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The Leader in Technical Knowledge for the Pelleting Industry
Conditioning for Pellet Quality

& Feed Safety
Presented by
Greg Alles
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Factors Affecting
Pelleting and
Pellet Quality
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Factors Affecting Pelleting and

Pellet Quality
40
35
30
Formulation
25
Conditioning
20
Particle Size
15 Die Specs
10 Cooling
5
0
F C PS DS Cool
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Factors Affecting Pelleting and

Pellet Quality
Formulation
Conditioning
Particle size
Die specs
Cooling
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Conditioning
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Controlled retention
time conditioner
Double conditioning
HTST conditioning feed expander
Double pelleting
Mix compress
Large size pellet mills Process design acc. salmonella
Long time conditioners Loss in weight feeding
Improved pellet mill conditioners Fully computerized pellet mill operation
1980 1985 1990 1995 2000 2005
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Conditioning Objectives
• Conditioning provides time for steam and other liquids
to be absorbed.
• Will improve pellet quality and operating characteristic
of the pellet mill.
• Uniformity of product.
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Conditioning requires activation of
natural binders through:
• Heat/Temperature
• Moisture
• Time
OPTIMIZES PELLET QUALITY

The correct conditioning of a feed
compound for pelleting is necessary in
order to obtain a good pellet quality and an
effective utilization of the pelleting
installation.
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Rule-of-thumb
• For every 20 degree increase in the mash
temperature, 1% moisture is added from
the steam.
• Approximate maximum moisture content
of the mash in the die chamber is 18%.
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Steam Quality
• It does not matter what kind of conditioner you
have if you have poor steam quality.
• Once you reach the moisture threshold of the
pellet mill, you will
not be able to increase
steam addition any
further and you have
reach the maximum
allowable temperature.
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Conditioner Types
• Small Conditioner with Feed Screw
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Conditioner Types
• ADJUSTABLE
PADDLES
• STEAM BUSTLE AT
INLET END – ALL
STEAM ADDED
SIMULTANEOUSLY
• LIQUID ADDITION
DOWNSTREAM OF
STEAM ADDITION
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Cascade Conditioners
• Large volume conditioner with a large diameter shaft and
individually adjustable stainless steel paddles.
• The shaft is mounted in pillow block bearings ensuring long
life and low maintenance.
• Stainless steel trough
with easily accessible
cleaning/service hatches.
• The conditioner has an
integrated steam manifold
with adjustable steam valves
down the length of the trough.
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Controlled steam and liquid addition
• The unique multiple orifice steam
injection manifold distributes steam to
the raw material depending on the
absorption capacity of the compound.
• Via injection nozzles molasses, fat etc.
are added ensuring optimum absorption
of steam and liquid additives thus
giving maximum temperature and
homogeneity in the conditioned
compound.
• The ability of the conditioner to
effectively mix raw materials and
liquids makes it suitable for a wide
range of mixing processes in pelleting
and extrusion plants.
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Applying liquids in parallel to steam

Improves absorbability of liquids
Addition of
Liquids with
Steam Injectors
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• Steam and liquid injection

• Method of steam injection is
important if uniformity of the
distribution is to be achieved also
critical for pasteurisation
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Controlled Retention Time Conditioning

• Retention time conditioner Type CRT
• Provides time for steam and other liquids to
be absorbed – typically operating at 2 to 4
min.
• The purpose of pasteurisation is to provide
sufficient time to ensure uniform distribution
of heat
• Material flow first in first out principle is
secured
• High filling degree
• Formatted to eliminate common salmonella
strains and equivalent bacteria
• Improve pellet quality and operating
characteristic for pellet product uniform well
absorbed, less blockage and smoother
running
• Conditioning is achieved at temperatures of
up to 200°F
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• Conditioner design
• Full flight stainless steel screw with
variable speed drive
• Clean design stainless steel
construction
• Self-cleaning PT 100 temperature
probes gives constant accurate
temperature control
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• Large inspection doors giving full
body access for clean and
maintenance
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• Rotary pocket feeder
• A self-cleaning stainless steel rotary
feeder with variable speed drive
• Gives an even feed to the pellet mill
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• Modular built conditioning systems I
• Module I
• Prebin
• Feeder screw II
• Mixer conditioner type CM
• Module II
• Retention time conditioner type CRT III
• Module III
• Retention time conditioner type CRT
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Feed Expander
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Feed Expander
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Feed Expander
Process advantages:
• Increased addition of liquids, fat/oil, molasses to the compound before
pelleting
• No negatively influence on pellet quality
• Increased possibilities to compose feed formulas without regard to the binding
properties of the raw material
• Improved activating of the raw material‘s natural binding abilities
• Improved productivity
• Less fines – less recirculation
• Larger capacity on the pellet mill
• Fewer blockages
• Longer lifetime for pellet mill wear parts
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Feed Expander
Product advantages:
• Improved physical pellet quality/hardness
• Reduction/elimination of bacteria and mould etc. by heat treatment
• Reduction of growth inhibiting substances
• Improved digestibility of the feed compound
• Gelatinisation of starch (corn)
• Full fat soya
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Feed Expander
• Arguments for HTT conditioning
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Feed Expander
Feed Expander
• Functional principle
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Feed Expander
Feed Expander FEX
• Short burst of energy provides a high temperature and pressure the result of which is a
high degree of starch modification = improved feed performance
4 120 63
110 50 Temp
3
Starch Modification
2 85 20
0 50 100 150 200
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Feed Expander FEX
• Installation examples
CM 2 HD – CRT Conditioning
Mass Flow based feeding
Gate to prevent steam Steam and liquid injection manifold

back-flow
Steam conditioning and

liquid blend-in
Gate for securing

feed sanitation before pass-on
CTR Retention Time

Pellet mill Equalizer Conditioner
Feeder
Pellet mill By-pass

(Forced feeder incl.)
Slide gate to prevent

steam from backflow
Standard F&B
into the pre-bin
feed screw:
Primary heat source: Steam

Multipoint injection
manifold
Connection for
40 HP gear drive unit. excess steam
Prepared for relief
Frequency converter.
Reversible paddle shaft

for optimum steam /
feed interaction until
pre-set temperature
Stainless steel barrel
with heat tracing and
insulation with
Stainless steel cladding
Pneumatically operated
gate for feed retention
until set temperature
Gate closed Gate Open

Pneumatically operated
outlet gates for safe closing
and even discharge
Temperature censors for feed & trough Temperature sensors

located in door for easy
access and cleaning.
PT100 sensor
housing for
temperature
measuring on
casing
PT100 sensor
housing for
feed
temperature
measuring
Dampers to support the

doors while servicing
Full opening for easy

cleaning & paddle
adjustment
• Pre-heated conditioner with insulated, electrically pre-heated and insulated

conditioner barrel.
• Pre set temperature of all feed particles from 1st. second of feeding by steam
injection until desired temperature (185 deg F) before pass on of feed from the
conditioner.
• Cascade + CRT Conditioner = Pre- set retention time of all feed particles in pre
heated and insulated barrel before pass on to the pellet press
• Cascade + CRT + Pelletmill front pre-heated and insulated is the best way to
hygienic feed pellet production.
• Automation system secures functionality and trace-ability of all process inclusions
and process temperatures.
Data log documentation for full sanitation conditioning from 1st. second
Step 1:
Cascade conditioner
securing 185 deg. F
in all feed particles
at line start –up, and
optimum conditioning
while running
Step 2:
CRT 1101 Conditioner
First in First out,
securing 60 to 120 sec.
(variable) at selected temp.
for all feed particles
before entering the
Pellet mill.
Integrated pneumatically
operated
leak free discharge gate
between
Cascade and CRT 1101
The gate first opens when

entire
volume of feed has reached
Pre-set conditioning
temperature
Cascade/ CRT Conditioning system
Discharge feeder from CRT retention time

conditioner to pellet mill
Pellet mill with forced feeder

incl. integrated by-pass and double wall
insulated stainless steel front door.
• Cascade conditioner with adjustable

paddles.
• Uniform filling for optimum

conditioning.
• Multipoint steam injection and heated

barrel insuring no condensation
• Reversible shaft motion until pre-set

temperature
• Conditioning provides time for steam and other liquids
to be absorbed.
• Will improve pellet quality and operating characteristic
of the pellet mill.
• Uniformity of product.
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Questions?
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The Leader in Technical Knowledge for the Pelleting Industry

Conditioning for Pellet Quality

Factors Affecting Pelleting and

Factors Affecting Pelleting and

HTST conditioning feed expander

Large size pellet mills Process design acc. salmonella

Long time conditioners Loss in weight feeding

Improved pellet mill conditioners Fully computerized pellet mill operation

1980 1985 1990 1995 2000 2005

OPTIMIZES PELLET QUALITY

Applying liquids in parallel to steam

• Steam and liquid injection

Controlled Retention Time Conditioning

Controlled Retention Time Conditioning

Controlled Retention Time Conditioning

Controlled Retention Time Conditioning

Controlled Retention Time Conditioning

0 50 100 150 200

Feed Expander FEX

Gate to prevent steam Steam and liquid injection manifold

Steam conditioning and

Gate for securing

CTR Retention Time

Pellet mill By-pass

Slide gate to prevent

Primary heat source: Steam

Reversible paddle shaft

Gate closed Gate Open

Temperature censors for feed & trough Temperature sensors

Dampers to support the

Full opening for easy

• Pre-heated conditioner with insulated, electrically pre-heated and insulated

The gate first opens when

Cascade/ CRT Conditioning system

Discharge feeder from CRT retention time

Pellet mill with forced feeder

• Cascade conditioner with adjustable

• Uniform filling for optimum

• Multipoint steam injection and heated

• Reversible shaft motion until pre-set

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