饲料制粒

PELLETING制粒MythsvsFacts理论与实践The“BIG”PelletMillatK-State堪萨斯州某加工厂内的大型制粒机ISSUESINPELLETING?有关制粒的话题？PELLETQUALITYVSPRODUCTIONRATE颗粒质量与产量PELLETQUALITYIS:…theabilityofpelletstotakehandlingwithoutgeneratingexcessivefines.颗粒质量是指颗粒抵抗各种处置而不产生过多细粉的能力PELLETTHROUGHPUTIS:…theabilitytofeedthebirds!!!颗粒产量是指能提供给畜禽饲料的数量PELLETQUALITYFACTORS40%15%5%20%20%Formulation配方Grind粉碎Die压模Conditioning调质Dry/Cool冷却器颗粒质量的影响因素PELLETQUALITY颗粒质量FORMATION配方PelletQualityisPrimarilyEstablishedintheConditioner,NotinthePelletDie.颗粒质量形成的第一位点是制粒机的调质器，而不是制粒机压模PELLETPRODUCTIONFACTORS40%25%25%10%Formulation配方Grind粉碎Die压模Conditioning调质颗粒产量的影响因素DIERESISTIVEFORCE压模的摩擦阻力压辊挤压力压模的表面反力饲料锲入压辊区防滑阻力压辊旋转方向工作区挤压区成形区压模旋转方向颗粒压模饲料压辊装配MAJORFACTORSAFFECTINGPRODUCTIONRATE影响制粒机产量的主要因素Formulation配方-Fat/Oilcontent油脂含量-AnimalProtein动物来源蛋白质-GrainType谷物种类-GrainMoisture谷物水分含量-PhosphateSource磷源FORMULATION配方Dietformulationisbasedonmeetingthenutrientrequirementsoftheanimalattheleastpossiblecostperton.日粮配制是以最低可能的成本满足畜禽对养分需要Littleconsiderationfor:很少考虑以下问题：-PelletQuality颗粒质量-ProductionRate生产率CONDITIONING:调质：....anymodificationoradditionmadetothemashafteritleavesthemixerandbeforeitreachesthepelletdiechamber...调质是指粉状饲料离开混合机直至到达制粒机压制室前所做的任何改变或添加操作MAJORFACTORSAFFECTINGPRODUCTIONRATE影响生产率的主要因素SteamConditioning蒸汽调质Thelevelofsteamconditioningpossibledependsonthe:蒸汽调质的程度取决于：-配方水分含量Formulamoisturecontent-配方中油脂含量Formulafat/oilcontent-蒸汽质量Steamquality-压模阻力和状况Dieresistanceandcondition-压辊表面和状况RollsurfaceandconditionMAJORFACTORSAFFECTINGPRODUCTIONRATE影响生产率的主要因素SteamConditioning蒸汽调质Asarule,thehigherthelevelofconditioning,thehigherthethroughputandpelletquality.通常来讲，调质的越充分制粒机产量越高，颗粒质量也越好。Condensedsteamactsasalubricant(uptoapoint!!)冷凝蒸汽起到润滑剂的作用（至关重要！！）STEAMCONDITIONING蒸汽调质Steamhastheabilitytocarryandtransferbothheatandmoistureefficientlythroughtheprocessof“CONDENSATION”.蒸汽通过凝结过程，能高效传递热与水分STEAMCONSIDERATIONS!!蒸汽需考虑的事项-质量？Quality?保温处理*Insulation汽水分离器*Traps阀*Valves-压力？Pressure?压力要求稳定*ConstantnotFluctuating蒸汽的热值变异要小*Makeslittledifferenceinheatcontent.CONDITIONINGLTERNATIVES调质的种类•SteamAddition-----常压蒸汽Atmospheric.•加压蒸汽-----压力蒸汽Pressure.•WaterAddition.加水•Expanding.膨化•Compacting.压实•Re-Pelleting.二次制粒•Ripening.熟化带夹套的调质器调质器方案选项CONDITIONEROPTIONS滞留时间RENTENTIONTIME1.调质器容积(单层及双层)ConditionerVolume(singlepassvs.doublepass)2.叶片角度Pick(paddle)Angle.3.调制器主轴转速ShaftSpeed.015457590叶片角度PickAngle(degrees)叶片角度调整PADDLEANGLEADJUSTMENTCONDITIONERVOLUME调质器的容积VSLargeLengthtoDiameterRatio大长度/直径比SmallLengthtoDiameterRatio小长度/直径比In-LineMoistureControl在线水分控制TheEffectofPreciseMoistureControlonPelletingOperations水分的精确控制在制粒过程中的作用OBJECTIVE:目的：TodetermineifprecisemoisturecontrolattheMixerwouldaffectpelletmilloperationsandpelletquality.测定在混合机中对物料进行精确的水分控制是否会影响制粒机的工作和颗粒质量PROCEEDURE:步骤：1.Cornwaslow-temp.driedandgroundthrougha8/64’’HMscreen.低温干燥的玉米，用8/64英寸HM筛片粉碎2.FeedType-corn-soypigfinishingration.饲料为典型的玉米－豆粕型肥育猪日粮3.Feedmixedina1,000lb(454Kg)ribbonmixer.饲料在一个1000磅/批的螺带混合机中混合4.Pelletingdonew/aCPMMastermodelpelletmillequippedw/a3/16”X1.5”die.制粒使用的是CPMMaster型制粒机，压模型号为2/16”X1.5’’5.Waterwasappliedtothemashinthemixerusinga“GrainPrep”autodeliverysystem.水通过一个“GrainPrep”自动添加系统添加到混合机的粉料中自动添加系统干料水分Incoming目标Target实际Actual经过调质Conditioned(%)(%)(%)(%)11.412.012.215.111.013.013.015.910.914.014.016.810.714.514.717.011.115.015.118.5水分与调质效果MoistureandConditioningResults7274767880828486889012131414.515PDI(%)添加的水分对颗粒质量的影响EffectofAddedMoistureonPelletQualityPDI%初始干粉料的水分StartingMashMoisture(%)MoistureManagementSummary水分控制小结1.Theautomatedsystemprovidedveryaccurateandprecisecontrolofcoldmashmoisture.自动系统可以实现对冷的粉料含水量的精准控制2.Finishedfeedpelletqualityincreasedwitheachincreaseincoldmashmoistureovertherangestudied在研究的范围内，随着冷的粉料中含水量的增加，颗粒质量提高。未来THEFUTURE!制粒与其它湿热加工工艺PELLETINGANDOTHERHYDROTHERMALPROCESSES膨胀器EXPANDERS未来THEFUTURE!压缩机Compactors制粒与其它湿热加工工艺PELLETINGANDOTHERHYDROTHERMALPROCESSES压缩（实）机压棍-3个附着于调制器主轴上液压缸以控制可调间隙板--3个喂料蒸汽轴承固定环隙板出料可调间隙板压缩机CompactorRollAssembly压缩机压辊总成未来THEFUTURE!通用制粒熟化机UNIVERSALPELLETCOOKERThe“UPC”fromWengerManufacturing制粒与其它湿热加工工艺PELLETINGANDOTHERHYDROTHERMALPROCESSES料仓喂料器2-3分钟的调制时间双轴差速调制器蒸汽添加定子/转子水分含量为14-18%的颗粒切刀制粒头未来THEFUTURE!加压制粒PressurePelleting制粒与其它湿热加工工艺PELLETINGANDOTHERHYDROTHERMALPROCESSESPRESSURIZEDCONDITIONING加压调质PCI,Inc.Wichita,Ks.进料口蒸汽未来THEFUTURE!在线压辊调节“ON-LINE”ROLLADJUSTMENT制粒与其它湿热加工工艺PELLETINGANDOTHERHYDROTHERMALPROCESSESRemoteRollAdjust远程压辊调节未来THEFUTURE!配方时应考虑颗粒质量FormulatingforPelletQuality!!能否办到？IsItPossible??制粒与其它湿热加工工艺PELLETINGANDOTHERHYDROTHERMALPROCESSES未来THEFUTURE!冷却器及其设计COOLERSANDCOOLERDESIGN逆流冷却器仍然在广泛应用CounterFlowCoolersAreHereToStay!未来THEFUTURE!冷却器及其设计COOLERSANDCOOLERDESIGN将来的设计中将具备干燥功能FutureDesignsWillIncludeDryingCapability未来THEFUTURE!PostPelletAdditiveApplication制粒后喷涂技术的应用*LowInclusionLiquids添加量小的液体-酶制剂Enzymes-药物Drugs-维生素Vitamins-生物制剂BiologicalsSource:AMANDUSKAHLSource:Hayes&StolzMfg.Co.小结SUMMARY(忠告ADVICE!!)保持信息灵通StayInformed!!!*务求经济实用Considertheeconomics*考虑替代途径Considerthealternatives*决策有理有据MakeLogical,RationalDecisions*关注相关进展WatchRelatedDevelopments