Forschungsinstitut FuttermitteltechnikResearch Institute of Feed Technology

Influence of a liquid application in the main mixer on mixture homogeneity of feeding stuffs

Dipl.-Ing. Alexandra Kirchner

IFF Research Institute of Feed Technology, Braunschweig-Thune, Germany

BRAUNSCHWEIG

Location of IFF

2

Braunschweig

Federal State of Lower Saxony

250,000 inhabitants

INTRODUCTION

International Research Association of Feed Technology

4

International Research Association of Feed Technology (IFF) in head points

founded in 1961 on the initiative of the German Association of Feed Industry

supports German and international members in the feed processing industry by

– results of joint research projects and

– service activities

maintains a Research Institute of its own

International Research Association of Feed Technology (IFF) in head points

100 members (national and international companies as well as associations and organisations)

SME oriented industrial cooperative research in the fields of

– feed quality and safety as well as – feed quality and safety as well as

– process optimization

member of the Working Pool of Industrial Research Associations (Arbeitsgemeinschaft industriellerForschungsvereinigungen “Otto von Guericke” e.V.) at Cologne, Germany, since 1964

Impressions

Impressions

RESEARCH INSTITUTE OF FEED TECHNOLOGY

International Research Association of Feed Technology

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Research Institute of Feed Technology in numbers

Head of the Institute: Dr.-Ing. Alexander Feil

4 scientists

3 technicians

2 laboratory technicians

1 assistant

Research Institute of Feed Technology in facts

Pilot plant/test facilities (capacities from 10 kg/h up to 1 t/h)

Milling: hammer and roller mill

Mixing (capacities from 10 up to 1,000 l):

single-shaft slanted vane mixer, ribbon mixer, double-shaft paddle mixer, vacuum twin-shaft paddle mixer, … paddle mixer, vacuum twin-shaft paddle mixer, …

Pelleting and agglomerating:

2 ring-die presses, laboratory flat-die press,

expander/extruder, belt cooler, vertical cooler

Conveying:

mechanical and pneumatical conveying devices

Research Institute of Feed Technology in facts

Physical analyses

density, bulk density, tap density, flowability

pellet & agglomerate abrasion/durability

dusting behaviour (rotation drum, single drop devices)

particle-size distribution (sieving analysis, laser-diffraction)

Chemical analysesChemical analyses

Weender analysis

wet-chemical analysis according to the VDLUFA method manual

fat indicators

photometry

element analysis (AAS), additive analysis (HPLC)

starch gelatinisation

protein dispersibility index

Examples of terminated research projects

Investigation and evaluation of alternative technological processes for the production of medicated feeding stuffs

Comparing investigations for improving the product safety of mash compound feed by low energetic irradiation and hydrothermal treatment

Investigations on the applicability of the vacuum-coatingprocess for the production of compound feed rich in energyand for the application of liquid formulated additives afterpelleting

Production of structurised and mixing-stable mineral feedswith high product safety and quality by using selected compaction processes

STARTING POINT AND SELECTED RESULTS

Research project on optimized liquid application

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Liquid addition to feeding stuff powders as an aspect of feed quality and safety

Liquids are added to feeding stuffs to

• decrease dusting behaviour,

• increase taste and nutritional value,• increase taste and nutritional value,

• avoid segregation.

Liquid application in the main mixer – Problems

caking and agglomerates

• feed quality

• cross-contamination

negative influence on mixture homogeneity

• feed quality and safety

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Liquid addition for avoidance of segregation

formation of liquid bridges – agglomeration

definition of the project must be to find an optimum between desired and undesired effects when adding liquids to feeding stuffsregarding• technological parameters• material characteristics

Technological parameters

fogging

two component nozzle

addition as droplets

one component nozzle

fluidizing of dispersible materials

addition as continuum

pipe

bulk / feeding stuff

mixer

mixing and wetting of bulk

dry mixingadditional mixing

replacement of liquids

Liquids

1.000

10.000

100.000

. v

isco

sity

[m

Pa

s]

Rübenmelasse (47%)

Rübenmelasse (42%), NZ

Rübenmelasse F-805 (42%)

Rübenmelasse F-934 (42%)

sugar beet molasses (47%)

sugar beet molasses (42%)

sugar beet molasses (42%)

sugar beet molasses (42%)

0

1

10

100

20 °C 32 °C 38 °C

dy

n.

vis

cosi

ty [

temperature

Betriebsmelasse (Rüben)

Betriebsmelasse (Rüben)

Apfelmelasse

Apfelmelasse

Vinasse

Sojaöl

Wasser

sugar beet molasses (42%)

sugar beet molasses (42%)

vinasses

apple molasses

apple molasses

soy oil

water

67 mm

Viscosity – Dispersibility of liquids in nozzles

32 °C 38 °C20 °C

15 mm

84 mm144 mm

51 mm

142 mm

One comp. nozzle 80 °sugar beet molasses F-909

Feil, Kirchner (2007), Final Report of the IGF-project “Melasse” No. 14210 N

Droplet size and droplet size distribution

equation author

x50/D≈6*Re-0,15 Panasenkov

x0,999/D=We-0,333(23,5+395*10-6*Re) Miesse

x32 /D=47/v (σ/ρG)0,25 (1+331*Oh) Tanasawa

Calculation of characteristic droplet diameters

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Re - Reynolds number

We - Weber number

Oh - Ohnesorg number

x50 - average droplet diameter

x32 - Sauter diameter

D - diameter of nozzle outlet

ρG - density of gas atmosphere

σ - surface tension

Particle-size distribution

0,50

0,75

1,00

dis

trib

uti

on

fun

ctio

nQ

3(x

)

0,00

0,25

10 100 1000 10000

dis

trib

uti

on

mesh width w [µm]

pig feed (F-752) pig feed (F-683) colour indicator cattle mineral feed (F-803)

pig mineral feed (F-802) cattle mineral feed (F-664) layer meal (F-857)

State-of-the-art

The binding of particles is caused by liquid bridges and therefore a reduction in the number of particles occurs

� negative influence on optimal mixture homogeneity but

� avoidance of segregation

Free flowability of particles is limited

� negative influence on mixture homogeneity

A dry mixing cycle is necessary because liquids may cause a “freezing” of the state of the mixture

The liquid must be evenly distributed in the mash to avoid the occurrence of rough agglomerates

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Experimental study

An experimental study was carried out to mark up

technological parameters and material properties for optimized discontinuous liquid application in the main mixer regarding feed quality in the cases of

– mixture homogeneity

– avoidance of segregation and – avoidance of segregation and

– dusting behaviour

and to minimise cross-contamination – caused by unbound fines on the one and caking on the other hand

The project is funded by the German Ministry of Economics via AiF (AiF-Code 16016 N, 2009-2011)

Experiment

mineral

concentrate

rough and fine dry mixing

twin shaft

paddle mixer

one component

nozzle

20 l

molasses

1-3%

rough and fine

compound feed

rough and fine

dry mixing

additional mixing

Cut out from experimental plan IGF-project “Flüssigkeitszugabe“ No. 16016 25

colourant as indicator

(micro component)

20 l

intensive mixer

pipe

45 l

vinasses

soy oil

Analysis

For the characterization of the mixture homogeneity a particulate organic colourant was used as additives’ indicator (ratio of 1:100,000 or 1:50,000)

The colourant can be detected photometrically with a low analytical error

The concentration of the indicator in single samples was The concentration of the indicator in single samples was analyzed and statistically evaluated by the coefficient of variation (CV)

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Mixture quality of cattle mineral feed

0,054

0,069

0,042

0,14

0,104

0,099

soy oil + subsequent mixing

colourant + oil addition

colourant + oil addition + subsequent mixing 1%

3%

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0,087

0,054

0,139

0,113

0,00 0,05 0,10 0,15

dry mixture

soy oil

coefficient of variation (CV)

area of good mixture homogeneity

Sample concentration of colourant

60

80

100

120

sam

ple

co

nce

ntr

ati

on

in

%

CV (colourant) = 0.054

CV (soy oil) = 0.087

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0

20

40

60

1 2 3 4 5 6 7 8 9 10

sam

ple

co

nce

ntr

ati

on

in

%

sample no.

colourant soy oil

Conclusions

The estimation that liquids must be evenly distributed in the mash to avoid the occurrence of rough agglomerates could be validated by the experimental study

It seems to be essential that the liquid is spread evenly on the particle surfaces of all particles to avoid undesired agglomerates and increase mixture homogeneity. Therefore a material specific amount of liquid is Therefore a material specific amount of liquid is necessary.

Under defined circumstances a dry mixing cycle is not necessarily needed to reach an adequate mixture homogeneity

At the moment a general conclusion on the influence of a liquid addition on the mixture homogeneity is not possible

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