System and method for controlling moisture in feed production

Abstract

The present technology relates to a pelleting system (1) and a method of making pellets in a pelleting system. The pelleting system has at least a feed material input (11, 12, 13), a conditioner (30), a pelleting machine (40), and a cooler (50). The method includes: continuously sensing a moisture content of the feed material input ("Min"), a temperature of the feed material input ("Tin"), a moisture content of the conditioned feed material ("Mcon"), and a temperature of the conditioned feed material ("Tcon"), using a temperature sensor and a microwave moisture sensor (111, 112, 113, 114) arranged in-line in the pelleting system; comparing the moisture content Mcon to a predetermined maximum moisture content ("Mmax"); comparing the temperature Tcon to a predetermined temperature range; and adjusting a steam input into the conditioner such that the moisture Mcon does not exceed Mmax and the temperature Tcon is within the predetermined temperature range.

Description

SYSTEM AND METHOD FOR CONTROLLING MOISTURE IN FEED PRODUCTIONCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 673,226, filed July 19, 2024, which is incorporated by reference herein in its entirety.BACKGROUND

[0002] Moisture content control is important in the food and feed industry, for example, in food and feed processing and manufacturing. The presence of humidity and moisture, if not monitored properly, can result in the food or feed being spoiled due to mold or bacteria. In addition, food and feed processing and production plants can save significant amounts of money with accurate moisture measurements and moisture control within the system. In many cases, raw materials, as well as the output of processes, are measured by weight. Thus, having accurate information about the moisture content within the materials throughout the process is beneficial. The ability to obtain accurate and timely information about the moisture content of the material and the product can also result in savings in analysis, shipping, and delivery.

[0003] The moisture content of materials during mixing and various other manufacturing steps can affect the end product’s consistency and quality, and too much or too little moisture may cause undesirable variations in the end product. Further, too much or too little moisture may negatively impact the ability to successfully perform a manufacturing step. For example, too much moisture may cause certain production equipment, such as a pelleting machine, to clog and cause production to be stopped until the blockage is cleared out. Such disruptions in production can be costly and should be avoided.

[0004] Existing moisture content control methods of pelleted feed typically rely on benchtop testing. In the cycle of manufacturing, benchtop test times exceed the window to adjust hydration levels in the process, and the product is often finished before action can be taken to correct a moisture content that is too high or too low. It would be desirable to provide a system and method that can monitor and provide information about moisture from unit operations substantially in real time. It would be desirable to provide a moisture control system and method for feed processing that is capable of determining the moisture content in the feed materials and adjusting the moisture control as needed during the feed processing. It would be desirable to provide an automated moisture control system and method that can be used to control the moisture content in feed materials withing pre-determined parameters.

[0005] Further improvements in monitoring and controlling moisture content in feed production are desired.SUMMARY

[0006] Some embodiments of the technology disclosed herein relate to a method of making pellets in a pelleting system. The pelleting system has a feed material input, a conditioner configured to mix steam with the feed material input to produce a conditioned feed material, a pelleting machine configured to receive the conditioned feed material and to compress the conditioned feed material into the pellets under elevated temperature and pressure, and a cooler configured to receive the pellets from the pelleting machine. The method includes: continuously sensing a moisture content of the feed material input (“Min”), a temperature of the feed material input (“Tin”), a moisture content of the conditioned feed material (“Mcon”), and a temperature of the conditioned feed material (“Tcon”), using a temperature sensor and a microwave moisture sensor arranged in-line in the pelleting system; comparing the moisture content Mcon to a predetermined maximum moisture content (“Mmax”); comparing the temperature Tcon to a predetermined temperature range; and adjusting a steam input into the conditioner such that the moisture Mcon does not exceed Mmax and the temperature Tcon is within the predetermined temperature range. A maximum achievable temperature Tmax for temperature Tcon is dependent on Mmax according to the following equation: ((Mmax - Min)- 100-20°F)+ Tin = Tmax.

[0007] Additionally or alternatively, adjusting the steam input by adjusting the moisture content Mcon is within 1 %, within 0.5 %, or within 0.25 % of Mmax. Additionally or alternatively, the maximum achievable temperature Tmax is 200 °F or lower. Additionally or alternatively, the microwave moisture sensor is arranged to measure the moisture of the feed material input in a line leading to or the conditioned feed material in a line leading out of the conditioner. Additionally or alternatively, the microwave moisture sensor is arranged within the conditioner. Additionally or alternatively, the microwave moisture sensor is arranged to measure the moisture of the conditioned feed material in a line leading to the pelleting machine. Additionally or alternatively, the microwave moisture sensor is arranged within the pelleting machine. Additionally or alternatively, the microwave moisture sensor is arranged to measure the moisture of the pellets in a line leading to or out of the cooler. Additionally or alternatively, the microwave moisture sensor is arranged within the cooler.

[0008] Additionally or alternatively, the feed material input includes starch, protein, fiber, and fat. Additionally or alternatively, the feed material input includes 10 wt-% to 50 wt-% of starch; 10 wt-% to 60 wt-% fiber; and 1 wt-% to 10 wt-% fat, by dry weight of the feed material input. Additionally or alternatively, the predetermined temperature range of temperature Tcon is in a range of about 110 °F to about 190 °F (about 43 °C to about 88 °C), about 120 °F to about 175 °F (about 49 °C to about 80 °C), about 120 °F to about 165 °F (about 49 °C to about 74 °C), or about 130 °F to about 160 °F (from 54 °C to about 71 °C). Additionally or alternatively, themoisture content Mcon is increased to 2 to 6 %-points above the moisture content Min of the feed material input. Additionally or alternatively, the elevated temperature of the pelleting machine is in a range of about 160 °F to about 200 °F (about 70 °C to about 94 °C), about 165 °F to about 190 °F (about 75 °C to about 88 °C), or about 175 °F to about 190 °F (about 80 °C to about 88 °C). Additionally or alternatively, the pelleting machine is configured to make the pellets having an average diameter in a range of 3 mm to 20 mm. Additionally or alternatively, the predetermined range of the moisture content Mcon is from 10 wt-% to 17 wt-%, from 11 wt-% to 17 wt-%, from 12 wt-% to 16 wt-%, or from 14 wt-% to 15.5 wt-%. Additionally or alternatively, the cooler is configured to cool the pellets to a temperature within about 5 °F to about 15 °F (about 2 °C to about 8 °C) of an ambient temperature. Additionally or alternatively, the pellets have a final moisture content after the cooler, in a range of 8 wt-% to 14 wt-%. Additionally or alternatively, the final moisture content is within 3 %-points, within 2.5 %- points, within 2%-points, within 1.5%-points, or within 1%-point of the moisture content Min of the feed material input.

[0009] Additionally or alternatively, the pelleting system further includes a mixer arranged to mix ingredients to produce the feed material input. Additionally or alternatively, the microwave moisture sensor is arranged to measure the moisture in a line leading to or in a line leading out of the mixer. Additionally or alternatively, the microwave moisture sensor is arranged within the mixer. Additionally or alternatively, the pelleting system includes one or more temperature sensors disposed in a line leading to the conditioner, within the conditioner, in a line leading to the pelleting machine, within the pelleting machine, in a line leading to the cooler, within the cooler, downstream of the cooler, or any combination of two or more thereof. Additionally or alternatively, the method further includes calibrating the microwave moisture sensor using a plurality of samples of the feed material input, the conditioned feed material, the pellets, or a combination of two or more thereof. Additionally or alternatively, the pelleting system includes a control unit configured to receive a signal from the microwave moisture sensor, to compare the moisture content to a predetermined value or range; and to adjust the amount of steam added to the feed material input.

[0010] Some embodiments of the technology disclosed herein relate to a pelleting system. The pelleting system has a feed material input; a conditioner configured to mix steam with the feed material input to produce a conditioned feed material; a pelleting machine configured to receive the conditioned feed material and compress the conditioned feed material into pellets under elevated temperature and pressure; a cooler configured to receive the pellets from the pelleting machine; a microwave moisture sensor arranged in-line and configured to sense a moisture content of the feed material input, the conditioned feed material, the pellets, or acombination thereof; and a control unit configured to compare the moisture content to a predetermined range.

[0011] Additionally or alternatively, the control unit is configured to increase the amount of steam added to the feed material input if the moisture content is below the predetermined range, and to reduce the amount of steam added to the feed material input if the moisture content is above the predetermined range. Additionally or alternatively, the microwave moisture sensor is arranged to measure the moisture of the feed material input in a line leading to or the conditioned feed material in a line leading out of the conditioner. Additionally or alternatively, the microwave moisture sensor is arranged within the conditioner. Additionally or alternatively, the microwave moisture sensor is arranged to measure the moisture of the conditioned feed material in a line leading to the pelleting machine. Additionally or alternatively, the microwave moisture sensor is arranged within the pelleting machine. Additionally or alternatively, the microwave moisture sensor is arranged to measure the moisture of the pellets in a line leading to or out of the cooler. Additionally or alternatively, the microwave moisture sensor is arranged within the cooler. Additionally or alternatively, the conditioner is configured to heat the conditioned feed material to a temperature in a range of about 110 °F to about 190 °F (about 43 °C to about 88 °C), about 120 °F to about 175 °F (about 49 °C to about 80 °C), about 120 °F to about 165 °F (about 49 °C to about 74 °C), or about 130 °F to about 160 °F (from 54 °C to about 71 °C). Additionally or alternatively, the conditioner is configured to increase the moisture content of the conditioned feed material by 2 to 6 %-points compared to the moisture content of the feed material input. Additionally or alternatively, the pelleting machine is configured to operate at a temperature in a range of about 160 °F to about 200 °F (about 70 °C to about 94 °C), about 165 °F to about 190 °F (about 75 °C to about 88 °C), or about 175 °F to about 190 °F (about 80 °C to about 88 °C). Additionally or alternatively, the pelleting machine includes a die having openings with an average diameter in a range of 3 mm to 20 mm. Additionally or alternatively, the cooler is configured to cool the pellets to a temperature within about 5 °F to about 15 °F (about 2 °C to about 8 °C) of an ambient temperature. Additionally or alternatively, the pelleting system further includes a mixer arranged to mix ingredients to produce the feed material input, and additionally or alternatively, the mixer includes a microwave moisture sensor. Additionally or alternatively, the pelleting system includes one or more temperature sensors disposed in a line leading to the conditioner, within the conditioner, in a line leading to the pelleting machine, within the pelleting machine, in a line leading to the cooler, within the cooler, downstream of the cooler, or any combination of two or more thereof.BRIEF DESCRIPTION OF DRAWINGS

[0012] FIG. 1 is a schematic process diagram of a feed manufacturing process according to an embodiment.

[0013] FIG. 2 illustrates a block diagram of a system and apparatus configured to perform the methods described herein.DEFINITIONS

[0014] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein and are not meant to limit the scope of the present disclosure.

[0015] The term “substantially” as used here has the same meaning as “significantly,” and can be understood to modify the term that follows by at least about 90 %, at least about 95 %, or at least about 98 %.

[0016] The term “not substantially” as used here has the same meaning as “not significantly,” and can be understood to have the inverse meaning of “substantially,” i.e., modifying the term that follows by not more than 25 %, not more than 10 %, not more than 5 %, or not more than 2 %.

[0017] The term “ambient temperature” is used here to refer to temperatures ranging from about 18 °C to about 26 °C. Some variations (e.g., up to about ± 5 °C) in ambient temperature are possible depending on environmental conditions, such as hot or cold weather, or a warm room temperature in a processing environment.

[0018] The term “about” is used here in conjunction with numeric values to include normal variations in measurements as expected by persons skilled in the art, and is understood to have the same meaning as “approximately” and to cover a typical margin of error, such as ±5 % of the stated value.

[0019] Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration.

[0020] The terms “a,” “an,” and “the” are used interchangeably with the term “at least one.” The phrases “at least one of’ and “comprises at least one of’ followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

[0021] As used here, the term “or” is generally employed in its usual sense including “and / or” unless the content clearly dictates otherwise. The term “and / or” means one or all of the listed elements or a combination of any two or more of the listed elements.

[0022] The recitations of numerical ranges by endpoints include all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc. or 10 or less includes 10, 9.4, 7.6, 5, 4.3, 2.9, 1.62, 0.3, etc.). Where a range of values is “up to” or “at least” a particular value, that value is included within the range.

[0023] As used here, “have,” “having,” “include,” “including,” “comprise,” “comprising,” or the like are used in their open-ended sense, and generally mean “including, but not limited to.” It will be understood that “consisting essentially of,” “consisting of,” and the like are subsumed in “comprising” and the like. As used herein, “consisting essentially of,” as it relates to a composition, product, method, or the like, means that the components of the composition, product, method, or the like are limited to the enumerated components and any other components that do not materially affect the basic and novel characteristic(s) of the composition, product, method, or the like.

[0024] The words “preferred” and “preferably” refer to embodiments that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, including the claims.

[0025] Any direction referred to here, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of an actual device or system or use of the device or system. Devices or systems as described herein may be used in a number of directions and orientations.DETAILED DESCRIPTION

[0026] The present disclosure relates to systems and methods for monitoring and controlling moisture content in feed manufacturing. In particular, the present disclosure relates to systems and methods for monitoring and controlling moisture content in manufacturing of pelleted feed.

[0027] According to embodiments, the systems and methods of the present disclosure are capable of determining the moisture content in the feed materials and adjusting the moisture control as needed during the feed processing. The systems and methods of the present disclosure provide an automated moisture control system and method that can be used to control the moisture content in feed materials within pre-determined parameters. The systems and methods of the present disclosure may help provide various benefits in feed production, including one or more of reducing energy costs, reducing product waste, reducing operator influence on the system, improving pelleting efficiency, improving quality control, improving mold control, improving shrink control, and improving formulation control.

[0028] In general, the systems and methods of the present disclosure may be used in conjunction with one or more unit operation during feed manufacturing. In particular, the systems and methods of the present disclosure may be useful with pelleting operations.

[0029] Referring now to FIG. 1, a system 1 that forms a part of a feed manufacturing process is shown. The system 1 includes ingredient inputs 11, 12, and 13. The ingredient inputs 11, 12, and 13 may include hoppers, tanks, or other typical input vessels. The number of inputs is not particularly limited and depends on the type of feed being manufactured, the ingredients used, and the desired final composition. The ingredients may include both dry and wet ingredients. Exemplary ingredient inputs may include grains and grain-based inputs, such as wheat, com, soybean, peas, rice, millet, sorghum, barley, oats, rye, DDG (distillers dried grains), DDGS (distillers dried grains with solubles), and the like; wet ingredients, such as oils, molasses, syrups, and the like; various nutritional additives or processing aids, such as vitamins, minerals, etc. Generally, the feed ingredients include macro nutrients, including starch, protein, fiber, and fat. The amounts of the macro nutrients may impact the processability of the feed material. For example, the presence of starch may cause gelling in the processing conditions involved in feed pelleting. In some cases, the feed material includes starch in a range of 2 wt-% to 50 wt-%, from 5 wt-% to 35 wt-%, or from 10 wt-% to 50 wt-%, on a dry weight basis. In some cases, the feed material includes fiber in a range of 2 wt-% to 70 wt-%, from 5 wt-% to 65 wt-%, or from 10 wt-% to 60 wt-%, on a dry weight basis. In some cases, the feed material includes fat in a range of 0.5 wt-% to 20 wt-%, from 1 wt-% to 15 wt-%, or from 1 wt-% to 10 wt-%, on a dry weight basis.

[0030] The ingredient inputs 11, 12, and 13 are directed into a mixer 20 to produce a feed material. The feed material is then directed into a conditioner 30, prior to being directed into a pelleting machine 40. In the conditioner 30, steam from a steam source 33 is injected and mixed into the feed material. The steam is used to increase the moisture level of the feed material, as well as to pre-heat the feed material. The pelleting machine 40 may be an extruder that extrudes the feed material into pellets. The pellets may then be directed into a cooler 50. The cooler 50 cools the pellets to ambient or near ambient temperature. The moisture content of the pellets may also be slightly lowered in the cooler 50.

[0031] According to an embodiment, the system 1 includes a moisture control system 100. The moisture control system 100 may include one or more sensors 111, 112, 113, 114 operatively coupled with a controller 120. In the embodiment shown, the moisture control system 100 includes a first sensor 111 arranged to sense the moisture content in the mixer 20; a second sensor 112 arranged to sense the moisture content in the conditioner 30; a third sensor 113 arranged to sense the moisture content in the pelleting machine 40; and a fourth sensor 114arranged to sense the moisture content in the cooler 50. In some embodiments, the moisture control system 100 includes only the second sensor 112 arranged to sense the moisture content in the conditioner 30. In some embodiments, the moisture control system 100 includes the second sensor 112 arranged to sense the moisture content in the conditioner 30 and one or more of the first, third, and fourth sensors 111, 113, 114. In some embodiments, the moisture control system 100 includes the second sensor 112 arranged to sense the moisture content in the conditioner 30 and the third sensor 113 arranged to sense the moisture content in the pelleting machine 40.

[0032] In FIG. 1, the position of the one or more sensors 111, 112, 113, 114 is shown schematically to indicate relativity to the given unit operation. However, the actual position of the one or more sensors 111, 112, 113, 114 is not limited to the particular position shown. The one or more sensors 111, 112, 113, 114 may include moisture sensors arranged to sense the moisture content of material inside the given unit operation. This may be the moisture content of the feed material at the inlet, at the outlet, or within the unit operation. For example, the one or more sensors 111, 112, 113, 114 may include moisture sensors arranged to sense the moisture content at the outlet of the conditioner 30. The one or more sensors 111, 112, 113, 114 may include moisture sensors arranged to sense the moisture content at the inlet of the pelleting machine 40. The one or more sensors 111, 112, 113, 114 may include moisture sensors arranged to sense the moisture content at the inlet of the conditioner 30. The one or more sensors 111, 112, 113, 114 may include moisture sensors arranged to sense the moisture content at the outlet of the pelleting machine 40. The one or more sensors 111, 112, 113, 114 are operatively coupled with the controller 120 and are configured to send information to the controller 120.

[0033] The moisture sensors of the one or more sensors 111, 112, 113, 114 may include any suitable sensor for use in the given unit operation. In some embodiments, the moisture sensor is or includes a microwave moisture sensor. A suitable microwave sensor is available, for example, from TEWS Elektronik GmbH & Co. KG in Hamburg, Germany (e.g., model MW 4200, 4260, or 4270). According to an embodiment a microwave moisture sensor is arranged to measure the moisture of the feed material input in a line 31 leading to the conditioner 30. In some embodiments, a microwave moisture sensor is arranged within the conditioner 30. In some embodiments, a microwave moisture sensor is arranged to measure the moisture of the conditioned feed material in a line 32 leading to the pelleting machine 40. In some embodiments, a microwave moisture sensor is arranged within the pelleting machine 40. In some embodiments, a microwave moisture sensor is arranged to measure the moisture of the pellets in a line 51 leading to the cooler 50. In some embodiments, a microwave moisture sensoris arranged within the cooler 50. In some embodiments, a microwave moisture sensor is arranged within the mixer 20 or at the outlet of the mixer 20.

[0034] According to an embodiment, the one or more sensors 111, 112, 113, 114 may include temperature sensors arranged to sense the temperature of feed material inside the given unit operation. This may be the temperature of the feed material at the inlet, at the outlet, or within the unit operation.

[0035] The system 1 may also include various other sensors, including sensors to detect or measure the temperature, pressure, flow rate, or other parameters in the various unit operations, the conduits between unit operations, pumps, valves, fans, and any combination thereof. Information from such other sensors may also be sent to the controller 120, or another controller configured to monitor the operation of the system 1.

[0036] The methods and processes described herein can be implemented on computer hardware, e.g., workstations, servers, or the like. In FIG. 2, a block diagram shows a system and computing apparatus 200 that may be used to implement methods according to various examples (e.g., as a computer, a mobile device, a server, a smart sensor, a control system, etc.). The components may be implemented as integrated circuits (ICs), portions thereof, discrete electronic devices, or other modules, instruction sets, programmable logic or algorithms, hardware, hardware accelerators, software, firmware, or a combination thereof, or as components otherwise incorporated within a chassis of a larger system.

[0037] The controller 120 may include conventional computing hardware such as a central processor 221, memory 222, input / output (I / O) interfaces 223, and a non-volatile data storage unit 224 (e.g., hard disk drives, solid state drives, or the like). The processor 221 may include any one or more of a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), and / or equivalent discrete or integrated logic circuitry. In some examples, the processor 221 may include multiple components, such as any combination of one or more microprocessors, one or more controllers, one or more DSPs, one or more ASICs, and / or one or more FPGAs, as well as other discrete or integrated logic circuitry. The functions attributed to the controller 120 and / or processor 221 herein may be embodied as software, firmware, hardware, or any combination of these. Certain functionality of the controller 120 may also be performed in the cloud or other distributed computing systems operably connected to the processor 221. It is to be understood that the computing devices described herein may be a set of computing devices that are communicatively coupled. For example, the computing devices may be communicatively coupled via a cloud-based system. According to various examples, controller 120 can be a system of multiple controllers that operate together in a cloud-based or other type of system.

[0038] The memory 222 may include any volatile, non-volatile, magnetic, optical, and / or electrical media, such as a random-access memory (RAM), read-only memory (ROM), nonvolatile RAM (NVRAM), electrically erasable programmable ROM (EEPROM), flash memory, and / or any other digital media. While shown as both being incorporated into the controller 120, the memory 222 and the processor 221 could be contained in separate modules.

[0039] The controller 120 includes an external data interface 226 that receives sensor data from the one or more sensors 111, 112, 113, 114. While four sensors are shown, it is to be understood that more than four sensors or less than four sensors may provide data to the controller 120. The processor 221 uses the sensor data to control one or more parameters of the system 1. For example, one or both of the moisture and the temperature of the feed material may be controlled via the moisture and temperature control 228. One or both of the moisture content and the temperature of the feed material may be adjusted automatically based on data received from one or more of the sensors 111, 112, 113, 114 using the automation system 234.

[0040] According to various examples, information regarding the system 1 may be accessed via a user interface 125 that communicates data to a user. For example, one or both of the temperature and moisture content of the feed material in or around (e.g., at the inlet or outlet) the mixer 20; in or around the conditioner 30; in or around the pelleting machine 40; and / or in or around the cooler 50 may be provided to a user via the user interface 125. The user may be able to at least partially manually adjust one or both of the moisture temperature and moisture content of the feed material via the user interface 125. In some examples, the user may be able to set one or more thresholds for one or both of the moisture content and the temperature of the feed material via the user interface 125. The one or more thresholds may include a minimum moisture content, a maximum moisture content, a minimum temperature, a maximum temperature, or a combination of any two or more thereof.

[0041] The moisture content and temperature of the feed material is adjusted in the conditioner 30 by injecting steam into the feed material. The moisture content and temperature are adjusted to be within pre-determined ranges to facilitate processing in the pelleting machine 40. As the conditioned feed material enters the conditioner, it has a feed material input moisture content (“Min”) and a feed material input temperature (“Tin”). After conditioning, the feed material has a conditioned feed material moisture content (“Mcon”) and a conditioned feed material temperature (“Tcon”). The second sensor 112 may be arranged to sense the conditioned feed material moisture content (“Mcon”). A sensor may also be arranged to sense the conditioned feed material temperature (“Tcon”). The controller 120 may be programmed to compare the moisture content Mcon to a predetermined maximum moisture content (“Mmax”) or a predetermined moisture range. The controller 120 may be further programmed to compare thetemperature Tcon to a predetermined temperature range. The controller 120 may be programmed to send a signal to the steam source 33 to adjust the steam input into the conditioner 30 such that the moisture Mcon does not exceed Mmax. The controller 120 may also be programmed to send a signal to the steam source 33 to adjust the steam input into the conditioner 30 such that the temperature Tcon is within the predetermined temperature range.

[0042] The maximum moisture content of the feed material may be limited by the ability of the pelleting machine 40 to process the feed material. That is, beyond a certain moisture content, the pelleting machine 40 may become clogged and may have to be stopped to clear the blockage. The exact moisture content that a given pelleting machine can handle depends on the configuration of the machine and the formulation of the feed material. Typical maximum moisture contents are in the range of 8 wt-% to 20 wt-%. In some embodiments, the pellets have a final moisture content after the cooler in a range of 8 wt-% to 14 wt-%. It is usually desirable to run the pelleting machine at the highest possible temperature, but because both the moisture and the temperature are affected by the amount of steam injected into the feed material, the maximum achievable temperature of the feed material is limited by the maximum moisture content. That is, the temperature cannot be increased beyond a maximum limit without increasing the moisture content above the maximum moisture content. According to an embodiment, the maximum achievable temperature Tmax for temperature Tcon is dependent on Mmax according to the following Equation 1 :

[0043] The predetermined maximum moisture content (“Mmax”) may be 18 wt-% or lower, 17 wt-% or lower, 16.5 wt-% or lower, 16 wt-% or lower, 15.5 wt-% or lower, or about 15 wt- %. The predetermined maximum moisture content (“Mmax”) may be 15 wt-% or higher, 15.5 wt- % or higher, or 16 wt-% or higher. The predetermined maximum moisture content (“Mmax”) may be in a range of 15 wt-% to 18 wt-%, 15 wt-% to 17 wt-%, or 15.5 wt-% to 16 wt-%.

[0044] The predetermined range of the moisture content Mcon may be 18 wt-% or lower, 17 wt-% or lower, 16.5 wt-% or lower, 16 wt-% or lower, 15.5 wt-% or lower, or about 15 wt-%. The predetermined range of the moisture content Mcon may be 10 wt-% or higher, 11 wt-% or higher, 12 wt-% or higher, 13 wt-% or higher, 14 wt-% or higher, or 15 wt-% or higher. The predetermined range of the moisture content Mcon may be in a range of 10 wt-% to 18 wt-%, 10 wt-% to 17 wt-%, from 11 wt-% to 17 wt-%, from 12 wt-% to 16 wt-%, from 14 wt-% to 16 wt- %, from 15 wt-% to 16 wt-%, or from 14 wt-% to 15.5 wt-%.

[0045] According to an embodiment, the controller 120 is configured to adjust the steam input so that the moisture content Mcon is within 1 %, within 0.5 %, or within 0.25 % of Mmax. Insome embodiments, the conditioned moisture content Mcon is from 2 to 6 %-points above the input moisture content Min of the feed material input. In some embodiments, the conditioned moisture content Mcon is from 2 to 4 %-points above the input moisture content Min of the feed material input. That is, if Min is 12 wt-%, Mcon may be from 14 wt-% to 16 wt-%. The controller 120 may be configured to adjust the steam input so that the moisture content Mcon is from 2 to 6 %-points above the input moisture content Min of the feed material input.

[0046] The controller 120 may be configured to adjust the steam input so that the temperature Tcon is in a range of about 110 °F to about 190 °F (about 43 °C to about 88 °C), about 120 °F to about 175 °F (about 49 °C to about 80 °C), about 120 °F to about 165 °F (about 49 °C to about 74 °C), or about 130 °F to about 160 °F (from 54 °C to about 71 °C). According to an embodiment, the controller 120 is configured to adjust the steam input so that the temperature Tcon is within 1 °F (or about 0.5 °C) of Tmax.

[0047] The pelleting machine 40 may be run at an elevated temperature. The elevated temperature of the pelleting machine 40 is in a range of about 160 °F to about 200 °F (about 70 °C to about 94 °C), about 165 °F to about 190 °F (about 75 °C to about 88 °C), or about 175 °F to about 190 °F (about 80 °C to about 88 °C). The elevated temperature of the pelleting machine 40 may be the result of the steam input from the steam source 32.

[0048] The pelleting machine 40 may configured to make pellets having an average diameter in a range of 3 mm to 20 mm, or from 4 mm to 16 mm. The pelleting machine 40 may include a die having openings. The openings of the die may have an average diameter in a range of 3 mm to 30 mm, or from 4 mm to 16 mm.

[0049] The cooler 50 may configured to cool the pellets to a temperature within about 5 °F to about 15 °F (about 2 °C to about 8 °C) of an ambient temperature. In some embodiments, the cooler 50 may configured to cool the pellets to a temperature within about 5 °F to about 10 °F (about 2 °C to about 6 °C) of an ambient temperature. After passing through the cooler 50, the pellets may have a final moisture content that is lower than the Mcon. The final moisture content of the pellets may be within 3 %-points, within 2.5 %-points, within 2%-points, within 1.5%- points, or within 1%-point of the moisture content Min of the feed material input.Methods

[0050] According to an embodiment, feed ingredients are fed into a mixer 20 from one or more ingredient inputs 11, 12, and 13. Typical ingredients and feed compositions are discussed above. The feed ingredients are mixed in the mixer 20 to form a feed material. The amount of hydration (e.g., in the form of wet ingredients) added during mixing may be adjusted based on a moisture reading during mixing. The feed material typically includes at least protein, fat, fiber, and starch. The feed material is then directed into a conditioner 30. The feed material has a feedmaterial input moisture content (“Min”) and a feed material input temperature (“Tin”). According to an embodiment, the feed material input moisture content (“Min”) and feed material input temperature (“Tin”) are measured using a first sensor 111. The first sensor 111 may include a moisture sensor and a temperature sensor. The first sensor 111 may include a microwave moisture sensor.

[0051] In the conditioner 30, steam is injected and mixed into the feed material from steam source 33. The steam raises the moisture content and temperature to a conditioned feed material moisture content (“Mcon”) and a conditioned feed material temperature (“Tcon”). The conditioned feed material moisture content (“Mcon”) and a conditioned feed material temperature (“Tcon”) may be monitored using a second sensor 112. The second sensor 112 may include a moisture sensor and a temperature sensor. The second sensor 112 may include a microwave moisture sensor. The second sensor 112 may be configured to send information to a controller 120.

[0052] The controller 120 may be programmed to compare the moisture content Mcon to a predetermined maximum moisture content (“Mmax”) or a predetermined moisture range. The controller 120 may be further programmed to compare the temperature Tcon to a predetermined temperature range. The controller 120 may be programmed to send a signal to the steam source 33 to adjust the steam input into the conditioner 30 such that the moisture Mcon does not exceed Mmax. The controller 120 may also be programmed to send a signal to the steam source 33 to adjust the steam input into the conditioner 30 such that the temperature Tcon is within the predetermined temperature range. This may create feedback loop that controls the moisture content Mcon and the temperature Tcon.

[0053] The predetermined maximum moisture content (“Mmax”) may be selected based on the desired feed moisture content and / or the moisture content below which the pelleting machine 40 may be operated without clogging. This moisture content may be determined via empirical testing for a given feed composition. The maximum achievable temperature Tmax for temperature Tcon may be determined using Equation 1 above.

[0054] The conditioned feed material, having moisture content Mcon and temperature Tcon, is directed into the pelleting machine 40 and formed into pellets. The conditioned feed material may be formed into pellets, for example, by extrusion. According to an embodiment, the pellets are formed from conditioned feed material having moisture content Mcon. Mcon may be 18 wt-% or lower, 17 wt-% or lower, 16.5 wt-% or lower, 16 wt-% or lower, 15.5 wt-% or lower, or about 15 wt-%. The moisture content Mcon may be 10 wt-% or higher, 11 wt-% or higher, 12 wt-% or higher, 13 wt-% or higher, 14 wt-% or higher, or 15 wt-% or higher. The moisture content Mcon may be in a range of 10 wt-% to 18 wt-%, 10 wt-% to 17 wt-%, from 11 wt-% to 17 wt-%, from 12 wt-% to 16 wt-%, from 14 wt-% to 16 wt-%, from 15 wt-% to 16 wt-%, or from 14 wt-% to15.5 wt-%. The moisture content Moon is within 1 %, within 0.5 %, or within 0.25 % of Mmax. The moisture content of the feed material may be monitored within the pelleting machine 40 using a third sensor 113. The third sensor 113 may include a microwave moisture sensor arranged to measure the moisture of the conditioned feed material in a line 32 leading to the pelleting machine 40, at the inlet of the pelleting machine 40, within the pelleting machine 40, at the outlet of the pelleting machine, in a line 51 leading to the cooler 50, or a combination thereof. The third sensor 113 may include a temperature sensor to monitor the temperature of the feed material or pellets in a line 32 leading to the pelleting machine 40, at the inlet of the pelleting machine 40, within the pelleting machine 40, at the outlet of the pelleting machine, in a line 51 leading to the cooler 50, or a combination thereof. The moisture content Mcon is controlled by the controller 120 and using the steam input from the steam source 33 into the conditioner 30.

[0055] The pelleting machine 40 may be run at an elevated temperature. The elevated temperature of the pelleting machine 40 is in a range of about 160 °F to about 200 °F (about 70 °C to about 94 °C), about 165 °F to about 190 °F (about 75 °C to about 88 °C), or about 175 °F to about 190 °F (about 80 °C to about 88 °C). The pelleting machine 40 may configured to make pellets having an average diameter in a range of 3 mm to 20 mm, or from 4 mm to 16 mm.

[0056] The pellets formed in the pelleting machine 40 are directed into the cooler 50 via line 51. The pellets are cooled in the cooler 50 using air flow that has a temperature lower than the temperature of the pellets. The pellets may further lose some moisture in the cooler 50. The pellets may be cooled in the cooler 50 to a temperature within about 5 °F to about 15 °F (about 2 °C to about 8 °C) of an ambient temperature. In some embodiments, the pellets may be cooled in the cooler 50 to a temperature within about 5 °F to about 10 °F (about 2 °C to about 6 °C) of an ambient temperature. After passing through the cooler 50, the pellets may have a final moisture content that is lower than the Mcon. The final moisture content of the pellets may be adjusted to be within a desired range for the final product. The final moisture content of the pellets may be within 3 %-points, within 2.5 %-points, within 2%-points, within 1.5%-points, or within 1%- point of the moisture content Min of the feed material input. The moisture content of the pellets may be monitored within the cooler 50 using a fourth sensor 114. The fourth sensor 114 may be arranged to sense the moisture content of the pellets within the cooler 50 or at the outlet of the cooler 50. The fourth sensor 114 may further include a temperature sensor. The information from the fourth sensor 114 may be sent to the controller 120. The information from the fourth sensor 114 may be used to adjust the fan speed of the cooler 50. The information from the fourth sensor 114 may be used to adjust the cooling time, i.e., the length of time the pellets spend in the cooler 50.

[0057] The one or more sensors 111, 112, 113, 114 may be calibrated by obtaining samples from the unit operations and bench testing the moisture content, for example, using an oven moisture loss method.

[0058] Returning to FIG. 2, the data storage unit 224 may store a machine learning model 230 that predicts various information about one or both of the temperature and the moisture content of the feed material based on historical and present sensor data and user input data. According to various examples, past data may be trended to predict a current or future temperature or moisture content of the feed material with or without input from the machine learning model 230. Other sources of data 218 may also be used as inputs to the controller 120, such as ambient temperatures, for example.

[0059] According to some examples, the processor 221 uses machine learning to analyze and automate actions. For example, an artificial intelligence (Al) model may be used to predict information about a current or future temperature or moisture content of the feed material. This information may include times when the moisture content is expected to reach a moisture threshold such as a maximum moisture threshold. As used herein, an “Al model” is a mathematical algorithm implemented in a programming language that recognizes patterns from data and / or performs a task, either automatically or by learning from data in a supervised, unsupervised, semi-supervised, or self-supervised fashion. The types of Al models may include generative models and predictive models, for example. An Al model is used herein synonymously with a machine learning or deep learning model and may comprise an artificial neural network. The Al model may be trained using one or both of past moisture and temperature data.

[0060] As used herein, “deep learning” is a sub-field of machine learning that does not require expert feature engineering, but rather learns data features automatically from large quantities of data. Deep learning algorithms or models may comprise an artificial neural network having multiple hidden layers and many (e.g., thousands, millions, or billions) of learnable parameters. Example deep learning algorithms include convolutional neural networks, generative adversarial networks, recurrent neural networks, transformers, autoencoders, and deep reinforcement learning models.EXAMPLES

[0061] A microwave moisture sensor was installed in the mixer of a feed processing plant that produces feed pellets according to methods described herein. The moisture sensor was connected to a control unit. Approximately 200 feed material samples were tested using the moisture sensor and were pulled from the mixer and tested for moisture content on a benchtopmoisture analyzer. Each sample was tested 3 times to validate. The tested benchtop moisture content of these samples was then uploaded back into the control unit and matched with the corresponding samples to build a calibration curve to achieve a standard deviation of no greater than 0.25 % between the benchtop analyzer and the microwave moisture sensor. This information can then be used by the plant control system to establish automated feed material hydration in the mixer.

[0062] A similar calibration process was repeated for a microwave moisture sensor installed in the cooler to monitor feed pellet moisture.An exemplary set of calibration sample results is shown in Table 1 below.Table 1.

[0063] To determine the relationship between the amount of moisture and the difference in temperature achieved by adding steam to the feed material, a steam quality assessment was performed. Approximately 20 samples of feed material samples made according to different recipes were pulled from the mixer, and the moisture and temperature of the samples were documented. Corresponding samples were drawn from the pellet mill. Steam was added to the feed material, and once the pellet machine was up to a desired temperature set point, samples were pulled at the conditioner discharge. The samples were tested using a handheld temperature probe and a benchtop moisture analyzer. The temperature and moisture were recorded and compared against corresponding mixer sample temperature and moisture. The correlation between temperature and moisture addition was determined, and was found to be 20 °F temperature increase for every 1 %-point change in moisture from added steam.

[0064] This information was used to generate the correlation shown in Eq. 1, that can be stored within the program logic to run automatic moisture and temperature control for the conditioning process.ADDITIONAL EXAMPLES

[0065] The following is a non-exhaustive list of examples of the invention.

[0066] Example 1. A method of making pellets in a pelleting system, the pelleting system comprising a feed material input, a conditioner configured to mix steam with the feed material input to produce a conditioned feed material, a pelleting machine configured to receive theconditioned feed material and to compress the conditioned feed material into the pellets under elevated temperature and pressure, and a cooler configured to receive the pellets from the pelleting machine, the method comprising: continuously sensing a moisture content of the feed material input (“Min”), a temperature of the feed material input (“Tin”), a moisture content of the conditioned feed material (“Mcon”), and a temperature of the conditioned feed material (“Tcon”), using a temperature sensor and a microwave moisture sensor arranged in-line in the pelleting system; comparing the moisture content Mcon to a predetermined maximum moisture content (“Mmax”); comparing the temperature Tconto a predetermined temperature range; and adjusting a steam input into the conditioner such that the moisture Mcondoes not exceed Mmax and the temperature Tcon is within the predetermined temperature range, wherein a maximum achievable temperature Tmax for temperature Tcon is dependent on Mmax according to the following equation: ((M_max-M_in )• 100-20°F)+T_in=T_max.

[0067] Example 2. The method of example 1, wherein adjusting the steam input adjusts the moisture content Mcon is within 1 %, within 0.5 %, or within 0.25 % of Mmax.

[0068] Example 3. The method of examples 1 or 2, wherein the maximum achievable temperature Tmax is 200 °F or lower.

[0069] Example 4. The method of any one of examples 1 to 3, wherein the microwave moisture sensor is arranged to measure the moisture of the feed material input in a line leading to or the conditioned feed material in a line leading out of the conditioner.

[0070] Example 5. The method of any one of examples 1 to 4, wherein the microwave moisture sensor is arranged within the conditioner.

[0071] Example 6. The method of any one of examples 1 to 5, wherein the microwave moisture sensor is arranged to measure the moisture of the conditioned feed material in a line leading to the pelleting machine.

[0072] Example 7. The method of any one of examples 1 to 6, wherein the microwave moisture sensor is arranged within the pelleting machine.

[0073] Example 8. The method of any one of examples 1 to 7, wherein the microwave moisture sensor is arranged to measure the moisture of the pellets in a line leading to or out of the cooler.

[0074] Example 9. The method of any one of examples 1 to 8, wherein the microwave moisture sensor is arranged within the cooler.

[0075] Example 10. The method of any one of examples 1 to 9, wherein the feed material input comprises starch, protein, fiber, and fat.

[0076] Example 11. The method of any one of examples 1 to 10, wherein the feed material input comprises 10 wt-% to 50 wt-% of starch; 10 wt-% to 60 wt-% fiber; and 1 wt-% to 10 wt- % fat, by dry weight of the feed material input.

[0077] Example 12. The method of any one of examples 1 to 11, wherein the predetermined temperature range of temperature Tcon is in a range of about 110 °F to about 190 °F (about 43 °C to about 88 °C), about 120 °F to about 175 °F (about 49 °C to about 80 °C), about 120 °F to about 165 °F (about 49 °C to about 74 °C), or about 130 °F to about 160 °F (from 54 °C to about 71 °C).

[0078] Example 13. The method of any one of examples 1 to 12, wherein the moisture content Mcon is increased to 2 to 6 %-points above the moisture content Min of the feed material input.

[0079] Example 14. The method of any one of examples 1 to 13, wherein the elevated temperature of the pelleting machine is in a range of about 160 °F to about 200 °F (about 70 °C to about 94 °C), about 165 °F to about 190 °F (about 75 °C to about 88 °C), or about 175 °F to about 190 °F (about 80 °C to about 88 °C).

[0080] Example 15. The method of any one of examples 1 to 14, wherein the pelleting machine is configured to make the pellets having an average diameter in a range of 3 mm to 20 mm.

[0081] Example 16. The method of any one of examples 1 to 15, wherein the predetermined range of the moisture content Mcon is from 10 wt-% to 17 wt-%, from 11 wt-% to 17 wt-%, from 12 wt-% to 16 wt-%, or from 14 wt-% to 15.5 wt-%.

[0082] Example 17. The method of any one of examples 1 to 16, wherein the cooler is configured to cool the pellets to a temperature within about 5 °F to about 15 °F (about 2 °C to about 8 °C) of an ambient temperature.

[0083] Example 18. The method of any one of examples 1 to 17, wherein the pellets have a final moisture content after the cooler, in a range of 8 wt-% to 14 wt-%.

[0084] Example 19. The method of example 18, wherein the final moisture content is within 3 %-points, within 2.5 %-points, within 2%-points, within 1.5%-points, or within 1%-point of the moisture content Min of the feed material input.

[0085] Example 20. The method of any one of examples 1 to 19, wherein the pelleting system further comprises a mixer arranged to mix ingredients to produce the feed material input.

[0086] Example 21. The method of example 20, wherein the microwave moisture sensor is arranged to measure the moisture in a line leading to or in a line leading out of the mixer.

[0087] Example 22. The method of example 20, wherein the microwave moisture sensor is arranged within the mixer.

[0088] Example 23. The method of any one of examples 1 to 22, wherein the pelleting system comprises one or more temperature sensors disposed in a line leading to the conditioner, within the conditioner, in a line leading to the pelleting machine, within the pelleting machine, in a line leading to the cooler, within the cooler, downstream of the cooler, or any combination of two or more thereof.

[0089] Example 24. The method of any one of examples 1 to 23, further comprising calibrating the microwave moisture sensor using a plurality of samples of the feed material input, the conditioned feed material, the pellets, or a combination of two or more thereof.

[0090] Example 25. The method of any one of examples 1 to 24, wherein the pelleting system comprises a control unit configured to receive a signal from the microwave moisture sensor, to compare the moisture content to a predetermined value or range; and to adjust the amount of steam added to the feed material input.

[0091] Example 26. A pelleting system comprising: a feed material input; a conditioner configured to mix steam with the feed material input to produce a conditioned feed material; a pelleting machine configured to receive the conditioned feed material and compress the conditioned feed material into pellets under elevated temperature and pressure; a cooler configured to receive the pellets from the pelleting machine; a microwave moisture sensor arranged in-line and configured to sense a moisture content of the feed material input, the conditioned feed material, the pellets, or a combination thereof; and a control unit configured to compare the moisture content to a predetermined range.

[0092] Example 27. The pelleting system of example 26, wherein the control unit is configured to increase the amount of steam added to the feed material input if the moisture content is below the predetermined range, and to reduce the amount of steam added to the feed material input if the moisture content is above the predetermined range.

[0093] Example 28. The pelleting system of example 26 or 27, wherein the microwave moisture sensor is arranged to measure the moisture of the feed material input in a line leading to or the conditioned feed material in a line leading out of the conditioner.

[0094] Example 29. The pelleting system of any one of examples 26 to 28, wherein the microwave moisture sensor is arranged within the conditioner.

[0095] Example 30. The pelleting system of any one of examples 26 to 29, wherein the microwave moisture sensor is arranged to measure the moisture of the conditioned feed material in a line leading to the pelleting machine.

[0096] Example 31. The pelleting system of any one of examples 26 to 30, wherein the microwave moisture sensor is arranged within the pelleting machine.

[0097] Example 32. The pelleting system of any one of examples 26 to 31, wherein the microwave moisture sensor is arranged to measure the moisture of the pellets in a line leading to or out of the cooler.

[0098] Example 33. The pelleting system of any one of examples 26 to 32, wherein the microwave moisture sensor is arranged within the cooler.

[0099] Example 34. The pelleting system of any one of examples 26 to 33, wherein the conditioner is configured to heat the conditioned feed material to a temperature in a range of about 110 °F to about 190 °F (about 43 °C to about 88 °C), about 120 °F to about 175 °F (about 49 °C to about 80 °C), about 120 °F to about 165 °F (about 49 °C to about 74 °C), or about 130 °F to about 160 °F (from 54 °C to about 71 °C).

[0100] Example 35. The pelleting system of any one of examples 26 to 34, wherein the conditioner is configured to increase the moisture content of the conditioned feed material by 2 to 6 %-points compared to the moisture content of the feed material input.

[0101] Example 36. The pelleting system of any one of examples 26 to 35, wherein the pelleting machine is configured to operate at a temperature in a range of about 160 °F to about 200 °F (about 70 °C to about 94 °C), about 165 °F to about 190 °F (about 75 °C to about 88 °C), or about 175 °F to about 190 °F (about 80 °C to about 88 °C).

[0102] Example 37. The pelleting system of any one of examples 26 to 36, wherein the pelleting machine comprises a die having openings with an average diameter in a range of 3 mm to 20 mm.

[0103] Example 38. The pelleting system of any one of examples 26 to 37, wherein the cooler is configured to cool the pellets to a temperature within about 5 °F to about 15 °F (about 2 °C to about 8 °C) of an ambient temperature.

[0104] Example 39. The pelleting system of any one of examples 26 to 38, wherein the pelleting system further comprises a mixer arranged to mix ingredients to produce the feed material input, and wherein the mixer comprises a microwave moisture sensor.

[0105] Example 40. The pelleting system of any one of examples 26 to 39, wherein the pelleting system comprises one or more temperature sensors disposed in a line leading to the conditioner, within the conditioner, in a line leading to the pelleting machine, within the pelleting machine, in a line leading to the cooler, within the cooler, downstream of the cooler, or any combination of two or more thereof.

[0106] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. It should be understood that this disclosure isnot intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the disclosure intended to be limited only by the claims set forth here.

Claims

CLAIMSWhat is claimed is:

1. A method of making pellets in a pelleting system, the pelleting system comprising a feed material input, a conditioner configured to mix steam with the feed material input to produce a conditioned feed material, a pelleting machine configured to receive the conditioned feed material and to compress the conditioned feed material into the pellets under elevated temperature and pressure, and a cooler configured to receive the pellets from the pelleting machine, the method comprising: continuously sensing a moisture content of the feed material input (“Min”), a temperature of the feed material input (“Tin”), a moisture content of the conditioned feed material (“Mcon”), and a temperature of the conditioned feed material (“Tcon”), using a temperature sensor and a microwave moisture sensor arranged in-line in the pelleting system; comparing the moisture content Mcon to a predetermined maximum moisture content (“Mmax”); comparing the temperature Tconto a predetermined temperature range; and adjusting a steam input into the conditioner such that the moisture Mcon does not exceed Mmax and the temperature Tcon is within the predetermined temperature range, wherein a maximum achievable temperature Tmax for temperature Tcon is dependent on Mmax according to the following equation:

2. The method of claim 1, wherein adjusting the steam input adjusts the moisture content Mcon is within 1 %, within 0.5 %, or within 0.25 % of Mmax.

3. The method of any one of claims 1 to 2, wherein the microwave moisture sensor is arranged to measure the moisture of the feed material input in a line leading to the conditioner; the conditioned feed material in a line leading out of the conditioner; or within the conditioner.

4. The method of any one of claims 1 to 3, wherein the microwave moisture sensor is arranged to measure the moisture of the conditioned feed material in a line leading to the pelleting machine or within the pelleting machine.

5. The method of any one of claims 1 to 4, wherein the microwave moisture sensor is arranged to measure the moisture of the pellets in a line leading to or out of the cooler or within the cooler.

6. The method of any one of claims 1 to 5, wherein the feed material input comprises 10 wt-% to 50 wt-% of starch; 10 wt-% to 60 wt-% fiber; and 1 wt-% to 10 wt-% fat, by dry weight of the feed material input.

7. The method of any one of claims 1 to 6, wherein the predetermined temperature range of temperature TCOn is in a range of about 110 °F to about 190 °F (about 43 °C to about 88 °C), about 120 °F to about 175 °F (about 49 °C to about 80 °C), about 120 °F to about 165 °F (about 49 °C to about 74 °C), or about 130 °F to about 160 °F (from 54 °C to about 71 °C).

8. The method of any one of claims 1 to 7, wherein the moisture content Mcon is increased to 2 to 6 %-points above the moisture content Min of the feed material input.

9. The method of any one of claims 1 to 8, wherein the elevated temperature of the pelleting machine is in a range of about 160 °F to about 200 °F (about 70 °C to about 94 °C), about 165 °F to about 190 °F (about 75 °C to about 88 °C), or about 175 °F to about 190 °F (about 80 °C to about 88 °C).

10. The method of any one of claims 1 to 9, wherein the predetermined range of the moisture content Mcon is from 10 wt-% to 17 wt-%, from 11 wt-% to 17 wt-%, from 12 wt-% to 16 wt-%, or from 14 wt-% to 15.5 wt-%.

11. The method of any one of claims 1 to 10, wherein the cooler is configured to cool the pellets to a temperature within about 5 °F to about 15 °F (about 2 °C to about 8 °C) of an ambient temperature.

12. The method of any one of claims 1 to 11, wherein the pelleting system comprises one or more temperature sensors disposed in a line leading to the conditioner, within the conditioner, in a line leading to the pelleting machine, within the pelleting machine, in a line leading to the cooler, within the cooler, downstream of the cooler, or any combination of two or more thereof.

13. The method of any one of claims 1 to 12, wherein the pelleting system comprises a control unit configured to receive a signal from the microwave moisture sensor, to compare the moisture content to a predetermined value or range; and to adjust the amount of steam added to the feed material input.

14. A pelleting system comprising: a feed material input; a conditioner configured to mix steam with the feed material input to produce a conditioned feed material; a pelleting machine configured to receive the conditioned feed material and compress the conditioned feed material into pellets under elevated temperature and pressure; a cooler configured to receive the pellets from the pelleting machine; a microwave moisture sensor arranged in-line and configured to sense a moisture content of the feed material input, the conditioned feed material, the pellets, or a combination thereof; and a control unit configured to compare the moisture content to a predetermined range.

15. The pelleting system of claim 14, wherein the control unit is configured to increase the amount of steam added to the feed material input if the moisture content is below the predetermined range, and to reduce the amount of steam added to the feed material input if the moisture content is above the predetermined range.

16. The pelleting system of claim 14 or 15, wherein the microwave moisture sensor is arranged to measure the moisture of the feed material input in a line leading to the conditioner; the conditioned feed material in a line leading out of the conditioner; or within the conditioner.

17. The pelleting system of any one of claims 14 to 16, wherein the microwave moisture sensor is arranged to measure the moisture of the conditioned feed material in a line leading to the pelleting machine or within the pelleting machine.

18. The pelleting system of any one of claims 14 to 17, wherein the microwave moisture sensor is arranged to measure the moisture of the pellets in a line leading to or out of the cooler or within the cooler.

19. The pelleting system of any one of claims 14 to 18, wherein the pelleting system further comprises a mixer arranged to mix ingredients to produce the feed material input, and wherein the mixer comprises a microwave moisture sensor.

20. The pelleting system of any one of claims 14 to 20, wherein the pelleting system comprises one or more temperature sensors disposed in a line leading to the conditioner, within the conditioner, in a line leading to the pelleting machine, within the pelleting machine, in a lineleading to the cooler, within the cooler, downstream of the cooler, or any combination of two or more thereof.

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