system design and optimization

1. Importance of Process Flow
Analysis and Layout
Planning

2. • Optimize Efficiency
Process flow analysis means looking at how things move through each step of
making something in a feed mill. When we study this, we can find where things
aren't working well and fix them. Fixing these problems makes everything work
better, faster, and cheaper.

3. • Resource Utilization
Good layout planning means organizing things like machines, workers, and
space in a smart way. When everything is arranged well, it saves time and
makes things work faster. It helps workers move less and get more done

4. • Safety
A tidy layout and clear way of doing things make work safer. When there are
clear paths to walk, places to keep things, and the right way to handle stuff, it
helps avoid accidents and keeps people from getting hurt.

5. • Quality Control
When the way things are made is planned out well, it helps to check if the quality
is good. If materials go through each step in a controlled way, it's easier to watch
and keep the quality of the product high.

6. Flexibility and Scalability
A smart layout design means the feed mill can easily change and grow. If they
need to make more or different things, they can adjust the layout without causing
big problems in how things work.

7. • Cost Reduction
Making the way materials are handled and how everything is set up more
efficient helps save money in different ways like paying workers less, using less
energy, and spending less on fixing things. By making operations smoother and
cutting out unnecessary stuff, the total cost of making things can be lowered.

8. • Customer Satisfaction
Making sure materials are handled well helps meet what customers want: good
quality products, the same every time, and delivered on time. If the feed mill is
well-arranged, it can make sure orders are completed quickly and correctly.

9. Capacity Requirement and Flow Rate
Calculation

10. • Identify Material and Products
Know what kinds of things (like ingredients before they're made into feed, extra
things added in, and the final feed products) are being used in the feed mill.

11. • Determine Production Requirements
Set up how much feed the mill needs to make in a certain time, like how many
tons it should produce per hour.

12. • Define Process Flow
Draw a map that shows how things move in the feed mill, starting from when raw
materials arrive to when finished products are packed. Find any places where
things are stored temporarily in between.

13. • Calculate Material Flow Rates
Figure out how fast materials move through each part of the process. This means
knowing how long it takes to process them at each step and how much of the
materials are being processed.

14. • Consider Handling Equipment
Choose the right tools to move materials, like belts or machines that lift, based on
what the materials are like, how fast they move, and how much space there is.
The tools should be able to handle the amount of materials needed without
slowing things down.

15. • Account for Downtime and Maintenance
Consider the time needed for fixing and cleaning machines. Make sure that even
when machines are being fixed or cleaned, the system can still make enough
products as planned.

16. • Safety and Regulatory Consideration
Make sure to follow the rules and standards to keep things safe when handling
materials and using equipment.

17. • Optimization
Keep an eye on how materials are handled all the time and make them work
better and cost less. This might mean changing how machines are set, making
processes simpler, or using machines that work automatically.

18. Some Specific Calculation that may be
Involved

19. • Conveyor Capacity

20. • Elevator or Conveyor Speed

21. • Silo Capacity

22. • Hammer Tips Speed

23. • Amount of Steam Required

24. • Boiler Heating Surface (ft2)

25. • Flow Rate
Flow Rate =
Volume or Weight of Material
Processing Time

26. Selecting Appropriate Equipment based
on Material Properties and Process
needs

27. 1. Conveyors
Type:
• Belt Conveyor
• Screw Conveyor
• Bucket Conveyor
• Pneumatic Conveyor

28. Selection Criteria
• Material Properties: Consider the size, shape, and flow characteristics of the materials
being handled. For example, powdery materials may require enclosed screw conveyors
to prevent dust emissions.
• Capacity Requirements: Choose conveyors with appropriate capacities to handle the
expected flow rates of materials.
• Process Needs: Select conveyors that can handle the required inclines, declines, or
horizontal transfers based on the layout of the feed mill and process flow.
• Space Constraints: Opt for conveyors that fit within the available space and can be
configured to minimize obstruction of other equipment or workflow.
• Budget: Balance performance requirements with cost considerations to select the most
cost-effective conveyor solution.

29. 2. Storage Silos and Bins
Types:
● Flat-Bottom Silos
● Hopper-Bottom Silos
● Bins

30. Selection Criteria
● Material Properties: Choose silos or bins made from materials compatible with the
stored materials to prevent contamination or spoilage.
● Capacity Requirements: Select silos or bins with sufficient capacity to store raw
materials, intermediate products, and finished products based on production needs.
● Process Needs: Consider factors such as ease of material discharge, flow control
mechanisms, and accessibility for cleaning and maintenance.
● Space Constraints: Determine the optimal size and configuration of silos or bins to fit
within the available space while allowing for efficient material handling and storage.
● Budget: Evaluate the cost-effectiveness of different storage solutions considering
factors such as material durability, insulation, and automation features.

31. 3. Mixers and Grinders
Types:
● Batch Mixers
● Continuous Mixers
● Hammer Mills
● Roller Mills

32. Selection Criteria
● Material Properties: Choose mixers and grinders capable of handling the size,
density, and moisture content of the raw materials.
● Capacity Requirements: Select equipment with appropriate batch or throughput
capacities to meet production targets.
● Process Needs: Consider factors such as mixing uniformity, particle size reduction
requirements, and energy efficiency.
● Space Constraints: Determine the footprint and layout requirements of mixers and
grinders within the production facility.
● Budget: Evaluate the upfront investment and operating costs associated with
different mixer and grinder options, considering factors such as power
consumption and maintenance requirements.

33. 4. Packaging Equipment
Types:
● Bagging machines
● bulk bag fillers
● palletizers

34. Selection Criteria:
● Material Properties: Choose packaging equipment compatible with the
packaging materials and formats used for finished products.
● Capacity Requirements: Select packaging equipment with appropriate
throughput capacities to match the production rates of the feed mill.
● Process Needs: Consider factors such as packaging accuracy, flexibility to
handle different product sizes and weights, and automation capabilities.
● Space Constraints: Determine the space required for packaging equipment
installation and integration into the production line.
● Budget: Evaluate the cost-effectiveness of packaging solutions based on
initial investment, operational efficiency, and maintenance costs.

35. Automation and Control Systems
Types:
● Programmable logic controllers (PLCs)
● supervisory control and data acquisition (SCADA) systems
● sensors
● actuators

36. Selection Criteria
● Process Needs: Choose automation and control systems that can effectively
monitor and optimize material handling processes, improve efficiency, and ensure
product quality.
● Integration: Select systems that can be integrated with existing equipment and
software platforms within the feed mill.
● Scalability: Consider the scalability of automation solutions to accommodate future
expansions or modifications of the production facility.
● Reliability: Evaluate the reliability and uptime of automation systems to minimize
the risk of production disruptions.
● Budget: Determine the cost-effectiveness of automation investments based on the
potential benefits in terms of productivity gains, labor savings, and error reduction.

37. Optimizing System Layout for Minimum
Distance and Handling Steps

38. 1. Process Flow Analysis
Start by looking at how everything moves in the feed mill, from when raw
materials come in to when finished products are packed. Find each thing that
happens, like moving materials, making them into feed, storing, and packing.
Draw a picture showing how materials move around, where they go, and if there
are any places where things might slow down or not work well.

39. 2. Identify Key Material Handling Points
Point out important places where materials are moved or worked on, like where
belts meet, where materials are stored, mixed, or packed. Figure out how often
and how much materials are moved at each place to decide which ones need to
be made better first.

40. 3. Minimize Handling Steps
Try to make it so that materials have to be moved around less in the system.
Combine steps and avoid moving materials between machines or places to store
them if it's not needed. Use straight paths to move materials directly when
possible to avoid moving them extra times.

41. 4. Optimize Equipment Placement
Organize machines and places where people work so that materials and workers
don't have to go far. Put things that are related together to make work easier and
shorten the distance they need to go. Put machines that are used a lot or are
really important near where the materials start or where the main work is done to
save time moving things around.

42. 5. Utilize Vertical Space
Make use of the space above by adding extra levels or shelves. Use machines
like lifts or elevators to move materials up and down between levels, saving
space on the ground for other things.

43. 6. Implement Lean Principles
Use smart manufacturing ideas to get rid of things that aren't needed and make
materials move better. Find and remove things that don't add value, like extra
moving around, waiting, or doing too much. Set up the layout so materials keep
moving smoothly, with less stuff sitting around and less big batches being
processed all at once.

44. 7. Consider Material Characteristics
Think about what the materials are like, such as how big, heavy, easy to move,
or how quickly they spoil. Make machines and arrange things in a way that works
best for each type of material, so they're handled in the most efficient way
possible.

45. 8. Use Simulation and Modeling Tools
Use computer programs or tools to pretend and see how different setups of the
layout would work. Test different ideas to see which one makes materials move
the least and requires the fewest steps, but still meets what needs to be made.

46. 9. Continuous Improvement
Set up a way to always check and make the material handling layout better. Ask
the people who work with it and others involved for ideas to make it work better
and fix things if needed. Keep an eye on how well it's working by looking at things
like how much gets done, how long it takes, and how much it costs to move
materials. This helps find ways to make it even better.

47. Integrating conveying systems with storage,
processing, and packaging equipment

48. 1. Conveyor System Integration
● Receiving Area: Conveyors can be integrated with receiving equipment such as
truck unloaders or receiving pits to transport incoming raw materials directly to
storage or processing areas.
● Storage Silos and Bins: Conveyors facilitate the transfer of materials between
storage silos or bins and processing equipment. Level sensors or automated
control systems can regulate material flow to maintain optimal inventory levels.
● Processing Equipment: Conveyors connect various processing stages such as
grinding, mixing, and pelleting, allowing for continuous material flow between
equipment. Adjustable speed controls and diverter gates can manage material
flow rates and route materials to the appropriate processing equipment.

49. ● Packaging Area: Conveyors transport finished products from processing
equipment to packaging stations. Accumulation conveyors or buffer zones
may be integrated to temporarily store products before packaging, ensuring a
steady supply to packaging equipment.
● Palletizing and Shipping: Conveyors can facilitate the transfer of packaged
products to palletizing stations and loading docks for shipment. Automated
palletizers and stretch wrappers can be integrated with conveyor systems to
streamline the packaging and shipping process.

50. 2. Storage and Processing Equipment Integration
● Material Flow Control: Storage and processing equipment can be equipped with
sensors, actuators, and automated controls to regulate material flow and
coordinate with conveying systems. For example, material level sensors in
storage silos can trigger conveyor systems to replenish materials as needed.
● Batching and Mixing Systems: Batching and mixing equipment can be integrated
with conveying systems to automate ingredient delivery and ensure accurate
recipe formulations. Material flow from storage bins to batching equipment can be
controlled using pneumatic gates or augers.
● Pellet Mills and Extruders: Pellet mills and extruders can be positioned in close
proximity to storage bins or mixers to minimize material transfer distances.
Conveyors equipped with magnets or metal detectors can remove foreign objects
before feeding materials into pellet mills or extruders.

51. 3. Packaging Equipment Integration
● Inline Packaging Systems: Packaging equipment such as bagging machines, bulk bag
fillers, and box formers can be integrated directly with conveying systems for seamless
product transfer. Conveyors transport finished products from processing equipment to
packaging stations, where they are automatically filled, sealed, and labeled.
● Automated Control Systems: Packaging equipment can be synchronized with
conveying systems through automated control systems to optimize throughput and
minimize downtime. Sensors and feedback mechanisms provide real-time data to
adjust conveyor speeds and packaging rates based on production demands.
● Palletizing and Stretch Wrapping: Conveyors transport packaged products to palletizing
stations, where automated palletizers stack products onto pallets according to
predefined patterns. Integrated stretch wrappers secure palletized loads before they
are transferred to shipping areas.

52. 4. Automation and Control Integration
● Centralized Control System: An integrated control system oversees the
operation of conveying systems, storage equipment, processing machinery,
and packaging systems. PLCs, HMIs, and SCADA systems provide
centralized monitoring and control capabilities to optimize material flow and
production efficiency.
● Data Integration and Analysis: Integration with data collection and analysis
systems allows for real-time performance monitoring, predictive maintenance,
and process optimization. Key performance indicators (KPIs) such as
throughput, downtime, and energy consumption are tracked to identify
opportunities for improvement and optimization.