MODELING AND OPTIMIZATION OF FEED MILL

6 ANALYSIS OF SUBSYSTEMS AND COMPUTER PROGRAM FOR THEIR DESIGN..... 190 MATHEMATICAL MODEL FOR LABOR REQUIREMENT...192 A... 219 REFERENCES...220 CHAPTER VI MATHEMATICAL MODEL FOR PROFIT

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Page CHAPTER I INTRODUCTION OF THE STUDY

INTRODUCTION 1

OBJECTIVES OF THE STUDY 2

APPROACHES 3

REFERENCES 4

CHAPTER I I MODELING AND COMPUTER PROGRAMMING OF FEED MILL INTRODUCTION 5

OBJECTIVES 6

METHODS AND ASSUMPTIONS 6

ANALYSIS OF SUBSYSTEMS AND COMPUTER PROGRAM FOR THEIR DESIGN - 8

1 RECEIVING SYSTEM 8

A A ssum ptions and C o n d itio n s f o r R e c e iv in g System d e s ig n 8

B Computer Program f o r R e c e iv in g System d e s ig n and I t s E x pected O u tp u t 21

2 STORAGE SYSTEM 26

A A ssum ptions and C o n d itio n s f o r S to ra g e System d e s ig n 27

B Computer Program f o r S to r a g e System D esign and I t s E xp ected O u tp u t 39

3 GRINDING SYSTEM 44

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B Computer Program f o r Mixing System

D esign and I t s Expected O u tp u t 67

6 BULK LOADOUT AND BAGGING SYSTEM 91

A Assumptions and C o n d itio n s f o r BulkLoadout and Bagging System D esign 92

B Computer Program f o r Bulk Loadout and Bagging System Design and T h eir Expected

O u tp u t 101

7 LIQUID STORAGE AND HANDLING SYSTEM 106

A Assumptions and C o n d itio n s f o r L iqu id

S to ra g e and H andling System D e s ig n 107

B Computer Program f o r L iq u id S to rag e and

H andling System Design and I t s Expected

8 MISCELLANEOUS 118

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A D ust C o lle c tin g System 119

B B o ile r System 129

C B o ile r Room and M aintenance sho p, and G eneral O f f ic e 131

D F o r k l i f t T ruck 132

E M a n lift and S t a i r w e l l 132

PLANT LATOUT AND GENERAL MODEL MILL 133

OOMEUTER PROGRAM FOR FEED MILL DESIGN 141

A In p u t D a ta 148

B Subprogram 150

C A p p lic a tio n o f th e Computer Program 160

DISCUSSION OF THE RESULTS 165

SUMMARY AND CONCLUSION 165

REFERENCES 166

CHAPTER I I I MATHEMATICAL MODEL FOR ENERGY CONSUMPTION INTRODUCTION 173

OBJECTIVES 174

METHODS AND ASSUMPTION 174

A E l e c t r i c a l Energy Usage 174

B F u el Energy Usage 175

MATHEMATICAL MODELS FOR INDIVIDUAL ENERGY USAGE 177

A E l e c t r i c a l Energy Consumption Model 177

B B o ile r F uel Consumption Model 179

C V eh icle F uel consum ption Model 181

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OBJECTIVES 190

METHODS AND ASSUMPTION 190

MATHEMATICAL MODEL FOR LABOR REQUIREMENT 192

A M athem atical Model f o r In d iv id u a l Labor R equirem ent 192

B G eneral Model f o r Labor c o s t = 1 9 5 SUMMARY AND CONCLUSION 198

REFERENCES 199

CHAPTER V MATHEMATICAL MODEL FOR CAPITAL REQUIREMENT INTRODUCTION 201

OBJECTIVES .202

METHODS AND ASSUMPTIONS 202

A Equipment 203

B I n s t a l l a t i o n and S h ip p in g 204

C Land and B u ild in g C o n s tru c tio n , 2 0 4 D E l e c t r i c a l System and I n s t a l l a t i o n 206

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A Equipment C o st 206

B Land C o st, B u ild in g and C o n s tru c tio n C o st 207 C E l e c t r i c a l System Equipment and I n s t a l l a t i o n 207

D Grand T o ta l Cost o f C a p ita l R equirem ent 211

MATHEMATICAL MODEL FOR CAPITAL REQUIREMENT 214

DISCUSSION OF THE RESULTS 217

SUMMARY AND CONCLUSIONS 219

REFERENCES 220

CHAPTER VI MATHEMATICAL MODEL FOR PROFIT OF THE MODEL MILL INTRODUCTION 223

OBJECTIVES 224

METHODS AND ASSUMPTIONS 224

A Fixed C o s t 224

B V a ria b le C o st 228

MATHEMATICAL MODEL OF THE EROFIT FOR THE MODEL MILL A Swine and P o u ltry Feed M ill, 1 - S h i f t o p e r a tio n s 232

B Swine and P o u ltry Feed M ill, 2 - S h i f t o p e r a tio n 233

C Complete P e lle te d D airy Feed M i l l 234

APPLICATION OF THE RESULTS A Swine and P o u ltry Feed M ill, 1 - S h i f t o p e r a tio n 235

B Swine and P o u ltry Feed M ill, 2 - S h if t

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METHODS AND ASSUMPTIONS 240

1 OPTIMUM DESIGN BY SINGLE OBJECTIVE PROGRAMMING PROBLEM 240

A Example Problem 1 240

B Example Problem I I 244

2 OPTIMJM DESIGN BY MULTI-OBJECTIVE DECISION MAKING METHODS 246

A F orm ulatio n o f an I t e r a t i v e N o nlinear Goal Programming Problem 246

B Example Problem I I 248

SENSITIVE ANALYSIS OF THE OPTIMUM PROBLEM A P r ic e D iffe re n c e s Between In g r e d ie n ts and F in is h e d Feed 260

B C a p ita l In v estm en t 261

SUMMARY AND CONCLUSIONS 264

REFERENCES 265

OJAPTER V III SUMMARY AND CONCLUSIONS 268

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APPENDIX 1 COMPUTER PROGRAM FOR FEED MILL DESIGN 275

APPENDIX 2 OUTPUT OF THE COMPUTER PROGRAM FOR FEED MILL DESIGN 309

APPENDIX 3 TEST RESULTS OF COMPUTER PROGRAM FOR FEED MILL DSIGN 317

APPENDIX 4 LABOR STANDARD FOR FEED MILL DESIGN 322

APPENDIX 5 LIST OF CONTRIBUTOR FOR THE STUDY 324

APPENDIX 6 SOURCE OF SYSTEM CATALOG AND PRICE QUOTATION 327

APPENDIX 7 AN EXAMPLE OF EQUIPMENT ODST ESTIMATION 333

APPENDIX 8 AN EXAMPLE OF CONSTRUCTION ODST ESTIMATION 337

APPENDIX 9 EQUIPMENT AND INSTALLATION OOST 341

APPENDIX 10 AN EXAMPLE OF COST ESTIMATION FOR AN ELECTRICAL SYSTEM AND INSTALLATION 347

ACKNOWLEDGEMENT 3 51 VITA 352

ABSTRACT 3 5 3

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F ig u re 2 4 Computer flew c h a r t o f re c e iv in g sy stem d e s ig n 24

F ig u re 2 5 Elem entary p r o c e s s flow diagram o f s to r a g e system 27

F ig u re 2 6 Flow diagram o f s to ra g e system 28

F ig u re 2 7 S to rag e system p la n (to p v ie w ) 29

F ig u re 2 8 C ost o f b in v s h e ig h t o f b in 32

F ig u re 2 9 Computer fle w c h a r t of s to r a g e s y s te m 42

F ig u re 2.10 V arious system s o f hammermill 44

F ig u re 2.11 Elem entary p ro c e s s flew diagram o f g rin d in g sy stem 46

F ig u re 2 12 Flow diagram o f th e g rin d in g s y ste m 47

F ig u re 2.13 G rinding system p la n 48

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F ig u re 2 1 5 Elem entary p ro c e s s fle w diagram o f m ixing sy stem 58

F ig u re 2 16 P ro c e ss fle w diagram o f m ixing sy stem 59

F ig u re 2.17 M ixing system p la n 60

F ig u re 2 1 8 Computer flew c h a r t of m ixing system d e s ig n 69

F ig u re 2 1 9 Elem entary p ro c e s s diagram o f p e l l e t i n g sy stem 73

F ig u re 2.20 Flew diagram o f p e l l e t i n g system 74

F ig u re 2 21 P e l l e t i n g system p la n (s id e v ie w ) 75

F ig u re 2.2 2 R equired HP o f p e l l e t m i l l 77

F ig u re 2.23 Computer flew c h a r t of p e l l e t i n g system d e s ig n 90

F ig u re 2 2 4 Elem entary p ro c e s s flow diagram o f b u lk lo a d o u t and bagging s y s t e m 93

F ig u re 2 2 5 Flow diagram o f b u lk lo a d o u t and bagging sy stem 94

F ig u re 2.26 Bulk lo a d o u t and bagging system 95

F ig u re 2.27 Computer flow c h a r t of b u lk lo a d o u t and bagging system d e s ig n 1 0 2 F ig u re 2 2 8 Elem entary p ro c e s s flow diagram o f l i q u i d s to r a g e and h a n d lin g s y s t e m 103

F ig u re 2 2 9 Flow diagram o f l i q u i d s to r a g e and h a n d lin g system

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and th e swing s p o u t d i s t r i b u t o r 1 2 5

F ig u re 2.33 D u st c o n tro l system flew d i a g r a m 128

F ig u re 2.34 R equired a r e a o f th e g e n e ra l o f f i c e , b o i l e r room and m aintenance shop 131

F ig u re 2 35 Elem entary flew diagram of whole system 135

F ig u re 2.36 Flow diagram o f whole system 136

F ig u re 2.37 F i r s t f lo o r p la n 137

F ig u re 2 3 8 Basement P la n 1 3 8 F ig u re 2 39 Roof p la n 139

F ig u re 2.40 S id e view ( s e c tio n A-A) 1 4 0 F ig u re 2 4 1 Flew c h a r t o f computer program 142

F ig u re 2.42 Flow c h a r t o f subprogram "YCXJN" 1 4 3 F ig u re 2.43 Flew c h a r t o f subprogram "SUKWOO" 144

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F ig u re 2 4 4 Flow c h a r t o f subprogram "SUKXUN" 1 5 9

F ig u re 3 1 F uel consum ption v s b o i l e r HP 176

F ig u re 3 2 E l e c t r i c a l energy u ses by e l e c t r i c a l motor in swine

and p o u ltr y fe e d m i l l 180

F ig u re 3.3 E l e c t r i c a l energy u ses by e l e c t r i c motor in

com plete p e l le te d d a iry feed m i l l 180

F ig u re 4 1 P ro d u c tio n la b o r req u irem en t f o r fe e d m i l l 193

F ig u re 4 2 M aintenance la b o r req u irem en t f o r fe e d m i l l 1 9 4

F ig u re 4 3 S u p erv iso ry la b o r req u irem en t f o r fe e d m i l l 195

F ig u re 5 1 I n d u s t r i a l c o rm o d itie s and com mercial b u ild in g c o s t

T able 2 5 Expected o u tp u t o f g rin d in g system d e s i g n 54

T able 2 6 Time a l lo c a t i o n f o r h o r iz o n ta l m ix er 62

T able 2.7 Horsepower req u ire m en t f o r th e h o r iz o n ta l m ix e r 65

T able 2 8 Perform ance o f r o ta r y fe e d d r e s s e r 6 6

Table 2 9 Expected o u tp u t o f m ixing system d e s ig n 70

T able 2.10 R equired HP o f th e fe e d c o n d itio n e r and th e screw fe e d e r

a t th e p e l l e t m i l l 79

T able 2.11 Minimum r e te n tio n tim e f o r most form ula f e e d 81

Table 2.12 R equired HP and p ro d u c tio n r a t e v s s iz e of p e l l e t

T able 2.13 Minimun c o o lin g a i r req u ire m en t f o r p e l l e t m i l l 83

Tfcble 2.14 S iz e o f cy clo n e v s a i r volum e 85

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T ab le 2.15 S p e c if ic a tio n s of th e crum bier f o r p e l l e t p r o d u c t i o n 8 6

T able 2.16 C ap ac ity and r e q u ir e d HP v s th e p e l l e t c le a n e r sc re e n

88

T able 2.17 Expected o u tp u t o f th e p e l l e t system d e s ig n 91

T ab le 2 18 Expected o u tp u t o f th e b ulk lo a d o u t and bagging system d e s ig n 103

T ab le 2.19 S iz e o f l i q u i d s to r a g e ta n k 110

T ab le 3.20 A ssum ptions f o r pump 53A (or 53B) s iz e s e l e c t i o n 112

T ab le 2.21 Assum ptions f o r pump 55A (55B, 58A o r 58B) s i z e s e l e t i o n 114

T ab le 2.22 V arious re q u ire d pump s i z e o f th e model m i l l 114

T ab le 2.23 Expected o u tp u t o f l i q u i d s to ra g e and h a n d lin g system 118 T ab le 2.24 Source of d u s t e m issio n i n th e av erag e fe e d p l a n t 120

T ab le 2.25 The p ro p er sp o u t s i z e f o r th e model m i l l 124

T ab le 2.26 R equired d ia m e te r and volume f o r d u s t c o l l e c t i n g system 129

T ab le 2.27 Program summary s h e e t 141

T a b le 2 2 8 Order o f in p u t d a t a 151

T ab le 2.29 S p e c if ic a tio n t a b l e f o r screw conveyor 154

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T able 5 6 C ost f o r e l e c t r i c a l system equipment and i t s

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T able 7 1 P ay o ff ta b le f o r fe e d m i l l d e sig n program 251

T able 7 2 E f f e c t of p r ic e d if f e r e n c e between in g r e d ie n ts and

p rim ary feed m anu facturing p la n ts and a b o u t 10,000 secondary m anufactur­

in g p l a n t s Feed r e p r e s e n ts 50%-75% o f th e c o s t o f producing m ilk , meat and eggs a t th e farm le v e l (AIWA, 1 9 8 1 )

There a r e app ro x im ately 800 d i f f e r e n t f in is h e d p ro d u c ts a v a ila b le

in t h e U S A ; however, th e m ajor c l a s s e s o f fe e d a r e p o u ltr y , d a iry and

sw in e They com prize ab o u t 80% o f t o t a l fe e d p ro d u c tio n (S ch o eff, 1976)

The type of fe e d can be c l a s s i f i e d a s mash, p e l l e t , b lo ck s and

l i q u i d s A lso , th e s e ty p e s o f fe e d can be su b d iv id ed a s bulk and bagged

f e e d Bagged fe e d has san e a d v an tag es, such a s ease of i d e n t i f i c a t i o n ;

c o n t r o l le d measurement; e ase o f in v e n to ry c o n t r o l ; uniform d i s t r i b u t i o n

o f t h e p ro d u c ts ; and econony of s a lv a g e The bagged fe e d p ro d u c tio n has

d e c re a se d d ra m a tic a lly because o f h ig h la b o r and in v e n to ry c o s t s P el­

l e t e d fe e d occupied around 21.4% o f t o t a l fe e d p ro d u c tio n in 1973 and

i t s p ro d u c tio n r a t e has in c re a s e d rem arkably s in c e (S ch o eff, 197 6)

S choeff (1976) re p o rte d t h a t sm all m i lls (89% o f th e t o t a l

r e g is t e r e d fe e d m ills ) produce from 1,000 to n s p er y e a r to 2,500 to n s per y e a r They produce o n ly 37% o f t o t a l feed p ro d u c tio n The r e l a t i v e l y

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la r g e fe e d m i lls produce around 63%.

D uring th e p a s t 10 y e a r s , many feed p la n ts have been b u i l t in

d evelo ping c o u n tr ie s because of a s tro n g demand f o r m eat, eggs and m ilk These p la n ts have been b u i l t w ith o u t c o n s id e rin g th e optimum s iz e or system f o r t h e i r p a r t i c u l a r s i t u a t i o n s They sim ply im ita te d th o se b u i l t

in th e U n ite d S ta t e s and e lse w h e re Problems in d e sig n in g a fe e d m ill

a re n o t o n ly c o n fin e d t o d evelop in g c o u n t r i e s , b u t a l s o t o th e U.S.A This i s prim ary becau se r e s e a rc h in m a n u factu rin g tech no lo gy and system s

d esig n in th e fe e d in d u s tr y has n o t been a s a c t i v e a s o th e r a r e a s , such

as n u t r i t i o n and fo rm u la tio n of f e e d Only a v e ry few re s e a rc h has been

re p o rte d e s p e c i a ll y t h a t o f system d e s ig n

OBJECTIVES OF THE STUDY

The o v e r a ll o b je c tiv e s o f th e stu d y a r e : 1) to c o n s tr u c t a fe e d

m ill model and t o d ev elo p a computer program f o r model m i ll d e s ig n ; 2)

to develop a m ath em atical model fo r energy consum ption; 3) t o d ev elo p a

m athem atical model f o r la b o r re q u ire m e n ts; 4) t o develop a m athem atical model f o r c a p i t a l re q u ire m e n ts; 5) t o d ev elo p a m ath em atical model fo r

p r o f i t of th e model m i l l ; and 6) t o dem o n strate th e methods f o r o b ta in ­

dev eloped b ased upon t h i s model m i l l

By u s in g th e com puter program developed i n C hapter I I , th e t o t a l amount of e l e c t r i c en erg y consum ption can be e s tim a te d in v a r io u s s iz e s and ty p e s o f feed m i l l s Based on th e s e d a t a , th e m ath em atical model of

e l e c t r i c en erg y consum ption i s developed i n C hapter I I I A lso, th e

m a th em atical model f o r b o i l e r f u e l energy consum ption and v e h i c le f u e l energ y consum ption a r e develo ped

C hapter IV p r e s e n ts th e m ath em atical model f o r la b o r req u irem en ts

i n fe e d m i l l s For th e developm ent o f m odels, a l l o f th e d a ta a r e c o l­

l e c te d from th e V o s lo h 's r e p o r t (19 76 )

C a p ita l req u ire m en t models f o r th e fe e d m i l l s a r e developed i n

C hapter V, b ased on th e model m i ll and th e com puter program developed in

C hapter I I , and th e d a ta c o l le c t e d from com m ercial feed m ill equipment

m a n u fa c tu re rs

C hapter VI c o n ta in s th e model o f p r o f i t f o r swine and p o u ltr y feed

m i l l s and com plete p e l l e t e d d a ir y fe e d m i l l s

C hapter V II d e m o n stra te s th e a p p l ic a t io n o f th e models developed

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w ith s i n g l e o b je c tiv e n o n lin e a r programming and m u ltip le o b je c tiv e d e c i­

s io n making method GREG n o n lin e a r programming and I t e r a t i v e N onlinear Goal Programming a r e used t o o b ta in th e optimum s i z e of fe e d m i l l s

C hapter V III i s an o v e r a l l summary and co n c lu sio n o f t h i s stu d y

The Appendix c o n s is ts of : 1) th e computer program f o r a fe e d m ill

2 S c h o e ff, R obert W 1976 The Formula Feed I n d u s tr y Feed Manufac­

t u r i n g Technology AFMA, A rlin g to n , Va

3 V osloh, J r C a rl J 1976 Feed M anufacturing C ost and C a p ita l

R equirem ents Economic R esearch S e rv ic e , A g r ic u ltu r a l Economic

R ep o rt No 335 USDA, W ashington, D.C

4 V osloh, J r C a rl J 1968 Cost and Economics o f S c ale in Feed

M an u factu rin g Economic R esearch S e r v ic e s , M arketing Research

R ep o rt No 815 USDA, W ashington, D.C

R e p r o d u c e d with perm ission of th e copyright owner F u rth er reproduction prohibited without perm ission.

I t i s a lo n g -c h e ris h e d d e s i r e in th e fe e d in d u s tr y to compare the

d i f f e r e n t ty p e s , k in d s o r / s i z e s o f feed m i lls in term s o f energy con­sum ption, la b o r req u ire m en ts and c a p i t a l re q u ire m e n ts There a r e many

f a c t o r s to be c o n sid e re d and much e f f o r t i s needed i n th e d e sig n o f a

s i n g l e feed m i l l Thus, i t i s alm o st im p o ssib le to d esig n a com bination

o f a l l d i f f e r e n t s iz e s and k in d s and k in d s For th e re a so n s above, th e

s im p le s t id e a , b u t th e most d i f f i c u l t to p erfo rm , would be to c o n s tr u c t

a g e n e ra l fe e d m ill model and develop a computer program f o r each

d e s ig n

So f a r , l i t t l e has been s tu d ie d in t h i s a r e a G en eral, b u t very

v a lu a b le in fo rm a tio n , has been in tro d u c e d through "Feed M anufacturingTechnology" p u b lis h e d by th e American Feed M anufacturing A sso c ia tio n (1 9 7 6 ) Ju ssc e n e t a l (1961) in tro d u c e d th e p ro c e ss flow d esig n of

fe e d m i l l s , and S tiv e r s e t a l (1976) dem on strated p l a n t la y o u t d esign

a c c o rd in g t o s p e c i f i c c o n d itio n s S tevens (1962) and Baker (1960) s t u ­

d ie d f a c t o r s a f f e c t i n g hammermill c a p a c i t i e s A lso w ith th e su p p o rt of

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AEWA, "Environm ental C o n tro ls f o r Feed M anufacturing and G rain H andling" was p u b lish e d (B riggs e t a l , 1971} A g e n e ra l g u id e l i n e f o r d u s t con­

t r o l , n o is e , o c c u p a tio n a l s a f e t y and o th e r en v iro n m en tal f a c t o r s were

p re s e n te d f o r fe e d m i l l d e s ig n Vosloh (I9 6 0 , 1976) re p o rte d on th e

c o s ts and c a p i t a l req u ire m en ts o f fe e d m i l l s In h i s s tu d y , th e model

m ills were c o n s tru c te d by su rv ey in g th e d a ta from tr a d e a s s o c ia t io n s , equipment m a n u fa c tu re rs and fe e d m a n u fa c tu re rs

OBJECTIVES

Hie prim ary o b je c tiv e s o f t h i s c h a p te r a r e : 1) t o c o n s tr u c t g e n e ra l models o f fe e d m i ll subsystem s and d ev elo p computer program s f o r t h e i r

d esig n by su b d iv id in g and a n a ly z in g ty p i c a l fe e d m i l l s ; and 2) to con­

s t r u c t a g e n e ra l model m ill of whole system o f a p la n t and a computer program f o r i t s d e s ig n

METHODS AND ASSUMPTIONS

Swine and p o u ltr y feed m i l l s and com plete p e l l e t e d d a ir y feed m ills produce two t h i r d s o f th e t o t a l U.S fe e d p ro d u c tio n in 1975 (V osloh,

197 6) Thus, p o u ltr y , swine and com plete p e l l e t d d a iry feed m i l l s a r e

s e le c te d f o r th e model m i ll in t h i s s tu d y

The model m i ll i s d iv id e d in t o e i g h t sub system s: th e re c e iv in g s y s ­tem; s to r a g e system ; g rin d in g sy stem ; m ixing sy stem ; p e l l e t i n g system ;

l i q u i d s to r a g e and h a n d lin g sy stem ; and bu lk lo a d o u t and packaging s y s

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e n g in e e rs

H ie dim ensions o f th e m i l l a r e d iv id e d i n t o a f ix e d dim ension and

v a r i a b l e d im ension For exam ple, th e number o f o u ts id e b in s and t h e i r

d ia m ete r and h e ig h t a r e c o n s id e re d to be v a r i a b l e dim en sio ns

A fte r each subsystem i s an aly zed and th e com puter program fo r i t s

d e s ig n i s fo rm u la te d , a l l system s a r e combined in t o a whole system Hie com puter program s f o r subsystem d e sig n a r e a l s o combined in t o whole sy s­tem d e s ig n A fte r t h i s s t e p , th e model m ill and th e computer program

f o r model m i ll d esig n a r e a n a ly z e d , t e s t e d and compared by changing th e

v a r io u s in p u t v a r i a b l e s In o rd e r to accom plish th e o b je c tiv e s o f th e

s tu d y th e fo llo w in g o v e r a l l assum ptions a r e made:

1 ) Hie model m i ll is assumed t o o p e ra te one e ig h t- h o u r s s h i f t a day

2 ) Hie ty p e s o f f in i s h e d fe e d s produced a r e mash b u lk , mash bagged,

p e l l e t b u lk , and p e l l e t bagged

3 ) In th e case where a c e r t a i n type o f fe e d would n o t be produced,

th e space f o r i t s 1 p ro d u c tio n system is p ro v id ed f o r f u tu r e

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n eed s.

4 ) One u n i t system i s lo c a te d so a s n o t t o i n t e r r u p t th e o th e r u n it system , even when th e s i z e o f each p ie c e o f equipment v a r i e s from

sm a ll to l a r g e

5 ) The model i s s u i t a b l e f o r a p ro d u c tio n r a t e o f frcm 10 to n / h r to

50 t o n / h r

6 ) The system i s assumed t o be a b a tc h type system

7) The m i ll basem ent e le v a tio n i s assumed t o be 18 f t r e g a r d le s s of

th e s iz e of th e m i l l The main reaso n f o r t h i s assum ption i s as

fo llo w s : At one tim e 14 f t t o 16 f t was connion However, now a 20

f t or more depth i s used, p a r t l y because of th e e lim in a tio n of

e le v a to r b o o t p i t s and p a r t l y because o f th e p e l l e t system (sho uld p e l l e t s n o t be produced, th e space i s l e f t f o r f u tu r e

n e e d s ) More d e t a ile d assum ptions w i l l be d e s c rib e d in th e n e x t

s e c ti o n

ANALYSIS OF SUBSYSTEMS AND THE COMPUTER PROGRAMS FOR THEIR DESIGN

1 RECEIVING SYSTEM

The d ry in g r e d ie n ts a r e re c e iv e d e i t h e r i n bulk o r i n b a g s The

b u lk in g r e d ie n ts su ch as g r a i n , m eat m eal, f i s h meal and lim e sto n e a r e

d e liv e r e d by r a i l o r tr u c k Hopper c a r s a r e d isc h a rg e d t o th e re c e iv in g

h o p p e rs These in g r e d ie n ts a r e conveyed frcm th e r e c e iv in g hopper to

th e re c e iv in g s c a lp e r thro ug h drag co n veyo rs Non-economic fo re ig n

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in g r e d ie n ts a r e s to r e d i n working b in s above th e m ill a r e a Bagged

in g r e d ie n ts a r e unloaded frcm r a i l c a r s o r tr u c k s , and lo a d ed on t o p a l­

l e t s , moved by f o r k l i f t tr u c k , and s to r e d in th e w arehouse L iq u id f a t and m o lasses h an d lin g w i l l be d is c u s s e d s e p a r a te ly in "L iq uid h an d lin g and s to ra g e system "

A Assumptions and C o n d itio n s f o r R eceiving System Design

The re c e iv in g system co n sid e re d c o n s is ts o f a r a i l re c e iv in g hopper, tru c k dump p i t , tru c k s c a l e , r a i l s c a le , v a r ia b le speed drag conveyor, v a r ia b le speed in c lin e d d rag conveyor, re c e iv in g s c a l p e r , drag conveyor, b u c k e t e l e v a t o r , screw conveyor 2 and 3 way d i v e r t e r v a lv e s and th r e e d rag co n v ey o rs

P ig 2 1 shews th e elem entary p ro c e ss flow diagram o f th e re c e iv in g system The flow diagram o f th e bulk re c e iv in g system and th e re c e iv in g system p la n ( s id e view) c o n s id e re d i n th e stu d y a r e shewn i n F ig 2 2 and

F ig 2 3 , r e s p e c t iv e l y

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MASH BULK INGREDIENT

X f l )

GRAIN BULK INGREDIENT

X ( M il)

BAGGED INGREDIENT XIM21J

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ITS* SO DESCB2PTI05

IT JH HO DESCRIPTION

1

2

2 h

M CEIYINO SCALPER DHAG COHVBTOa 3DCH T ELEVATOR SCRZV COBVETOB D17ERTEU 7A1YE, DRAG COHYETOR OUTSIDE STORAGE B IS FLOOR DTOP P IT 30CEET ELS7ATOR IHSIDE WOHENG 3IH DUST COLLECTOR

sy stem i s e s tim a te d by th e fo llo w in g e q u a tio n s :

M2 = number o f in g r e d ie n t re c e iv e d i n mash and g r a in b ulk s t a t e

( b ) P a i l hopper c a r re c e iv in g hopper (item #4)

A r e c ta n g u la r s t e e l hopper, w ith a to p opening 6 f t long and 4 f t

w ide, i s s i t u a t e d beneath th e r a i l tr a c k t o re c e iv e th e m a te r ia ls flow ­

in g from one o f th e s lo p e s t o in s u r e th e f r e e flow o f in g r e d ie n ts frcm

th e h o p p er Hie d is ta n c e from th e b u ild in g to th e c e n te r of th e r a i l i s

in g d rag conveyor through a s h u t- o f f g a te The to p o f th e hopper i s

co vered w ith a s e lf - c l e a n in g g r a t e having a minimum opening o f 3 sq u a re

i n

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( e ) Truck and R a il s c a le s (item #1, item #2) and R eceiving s c a l e room (item #78)

A 72 f t lo n g , 2 00 -to n c a p a c ity r a i l r o a d tr a c k s c a le i s p ro v id ed f o r

w eighing inbound and outbound r a i l sh ip m e n ts A lso a 10 f t by 70 f t

p la tf o r m , 6 0 -to n c a p a c ity d i a l s c a le i s p ro v id ed f o r tru c k r e c e iv in g Both s c a le s have a g u aran teed ac c u ra c y o f o n e - te n th of one p e rc e n t o f

th e f u l l range to m eet a l l s t a t e , f e d e r a l and m u n icip al req u ire m en ts and

r e g u la tio n s

( f ) R eceiving conveyor (item #5A)

S in ce d rag conveyors a r e r e l a t i v e l y in e x p e n siv e conv eyors, r e q u ir ­

in g l i t t l e m aintenance and r e q u ir in g th e same amount o f power p e r to n conveyed by a screw conveyor, and have good c le a n in g c h a r a c t e r i s t i c s a t

th e end o f a ru n , a s e lf - c l e a n in g , d u s t t i g h t and v a r ia b le speed drag conveyor i s s e le c te d t o convey feed in g r e d ie n ts frcm th e tru c k re c e iv in g hopper to th e in c lin e d drag conveyor H ie fo llo w in g form ula i s used t o

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c a l c u l a t e th e horsepow er re q u ire d f o r h o r iz o n ta l d ra g conveyors (Rempe,

( g ) I n c lin e d r e c e iv in g conveyor (item #5B)

T here a r e two re a s o n s f o r i n s t a l l i n g an in c lin e d conveyor in s te a d

o f u s in g a h o r iz o n t a l conveyor H ie f i r s t i s so th e re c e iv in g s c a lp e r can be lo c a te d in th e basem ent r a t h e r th a n a t th e to p o f m i l l The

o th e r re a s o n i s t o av o id an e le v a to r b o o t p i t i n th e basem ent Both reaso n s a llo w f o r easy c le a n in g and m aintenance o f th e m i l l Because of

S te p 2 A d ju st th e c a p a c ity (CID) frcm th e c a p a c ity c h a r t of th e

drag conveyor (Rempe, 1976) so t h a t CID i s s l i g h t l y la r g e r

th a n th e i n i t i a l c a p a c ity (C ID l) A lso, th e s i z e of th econveyor can be determ ined frcm t h i s c h a r t

S te p 3 C a lc u la te th e re q u ire d horsepow er by th e fo llo w in g fo rm u la

cause s e r io u s damage to subsequent eq u ip n en t in th e p ro c e s s in g system

T h is u n i t i s equipped w ith an in c lin e d s c re e n hav in g c o a rse openings (1 /4 in c h e s t o 2 in c h e s mash) t h a t p ro v id e h ig h c a p a c ity s c a lp in g o f

f o r e ig n m a t e r i a l A fte r e n te rin g th e i n l e t , th e m a te r ia l sp read s over

th e f u l l w id th o f th e s ie v e and t r a v e l s g e n tly down th e in c lin e d s c re e n The o v e r s , u n a c c e p ta b le m a te r ia ls , a r e d is c h a rg e d thro ug h a d e s ig n a te d

o u t l e t and th e f i n e s f a l l to a drag conveyor (#6A) The c a p a c ity , or

re q u ir e d HP, o f th e s c a lp e r v a r ie s depending upon th e opening s i z e of

th e s ie v e , sc re e n a r e a , and m a te r ia ls b ein g h a n d le d By s e le c tin g a 1 /2

in c h opening s iz e a s a u su al case in com mercial fe e d m i l l s , th e condi­

( i ) Drag conveyor (ite m #6A)

A h o r iz o n ta l d ra g conveyor i s co nnected between th e re c e iv in g

s c a lp e r and th e b u c k e t e l e v a to r A ll of th e d e s ig n c o n d itio n s and s iz e

s e l e c t i o n c r i t e r i a a r e th e same a s item #5A

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