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expand further into the free-range egg market, which it believes offers potential for growth, particularly in South Wales where there are a lot of existing producers and plenty of potential future ones, too. The third feed production facility, located at Rhosfawr in North


West Wales is, says Steve Brown: “A typical blending plant, with raw materials stored in bunkers, picked up by front-end loader and put through a mixer. It is fully traceable, but a simple blending plant as opposed to a compound mill.” It produces some 22-24 tonnes of blends per hour. So, in total, including the two mills and the blending operation,


the Wynnstay Group produces a range of dairy feeds, beef and other cattle feeds, sheep feeds, poultry feeds (including some game bird feeds), pig feeds and blends (some of which is through the mills and some through Rhosfawr). The split in compound production overall is approximately 80% ruminant and 20% monogastric; poultry feed sales have grown significantly in recent years and continue to do so in line with the strategy of building a presence as a supplier in the free range eggs market. Organic feeds and nuggets are contract manufactured for Wynnstay, enhancing productivity at the mills through simplifying the operation and avoiding the need for additional die changes. Examining the production set up in more detail, Llansantffraid is a


post-grind mill, using a Tietjen grinder with a nominal 80 tph capacity and with automatic screen changing built in to facilitate changes in grist quality. From the three-tier mixer, while meal goes to finished bins, the balance goes to press bins above the three cubing lines, each of which is equipped with a Boa and capable of around 14-15 tph (on 6mm pellet production). The Boa is a piece of kit I am seeing more and more frequently on my visits to mills, these days. It conditions the meal prior to pelleting with a combination of steam and pressure (as well as offering the capability of adding molasses). The result is feed which is not only enhanced nutritionally, but will also pellet much more easily and with an overall reduction in the energy required – Richard believes that this equipment virtually doubles the rate of output of the presses. Unusually, for three lines, the mill has five presses. One line has a single press producing nothing but 6mm pellets, but the other two have two presses each which allows for very rapid changeover between pellet sizes (usually 3mm and 6mm, although some 2mm pellets are made) without losing production while changing dies and rolls. From the presses, the feed is cooled in Geelen box coolers, which are, says Richard, very efficient as the air comes in at the bottom and has to pass through the product to escape. All vitamins, amino acids and trace minerals are fed into the mix


from micro-ingredients dispensers, which weigh these products in exactly the same way as wheat and barley, except on a scale capable of weighing to within a few grams. This ensures accuracy and provides the confidence to know that these expensive and essential ingredients are included without the risk of under or oversupply. Formulation of diets and producing labels is controlled by Format,


while administration is on Great Plains Microsoft-based software and process control has recently been upgraded to the latest offering from Promtek; naturally, all three systems are integrated to allow transfer of information from one to the other. The process control system is very sophisticated and very strong on cross-contamination control, which is extremely important in a multi-species mill. “Promtek has done exactly what was promised and works wonderfully well,” says Richard. Since its installation, daily output has pushed on from 700 tonnes to a new


Left top: One of three Boas Left middle: Two of the three lines have two pelleting presses Left bottom: The micro-ingredients dispensers Right top: The control room


PAGE 26 MARCH 2011 FEED COMPOUNDER


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