with sweep sections varying from 300 CFH to 1,800 CFH.

 

Turnheads

Four (4) 8” diameter turnheads with 10 position electric distributors.

 

Bucket Elevators

            One (1) 1,800 CFH bucket elevator rated @ 45 PCF for discharge at 78’-0”.

 

            One (1) 1,500 CFH bucket elevator rated @ 40 PCF for discharge at 76’-6”.

 

            Two (2) 300 CFH bucket elevators rated @ 40 PCF for discharge at 76’-6”.

 

Weigh Buggies

Two (2) portable non-powered bulk weigh buggies with 1,000 pound capacity and quick opening floor level discharge gate.

 

Baghouse

One (1) baghouse with hopper at 3’-0” discharge height, pulse air cleaning and 1,175 square foot cloth area.

 

Cyclones

            One (1) stainless steel high efficiency cyclone rated at 1,950 ACFM

(180º F).

 

One (1) stainless steel high efficiency cyclone rated at 3,900 ACFM

(180º F).

 

Fans

            One (1) radial blade fan rated at 4,700 ACFM (100º F) @ 20” W.C.

 

            One (1) radial blade fan rated at 1,950 ACFM (180º F) @ 20” W.C.

 

            One (1) radial blade fan rated at 3,900 ACFM (180º F) @ 20” W.C.

 

Airlocks

Two (2) 12” x 10” rotary airlock with cast iron housing and 4-vane carbon steel rotor.

 

One (1) 12” x 10” rotary airlock with cast iron housing and 6-vane carbon steel rotor.

 

Boiler System

One (1) 50 HP self-contained high-pressure electric (480V) steam boiler (150 PSIG) meeting ASME boiler code.

 

One (1) boiler feed water system with receiver tank and two (2) centrifugal pumps.

 

One (1) blow down separator with temperature regulator valve package.

 

Air Compressor

            One (1) 10 HP rotary screw compressor.

 

            One (1) 100 gallon ASME vertical air receiver tank with automatic drain.

 

            One (1) refrigerated air dryer.

 

Bagging System

One (1) gravity fed open mouth bagging scale with pneumatically operated bag clamps, 2 position gate, load cells and controls.

 

One (1) variable speed conveyor with paper and woven polypropylene bag sewing system with portable sewing machine head that has adjustable sewing height.

 

Bins/Tanks

Assortment of smooth and corrugated hopper bottom metal tanks ranging from 5 to 139 tons.

 

Miscellaneous Fabrication

            Assortment of carbon steel and stainless steel fabricated items including:

 

·                     Batching Scale

·                     Truck Receiving Hopper

·                     Hand Add Hopper

·                     Cooler Duct Work

·                     Transitions

·                     Surge Bins

 

Electrical System Requirements

            The majority of motors for major equipment listed above will be 3-phase 480V.