A water-saving and energy-saving production process and equipment for corn flake feed

Abstract

The present invention relates to the technical field of ruminant feed, and in particular to a water-saving and energy-saving production process and production equipment for corn flake feed. Heating steam indirectly contacts the material through an air needle, and after heat transfer, it flows back to the steam source from the end seat of the air needle for recycling. Compared with a process scheme in which steam directly contacts the material, steam leakage can be avoided, thereby reducing water and energy consumption. Compared with a process scheme in which the steam heat transfer is isolated on the working surface of a conveyor belt, heat can be directly transferred within the material, so that the material is heated evenly, the process quality stability is improved, and the restriction on material thickness is relaxed. The characteristic design of corn flake products based on mixed grass fibers can further reduce water and energy consumption in corn flake production, and has little restriction on the thickness of corn flake products, which can greatly improve production efficiency.

Description

Technical field:

[0001] The invention relates to the technical field of ruminant feed, and in particular to a water-saving and energy-saving production process and production equipment for corn flake feed. Background technology:

[0002] Corn flaking is one of the commonly used feed technologies for livestock feeding. It can mature corn starch to make it soluble, greatly improving the digestion and absorption rate of livestock.

[0003] The current corn flaking process is mostly a steam-ripening and pressing process. During the process, the dry corn kernel raw materials need to be crushed and then watered to adjust to a high moisture content (20% to 30% by mass) for sufficient moistening and gelatinization. After that, steam drying is adjusted to a low moisture content (10% by mass) and then hot roller pressing is performed. During this period, heating and evaporation of water accounting for about 20% of the mass of the material are required. This process consumes a lot of energy and water. Although some energy and water can be recycled through heat recovery cycle design and water recovery cycle design, it still constitutes the main process cost of the corn flaking process. If this part of energy and water consumption can be reduced, the cost of corn flaking feed can be greatly reduced, promoting the promotion of this advanced technology.

[0004] At the same time, current related production is all based on the compression of simple corn raw materials. When feeding ruminants, due to the lack of wood fiber in corn raw materials, the stimulation to the reticulum is relatively low. Using it alone as feed can easily lead to reduced rumination, rumen food accumulation and bloating in livestock such as cattle and sheep. It usually needs to be mixed with fibrous feeds such as silage. However, the two feeds are easy to stratify due to differences in physical properties, resulting in uncontrollable feed intake ratios for individual livestock, and the above-mentioned problem of reduced rumination cannot be completely solved.

[0005] Based on the above considerations, the applicant in this case designed a set of corn flake products mixed with grass fiber and its production process, which solved the above problems. However, the implementation of the heating and pressing process of this product still uses existing equipment, and there is still steam overflow loss. Considering that the product is pre-shaped after being mixed with grass fiber before heating and pressing, improving the production equipment based on this product feature has the prospect of further reducing water and energy consumption. Summary of the invention:

[0006] In view of this, it is necessary to provide a new water-saving and energy-saving production process and production equipment for corn flake feed based on the characteristics of corn flake products mixed with grass fiber, so as to further reduce the water and energy consumption of the production process.

[0007] The invention discloses a water-saving and energy-saving production process for corn flaked feed. The corn flaked feed product is composed of a gelatinized pressed product of cooked corn kernels, a grass fiber binder and additives.

[0008] Among them, the gelatinized pressed material of cooked corn kernels is processed from dry corn kernels, and the processing process is: 1. Screening out debris such as gravel and metal; 2. Crush the dry corn kernels and add 20% to 30% water by mass, stir evenly and let it stand; 3. Heat and maintain at 90 to 110 degrees Celsius for 40 to 55 minutes, during which time some water is filtered out to reduce the moisture content of the material to 12% to 15% by mass; 4. Press the material and further remove the moisture therein to form thin slices with a thickness of less than 5 mm and a moisture content of less than 8% by mass, and the temperature of the pressing process is controlled at 60 to 75 degrees Celsius; 5. Roll cut into the required size and let it stand to air dry and cool to form the gelatinized pressed material of cooked corn kernels.

[0009] The grass fiber adhesive accounts for 3% to 7% by mass in the corn flake feed product. Its processing process is as follows: 1. Silage grass is used as the raw material, and after removing debris such as gravel and metal, the moisture content is adjusted to 10% by mass; 2. The raw material is processed in one direction using a roller to crush it into needle-shaped materials with a length of 5 to 15 mm and a diameter of 0.3 to 0.5 mm; 3. The needle-shaped materials are evenly spread on a material plate and flattened to a thickness of 0.8 to 1.1 mm. A liquid slurry containing 4% to 6% corn starch by mass is added and allowed to settle at 40 to 50 degrees Celsius for 30 minutes, so that the needle-shaped materials are bonded into a network by the precipitated corn starch, thus forming the grass fiber adhesive; 5. The network material is bonded to the above-mentioned mature corn kernel gelatinized pressed material to form the addition of the grass fiber adhesive to the corn flake feed.

[0010] In the step of heating the material and maintaining it at 90-110 degrees Celsius for 40-55 minutes, a screen rack is set in the heat preservation box, and the material is spread flat on the screen rack and steam is introduced for heating.

[0011] The steps of pressing the material and further removing moisture therefrom are carried out using a steam pipe conveyor belt.

[0012] The steam pipe conveyor belt is composed of a material conveyor belt, an extrusion conveyor belt, an extrusion roller, a steam pipe device and a steam pipe action device; wherein the material conveyor belt and the extrusion conveyor belt are belt conveyor belt devices, the extrusion conveyor belt is arranged above the material conveyor belt, the working surface of the extrusion conveyor belt is downward, the processed material is clamped between the working surface of the material conveyor belt and the working surface of the extrusion conveyor belt, the extrusion roller is arranged below the working surface of the material conveyor belt and above the working surface of the extrusion conveyor belt and pressurizes the material conveyor belt and the extrusion conveyor belt to complete the pressing process when the material passes through the material conveyor belt; the steam pipe device is composed of an air needle array, an air needle starting seat, an starting seat guide rail and an air needle end seat, the two ends of the air needle array are connected to the air needle starting seat and the air needle end seat respectively, the air needle starting seat It is installed on the starting seat guide rail and connected to the steam pipe action device to drive the air needle to slide along the starting seat guide rail; in the process of completing the process steps, the air needle array and the material are clamped between the material conveyor belt and the extrusion conveyor belt, and steam is introduced into the air needles in the air needle array from the air needle starting seat to the air needle end seat, thereby heating and controlling the temperature of the material. After the heating and pressing steps are completed, the air needle starting seat drives the air needle array to move along the starting seat guide rail, so that the air needle and the air needle end seat are separated and extracted from the material. During this period, the air supply of the air needle starting seat is replaced with heated dry air, and the dry air moves along the hole formed when the air needle extracts the material, thereby achieving the process purpose of reducing the moisture content of the material to 8%; the above-mentioned steam pipe device moves with the material conveyor belt and the extrusion conveyor belt.

[0013] During the material pressing process, the above-mentioned process scheme allows heated steam to indirectly contact the material through the air needle. After heat transfer, it flows back to the steam source through the air needle end seat for recycling. Compared with processes where steam directly contacts the material, this can avoid steam leakage, thereby reducing water and energy consumption. Compared with processes where steam heat transfer is isolated from the conveyor belt working surface, heat can be directly transferred within the material, ensuring uniform heating of the material, improving process quality stability, and relaxing restrictions on material thickness. Furthermore, the holes left behind by the air needle after it is removed from the material can increase the cooling and drying speed of the material, relaxing the thickness restrictions on corn flake products and improving production efficiency.

[0014] Preferably, in order to prevent blockage caused by poor drainage of condensed water in the air needle, the steam pipe conveyor belt should be set at an angle, with the end seat of the air needle lower than the starting seat of the air needle.

[0015] Preferably, the extrusion conveyor belt is a hard roller, the steam pipe device is connected and installed on the hard roller and moves with it, and the material conveyor belt is tensioned by the tensioning wheel and attached to the lower surface of the extrusion conveyor belt and extends to both sides over the tensioning wheel to facilitate feeding and unloading.

[0016] The invention discloses water-saving and energy-saving production equipment for corn flake feed, which comprises a material conveyor belt, an extrusion conveyor belt, an extrusion roller, a steam pipe device and a steam pipe actuating device.

[0017] The material conveyor belt and the extrusion conveyor belt are belt conveyor belt devices, the extrusion conveyor belt is arranged above the material conveyor belt, the working surface of the extrusion conveyor belt is downward, the processed material is clamped between the working surface of the material conveyor belt and the working surface of the extrusion conveyor belt, the extrusion rollers are arranged below the working surface of the material conveyor belt and above the working surface of the extrusion conveyor belt and pressurize the material conveyor belt and the extrusion conveyor belt to complete the pressing process in the process of the material conveyor belt passing through the material conveyor belt; the steam pipe device is composed of an air needle array, an air needle starting seat, a starting seat guide rail and an air needle end seat, the two ends of the air needle array are respectively connected to the air needle starting seat and the air needle end seat, the air needle starting seat is installed on the starting seat guide rail, and is connected to the steam pipe action device to drive the air needle to slide along the starting seat guide rail; the above-mentioned steam pipe device moves with the material conveyor belt and the extrusion conveyor belt.

[0018] The present invention provides a water-saving and energy-saving production process and production equipment for corn flake feed. Based on the characteristic design of corn flake products mixed with grass fibers, the water and energy consumption of corn flake production can be further reduced, and the thickness limit of corn flake products is small, which can greatly improve production efficiency. Description of the drawings:

[0019] Figure 1 This is a schematic diagram of the principle structure of a specific embodiment of a water-saving and energy-saving production equipment for corn flake feed;

[0020] Figure 2 The present invention is a schematic top view of a specific embodiment of a water-saving and energy-saving production equipment for corn flake feed;

[0021] Figure 3 This is a schematic diagram of the principle structure of a specific embodiment of a water-saving and energy-saving production equipment for corn flake feed;

[0022] Figure 4 The present invention is a schematic diagram of a top view of a specific embodiment of a water-saving and energy-saving production equipment for corn flake feed, showing a state where an air needle array is withdrawn.

[0023] In the figure: material conveyor belt 1, extrusion conveyor belt 2, extrusion roller 3, air needle array 401, air needle starting end seat 402, starting end seat guide 403, air needle end seat 404, material 5, hard roller 6. Specific implementation method:

[0024] The invention discloses a water-saving and energy-saving production process for corn flaked feed. The corn flaked feed product is composed of a gelatinized pressed product of cooked corn kernels, a grass fiber binder and additives.

[0025] Among them, the gelatinized pressed material of cooked corn kernels is processed from dry corn kernels, and the processing process is: 1. Screening out debris such as gravel and metal; 2. Crush the dry corn kernels and add 20% to 30% water by mass, stir evenly and let it stand; 3. Heat and maintain at 90 to 110 degrees Celsius for 40 to 55 minutes, during which time some water is filtered out to reduce the moisture content of the material to 12% to 15% by mass; 4. Press the material and further remove the moisture therein to form thin slices with a thickness of less than 5 mm and a moisture content of less than 8% by mass, and the temperature of the pressing process is controlled at 60 to 75 degrees Celsius; 5. Roll cut into the required size and let it stand to air dry and cool to form the gelatinized pressed material of cooked corn kernels.

[0026] The grass fiber adhesive accounts for 3% to 7% by mass in the corn flake feed product. Its processing process is as follows: 1. Silage grass is used as the raw material, and after removing debris such as gravel and metal, the moisture content is adjusted to 10% by mass; 2. The raw material is processed in one direction using a roller to crush it into needle-shaped materials with a length of 5 to 15 mm and a diameter of 0.3 to 0.5 mm; 3. The needle-shaped materials are evenly spread on a material plate and flattened to a thickness of 0.8 to 1.1 mm. A liquid slurry containing 4% to 6% corn starch by mass is added and allowed to settle at 40 to 50 degrees Celsius for 30 minutes, so that the needle-shaped materials are bonded into a network by the precipitated corn starch, thus forming the grass fiber adhesive; 5. The network material is bonded to the above-mentioned mature corn kernel gelatinized pressed material to form the addition of the grass fiber adhesive to the corn flake feed.

[0027] In the step of heating the material and maintaining it at 90-110 degrees Celsius for 40-55 minutes, a screen rack is set in the heat preservation box, and the material is spread flat on the screen rack and steam is introduced for heating.

[0028] The steps of pressing the material and further removing moisture therefrom are carried out using a steam pipe conveyor belt.

[0029] The steam pipe conveyor belt is composed of a material conveyor belt, an extrusion conveyor belt, an extrusion roller, a steam pipe device and a steam pipe action device; wherein the material conveyor belt and the extrusion conveyor belt are belt conveyor belt devices, the extrusion conveyor belt is arranged above the material conveyor belt, the working surface of the extrusion conveyor belt is downward, the processed material is clamped between the working surface of the material conveyor belt and the working surface of the extrusion conveyor belt, the extrusion roller is arranged below the working surface of the material conveyor belt and above the working surface of the extrusion conveyor belt and pressurizes the material conveyor belt and the extrusion conveyor belt to complete the pressing process when the material passes through the material conveyor belt; the steam pipe device is composed of an air needle array, an air needle starting seat, an starting seat guide rail and an air needle end seat, the two ends of the air needle array are connected to the air needle starting seat and the air needle end seat respectively, the air needle starting seat It is installed on the starting seat guide rail and connected to the steam pipe action device to drive the air needle to slide along the starting seat guide rail; in the process of completing the process steps, the air needle array and the material are clamped between the material conveyor belt and the extrusion conveyor belt, and steam is introduced into the air needles in the air needle array from the air needle starting seat to the air needle end seat, thereby heating and controlling the temperature of the material. After the heating and pressing steps are completed, the air needle starting seat drives the air needle array to move along the starting seat guide rail, so that the air needle and the air needle end seat are separated and extracted from the material. During this period, the air supply of the air needle starting seat is replaced with heated dry air, and the dry air moves along the hole formed when the air needle extracts the material, thereby achieving the process purpose of reducing the moisture content of the material to 8%; the above-mentioned steam pipe device moves with the material conveyor belt and the extrusion conveyor belt.

[0030] During the material pressing process, the above-mentioned process scheme allows heated steam to indirectly contact the material through the air needle. After heat transfer, it flows back to the steam source through the air needle end seat for recycling. Compared with processes where steam directly contacts the material, this can avoid steam leakage, thereby reducing water and energy consumption. Compared with processes where steam heat transfer is isolated from the conveyor belt working surface, heat can be directly transferred within the material, ensuring uniform heating of the material, improving process quality stability, and relaxing restrictions on material thickness. Furthermore, the holes left behind by the air needle after it is removed from the material can increase the cooling and drying speed of the material, relaxing the thickness restrictions on corn flake products and improving production efficiency.

[0031] In order to prevent blockage caused by the poor drainage of condensed water in the gas needle, the steam pipe conveyor belt should be set at an angle, with the end seat of the gas needle lower than the starting seat of the gas needle.

[0032] The extrusion conveyor belt is a hard roller, and the steam pipe device is connected and installed on the hard roller and moves with it. The material conveyor belt is tensioned by the tensioning wheel and attached to the lower surface of the extrusion conveyor belt and extends to both sides over the tensioning wheel to facilitate feeding and unloading.

[0033] A water-saving and energy-saving production device for corn flake feed comprises a material conveyor belt 1, an extrusion conveyor belt 2, an extrusion roller 3, a steam pipe device and a steam pipe actuating device.

[0034] The material conveyor belt 1 and the extrusion conveyor belt 2 are belt conveyor belt devices, the extrusion conveyor belt 2 is arranged above the material conveyor belt 1, the working surface of the extrusion conveyor belt 2 is downward, and the processed material 5 is clamped between the working surface of the material conveyor belt 1 and the working surface of the extrusion conveyor belt 2, and the extrusion roller 3 is arranged below the working surface of the material conveyor belt 1 and above the working surface of the extrusion conveyor belt 2 and pressurizes the material conveyor belt 1 and the extrusion conveyor belt 2, so that the material 5 completes the pressing process during the process of passing through the material conveyor belt 1; the steam pipe device is composed of an air needle array 401, an air needle starting seat 402, a starting seat guide rail 403 and an air needle end seat 404, the two ends of the air needle array 401 are respectively connected to the air needle starting seat 402 and the air needle end seat 404, the air needle starting seat 402 is installed on the starting seat guide rail 403, and is connected to the steam pipe action device to drive the air needle to slide along the starting seat guide rail 403; the above-mentioned steam pipe device moves with the material conveyor belt 1 and the extrusion conveyor belt 2.

[0035] The steam pipe conveyor belt is tilted, and the air needle end seat 404 is lower than the air needle start seat 402.

[0036] like Figure 3 As shown, this design can also use a hard roller 6 to replace the extrusion conveyor belt 2 and the extrusion conveyor belt side extrusion roller 3, and install the steam pipe device on the hard roller 6 to ensure synchronous movement. When adopting this solution, the material conveyor belt 1 is tightened by the tensioning wheel and attached to the lower surface of the hard roller 6 and extends to both sides over the tensioning wheel to facilitate loading and unloading.

Claims

1. A corn flake feed production equipment, characterized in that: The corn flake feed production equipment is a steam pipe conveyor belt, which is composed of a material conveyor belt, an extrusion conveyor belt, an extrusion roller, a steam pipe device and a steam pipe action device; wherein the material conveyor belt and the extrusion conveyor belt are belt conveyor belt devices, the extrusion conveyor belt is arranged above the material conveyor belt, the extrusion conveyor belt working surface is downward, the processed material is clamped between the working surface of the material conveyor belt and the working surface of the extrusion conveyor belt, the extrusion roller is arranged below the working surface of the material conveyor belt and above the working surface of the extrusion conveyor belt and pressurizes the material conveyor belt and the extrusion conveyor belt to complete the pressing process when the material passes through the material conveyor belt; the steam pipe device is composed of an air needle array, an air needle starting end seat, a starting end seat guide rail and an air needle end seat, and the two ends of the air needle array are respectively connected to the air needle The starting seat and the air needle end seat, the air needle starting seat is installed on the starting seat guide rail, and is connected to the steam pipe action device to drive the air needle to slide along the starting seat guide rail; in the process of completing the process steps, the air needle array and the material are clamped together between the material conveyor belt and the extrusion conveyor belt, and steam is introduced into the air needles in the air needle array from the air needle starting seat to the air needle end seat, thereby heating and controlling the temperature of the material. After the heating and pressing steps are completed, the air needle starting seat drives the air needle array to move along the starting seat guide rail, so that the air needle and the air needle end seat are separated and extracted from the material. During this period, the air supply of the air needle starting seat is replaced with heated dry air, and the dry air moves along the hole formed when the air needle extracts the material, reducing the moisture content of the material; the above-mentioned steam pipe device moves with the material conveyor belt and the extrusion conveyor belt.

2. A corn flake feed production process, which uses the corn flake feed production equipment described in claim 1 to process corn flake feed, wherein the corn flake feed production equipment is a steam pipe conveyor belt, characterized in that: Corn flake feed products are composed of cooked corn kernel gelatinized pressed material, grass fiber binder and additives; The cooked corn kernel gelatinized pressed material is made from dried corn kernels in the following process:

1. Screening out impurities including gravel and metal; 2. Crushing the dried corn kernels, adding 20% ​​to 30% water by weight, stirring evenly, and then allowing to stand; 3. Heating and maintaining the temperature at 90 to 110 degrees Celsius for 40 to 55 minutes, during which time some water is filtered out to reduce the moisture content of the material to 12% to 15% by weight; 4. Pressing the material and further removing moisture to form thin sheets with a thickness of less than 5 mm and a moisture content of less than 8% by weight, with the pressing temperature controlled at 60 to 75 degrees Celsius; 5. Roll-cutting the material into the desired size, and then allowing the material to air-dry and cool, thereby forming the cooked corn kernel gelatinized pressed material. The grass fiber adhesive accounts for 3% to 7% by weight in corn flake feed products. The processing process is as follows:

1. Silage is used as the raw material, and after removing impurities including gravel and metal, the moisture content is adjusted to 10% by weight; 2. The raw material is processed in a single direction using a roller to crush it into needle-shaped materials with a length of 5 to 15 mm and a diameter of 0.3 to 0.5 mm; 3. The needle-shaped materials are evenly spread on a material plate and flattened to a thickness of 0.8 to 1.1 mm. A liquid slurry containing 4% to 6% corn starch by weight is added and allowed to settle at 40 to 50 degrees Celsius for 30 minutes. The needle-shaped materials are bonded into a network by the precipitated corn starch, thus forming the grass fiber adhesive; The grass fiber adhesive is bonded to the above-mentioned cooked corn kernel gelatinized compressed material to form the addition of the grass fiber adhesive to the corn flake feed; In the above-mentioned step of heating and maintaining at 90-110 degrees Celsius for 40-55 minutes, a screen rack is set in an insulation box, and the material is spread flat on the screen rack and steam is passed through to heat the material; The steps of pressing the material and further removing moisture therefrom are carried out using a steam pipe conveyor belt.

3. A corn flake feed production equipment according to claim 1, characterized in that: The steam pipe conveyor belt is arranged obliquely, and the end seat of the gas needle is lower than the start seat of the gas needle.

4. The corn flake feed production equipment according to claim 1, characterized in that: The extrusion conveyor belt is a hard roller, and the steam pipe device is connected and installed on the hard roller and moves with it.

Images