HOW TO START MANUFACTURING INDUSTRIES
(A Publication of N.C. Gilbert Dev. Co. Ltd)
Animal feed pellets manufacturing plant
The use of scientifically balanced diet is a widely recognized necessity for obtaining best results in the raising of animals and poultry. The diets vary with the type of animal, its age, and the purpose for raising In addition, the knowledge gained through research results informs continuous changes in the recommended diets.
This profile is written to provide information for a prospective investor on the plant requirement to set up an industry that can manufacture feeds for: (a) poultry (b) cattle (c) pigs (d) goats and sheep.
Market
There is a big market for animal feed in the country presently. Experts believe that Nigeria’s potential for an expanded animal feed industry in huge. According to this field of thought, for a country with a massively growing population and rising nutrition awareness, there exist a potential demand for growth in the livestock products, thus, opening up an opportunity for increased demand for animal feed to keep up with the demands by farmers.
Currently, the combined annual output of the animal feed industry in Nigeria is estimated at 5.5mt/yr and 85% of this output is mainly for poultry. This means that, ruminants such as cows, goats, sheep and pigs are largely not fed with scientific formula. It is therefore, imperative that modernization of the system of ruminant’s production is urgently needed to address the current meat supply gap. Furthermore, present statistics from government department has disclosed that the country currently targets over 50 million
metrics tones per annum of feeds to meet the urgent requirements of a modernized animal farming industry, as against the current 5.5 MT output which is far less than 25% of what the industry requires for sustenance .
Another, identified anomaly is that more than 80% of the animal feed manufacturing industries in the country are located in the South Western Zone. There is therefore, the need for sitting of more animal feed production industry in other zones.
In summarizing, increase in the demand for livestock products driven largely by human population growth, Income growth and urbanization is expected to continue for the next three decades in the least, thus making investment in animal feed production a worthwhile venture.
1. RAW MATERIALS FOR ANIMAL PRODUCTION
Animal feed is produced from varieties of raw materials (feed ingredients) based on local availability and formulation. These materials are grouped into: (1) carbohydrates source (2) protein source (3) Vitamin source
(4) fibre (5) fat & oil source
3.1 PROTEIN SOURCE:
Protein source used in feed formulations includes: Synthetic amino acids (i.e. feed grade lysine and methionine) fish and meat scraps, soybeans, palm kernel cake, cotton seed cake, Safflower meal and canola meal.
3.2 VITAMIN / MINERAL SOURCE:
This includes: bone meal, salt, oyster or sea shells: Multi-vitamin/mineral premix.
3.3 CARBOHYDRATE:
Sources of Carbohydrate in animal feed includes: corn, broken rice and wheat bran. (Offal)
3.4 FAT SOURCE:
This includes: palm oil, soybean oil vegetable fat powder, full fat soybeans.
3.5 FIBRE
Rice bran, rice husk, soybean stalk, corn fibre.
3.6 FEED BINDER
Feed binder is usually added to the formula (ingredients) in production of feed pellets. They act to hold the ingredients together. Feed binder usually used include: molasses, corn steep liquor, pellet binder and wheat middle.
4. PRODUCTION PROCESS
The process for making feed pellets is one of weighing, grinding and m i x i n g and pelletizing. Briefly, the process begins with weighing out the correct amount of materials based on one batch of a formula, grinding the material where necessary and then thoroughly mixing them together.
The advantage of Formula over the usual use of owner grown feeds is that it contains all of the necessary feed elements for proper growth and development. However, unless the mixing of the formula is thorough this advantage will be lost. This is particularly true where highly concentrated vitamin supplements are used. Unless they are evenly spread throughout the entire formula batch some animals or poultry will be getting more vitamin than they can efficiently use while others will get less than they require. Thus the mixing process is critical and requires a well designed Equipment for the purpose.
The flow of materials through the plant is shown schematically in the figure below.
The large volume items received such as maize, palm kernel cake etc. are dumped in the receiving hopper and carried by conveyors to the storage tanks. Small volume items are stored in their original containers adjacent to the scales. Three or four low skill men are required to handle incoming material, depending on how it is received. In addition a receiving clerk is necessary to record materials received.
As the material in a storage tank is required for a formula, it is moved by conveyor to the batch bins and the proper quantity is weighed out on the scale. From the scale it is conveyed to the crusher or hammer mill or both and then to the collectors for the mixer. Movement of materials through the machines is automated.
Materials which are used only in relatively small quantity are emptied from their original container at the scale. One man is required full time for this part of operation. An additional man may be required part time to move the low volume materials from storage to the scales.
After all the dry and ground materials for a batch are in the collector bin, they are emptied into a mixer where the materials are blended together. The time required to mix thoroughly the materials varies with the formula.
When the formula leaves the mixers it may be bagged or it may be mixed with binder, and then pelletized in the pelletizing equipment. The pelletizing equipment also use steam from boiler to gelatize starch in the formula. The final form depends on the customer’s requirements. The bagging of the formula requires two unskilled men. As each bags is filled it is closed and placed in a wooden pallet. These men use hand operated lift truck to move the filled pallet far enough to keep their immediate area clear. Each of the pallets holds 20 bags each (one tone) in four layers of five bags each. These pallets are moved to storage and stacked by a powered lift truck that is also used in shipping.
4. PRODUCTION UNIT:
The capacity of the proposed plant is about 1ton/hr or 20tons/day of two shift production.
- Different kinds of feeds can be produced in this plant to include: Chicken starter mash/pellets
- Chicken laying mash/pellets Broiler mash/pellets
- Calf starter
- Beef cattle supplement Pig ration
4.1 EQUIPMENT REQUIREMENTS:
The majority of the equipment in a feed mill is of a standard type. However, it must be specialized for a particular installation. For this reason, a single price covers the complete equipment necessary to set up the production facilities of the plant. The purchase of all production equipment from one dependable source ensures a well engineered plant with balanced productive capacities of the individual units.
Also grain storage tanks, steam boiler and ware house equipment comprising Gasoline powered lift truck, manual pallet truck and wooden pallets are included in production equipment since they are directly connected to the production line. Similarly, the use of a lift truck and pallets reduces the manpower required for moving incoming and outgoing material.
Production: tools and equipment needed are listed below:
- Hammer Mill
- Screw Conveyor
- Horizontal Feed Mixer
- Feed Pellet Machine
- Bucket Conveyor
- Pellet Cooler & Screen
- Packing Machine
- Control Cabinet
Total cost of production equipments including boiler and pellet trucks is N45,000,000.00 (Forty-Five Million Naira) Only.
4.1 MANPOWER REQUIRED
Description Number needed
Manager 1
Foremen 2
Maintenance 3
Accountant 1
Secretary 1
Receiving and shipping
Clerks 10
Truck drivers 2
Operators 6
Material handlers 6
Total 32
4.2 PLANT SITE AND BUILDING
The first consideration in determine the plant site is its nearness to Raw materials Source on another hand and customer on another hand so that freight costs will not be excessive. The total land area required is approximately one acre. This will permit expansion.
The site should be fairly level to minimize construction cost. It should be served by motor able road network.
The suggested building is a steel framed structure with concrete floor.
The main factor building is 42ft x 30ft x 20 (L x W x H).
The warehouse is 20ft x 116ft x 30ft (H x L x W).
Boiler unit – 10ft x 20ft (W x L).
4.3 POWER AND WATER
1. The total power requirement of the plant is 75KW.
2. Water is required for boiler operation, sanitary purposes and fire protection. For this reason a borehole with water treatment and distribution facilities is required.
3. PROFITABILITY
Expected profit before tax = 26 – 30% of Gross sales
For further information, enquiry or consultancy please contact N.C Gilbert development co. ltd. We can provide the following project services.
Prepare a detailed business plan for this project for a client.
Set up this plant on turnkey basis for a client; i.e. design, procure and install equipment for this project.
Supervise the training of operators and staffs for this industry.
Carry out after sales maintenance of equipment.
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