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    Ukraine, 69091 Zaporizhzhia
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Fodder production line management system

Combined feed (fodder) is a homogeneous mixture of forage resources (grain, bran, fodder of animal origin, mineral supplements) high in protein, vitamins and minerals for farm animals and poultry nutrition. Depending on fodder feeding value it is divided into: full fodder, mixed fodder concentrates, balancing fodder supplement (protein-vitamin, protein-vitamin-mineral) and premixes.

Extrusion method is the most popular among all methods of animal feed production. It allows to improve the qualitative properties of the end product compared to traditional methods. During the production process the feed is effected by brief and very intense mechanical and barothermal impacts, which are followed by structural, mechanical and chemical feedstock changes. Due to the short duration of the process, vitamins and amino acids, which are contained in grains, are almost completely saved. And digestibility is increased to 90%. Extruded feedstock is practically not affected by bacteria when stored under normal warehouse conditions (for 3-4 months). This fact is of special value for the fattening of young animals (cattle, pigs, horses, rabbits, etc.). Feeding young animals with extruded feedstock 1,5-2 times reduces their gastrointestinal disease mortality. It should be noted that the quality of the finished product is not affected by humidity of the processed raw materials and possible small number of seeds of other crops.

Flowsheet and equipment are selected depending on formulation and the manufactured feed.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
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Technology of production

One of the most simple and effective technological schemes of animal feed production is serial (in-line) scheme. The source components are pre-cleaned and each one is placed into separate bunker. After that the components are weighed metered depending on the form of manufactured feed. Prepared mixture goes into crusher, which simultaneously does component shredding and mixing. Then mixture is sieved goes into extruder. While extrusion milled mixture is treated by high mechanical pressure (30-50 atm), it heats up due to friction (120-150 ºC) and turns into crashed mass. At the exit of the extruder the mass swells , due to the large pressure drop. The starch contained in the end feedstock turns into dextrin, which is easily assimilated by the animal organism, and a large part of the micro flora (bacteria, fungi) is destroyed.


Developed management system provides fodder production with:

  • continuous operation and equipment control of the unit;
  • manual and automatic control of transport (conveyors, bucket elevators, valves, changeover valves) and process (crusher, extruder) equipment of the unit;
  • control of the silos filling level(with the use of level sensors with analog & discrete signals);
  • crusher smooth start(200 kW);
  • regulating of feedstock supply to the crusher depending on crusher load level;
  • display of equipment operating modes status and emergency situations.

In development of the control system was performed integration into extruder automation system which is unique for Ukraine – ExtruTech, Bliss (USA) performance 6 t/h.

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