Grain bulk densifying die apparatus and method

Abstract

An apparatus and method for processing grain material to generate a consistently high densified grain with a desired length, shape and size. The densified grain processing apparatus comprises a die assembly, a cooling assembly and a break-off assembly. The method includes receiving the grain material by the die assembly and forcing the grain material through an extrusion passageway that evenly distributes the grain material into a plurality of orifices thereby producing a high density shaped grain before the grain material exits the die assembly. A coolant is pumped to a coolant passage by means of an at least one pump and cools the shaped grain by passing the shaped grain through at least one of the cooling tube inside a cooling chamber. The break-off assembly then breaks off a predetermined length of the shaped grain.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation of U.S. patent application Ser. No. 15 / 132,991 filed Apr. 19, 2016, which will issue as U.S. Pat. No. 9,750,268 on Sep. 5, 2017.BACKGROUND OF THE DISCLOSURETechnical Field of the Disclosure[0002]The present teachings relate to devices and methods for producing a consistently high density material having a desired length and size.Description of the Related Art[0003]In the field of food and feed processing, grain densifying and die systems are used to produce high quality densified grain for industrial purpose and animal consumption. In general, it has been recognized that construction of the die apparatus, also commonly known as a pellet mill or extruder die, is a critical factor in obtaining desirable pellets as well as high production rates. For example, the thickness of the die, the number of holes in the die, and the surface finish of the die have all been found to affect pellet quality.[0004]In a typ...

AI Technical Summary

Benefits of technology

This patent describes an apparatus for making high-density grain. It includes a die assembly, a die head, a cooling chamber, and a break-off assembly. The die assembly has a triangular nose cone member at the middle, which helps to force the grain material through the extrusion passageway and evenly distribute it into each of the orifices. The result is a high-density grain.

Problems solved by technology

However, some existing processes fail to remove all the moisture or air or both from the final pellet, which subjects the pellets to increased decomposition and breakdown during normal handling, storage, and transport.

This decreases the percentage of useful pellets.

While steam is being added to the raw material, air is also continuously introduced into the raw material causing the material to contain substantially more air and water, which adversely affects the ultimate density.

Therefore, when the final product is subjected to vibrations and jostling, for example, associated with vehicular transport or transport to an accumulation bin, the product may begin to crumble, split or break apart at sites along weak points where the water and air are mixed within the product.

These breaking points in the products create fines, which are the materials that result from products, such as pellets, disintegrating, due to poor quality.

Furthermore, when large diameter or oversized products are produced, they will become even hotter when the raw material mixed with the steam and air is pushed into the final die for forming the shape of the final product.

One method to mitigate the breaking up of such oversized products is reducing the throughput of raw material through the die, which diminishes the output.

The problem with this method is that it drastically reduces the nutritional value of the final product by as much as 60%.

The pellet quality can be seriously affected with the addition of too much binder.

Lowering the nutritional value increases the cost and negatively affects the final product as a nutritional feed product.

The farmer has to feed twice as much tonnage to his animals on a daily basis, which is very costly.

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