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Batching and Mixing
Batching and Mixing

Charles Stark North Carolina State University

Batching and Mixing Charles Stark North Carolina State University
Batching & Mixing Objective  Accurately weigh each ingredient  Minimize batching time  Produce

Batching & Mixing Objective

Accurately weigh each ingredient Minimize batching time Produce a feed that has a uniform distribution of nutrients and medications

Ingredient Factors  Particle size and shape  Density  Electrostatic charge  Hygroscopicity 

Ingredient Factors

Particle size and shape

Density

Electrostatic charge

Hygroscopicity

Flowability

Particle Size Specification  Ingredients & Minerals  Supplier specifications  Customer specifications 

Particle Size Specification

Ingredients & Minerals

Supplier specifications Customer specifications

Example SBM, DDGS (600 – 1200 microns)

Specifications based on screen size

Thru a US #

Premixes

Carrier Particles per gram

Feed Segregation  Segregation occurs primarily as a result of differences in particle size, the

Feed Segregation

Segregation occurs primarily as a result of differences in particle size, the difficulty of mixing multiple components can be reduced by making the sizes of the components as close as possible and also by reducing the absolute size of the particles.

Ingredient Characteristics  Particle size  Shape  Flat  Round  Density  Wheat

Ingredient Characteristics

Particle size

Shape

Flat

Round

Density

Wheat Midds Ground Corn SBM Limestone

size  Shape  Flat  Round  Density  Wheat Midds  Ground Corn 
size  Shape  Flat  Round  Density  Wheat Midds  Ground Corn 
size  Shape  Flat  Round  Density  Wheat Midds  Ground Corn 
size  Shape  Flat  Round  Density  Wheat Midds  Ground Corn 

Source: IMC 1995

Particle Differences  Large Particles - For coarse particles, the attractive force between two particles

Particle Differences

Large Particles - For coarse particles, the attractive force between two particles in contact is small compared with the weight of a particle, leading to a free flowing material. Small Particles - If the particle size is reduced, the weight of a particle falls more rapidly than the attractive force between the particles, and eventually the stage is reached where the particles stick together. Segregation is then prevented, because particles are no longer free to move relative to each other.

Feed Mill Designs Pre-batch grind Post-mix grind P o s t - b a t

Feed Mill Designs

Feed Mill Designs Pre-batch grind Post-mix grind P o s t - b a t c
Feed Mill Designs Pre-batch grind Post-mix grind P o s t - b a t c

Pre-batch grind

Post-mix grind

Feed Mill Designs Pre-batch grind Post-mix grind P o s t - b a t c

Post-batch grind

Feed Mill Designs Pre-batch grind Post-mix grind P o s t - b a t c

Post-pellet blend

Feed Mill Designs Pre-batch grind Post-mix grind P o s t - b a t c
Batching Equipment  Micro Bin Systems  Tote Bag Systems  Scales  Major 

Batching Equipment

Micro Bin Systems

Tote Bag Systems

Scales

Major

Minor

Weigh Buggy

Liquid Pumps & Meters

Scales
Scales
Batching – Scale Fill Test 2/3 1/3 200 lb  Major & Minor Scales 

Batching – Scale Fill Test

2/3 1/3 200 lb
2/3
1/3
200 lb

Major & Minor Scales

Fill test evaluates full range of load cells

Add test weights

Record weight

Remove weights

Fill scale to 1/3 capacity

Add test weights

Record weight

Remove weights

Fill scale to 2/3 capacity

Add test weights

Record weight

Document results

Batching – Micro System Multiple Hopper Scale S i n g l e H o

Batching – Micro System

Multiple Hopper Scale

Single Hopper Scale

Batching – Micro System Multiple Hopper Scale S i n g l e H o p
Batching – Micro System Multiple Hopper Scale S i n g l e H o p
Batching – Micro System Multiple Hopper Scale S i n g l e H o p
Batching – Micro System Multiple Hopper Scale S i n g l e H o p
Batching - Totes Totes & Scales Tote Transfer

Batching - Totes

Totes & Scales

Tote Transfer

Batching - Totes Totes & Scales Tote Transfer
Batching - Totes Totes & Scales Tote Transfer
Liquid Ingredients Self Contained System Tank & Dike System

Liquid Ingredients

Self Contained System

Liquid Ingredients Self Contained System Tank & Dike System

Tank & Dike System

Liquid Ingredients Self Contained System Tank & Dike System
Liquid Addition Layout

Liquid Addition Layout

Liquid Addition Layout
Liquid Addition Equipment Meters Pumps

Liquid Addition Equipment

Meters

Liquid Addition Equipment Meters Pumps

Pumps

Liquid Addition Equipment Meters Pumps
Mass Flow System – Liquid Component Coriolis Meter

Mass Flow System – Liquid Component

Coriolis Meter

Mass Flow System – Liquid Component Coriolis Meter
Mass Flow System – Coriolis Meter

Mass Flow System – Coriolis Meter

Mass Flow System – Coriolis Meter
Mass Flow System – Coriolis Meter
Batching Sequence Major Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple

Batching Sequence

Major Scale:

Batching System

Batching Sequence Major Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins

Micro Scale

Major Scale
Major
Scale
Minor Scale
Minor
Scale
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major
Scale: Batching System Micro Scale Major Scale Minor Scale Computer draws multiple bins to the major

Computer draws multiple bins to the major scale.

Computer switches to one bin and jogs at the end of the each ingredient.

Major Ingredients Corn/Wheat SBM Midds DDGS

Batching Sequence Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws

Batching Sequence

Batching System

Batching Sequence Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws single
Major Scale
Major
Scale
Micro Scale Minor Scale
Micro Scale
Minor
Scale
Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws single bins to
Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws single bins to
Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws single bins to
Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws single bins to
Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws single bins to
Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws single bins to
Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws single bins to
Batching System Major Scale Micro Scale Minor Scale Minor Scale Fill: Computer draws single bins to

Minor Scale Fill:

Computer draws single bins to the minor scale and jogs at the end of the each ingredient.

Minor Ingredients Dical Limestone Salt Lysine

Batching Sequence Batching System Micro Scale Fill: Micro Major Scale Scale Minor Scale Computer draws

Batching Sequence

Batching System

Micro Scale Fill:

Batching Sequence Batching System Micro Scale Fill: Micro Major Scale Scale Minor Scale Computer draws single

Micro

Major Scale
Major
Scale
Scale Minor Scale
Scale
Minor
Scale
Micro Scale Fill: Micro Major Scale Scale Minor Scale Computer draws single bins to the micro
Micro Scale Fill: Micro Major Scale Scale Minor Scale Computer draws single bins to the micro
Micro Scale Fill: Micro Major Scale Scale Minor Scale Computer draws single bins to the micro

Computer draws single bins to the micro scale and jogs at the end of the each ingredient.

Micro Ingredients Vitamins Trace Minerals Medications Amino Acids

Batching Sequence Batching System Micro Scale Major Scale Minor Scale Scale Considerations: Major Scale 80-90%

Batching Sequence

Batching System

Batching Sequence Batching System Micro Scale Major Scale Minor Scale Scale Considerations: Major Scale 80-90% Minor

Micro Scale

Major Scale
Major
Scale
Minor Scale
Minor
Scale

Scale Considerations:

Major Scale 80-90% Minor Scale 10-15% Micro Scale < 5%

Micro Scale Major Scale Minor Scale Scale Considerations: Major Scale 80-90% Minor Scale 10-15% Micro Scale
Micro Scale Major Scale Minor Scale Scale Considerations: Major Scale 80-90% Minor Scale 10-15% Micro Scale
Micro Scale Major Scale Minor Scale Scale Considerations: Major Scale 80-90% Minor Scale 10-15% Micro Scale
Batching Sequence Batching System Major Scale Discharges First Fills the dead space between the ribbons

Batching Sequence

Batching System

Major Scale Discharges First

Fills the dead space between the ribbons and tub.

Major Scale Discharges First Fills the dead space between the ribbons and tub. Micro Scale Major

Micro Scale

Major Scale
Major
Scale
Minor Scale
Minor
Scale
Major Scale Discharges First Fills the dead space between the ribbons and tub. Micro Scale Major
Batching Sequence B a t c h i n g S y s t e

Batching Sequence

Batching System

Batching Sequence B a t c h i n g S y s t e m

Micro Scale

Major Scale
Major
Scale
Minor Scale
Minor
Scale

Minor Scale Discharges after a 5-10 second delay

Minor ingredients mix with the major ingredients

Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Scale Minor Scale Minor Scale Discharges after a 5-10 second delay Minor ingredients mix with the
Batching Sequence B a t c h i n g S y s t e

Batching Sequence

Batching System

Batching Sequence B a t c h i n g S y s t e m

Micro Scale

Major Scale
Major
Scale
Minor Scale
Minor
Scale

Micro Scale Discharges after a 0-5 second delay

Micro tub or scales open and the material is transferred with a drag conveyor

Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Scale Discharges after a 0-5 second delay Micro tub or scales open and the material is
Batching Batching System Micro Scale Major Scale Minor Scale Mixing Time Horizontal Double Ribbon 30-60

Batching

Batching System

Batching Batching System Micro Scale Major Scale Minor Scale Mixing Time Horizontal Double Ribbon 30-60 second

Micro Scale

Major Scale
Major
Scale
Minor Scale
Minor
Scale

Mixing Time Horizontal Double Ribbon 30-60 second Dry Mix 120-180 second Wet Mix Liquid Addition Volumetric (meter) Gravimetric (weighed)

Liquid Ingredients:

Fat Molasses Choline Amino acids

Spray Here

Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Addition Volumetric (meter) Gravimetric (weighed) Liquid Ingredients: Fat Molasses Choline Amino acids Spray Here
Discharge Process
Discharge Process

Batching Sequence

Batching/Mixing System

Discharge Process Batching Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge

Micro Scale

Mixer opens and material drops to a surge hopper

Major Scale
Major
Scale
Minor Scale
Minor
Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Sequence Batching/Mixing System Micro Scale Mixer opens and material drops to a surge hopper Major Scale
Batch Cycle Batch Cycle – 4 mins Weighing 2 min Discharge 1 min Mixing 3

Batch Cycle

Batch Cycle – 4 mins Weighing 2 min Discharge 1 min Mixing 3 min Weighing
Batch Cycle – 4 mins
Weighing 2 min
Discharge
1 min
Mixing 3 min
Weighing 2 min
Discharge
1 min
Mixing 3 min
MIXING EQUIPMENT

MIXING EQUIPMENT

Automation System

Automation System

Automation System
Automation Hardware PC Server PLC

Automation Hardware

PC

Server
Server
PLC
PLC
PLC PLC PLC Cards/Modules

PLC

PLC
PLC

PLC Cards/Modules

PLC PLC PLC Cards/Modules
PLC Computer Inputs Theromcouple Hand Add Buttons Micro Switch Scale Indicator

PLC Computer Inputs

PLC Computer Inputs Theromcouple Hand Add Buttons Micro Switch Scale Indicator

Theromcouple

PLC Computer Inputs Theromcouple Hand Add Buttons Micro Switch Scale Indicator
PLC Computer Inputs Theromcouple Hand Add Buttons Micro Switch Scale Indicator

Hand Add Buttons

Micro Switch

PLC Computer Inputs Theromcouple Hand Add Buttons Micro Switch Scale Indicator

Scale Indicator

PLC Computer Inputs Theromcouple Hand Add Buttons Micro Switch Scale Indicator
PLC Outputs Motor Starter VFD

PLC Outputs

Motor Starter

VFD
VFD
Batch Production Report
Batch Production Report
Batch Production Report
Batch Production Report
Recommended mix times Mixer Dry Mix Wet Mix Paddle 3 3 Twin Shaft Paddle 0.5

Recommended mix times

Mixer

Dry Mix

Wet Mix

Paddle

3

3

Twin Shaft Paddle

0.5

1

Double Ribbon

1-2

2-3

Twin Shaft Ribbon

0.75-1

2

Vertical

5-10

5-10

Mixer Design Factors  Dimensions  Short x Wide  Long x Narrow  Ribbon/Paddle

Mixer Design Factors

Dimensions

Short x Wide Long x Narrow

Ribbon/Paddle Angle

Ribbon Width(s)

Ribbon Tip Speed

Total Surface Area

x Wide  Long x Narrow  Ribbon/Paddle Angle  Ribbon Width(s)  Ribbon Tip Speed
x Wide  Long x Narrow  Ribbon/Paddle Angle  Ribbon Width(s)  Ribbon Tip Speed
Mixer Sizes 200 CF Mixer Feed (lbs/cft) 35 - 7000 lbs 40 – 8000 lbs

Mixer Sizes

Mixer Sizes 200 CF Mixer Feed (lbs/cft) 35 - 7000 lbs 40 – 8000 lbs 45

200 CF Mixer

Feed (lbs/cft)

35

- 7000 lbs

40

– 8000 lbs

45

– 9000 lbs

Horizontal Ribbon Mixer
Horizontal Ribbon Mixer
Ribbon mixer – Multiple ribbons

Ribbon mixer – Multiple ribbons

Ribbon mixer – Multiple ribbons
Ribbon mixer – Multiple ribbons
Double ribbon – Single shaft

Double ribbon – Single shaft

Double ribbon – Single shaft
Double Ribbon Mixer – Mixing Zones Feed Flow Main Mixing Zone Main Mixing Zone Typical

Double Ribbon Mixer – Mixing Zones

Feed Flow Main Mixing Zone Main Mixing Zone
Feed Flow
Main Mixing Zone
Main Mixing Zone

Typical mix time = 3-4 min

Double Ribbon Horizontal Mixer

Double Ribbon Horizontal Mixer

Double Ribbon Horizontal Mixer
Paddle Mixer

Paddle Mixer

Paddle Mixer
Paddle Mixer
Paddle Mixer
Paddle mixer

Paddle mixer

Paddle mixer
Paddle Mixer – Mixing Zones Feed Flow Main Mixing Some Main Mixing Mixing Some Main

Paddle Mixer – Mixing Zones

Feed Flow Main Mixing Some Main Mixing Mixing Some Main Mixing Main Mixing Mixing
Feed Flow
Main Mixing
Some
Main Mixing
Mixing
Some
Main Mixing
Main Mixing
Mixing
Horizontal Paddle Mixer

Horizontal Paddle Mixer

Horizontal Paddle Mixer
Rotating Drum Mixer – Mixing Zones

Rotating Drum Mixer – Mixing Zones

Rotating Drum Mixer – Mixing Zones
Drum Mixer

Drum Mixer

Drum Mixer
Ribbon Mixer - Counterpoise

Ribbon Mixer - Counterpoise

Ribbon Mixer - Counterpoise
Ribbon Mixer - Counterpoise
Ribbon Mixer – Counterpoise Mixing Zone http://www.hayes-stolz.com/

Ribbon Mixer – Counterpoise Mixing Zone

Ribbon Mixer – Counterpoise Mixing Zone http://www.hayes-stolz.com/
Forberg Fluid Bed Mixer

Forberg Fluid Bed Mixer

Forberg Fluid Bed Mixer
Forberg Mixer

Forberg Mixer

Forberg Mixer
Vertical Mixer

Vertical Mixer

Vertical Mixer
Vertical Mixer – Mixing Zones Main Main Mixing Mixing Zone Zone Main Mixing Zone

Vertical Mixer – Mixing Zones

Main Main Mixing Mixing Zone Zone Main
Main
Main
Mixing
Mixing
Zone
Zone
Main
Mixing Zone
Mixing
Zone
Vertical Mixer – Mixing Zones Main Main Mixing Mixing Zone Zone Main Mixing Zone
Vertical Mixer – Mixing Zones Main Main Mixing Mixing Zone Zone Main Mixing Zone
Vertical Mixer – Mixing Zones Main Main Mixing Mixing Zone Zone Main Mixing Zone
Vertical Mixer – Mixing Zones Main Main Mixing Mixing Zone Zone Main Mixing Zone
Vertical Mixer

Vertical Mixer

Vertical Mixer
Mixer-Problems Liquid Spray Nozzle Material Build up

Mixer-Problems

Liquid Spray Nozzle

Mixer-Problems Liquid Spray Nozzle Material Build up

Material Build up

Mixer-Problems Liquid Spray Nozzle Material Build up
Mixer Problems Material on ribbons Material on paddles

Mixer Problems

Material on ribbons

Material on paddles

Mixer Problems Material on ribbons Material on paddles
Mixer Problems Material on ribbons Material on paddles
Batching & Mixing Problems Fat sprayed on ribbon and shaft Fat lumps created by poor

Batching & Mixing Problems

Fat sprayed on ribbon and shaft

Batching & Mixing Problems Fat sprayed on ribbon and shaft Fat lumps created by poor liquid

Fat lumps created by poor liquid application and mixing

Batching & Mixing Problems Fat sprayed on ribbon and shaft Fat lumps created by poor liquid
MIXER UNIFORMITY ANALYSIS

MIXER UNIFORMITY ANALYSIS

Factors Affecting Uniformity  Particle Shape  Spherical, square, flat  Particle Size  Different

Factors Affecting Uniformity

Particle Shape

Spherical, square, flat

Particle Size

Different particle size can separate during the handling process

Density

Heavy particles may settle out during conveying and discharge to a bin

Static Charge

Particles will adhere to equipment if not properly grounded

Hydroscopicity

Vitamins or Feed Additives may absorb water

Adhesiveness

Fats or molasses may adhere to equipment

 Vitamins or Feed Additives may absorb water  Adhesiveness  Fats or molasses may adhere
What Represents the Goal of Mixing? Perfect Mix Random Mix Segregated Mix

What Represents the Goal of Mixing?

What Represents the Goal of Mixing? Perfect Mix Random Mix Segregated Mix

Perfect Mix

What Represents the Goal of Mixing? Perfect Mix Random Mix Segregated Mix

Random Mix

Segregated

Mix

What Represents the Goal of Mixing? Perfect Mix Random Mix Segregated Mix
What Represents the Goal of Mixing? Perfect Mix Random Mix Segregated Mix
Distribution of weighing errors

Distribution of weighing errors

Distribution of weighing errors
Are You Weighing Ingredients Correctly? Weighing Precision  Variation in weighing within ingredients, expressed as

Are You Weighing Ingredients Correctly?

Weighing Precision

Variation in weighing within ingredients, expressed as Coefficient of Variation (CV)

Weighing CV ranges on average of about 5% (0.6 - 11% CV)

Causes of Weighing Variation  Hand-weighing ingredients  People tend to overdose by about 1%

Causes of Weighing Variation

Hand-weighing ingredients

People tend to overdose by about 1% when ingredients are weighed by hand

Micro-ingredients and premix dose errors

Micro-ingredients scales seem to be more variable than macro-ingredient scales because of the size of the call

Descrepancies between call size and scale resolution

Average weighing discrepancies in feed mill is about 2% but can range up to 20%

For example, requesting 11.3 lbs of an ingredient when the scale has a resolution of only 2 lbs.

Ratio of call size to scale resolution

Weighing errors and CV decreases as the call size to scale resolution increases. For example, a call for 100 lbs to be weighed on a scale with a resolution of 5 lbs gives a call/scale resolution of 20, where as a call for the same 100 lbs on a scale with a resolution of 2 lbs gives a ratio of 50.

resolution of 20 , where as a call for the same 100 lbs on a scale
Mixer Uniformity Analysis  Mixer Markers  Single nutrient/ingredient  Salt  Synthetic Amino Acids

Mixer Uniformity Analysis

Mixer Markers

Single nutrient/ingredient

Salt

Synthetic Amino Acids (Lysine or Methonine) Dry Mix Uniformity

Economical Accurate and precise at inclusion level

Test twice per year

Ten samples from the same batch of feed

Sample mixer or a point closest to the discharge

Feed Quality Assurance – Mixer Test Sample mixer Sample surge  Mixer or Surge samples

Feed Quality Assurance – Mixer Test

Sample mixer

Feed Quality Assurance – Mixer Test Sample mixer Sample surge  Mixer or Surge samples provides

Sample surge

Mixer or Surge samples provides information on dead spots in the mixer or mixer maintenance issues

Sampling during the discharge process provides representative samples of the feed as it moves through the system.

discharge process provides representative samples of the feed as it moves through the system. Sample discharge

Sample discharge conveyor

discharge process provides representative samples of the feed as it moves through the system. Sample discharge
discharge process provides representative samples of the feed as it moves through the system. Sample discharge
Mixer Uniformity Analysis - Quantab™

Mixer Uniformity Analysis - Quantab™

Mixer Uniformity Analysis - Quantab™
Mixer Uniformity Analysis - Quantab™
Mixer Uniformity Analysis - Quantab™  Weigh 10 gram sample of feed into a dish

Mixer Uniformity Analysis - Quantab™

Mixer Uniformity Analysis - Quantab™  Weigh 10 gram sample of feed into a dish 
Mixer Uniformity Analysis - Quantab™  Weigh 10 gram sample of feed into a dish 

Weigh 10 gram sample of feed into a dish Scale +/- 0.1 g

Mixer Uniformity Analysis - Quantab™  Weigh 10 gram sample of feed into a dish 
Mixer Uniformity Analysis - Quantab™ Fold filter paper to create a cone

Mixer Uniformity Analysis - Quantab™

Fold filter paper to create a cone

Mixer Uniformity Analysis - Quantab™ Fold filter paper to create a cone
Mixer Uniformity Analysis - Quantab™ Fold filter paper to create a cone
Mixer Uniformity Analysis - Quantab™ Fold filter paper to create a cone
Mixer Uniformity Analysis - Quantab™ Fold filter paper to create a cone
Mixer Uniformity Analysis - Quantab™  Measure out 90 ml of HOT distilled water 

Mixer Uniformity Analysis - Quantab™

Mixer Uniformity Analysis - Quantab™  Measure out 90 ml of HOT distilled water  SAFETY
Mixer Uniformity Analysis - Quantab™  Measure out 90 ml of HOT distilled water  SAFETY

Measure out 90 ml of HOT distilled water SAFETY

Hot Water Burns!!

Mixer Uniformity Analysis  Mix sample and water for 30 sec wait and re-mix for

Mixer Uniformity Analysis

Mixer Uniformity Analysis  Mix sample and water for 30 sec wait and re-mix for 30
Mixer Uniformity Analysis  Mix sample and water for 30 sec wait and re-mix for 30

Mix sample and water for 30 sec wait and re-mix for 30 sec.

Place filter paper cone in cup

Place Quantab strip into the filter cone

Indicator strip at the top will turn black when complete

cone in cup  Place Quantab strip into the filter cone  Indicator strip at the
Mixer Uniformity Analysis - Quantab™  Read highest point on the strip  Determine NaCl

Mixer Uniformity Analysis - Quantab™

Mixer Uniformity Analysis - Quantab™  Read highest point on the strip  Determine NaCl level
Mixer Uniformity Analysis - Quantab™  Read highest point on the strip  Determine NaCl level

Read highest point on the strip Determine NaCl level based on the calibration chart on the bottle. Multiple by 10

(10:1 dilution)

Mixer Uniformity Analysis Calculations  Calculation of Mixer CV  Mean of samples  Standard

Mixer Uniformity Analysis Calculations

Calculation of Mixer CV

Mean of samples Standard deviation of samples

CV % = standard deviation x 100

mean

Mixer Uniformity Analysis Calculations NAME:     DATE:   ADDRESS:       SAMPLE:

Mixer Uniformity Analysis Calculations

NAME:

   

DATE:

 

ADDRESS:

     

SAMPLE:

     

QUANTAB READINGS

   

1

0.20

     

2

0.21

     

3

0.22

     

4

0.17

     

5

0.17

     

6

0.18

     

7

0.20

     

8

0.17

     

9

0.18

     

10

0.18

     

STANDARD DEVI

0.02

   

MEAN

 

0.19

   

COEFFICIENT OF VARIATION (CV)

9.65

Micro Tracer Rotary Detector Method  Materials  Rotary Detector.  Scale.  Demagnetizer. 

Micro Tracer Rotary Detector Method

Materials

Rotary Detector.

Scale.

Demagnetizer.

Heating plate.

Developing Solution.

Filter paper 7.5 mm

Grinder for pelleted feed

Test Method

Weigh 100 g sample

Place filter paper on the spindle of the rotary magnet.

Transfer the sample of feed to the top hopper of the Rotary

Transfer the Microtracerto a scoop, demagnetize, then disperse over a large wetted filter paper on an aluminium plate. Then dry on hot plate to develop spots. Count the spots.

MicroTracter Rotary Detector Source: www.microtracers.com

MicroTracter Rotary Detector

MicroTracter Rotary Detector Source: www.microtracers.com
FS-Red/ Natural Yellow Spots Developed with 50% Water and Alcohol Source: www.microtracers.com

FS-Red/ Natural Yellow

Spots Developed with 50% Water and Alcohol

FS-Red/ Natural Yellow Spots Developed with 50% Water and Alcohol Source: www.microtracers.com
Mixer Uniformity Evaluation CV RATING CORRECTIVE ACTION < 10% Excellent None 10-15% Good

Mixer Uniformity Evaluation

CV

RATING

CORRECTIVE ACTION

< 10%

Excellent

None

10-15%

Good

Increase mixing time by 25-30%

15

20%

Fair

Increase mixing time by 50%, look for worn equipment, overfilling, or sequence of ingredient addition

20% +

Poor

Possible combination of all the above Consults extension personnel or feed equipment manufacturer

Double Ribbon Mixer – RPM’s

Double Ribbon Mixer – RPM’s

Double Ribbon Mixer – RPM’s
Double Ribbon Mixer – Worn Ribbons

Double Ribbon Mixer – Worn Ribbons

Double Ribbon Mixer – Worn Ribbons
Double Ribbon Mixer – Wrong Rotation

Double Ribbon Mixer – Wrong Rotation

Double Ribbon Mixer – Wrong Rotation
Double Ribbon Mixer – Build-Up

Double Ribbon Mixer – Build-Up

Double Ribbon Mixer – Build-Up
Questions
Questions
Questions