Technology of production of dry feeds  

     The manufacturing of dry feed at OJSC Zhabinka feed mill is a multistage and continuously monitored at all stages of production process.

OJSC Zhabinka feed mill as self-respecting manufacturer has a well-established range of suppliers of raw materials, developed during the years of cooperation. Contracts are negotiated with each supplier, in which the requirements for basic materials, used in the feed production, are shown in details. Moreover, these requirements are not abstract, but are very exact numbers that determine how many and what elements (vitamins, minerals, amino acids and so on) must be contained in one or another ingredient, and what official acts for supplied raw materials should be preserved. In addition, all raw materials, which enter the plant, pass the input laboratory control. And only after the original ingredients are received and checked, they can be used directly in the production process.

Dry pet food recipes are developed by the technologist of the company, who is guided by the technical conditions of Belarus, that have been developed by the central research laboratory of bakeries and have been approved by the Bakery Department of the Republic of Belarus as well as by the experience of foreign producers. Defined setting of the production line is made for the production of each feed type, the exact proportions of each ingredient are measured. This is quite laborious and responsible process, because feed balance implies a very precise dosing of all the components. All the ingredients are grounded in a special mill to the standard sizes. Crushed particles go into a special mixer - the bunker, where they are thoroughly mixed. Uniformity of mixing is 92-98%.

After passing through the magnetic control on the conveyor dry feed enters the extrusion line. Extrusion line made by the company «Insta Pro» (USA) is a multi-stage revision of feed. A crude food enters the air conditioner-mixer, where moisture and blending take place. After final mixing feed enters the extruder. There is heat treatment at the temperature of about 120° C. At this temperature sterilization is made it means that all the germs and bacteria are perished, but valuable trace elements are not destroyed. Then extruded feed by conveyor belt appears in the dryer, while drying 3-5% of moisture is removed. Dried product is controlled in the sifter and sent to the fat applicator, where the product is enriched with oil or melted fat.

Finished product after cooling in a cooler, having a magnetic control, is given to the storage bin, and then by conveyor belt to packing line. After feed is packaged, a label is pasted with the date of production and expiration date. In fact, the production is completed, and feed begins its way to consumers.

 

 Granulating Technology

In 1971 granulation line was installed at OJSC Zhabinka feed mill, granulation line setting tackled a number of shortcomings of loose feed: bundle of fodder during transportation and storage, selective feed consumption by animals, especially by poultry, low efficiency of feed use. Granulation - fodder production in the form of granules. Diameter of granules may be 3,2 mm., 4,7 mm. and 7,7 mm., depending on the type of feed.

Feed production in granular form is one of the means of saving and rational use of feed, raw materials that allows to mechanize the process of birds, fish and other animals feeding, improves working conditions in poultry keeping, conditions of loading, storage and transportation of animal feed, ensures complete safety of nutrients.

 

Extrusion Technology

One of the effective impact ways on biochemical indices of grain components is the processing in extruder, where the product becomes under high pressure and temperature. Extrusion process takes less than 30 seconds. During this time the raw material has time to go through several stages of processing: heat, sterilization and disinfection, grinding and mixing, partial (up to 50% of the initial), dehydration, stabilization, texturing, expansion and profiling.

 

Expansion Technology

World experience shows that to solve such drawbacks of granulated fodder as a low hygienic standard due to low temperature during granulation; limited fluids additive, such as fat up to 3%; putting a high percentage of fat on the finished granules, which can lead to fat oxidation during storage; granules quality improvement is solved by the process of expansion that was introduced in 1989 by “Amandus Kahl” in the feed mill industry. In 2002 Zhabinka feed mill installed expansion line in the enterprise.

Expansion is hydrothermal feed treatment with the help of the expander that allows obtaining of expanded structured feed ready for feeding in the form of crushed pellet.