Mill Process Efficiency

IGFA H&S/Engineering Seminar

Maldron Hotel Portlaoise

25th of April 2013

� Adesco Nutricines� at a glance

� what we do

� Mill Process Efficiency� Definition

Presentation Content

� Definition

� Programmes

� Raw Material Management

� Moisture Management

� Efficiency Benefits

� Future

Founded: 2007 by Michael McDonagh & Jack O’Hare

Employees: 4 Full time, 3 part time/contract

AT A GLANCE

Sector: Agricultural Feed Industry

Business Units: Mill & Grain

Nutritional Ingredients

Key Market: Island of Ireland

We deliver advanced solutions that enable grain merchants,

ingredient pre-mixers and feed compounders to harness

the power of nature to lower costs, optimise product

We are a functional and nutritional ingredients company in

the agricultural feed sector.

the power of nature to lower costs, optimise product

quality and improve efficiency.

Our ambition is to be the market leader for those seeking

commercial performance breakthroughs in a competitive and

dynamic market.

Transferable knowledge

Shared

Expertise Expertise

=

Better

Solutions

Grain

Farmer

Grain

Merchant

Feed Compounder

Ingredient

Pre-Mixer

Lifestock

Producer

Processor /

Retailer

Consumer

Market

Field Lower Cost – Optimise Quality – Improve Efficiency Fork

where Adesco fit 9..

Farmer Merchant CompounderPre-Mixer Producer Retailer Market

Products Plus model

At the least

Cost

Definition: The conversion of Purchased Raw Materials into Saleable Finished Products

In the

shortest time

To required

Customer

Standard

With no

Physical

Loss

Energy,

Cost of

Manufacture

kWh and

Oil or Gas/tonneMaintenance, services,

depreciation

Complaints, Returns

Tonnes/hr,

Labour

Physical

quality,

Customer

satisfactionYield

Sales

= or >

Purchases

Man hrs/tonneTonnes/hour

Downtime

Complaints, Returns

Discounts/Credit notes

Holmen Results

COST of MANUFACTURE - Sources

Cost-Kinds: Labour, Maintenance, Energy, Quality, Depreciation, etc

Cost-Places: Intake, Grinding, Mixing, Pelleting, BaggingCost-Places: Intake, Grinding, Mixing, Pelleting, Bagging

Cost-Types: Bulk, Bags, IBCs, Collected,

Coarse, Pellets, Meals, SPECIALS?

Dairy, Beef, Pig Poultry

Focus on Physical values

MEASURE

The Efficiency Cycle

IMPROVE MANAGE

CONTROL

4 Key Performance Indicators (KPIs) measured

Reduce

Energy Costs

Improve Pellet

Quality

The

Adesco

Edge

Increase

Production Yield

Increased

Throughput

4

23

2

0.5 3.54 3 Raw Materials

Depreciation etc

Energy

Understanding where the customers €100 goes

78

4 Labour

Maintenance

Misc.

Distribution

Sales/ Overhead

Profit

Raw Material Management – the role of

grain management in mill process

efficiency

Grain Treatment - retain moisture at harvest

� Cost benefit vs. drying

� Quality benefit vs. aeration

Grain Management Programmes

Grain Conditioning - addition of conditioned moisture

� Reduction in dust

� Increase in yield

� Reduction in energy used in Rolling

� Increased Throughput

6

8

10

% of rolled product passing through a

1.18mm screen

Dry Rolled

0

2

4

6

Dry Rolled Conditioned Rolled

Dry Rolled

Conditioned

Rolled

100

101

102

103

104

105

Weight before

rolling

96

97

98

99

100

Dry Conditioned

Weight after

rolling

2.3

2.4

2.5

2.6

kWh/t rolled

2

2.1

2.2

2.3

Dry Conditioned

8.4

8.6

8.8

9

9.2

Roller throughput t/h

7.6

7.8

8

8.2

8.4

Dry Conditioned

Unlocking mill process potential through

Raw Material Management

Focus on what is important

Raw MaterialsRaw Materials

= Yield

Moisture

The Role of Moisture in Feed

• Can easily be lost within the process- must replace it.

• Optimum level for pelleting where it acts as a lubricant

and as a binder.

• It is these contrasting actions which show the

uniqueness of moisture as an ingredient in animal feeds

Measure Moisture

• Raw Materials

• In Process• In Process

• Finished Products

Know Values Set Targets

No. of Tests Av. Moist.% Range C.V.

Hi-Pro soya 79 12.13 10.8 - 13.3 4.12

Raw Material Moistures (Over 5 months 2010)

Rapeseed 65 11.5 10.5 - 12.6 4.78

Arg.Suns 46 11.72 10.6 - 12.9 4.69

Wheat Feed 21 13.82 11.1 - 15.0 6.58

Citrus 21 10.31 8.8 - 11.6 7.47

Palm Kernal 28 8.17 7.2 - 9.5 8.08

Soya Hulls 33 11.96 11.2 - 12.2 3.76

Distillers* 97 8.61 6.6 - 11.2 10.69

Corn Gluten 12 10.7 9.5-13.8 11.20

Know what is happening in the process

In Process Moisture changes

Losses in Grinding- - 1%

Addition in Main Mixer + 1 - 3%

Addition at Conditioning :

Molasses etc + 1 - 3%

Steam + 1 - 4%

Losses at Cooling - 1 - 4%

MOISTURE

OPTIMISATION

PROGRAMME

-

CONTINUOUS, CO

Moisture control capability drives

processing efficiency.

WATER

-

OFF SITE

MEASUREMENT

PRODUCT /

MANUAL SYSTEM

-

OFFLINE

MEASUREMENT

INTEGRATED

PRODUCT /

APPLICATION

SYSTEM

-

SPOT

IN-LINE

MEASUREMENT

CONTINUOUS, CO

MPLETE &

ACCURATE

MEASUREMENT

-

PERFORMANCE

BENCHMARKING

Mill

Pro

ce

ss E

ffic

ien

cy

Moisture Control Capability

Get it right for your Pelleting Process

�Optimise moisture

Conditioner

Cooler

Mixer

Finished Product Moisture

Set Targets

Realistic� Realistic

� Suitable

� Legal

Moisture Management: Get it right for your Business

4 Key Performance Indicators (KPIs) measured

Reduce

Energy Costs

Improve Pellet

Quality

The

Adesco

Edge

Increase

Production Yield

Increased

Throughput

14%

7%

2% 1%Energy: where it goes

Pelleting 60%

Grinding 16%

60%16%

Grinding 16%

Conveying 14%

Intake 7%

Mixing 2%

Other 1%

95%

100%

105%

110%

Moisture Optimised: Reduced Energy

60%

65%

70%

75%

80%

85%

90%

95%

Energy

Dry

Moisture Optimised

Get it right for your Business

�Reduce Energy Consumption

� Increase Throughput

95%

100%

105%

110%

Moisture Optimised: Increased Throughput

60%

65%

70%

75%

80%

85%

90%

95%

Energy Throughput

Dry

Moisture Optimised

Get it right for your Business

�Reduce Energy Consumption

� Increase Throughput

� Improve Pellet Quality� Improve Pellet Quality

40%

15%

5%Raw Materials 40%

Grinding 20%

Physical Quality - parameters affecting pellet quality

40%

20%

20%

Conditioning 20%

Die /Rolls 15%

Cooling 5%

95%

100%

105%

110%

Moisture Optimised: Improved Pellet Quality

60%

65%

70%

75%

80%

85%

90%

95%

Energy Throughput Durability

Dry

Moisture Optimised

Get it right for your Business

�Reduce Energy Consumption

� Increase Throughput

� Improve Pellet Quality� Improve Pellet Quality

�Yield

100%

105%

110%

Moisture Optimised: Increased Yield

75%

80%

85%

90%

95%

Energy Throughput Durability Yield

Dry

Moisture Optimised

What needs to be done9.What needs to be done9.

Develop Your Own Weekly KPIs to cover

� Plant Throughput

� Labour Utilisation� Labour Utilisation

� Energy Use

� Customer Issues

� Raw Material Utilisation

Measure Manage Control Improve

Future Improvements in Processing Efficiency

� Increased use of Process Automation� Increased use of Process Automation

� Increased Monitoring of Process

�Reduction in Energy Use

� Increased Plant Capacity- Fewer Mills

�Effect of Increasing Farm Scale

Adesco Research and Development

2006 – 2012

� Unique grain preservation and hygiene solutions

� Next generation MPE products – MycroMill

2013 and beyond2013 and beyond

� Animal performance trial with monogastric and ruminant animals to

support Grain Management Programme

� Funding approved for a €150,000 project through the Intertrade

Ireland Innova fund.

� Total research budget for 2013 > €100,000 (some of which part

funded)

Thank You

Prepared By Tom Burns Adesco Nutricines