1. Overview
This article discusses large pig pellets, focusing on the evolving dynamics of the feed market. With increasing competition and changing farming practices, there has been a shift in demand from pelletized feed to more efficient pellet feed. To remain competitive, feed mills must manage costs effectively, with the efficiency of pellet machines playing a crucial role in reducing overall expenses.
2. Basic Parameters
The tests were conducted under consistent conditions to ensure accurate comparisons. The formula contained approximately 65% corn, 34% protein sources, and 1% minerals and other additives. All raw materials were from the same batch, ensuring uniform moisture and impurity levels. The crushing fineness was set at 2.0mm, with a water content of around 12.5%. Granulation pressure was maintained at 8 bar before compression and 5 bar after decompression, with a temperature range of 80-85°C. The granulator motor operated at 150KW with an actual current of 230A. Pellets had a diameter of 4.0mm, and the cooling fan damper and unloading position remained unchanged throughout the process. A two-layer sieve (top mesh 3, bottom mesh 8) was used for grading.
3. Test Pellet Machine Model (Shepherd MUZL610TW)
The tests involved different compression ratios using the same ring die material (4Cr13), with an opening ratio of approximately 38.6%. For the 1:6 compression ratio, the production time was 12.6 hours, with a total output of 200 tons, a powder rate of about 5%, and an average production rate of 15.9 tons per hour. The finished product moisture was around 12.3%. For the 1:5 compression ratio, the production time was reduced to 10.1 hours, with a higher average output of 19.8 tons per hour and a slightly increased powder rate of 5.3%. Moisture levels remained similar at 12.4%.
4. Test Results Comparison
Electricity consumption for the 1:6 compression ratio was 1890 kWh, resulting in an electricity cost of approximately 5.3 yuan per ton. For the 1:5 compression ratio, the energy usage was 1515 kWh, leading to a lower cost of about 4.24 yuan per ton. This means a reduction of roughly 1.1 yuan per ton in electricity costs. Additionally, the finished product moisture was slightly lower, reducing losses by about 0.1%, which can improve yield and indirectly reduce costs. At a price of 3000 yuan per ton, this could increase revenue by around 3 yuan per ton. Overall, the cost per ton was reduced by approximately 4.1 yuan. If annual output reaches 50,000 tons, the annual cost savings would be around 205,000 yuan.
5. Discussion
The test results indicate that adjusting the compression ratio significantly impacts both granulation efficiency and feed quality. Higher compression ratios lead to better starch gelatinization, improving feed palatability. For large pigs, the compression ratio does not negatively affect product quality but enhances production efficiency, contributing to cost reductions. Improvements in granulation efficiency also benefit related processes, offering further cost-saving opportunities. However, due to limited testing conditions, some performance aspects of the feed were not fully evaluated. This study primarily focused on power consumption, providing a useful reference for real-world applications where such factors may become critical bottlenecks in cost control.
6. Conclusion
The experimental results show a significant improvement in pellet machine efficiency compared to previous compression ratios of 1:10–12. This reflects the growing maturity and efficiency of the livestock industry, which has led to substantial improvements in production efficiency. These changes have also enhanced the competitiveness of feed mills in the market, demonstrating the importance of optimizing feed production processes for long-term success.
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