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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