Feed Pellet Nuclei Agglomeration and Binder Application
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Solution Overview
Problem
Existing methods for producing animal feed pellets require high pressures and high melting-point binders, which can be inefficient and costly, and are not suitable for all nutritional components, particularly for animal feed where specific nutrient ratios are crucial.
Innovation Solution
A method involving a two-step process where ingredients are agglomerated in a first apparatus to form nuclei, then tumbled in a second apparatus while receiving additional ingredients, forming a feed pellet with specific nutrient ratios, including calcium, salt, and non-protein nitrogen, using binders like molasses or vital wheat gluten.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high pressure and high melting-point binders are used in pellet mill production, then pellet formation is achieved, but production cost and energy consumption increase
Solution Approach 1:
The invention changes the physical state parameters of the binder from solid (high melting-point) to liquid form, enabling pellet formation at lower temperatures and pressures. The liquid binder is applied to pre-formed pellets, allowing the binding process to occur without the high energy input required by traditional high-pressure pellet mills.
Solution Approach 2:
The pellet formation process is divided into two separate stages: (1) forming solid pellets from feed ingredients using a pellet mill, and (2) applying liquid binder to the formed pellets. This segmentation allows each stage to operate under optimized conditions, avoiding the need for high-pressure binding throughout the entire process.
2Ease of manufacture
If traditional pellet mill process is used, then pellets are formed, but control over nutrient composition and ratios is limited
Solution Approach 1:
The feed formulation process is separated into distinct components: solid feed ingredients are processed into pellets first, then liquid binder containing specific nutrients is applied afterward. This allows independent formulation and control of solid and liquid nutrient components, enabling precise adjustment of final nutrient ratios without compromising pellet formation.
Solution Approach 2:
The solid feed ingredients and their nutrient composition are prepared and formulated in advance before pellet formation. This preliminary formulation allows for precise control of the solid component nutrients, while the liquid binder can then be tailored to provide complementary nutrients, achieving overall precise nutrient composition control.
3Ease of manufacture
If high pressure processing is used, then pellets are formed, but production cost increases
Solution Approach 1:
The binding function is separated from the pellet formation function. Pellets are formed first under controlled pressure, then liquid binder is applied in a separate low-energy step. This eliminates the need for continuous high-pressure processing throughout the entire manufacturing cycle, significantly reducing energy consumption and production costs.
Solution Approach 2:
The binder is changed from requiring high-pressure application (solid state) to liquid state application at ambient or near-ambient conditions. This parameter change in the binder's physical state dramatically reduces the energy and cost requirements for the binding operation.
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 allows for the creation of feed pellets with precise nutrient compositions and improved durability, reducing production costs and energy requirements while ensuring nutritional adequacy for animals.
Implementation Method 1
The binder adheres the feed ingredients to each other
Implementation Method 2
tumbling the plurality of nuclei in a second apparatus and simultaneously providing additional amounts of the at least two ingredients to the second apparatus, thereby forming a plurality of feed pellets
Data Source
AI summary
The present disclosure relates to methods of making a feed pellet for an animal by agglomerating at least two ingredients in a first apparatus to form a plurality of nuclei and tumbling the plurality of nuclei in a second apparatus and simultaneously providing additional amounts of the at least two ingredients to the second apparatus, thereby forming a plurality of feed pellets for an animal. The present disclosure also relates to associated feed pellets and systems.