Technique of the mixing process in the manufacture of feed for pigs:1 Design and

construction of a feed mixer for pigs at the Industrial University of Santander

MANTILLA WHEEL ANDRÉS FELIPE - 2141800

RANGEL IANIRI CARLOS MAURICIO - 2142945

INDUSTRIAL UNIVERSITY OF SANTANDER

FACULTY OF PHYSICAL-MECHANICAL ENGINEERING
SCHOOL OF MECHANICAL ENGINEERING
BUCARAMANGA
2019

1
Technique of the mixing process in the manufacture of feed for pigs:1 Design and
construction of a feed mixer for pigs at the Industrial University of Santander

MANTILLA WHEEL ANDRÉS FELIPE - 2141800

RANGEL IANIRI CARLOS MAURICIO - 2142945

Delivery of the final project

Investigation methodology

Teacher:
SANDRA PATRICIA BASTO
Doctor in bioethics

INDUSTRIAL UNIVERSITY OF SANTANDER

FACULTY OF PHYSICAL-MECHANICAL ENGINEERING
SCHOOL OF MECHANICAL ENGINEERING
BUCARAMANGA
2019
TABLE OF CONTENTS

2
 1. DESCRIPTION OF THE PROBLEM…………………………………………………………..
…. 5 .

2. JUSTIFICATION…………………………………………………………………………..…...9
3. OBJECTIVES………………………………………………………………………………..
….11
3.1. General objective………………………………………………………………..
…..11
3.2. Specific objectives………………………………………..……………………. .
eleven
4. THEORETICAL FRAMEWORK……………………..
………………………………………………. . 12
4.1. Background of the research problem………..………………………… . 12
4.1.1. International background………………………………………………………… .
12
4.1.1.1. Balanced feed mixing machine for
preparation of multi-nutritional blocks………….…………………...….12
4.1.1.2. Production of balanced foods in a plant
processing company in the Cevallos Canton……………………………….
………...13
4.1.1.3. Design and Fabrication of Horizontal Screw Type Mixer
for Livestock Feed Meal……………………………………….………... 13
4.1.1.4. Modern food processing technology
balanced for Animals……………………………….……………….. . 14 .

4.1.1.5. Design and Fabrication of an Animal Feed Mixing

Machine…………………………….………………………………………….. .
fifteen
4.1.1.6. Design and Development of a Livestock Feed Mixer with
Spring-Controlled Packaging Unit………………………………………….. . 16
4.1.2 National Background……………………………………………….………… . 17
4.1.2.1. Redesign of the current production line for the
manufacturing of a new balanced feed reference
for pigs………………………………………………………….………..17

3
 4.1.2.2. Evaluation of the quality of extruded pellets made with
non-conventional raw materials for food
of pigs………………………………………………………….…………….18
4.1.2.3. Design of a cleaner production program for
the line of the pork sector in the food industry
balanced Italcol SA Funza…………………………….. . .……………...twenty
4.2 Theoretical References……………………………………….
………………………..21
4.2.1 Feed for pigs……………………………………………….……….. . twenty-one
4.2.1.1 Generalities…………………………………….……………………………….21
4.2.1.2 Composition and Characteristics…………………………………….
…………… . 22
4.2.1.3 Manufacturing Process…………………………………….
…………………….25
4.2.1.4 Nutritional requirements……………………………………….……..…. 25 .

4.2.1.5 Granulometry……………………………………………….………………..... . .

27
4.2.1.6 Mixing process………………………………………….……………… . 30
4.2.2 Feed mixers……………………………………………….…………….31
4.2.2.1 Vertical mixers………………………………………………………….……..32
4.2.2.2 Horizontal Mixers…………………………………………….…….... . 3. 4
4.2.2.3 Drum Mixers…………………………………………….………... . 37
4.2.3 Common problems……………………………………………….
…………………… . .38
4.2.3.1 Problems in horizontal mixers…………………………….……... 38 ..

4.2.3.2 Problems in vertical mixers…………………………………….… 39 .

4.2.4 Available materials………………………………………………….……..… . 41

4.2.4.1 Stainless steels………………………………………………………….……. 41 .

4.2.4.2 Aluminum and alloys………………………………………………….……… 42 .

4.2.4.3 Polymeric Materials………………………………………………….…….. 42 .

4.3 Conceptual
Framework…………………………………………………………………….…… . 43

4
 5. METHODOLOGICAL DESIGN……………………………….
………………………..45
5.1 Analysis of socio-environmental conditions………………………….……….. .
Four. Five
5.2 Verification of selected materials………………………….……………. Four. Five .

5.3 Realization of the digital 3D model in SolidWorks………………………….…... .

Four. Five
5.4 Development of quality evaluation methodology………………………….….46
6. SCHEDULE………………………………………………………….………. . 47
7. BUDGET……….…………………………………………………………………….48
8. BILIOGRAPHY…………………………………….………………………………… . . .

49
9. ANNEX 1………………………………………………….…………………………..50

TABLE OF FIGURES
Figure 1. Evolution of protein consumption in Colombia………………………………..23
Figure 2. Nutritional requirements of breeding pigs…………………………………… . 27
Figure 3. Nutritional requirements of Starter, Raising and Fattening pigs……. . 27
Figure 4. Shape of the blades of a food mixer ………………………………31
Figure 5. Mixing pattern in vertical mixers……………………………………… 33 .

Figure 6. Vertical floor hopper mixer………………………………………………………….. . 3. 4

Figure 7. Vertical rotary hopper mixer………………………………………………………….35
Figure 8. Mixing pattern in horizontal slat mixer………………………….36
Figure 9. Mixing pattern in horizontal paddle mixer…………………………. . 36
Figure 10. Horizontal slat type mixer……………………………………………….37
Figure 11. Horizontal type paddle mixer………………………………………………..38
Figure 12. Mixing pattern in horizontal drum type mixer…………………………. . 39
Figure 13. Mixing minutes for different RPM………………………………………… . 40
Figure 14. Wear vs. Efficiency in a horizontal mixer…………………………….40
Figure 15. Overfill analysis……………………………………………………………… . 41

5
 LIST OF TABLES
Table 1. Increase in consumption of different meats in 10 years…………………………...6
Table 2. Types of food……………………………………………………………………..24
Table 3. Effect of wet and dry ration on pig feed……………………...30
Table 4. Effect of particle size in the digestive tract in
fattening pigs………………………………………………………………. . .30
Table 5. Chemical composition of grade 300 stainless steels…………………… . 43

1. DESCRIPTION OF THE PROBLEM

According to the United Nations, the current world population is 7.6 billion people
and will reach 8.6 billion by 2030. In addition, it will reach 9.8 billion by 2050 and
11,200 by 2100.1

This alarming growth, at an approximate rate of 83 million each year, requires a

high demand for food products, such as meat, which, according to the United
Nations Food and Agriculture Organization (FAO, 2017), is estimated to be By
2050, per capita consumption of all types of meat will grow approximately 36%2 .

1
UNITED NATIONS. The world population will increase by 1 billion by 2030. Consulted on October 1, 2018.
Available at: https://www.un.org/development/desa/es/news/population/world-population-prospects-
2017.html
2
UNITED NATIONS FOOD AND AGRICULTURE ORGANIZATION. MEAT Market situation and its relevant
aspects. Consulted on October 1, 2018. Available at: http://www.fao.org/3/a-BT089s.pdf

6
Currently in Colombia this growing demand for meat is reflected with a
considerable increase compared to the last decade, this is reflected in the following
table:

Table 1. Increase in consumption of different meats in 10 years.

FOOD INCREASE FOUNTAIN
Chicken meat 65 % FENAVI (2015)3
Egg 30,7 % FENAVI (2015)4
Pork Meat 122,34 % FEDEGAN (2017)5
Beef 2,43% FEDEGAN (2017)6

Source: self made

The increase in the production of balanced foods in Colombia has "presented an

important dynamic in the growth of poultry meat production by 64.3%, pork by
15.5% and beef by 11%"7 . The remaining percentages correspond to the
manufacture of pet food.

The growing demand for meat, such as pork, requires a greater requirement for
these animals, but it is also necessary that these animals be in very good
condition, since if they present any type of defect in it, it can have a negative
impact on meat, and therefore, affect human health. One of the factors causing
these defects (problems in the growth of pigs, poor absorption of nutrients and
generation of ulcers, among others) is the food used for pig feeding, since these,
when not processed in a good way, cause these defects. drawbacks.

3
NATIONAL FEDERATION OF POULTRY FARMERS OF COLOMBIA. Statistics. Consulted on October 1, 2018.
Available at: http://fenavi.org/estadisticas/
4
Ibid.
5
COLOMBIAN FEDERATION OF LIVESTOCK BREEDERS. Meat consumption statistics. Consulted on October 1,
2018. Available at: http://www.fedegan.org.co/estadisticas/consumo-0
6
Ibid.
7
National Association of Industrialists (ANDI). Chamber of the Balanced Food Industry. Productive chain of
concentrated and balanced foods for the poultry and pork industry. Diagnosis of free competition. Colombia:
Superintendency of Industry and Commerce, 2009-2011. p. 2. [Online]. (Retrieved on September 14, 2018).
Available at: http://www.sic.gov.co/recursos_user/documentos/promocion_competencia/
Economic_Studies/FOODS%20BALANCED.pdf

7
Although the pig feed mixer is common equipment in the swine industry, current
designs present certain imperfections or points that can be optimized from a
mechanical point of view, such as the homogenization of the mixing and process
times, hence they have an impact on the quality of the processed product itself,
being controllable factors of high interest to optimize8 .

The process of mixing pig feed has long been carried out using artisanal methods.
Due to this, the quality of pork was affected by human intervention in the unification
of ingredients.

The bad reputation of pork for human consumption decreased over the years and
with changes in breeding through technological advances by companies in the pork
sector. This de-stigmatization campaign began with the implementation of good
balanced food processing practices for pig nutrition, establishing strict nutritional
parameters in the animals' food depending on their stage and development.

Inadequate mixing due to lack of uniformity of the feed will affect the distribution of
important ingredients such as vitamins, proteins, fats, fibers, medications, etc.,
which will represent a problem for the pigs and make it difficult to control their
growth and performance. physical characteristics. In addition, the following
drawbacks are highlighted in traditional mixing practices: food health problems due
to the hygiene of mixing, the environmental impact generated by the poor
management of waste produced during this process, the increase in costs due to
inability to make the most of the ingredients in the mixture, the difficulty in meeting
the nutritional demand of the animals as their consumption and marketing grows,
among others.9

8
US SOYBEAN EXPORT COUNCIL. Practical problems in the manufacture and use of food. Consulted on
February 18, 2019. Available at:
http://www.ciabcr.com/charlas/Nutricion%20Animal%202014/ProblemPract.pdf. P. 90.
9
GONZALEZ, Emilio Vargas. Mixing and uniformity problems in the animal feed industry. Consulted on
February 18, 2019. Available at:
http://www.cina.ucr.ac.cr/recursos/docs/Revista/problemas_de_mezclado_y_uniformidad_en_la_industria
_de_alimentos_para_animales.pdf. Page 8.

8
Consequently, the mixing process is one of the most important in the production of
pig feed. It is essential to ensure the correct implementation of this practice,
optimizing mixing times and improving the state of the final product, through the
design and construction of a mixer that satisfactorily meets all established
economic, hygienic, legal and engineering requirements.

Consequently, it is necessary to implement easy-to-operate equipment designed

under engineering requirements and that meets the requested hygiene
characteristics, to promote the modernization of the mixing process in the
manufacture of feed for pigs, all through the design and construction of a pig feed
mixer.

9
 2. JUSTIFICATION

Although poultry feed is the one with the greatest development and economic
growth, the campaigns carried out by the pork sector in Colombia have allowed the
population's consumption of pork to increase, and the concept that "pork is the
everyday one" (PorkColombia, 2017).

The increase in demand for this type of meat justifies the modernization of the
processes for manufacturing pig feed and the high quality standards required by
national regulatory entities, such as the National Institute for Food and Drug
Surveillance (INVIMA). .

Pork in Colombia, due to various social factors, has faced stigmatization and
rejection by the national community, despite the recent increase in the quality of
production. The invitation for new design proposals in the mechanical field, for the
sake of quality improvement, presents a strong argument that accompanies the
recent increase in pork consumption; These proposals go hand in hand with the
social change reflected in the reality of the data reported by the relevant
organizations.

From the above you can see an expectation of increase in the purchase and sale
of pork products, which implies an increase in the required production and
therefore, an optimization of times and mass flow in the various phases of the
same. . Likewise, the reduction of operating cycles allows a cut in operating costs
and power required by the different process equipment.

The implementation of the mixer also has an impact on the social sphere, since the
reduction in costs in the production of pork has reduced its price to a very

10
affordable price compared to beef and chicken. 10 , which benefits low-income
families by allowing them to consume meat.

10
GONZALEZ, Emilio Vargas. Mixing and uniformity problems in the animal feed industry.
Consulted on February 18, 2019. Available at:
http://www.cina.ucr.ac.cr/recursos/docs/Revista/problemas_de_mezclado_y_uniformidad_en_la_ind
ustria_de_alimentos_para_animales.pdf . Page 8.

11
 3. GOALS
3.1 General objective

- Build a prototype of a horizontal helical belt mixer for pork feed in

order to improve its quality, using local and relevant ingredients in
the national framework.

3.2 Specific objectives

 Analyze the socio-environmental conditions of the Santander

region for the implementation of the mixing machine without
generating negative impacts on society.

 Verify that the ingredients selected for the food do not cause
malfunctions in the equipment such as corrosion or high wear.

 Make a digital model of the mixer using computer-aided design

tools such as SolidWorks 2018 software as a support method for
3D visualization of the machine.

 Develop a methodology that allows verifying the quality in the

homogenization of the ingredients necessary for the manufacture
of pig feed, complying with the legal regulatory parameters
established at the national level.

12
 4. THEORETICAL FRAMEWORK

4.1 RESEARCH BACKGROUND

Below are some previous research works of international and national

scope, which are related to our selected project. This provided us with
valuable data that helped us resolve certain doubts that existed in some
areas, as well as complement some previously defined approaches.

4.1.1 International background

4.1.1.1 Balanced feed mixing machine for the production of

multinutritional blocks.11

The objective of the project was to mechanize the balanced feed mixing
process to obtain a homogeneous mass in any proportion for the production
of multinutritional blocks.

A machine was designed based on a prior analysis of its main components,

such as the container, the mixing shaft, among others. Said analysis
consisted of determining the dimensions, materials and loads that will be
applied to these elements, as well as the costs of these elements. All this in
order to know if the design they selected is optimal for the work they will do.
After this first exhaustive analysis, other elements were decided, such as
the electrical system (motors, control system).

The results obtained with this design were a reduction in mixing time
compared to other machines on the market, without sacrificing the quality of
homogenization.

This project provides the idea of implementing a control system, in order to

be able to monitor at all times that the mixing process is being done without
any problem.

11
MANYA, Diego Javier. Balanced feed mixing machine for the production of multi-nutritional blocks. Degree
work: Technical University of the North. Ibarra, Ecuador. 2014. Consulted on February 5, 2019. {Available at:
http://repositorio.utn.edu.ec/bitstream/123456789/2790/1/04%20MEC%20039%20TESIS.pdf}

13
 4.1.1.2 Production of balanced foods in a processing plant in the
Cevallos Canton12 .

The objective of this project was to design a balanced food processing plant
in an area with high volcanic activity, in order to protect food crops from
volcanic ash.

First, a study of the land was carried out to see if it was possible to have the
plant in that location, after verifying that it was, the company set out to
purchase all the required machinery, both for the construction of the facility
and for the production activity of food.

The results generated in this project consist, mainly, in the protection of the
components of the balanced food. Also by having a production plant near a
community with strong agricultural activity, food shipping costs are reduced,
thus generating greater profits.

This project provided knowledge about some components of pork feed that
can cause corrosion in the mixing shaft, for which a special coating will be
selected for the shaft to prevent said corrosion.

4.1.1.3 Design and Fabrication of Horizontal Screw Type Mixer for

Livestock Feed Meal13

The objective of this work was to meet the need for the design and
construction of a livestock feed mixing machine, improving mixing times and
production efficiency, for small-scale livestock producers. Mixing times vary
depending on the design, so a horizontal screw type mixer was chosen to
reduce these times.

The horizontal screw type livestock feed mixer was manufactured using
metal working concepts. The main components are the casing, hub, rotor
assembly and gearbox. The experimental design was carried out to obtain
the performance of the machine with regard to the transmission by pulleys,
number of blades and the transmission ratio in the box. The machine used
pulleys of four (4) inches in diameter and seven (7) inches between the
12
CHACHAPOYA, Diego Leonardo. Production of balanced foods in a processing plant in the Cevallos Canton.
Degree work: National Polytechnic School. Quito, Ecuador. 2014. Consulted on February 5, 2019. {Available
at: http://bibdigital.epn.edu.ec/bitstream/15000/8927/3/CD-5974.pdf}
13
REYNANTE, Jayson. Design and Fabrication of Horizontal Screw Type Mixer for Livestock Feed Meal. JPAIR
Multidisciplinary Research. 2014. Ilocos Sur, Philippines. Accessed February 20, 2019. {Available at:
https://www.researchgate.net/publication/287503864_Design_and_Fabrication_of_Horizontal_Screw_Type
_Mixer_for_Livestock_Feed_Meal}

14
 motor and the box, connected by V-belts; 8 vanes were installed on the rotor
shaft for better mixing capacity. The driving gear was designed with
eighteen (18) teeth on the upper sprocket and thirty-six (36) on the lower
sprocket to obtain better mixing of the materials. Power is provided by a
half-horsepower (0.5 Hp) electric motor. The machine produces an average
of 15 kilograms in two minutes.

The construction details of this machine are of extreme relevance due to the
similarity of the project, it being imperative to highlight that the desired
production for the case itself is much greater, since it is desired to be
implemented in medium and large pig feed production plants. scale. The
decision points and the factors that guided these decisions are important,
since differences in environments and regulations can modify the
parameters of the machine itself.

4.1.1.4 Modern technology for the production of balanced feed for

animals14

The objective of this project was to determine the operation and evaluation
variables in detail of the equipment of Chinese origin acquired by the
company Agro Industrial Alimentos Procesados SA for the increase in its
production of food for various types of animals such as poultry, cattle and
pigs. , among others.

The production method begins by mixing the raw material, grinding it, mixing
the ground, then it goes to the pelletizing press and/or the extruder,
obtaining pelletized pellets and extruded pellets, respectively. To increase
productivity, lower costs, meet increased customer orders and improve
technology; The company decided to expand the plant to 2500 MTPM in the
pellet mill and 250 MTPM in the extruder. The analysis of the acquired
machinery was carried out: coarse and fine grinding mills, horizontal helical
belt mixer and pelletizing press.

The relevance of this project for the manufacture of the own mixer lies in the
analysis of an already functional machine acquired by an industrial company
of considerable production, whose characteristics are significantly similar to
those desired by the own project.

14
MARTINEZ, Roberto Godofredo. Modern technology for the production of balanced food for animals.
Degree work: National University of San Agustín de Arequipa. Arequipa, Peru. 2018. Accessed February 20,
2019. {Available at: http://repositorio.unsa.edu.pe/handle/UNSA/7533?show=full}

15
 4.1.1.5 Design and Fabrication of an Animal Feed Mixing Machine 15

In this project, a livestock feed mixing machine was designed, manufactured

and tested. The computational requirements of 25 kg of feed mass were
carried out in MS Excel for an appropriate design. The machine was built
using Creo parametric design software and the appropriate material
selection was made prior to the assembly and manufacturing of the parts.
High efficiency values, low production costs and a high quality post-mixed
feed were obtained. The tests were carried out using: 3.5 kg of corn bran,
1.25 kg of cotton and sunflower cake, 0.15 kg of lime, 0.075 kg of bone meal
and 0.018 kg of salt. It was mixed 3 times in periods of 10 and 20 minutes.
The average CV obtained was 5.93%, which shows a significant reduction in
the feed components in the tested samples. The mixing degree was
94.06%.

This work allowed us to compare the results obtained by a manual mixing

machine, with a design similar to our own, so that various characteristics
and considerations could be taken into account when designing our own
mixing machine. The use of a motor as a power transmission method for the
mixing process allows constant revolutions to be obtained, which allows the
mixing to be more uniform and effective, unlike the mixing carried out by an
operator manually, which at a certain point becomes tires and reduces
mixing rpms.

4.1.1.6 Design and Development of a Livestock Feed Mixer with Spring-

Controlled Packaging Unit16

The objective of this project was the design, construction and testing of a
spring-controlled vertical livestock feed mixer. The design was focused on
weight and the calibration mechanism, which allowed a semi-automatic
cover in conjunction with the mixing and discharge operations. The main

15
. MAKANGE, Nelson; PARMAR, Raghuvirsinh & SUNGWA, N. Design and Fabrication of an Animal Feed
Mixing Machine. Advances in Life science,. 2016. Consulted on March 4, 2019. {Available at:
https://www.researchgate.net/publication/304169982_Design_and_Fabrication_of_an_Animal_Feed_Mixin
g_Machine}
16
OLANIYAN, Adesoji & ODEWOLE, Michael. (2013). Design and Development of a Livestock Feed Mixer with
Spring-Controlled Packaging Unit. International Journal of Engineering Research in Africa. Hey Nigeria. 2013.
Consulted on March 4, 2019. {Available at:
https://www.researchgate.net/publication/272607972_Design_and_Development_of_a_Livestock_Feed_Mi
xer_with_Spring-Controlled_Packaging_Unit}

16
components of the machine include a double-walled cylindrical mixing
chamber, with a recycling, discharge and evacuation gate; window and a
transport screw in the internal cylinder. The packing mechanism was
connected to the discharge gate and the base of the frame being the
structural support of the machine.

The main design parameters of the conveying screw were helix angle, filling
ratio, normal pressure due to feed loading, axial force per step, total screw
torque, capacity and required power. The conceptual design of the packing
mechanism involved determining the free spring length, total active length,
spring pitch, spring rate, stiffness, maximum shear stress, and total spring
velocity. Preliminary tests were carried out to determine the discharge rate
and performance of the packed mechanism, the results showed an average
discharge of 0.356 kg/s. Powered by a 2-horsepower (Hp) single-phase
electric motor, the machine has a mixing capacity of 4,124 m3/h with a
production cost of $470.

17
 4.1.2 National background

4.1.2.1 Redesign of the current production line for the manufacture of a

new reference of balanced feed for pigs17 .

The objective was to redesign the current production line for the manufacture of
a new reference of balanced concentrate for swine using quantitative industrial
engineering tools to support the growth of the company in a profitable way.

In the first instance, the current production line was reviewed, as well as the
food ingredients in search of components that could slow down production or
reduce quality. Then, carrying out an economic and engineering analysis, the
plant was restructured, changing machinery that delayed the process for new
ones that, in addition to replacing the previous ones, have better work efficiency
and energy consumption, which results in greater economic benefits.

The application of this project generated good results in the company, such as
better food quality, since having carried out an exhaustive analysis, certain
ingredients were determined that delayed the homogenization time, causing it
to not be in the best way. , causing a decrease in its quality. Another positive
result was the renewal of equipment, since this allowed them to produce
greater food, generating greater profits.

The contribution of this work is the in-depth analysis of the components of the
pig feed, since these, having different densities, the mixing requires greater
power or longer mixing time, since by not making any of these options the feed
It will not come out in its optimal conditions.

4.1.2.2 Evaluation of the quality of extruded pellets made with non-

conventional raw materials for pig feeding18

17
RODRÍGUEZ et al. Redesign of the current production line for the manufacture of a new reference of
balanced feed for pigs. Degree work: Pontifical Javeriana University. Cali, Colombia. Consulted on February
5, 2019. {Available at:
http://vitela.javerianacali.edu.co/bitstream/handle/11522/10364/Rediseno_de_la_linea.pdf?
sequence=8&isAllowed=y}
18
MOSQUERA, Dissa Enith. Evaluation of the quality of extruded pellets made with non-conventional raw
materials for pig feeding. Master's thesis: National University of Colombia. Bogota Colombia. 2015. Accessed
February 20, 2019. {Available at: http://www.bdigital.unal.edu.co/48701/}

18
The objective of this research was to evaluate the nutritional value of various
non-conventional raw materials for feeding pigs in the pre-fattening phase,
extruded in the form of pellets.

The chemical compositions and digestibility of the selected foods were

determined as a first step. These materials were Colacassia esculenta,
Artocarpus altilis and Gustavia superba, as well as agricultural by-products
such as shells of Bactris gasipaess and Musa paradisiaca ; The leaves of
Artocarpus altilis and the peels of Bactris gasipaess were selected for their
composition and availability, and balanced diets were formulated based on this.
The diets were formulated taking into account food drying times of 6 and 12
hours, and the size of each ingredient was estimated.

For the pelletizing process, extrusion tests were carried out and humidity and
hardness in the pellets were evaluated. Finally, the digestibility of the extruded
pellets in vitro was verified.

In this research it was found that regarding the presence of anti-nutritional

factors in forages, they do not contain alkaloids and coumarins, however, they
present different proportions of flavonoids, tannins and phenolic complexes. In
relation to the content of microorganisms in the by-products, the Chontaduro
and Plantain peels presented a high proportion of mesophilic aerobic bacteria,
the content of mold and total coliforms in Plantain peels is high, and no
Escherichiae coli or Salmonella bacteria were found. in no byproduct.

On the other hand, in vitro digestibility analyzes indicated that Chontaduro

peels and Achín leaves presented greater prececal digestibility of dry matter
with 79.17 and 69.75%, respectively; while, cecal digestibility was higher in
Plantain peels with a gas production of 244.37 ml, followed by Chontaduro
peels (223.80 ml).

It was observed through drying curves that with respect to the drying time of
Breadfruit leaves and Chontaduro peels, the moisture content tends to be
stable after 10 hours of processing. The final moisture content (dry basis) was
3,456 kg of vapor/kg of water for Breadfruit leaves and 1,195 kg of vapor/kg of
water in Chontaduro peels; while the proportion of free moisture was 0 kg of
water/kg of dry solid. Regarding the evaluation of particle size, the ingredients
that accompanied the raw materials described above presented an irregular
size, therefore, they were sieved with a 350 µm mesh for use in the diets.
Regarding the extrusion tests, the pellets extruded at a temperature of 140°C

19
and mass humidity of 20%, presented higher hardness results. Finally, better in
vitro prececal digestibility of dry matter was obtained with the diets T1 breadfruit
leaves inclusion 10% (81.75%), T4 Chontaduro peels 20% (81.35%) and TC
diet control conventional food ( 80.62%); In turn, for cecal in vitro digestibility,
the highest gas production was presented by diets T3 (243 ml of gas / g of dry
matter), TC (200 ml of gas / g of dry matter) and T4 (198 ml of gas / g of dry
matter).

The relevance of said research for this work lies in the evaluation of the impact
on the digestibility of the evaluated raw materials, particularly in the Bogotá
area, as well as the pelleting process as a reference for the optimal mixing
results desired in order to reduce power consumption in subsequent processes
of pig feed manufacturing. Likewise, the components to be mixed may present
drawbacks in the mixing process depending on their topology or composition,
so the consideration of additional coatings and health precautions during the
process is of vital importance.

20
 4.1.2.3 Design of a cleaner production program for the pork sector line in
the balanced food industry Italcol SA Funza19

The objective of this work was to diagnose the critical points of operation in the
food development process for the pork sector at the Italcol SA plant in Funza,
Cundinamarca; in order to reduce the environmental impact and pollution of
various kinds produced in said critical points.

The equipment in the plant, due to its magnitude, use, and low maintenance
frequency, generate high levels of noise, which affects the community
surrounding the Francisco Martínez Rico neighborhood. This physical structure
requires a large amount of natural resources for its operation, generating
polluting emissions into the atmosphere (CO, CO2, particulate matter, SOx,
NOx) mainly due to the use and operation of the boiler, which generates steam
and heat necessary to transform raw materials.

Italcol SA produces environmental impacts affecting the quality of air and water.
To establish the degree of said impact, the recognition of the facilities was
developed and statistical data on production, use and cost of raw materials in
the production of food and products were included. consumables used. The
environmental diagnosis was completed, where the characterization and
physical-chemical analysis of the impacted media was carried out (occupational
noise, air quality, generation of solid and hazardous waste, and the level of
lighting and thermal stress were evaluated). Through the different diagnostic
tools (MED Matrix, SWOT Matrix, and Leopold Environmental Impact Matrix),
the results were obtained where critical operating points were identified, which
are (Pelletizing, Grinding, and Boiler), and environmental impact. . Cleaner
production alternatives were formulated where the analysis of the alternatives
and the costs of each of these was carried out.

This work allowed us to verify the sources of contamination produced in the

mixing process and their possibilities of becoming critical points, in a real
industrial environment. Various points of relevance in the pelletizing process
are directly linked to the mixing process, so it was imperative to analyze the
factors that affect the process developed by Italcol SA in said plant as a
reference to polish the details of the mixing machine. of this work.

19
ALDANA, Karen Gineth and DAZA, Mayra Paola, Design of a cleaner production program for the pork
sector line in the Italcol SA Funza balanced food industry. Degree Project: De la Salle University. Bogota
Colombia. 2015. Accessed February 20, 2019. {Available at:
http://repository.lasalle.edu.co/handle/10185/18000}

21
 4.2 THEORETICAL REFERENCES

In this section, the theoretical foundations that govern the selected project will
be explained in a clear and concise manner, so that the reader can learn all the
science behind something like a pig feed mixer.

4.2.1 Pig feed20

4.2.1.1 Generalities. According to statistical data, pig feeding represents

approximately 80% of production costs in a piggery.

Therefore, it is vitally important for the owner(s) to understand the theoretical

principles of correct nutrition and how to achieve it easily and economically, in
order to establish feeding strategies based on efficiency and effectiveness to
add to the final result a business with good profits and with pigs of high quality
standards.

Although the increase in imports of pork at low prices does not entirely mean
that the consumption of this product in the country increases abruptly, since a
good percentage of the population refrains from consuming it due to the high
bacterial index that this food contains. It entails, and in this case, correct pig
feeding (in addition to other care), contributes greatly to reducing these health
risk rates, always focused on offering a quality product.

Despite all these drawbacks, pork consumption in Colombia has had notable
growth, above other types of proteins (see Figure 1).

Figure 1. Evolution of protein consumption in Colombia

20
VEGA, Juan Pablo. Pork consumption in Colombia grew 56% during the last five years. [Online]. In the
Republic. Bogotá DC 7, April, 2018. (Retrieved on September 14, 2018).

22
Source: Available at: https://www.larepublica.co/economia/consumo-de-carne-de-cerdo-en-el-pais-crecio-56-
en-los-ultimos-cinco-anos-2710218

There are several concepts that a pig farmer must take into account to achieve a
feeding program that is efficient so that the product reaches weight in the shortest
possible time and in good health conditions, in addition to obtaining sows with a
high productive capacity of piglets; the above taking into account that there are
different breeds of pigs, which have different feeding schemes.

The most important aspects that must be known for an optimal production process
are the life stages, the nutrients with which the animal must be fed, the ingredients
and what components they contain, with emphasis on economical food, of good
quality and that is of taste for the pig.

4.2.1.2 Composition and characteristics. It is important to produce quality food

for pigs, and to achieve this, certain factors must be considered to ensure this
objective:

 Quality of raw material.

 Adequate nutritional composition of the food.
 Processing under hygiene and health standards.
 Management and disposal of food in its final stage.

The types of ingredients in pig feed (see Table 1) are summarized from the
information presented by Yoedil Parra.21

One of the most relevant considerations in the form of feed for pigs is that it should
be preferred in granules. In the diet, the amount of dust in the food can have
detrimental repercussions on the animal's health, and also hinder the efficiency of
production lines.

Additionally, it is worth highlighting the ease with which pigs ingest food in the form
of pellets.
21
PARRA, Yoedil. Four important aspects in pig feed that will help in pig production. [Online]. Agronomaster.
(Retrieved on September 14, 2018). Available at: http://agronomaster.com/alimento-para-cerdos/

23
Table 2. Types of ingredients in pig feed

Source: Prepared by authors.

Kevin González , a zootechnician with a specialization in project management,

specifies that the ingredients in the production of pig feed depend mainly on the
species, sex and the productive stage in which they are found. Likewise, it
establishes that "the most important nutrients are those that provide energy
(carbohydrates and fats), protein (amino acids), minerals (macro and micro-
minerals), vitamins (fat-soluble and water-soluble) and water" 22 . Pig feed is made
up of the following nutrients:

 Energy: It is one of the most important for fattening pigs. They must be
handled with care to avoid contamination and their nutritional
characteristics.

The main ones are obtained "from distillers grains such as: wheat, corn,
sorghum and barley, depending on availability and costs."23

 Proteins: The adequate percentage value of proteins ingested by the pig in

its diet is a determining factor in the correct proportion of amino acids.

According to González24 The main sources of protein are:

Cereals such as corn, wheat, sorghum and barley are the primary ingredients
that, in addition to providing energy to the diet, provide between 30-60% of the
total requirement for amino acids. (…) Among the essential amino acids that are

22
GONZÁLEZ, Kevin. Pig feed. [Online]. Sucre: University of Sucre. 2018. (Retrieved on September 14, 2018).
Available at: https://laporccultura.com/alimentacion-del-cerdo/alimentos-para-cerdos/
23
GONZÁLEZ, Kevin. Pig feed. [Online]. Sucre: University of Sucre. 2018. (Retrieved on September 14, 2018).
Available at: https://laporccultura.com/alimentacion-del-cerdo/alimentos-para-cerdos/
24
Ibid.

24
 supplemented are lysine, methionine, cysteine, threonine, leucine, isoleucine,
tryptophan and arginine.

 Minerals: They influence the bone growth of pigs and the

development of certain biological functions.
Because some are not provided in the food, the amount and type of
minerals that are added through extra procedures on the animal will
limit those that must be added to the food.

Particularly, "the sources of microminerals are iron, zinc, copper, selenium,

iodine."25

 Vitamins: Necessary for the metabolic stimuli that pigs require at different
stages of their growth.

 Pre-mixes: They are responsible for supplementing the deficiencies

presented in the majority of additions of energy nutrients, proteins, minerals
and vitamins.
Generally, "pre-mixes are prepared by including in the final mixture, levels
greater than 1% of minerals (Calcium, Phosphorus, Magnesium, Sodium),
synthetic amino acids, micro-minerals (Zinc, Iron, Copper and Selenium),
vitamins and additives".

4.2.1.3 Manufacturing process26 . The manufacturing process of balanced feed

for pigs (and for other types of farm animals) is based on the transformation of
different raw materials with unique chemical and physical characteristics, which
were selected to effectively satisfy the nutritional requirements of pigs.

The technical and technological processes most used in the production of

balanced foods, according to Hans Mann, are:

 The grinding.
 The mixed.
 The pre-conditioning.
 The molasses.
 The pellet mill.
 Cooling and drying.

25
Ibid.
26
MANN, Hans. Balanced food: from manufacturing in a food plant to consumption on farms. [Online].
Engormix. Guatemala: Central Agricultural Group. 2010. (Retrieved on September 15, 2018). {Available at:
https://www.engormix.com/avicultura/articulos/fabricacion-de-alimento-balanceado-t28616.htm}

25
For the development of this work, attention will focus on the mixing process.
"Mixing is so critical, especially when it comes to additives that are delicate in use,
or that are limiting in the development of the pig in its evolutionary stages." If the
objective of mixing (to homogenize all the ingredients satisfactorily) is not met, the
uniformity of the pigs will be disastrous for the production of this type of meat on
farms.

4.2.1.4 Nutritional requirements of the pig during its growth27 .

The amount of nutrients that make up pig feed depending on their stage of
development (breeding, starters, rearing or fattening), and the suggested
frequency of consumption, are shown in Figures 2 and 3.

27
CIPA. Pork products. [Online]. (Retrieved on September 14, 2018).

26
 Figure 2. Nutritional requirements of pigs in breeding

Source: Available at: http://www.cipa.com.co/productos-cipa/porcícola/

Figure 3. Nutritional requirements of starter, raising and fattening pigs

Source: Available at: http://www.cipa.com.co/productos-cipa/porcícola/

27
4.2.1.5 Granulometry. The size of the grains in pig feed can significantly
influence the digestion of the nutrients that these foods contain and, as a
consequence, the maximization of the response by the animal.

Due to this, there is a process called milling, which has the task of reducing the
size of the grains with the sole purpose of improving their nutritional value,
basically producing an improvement in their digestibility by reducing the particle
size. It is as Peducassé explains28 In his degree thesis, it has been shown that the
smaller the size of the grain, the greater the digestive action and allows the
production of liquids from the digestive system, and a greater condition for the
action of enzymes specialized in breaking down the raw material.

Another point in favor presented by Peducassé29 is that the rate of passage

through the gastrointestinal tract is decreased, further increasing the feed
conversion. At the same time, the work of chewing is reduced, which is a waste of
energy, saving time in ingestion and the energy that would be used for this
purpose, achieving quantifiable benefits with the simple fact of breaking up the
grain.

The main energy component of pig feed is corn, which if its granulometry is not
well controlled can influence technical and economic aspects such as production
costs, nutrient digestibility, animal performance, development of lesions.
esophago-gastric, among others, so a good corn grinding process is of vital
importance.

Although corn has a high energy component, it is more difficult to reduce its size
compared to grains such as sorghum and wheat, which makes the implementation
of these grains worthwhile since, despite not having as much energy as corn, corn,
since these can be more compacted, there may be a greater concentration of
sorghum and wheat in the feed, which increases the amount of energy provided to
the pig.

For Goodband, et al cited by Peducassé:

In the past there has been confusion regarding the optimum particle size in
swine feed. This is due to a very broad generalization in the particle size
classification for diets, these terms are: fine, medium or coarse, recently a more
precise classification method has been developed, based more properly on the
28
PEDUCASSE, J. M. Granulometry monitoring of corn and sorghum in pig rations. [Online]. Degree thesis for
a degree in Veterinary Medicine. Santa Cruz: Gabriel René Moreno Autonomous University. Faculty of
Veterinary Medicine and Zootechnics, 39p. (Retrieved on September 15, 2018). {Available at:
http://www.ciap.org.ar/ciap/Sitio/Archivos/MONITOREO%20DE%20GRANULOMETRIA%20DE%20MAIZ%20Y
%20SORGO%20EN%20RACIONES%20PARA%20CERDOS.pdf}
29
Ibid,

28
 Mean Geometric Diameter (GMD). ) of the particles measured in micrometers
(µm) and the Standard deviation of the mean of the geometric diameter of the
particles or their distributions, these measurements allow greater precision in
the definition of the particle size and allow us to make more specific
recommendations to optimize pig performance.30

Due to the careless way in which the pig ingests food, the animal can be
prone to respiratory diseases because very fine particles are introduced
into its respiratory system. To avoid this problem, alternatives are
considered in the presentation of ingredients, for example, moistening,
presenting food in liquid form, pelleting or “granulating” the ration.

Table 2 shows the way in which the supply of food in liquid or pelleted form
influences the digestibility and use of nutrients.

Table 3 shows the effect of particle size in pig feed. These reduced particle
sizes can generate ulcerations in animals, so we must know the ideal
particle size to use most efficiently in feeding.

30
GOODBAND, D. R.,et al. General nutrition principles for swine. Cited by PEDUCASSÉ, J. M. Granulometry
monitoring of corn and sorghum in pig rations. [Online]. Degree thesis for a degree in Veterinary Medicine.
Santa Cruz: Gabriel René Moreno Autonomous University. Faculty of Veterinary Medicine and Zootechnics,
39p. (Retrieved on September 15, 2018). {Available at:
http://www.ciap.org.ar/ciap/Sitio/Archivos/MONITOREO%20DE%20GRANULOMETRIA%20DE%20MAIZ%20Y
%20SRGO%20EN%20RACIONES%20PARA%20CERDOS.pdf}

29
Table 3. Effect of wet and dry ration on pig feed.

Source: Available at: http://www.ciap.org.ar/ciap/Sitio/Archivos/MONITOREO%20DE

%20GRANULOMETRIA%20DE%20MAIZ%20Y%20SORGO%20EN%20RACIONES
%20PARA%20CERDOS.pdf

Table 4. Effect of particle size on the digestive tract in feeding pigs

for fattening

Source: Available at: http://www.ciap.org.ar/ciap/Sitio/Archivos/MONITOREO%20DE

%20GRANULOMETRIA%20DE%20MAIZ%20Y%20SORGO%20EN%20RACIONES
%20PARA%20CERDOS.pdf

The recommended particle size consists of an average of 700 µm of mean

geometric diameter, however the production or processing of grains in
some grinding equipment is not uniform, which is why it is handled in a
range of 500 to 800 µm. , to obtain good results.

30
4.2.1.6 Food mixing process. The pig feed mixing process consists of
a mechanical process in which the previously ground raw material and
injected liquids and micro-ingredients are introduced into a container.

Samuel Maya31 He explains in his degree thesis that for this part of the process,
which is called dry mixing, an approximate time of 30 seconds is assigned to
achieve a homogeneous mixture. After this sub-process, some pre-mixes, amino
acids or medications are added to improve the conditions of the pig and the
injection of oil and molasses is also carried out and a second mixing process is
carried out, called wet mixing, which takes 180 minutes. seconds to complete. The
entire process, from pouring the elements to leaving the already mixed food to
continue with the rest of the production line, requires approximately 7 minutes.

The mixing is done in a container that contains an axis, which has blades or
propellers that rotate with the intention of mixing the ingredients found in the
element. This rotation is achieved thanks to the drive of a belt system, and the
implementation of an electric motor.

Figure 4. Shape of the blades of a food mixer.

Source: ALLBIZ, International Center for Electronic Commerce. Food mixer. [Online]. (Retrieved on September
15, 2018). Available at: https://ve.all.biz/mezclador-de-alimentos-g6106

The process not only consists of the aforementioned, it is also a

fundamental stage to control certain factors that can be generated before
or during the mixing process, because when omitted, they can affect the
31
MAYA HENAO, Samuel. Balanced food production processes: COLANTA Itagüí concentrate plant. [Online].
Degree thesis for the title of Zootechnics. Caldas: Lasallian University Corporation. Faculty of Agricultural
Administrative Sciences, 2016, 65p. (Retrieved on September 15, 2018). {Available at:
http://repository.lasallista.edu.co/dspace/bitstream/10567/1492/1/
Procesos_Produccion_Alimentos_balanceados_COLANTA.pdf}

31
quality of the animal's feeding, and in turn generate negative effects on the
pig that will consume that food.

Emilio Vargas expresses in his research work that:

These factors can be: The characteristics of the ingredients, insufficient

mixing time, overload of the mixer, overuse of the mixer, dirt in the
mixing system, poor sequence in the addition of ingredients, weighing
errors, post-mixing segregation and deteriorated mixing equipment.32

4.2.2 Pig feed mixers . One of the most important aspects in the agricultural
industry is the nutrition of the animals, therefore, it must be ensured that each
animal receives the required amount of nutrients, for which a good mixing process
is necessary, otherwise, it could cause a serious consequence on the correct
feeding of animals.

Efficient mixing occurs when there is a maximum of movement in the particles of

the mixture, that is, each particle of an ingredient must give way to another while
the movement occurs.

As we know, each ingredient has different physical or chemical characteristics that

can affect the mixing process in one way or another, however, the characteristic
that most affects said process is the size of the particle, in theory, if all the
ingredients' particles were Likewise, mixing would be very simple, however, this
does not happen in reality, in practice we find a great variety of sizes, therefore
more time and certain strategies will be required to achieve the ideal mixing of the
food.

Throughout history and the confrontation of different types of problems in this area
of application of knowledge, different ways of mixing have been found for different
types of needs. Based on studies and empirical knowledge, humanity has found
three basic types of mixers:

 Vertical mixers.
 Horizontal mixers.
 Horizontal slat or ribbon mixers.
 Horizontal paddle mixers.
 Drum or tombola mixers.

32
VARGAS GONZÁLEZ, Emilio. Mixing and uniformity problems in the animal feed industry. [Online]. San
José: University of Costa Rica. (Retrieved on September 15, 2018). {Available at:
http://www.cina.ucr.ac.cr/recursos/docs/Revista/problemas_de_mezclado_y_uniformidad_en_la_industria
_de_alimentos_para_animales.pdf}

32
4.2.2.1 Vertical mixers. In this type of mixers very little feed is mixed at the
same time and this is because the ingredients move from an elevator and a worm
causing the feed to recirculate throughout the mixer, see Figure 5.

Figure 5. Mixing pattern in vertical mixers

Source: Available at: http://www.perulactea.com/2016/06/28/la-mezcla-tambien-cuenta-importancia-

de-un-buen-mezclado/

However, we can realize that the mixing process itself occurs thanks to the
elevator tube, therefore, not all the food is being mixed at the same time, which will
make it take longer for the food to reach its uniformity, times are approximately 13
minutes for a single worm; However, if a double worm system is used the time can
be reduced to approximately 9 minutes, which is important for an industry where
feed is required continuously.33

These mixers were designed to mix flour-based foods such as concentrates or

pastas for pigs, cattle and poultry. We can realize that these foods are dry because
if this were not the case or if some liquid substance were introduced , said
substance would accumulate at the bottom of the mixer causing mechanical
damage, mainly to the machine's bearing.

In the industry there are two types of vertical mixers:

 Floor hopper (see Figure 6).

 Rotating hopper (see Figure 7).

The difference between these two types lies in the change in the mixing formula,
which brings with it different consequences in the maintenance of the machine and
in its use due to its cleanliness.

The floor hopper is used when a constant change of the mixing formula is not
required, which makes it ideal for large quantities, that is, industrial productions.
And the rotating hopper is the opposite, it is used when a constant change in the
33
ZALDIVAR VALER, Ramón. The mixture also counts: importance of good mixing. [Online]. June 28, 2016.
Perulactea. (Retrieved on September 16, 2018). {Available at: http://www.perulactea.com/2016/06/28/la-
mezcla-tambien-cuenta-importancia-de-un-buen-mezclado/}

33
mixing formula is required, which consequently brings with it a greater cleaning
frequency for the same use.

The two types of mixer can have a range of capacities from 250 kg to 2000 kg of
dry food, they can use transmissions with different types of motor, whether electric
or internal combustion, there are certain types of food that are not recommended
since they are very light and their characteristics do not allow correct recirculation
through the mixer or correct functioning of the worm, these foods are: cotton
seeds, rice hulls, ground stubble, alfalfa, etc.34

Figure 6. Vertical floor hopper mixer.

Source: Available at: https://www.engormix.com/balanceados/articulos/mezcladoras-horizontales-

mezcladoras-verticales-t32672.htm

Figure 7. Vertical rotating hopper mixer.

34
MOLINOS AZTECA, Technical Department. Horizontal mixer vs. vertical mixers. [Online]. October 19, 2015.
Engormix. (Retrieved on September 16, 2018). {Available at:
https://www.engormix.com/balanceados/articulos/mezcladoras-horizontales-mezcladoras-verticales-
t32672.htm}

34
Source:Available at: https://www.engormix.com/balanceados/articulos/mezcladoras-horizontales-
mezcladoras-verticales-t32672.htm

4.2.2.2 Horizontal mixers. Mixers designed so that all food particles are
in constant movement. It is as specified by Ergomix35 , horizontal mixers can mix
concentrates, grains, agricultural waste, pastes and foods with molasses or
another different type of liquid, whether viscous or not, producing a homogeneous
mixture in a time of approximately 3 minutes.

Due to the constant stress of the components of these mixers, a much more
resistant material is required compared to vertical mixers, which makes this type of
mixers much more expensive. They have the disadvantage that most of them are
stationary and the advantage that their wear is much less compared to other
mixers.

In the industry, two types of horizontal mixers are known, their difference being in
the mixing pattern, as follows:

 Of slats or ribbons (see Figure 8).

 From pallets (see Figure 9).

Figure 8. Mixing pattern in horizontal slat mixer

35
MOLINOS AZTECA, Technical Department. Horizontal mixer vs. vertical mixers. [Online]. October 19, 2015.
Engormix. (Retrieved on September 16, 2018). {Available at:
https://www.engormix.com/balanceados/articulos/mezcladoras-horizontales-mezcladoras-verticales-
t32672.htm}

35
Source: ZALDIVAR VALER, Ramón. The mixture also counts: importance of good mixing. [Online].
June 28, 2016. Perulactea. (Retrieved on September 16, 2018). Available at:
http://www.perulactea.com/2016/06/28/la-mezcla-tambien-cuenta-importancia-de-un-buen-
mezclado/

Figure 9. Mixing pattern in horizontal paddle mixer.

Source: ZALDIVAR VALER, Ramón. The mixture also counts: importance of good mixing. [Online].
June 28, 2016. Perulactea. (Retrieved on September 16, 2018). Available at:
http://www.perulactea.com/2016/06/28/la-mezcla-tambien-cuenta-importancia-de-un-buen-
mezclado/

 Horizontal slat or ribbon mixers.

36
The main feature of this mixer is the helical rotating metal belts (see Figure 10),
which make the food move vertically and horizontally through it, with a mixing time
estimated by Engormix of only three (3 minutes.

The capacity of this type of mixers can vary depending on its transmission and
motor, for electric motor, geared motor or tractor force its capacity varies from 250
kg to 1000 kg and for arrow-mounted motor or geared motor its capacity varies
from 2000 kg to 5000 kg .36

Figure 10. Horizontal slat type mixer.

Source: MECALUX, Logismarket. Jersa ribbon mixers. [Online]. (Retrieved on September 16,
2018). Available at: https://www.logismarket.cl/maquinaria-jersa/mezcladoras-tipo-pantalon-
liston/6657268138-5465227200-p.html

 Horizontal paddle mixers.

This type of mixer has paddles to carry out the mixing process, as shown in figure
11. In industry, its use is mainly in pigs, cattle and poultry, it has the drawback that
it takes a little longer than the helical belt mixer (5 min for mixing).

Figure 11. Horizontal paddle mixer.

36
MOLINOS AZTECA, Technical Department. Horizontal mixer vs. vertical mixers. [Online]. October 19, 2015.
Engormix. (Retrieved on September 16, 2018). {Available at:
https://www.engormix.com/balanceados/articulos/mezcladoras-horizontales-mezcladoras-verticales-
t32672.htm}

37
Source: SoloStocks. Horizontal mixer. [Online]. (Retrieved on September 16, 2018). Available at:
https://www.solostocks.com/venta-productos/equipamientos-hoteles-restaurantes/otros-articulos-
hoteles-restaurantes/amasadora-mezcladora-horizontal-6502330

The capacities of this type of mixers differ quite a bit for large productions from the
helical ones, we have an electric motor or gear motor from 1000 to 2000 kg or from
3000 to 5000 kg an arrow-mounted motor or gear motor.37

4.2.2.3 Drum mixers.38 This type of mixer uses the same mixing pattern as
concrete mixers (see Fig. 12).

However, these mixers have a limitation, and that is that they present problems
(like vertical mixers) with liquids, whether oil, molasses or another viscous liquid.
There is not much information about this type of mixers because their use is
limited. Throughout history it is barely being imposed, so there is no reliability in the
uniformity of the desired final food.

Figure 12. Mixing pattern in drum type mixers

37
MOLINOS AZTECA, Technical Department. Horizontal mixer vs. vertical mixers. [Online]. October 19, 2015.
Engormix. (Retrieved on September 16, 2018). {Available at:
https://www.engormix.com/balanceados/articulos/mezcladoras-horizontales-mezcladoras-verticales-
t32672.htm}
38
ZALDIVAR VALER, Ramón. The mixture also counts: importance of good mixing. [Online]. June 28, 2016.
Perulactea. (Retrieved on September 16, 2018). {Available at: http://www.perulactea.com/2016/06/28/la-
mezcla-tambien-cuenta-importancia-de-un-buen-mezclado/}

38
Source: Available at: http://www.perulactea.com/2016/06/28/la-mezcla-tambien-cuenta-importancia-
de-un-buen-mezclado/

4.2.3 Common problems in mixers . Very common problems occur in horizontal

and vertical type mixers, and these are shown below:

4.2.3.1 Common problems in horizontal mixers. In practice, mixers present

two very common types of problems, underfilling and overfilling. In the article
presented by Eng. Juan C. Rodriguez39 It is recommended, for horizontal mixers, to
fill at least a third of their capacity and a maximum of 5 centimeters from the slat or
paddles.

Likewise, another factor that can affect for better or worse is the revolutions per
minute in the mixing process. This is of vital importance if you have a production
line, as can be seen in figure 13 if the process is done with a very low number of
revolutions per minute (rpm), the mixing time will increase greatly, therefore, in
practice it is advisable to implement a statistical process for each formula to find
the optimal revolutions per minute for it, according to the Figure 13 the optimal
revolutions are from 30 rpm to 40 rpm However, this should not be a straitjacket,
because each formula will have unique characteristics that will make the mixing
process different.

Wear on the mixer will also affect the mixing process, therefore, the ideal is to do
recurring maintenance, paying attention mainly between the space of the slats or
paddles and the wall of the mixer, since the maximum space that should exist
between them is not It should exceed a quarter of an inch. It can be seen in Figure
14 that the more worn the mixing tool is, the less efficient the process will be.

Figure 13. Mixing minutes for different RPM.

39
RODRÍGUEZ C., Juan Carlos. Mixing and mixers. [Online]. Nutrimentos concentra SA de CV (Retrieved on
September 16, 2019). {Available at: http://www.cpbmexico.com.mx/PDF/mez4b566.pdf}

39
Source: RODRÍGUEZ C., Juan Carlos. Mixing and mixers. [Online]. Nutrimentos concentra SA de CV
(Retrieved on September 16, 2018). Available at: http://www.cpbmexico.com.mx/PDF/mez4b566.pdf

Figure 14. Wear vs. Efficiency in a horizontal mixer.

Source: Available at: http://www.cpbmexico.com.mx/PDF/mez4b566.pdf

It is recommended that in the mixing process an order be followed when adding the
ingredients, this order should always go from highest to lowest, for example, first
the largest ingredients such as grains or pasta should be added, then, the minor
ones, such as pre-mixtures, then the additives such as antibiotics and finally the
liquids such as molasses.40

40
RODRÍGUEZ C., Juan Carlos. Mixing and mixers. [Online]. Nutrimentos concentra SA de CV (Retrieved on
September 16, 2019). {Available at: http://www.cpbmexico.com.mx/PDF/mez4b566.pdf}

40
4.2.3.2 Common problems in vertical mixers. Just as in the horizontal
mixer, two drawbacks occur: Overfilling and semi-filling (see Figure 15).
Generally, there should be around 25 centimeters between the level of the tube
and the food surface to avoid overfilling, which turns out to be the biggest
drawback for this mixer.

Figure 15. Overfill analysis.

Source: RODRÍGUEZ C., Juan Carlos. Mixing and mixers. [Online]. Nutrimentos concentra SA de CV
(Retrieved on September 16, 2018). Available at: http://www.cpbmexico.com.mx/PDF/mez4b566.pdf

In more detail, in the article presented by Eng. Juan Carlos Rodríguez 41 The
following recommendations are specified: The wear of the worm reduces the
efficiency of the mixture, therefore, recurring maintenance must also be carried out,
paying attention to the space that exists between the worm and the wall of the
tube, which should be a maximum of 1 inch, if it exceeds this measurement, the
correct thing is to replace the worm with a new one.

Also, ensure that pre-mixes or ingredients of a very small size are added when half
of the larger ingredients are already in the mixer to ensure that the lighter elements
can reach the mixing chamber, these mixers must work from 200 to 300 rpm

As had been said, it is preferred not to use liquids in this type of mixers due to their
accumulation and the maintenance of the machine. However, if it is absolutely
necessary, the liquid should be added when all the dry elements are completely
mixed and their proportion It should not be more than 2% of the total mixture.

41
Ibid,

41
4.2.4 Materials available for machines in contact with food products. 42 After
everything specified in the national and international legal framework, it is evident
that the restrictions on the available materials that can be used in the design of
equipment that is in contact with food are many and limit their use.

Below is a list of the most used and permitted materials within legal regulations,
and their respective characteristics:

4.2.4.1 Stainless steels. They are the most used material in the manufacture of
equipment for the food industry. Preferred for their excellent anticorrosive capacity.
The presence of approximately twelve percent (12%) Chromium (Cr) stands out in
its composition, which allows the steel to be isolated from the oxygen in the
environment, through a thin surface layer of chromium oxide.

According to the AISI standard, the most used stainless steels in this industry due
to their current commercial cost are grade 300. Table 4 shows the chemical
composition of these steels, where the quantities are presented as percentages of
the element.

42
CASTAÑEDA MARTÍN, Ernesto. Hygienic design of food processing equipment. [Online]. Madrid: Royal
National Academy of Pharmacy, 2010. (Retrieved on September 19, 2018). {Available at:
http://www.analesranf.com/index.php/mono/article/view/1114/1131}

42
Table 4. Chemical composition of grade 300 stainless steels.

Source: Available at: http://www.analesranf.com/index.php/mono/article/view/1114/1131

Some recommendations and application characteristics of these steels are

summarized as follows:

 AISI 304 is resistant to corrosion caused by most foods and cleaning

agents, does not cause discoloration, is easy to clean and relatively
cheap. However, it is sensitive to SO2, so its use in the wine industry is
only advisable for wines and musts with low sulfur content. For values
greater than 70 mg/l of SO2 it is preferable to use AISI 316.
 Likewise, when more pronounced corrosion problems are expected, such
as in the case of brines and very acidic foods (vinegar), AISI 316 should
be used, given its higher nickel content and, above all, the 2-3% of
molybdenum present. . The same occurs in the confectionery industry,
where solutions of glucose and citric acid, with the presence of chloride
ions and temperatures of up to 100 ºC, could generate corrosion
problems.
 On the other hand, in those applications that require welding, steels with
low carbon content (AISI 304L and 316L) are recommended to reduce the
risks of intergranular corrosion. Under no circumstances should weld
beads be polished with abrasives containing iron, as this may cause rust
stains to appear.

4.2.4.2 Aluminum and its alloys.43 Used in its pure state, or with alloys of
ninety-nine percent (99%) aluminum content.
43
CASTAÑEDA MARTÍN, Ernesto. Hygienic design of food processing equipment. [Online]. Madrid: Royal
National Academy of Pharmacy, 2010. (Retrieved on September 19, 2018). {Available at:
http://www.analesranf.com/index.php/mono/article/view/1114/1131}

43
Among its advantages are:

 Excellent corrosion resistance "since it reacts with oxygen to form a very

thin layer of aluminum oxide, reinforced by physical and chemical means,
which protects it from corrosive media . "
 Light metal with good thermal and electrical conductivity.
 Alloys can be hardened to improve tensile strength.

And its most notable disadvantages are:

 Low wear resistance (a consequence of its low hardness).

 "Aluminum has a low modulus of elasticity and a low fatigue limit, in addition
to its use at high temperatures being very limited, given its low melting
point."

4.2.4.3 Polymeric materials.44 Depending on the raw material, the physical and
chemical properties of polymers are very varied. However, the determining factor in
the use of this type of materials continues to be to avoid that, when in contact with
the food, it can cause its modification in any way, or even lead to toxicity levels that
are detrimental to the well-being of the animals. .

Among the most notable are elastomers, due to their frequent use in the
manufacture of bands, closures, or insulating gaskets.

4.3 CONCEPTUAL FRAMEWORK

 Mixer: Device or machine used to mix various substances.

 I think: It is a mixture of different raw materials that are processed together.

It is usually presented in the form of flour or in granules of different sizes
depending on the age of the pigs for which it is intended.

 Homogenize: Transform one thing so that it has common and uniform

characteristics with another or others.

 Gearmotor : Speed reducer formed by an asynchronous motor that is

coupled to a balanced planetary gear reducer.

 Helical Belt: Mechanical element in the shape of a helix, whose function is

the transport or mixing of material.

44
Ibid, p. 309

44
 Granulometry: Classification of the grains or particles of a granular
substance according to the various sizes.

 Stainless Steel: Corrosion-resistant chromium steel. Usually used in the

food industry.

 Protein: Organic substance or compound with high molecular weight and

complex structure, formed by the union of numerous amino acids through
peptide bonds.

 Mineral: Solid inorganic body composed of one or more chemical elements.

 Vitamin: Organic substance that exists in food and that, in small quantities,
is necessary for growth and the perfect balance of vital functions.

45
 5. METHODOLOGICAL DESIGN

This section of the project mentions the methods or steps required to achieve the
specific objectives presented and therefore the general objective of said project.

5.1 Analyze the socio-environmental conditions of the Santander region for

the implementation of the mixing machine without generating negative
impacts on society.

A study is carried out in the locality selected for the project, in this case
Bucaramanga, on the viability and the effects that the implementation of the pig
feed mixer may generate in said locality.

Based on the results obtained by the study, key observations are made on certain
aspects revealed by the study that allow better decisions to be made to solve
possible adverse factors in the social and environmental sphere.

5.2 Verify that the ingredients selected for the food do not cause
malfunctions in the equipment such as corrosion or high wear.

An analysis is carried out that allows us to know, in detail, the chemical

composition of the various ingredients that are present in the pig feed that is
commonly used in the region to be worked.

After completing the analysis, we proceed to verify that said components do not
present certain characteristics that could chemically or mechanically attack the
mechanical components used in the mixer and thus perform their work correctly.

5.3 Make a digital model of the mixer using computer-aided design tools
such as SolidWorks 2018 software as a support method for 3D visualization
of the machine.

By using the SolidWorks 2018 tool, a three-dimensional design of the machine is

created according to the actual dimension and density parameters for each
machine implement. This model allows confirming the construction calculations
and checking its viability prior to the purchase of the implements to detect
problems and solve discrepancies not detected in the mechanical design at hand.
The tool allows for material handling and a wide range of operations that facilitate
the modeling of the mixer without the need for additional plugins.

46
5.4 Develop a methodology that allows verifying the quality in the
homogenization of the ingredients necessary for the manufacture of pig feed,
complying with the legal regulatory parameters established at the national
level.

In the first instance, a pilot test is carried out, in order to corroborate the good
assembly of the mixer and analyze the quality of homogenization, that is, how well
the machine mixes.

After carrying out the first test, control devices capable of knowing and displaying
the homogenization values of the mixture are applied and thus generate a
verification protocol in accordance with the selected regional variables, so that
national standards are met.

6. SCHEDULE

47
 Actividad

Act.10 Revisión de los planos

Act.11 Cotización de la mezcladora

Cotización de los componentes

Act.12
mecánicos adicionales
Summary Days
Project start 1
End of project 72
Gantt Chart ( See Annex 1)

48
7. BUDGET

49
 8. BIBLIOGRAPHY

 UNITED NATIONS. The world population will increase by 1 billion by 2030.

Consulted on October 1, 2018. Available at:
https://www.un.org/development/desa/es/news/population/world-population-
prospects-2017.html

 UNITED NATIONS FOOD AND AGRICULTURE ORGANIZATION. MEAT

Market situation and its relevant aspects. Consulted on October 1, 2018.
Available at: http://www.fao.org/3/a-BT089s.pdf

 NATIONAL FEDERATION OF POULTRY FARMERS OF COLOMBIA.

Statistics. Consulted on October 1, 2018. Available at:
http://fenavi.org/estadisticas/

 COLOMBIAN FEDERATION OF LIVESTOCK BREEDERS. Meat

consumption statistics. Consulted on October 1, 2018. Available at:
http://www.fedegan.org.co/estadisticas/consumo-0

 National Association of Industrialists (ANDI). Chamber of the Balanced Food

Industry. Productive chain of concentrated and balanced foods for the
poultry and pork industry. Diagnosis of free competition. Colombia:
Superintendency of Industry and Commerce, 2009-2011. p. 2. [Online].
(Retrieved on September 14, 2018). Available at:
http://www.sic.gov.co/recursos_user/documentos/promocion_competencia/
Estudios_Economicos/ALIMENTOS%20BALANCEADOS.pdf

 US SOYBEAN EXPORT COUNCIL. Practical problems in the manufacture

and use of food. Consulted on February 18, 2019. Available at:
http://www.ciabcr.com/charlas/Nutricion%20Animal%202014/ProblemPract.
pdf. P. 90.

 GONZALEZ, Emilio Vargas. Mixing and uniformity problems in the animal

feed industry. Consulted on February 18, 2019. Available at:
http://www.cina.ucr.ac.cr/recursos/docs/Revista/problemas_de_mezclado_y
_uniformidad_en_la_industria_de_alimentos_para_animales.pdf. Page 8.

50
Appendix 1

51