From grain to granules: how oilseed processing and extrusion lines work in the production of compound feeds

It should be recalled that the basic ingredients for the production of granular compound feed are obtained during the processing of oilseeds and cereals. The basis of successful production lies in the proper selection and pretreatment of all components of the raw material base.

By processing plant raw materials on Globalprodservice equipment, farms acquire a unique option — the ability to manufacture compound feeds according to their own recipe. This means that an agricultural enterprise can not only produce its own high-quality granular compound feed at an affordable price, but (and this is the most important thing) the product will be adapted to the needs of a particular livestock at a particular enterprise.

Globalprodservice is one of the few companies in the Union state market. Which has expertise in the production of oil-pressing and extrusion equipment, spare parts and components. The innovative solutions created by Belarusian engineers for processing oilseeds and extruding raw materials have been widely used by the flagship enterprises of Belarus and Russia for 13 years.

For example, high-protein compound feeds, protein-energy and protein-vitamin-mineral concentrates for poultry, pigs, cattle with a content of 22-35% of crude protein are currently in high demand.

If you have your own equipment, then to reduce the cost of feed, instead of expensive animal proteins and soybean meal, more affordable oilseed cake can be introduced into recipes, obtained by pressing with extrusion on the oilseed processing line and grain extrudate produced by high-temperature grain processing under pressure on the extrusion line.

Highly nutritious rapeseed cake is formed during the extraction of oil from oilseeds. It contains up to 35-40% protein (more than 300 g/kg), fat (7-9% of high quality), a rich set of trace elements (calcium, phosphorus, potassium, magnesium, copper, manganese) and amino acids (lysine, threonine, methionine (325 g/kg), has a high energy value. Due to the high concentration of easily digestible protein and the optimal amino acid profile, rapeseed cake is the standard of nutritional value relative to which other sources of feed protein are evaluated.

Grain extrudate is a special grain processing product with improved nutritional and absorbent properties (crude protein 24-26%, fat 8-10%, feed units - 1.35 per kg of product, exchange energy 13.5-14.5 MJ/kg).

The versatility of the grain extrudate is manifested in its wide application: from the feeding of young animals (weaned piglets and calves) to the full-fledged feeding of adults — cattle, pigs, birds and small cattle, as a component of prestater and starter feeds. The porous, expanded extrudate serves as an excellent basis for the production of granular compound feeds, providing impressive results: increased productivity by 20-30%, improved digestibility by up to 95% and reduced feed consumption by 2-8%.

Rapeseed cake and grain extrudate are two key components that form the raw material base for modern production of granular compound feeds. Their combination makes it possible to create balanced feed mixes with optimal nutritional characteristics.

Modern technologies open up new opportunities for the development of agribusiness. The oilseed processing line is not just an equipment, but a strategic step towards prosperity, stable income, financial stability, independence and independence of an agricultural enterprise.

The technological line for processing oilseeds is a set of equipment that ensures the production of rapeseed cake and vegetable oil by heat treatment and passing the feedstock through various technological operations, including oil extraction followed by cake extrusion according to the press–extruder–press scheme.

The basic equipment of the Globalprodservice line includes highly efficient cold and hot pressed oil presses, a separator for cleaning raw materials from mechanical and magnetic impurities, an active storage tank, a normalizer, an extruder, a cooler, a filter, scales, containers for collecting and primary accumulation of oil. The integrated line includes an automated process control system that monitors all processes and registers all key production indicators.

The efficiency of the press is determined by the quality of oil extraction to achieve the best residual oil content in the cake. The press provides stable oil content of up to 8% when processing rapeseed, up to 7% when processing soybeans and up to 12% when processing sunflower.

The tasks of the extruder are no less important. This machine is used for:

• reducing the content of trypsin (urease) inhibitors in soy products;
• opening of fat cells (which ensures the availability of fat in feed);
• heating of raw materials before oil extraction;
• destruction of harmful microorganisms in the components;
• to increase the digestibility of extruded products when consumed by farm animals and poultry.

It should also be recalled that the protein of the most common cakes (rapeseed and sunflower) is largely (up to 80-90%) broken down by the rumen microbiota. This leads to inefficient use of protein, since a significant part of nitrogen in the form of ammonia is removed from the body. To avoid this, high-protein feeds must be extruded and included in the composition of granular compound feeds.

The equipment for processing oilseeds guarantees high productivity, quality of the final product, ease of operation, and reliability in operation. The installation by agricultural enterprises of their own oilseed processing lines allows not only to receive additional income from the sale of oil, but also to provide farms with cheap protein, reducing dependence on external suppliers.

We also mention rapeseed cake. This is an important product. With the correct inclusion of rapeseed cake in the composition of granular compound feeds, an optimal ratio of nutritional value and economic efficiency of production is achieved. The recommended dosages for the inclusion of rapeseed oil cake as a basic component for the production of compound feeds are as follows:

For cattle — up to 30% of the total volume
For pigs — 10% of the diet
For poultry (broilers) — 10-15% of the total volume
The addition of cake to compound feed increases the intensity of animal growth, improves the quality of milk, increases the fat content of dairy products, and increases the digestibility of nutrients.

The extrusion production line is a complex of equipment for the production of high—quality feed by extrusion. It allows you to dramatically increase the nutritional value of the feedstock. Properly selected equipment makes it possible to produce high-quality grain extrudate with maximum efficiency and minimal costs. The main equipment in the line from Globalprodservice is: a grain extruder, an extrudate shredder, an automated control system, and transportation equipment.

In the extruder, starch breaks down into simple sugars, complex proteins and carbohydrates are broken down into simple ones, and fiber is converted into secondary sugars. Since the temperature effect lasts only a few seconds, useful vitamins and minerals are completely preserved, and pathogenic microflora and pests die.

The line allows processing: grain crops (wheat, barley, corn); legumes (peas, soybeans) and grain mixtures in various proportions.

Long-term operation in flagship farms has proved that the extrusion line is economically profitable and highly efficient. It provides a quick return on investment in equipment, is durable, and provides high-speed processing of raw materials. At the same time, the equipment not only allows for a continuous process and makes it possible to automate many operations, but also leaves room for scaling production. The result is the technological advantage of the enterprise, optimization of feed costs, and increased productivity of animals. In addition, the creation of an efficient feed production with high added value often helps to strengthen the financial independence of the enterprise: after all, it is profitable to sell not only milk.

The pelletizing line is a high—tech complex of equipment for the production of granular feed from loose mixtures by pressing crushed raw materials into dense granules.  

The technological granulation line includes several stages: receiving raw materials, preparing raw materials, mixing them with water or steam, feeding the mixture into a granulator for granulation, cooling the granules (lowering the temperature, removing excess moisture, separating dust and fine particles), packing the finished product (bagging, loading into big bags). The technology allows to significantly improve the quality, consumer characteristics, convenience of use, storage and transportation of compound feeds.

During the granulation process, the raw material is subjected to high pressure and temperature, which leads to its agglomeration into granules of a certain shape and size. This is a technologically complex process that requires the use of special equipment and control of production parameters to achieve optimal results.

Globalprodservice is known as a reliable supplier of complete lines for the production of granular compound feeds with a capacity from 3 to 40 t/h, including the following equipment:

• Crushing plants for crushing raw materials
• Dosing units for precise automated delivery of substances in specified proportions
• Mixers for uniform distribution of components
• Granulators for structure formation
• Cooling systems for pellet stabilization
• Screening mechanisms for sorting
• Packaging and storage systems
• Automated process control system — parameter control system, compliance with technology, safety and quality of finished products
• Additional options on demand

At the request of the customer, the line can be adapted to different types of raw materials, different feed formulations, and the required production volume.

The use of granulation in the production of compound feed makes it possible to improve production efficiency, since such feeds have a number of advantages over loose feeds. Here are just a few of them:

• Uniform distribution of nutrients in each granule;
• Long shelf life of the finished product;
• Destruction of harmful microorganisms during heat treatment;
• Reduction of losses during transportation and feeding;
• Convenience of storage and dosing;
• Improved digestibility of animal feed.

The modern industrial complex from Globalprodservice is an integrated system and functions thanks to the well-coordinated interaction of three key technological lines: granulation, extrusion and processing of oilseeds.

An integrated approach makes it possible:

• Optimize production processes through efficient use of capacities;
• Reduce operating costs;
• Minimize logistics and storage costs;
• Increase profitability by diversifying products;
• Improve product quality through an integrated approach to raw material processing;
• Create balanced feed rations.
• The integration of granulating, oilseed processing and extrusion lines is currently one of the most promising areas for the development of feed production. This approach makes it possible to create a unique production ecosystem capable of maximizing the use of raw materials. In the context of growing competition in the market of feed products, it is an integrated approach to the organization of production that often becomes a key factor in the success and sustainable development of agro-industrial enterprises.

Globalprodservice, a Belarusian manufacturing and engineering company specializing in the creation of high-tech equipment for processing and extruding oilseeds, is one of the largest suppliers of equipment for the production of animal feed. The company's capabilities and competencies are sufficient to meet the needs of the most demanding, quality-oriented customer. The company's customers value not only the quality of Globalprodservice equipment, but also the promptness of service. The company produces spare parts and accessories for the entire range of manufactured equipment, and there is always the right part in stock.

Over the past 13 years, Globalprodservice has not only achieved impressive results, but also laid a solid foundation for further growth. Right now, our specialists are putting into operation several new oilseed processing lines in conjunction with an extrusion line in the Minsk and Mogilev regions. The construction of a feed mill in the Vitebsk region is nearing completion.

Strategic partnership with the largest enterprises is the driver of the success of a technological enterprise. Globalprodservice's experience and achievements serve as a benchmark for the industry, confirming its status as a leader and setting high standards for future projects in the market.