Complete Feed Pellet Line: Process Flow From Raw Material to Packed Pellets

What a Complete Feed Pellet Line Includes

A complete feed pellet line is an integrated set of machines that turns loose grain, oil cakes and meals into dense, uniform pellets for livestock, poultry and aquaculture feeding. The equipment is arranged in a fixed sequence: raw material preparation, crushing, batching and mixing, pelletizing, cooling, drying, screening and bagging. Each stage hands its output to the next, so the physical quality of the finished pellet is decided by the accumulated precision of every machine upstream. A line can be built as a compact 0.3 to 0.5 t/h workshop unit or scaled to several tonnes per hour by matching the pellet mill to the dryer and cooler that follow it.

Stage 1: Raw Material Preparation

The process starts with raw material preparation. Freshness and safety have to be guaranteed, and the ingredient ratio must be adjusted precisely according to the different breeding species and growth stages so that the formula matches the nutritional needs of the animals. Moisture control also starts here: grain that arrives too wet crushes unevenly and disturbs the conditioning step that follows. Consistent ingredient quality at this stage makes every later step more predictable and reduces the corrective adjustment needed at the pellet mill.

Inspect incoming grain and cakes for moisture, foreign matter and mould before intake.

Store ingredients separately so that batching follows the formula rather than availability.

Record each batch so a finished pellet can be traced back to its raw material lot.

Stage 2: Crushing and Mixing

Crushing refines the raw materials into a uniform, fine powder, which improves the utilization rate of the feed and prepares the mash for even blending. A hammer mill or roller mill is normally used, and the screen aperture is chosen according to the pellet diameter the line will produce. The mixer then ensures that the various raw materials are fully blended into a uniform mixture, laying a solid foundation for the subsequent granulation stage. A consistent particle size and a homogeneous mix are the two prerequisites for stable pellet quality: uneven grinding produces pellets that break easily, while short mixing times leave nutrients concentrated in a few pellets instead of in every pellet.

Stage 3: Pelletizing With a Pellet Mill

Granulation is the key link in the entire process and determines the quality and palatability of the feed pellets. By accurately adjusting the parameters of the pellet machine, such as pressure, temperature and particle size, operators ensure that the pellets produced meet the required standard and match the digestion needs of the animals. Conditioner steam softens and cooks the starch, which binds particles together and reduces the fines generated during extrusion. The pellet mill also defines the capacity ceiling of the whole line, so a dryer or cooler rated above the mill will simply run below its rating.

Model	Capacity (t/h)	Power (kW)	Screw Diameter (mm)	Weight (kg)
75-B	0.3-0.4	22	80	1000
85-B	0.5-0.6	30	90	2000
90-B	0.6-0.7	37	100	2100
100-B	0.7-0.8	55	120	2200
135-B	1-1.5	75	135	3200
145-B	2-3	90	145	4000

The table lists common pelletizing configurations for small and medium feed lines and compares capacity, power, screw diameter and weight. Final throughput depends on formula, moisture and die specification, so the same model can shift within the quoted band.

Stage 4: Cooling, Drying, Screening and Packaging

Cooling and drying are the post-processing stages that ensure the safety and stability of the feed. Appropriate cooling prevents the pellets from sticking and agglomerating, while drying effectively prevents mould and deterioration and supports long-term storage. Screening removes unqualified particles and impurities, returning oversize material and fines to the process. Packaging keeps feed moisture-proof, oxidation-resistant and tightly sealed, which protects its safety and hygiene during transport and storage.

Quality Control Points and FAQ

Before a line is signed off, run a moisture and durability test on three consecutive batches and compare the results with the specification sheet. The checks below cover the questions most often raised during commissioning.

Q: What capacity can a small feed pellet line reach?
The configurations listed above cover roughly 0.3 to 3 t/h, which suits farm-scale and district-scale production. A larger line is built by matching a bigger pellet mill to a proportionally larger dryer, cooler and packing unit.

Q: Why do pellets break inside the bag?
Breakage usually points to a mash that was too coarse, mash moisture outside the working range, or cooling that was too aggressive. Check screen aperture and conditioner moisture first, then reduce the cooling air rate.

Q: Is a dryer always required?
No. If pellet moisture after cooling stays below roughly 12 to 13 percent, the dryer can be omitted. In humid climates a dryer is normally kept because it stabilises shelf life.

Q: Can one line produce both poultry and aquatic feed?
Yes, but die aperture and conditioning parameters must be reset between campaigns. Poultry pellets are usually larger and firmer, while aquatic pellets need higher water stability.

Q: How many operators does a small line need?
Two to three operators per shift are enough for a line up to about 1.5 t/h once batching and packing are semi-automatic.

Q: How often should dies and rollers be inspected?
Inspect daily for wear patterns and re-check the roller gap weekly. A worn die raises fines and energy consumption long before pellets visibly fail.