As the poultry farming industry continues to grow, there is an increasing demand for finished feed, leading to a significant expansion in the production scale of compound feed. Previously, production was limited to 2t/h, but now it has increased to 20t/h, 30t/h, and even higher. The main raw materials used in compound feed include corn, wheat bran, fishmeal, soybean meal, additives, and animal drugs. In short-term production, various ingredients must be weighed according to the formula and then mixed. Manual operations are time-consuming and prone to errors, making it increasingly essential to implement intelligent automatic batch weighing systems in modern feed production.
There are two common methods for weighing feed ingredients. The first method involves using a weighing bucket to handle 12 to 16 different feed ingredients. The second method uses 8 measuring buckets to sequentially weigh 8 to 12 types of ingredients and directly discharge them into the mixer. Although each plant may have different formulas and ingredient quantities, the overall production process remains similar, with comparable weighing techniques.
The production process typically begins with a bucket elevator that lifts the raw materials to a high screw conveyor. An electronically controlled rotary distributor then distributes the materials into storage bins located on the upper level of the facility. Under the control of the batching system, the screw conveyors for each silo release the materials into the measuring bucket according to the set amount. Once all ingredients are properly measured, the bucket automatically opens, sending the mixture to the mixer. At the same time, oil is added, and the mixture proceeds to the next stage, such as pelletizing.
Measuring buckets generally have a capacity of 800kg to 1200kg and are often designed as inverted cone-shaped structures. To prevent swinging caused by material leakage, it's preferable to use pressure-type load cells. Since most materials are loose powders, they tend to form a pile inside the bucket. Therefore, the volume of the measuring bucket should be multiplied by a factor (typically 1.3 to 1.4) depending on the material’s density and particle size. The taper angle at the discharge port is critical to ensure smooth material flow. If improperly designed, dry materials may form a self-supporting arch, which can hinder flow and affect measurement accuracy. The cone angle should ideally be less than 60 degrees to avoid this issue.
To improve efficiency and prevent moisture-sensitive materials from sticking to the inner walls, external wall vibrators can be installed on the measuring bucket. A triangular structure can also be placed at the top of the discharge port to break any arch formation. Above the measuring bucket, there are usually 12 to 16 feeding ports from screw conveyors. Ensuring even distribution of these feeds is crucial for accurate and fast weighing. For calibration purposes, a steel mesh frame or hooks can be welded around the bucket to hold weights during testing.
Modern feed mills rely on programmable logic controllers (PLCs) for their control systems. This reduces the size of the control cabinet and minimizes the number of relays and other electrical components. PLCs allow for easier debugging through ladder logic programming, and changes can be made without replacing hardware. Output controls can be directly connected to the PLC, and the system includes a comprehensive report printing function. It can generate data reports, operational logs, material consumption records, recipe details, and ingredient specifications. These features make the system highly suitable for automated feed production in modern facilities.
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