Gerry Maroulis
Sales Manager Latin America
CPM/Roskamp Champion
Waterloo, Iowa, USA
Conditioning
The most important part
of the pelleting process
Conditioning
WHY??
Results/Benefits are:
Reasons for conditioning
• Better conversion rate for bird/animal
• Better physical pellet quality
• Sterilization
Pellet Durability Factors
Cooling
5%
Die Spec
15%
Formulation
40%
Conditioning
20%
Particle Size
20%
–Temperature
–Moisture
–Time
–Pressure
–Shear
Water or steam conditioning
Gelatinization
Rupture of the starch granules is a function
of:
–Temperature
–Moisture
–Time
–Pressure
–Shear
Water addition in conditioner
Moisture
• lubrication
• softening
• overcome shrinkage
• gelatinization of starch
Heat Moisture
• gelatinization of • lubrication
starch
• Plasticize protein • softening
• sterilization • overcome shrinkage
• gelatinization of
starch
Steam conditioning
rule of thumb
• 1% Saturated Steam will temp ~30 deg. F
• Max steam addition 5 – 6% on high grain
formulas
• Max steam addition 0-1.5% on high protein
supplements
• Max moist. for pellet mill =17% (18% with
expander) before choke/roll slip
CONDITIONING FACTORS
(What affects conditioning?)
• PARTICLE SIZE
• INGREDIENT CHARACTERISTICS
(bulk density/heat sensitive, etc.)
Ingredient Protein and Density help predict
pellet mill throughput and pellet quality*
P
r
o
High Protein = Good quality pellets t
e
Low Protein = Lower quality pellets i
n
Pellet Quality
• Proper conditioning = $
Reduced consumption of electrical
energy
Steam Steam
Steam Steam
• Salmonella
• E-colli
REASONS FOR THE ABILITY TO REACH HIGH
TEMPERATURES IN THE CONDITIONER ON
SOME DAYS BUT NOT ON OTHERS, WHEN
PROCESSING HIGH GRAIN FORMULAS SUCH
AS POULTRY AND PIG FEEDS
• THE TOTAL MOISTURE CONTENT OF THE
FORMULATED FEED PRIOR TO THE PELLETING
PROCESS IS CONSTANTLY CHANGING
• THE MOISTURE CONTENT OF THE RAW
INGREDIENTS (SUCH AS CORN) CAN VARY FROM
10% TO 15 ½ %
• HIGH TO LOW HUMIDITY CONDITIONS CAN CAUSE
FEED MATERIALS TO ABSORB VARYING AMOUNTS
OF MOISTURE FROM THE ATMOSPHERE
EXAMPLE
• USING A DIE WITH A CHOKE POINT OF
17% MOISTURE
• USING AN AMBIENT TEMPERATURE OF
22°C (72°F)
• USING A STEAM SYSTEM CAPABLE OF
RAISING THE TEMPERATURE 11°C (20°F)
FOR EACH 1% MOISTURE ADDED
EXAMPLE
CONTINUED…
TOTAL MOISTURE
CONTENT OF 11% 12% 13%
FORMULATED FEED
PRIOR TO THE
PELLETING PROCESS
AMOUNT OF MOISTURE
CAPABLE OF BEING 6% 5% 4%
ADDED TO THE FEED
BEFORE CHOKE POINT
IS REACHED
EXAMPLE
CONTINUED…
APPROXIMATE 88°C 77°C 66°C
CORRESPONDING (190°F) (170°F) (150°F)
TEMPERATURE AT
CONDITIONER
NOTES: THE IDEAL CONDITIONING TEMPERATURE
FOR HIGH GRAIN RATIONS IS 85°C TO 90°C (185°F TO
195°F) IN ORDER TO PRODUCE THE BEST PELLET
QUALITY A THE MAXIMUM CAPACITY.
STEAM SYSTEMS PRODUCING A BETTER QUALITY
STEAM THAN THAT REFERED TO IN THE EXAMPLE
ABOVE, ARE CAPABLE OF RAISING THE
TEMPERATURE OF THE FEED IN THE CONDITIONER
16°C (29°F) FOR EVERY 1% MOISTURE ADDED, THUS
ALLOWING HIGHER CONDITIONING TEMPERATURES
BEFORE THE CHOKE POINT OF THE DIE IS REACHED.
THE THREE TYPES OF STEAM
WET SATURATED SUPERHEATED