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Mill Process Efficiency

IGFA H&S/Engineering Seminar Maldron Hotel Portlaoise 25th of April 2013

Presentation Content
Adesco Nutricines
at a glance what we do

Mill Process Efficiency


Definition Programmes Raw Material Management Moisture Management Efficiency Benefits

Future

AT A GLANCE

Founded: Employees: Sector:

2007 by Michael McDonagh & Jack OHare 4 Full time, 3 part time/contract Agricultural Feed Industry

Business Units: Mill & Grain Nutritional Ingredients Key Market: Island of Ireland

We are a functional and nutritional ingredients company in the agricultural feed sector. 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 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 = Better Solutions

where Adesco fit 9..


Field
Lower Cost Optimise Quality Improve Efficiency

Fork

Grain Farmer

Grain Merchant

Ingredient Pre-Mixer

Feed
Compounder

Lifestock Producer

Processor / Retailer

Consumer Market

Products Plus model

Definition: The conversion of Purchased Raw Materials into Saleable Finished Products
At the least Cost

To required Customer Standard

With no Physical Loss

In the shortest time

Maintenance, services, depreciation

kWh and Oil or Gas/tonne

Energy, Cost of Manufacture


Complaints, Returns Discounts/Credit notes

Physical quality, Customer satisfaction

Yield

Sales = or > Purchases

Holmen Results

Tonnes/hr, Labour
Tonnes/hour Downtime

Man hrs/tonne

COST of MANUFACTURE - Sources Cost-Kinds: Labour, Maintenance, Energy, Quality, Depreciation, etc

Cost-Places: Intake, Grinding, Mixing, Pelleting, Bagging Cost-Types: Bulk, Bags, IBCs, Collected, Coarse, Pellets, Meals, Dairy, Beef, Pig Poultry

SPECIALS?

Focus on Physical values

The Efficiency Cycle


MEASURE

IMPROVE

MANAGE

CONTROL

4 Key Performance Indicators (KPIs) measured

Improve Pellet Quality

Reduce Energy Costs

The Adesco Edge


Increased Throughput Increase Production Yield

Understanding where the customers 100 goes


0.5 3.5 2 3 2 4

4 3

Raw Materials Depreciation etc Energy Labour Maintenance Misc. Distribution Sales/ Overhead 78 Profit

Raw Material Management the role of grain management in mill process efficiency

Grain Management Programmes


Grain Treatment - retain moisture at harvest Cost benefit vs. drying Quality benefit vs. aeration Grain Conditioning - addition of conditioned moisture Reduction in dust Increase in yield Reduction in energy used in Rolling Increased Throughput

% of rolled product passing through a 1.18mm screen


10 8 6 4 2 0 Dry Rolled Conditioned Rolled Dry Rolled Conditioned Rolled

105 104 103 102 101 100 99 98 97 96 Dry Conditioned Weight before rolling Weight after rolling

kWh/t rolled
2.6 2.5 2.4 2.3 2.2 2.1 2 Dry Conditioned

Roller throughput t/h


9.2 9 8.8 8.6 8.4 8.2 8 7.8 7.6 Dry Conditioned

Unlocking mill process potential through Raw Material Management

Focus on what is important

Raw 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 Finished Products Know Values Set Targets

Raw Material Moistures

(Over 5 months 2010)

No. of Tests Hi-Pro soya Rapeseed Arg.Suns Wheat Feed Citrus Palm Kernal Soya Hulls Distillers* Corn Gluten 79 65 46 21 21 28 33 97 12

Av. Moist.% 12.13 11.5 11.72 13.82 10.31 8.17 11.96 8.61 10.7

Range 10.8 - 13.3 10.5 - 12.6 10.6 - 12.9 11.1 - 15.0 8.8 - 11.6 7.2 - 9.5 11.2 - 12.2 6.6 - 11.2 9.5-13.8

C.V. 4.12 4.78 4.69 6.58 7.47 8.08 3.76 10.69 11.20

Know what is happening in the process


In Process Moisture changes Losses in GrindingAddition in Main Mixer Addition at Conditioning : Molasses etc Steam Losses at Cooling

- 1% + 1 - 3%

+ 1 - 3% + 1 - 4% - 1 - 4%

Moisture control capability drives processing efficiency.

MOISTURE OPTIMISATION PROGRAMME INTEGRATED PRODUCT / APPLICATION SYSTEM SPOT IN-LINE MEASUREMENT CONTINUOUS, CO MPLETE & ACCURATE MEASUREMENT PERFORMANCE BENCHMARKING

Mill Process Efficiency

WATER OFF SITE MEASUREMENT

PRODUCT / MANUAL SYSTEM OFFLINE MEASUREMENT

Moisture Control Capability

Get it right for your Pelleting Process Optimise moisture

Conditioner

Cooler Mixer

Finished Product Moisture Set Targets Realistic Suitable Legal

Moisture Management: Get it right for your Business

4 Key Performance Indicators (KPIs) measured

Improve Pellet Quality

Reduce Energy Costs

The Adesco Edge


Increased Throughput Increase Production Yield

Energy: where it goes

2% 1% 7%

14%

Pelleting 60% Grinding 16% Conveying 14% Intake 7%

16%

60%

Mixing 2% Other 1%

Moisture Optimised: Reduced Energy


110% 105% 100% 95% 90% 85% 80% 75% 70% 65% 60% Energy Dry Moisture Optimised

Get it right for your Business Reduce Energy Consumption Increase Throughput

Moisture Optimised: Increased Throughput


110% 105% 100% 95% 90% 85% 80% 75% 70% 65% 60% Energy Throughput Dry Moisture Optimised

Get it right for your Business Reduce Energy Consumption Increase Throughput Improve Pellet Quality

Physical Quality - parameters affecting pellet quality 5%


Raw Materials 40%

15% 40% 20%


Grinding 20% Conditioning 20% Die /Rolls 15% Cooling 5%

20%

Moisture Optimised: Improved Pellet Quality


110% 105% 100% 95% 90% 85% 80% 75% 70% 65% 60% Energy Throughput Durability Dry Moisture Optimised

Get it right for your Business Reduce Energy Consumption Increase Throughput Improve Pellet Quality Yield

Moisture Optimised: Increased Yield


110% 105% 100% 95% Dry 90% 85% 80% 75% Energy Throughput Durability Yield Moisture Optimised

What needs to be done9.

Develop Your Own Weekly KPIs to cover Plant Throughput Labour Utilisation Energy Use Customer Issues Raw Material Utilisation Measure Manage Control Improve

Future Improvements in Processing Efficiency 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 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

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