As the poultry industry continues to expand, the demand for finished feed has significantly increased. This growth has led to a substantial rise in the production scale of compound feed, moving from 2t/h to as high as 20t/h, 30t/h, or even more. The main raw materials used in compound feed production include corn, wheat bran, fishmeal, soybean meal, and various additives and animal drugs. In short-term production, different raw materials must be accurately measured and placed into the weighing bucket according to the formula. However, relying on manual labor for this process is both time-consuming and prone to errors, making the adoption of intelligent automatic batch weighing systems increasingly essential.
There are two primary methods for weighing feed ingredients. The first involves using a single weighing bucket to handle 12 to 16 types of feed ingredients. The second method utilizes 8 measuring buckets that sequentially weigh 8 to 12 different ingredients before discharging them directly into the mixer. Although each plant may have unique formulas and ingredient quantities, the overall production process remains similar, with weighing techniques largely consistent across facilities.
The typical production process begins with a bucket elevator that lifts raw materials to a high screw conveyor. These materials are then distributed by an electronically controlled rotary distributor into storage bins located at the upper level of the facility. Under the control of a batching controller, the screw conveyors for each silo release the materials into the measuring bucket in the specified amounts. Once all ingredients are properly weighed, the measuring bucket automatically opens its discharge door, sending the mixture to the mixer. At the same time, oil is added, and the final blend is sent to the next stage, such as pelletizing.
Measuring buckets typically have a capacity ranging from 800kg to 1200kg and often use an inverted cone design. To prevent swinging caused by material movement, it is recommended to use a pressure-type load cell. Since most raw materials are loose powders, they tend to form a mountain-like pile inside the bucket. Therefore, the volume of the measuring bucket should be multiplied by a factor—usually between 1.3 and 1.4—depending on the material's density and particle size. The angle of the discharge port is critical for ensuring smooth material flow. If improperly designed, dry materials may form a self-supporting arch, leading to blockages and affecting measurement accuracy. A cone angle of less than 60 degrees is generally recommended.
To ensure optimal performance, vibration devices can be installed on the outside of the measuring bucket to prevent moisture-absorbing materials from sticking to the inner walls. This helps maintain accurate measurements and efficient discharge. A triangular structure can also be added at the top of the discharge port to break any potential arches. Above the measuring bucket, there are usually 12 to 16 feeding ports from different raw material screw conveyors. Proper distribution of these feeding points is crucial for fast and accurate weighing. It also facilitates maintenance and operation.
For control, programmable logic controllers (PLCs) are widely used. They reduce the size of the control cabinet and minimize the number of electrical components like relays. By programming the control logic in ladder language, debugging becomes more straightforward. If changes are needed, only the software needs updating, not the hardware. Additionally, PLCs offer comprehensive reporting functions, including system data reports, operational logs, material consumption records, recipe production details, and ingredient specifications. These features make PLCs ideal for modern automated feed mill operations.
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