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Design and development of livestock feed pelleting machine

Article in Journal of Engineering Research · January 2009

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 Journal of Engineering Research, Vol. 14, No. 1, March 2009. J.I. Orisaleye, S.J. Ojolo
and A.B. Fashina

DESIGN AND DEVELOPMENT OF A LIVESTOCK FEED PELLETING MACHINE

By

J.I. ORISALEYE*, S.J. OJOLO**, A.B. FASHINA***

* Mechanical Engineering Department, Lagos State University,
Epe Campus. Lagos. Nigeria.

** Mechanical Engineering Department, University of Lagos, Lagos. Nigeria.

***Agricultural Engineering Department, Ladoke Akintola University of Technology, Ogbomoso.

Nigeria.
ABSTRACT
Feeding pellets to livestock is advantageous to both the livestock and its farmer as it supplies the
required nutrients to the livestock and is also economical. However, livestock feed pelleting equipment
are known to be expensive and unaffordable particularly to the local farmer. A prototype of the pelleting
machine was designed and developed for affordability. The machine was also tested to evaluate its
performance. The machine consisted of a screw conveyor, die, barrel and hopper. It can be driven by an
electric motor or a prime mover. The machine was tested with broiler’s mash and at different levels of
moisture content using 500, 750 and 1000 cm3 each of water and starch binder as preconditioners. The
best pellets were formed using 750 cm3 of either starch or water. The average specific energy
consumption when 750 cm3 of starch binder was used was 0.69 kWh/kg while it was 0.93 kWh/kg when
water was used as preconditioner. The density of the pellets varied between 0.7 and 1 g/cm3. This
machine can be manufactured at a local machine shop for small-scale livestock farmers in developing
countries.

Key words: Development, livestock feed, pellets, machine

1.0 INTRODUCTION For many years, simple and common techniques

have been used in processing livestock feeds,
Feed represents the major cost to animal
which are basically cereal grains and their by-
production. Thus, the efficiency of its use, or
products. They have been classified into hot or
quality control, can have a considerable impact
cold processes depending on the requirement of
on the performance of an enterprise (Halley and
heat. Another classification is based on whether
Scoffe, 1988; Hasting and Higgs, 2000; Elmer,
the process is wet or dry. The techniques that
1990).
have been in use are grinding or particle size
The value of a feed is dependent on how much reduction, crushing, rolling, steam-flaking,
particular nutrients in the feed that the animal is micronisation, roasting, chopping, cracking or
able to utilize to meet the requirements of crimping, popping, hot and cold pelleting
various body processes (Halley and Scoffe, (Halley and Scoffe, 1988; Harris, 1990;
1988). The aim of processing livestock feed is McDonald, 1987; FAO, 1997; Hasting and
to increase the efficiency of utilization of the Higgs, 2000).
nutrients (Tillman and Waldroup, 1986;
Kabuage, 1996).
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 Journal of Engineering Research, Vol. 14, No. 1, March 2009. J.I. Orisaleye, S.J. Ojolo
and A.B. Fashina

Studies have revealed that feeding certain and the ring die pelleters (FAO, 1997).
livestock with pellets have great benefits. Generally, the pelleting equipment consist of a
Kabuage et al. (2000) noted that pelleting pelleting device, a steam generator, an oil and
amaranth diets improved the nutritional value molasses doser, a cooling device, a separator
and was beneficial in improving growth of and a sieve (Galen et al., 2000).
chicks. Salmatec (2000) also stated that highly It has been pointed out that the mean particle
compressed pellets facilitate storage and size or grind of ingredient, and formulation play
transportation, they save space, extend storage a major role in producing high quality pellets
life and permit large quantities to be carried (Galen et al., 2000; FAO, 2000). However, there
economically. Galen et al. (2000) pointed out is a limitation to the use of the livestock feed
that pelleting feeds produced many traits desired pelleting machine because of the high cost of
by livestock producers which include decreased the equipment for pellet processing (FAO, 1997;
feed wastage, reduced selective feeding, Kabuage et al., 2000; Eugene, 2002). Hence, the
improved feed efficiency, better handling local livestock farmer, in Nigeria in particular,
characteristics, destruction of undesirable cannot afford to utilize the sophisticated
micro-organisms and increased bulk density.
livestock feed pelleting machine. This work
They added that qualities added to the livestock aims at designing and developing a livestock
feed include complete pasteurization, improved feed pelleting machine and evaluating its
pellet quality (better durability and fewer fines), performance.
increased feed utilization, increased starch
gelatinization and production of by-pass fat and 2.0 MATERIALS AND METHODS
by-pass protein. Their views are shared by 2.1 Components Description and
McDonald (1987), MikroTechnik (2002), Specifications
Halley and Scoffe (1988), Salmatec (2000), The parts that make up the livestock feed
Eugene (2002) and FAO (1997). pelleting machine are the frame, barrel, hopper,
screw conveyor or auger, die, pulley and motor.
The pelleting equipment have been classified The machined components were made of mild
into two, based on the type of die: the disc die steel (Figure 1).

Figure 1: Livestock feed pelleting machine

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 Journal of Engineering Research, Vol. 14, No. 1, March 2009. J.I. Orisaleye, S.J. Ojolo
and A.B. Fashina

2.1.1 The Frame 2.2 DESIGN CONSIDERATIONS AND

The frame acted as a support to other SPECIFICATIONS
components. It was a rigid structure and was 2.2.1 The Screw Conveyor
designed to withstand dynamic stresses. Welded The parameters considered in the design of the
to the base was the bearing support. The barrel screw conveyor were obtained from design
was also welded to the vertical part of the frame. specifications and relevant tables which give
2.1.2 The Barrel parameters corresponding to the nominal screw
The barrel is a cylinder with internal diameter of diameter and the material to be pelleted (the feed
80 mm and thickness of 5 mm. It has a length of in this case). The parameters obtained were
300 mm. A flange was welded to the end of the (Singh, 2003):
barrel to support the die plate. Nominal screw diameter, D = 80 mm
2.1.3 The Hopper Length of the Screw Conveyor, L=300 mm
The hopper is a funnel shaped frustum cut out of Pitch of the Screw, s = 80 mm
a square pyramid. The height of the frustum is Maximum speed of screw, n = 170 rpm
150 mm and it has a square top of length 200 Solid shaft diameter, d = 25 mm
mm. Loading efficiency,  = 0.25
2.1.4 The Die Plate Friction factor for material,  = 0.6
The pelleting die is required to restrict the flow Factor of inclination, C = 1 for horizontal
of feed material and provide the cylindrical conveyors
shape of the pellet. The die plate had a thickness Material Factor, Wo = 4
of 5 mm. The effective diameter of the die plate Angle of inclination of screw to the horizontal, 
was 80 mm. Thirty-six die inserts of 8 mm were =
drilled into the plate.
Maximum density of material to be pelleted (the
2.1.5 The Screw Conveyor
feed),  = 800 kg/m3
The screw conveyor was a worm wound round a
Effeciency of gear reducer,  = 1 (100%
cylindrical shaft. The maximum outer diameter
efficiency assumed)
of the worm was 78 mm to give clearance
The capacity of the screw conveyor was
between screw and barrel. The screw conveyor
calculated using:
was carried on a solid shaft of 25 mm which is
driven by a pulley.
(Singh, 2003)

The power required to drive the screw was evaluated using:

(Singh, 2003)

Sin = 0;  = 1. Hence,

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 Journal of Engineering Research, Vol. 14, No. 1, March 2009. J.I. Orisaleye, S.J. Ojolo
and A.B. Fashina

The load propulsion speed is

(Singh, 2003)

The load per meter length of the screw is

(Singh, 2003)

The axial thrust experienced by the conveyor was evaluated by

(Singh, 2003)

2.2.2 Shaft Design

For the rotating shaft, pure torsion is assumed. Hence, the maximum shear stress due to torsion and the
angle of twist are considered.

(Burr, 1982; Khurmi and Gupta, 1979)

Diameter of shaft = 0.025 m

Active length of shaft = 0.34 m
Maximum stress due to torsion is
(Burr, 1982; Khurmi and Gupta, 1979)

Angle of twist of the shaft is

(Burr, 1982; Khurmi and Gupta, 1979)

2.3 Testing of the Livestock Feed Pelleting The feed was fed through the hopper and is
Machine carried through the barrel length by the screw
conveyor. Between the screw conveyor and the
The livestock feed pelleting machine was
die is a space which allows for caking of the
powered by an electric motor which rotated the
feed. The feed then passes through the die where
shaft carrying the screw conveyor. The rotation
the cylindrical shape of the pellets is formed.
of the shaft is such that the screw conveyor
moves the feed towards the die. 2.4 Test Procedure for the Livestock Feed
Pelleting Machine

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 Journal of Engineering Research, Vol. 14, No. 1, March 2009. J.I. Orisaleye, S.J. Ojolo
and A.B. Fashina

The livestock feed pelleting machine was 4. 500 cm3 of starch was added to one part
powered using a 3 kW electric motor and was and was thoroughly mixed.
tested to determine the output of the machine and 5. The machine was powered and the moist
quality of pellets produced by the machine under feed was fed through the hopper
varying conditions. The test materials were gradually.
Broiler’s mash, which was the feed mix used,
water and cassava starch. Cassava starch was 6. The pellets formed were collected on a
used as a substitute for molasses, which was to tray and dried.
serve as binder. 7. Ten pellets selected randomly were
2.4.1 Procedure for Testing using Water weighed and their dimensions were taken.

1. Three parts of feed mix, each 1 kg, were 8. The test was repeated for the other two
prepared. parts using 750 and 1000 cm3 of starch
respectively.
2. 500 cm3 of water was added to one part
and was thoroughly mixed. 2.5 Pelleting Machine Operation
Parameters
3. The machine was powered and the moist
feed was fed through the hopper The throughput or production rate of the
gradually. machine was calculated using:

4. The pellets resulting were collected on a

tray and dried.
5. Ten pellets selected randomly were
weighed and their dimensions were taken. The specific energy consumption of the machine
6. The test was repeated for the other two was evaluated using
parts using 750 and 1000 cm3 of water
respectively.
2.4.2 Procedure for Testing using Starch as
binder
3.0 RESULTS AND DISCUSSIONS
1. 100 g of starch was diluted in water at
room temperature and stirred until a 3.1 Results
uniform mix was achieved. The summary of results from the testing of the
2. Hot water at 100 oC was added to the mix livestock feed pelleting machine are presented in
and stirring was continued until the starch Tables 1 and 2. Table 1 shows the average
mixture becomes viscous. length, diameter and masses of the samples of
pellets selected at random. Table 2 shows the
3. 3 parts of feed mix, each 1 kg, were mass of pellets produced, time taken, throughput
prepared. and specific energy consumption of the machine.

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 Journal of Engineering Research, Vol. 14, No. 1, March 2009. J.I. Orisaleye, S.J. Ojolo
and A.B. Fashina

Table 1: Average dimensions, mass and density of samples of pellets produced by the Livestock Feed
Pelleting machine.

Average Average Average Length to

Mass of 10 Average
length Diameter density diameter
samples (g) mass (g)
(mm) (mm) (g/cm3) ratio

500 cm3
24.935 6.604 6.70 0.670 0.78 3.8
of starch

750 cm3
16.580 6.435 5.10 0.510 0.95 2.6
of starch
Feed mix with

1000 cm3
12.485 5.715 4.95 0.495 1.55 2.2
of starch

500 cm3
23.200 6.105 4.40 0.440 0.65 3.8
of water

750 cm3
17.105 6.440 3.85 0.385 0.69 2.7
of water

1000 cm3
No pellets formed
of water

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 Journal of Engineering Research, Vol. 14, No. 1, March 2009. J.I. Orisaleye, S.J. Ojolo
and A.B. Fashina

Table 2: Summary of test for each part of feed mix fed into the machine

Starch Water

1st
1st part 2nd part 3rd part 2nd part 3rd part
part

Mass of feed used (kg) 1 1 1 1 1 1

Quantity of starch/water
500 750 1000 500 750 1000
added (cm3)
Mass of pellets formed
0.90 0.95 1.01 0.90 0.90 0.95
(kg)
Mass of unpelleted feed
in the caking section 0.13 0.10 0.05 0.10 0.10 0.05
(kg)

Time taken (hr) 0.50 0.22 0.14 0.48 0.28 0.06

Capacity / Throughput No pellets

1.80 4.32 7.21 1.88 3.21
of the machine (kgh-1) formed

Specific Energy
1.67 0.69 0.42 1.60 0.93 0.19
Consumption (kWhkg-1)

3.2 Discussions formed. This was due to the excessive moisture

in the feed which overcame the required friction
When starch was used as binder, the pulse of
needed as feed passed through the die. Hence the
feed through the die was generally smooth for all
feed could not be caked as there were no
mixes as against when water alone was used to
restrictions to keep it in the caking section. In
condition the feed. The pellets formed with
addition, the pellets derived when 1000 cm3 of
starch binder were smooth and brightly coloured
starch was used were poorly formed. This was
but those formed with water were scorched and
also due to the same reason as for 1000 cm3 of
pale. This was due to the friction and the heat
water. Pellets were formed though, probably due
generated during the process which was higher
to the binding effect of the starch on the feed.
with just water being used as preconditioner.
This was evidenced by the temperature around An acceptable standard by FAO (1996) proposes
the caking section which was relatively hotter that good pellets which are properly formed have
when water was used as preconditioner than with their lengths to be about two and a half times
starch. their diameters. This was particularly so for
pellets formed using 750 cm3 of water as
The pellets with 500 and 750 cm3 of starch or
water were properly formed. However, when preconditioner and 750 cm3 of starch as binder.
The length to diameter ratio was higher when
1000 cm3 of water was used, no pellets were
500 cm3 of either starch or water was used and
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 Journal of Engineering Research, Vol. 14, No. 1, March 2009. J.I. Orisaleye, S.J. Ojolo
and A.B. Fashina

lower when 1000 cm3 of starch was used. The with water as preconditioner. This is higher than
results also show that the pellets formed using 0.14 kWh/kg obtained by Rose and Miller
binder were generally denser than those formed (1973). The total energy expended by a machine
when water was used as a preconditioner. This used by Groesbeck et al. (2007) was less than
may probably suggest the advantage of using a 0.01 kWh/kg. The low capacity and high specific
binder. power consumption may be improved with
accessories like the steam generator, oil and
When the feed was pelleted at sufficient and
molasses doser (FAO, 1996) and also with the
reasonable moisture content, say 750 cm3 of
addition of additives like glycerol and soy oil as
starch or water, it was observed that the specific
was observed by Groesbeck et al. (2007).
energy consumption was lower with starch as
binder. It was also observed that the throughput 3.3 Conclusion
of the pelleting machine that produced A livestock feed pelleting machine has been
acceptable pellets was higher when the starch developed for the use of the local small scale
binder was used. Also, when a higher volume of farmer. The machine has a capacity which suits
binder was used, the specific energy its purpose but can be improved and modified to
consumption was reduced but at the expense of reduce the specific power consumption. The
the quality of the pellet as indicated earlier. This machine can be fabricated affordably at small
is also true with using water as preconditioner. workshops or machine shops in developing
The higher energy consumption was also noticed countries.
in the response of the electric motor when the
machine was loaded. REFERENCES

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 Journal of Engineering Research, Vol. 14, No. 1, March 2009. J.I. Orisaleye, S.J. Ojolo
and A.B. Fashina

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