Feed milling (broiler + layer feeds) · 20 t/h · 120,000 t/year
Integrated feed mill — Ghana
Illustrative scenario: turnkey 20 t/h pelleted feed mill supplying an integrator's broiler and layer flocks across southern Ghana. Sourcing covered raw-material intake, hammer mill, mixer, pellet press, cooler, bagging and bulk out-loading, with soybean and maize handled locally alongside imported additives.
Load requirements
Design loads used to size housing, utilities and equipment.
Line capacity
20 t/h pellet, 6 t/h mash bypass
Silo storage
8 × 500 t raw + 6 × 200 t finished
Peak electrical load
1.35 MW installed, 900 kW running
Steam demand
1.8 t/h saturated at 6 bar
Batch cycle
6 min mixer cycle, 4 batches queued
Bulk out-loading
40 t truck load in ≤25 min
System design choices
Why each subsystem was specified the way it was.
| Area | Choice | Rationale |
|---|---|---|
| Grinding | 1,200 mm hammer mill + hopper aspiration | Handles 25 t/h maize at 3 mm screen with steady amp draw and low dust carry-over. |
| Mixing | 2 t twin-shaft paddle mixer + liquid dosing | Achieves CV <5% in ≤75 s and dosing accuracy ±0.3% for fats and enzymes. |
| Pelleting | 250 kW ring-die + double conditioner | Double conditioner raises meal temp to 82 °C, improves PDI ~4 pts vs single conditioner. |
| Cooling | Counter-flow cooler + rotary sifter | Pellet temp within 5 °C of ambient at exit; fines returned to conditioner for re-pelleting. |
| Traceability | PLC-linked batch records + lot codes at bagging | Required by Ghana FDA feed-safety inspection and integrator's HACCP program. |
Results
Representative KPIs achieved on projects of this scope.
Pellet durability (PDI)
93.2%
Fines at bagging
3.1% by weight
Energy per tonne
38 kWh/t (grind + pellet)
Line uptime
88% (18 h/day × 6 days)
Cross-contamination
<0.5% between broiler/layer runs
Representative outcomes
- Typical scope: 20 t/h pelleted, 2 mash side-streams
- Typical outcome: pellet durability index (PDI) ~93%
- Typical outcome: 4 formulas produced with <0.5% cross-contamination
Note: This case study is an anonymized reference scenario. Specific client identities, contract values and commercial terms are withheld under NDA. Figures reflect typical outcomes for projects of this scope and are not a guarantee for your project.