Installed for Mahen, a medium-scale integrated pig farm in Indonesia, this 3-5TPH pig feed pellet line converts 60% grain and 40% protein concentrate powder into uniform 3.5mm pellets at 162kW installed power. The project is a working reference for any farm owner weighing whether to produce feed in-house.
- Client: Mahen (Indonesia)
- Factory Output: 3-5TPH
- Pellet Diameter: 3.5 mm (one standard size)
- Installed Power: 162 kW
- Power Supply :380V / 50Hz three-phase
- Application: Breeding sows, finishing pigs, nursery piglets
The line delivers a stable hourly output of 3–5 tons, standardized at 3.5mm pellets that cover breeding sows, finishing pigs and nursery piglets at all growth stages. Designed for a medium-scale integrated pig farm and regional feed processing workshop, it runs entirely on Indonesia’s mainstream 380V/50Hz three-phase industrial power — no voltage transformation equipment is required on site.
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Pig Feed Pellt Plant Installation & Commissioning in Indonesia
Commissioning followed three priorities: power adaptation, operator training, and auxiliary system integration.
- Power adaptation
The 162kW line was verified against the site’s 380V/50Hz three-phase supply, and all motors above 15kW were confirmed on soft-start delay settings before the first full-load run.
- Operator training
Because the push-button cabinet needs no programming, training focused on section-level start-stop sequences and interlock logic. Daily operation settled at 1–2 workers per shift.
- Auxiliary integration
The 0.3-ton steam boiler, air compressor and liquid oil adding system were synchronized with the conditioning and pelleting sections, so steam pressure and oil spray rates follow the production load automatically.
Seven Core Technologies Behind the Feed Production Line
Fine Crushing: SFSP 56×36 Hammer Mill
The SFSP 56×36 large hammer mill uses tungsten-sprayed wear-resistant hammer blades and a fully open quick-replace screen door for fast screen changes. Matched fans and cyclone collectors form a negative-pressure dust removal system that lowers workshop dust concentration. The result is stable crushing of high-proportion concentrated powder without fine powder overflow or material loss, while reducing wear on the equipment itself.
Precision Weighing & Mixing: ≤7% CV
The single-shaft double-ring belt mixer handles 1 ton per batch with a mixing uniformity variation coefficient ≤7%. High-precision load cells at the bottom deliver 0.1% FS static and 0.3% FS dynamic accuracy, so the 60% grain / 40% concentrate ratio is held batch after batch. The rotor pulls out fully for maintenance and leaves minimal residue inside the cylinder, preventing stratification and waste in high-powder formulas.
Dual Conditioner + 4-Minute Retention: Core Upgraded Craft
This is the signature upgrade for high-concentrate powder formulas, superior to traditional single-conditioner lines. Two 304 stainless steel conditioners, each fitted with an original Danfoss frequency converter, hold the material for 35 seconds of primary steam softening, fully moistening the high-protein powder. A sandwich-insulated retention chamber then extends thermal maturing to 4 minutes: grain starch is fully gelatinized, protein softened, and harmful bacteria in the raw material killed. Digestibility and pellet bonding strength both rise, eliminating the fragile-pellet and poor-forming defects typical of high-powder formulas.
Ring Die Pellet Mill: 250–350mm Die
The ring die comes in 250mm, 300mm and 350mm diameters, paired with two 304 stainless steel pressing rollers. Ring die feed pelletizer is equipped with two 304 stainless steel press rollers. Power is transmitted via flexible couplings from two motors, ensuring stable operation. Blockages are eliminated, while pellet hardness stays consistent and the pellet surface stays smooth.
16×16 Counter-Flow Cooler
The 16×16 counter-flow cooler uses a fully enclosed air supply system, fixing the air-leakage and uneven-cooling defects of traditional horizontal coolers. Cold air flows upward against hot pellets for gradual heat exchange that prevents pellet cracking. A variable cone slide valve discharges evenly, reducing finished pellet breakage; large fans and cyclone separators recover fines for re-mixing and re-pelletizing, achieving zero raw material waste and extending shelf life.
Push-Button Centralized Control
The integrated push-button centralized electric cabinet manages every machine uniformly, with an independent control button per motor and a lockable emergency stop on the cabinet. All motors above 15kW are equipped with delayed soft starters, plus start-stop interlock and power-off fault protection. The system matches the operating habits of local workers in Indonesia — no programming technicians required — and only 1–2 operators are needed for daily supervision. Auxiliary equipment includes a 0.3-ton steam boiler, an air compressor and a stainless steel liquid oil adding system that automatically sprays animal and vegetable oil to improve palatability of high-protein feed.
Sealed Dust Recovery & Circulation
Cyclone separators and air locks are installed at the crushing, cooling and packaging sections. Fine powder and broken pellets generated by high-concentrate production are fully recovered and returned to the mixing section for re-pelletizing. Raw material utilization is maximized, waste discharge is zero, and the workshop stays clean under high-powder working conditions.
- Why does a 40% concentrate formula need dual-conditioner technology?
- Concentrate powder has low starch content and poor binding. A single conditioner cannot fully gelatinize starch or kill bacteria within the short retention time. The dual conditioner (35 s) plus retention chamber (4 min) achieves complete gelatinization and sterilization, which is why pellets stay hard instead of cracking.
- How many operators are needed daily?
- One to two operators per shift. The push-button centralized cabinet requires no programming skills, and start-stop interlock prevents mis-operation.
- How does the dust recovery system reduce material loss?
- Cyclone separators and air locks at crushing, cooling and packing sections capture fines and broken pellets, returning them to the mixing section for re-pelletizing. Material utilization is maximized with zero waste discharge.
