Mini Feedmill

Processing of animal feeds: Mini feed mills

1. Feed digestibility and ADG (average daily gains) for ruminants and poultry increases dramatically.
2. The concept of low cost, low tech, low impact on electrical and other processing resource use, low maintenance, low skilled and high output results have shown this concept to be a winner.
3. An entirely vertically integrated plant starting at raw corn and soy bean and roughage level to completely processed and balanced feed.
4. An output in excess of one ton per hour on a 12 hour shift is sufficient to feed an average of 200,000 chickens per day at average 50 grams of feed daily or some 1,200 cattle at 9 kg of feed, excluding roughage per day.
5. It has been proven during the 1960’s by TW Perry that 8% more rapid gain is experienced when using roasted vs raw processed maize. The hectolitre mass of roasted maize is some 12% lower than raw maize and with 5-7% lower moisture, resulting in lower intake of grain and higher daily gain through better conversion of the same amount of dry matter. The digestibility and acceptability of roasted corn is much higher.
6. Soy beans are similarly roasted for higher conversion rates of protein and fibre releasing the trypsin inhibitor to protein uptake in ruminants and poultry.
7. The system consists of:**
   1. Grain intake
   2. Grain storage – at least 2 bins for maize and soy beans
   3. Grain cleaning
   4. Roasting of soy beans / and or maize – optionally expelling of oil from soy beans.
   5. Batching
   6. Mixing
   7. Pelleting including steam generator
   8. Pellet Cooling, grading, packing
   9. Loading either in bulk or in bags.
8. Conversion cost per ton: Electricity – 50 kW @ R1.25/kW = R62.50
   Diesel – 12 liter @ R12/lt = R144-00
   Labour: 4 persons at farm labour rates of R10/hr = R40 per ton.
   Total direct costs: R246.50
9. Total ingredient cost: R3,500 per ton *.
10. Interest in capital investment at 10% : R58 per ton based on 300 tons per month (50% of capacity)
11. Other overhead costs including rent, salaries, packing etc.: R360 per ton
12. Average selling price of broiler finisher* per ton: R5,000 per ton.
13. Gross profit: R1,500 per ton
14. Net profit per ton: R900 per ton or R270,000 per month
15. Estimated cost of plant, delivered and installed: R1,750,000.
16. Payback period: 6.5 months.

It is therefore clear that the large scale farmer can save some R270,000 per month for mixing his own feed and an individual entrepreneur may have a lucrative business opportunity in installing an ABC Hansen Mini Feed Mill. At a cost of around R1,5 million ex works Pretoria for a complete integrated mill from reception of grain notably maize and soy beans, through storage, processing of soy beans, milling, blending, pelleting and packaging including electrical control systems this offers great value for money at a capacity of more than 1 ton per hour.

*Typical broiler finisher mix consist of the following:

• Maize 600kg
• Full fat soy 138kg
• Low fat soy 240kg
• Limestone 13kg
• This consist of 989 kg. from the total mix of 1,000kg
• Other small ingredients
• Salt 4kg
• Monocalcium Phosphate 1.5kg
• DL Methionine 1.7kg
• Salinocox 0.5kg
• Tylosin 0.5kg
• Broiler finish PX 2.5kg
• Rovabio 0.2kg
• Total 1,000 kg
• Total input cost: R3,500 per ton

**The above layout excludes equipment listed above such as intake, storage, roasting, various bins easing the production flow into a less labour intensive operation.