Animal Feed Block Manufacturing Process Control
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Solution Overview
Problem
The production of animal feed blocks is hindered by inconsistent chemical reactions and significant waste due to the hydration of calcium or magnesium oxides when they come into contact with moisture, leading to variable product quality and repeatability issues.
Innovation Solution
A continuous process involving precise measurement and proportionate mixing of dry and wet pre-mixes with an active ingredient in an apparatus that ensures accurate formulation, using load cells and process control systems to maintain consistency and prevent spoilage, forming the feed blocks without heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If calcium oxide or magnesium oxide is used as a catalyst in feed block production, then the chemical reactions proceed, but significant waste material is generated due to hydration when they come into contact with moisture
Solution Approach 1:
The patent applies preliminary action by pre-drying the calcium oxide or magnesium oxide catalyst before use, and by controlling the moisture content of raw materials beforehand. This prevents premature hydration reactions that would generate waste material, allowing the chemical reactions to proceed efficiently while minimizing catalyst waste.
Solution Approach 2:
The patent changes the parameter of moisture content throughout the process. By maintaining low moisture conditions during catalyst handling and only introducing moisture at controlled stages, the hydration of calcium oxide or magnesium oxide is minimized, reducing waste material generation while still enabling necessary chemical reactions.
2Adaptability or versatility
If minor adjustments are made in quantity, weight or particle size of ingredients, then the formulation can be modified, but inconsistent product quality occurs due to severe reaction variability
Solution Approach 1:
The patent implements feedback control by monitoring the chemical reactions during the feed block formation process. Sensors detect parameters such as temperature, moisture content, and reaction progress, and this information is fed back to adjust process conditions in real-time. This ensures that even when ingredient quantities or particle sizes are adjusted for different formulations, the chemical reactions remain controlled and product quality remains consistent.
Solution Approach 2:
The patent applies dynamics by making the process conditions adjustable and responsive. Rather than fixed parameters, the process allows dynamic adjustment of mixing time, moisture addition rate, and reaction temperature based on the specific formulation requirements. This enables flexible ingredient adjustments while maintaining reaction control through real-time process modification.
3Ease of manufacture
If chemical reactions are used in feed block production, then the feed blocks can be formed, but the reactions are difficult to control and lead to variable product quality
Solution Approach 1:
The patent introduces an intermediary substance or controlled environment to mediate the chemical reactions between calcium oxide/magnesium oxide and moisture. By using controlled additives or intermediate processing steps, the reactions proceed as needed for feed block formation but are buffered against uncontrolled variability, improving reliability while maintaining ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process ensures consistent and repeatable production of animal feed blocks with precise nutritional formulation, reducing waste and variability, and maintaining product quality across batches.
Implementation Method 1
A first load cell fitted to the first hopper measures a weight of the dry pre-mix in the first hopper. A second load cell fitted to the second hopper measures a loss in weight of the active ingredient in the second hopper.
Implementation Method 2
The oxides hydrate when they come into contact with moisture contained in the wet materials. Many chemical reactions which occur during production of a feed block are not fully understood and bear a resemblance to cement chemistry.
Implementation Method 3
Typically the process is carried out without heating. For example, the animal feed block is a chemical feed block which is formed exothermically during steps (C), (D) and (E).
Data Source
AI summary
The present invention relates to a process for the manufacture of an animal feed block according to a target constituent formulation. The process eliminates spoiling of product by inconsistent and fluctuating levels of active ingredient and wet ingredients so as to ensure repeatability from one batch to another.