3. INTRODUCTION
Quality is never an accident.
It is always a result of an
intelligent effort.
-John Ruskin
RUMINANT FEED PELLET QUALITY IMPROVEMENT BY OPTIMIZATION
4. QUALITY OF RUMINANT FEED IMPROVEMENT
Earlier single stage Roller mill was being used for producing both mash feed and ruminant pellet, as
a result the mash feed was OK, but the ruminant pellet feed quality was not up to the mark as the
corn was not properly being grinded resulting not so good texture of pellet and the breakage of
finished feed pellet.
As a solution, we have diverted the material after poultry hammer mill grinding to the ruminant pellet
press, so the material would be properly grinded and further proceed to ruminant pellet press to
form a good quality of ruminant pellet feed.
In coming days, we will further plan to replace roller mill with hammermill as the roller mill has a lot
of limitations and can be only used for mash, whereas we can use the hammer mill for both mash and
pelleted feed just by changing the screen size.
The investment on hammermill will maintain sustainable quality feed and will keep us ahead in
market competition.
RUMINANT FEED PELLET QUALITY IMPROVEMENT BY OPTIMIZATION
5. PRICE SUMMARY
RUMINANT FEED PELLET QUALITY IMPROVEMENT BY OPTIMIZATION
EQUIPMENT KAHL COST IN-HOUSE COST
Duplex Chain Conveyor (8mts-
10KW)
19,160 Euros Sourced from unused chain conveyor in
plant
Diverter 9,000 Euros Sourced from unused diverter in plant
Pneumatic cylinder 1,100 Euros Repaired a faulty cylinder
Position sensors 600 Euros Sourced from spare
Valve 100 Euros Sourced from spare
Spouts and other fittings 500 Euros Sourced from leftover while commissioning
Automation 1,000 Euros By Maintenance Engineer
Manpower cost 200-250SAR/Day (External
Contractors)(Sr-250x 6 Workers x 6-
Working days=Sr-/9,000.00.
Avg. Salary- 3,500SAR
(8Workers)Total Working Hours- 400
*14.58/Hr
Total (32,460 Euros )= Sr-(123,348 +
9,000.00 = 132,340.00. )
Project in-house cost-5,832SAR
Kahl Cost source: Quotation from Kahl received recently for expansion project
6. TIMELINE
Initial Tasks
Identified the
unused
equipments
(Chain Conveyors
and diverter) in
plant to be used.
Sourcing
Equipments
Collected
equipments from
scrap,
warehouses, and
refurbished for
use.
Coordinating
Coordinated with
production team
about the gap in
orders from sales
and identified the
perfect time for
execution of task.
Executing
Pulled out the
unused chain
conveyor and
diverter,
refabricated as
required and
installed. Did
automation as per
required process
flow.
Handing over
Observed the
process flow for
leakages and
smooth diverting.
Instructed the
operators to use
the diverter and
its use case as
and when
required.
RUMINANT FEED PELLET QUALITY IMPROVEMENT BY OPTIMIZATION
8. PROCESS FLOW
RUMINANT FEED PELLET QUALITY IMPROVEMENT BY OPTIMIZATION
BEFORE AFTER
Process flow diagram has been revised and updated
9. RESULTS
By doing this, we have observed a significant
improvement in ruminant feed pellet quality
Granulation has been improved.
Texture has been improved.
Pellet quality has been improved.
Torque on ruminant pellet press has been reduced, and
considerable amount of power can be saved in long run.
Capacity of ruminant pellet press has been improved.
RUMINANT FEED PELLET QUALITY IMPROVEMENT BY OPTIMIZATION
