PRINCIPLES OF MATERIAL HANDLING IN RELATION TO THE FEED MILLING

INDUSTRY

HISTORY OF PILMICO
Pilmico Foods Corporation, a subsidiary of the Aboitiz Group, has been in the food and
agribusiness industry since 1962. It began as a flour milling company and has grown to be a significant
player in the industry. The company entered the animal nutrition industry in 1998 with commercial swine
farms and a feed milling facility in Capas, Tarlac. Since then, Pilmico has expanded its operations further
down the food value chain, including poultry layer farms, a meat processing plant, and a meats retail
brand.

FEED MILLING INDUSTRY

Feed milling industry is a important component of the agricultural sector, producing or providing
animals feeds that are essential for the livestock, poultry, and aquaculture industry.
It involves the transformation of raw materials into nutritionally balanced and safe feeds that meet the
specific dietary requirements of different animals.

BULK MATERIAL HANDLING

Bulk material handling is a key part or aspect of the feed milling industry. It refers to the
management, and movement of finished product and large quantities of raw materials : such as grains,
proteins, vitamins, minerals, during the manufacturing process. This includes the handling, storage, and
transportation of these materials in bulk form.

THE SIGNIFICANT IMPACT OF EFFICIENT MATERIAL HANDLING IN THE FEED MILLING

INDUSTRY
1. Production Costs:
Efficient material handling helps reduce production costs by,
• Minimizing waste ( proper handling and storage of raw materials prevent spoilage,
contamination, and product loss).
• Automated material handling systems ( optimize the movement of materials, reducing manual
labor, lowering labor cost and increasing production efficiency).
2. Product Quality:
Efficient material handling plays a crucial role in maintaining product quality by,
• Preventing Contamination ( hygienic handling practices and proper storage systems minimize the
risk of contamination, ensuring the feeds quality and safety standards).
 • Accurate weighing, mixing, and blending of ingredients ( resulting the right amount of
distribution of nutrients and additives in the feed to achieve the nutritional value for the animals
performance.
3. Safety:
Efficient material handling contributes to a safer working environment by,
• Injury Prevention ( automated systems reduce the need for manual handling of heavy or
hazardous materials caused of that they minimize the risk of injuries to the workers ).
• Controlling Hazards ( such as dust or airborne particles, ensuring employee safety and reducing
the risk of respiratory issues ).
• Compliance with Regulations ( related to hygiene, safety, and product quality, avoiding penalties
and maintaining a positive reputation ).

STAGES OF MATERIAL HANDLING IN A FEED MILL

1. Receiving :
This is the first stage where the raw materials, such as grains, oilseeds, protein sources, and additives, are
delivered to the feed mill.
• The material are received in bulk through trucks or other transportation methods.
• The materials are inspected for quality, moisture content, and potential contaminants before
being accepted, unloaded and stored.
2. Storage:
• After the raw materials are received, they are stored in silos, bins, or other storage facilities.
These storage systems are designed to protect the materials from environmental factors, such as
moisture, pests, and other contaminants. Proper inventory management is essential to ensure a
continuous supply of materials for production.
3. Conveying:
• Conveying systems, such as belt conveyors, screw conveyors, or pneumatic systems, are used to
transport the raw materials from storage to the different processing areas within the feed mill.
Efficient conveying systems ensure a smooth and continuous flow of materials, minimizing
downtime and optimizing production efficiency.
4.. Grinding:
• Some raw materials, such as grains or oilseeds, may require grinding or particle size reduction to
enhance digestibility and improve feed quality. Grinding breaks down the raw materials into
smaller particles. Hammer mills or roller mills are commonly used for this purpose.
5. Mixing:
 • In the mixing stage, different ingredients are combined to create a uniform feed formulation. This
is done to ensure that animals receive all the necessary nutrients in their diet. Mixing can be done
in batch mixers or continuous mixers.
6. Pelleting:
• After the grinding stage, the feed mixture is conditioned by adding steam or water to improve its
texture and enhance pellet formation. The feed is compressed through a die with small holes,
forming cylindrical pellets. Pelleting improves feed quality, reduces dust, and enhances feed
efficiency.
7. Packing:
• Once the pellets are produced, they are cooled and transferred to the packing area. The feed
pellets are packaged in bags or bulk containers, ready for distribution and sale. Proper packaging
ensures the preservation of feed quality and protects the pellets from contamination or damage
during transportation.
8. Shipping:
• The final stage of material handling in a feed mill is shipping. The packaged feed products are
loaded onto trucks, railcars, or containers for transportation to farms, feed retailers, or other
destinations. Efficient shipping processes ensure timely delivery and proper handling of the feed
products.

II. MATERIAL PROPERTIES AND HANDLING CHALLENGES

MATERIAL PROPERTIES IN FEED MILL

1. Grains
Grains can have varying sizes and hardness. Grains need to be ground or milled to achieve the
desired particle size. Its moisture content impacts their storage stability. Grains provide carbohydrates,
proteins, fats, vitamins, and minerals to animal feed. Type of grain; corn, wheat, barley etc.

2. Oilseeds

Oilseeds, such as soybeans, peanuts, and sunflower seeds, are processed for their oil content.
Oilseeds can be a significant source of protein in animal feed. Oilseeds have different fatty acid profiles,
which contribute to their nutritional properties and suitability for specific animal diets.
3. Minerals and additives

Minerals are essential for animal health and growth. Different minerals, such as calcium,
phosphorus, and zinc, have specific roles in animal nutrition. Additives characteristics are functional,
stable, and soluble. Its purpose is to improve the feed quality, enhancing animal performance, and
preventing disease.

SPECIFIC HANDLING CHALLENGES ASSOCIATED WITH EACH MATERIAL TYPE

1. DUST GENERATION
During handling and processing of grains and oilseeds (grinding or crushing), and mineral and
additive powders, dust can generate and can lead to respiratory hazards for workers and can cause
cleanliness issues in the workplace.
2. FLOWABILITY
Grains, such as corn or wheat, some minerals and additives may have poor flowability due to
their shape or moisture content while oilseeds, especially those with high oil content, may have poor
flowability due to their sticky nature. Poor flowability can lead to flow disruptions, blockages in
equipment and uneven mixing.
3. SEGREGATION
During handling, grains can be segregated based on size, density, or shape; minerals and
additives is based on size and density while oilseeds can be segregated based on size, density, or oil
content. Segregation of grains and oilseeds may result in uneven distribution of nutrients in the final feed
product while in minerals and additives may result in uneven or inconsistent distribution in the feed
mixture.
4. DEGRADATION
Repeated handling and processing of grains may lead to particle breakage or damage which
affects their quality and nutritional value. Oilseeds degrades especially when exposed to heat or moisture
resulting in changes in oil quality and nutritional composition. Moreover, minerals such as vitamins or
heat-sensitive additives also degrades when exposed to moisture, light, or high temperatures. Lastly, some
additives, such as enzymes or probiotics are also sensitive to heat, moisture, or prolonged storage which
why when exposed, it results to reduced effectiveness or loss of activity.

To address these handling challenges, feed mills implement various measures such as
dust control systems, proper ventilation, equipment design optimization, and proper storage conditions.
However, regular maintenance and monitoring of equipment are also important to minimize degradation
and ensure consistent feed quality.
THE CONCEPT OF COMPATIBILITY BETWEEN MATERIALS AND HANDLING
EQUIPMENT

The compatibility between materials and handling equipment in feed mills refers to the ability of
the equipment to be effectively and efficiently handle different types of materials without causing
excessive wear, damage, etc. It involves selecting the appropriate equipment and designing the handling
processes to ensure smooth and reliable material flow.
 By ensuring compatibility between materials and handling equipment, feed mills can optimize
their operations, lessen interruption, reduce costs related with equipment maintenance and replacement,
and maintain consistent feed quality.

III. EQUIPMENT AND SYSTEM OPTION

RECEIVING
● Bulk Feed Trucks - also known as bulk feed truck, feed truck, are mainly used to transport
bulk feed finished products or feed production raw grains from feed factories to livestock
farms, poultry farms and feed processing users.
● Dump Pit - are used to receive grain or other products from incoming trucks or trains. Dump pits
are set in the ground, and receive products either from hoppers located on the bottom of semi-
trailers and railcars, or directly from straight trucks, both which operate through gravity or
pneumatic means.
● Hoppers - are machines with holding trays designed to pour or ‘feed’ large amounts of materials
into a separate container. These can include feed hopper bins or metal balers. They’re most often
used to transport large amounts of loose materials and have a purpose in many industrial settings.
 ● Silos - is a structure for storing bulk materials. Silos are used in agriculture to store grain or
fermented feed known as silage. Silos are more commonly used for bulk storage of grain,
food products.

TYPES OF DUST COLLECTOR

● Pulse Jet Dust Collectors - The most widely used dust collector is an industrial-scale fabric
filtration system commonly referred to as a baghouse. Two popular baghouse system designs are
the pulse jet dust collector and the shaker dust collector. The bags are housed in large skeletal
frames or housings that draw dust, particulates, and gases through an intake that directs the
airstream to the baghouse compartment.
● Shaker Dust Collectors - Where compressed air is not available or impractical, shake-cleaning
baghouse systems, or simply, shaker dust collectors are an excellent alternative. Shaker fabric
filtration uses a shaker cleaning system to release the collected dust particles from filter media
surfaces by mechanically shaking the filter bags.
● Cartridge Collectors - are another type of fabric filter designed for specific configurations and
applications. They are ideally suited for placement in smaller spaces that have the same airflow of
a larger baghouse system. Cartridge collectors are cost-effective systems that present minimal
safety hazards.
● Cyclone Dust Collectors - are a type of mechanical inertial separator that removes dust from a
gas stream through centrifugal or cyclonic force within a hopper chamber. As the name suggests,
cyclone dust collectors create an intense circular airflow, a vortex in effect, to separate particles
from the air.

TYPES OF CONVEYORS
● Gravity Roller Conveyor - A series of rollers mounted on a side frame provides the rolling
surface. When mounted on a decline angle, parts move by themselves. However if using gravity
conveyors for parts of different size and weight it can be more difficult, you will need to control
the speed and angle.
● Chain Conveyors - Floor mounted chain conveyors are great for heavy items. They are
especially useful for items that have an uneven lower surface. The conveyor chain provide two or
three contact points on the bottom of the load. As the chain moves it carries the product forward.
They’re used to carry pallets and large industrial containers.
● Screw Conveyors - are industrial equipment used in transporting bulk quantities of granular
solids (e.g., powder, grains, granules), semi-solids, liquids, and even non-flowing materials from
one point to another. Screw conveyors primarily consist of a rotating screw shaft that is installed
within a trough.
● Bucket Elevator - bucket elevators vertically convey bulk materials using buckets attached to a
belt or chain, which rotates around two pulleys. The buckets pick up material in the boot section,
carry it to the top of the elevator (the head section), discharge material, and finally, return to the
starting point to pick up a new load.
 ● Belt Type Bucket Elevator - The use of belt + hopper to lift and transport materials has been
involved in grain, coal, fly ash, cement, crushed ore, quartz sand, carbon and other industries, and
has been well applied.
● Chain Bucket Elevator - The circular chain or leaf chain is used as the traction component,
which has good wear resistance and reliability, and is suitable for vertical lifting of powdery,
granular, and small pieces of low-abrasive materials, such as: coal, cement, gravel, sand,
Fertilizer, etc.
● Z Type Bucket Elevator - Horizontal-vertical-horizontal combined conveying, suitable for
packaging and conveying into warehouses of bulk products, such as feed, plastic granules, potato
chips, low material damage rate, single-point or multi-point feeding.
● Drag Chain Conveyor - These are heavy-duty conveyors that are capable of operating in harsh
environments and withstand excessive elemental forces. Generally, these systems are required to
handle substances that conventional conveyor systems are incapable of surviving.

PRE – BATCHING
● Drum Scalper - is intended for separation of coarse impurities such as straws, strings,
paper, splinters of wood, maize husks etc. from granular or mealy bulk products.
Elimination of these impurities will exert a favorable effect on the functional reliability and
performance of the machines and conveying elements of the processing line.
● Distributors - With this distributor, the raw material of feed can be categorized into bins
with certain quantity. This process during production greatly improves the efficiency and
saves labor cost and time. Moreover, this distributor settles the problem of getting rid of
impurities and cleaning, and avoids waste of raw material.
● Feed Bin - Feed bin systems enable you to maximize feed storage capacity and manage and
monitor the bin’s contents more efficiently.
● Weighers - The weighers can be used for weighing of cereals with kernel sizes up to 15 mm
and coarse ground materials (not too fine), which are not bridging. The weighing system is
based on a compartment containing a certain amount of grain (ingredients).
● SCADA - stands for Supervisory Control and Data Acquisition. Simply put, SCADA
systems gather and quickly analyze real-time data. In the manufacturing sector, they’re
used to monitor and automate the control processes of industrial automation.

GRINDING
● Hammer Mills - A hammer mill, also known as a pulverizer, is designed to mill, grind and
crush material. These mills have been in use for much of human history and function by
using hammer blows at high speed to grind material. The material is shattered and
disintegrated by the internal hammer.
TYPES OF HAMMER MILLS
● Lump Breakers Hammer Mill - is quite different from other types of hammer mills. The
parts of a hammer mill differ, as lump breakers do not have any swinging hammers.
Instead, they have a fixed hammer structure, referred to as a comb. Rather than reducing
particle size, this mill is used to smoothen paste or powder.
● Full Circle Hammer Mill - features a rotating screen to improve particle evacuation. This
hammer mill can be used to reduce the size of lightweight components that do not require
any initial grinding, such as grasses, grain, sawdust, corn and spices.
● Gravity Discharge Hammer Mill - This type of hammer mill contains a rectangular steel
chamber with swinging hammers that are mounted on a shaft. The shaft rotates at a high
speed and the hammering aids in particle size reduction.
● Horizontal In-Feed Hammer Mill - is designed in a way that allows the material to be
inserted from the side rather than the top. In function, this type of hammer mill is
aggressive and used to grind heavy particles. This mill features pallet grinders and trim
scrap grinders to conduct hardcore industrial grinding.
● Pneumatic Discharge Hammer Mill - the hammering function in a pneumatic discharge mill
is similar to a gravity discharge hammer mill. The difference is that this type of hammer
mill also contains a plate dashboard for size reduction. The air evacuation process assists
the discharge to enhance the output.

MAIN BATCHING
● Feed Mixers - is a kind of machine equipment specially used to mix feed. The feed
mixer can mix many different feeds, such as grains, proteins, vitamins, minerals,
carbohydrates, etc., to make a comprehensive and balanced feed.
TYPES OF FEED MIXERS
● Vertical Mixers - are suitable for materials with larger particles and larger density
differences, such as granular, lumpy or powdery materials. It is commonly used in
metallurgy, mining, building materials and other industries.
● Horizontal Mixers - is suitable for materials with smaller particles and smaller density
differences, such as powder and granular materials. It is commonly used in chemical,
pharmaceutical, food processing and other industries.

PELLETING
● Conditioner - Conditioning or adding heat and moisture in the feed mill during the pelleting
process, is a way to optimize pellet quality.
● Boiler - The function of a boiler is to either produce hot water or steam. Hot water boilers
heat water for the purpose of domestic or commercial heating and hot water supply.
 ● Feed Pellet Cooler - is a key piece of equipment for cooling and dehumidifying the hot and
humid pellets feed after granulating. The temperature of the granular feed that has just
been suppressed from the granulator is about 60~90 degree Celsius, and the moisture is
about 14% ~ 15%.
● Crumbler - The crumbler produces crumbled feed to control reduction to a specific particle
size with a minimum of fines. It's a roller mill with rolls specially designed for crumbling
feed pellets, as well as in the flour milling and oilseed processing.
● Rotary Screener - is utilized in complete feed pellet production line to screen and separate
powder or undesirable feed particles from standard feed pellets. And the separated powder
and particles will go back for reproduction.

TYPES OF SCREENERS
● Vibratory Screeners - are one of the most commonly used types of industrial screening
machines. The basic working principle behind a vibratory screener is that they work by
using a series of screens or meshes to separate materials based on their size and densities.
● Rotary Screeners - are ideal for separating materials based on their size and shape. They
typically consist of a rotating drum or cylinder that is perforated with a series of holes or
meshes.
● Static Screens - also known as stationary screens, are used to separate materials based on
their size and shape. They consist of a stationary frame or structure that is fitted with a
series of screens or meshes. Materials are fed onto the screen, and larger materials are
separated from smaller ones. Static screening machines are commonly used in industries
such as mining, construction, and agriculture.
● Flip-Flow Screening Machines - are ideal for separating materials that are difficult to
screen, such as sticky or wet materials. They work by using a series of flexible screens that
flip back and forth, allowing materials to deagglomerate and separate from each other. Flip-
flop screeners also referred to as Flip-Flow screening machines are commonly used in
industries such as mining, construction, and waste management.
● Tumbler Screeners - are ideal for separating materials based on their size, shape, and
density. They work by using a gyrating motion to separate materials as they pass over the
screen. Gyratory screens are commonly used in industries such as food and beverage,
pharmaceutical industry, chemical industry, recycling industry, construction, super
absorbents and many others.
● Air Classifiers - are used to separate materials based on their density. The machine uses air
flow to separate the material, with the lighter particles being carried away by the air while
the heavier particles fall to the bottom. This type of screening equipment is commonly used
in the mining and construction industries.

PACKAGING
 ● Sacks - feed bags are an economical and effective way to package and store dry goods, such
as grains, pellets, and feed. The combination of strength, durability and low cost makes
them ideal for many uses, from agricultural storage to industrial packaging.
● Sewing Machine - An industrial bag sewing machine is an essential component in the
production line. It automates bag closing thus reducing spillage or leakage and also ensures
uniformity of finished packaging.

IV. SYSTEM DESIGN AND OPTIMIZATION

Importance of Process Flow Analysis and Layout Planning

 Optimize Efficiency
Process flow analysis means looking at how things move through each step of
making something in a feed mill. When we study this, we can find where things aren't working well
and fix them. Fixing these problems makes everything work better, faster, and cheaper.

 Resource Utilization
Good layout planning means organizing things like machines, workers, and space in
a smart way. When everything is arranged well, it saves time and makes things work faster. It helps
workers move less and get more done

 Safety
A tidy layout and clear way of doing things make work safer. When there are clear
paths to walk, places to keep things, and the right way to handle stuff, it helps avoid accidents and
keeps people from getting hurt.

 Quality Control
When the way things are made is planned out well, it helps to check if the quality is
good. If materials go through each step in a controlled way, it's easier to watch and keep the quality
of the product high.

 Flexibility and Scalability

A smart layout design means the feed mill can easily change and grow. If they need
to make more or different things, they can adjust the layout without causing big problems in how
things work.

 Cost Reduction
Making the way materials are handled and how everything is set up more efficient
helps save money in different ways like paying workers less, using less energy, and spending less on
fixing things. By making operations smoother and cutting out unnecessary stuff, the total cost of
making things can be lowered.

 Customer Satisfaction
 Making sure materials are handled well helps meet what customers want: good
quality products, the same every time, and delivered on time. If the feed mill is well-arranged, it can
make sure orders are completed quickly and correctly.

Capacity Requirement and Flow Rate Calculation

 Identify Material and Products

Know what kinds of things (like ingredients before they're made into feed, extra
things added in, and the final feed products) are being used in the feed mill.

 Determine Production Requirements

Set up how much feed the mill needs to make in a certain time, like how many tons
it should produce per hour.

 Define Process Flow

Draw a map that shows how things move in the feed mill, starting from when raw
materials arrive to when finished products are packed. Find any places where things are stored
temporarily in between.

 Calculate Material Flow Rates

Figure out how fast materials move through each part of the process. This means
knowing how long it takes to process them at each step and how much of the materials are being
processed.

 Consider Handling Equipment

Choose the right tools to move materials, like belts or machines that lift, based on
what the materials are like, how fast they move, and how much space there is. The tools should be
able to handle the amount of materials needed without slowing things down.

 Account for Downtime and Maintenance

Consider the time needed for fixing and cleaning machines. Make sure that even
when machines are being fixed or cleaned, the system can still make enough products as planned.

 Safety and Regulatory Consideration

Make sure to follow the rules and standards to keep things safe when handling
materials and using equipment.

 Optimization
Keep an eye on how materials are handled all the time and make them work better
and cost less. This might mean changing how machines are set, making processes simpler, or using
machines that work automatically.
Some Specific Calculation that may be Involved

 Conveyor Capacity

L X W X H X rpm x 60
Elevator Capacity =
1000

 Elevator or Conveyor Speed

Gear rpm x A
Rpm =
B

Where:
A – No. of cog teeth attached with gear
B – No. of cog teeth attached in opposite direction of A

 Silo Capacity

π 2
Silo Capacity = ( D )(h)(Stocking Density)
4

Where:
D – Diameter
R – Radius
H – Height

 Hammer Tips Speed

πD x Shaft rpm
Hammer Tips Speed =
12
  Amount of Steam Required
 6% of pellet capacity

 Boiler Heating Surface (ft2)

A= T+F+S

Where:
T (tubes) = πDL (No. of Tubes)

F (flue) = πDL

S (shell) = Πdl x Heating Area ¿ ( D4 )

D- Diameter in ft
L – Length in ft

 Flow Rate

Volume or Weight of Material

Flow Rate =
Processing Time

Selecting Appropriate Equipment based on Material Properties and Process needs

1. Conveyors

Type:
• Belt Conveyor
• Screw Conveyor
• Bucket Conveyor
 • Pneumatic Conveyor

Selection Criteria:
• Material Properties: Consider the size, shape, and flow characteristics of the materials being
handled. For example, powdery materials may require enclosed screw conveyors to prevent dust
emissions.
• Capacity Requirements: Choose conveyors with appropriate capacities to handle the expected
flow rates of materials.
• Process Needs: Select conveyors that can handle the required inclines, declines, or horizontal
transfers based on the layout of the feed mill and process flow.
• Space Constraints: opt for conveyors that fit within the available space and can be configured to
minimize obstruction of other equipment or workflow.
• Budget: Balance performance requirements with cost considerations to select the most cost-
effective conveyor solution.

2. Storage Silos and Bins

Types:
● Flat-Bottom Silos
● Hopper-Bottom Silos
● Bins

Selection Criteria:
● Material Properties: Choose silos or bins made from materials compatible with the stored
materials to prevent contamination or spoilage.
● Capacity Requirements: Select silos or bins with sufficient capacity to store raw materials,
intermediate products, and finished products based on production needs.
● Process Needs: Consider factors such as ease of material discharge, flow control mechanisms,
and accessibility for cleaning and maintenance.
● Space Constraints: Determine the optimal size and configuration of silos or bins to fit within the
available space while allowing for efficient material handling and storage.
● Budget: Evaluate the cost-effectiveness of different storage solutions considering factors such as
material durability, insulation, and automation features.
 3. Mixers and Grinders
Types:
● Batch Mixers
● Continuous Mixers
● Hammer Mills
● Roller Mills
Selection Criteria:
● Material Properties: Choose mixers and grinders capable of handling the size, density, and
moisture content of the raw materials.
● Capacity Requirements: Select equipment with appropriate batch or throughput capacities to meet
production targets.
● Process Needs: Consider factors such as mixing uniformity, particle size reduction requirements,
and energy efficiency.
● Space Constraints: Determine the footprint and layout requirements of mixers and grinders within
the production facility.
● Budget: Evaluate the upfront investment and operating costs associated with different mixer and
grinder options, considering factors such as power consumption and maintenance requirements.

4. Packaging Equipment
Types:
● Bagging machines
● bulk bag fillers
● palletizers
Selection Criteria:
● Material Properties: Choose packaging equipment compatible with the packaging materials and
formats used for finished products.
● Capacity Requirements: Select packaging equipment with appropriate throughput capacities to
match the production rates of the feed mill.
 ● Process Needs: Consider factors such as packaging accuracy, flexibility to handle different
product sizes and weights, and automation capabilities.
● Space Constraints: Determine the space required for packaging equipment installation and
integration into the production line.
● Budget: Evaluate the cost-effectiveness of packaging solutions based on initial investment,
operational efficiency, and maintenance costs.

5. Automation and Control Systems

Types:
● Programmable logic controllers (PLCs)
● supervisory control and data acquisition (SCADA) systems
● sensors
● actuators
Selection Criteria:
● Process Needs: Choose automation and control systems that can effectively monitor and optimize
material handling processes, improve efficiency, and ensure product quality.
● Integration: Select systems that can be integrated with existing equipment and software platforms
within the feed mill.
● Scalability: Consider the scalability of automation solutions to accommodate future expansions or
modifications of the production facility.
● Reliability: Evaluate the reliability and uptime of automation systems to minimize the risk of
production disruptions.
● Budget: Determine the cost-effectiveness of automation investments based on the potential
benefits in terms of productivity gains, labor savings, and error reduction.

Optimizing System Layout for Minimum Distance and Handling Steps

1. Process Flow Analysis

- Start by looking at how everything moves in the feed mill, from when raw materials
come in to when finished products are packed. Find each thing that happens, like moving
materials, making them into feed, storing, and packing. Draw a picture showing how
materials move around, where they go, and if there are any places where things might
slow down or not work well.
2. Identify Key Material Handling Points
 - Point out important places where materials are moved or worked on, like where belts
meet, where materials are stored, mixed, or packed. Figure out how often and how much
materials are moved at each place to decide which ones need to be made better first.
3. Minimize Handling Steps
- Try to make it so that materials have to be moved around less in the system. Combine
steps and avoid moving materials between machines or places to store them if it's not
needed. Use straight paths to move materials directly when possible to avoid moving
them extra times.
4. Optimize Equipment Placement
- Organize machines and places where people work so that materials and workers don't
have to go far. Put things that are related together to make work easier and shorten the
distance they need to go. Put machines that are used a lot or are really important near
where the materials start or where the main work is done to save time moving things
around.
5. Utilize Vertical Space
- Make use of the space above by adding extra levels or shelves. Use machines like lifts or
elevators to move materials up and down between levels, saving space on the ground for
other things.
6. Implement Lean Principles
- Use smart manufacturing ideas to get rid of things that aren't needed and make materials
move better. Find and remove things that don't add value, like extra moving around,
waiting, or doing too much. Set up the layout so materials keep moving smoothly, with
less stuff sitting around and less big batches being processed all at once.
7. Consider Material Characteristics
- Think about what the materials are like, such as how big, heavy, easy to move, or how
quickly they spoil. Make machines and arrange things in a way that works best for each
type of material, so they're handled in the most efficient way possible.
8. Use Simulation and Modeling Tools
- Use computer programs or tools to pretend and see how different setups of the layout
would work. Test different ideas to see which one makes materials move the least and
requires the fewest steps, but still meets what needs to be made.
9. Continuous Improvement
- Set up a way to always check and make the material handling layout better. Ask the
people who work with it and others involved for ideas to make it work better and fix
things if needed. Keep an eye on how well it's working by looking at things like how
much gets done, how long it takes, and how much it costs to move materials. This helps
find ways to make it even better.

Integrating conveying systems with storage, processing, and packaging equipment

1. Conveyor System Integration

- Receiving Area: Conveyors can be integrated with receiving equipment such as truck
unloaders or receiving pits to transport incoming raw materials directly to storage or
processing areas.
 - Storage Silos and Bins: Conveyors facilitate the transfer of materials between storage
silos or bins and processing equipment. Level sensors or automated control systems can
regulate material flow to maintain optimal inventory levels.
- Processing Equipment: Conveyors connect various processing stages such as grinding,
mixing, and pelleting, allowing for continuous material flow between equipment.
Adjustable speed controls and diverter gates can manage material flow rates and route
materials to the appropriate processing equipment.
- Packaging Area: Conveyors transport finished products from processing equipment to
packaging stations. Accumulation conveyors or buffer zones may be integrated to
temporarily store products before packaging, ensuring a steady supply to packaging
equipment.
- Palletizing and Shipping: Conveyors can facilitate the transfer of packaged products to
palletizing stations and loading docks for shipment. Automated palletizers and stretch
wrappers can be integrated with conveyor systems to streamline the packaging and
shipping process.
2. Storage and Processing Equipment Integration
- Material Flow Control: Storage and processing equipment can be equipped with sensors,
actuators, and automated controls to regulate material flow and coordinate with
conveying systems. For example, material level sensors in storage silos can trigger
conveyor systems to replenish materials as needed.
- Batching and Mixing Systems: Batching and mixing equipment can be integrated with
conveying systems to automate ingredient delivery and ensure accurate recipe
formulations. Material flow from storage bins to batching equipment can be controlled
using pneumatic gates or augers.
- Pellet Mills and Extruders: Pellet mills and extruders can be positioned in close proximity
to storage bins or mixers to minimize material transfer distances. Conveyors equipped
with magnets or metal detectors can remove foreign objects before feeding materials into
pellet mills or extruders.
3. Packaging Equipment Integration
- Inline Packaging Systems: Packaging equipment such as bagging machines, bulk bag
fillers, and box formers can be integrated directly with conveying systems for seamless
product transfer. Conveyors transport finished products from processing equipment to
packaging stations, where they are automatically filled, sealed, and labeled.
- Automated Control Systems: Packaging equipment can be synchronized with conveying
systems through automated control systems to optimize throughput and minimize
downtime. Sensors and feedback mechanisms provide real-time data to adjust conveyor
speeds and packaging rates based on production demands.
- Palletizing and Stretch Wrapping: Conveyors transport packaged products to palletizing
stations, where automated palletizers stack products onto pallets according to predefined
patterns. Integrated stretch wrappers secure palletized loads before they are transferred to
shipping areas.
4. Automation and Control Integration
- Centralized Control System: An integrated control system oversees the operation of
conveying systems, storage equipment, processing machinery, and packaging systems.
PLCs, HMIs, and SCADA systems provide centralized monitoring and control
capabilities to optimize material flow and production efficiency.
 - Data Integration and Analysis: Integration with data collection and analysis systems
allows for real-time performance monitoring, predictive maintenance, and process
optimization. Key performance indicators (KPIs) such as throughput, downtime, and
energy consumption are tracked to identify opportunities for improvement and
optimization.

Selection Criteria
● Process Needs: Choose automation and control systems that can effectively monitor
and optimize material handling processes, improve efficiency, and ensure product quality.
● Integration: Select systems that can be integrated with existing equipment and software
platforms within the feed mill.
● Scalability: Consider the scalability of automation solutions to accommodate future
expansions or modifications of the production facility.
● Reliability: Evaluate the reliability and uptime of automation systems to minimize the risk
of production disruptions.
● Budget: Determine the cost-effectiveness of automation investments based on the potential
benefits in terms of productivity gains, labor savings, and error reduction.

Optimizing System Layout for Minimum Distance and Handling Steps

1. Process Flow Analysis

Start by looking at how everything moves in the feed mill, from when raw materials come in
to when finished products are packed. Find each thing that happens, like moving materials, making
them into feed, storing, and packing. Draw a picture showing how materials move around, where
they go, and if there are any places where things might slow down or not work well.

2. Identify Key Material Handling Points

Point out important places where materials are moved or worked on, like where belts meet,
where materials are stored, mixed, or packed. Figure out how often and how much materials are
moved at each place to decide which ones need to be made better first.

3. Minimize Handling Steps

Try to make it so that materials have to be moved around less in the system. Combine steps
and avoid moving materials between machines or places to store them if it's not needed. Use
straight paths to move materials directly when possible to avoid moving them extra times.
4. Optimize Equipment Placement
Organize machines and places where people work so that materials and workers don't have
to go far. Put things that are related together to make work easier and shorten the distance they
need to go. Put machines that are used a lot or are really important near where the materials start
or where the main work is done to save time moving things around.

5. Utilize Vertical Space

Make use of the space above by adding extra levels or shelves. Use machines like lifts or
elevators to move materials up and down between levels, saving space on the ground for other
things.

6. Implement Lean Principles

Use smart manufacturing ideas to get rid of things that aren't needed and make materials
move better. Find and remove things that don't add value, like extra moving around, waiting, or
doing too much. Set up the layout so materials keep moving smoothly, with less stuff sitting around
and less big batches being processed all at once.

7. Consider Material Characteristics

Think about what the materials are like, such as how big, heavy, easy to move, or how
quickly they spoil. Make machines and arrange things in a way that works best for each type of
material, so they're handled in the most efficient way possible.

8. Use Simulation and Modeling Tools

Use computer programs or tools to pretend and see how different setups of the layout would
work. Test different ideas to see which one makes materials move the least and requires the fewest
steps, but still meets what needs to be made.

9. Continuous Improvement
Set up a way to always check and make the material handling layout better. Ask the people
who work with it and others involved for ideas to make it work better and fix things if needed. Keep
an eye on how well it's working by looking at things like how much gets done, how long it takes, and
how much it costs to move materials. This helps find ways to make it even better.
Integrating conveying systems with storage, processing, and packaging equipment

1. Conveyor System Integration

● Receiving Area: Conveyors can be integrated with receiving equipment such as truck
unloaders or receiving pits to transport incoming raw materials directly to storage or
processing areas.
● Storage Silos and Bins: Conveyors facilitate the transfer of materials between storage silos
or bins and processing equipment. Level sensors or automated control systems can regulate
material flow to maintain optimal inventory levels.
● Processing Equipment: Conveyors connect various processing stages such as grinding,
mixing, and pelleting, allowing for continuous material flow between equipment. Adjustable
speed controls and diverter gates can manage material flow rates and route materials to the
appropriate processing equipment.
● Packaging Area: Conveyors transport finished products from processing equipment to
packaging stations. Accumulation conveyors or buffer zones may be integrated to
temporarily store products before packaging, ensuring a steady supply to packaging
equipment.
● Palletizing and Shipping: Conveyors can facilitate the transfer of packaged products to
palletizing stations and loading docks for shipment. Automated palletizers and stretch
wrappers can be integrated with conveyor systems to streamline the packaging and
shipping process.

2. Storage and Processing Equipment Integration

● Material Flow Control: Storage and processing equipment can be equipped with sensors,
actuators, and automated controls to regulate material flow and coordinate with conveying
systems. For example, material level sensors in storage silos can trigger conveyor systems to
replenish materials as needed.
● Batching and Mixing Systems: Batching and mixing equipment can be integrated with
conveying systems to automate ingredient delivery and ensure accurate recipe formulations.
Material flow from storage bins to batching equipment can be controlled using pneumatic
gates or augers.
● Pellet Mills and Extruders: Pellet mills and extruders can be positioned in close proximity
to storage bins or mixers to minimize material transfer distances. Conveyors equipped with
magnets or metal detectors can remove foreign objects before feeding materials into pellet
mills or extruders.

3. Packaging Equipment Integration

 ● Inline Packaging Systems: Packaging equipment such as bagging machines, bulk bag fillers,
and box formers can be integrated directly with conveying systems for seamless product
transfer. Conveyors transport finished products from processing equipment to packaging
stations, where they are automatically filled, sealed, and labeled.
● Automated Control Systems: Packaging equipment can be synchronized with conveying
systems through automated control systems to optimize throughput and minimize
downtime. Sensors and feedback mechanisms provide real-time data to adjust conveyor
speeds and packaging rates based on production demands.
● Palletizing and Stretch Wrapping: Conveyors transport packaged products to palletizing
stations, where automated palletizers stack products onto pallets according to predefined
patterns. Integrated stretch wrappers secure palletized loads before they are transferred to
shipping areas.

4. Automation and Control Integration

● Centralized Control System: An integrated control system oversees the operation of
conveying systems, storage equipment, processing machinery, and packaging systems.
PLCs, HMIs, and SCADA systems provide centralized monitoring and control capabilities
to optimize material flow and production efficiency.
● Data Integration and Analysis: Integration with data collection and analysis systems allows
for real-time performance monitoring, predictive maintenance, and process optimization.
Key performance indicators (KPIs) such as throughput, downtime, and energy consumption
are tracked to identify opportunities for improvement and optimization.

V. SAFETY AND HAZARD CONTROL

Potential Hazards Associated with Material Handling Systems

1. Mechanical Hazards

- If we don't have the right protections, people can get hurt by getting caught in or crushed
by moving parts like conveyor belts or augers. If machines stop working properly, they
might suddenly move and hurt people nearby.
2. Falls and Trips

- Uneven floors, spills, or stuff lying around in the areas where materials are handled can
make workers trip and fall, which can lead to injuries. Working up high to fix or take care
of material handling machines can be risky if there aren't safeguards to prevent falls.
3. Ergonomic Hazards
 - Doing the same tasks over and over again, like lifting bags or using controls, can hurt
muscles and bones if we don't handle them right. Having to bend or twist in strange ways
to do things, like loading or unloading materials, can also cause ergonomic problems.
4. Chemical Exposure

- When workers handle certain feed ingredients or additives, they could be exposed to
harmful chemicals or dust. If they don't wear the proper protective gear, it can affect their
breathing and irritate their skin. If these substances spill, they can harm the environment
and cause illness.
5. Electrical Hazards

- If electrical parts of machines used for handling materials get broken or aren't looked
after well, they can shock or even kill someone. Places in feed mills where it's wet or
damp can make these electrical dangers even worse.
6. Fire and Explosion Risks

- If dust from feed ingredients or additives builds up in the machines used to handle
materials, it can cause fires or explosions if we don't handle it right. If machines like
conveyors or mixers get too hot or rub against each other too much, they can set this dust
on fire, which could be really bad.
7. Confined Space Hazards

- Certain machines used for moving materials may need workers to go into small, enclosed
areas to fix or maintain them. This can be risky as it could lead to difficulties in
breathing, being trapped, or exposure to harmful gases if workers don't follow the correct
procedures for entering these spaces.
8. Noise Exposure

- Equipment used to handle materials, like crushers, mixers, or air-powered systems, can
make really loud noises, which could hurt workers' ears if they don't wear the right
hearing protection.
9. Dust Explosions

- Dust explosions are a big danger in feed mills because of the fine dust made during
handling materials. Ingredients like grains, proteins, and minerals used to make feed can
create dust that builds up in machines and buildings. If there's enough dust and something
sets it off, like sparks from machines or static electricity, it can explode quickly. Dust
explosions can wreck machines, hurt people, and even kill, as well as cause more fires
and damage to buildings.

10. Equipment Malfunctions

 - Equipment used to handle materials in feed mills, like belts, lifts, and mixers, can get
worn out, break, or stop working properly. If we don't take care of them and check them
regularly, they might suddenly stop working or have problems, which can mess up how
materials move and might cause accidents. When machines go wrong, they might
suddenly move or get stuck, which could hurt people nearby. If the electrical parts of
automated systems or control panels break, it could also make the equipment stop
working right and be dangerous if we don't fix it quickly.

Safety Regulation and Standards for Feed Mill Operations

1. Occupational Safety and Health Administration (OSHA)

• General Industry Standards (29 CFR 1910), which cover various aspects of workplace safety,
including material handling, machine guarding, electrical safety, and hazard communication.
• Specific standards such as 29 CFR 1910.272 - Grain Handling Facilities, which addresses hazards
related to grain handling, storage, and processing, including feed mills.
2. National Fire Protection Association (NFPA)
• NFPA 61 - Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food
Processing Facilities, which provides guidance on controlling fire and explosion hazards
associated with handling agricultural and food products, including feed ingredients.
• NFPA 654 - Standard for the Prevention of Fire and Dust Explosions from the Manufacturing,
Processing, and Handling of Combustible Particulate Solids, which addresses the prevention of
dust explosions in various industries, including feed manufacturing.

3. American National Standards Institute (ANSI)

• ANSI/ASSE A1264 Series - Safety Requirements for Workplace Walking/Working Surfaces and
Their Access, which provides guidelines for preventing slips, trips, and falls in industrial settings,
including material handling areas.
• ANSI B20.1 - Safety Standard for Conveyors and Related Equipment, which outlines safety
requirements for conveyor systems used in material handling operations.
4. Good Manufacturing Practices (GMP)

- GMP rules and advice, like those given by the FDA in the U.S., set out what needs to be
done to make food and feed safely. For feed mills, these include keeping raw materials
and finished products safe from getting dirty and keeping them in good condition. It also
means making sure equipment and buildings are kept clean and tidy.
5. Local Regulations
 - Feed mills might have to follow extra safety rules and standards from the state, province,
or local government. These rules could cover things like where the mill can be built,
environmental protection, and how the building should be constructed.
6. PNS/BAFS
PNS/BAFS 163:2015 - Animal Feed Ingredients:

- Scope: This standard applies to the quality and safety parameters of feed ingredients,
including their classification, descriptions, and purchase specifications, being used in
animal feeds intended for domesticated livestock and poultry animals.
PNS/BAFS 123:2016 - Good Manufacturing Practices for Animal Feeds:

- Scope: This standard outlines the principles and guidelines for the production of safe and
high-quality animal feeds. It covers aspects such as facilities, equipment, personnel, and
record-keeping. Compliance with these practices ensures the safety of feed products for
animals
PNS/BAFS 282:2019 - Code of Good Animal Feeding:

- Scope: This standard establishes a comprehensive feed quality and safety system for
food-producing animals. It covers the entire feed chain, from raw material sourcing to
feeding practices on farms. The code emphasizes animal welfare considerations alongside
feed safety and quality DRAFT
PNS/BAFS XXX:2019 - Code of Good Animal Feeding:

- Scope: Establishes a feed quality and safety system for food-producing animals, covering
the entire feed chain. Relevant aspects of animal welfare are taken into account

7. Labor Code of the Philippines

- The Labor Code of the Philippines stands as the primary law governing employment practices
and labor relations in the country. It was enacted on Labor Day in 1974 by President Ferdinand Marcos.
While it covers a wide range of labor-related matters, it also includes provisions related to safety and
health in the workplace12. Implementing Rules and Regulations (IRR): The IRR provides detailed
guidelines for implementing various provisions of the Labor Code. It covers specific aspects related to
labor standards, safety, and health. For material handling, it outlines practices and precautions to ensure
the well-being of workers during tasks involving lifting, moving, and transporting materials. You can find
the IRR on the Department of Labor and Employment website3. Occupational Safety and Health Center
(OSHC): The OSHC is a government agency under DOLE that focuses on promoting occupational safety
and health. It provides training, research, and technical assistance to employers, workers, and safety
practitioners. Visit the OSHC website for resources related to material handling safety4. OSH Standards:
The OSH Standards include guidelines specific to occupational safety and health. While not exclusively
focused on material handling, they cover various aspects of workplace safety. These standards are
essential for ensuring safe practices in all industries.
8. International Organization for Standardization (ISO)
• ISO 22000: Food Safety Management Systems - This standard specifies requirements for a food
safety management system where an organization in the food chain needs to demonstrate its
ability to control food safety hazards in order to ensure that food is safe at the time of human
consumption.
• ISO 9001: Quality Management Systems - While not specific to the feed milling industry, ISO
9001 provides a framework for organizations to demonstrate their ability to consistently provide
products and services that meet customer and regulatory requirements.
• ISO 22002-1: Prerequisite programmes on food safety - Part 1: Food manufacturing - This
standard specifies requirements for establishing, implementing, maintaining, and updating
prerequisite programs (PRPs) to assist in controlling food safety hazards.
• ISO/TS 22002-6: Prerequisite programmes on food safety - Part 6: Feed and animal food
production - This technical specification specifies requirements for establishing, implementing,
maintaining, and updating prerequisite programs (PRPs) to assist in controlling food safety
hazards in the feed and animal food production sector.

9. National Organic Program (NOP)

If producing organic feed, compliance with NOP regulations is essential. This includes sourcing
organic ingredients and following specific production standards outlined by the program.

10. Quality Assurance (QA) and Quality Control (QC)

Feed mills need strong systems to make sure their feed is good enough. They should regularly
check the ingredients and finished feed to make sure they're safe, high-quality, and have the right
nutrients.

11. Hazard Analysis and Critical Control Points (HACCP)

In the feed manufacturing process, dangers like as microbial contamination are recognized and
controlled using the concepts of HACCP. Sanitation and cleaning practices are essential checkpoints to
stop the development and spread of dangerous microbes

Importance of Proper Equipment Selection, Maintenance, and Operator Training in Prevent

Accidents

1. Equipment Selection
 - Picking the correct equipment for moving materials is crucial for keeping feed mill work
safe and effective. The choice should depend on things like what materials are being
moved, how much, how the building is set up, and what the job needs. Good equipment
will have safety features like guards, emergency stops, and surfaces that are hard to slip
on. If the equipment isn't right or doesn't match what's needed, accidents could happen,
like overloading belts or using the wrong lifting machines, which could hurt people and
damage equipment.

2. Equipment Maintenance

- Taking care of material handling machines regularly is really important to make sure they
work safely and well. Doing things like adding oil, checking them, and changing parts
when needed helps find and fix problems before they cause accidents or stop the
machines from working. If we don't look after them properly, they might stop working
right, like belts getting stuck or machines breaking down, which could be dangerous and
stop work. Keeping up with maintenance also makes machines last longer, which means
they're less likely to break suddenly and need expensive fixes or replacements.
3. Operator Training

- It's really important to give equipment operators thorough training so they know how to
use material handling machines safely and well. Training should cover things like how to
use the machines, staying safe, spotting dangers, and what to do in emergencies.
Operators should learn to see potential dangers, like moving machine parts or places
where they could get hurt, and how to make them safer. Good training can stop accidents
caused by mistakes, like using controls wrong, not wearing safety gear, or not knowing
what to do to stay safe. Operators need to keep learning with regular training to stay on
top of the best ways to work safely, changes in equipment, and new safety rules.

VI. CASE STUDIES AND DISCUSSION

Present real-world examples of efficient and innovative material handling solution in feed mills

The feed mill that Pilmico is using was the vertical conveyor type due to lesser use of motor that is more
inexpensive and lower cost of power consumption, small space is needed and occupied.
Present real-world examples of efficient and innovative material handling solution in feed mills
The SCADA Control System is the innovative control system of Pilmico is using. This system can easily
detected where and what the problem of the equipment is. It is also efficient to use because it can monitor
the equipment and gives data of the process flow.

Facilitate student discussion on challenges and solutions encountered in specific material handling
application

1. The raw materials were limited during the time of crisis (Ukraine and Russia war).
Solution: They used the silos serves as a storage for their raw materials.
2. Even when COVID-19 pandemic, the company is lack of manpower.
Solution:
3. Error on the elevator bucket conveyor sensor
4. Solution: SCADA system is used to easily detect the errors of the machine.

Encourage critical thinking about optimizing systems for various production capacities and product
types
• Be mindful on the process
• Be innovative
• Be observant
• Be a problem-solver

VII. CONCLUSION

Conclusion
In conclusion, in choosing a material handling system the factors that are considered is the
cost, maintenance, energy efficiency, enhances work place safety and improve productivity. The
vertical conveyor design is most preferred by Pilmico for the reason that it just needed smaller
space.
SCADA software is the innovative system that they are using to provide networked data
communication, graphical user interfaces for advanced supervision of machines and processes.
SCADA covers sensors and monitoring using the programmable logic controller.
Students must explore advancement in technologies and joining different seminars to enhance their
ideas. Creating a new design of material handling equipment that is efficient, low cost of energy and
easy to maintain.