Shahzor Feeds ( Pvt.) Ltd.

Introduction:

It is located at 13-Km Faisalabad road, sheikhpura.it is established in 1996 and area of the feed mill is 12 acres.The owner of this factory is Dr. Sabir .Shahzor feed mill is one of the biggest feed mill , as of capacity , in the country. In the beginning the feed mill was running only with a pellet mill and its production capacity was 14,400 Tons Per Month. Now a days this capacity has been increased up to 8, 35,200 Bags Or 41,760 Tons Per Month.It produces feeds both for poultry and large animal , but for large animal feed is produced only when is demanded

Storage areas for raw material are consisting of 5 big godowns and 18 silos.

Managerial Setup :

Production Manager : Dr. Abid Maqbol

Asst.Production Manager : Dr.Qamar-u-Zaman

Mechanical Department Foreman : M.Arshad

Electrical Department Foreman: M.Asif

Lab. In charge : Khalid Mahmood

Samplers: Mushraf , Sohail

Receiving Operations :

It consist of

1. Sampling

2. Unloading

1- Sampling:

Sampling is done with a probe approximately from every bag , samples are taken in polythene bags ,and the evaluation of these samples is done in following ways :

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1. Physically

2. Microscopically

3. Lab. Analysis

Material Inclusion Level and Availability

Sr.# Ingredients Inclusion Availability From

1 Maize  35-45 Central punjab Haripur and Mansehra

2 Rice Broken 35-45Gujranwala, Gujrat, Sialkot, Okara, sheikhupura , shikarpur and jocabbabad

3 Rice Polish 10-15Gurjanwala , gujrat ,Noshehra ,Daska, sheikhupura, Jalalpur

4 Wheat Bran 5 Floor Mill Of Local Area

5 C.G. 60% 3-4 Rafhan,

6 Canola Meal 8-12 Solvent Plant of Multan,

7Sun Flower Meal 8-13 Solvent Plant of Multan

10 Guar Meal 0-5 Karachi

11Soyabean Meal 8-20 India

12 Fish Meal 4-7 Karachi

13 Molasses 2-5 Sugar Industries

14Cotton seed meal 3-5 Multan

15 Bone Ash 0-2 Wazirabad, Faislabad , Lahore

16 Bone Meal 0-2 Wazirabad, Karachi

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Raw Materials and Their Tests In Shahzor Feeds:

Ingredients Proposed analysis

A. Grains & by products:

Maize Moisture, CP, Aflatoxin, EE

Rice tips Moisture, CP, Aflatoxin

Rice polish Moisture, Cp, CF, EE, POV

B. Vegetable proteins:

Soya bean meal Moisture, CP, CF, Ash, KOH solubility

Rape seed meal Moisture, CP, salt (NaCl), CF

Canola meal Moisture, CP, CF, Ash

Sunflower meal Moisture, CP, CF, Afla Toxin

C. Animal proteins:

Fish meal Moisture, CP, Ash, Salt, EE, NPN, Pepsin dig.

Feather meal (APC) Moisture, CP, Ash, EE, Salt, Pepsin dig.

D. Ca & P:

DCP Moisture, Ca, P

Limestone (Chips) Moisture, Ca

MCP Moisture, Ca, P

Sampling of different ingredients:

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Grains and their by products:

Corn:

Three varieties are common.

a. Yellow b. White c. Red

Material is selected on the basis of moisture and toxin level. Normally 1% toxin is acceptable and above is rejected. Toxins present in corn are aflatoxin, ochratoxin, and zearalinone.

Rice tips:

It is also selected on the basis of moisture and toxin level. Physical appearance is also important if damage, brown and husk are present, then it is rejected.

Rice polish:

It is by-product from rice mills and most valuable raw material. It has many standards and it accepted on the basis of physical appearance, smell, fat, ash, husk to tips proportion, adulteration (like mud, sand, chips etc). If it fulfills the above standards then it is accepted otherwise rejected.

Wheat straw:

It is by product of wheat. It is selected on the basis of moisture, CP levels. It is also selected by physically appearance including smell, texture.

Vegetable protein sources:

Soybean meal:

It imports from India. It is selected on the basis of CP, KOH solubility, Fiber tests and general appearance.

Rape seed meal:

It is selected on the basis of moisture, CP, salt, and, CF tests.

Canola meal:

It is selected on the basis of physical appearance, moisture, CP, ash.

Sunflower meal:4

It is selected on the basis of aflatoxin level, moisture, CP, CF tests.

Animal proteins sources:

Fish meal:

It is selected on the basis of physical appearance, smell, moisture, salt test and CP test.

Feather meal:

It is also physically check. Moisture, CP, ash and pepsin digestibility tests are applied on it.

Inorganic sources:

Dicalcium phosphate ( DCP ):

It is accepted on the basis of physical appearance, moisture, Ca, and P test.

Mono calcium phosphate (MCP):

It is selected on the basis of physical appearance, moisture, Ca, P Test.

Limestone/Chips:

Color is white. Brownish and blackish color indicates bad quality. It is selected on the basis of moisture, Ca test.

Bulk density of materials:

Bulk density of material represents the mass per unit volume. It is commonly expressed as kg/ft3. It can affect by moisture, texture and adulteration

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Ingredients Bulk density kg/ ft3

Maize 20.40

Rice polish 13.45

Rice tips 23.05

Wheat bran 10.00

Soya bean meal 17.10

Rape seed meal 21.15

Sunflower meal 15.50

Canola meal 16.15

Fish meal 14.05

Feather meal 11.25

MCP 27.95

DCP 22.70

Chips 44.80

2- Unloading and Storing of Materials:

After sampling and selection, materials are unloaded to their respective sires either in a) Godowns or b) Silos

Godowns :

There are 5 big godowns in the mill. Godowns are used for the storage of vegetable and animal protein sources , medicines etc.

Silos:

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There are 18 silos of BROCK company in the mill. Grains are stored in silos, they are unloaded in dumping pits, from where, with the elevator carried to drum cleaner to remove adulterants like threads, dust particles , a cyclone is attached with cleaner for removal of dust particles. After cleaning material is taken to the silo with elevator to top conveyer which take the material and empty it in the silo , who’s gate is opened.

Silo Specifications:

Diameter of silo = 48 ft

Height including cone = 53 ft

Height excluding cone = 42 ft

No. of sheets along the diameter = 15

No. of sheets along the length = 21

The capacity of a silo is determined by π r 2 h × Bulk density of material . Moisture content and temp. within a stored grain mass have a direct impact upon the number of days that grain can be stored. To control the moisture level and temp. two fans are connected to each silo , the requirement of air ranges between 0.054-0.22 cubic meters of air per minute for each metric ton of grain. The air is pumped by the fans into the silo which takes the moisture from grains and exhaust from vents on the roof of silo. The temp. detection system is an electronic device attached to special cables, suspended from the roof of the silo, these are 7 in nos. The cables contain temperature sensors at approximately two-meter vertical intervals, and normally temp. is checked once a week.

Two types of conveyers are used , one is upper conveyer ( for silo filling pupose ) and 2nd is for material receiving. Material received from silo outlet with the help of gravity and discgarge conveyer.

Production unit:

Production is completed with the help following departments.

1) Production department

2) Mechanical department

3) Electrical department

4) Boiler section

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5) Houdi operators

6) Loading Section

1- Processing Section:

Feed production is completed by the combination of following processes

Receiving

Grinding

Batching

Mixing

Pelleting

Cooling

Crumbling

Grading

Packing

Receiving:

Material is received in production unit from silos and godowns with the help of conveyers and elevators.

Grinding and Batching:

Material in two forms is received fine form and coarse form material. The fine material is taken directly to dosing bins witout grinding , while , coarse material is taken into the sifter , after cleaning , material is grinded by hammer mill. There are two hammer mills and a roller body used for griding purpose in shahzor.After grinding of coarse material , it is taken with elevator to the the top of production tower where material in ground form is passed through a scieve for its screening and with the help of rotory distributer material is taken in dosing bins , which are 18 in nos. Then material from different dosing bins is taken into scale hopper for batching according to fomula, in shahzor one batch is of 3000 kgs .

Mixing:

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After batching material goes to mixers , ribbon type mixer is used there , . Mixing of material is done for 2 minutes and the capacity of each mixer is 3 ton and speed of each mixer is 27 rpm. Sprinkler are connected to mixers which aid in liquid addition , like choline chloride , and shower the material during mixing. Premixes are added in mixers , for 100 ton of feed 175 kgs of premix is added.

Pelleting:

After mixing material is taken with the help of screw conveyer to the elevator which takes the material at the top of production tower and empties it into a sifter ,and after sieving material goes to pelleting bins. Then come into feeder which control the speed of material so material is fed to conditioner wher steam and mollase are added to this material , steam not only increase moisture content of material , helpful for pelleting process , but also decrease the microbial load from the material.From conditioner material goes to the pellet mill , there are 3 pellet mills , two of them are of capacity 20 ton/hr and one is of 18 ton/hr. This mixture is changed into pellet form by the combination of die and roll shells.Here the temperature of material is 80 oC. Pellet operator and helpers are required to run a pellet machine.

Cooling:

After pelleting , pellets are distributed in cooler by the rotory distributer so pellets are evenly distributed in cooler to avoid lump formation. Blower is attached is to cooler , the no. of coolers is as of pellet machines , which sucks the air from cooler and exhaust it to atmosphere so to lower down the temp. of pellets.The discharging of pellets from cooler to crumbler is controlled by discharging gate attached to a 5 Hp motor.

Crumbling:

After discharging material comes from cooler to crumbler, is roller mill with rools . Each crumbler has two pairs of rollers , one roller has spherical grooves it cuts the pellet into crumbs and 2nd roller has lengthwise groove which pushe down the pellets. The size of crumbs is adjusted with the distance between rollers by a roll adjustment. A by –pass valve is also present , we can divert the pellets from crumbler with the help of this valve. After the formation of crumbs these crumbs are taken to the elevator with the help of a belt , used to minimize the break down of crumbs.

Grading:

These crumbs are taken into the separator with the elevator, the separator separates these crumbs into three forms too large size particles , medium or required size particles and fine size paricles. Three pipe lines are attached to each of three seperators, one takes the fine size particles to pellet bins , 2nd takes the too large size particles into the cooler so for to pass these

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particles again into the crumbler for crumbling and the 3rd takes the medium or required size particles to the packaging bins.

Packing:

The material is then packed into the bags. There are three packing points in the mill , where automatic packing is done. 8-10 bags are packed automatically/min.

2)- Mechanical Department:

This department is under the supervision of mechanical foreman. In this section fabrication and maintenance is done. Following equipments are used for maintenance and fabrication.

a) Cutter

b) Hand Grinder

c) Gas Cutter

d) Tool box kit

e) Welding Plant

3)- Electrical Department:

This section is under the supervision of electrical foreman. There a generator of 910 kv capacity is present which is used in case of electrical failure, a step down transformer which step down the voltage as requirement of production unit.

4)- Boiler Section:

Boiler is run by a boiler engineer. There are two boilers in feed mill one is of capacity 3.5 ton/hr , which is in standby condition, and the 2nd is of 5.5 ton capacity/hr. Boiler is used to produce steam to be used in production.

Boiler Working:

There boiler fuel is furnace oil. Water comes first through pump into water softening plant in which zeorolite and salts are added for its softening and softening of the water is checked with EDTA black arichrome sol. , if water with it gives blue color it is softened and if red then it is still hard , after softening water goes to feeder tank , where steam coming from production unit is added to raise its temp. because direct supply of water without

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heating is not suitable for boiler. Fire tube boiler is used there and the pressure limit in boiler is 150psi and if pressure increases from the limit it is released through safty vavle.

Steam goes to the production unit with the help of steam ducts, for production of 20 ton feed 1-1.5 ton of steam is required

5)- Houdi Operator:

To convey the material from godowns and silos to dosing bins houdi operatore are required.

Mash Production Plant:

Material after cleaning and grinding comes in mash bin if we want to make mash feed. From mash bin material comes into mash blender with the help of feeder. Here molasses add into the material and then it comes into mash screener and it is ready for packing.

Feed Nos. in Shahzor Feed Mill

Sr. No Feed No. Kind of feed

1 4 (Mash) Broiler starter

2 7A (Mash) Broiler starter

3 9 (Crumbs) Broiler starter crumbs

4 9-C (Crumbs) Broiler starter crumbs control

5 9-Cb (Crumbs) Broiler finisher crumbs control

6 10 (Crumbs) Broiler finisher crumbs

7 1A (Crumbs) Layer starter

8 2A (Crumbs) Layer grower

9 3A (Crumbs) Layer finisher

10 21 (Crumbs) Breeder starter

11 22 (Crumbs) Grower starter

12 23 (Crumbs) Layer breeder crumbs

13 24 (Crumbs) Broiler breeder pre-layer

14 25 (Crumbs) Broiler breeder male11

6)- Loading Section:

In this section, packed finished feed bags are loaded on vehicles and dispatched from the mil.

Analysis of feed Ingredients

Different tests are done for the analysis of feed stuff in Shahzor which are given with their procedures as follows:

1-Moisture Test:

Mix the material thoroughly.

Take Petri dish and weigh

Take sample in petri dish of 20 gm with spatula.

Take sample in Petri dish and put it in oven at 120 oC for 2 hours.

After 2 hours put the Petri dish in Desicater for 10-15 min.

Weigh the Petri dish.

Calculation:

Wt. of Petri dish = 47.737g --------------------A

Wt. of sample = 20.0g --------------------B

Wt. of Petri dish with sample after drying = 65.677g --------------------C

Moisture % =A+B-C/B×100

=47.137+20-65.677/20×100= 7.30%

2)-Ash test:

Weigh the crucible without sample (W1). Weigh about 5gm sample in crucible. Heat the sample content crucible until the sample is charred. Transfer it in the furnace for 2 hours (Temperature 550oC). After 2 hours cool in a desicator. Weigh the Ash with crucible (W2).

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Calculation: % of Ash = (W2 – W1) /5* 100

3)- Crude Protein Test:

Digestion

Weigh 0.30 gm of finely ground Sample add 5gm Digestion Mixture on a butter paper. Place it into the digestion tube. Add about 10ml commercial Sulfuric Acid in tube. Set the temperature of stove on 420 C. Digest this solution for 60 minutes in Digestive stove (light green color). Then allow it to cool for 30 minutes, add about 5-10 ml D.W. Distillation

Take 20 ml Boric Acid (2 %) solution in a 250ml conical flask placed it on its position in the distillation unit.

Insert both pipes (NaOH pipe and D.W pipe) in to its Solutions. Turn on the Alkali Switch; add suitable amount of NaOH (Until distillate becomes Black)

and turns its off. Ensure the Water is always running. Turn on the Steam Switch; allow the distillation of Ammonia into the Boric Acid solution

about 120-150 ml. (it takes just 4-5 minutes) Titration

Titrate the distillate against 0.5N Sulphuric Acid; the color changes from green to light Purple, read the end point.

Accessories:

Digestion Mixture =Potassium Sulphate 150 gm+ Copper Sulphate = 10 gm

Boric Acid 2 % =20 gm Boric Acid in 100 ml hot D.W and mix well, transfer this solution in to the 1000 flask add about 500 ml D.W. cool this solution, Then add 7 ml of Methyl red Indicator + 10 ml of Bromocresol green Indicator and make the Volume 1000 ml with D.W.

NaOH 40 % = 400 gm NaOH in 200 ml D.W allow to cool and make the volume up to the 1000 ml with D.W.

Methyl red Indicator = 0.1 gm Methyl red in 100 ml Ethanol.

Calculation: % of C.P = Burette Reading-B (blank) * 14.583

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Determination of KOH solubility:

Take1.5g sample in conical flask (500ml) and add 75ml (0.2% KOH) solution in it.Stirrer it on a magnetic stirrer for 30 min. After stirring centrifuge the sample in 5 tubes for 15 min. at 2700 rpm. Then take 15 ml sample from supernatant, it is the portion of the meal which is soluble, of tubes in kjeldahl flask. Add 5 g digestion mixture, 30ml H2So4 and digest it for 3 hrs. After digestion make volume 250 ml. Then distill, titrate it and calculate the C.P. then KOH solubility.

KOH solubility = A-B×72.9/C.P×100

Urease Activity:

Small amount of sample is taken in a petri dish. Small amount of urea solution is poured on it. After 5 minutes , check the amount of reddish particles in sample from bottom side of the pettri dish. Red particles show urea solubility ( if red are less in amount , it means urea activity is less , if more it mean urea activity is more.

Urea solution composition:

KH2PO4 = 1.7015 gm

K2HPO4 = 2.1775

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