Process for the manufacture of an animal feed block

摘要

The present invention relates to a process for the manufacture of an animal feed block according to a target constituent formulation. The process eliminates spoiling of product by inconsistent and fluctuating levels of active ingredient and wet ingredients so as to ensure repeatability from one batch to another.

主权项

1. A process for manufacturing an animal feed block according to a target constituent formulation in an apparatus which comprises
(A) in a dry feeding zone, a first dry feeder which includes a first dry hopper charged with a dry pre-mix and a first material handling conveyor and a second dry feeder which includes a second dry hopper charged with an active ingredient and a second material handling conveyor, (B) in a dry mixing zone downstream from the dry feeding zone, a dry mixer and an under hopper downstream from the dry mixer, (C) in a liquid feeding zone, a first liquid feeder which includes a first liquid feeding device and a first liquid tank charged with a wet pre-mix which includes a liquid by-product and a liquid additive, (D) a slurry mixer downstream from the dry mixing zone and the liquid feeding zone and (E) a dispensing assembly downstream from the slurry mixer,the process comprising:
(A1) discharging and conveying the dry pre-mix from the first dry hopper to the dry mixer by the first material handling conveyor; (A2) measuring the cumulative weight of the dry pre-mix in the dry mixer; (A3) calculating a target weight of active ingredient to be conveyed to the dry mixer, wherein the target weight of the active ingredient and the cumulative weight of the dry pre-mix are constituently proportionate to the target constituent formulation; (A4) discharging and conveying the active ingredient from the second dry hopper to the dry mixer by the second material handling conveyor; (A5) during step (A4) either measuring the loss in weight of the active ingredient in the second dry hopper and causing step (A4) to cease when the loss in weight of the active ingredient equates to the target weight of the active ingredient calculated in step (A3) or measuring the weight of dry material in the dry mixer and causing step (A4) to cease when the weight of dry material in the dry mixer equates to the sum of the target weight of the active ingredient calculated in step (A3) and the cumulative weight of the dry pre-mix measured in step (A2); (B1) mixing the active ingredient and the dry pre-mix in the dry mixer into a substantially homogeneous dry mix; (B2) discharging the substantially homogeneous dry mix into the under hopper; (B3) measuring the weight of the substantially homogeneous dry mix in the under hopper; (B4) discharging and conveying the substantially homogeneous dry mix from the under hopper to the slurry mixer; (B5) measuring the rate of the loss in weight of the substantially homogeneous dry mix in the under hopper during step (B4); (C1) calculating a target flow rate of the wet pre-mix to be conveyed to the slurry mixer, wherein the target flow rate of the wet pre-mix and the rate of the loss in weight of the substantially homogeneous dry mix measured in step (B5) are constituently proportionate to the target constituent formulation; (C2) discharging and conveying the wet pre-mix from the first liquid tank to the slurry mixer at an actual flow rate; (C3) measuring the actual flow rate of the wet pre-mix; (C4) adjusting continuously the actual flow rate to achieve the target flow rate; (D1) mixing the substantially homogeneous dry mix and the wet pre-mix in the slurry mixer into a substantially homogeneous slurry; (E1) discharging the substantially homogeneous slurry into the dispensing assembly; (E2) dispensing the substantially homogeneous slurry portionwise from the dispensing assembly into receptacles; and (E3) allowing the substantially homogeneous slurry in each receptacle to cool to form an animal feed block.