A, electricity
Electricity is the largest part of the power cost of feed plant, and crushing is not only a necessary process in feed processing, but also one of the highest power consumption processes. The power consumption of the crusher probably accounts for about 40% of the total power consumption of the feed plant. The grinding efficiency directly affects the cost of electricity consumption. Grinding efficiency and the company's requirements for the use of raw material variety, grinding size, performance of the crusher, hammer screen clearance adjustment (such as 2.0mm screen, hammer screen clearance is 10-13mm; The hammer screen clearance is adjusted according to the mesh aperture), hammer wear, whether the crusher is operating at full load, shakelon and pulse dust removal effect and other factors have a great relationship. The pelletizer machine consumption accounts for about 30% of the total power consumption of the feed plant. There are three key operating parameters for the pelletizer operation: steam supply, feeding speed, ring die and roller clearance. The steam supply and feeding speed are mainly determined by the moisture content and formula composition of the material to be granulated. If these two parameters are not adjusted properly, it is easy to block the machine, thus reducing the capacity of the pelletizer and increasing the power consumption per ton of the pelletizer. If the gap between ring die and press roll is too small, the press roll ring die is easy to wear. If the gap is too large, the material between the press roller and the ring die will be too thick and uneven distribution, resulting in the material can not be extruded out and the phenomenon of blocking the machine. In addition, the larger the rING-mode compression ratio is, the higher the particle hardness is, but the lower the output is, the higher the electricity cost is. The lower the opening rate of ring die is, the more likely it is to be blocked. The greater the wear degree of the press roll, the lower the output, the greater the wear of the ring die.
The main methods to reduce the power consumption of feed plant are as follows:
1, the production process is fully prepared, the connection arrangement is compact, reduce the production preparation time and equipment idling, avoid the waste of labor, power, fuel, time cost.
2. Use stepped electricity price to organize production and reduce electricity cost of production. Electricity prices are usually about three times higher at peak times than at low times. Because the electricity fee is in the trough period at night, it is necessary to arrange night shift production of granulator as far as possible, and reduce the blocking phenomenon of night shift granulator.
3, as far as possible to reduce the variety and number of material transfer (if necessary, appropriate increase of finished product inventory, can reduce the number of material transfer).
4, production control, granulating equipment machine, for fear of the crusher and pelletizer current control in rated current 60% to 70%, or less, make the most of the feed mills crusher, granulator equipment is under load and idle phenomenon, there is no such as crusher, granulator, equipment to operate at full capacity, so the power consumption to increase, This requires the personal supervision of the factory director and assistant, each discovery should be timely warning, if necessary, to give appropriate assessment and reward and punishment;
5, reduce equipment downtime and maintenance time.
6, the use of different performance of equipment and technology, power consumption is huge. For example, when the soybean meal is finely crushed, the power consumption of the wide multi-cavity crusher with the same power is more than 1/3 lower than that of the common water drop crusher. From the above analysis, it can be seen that electricity waste is widespread in some feed factories (especially those with poor management), and there is great potential to reduce the power consumption in the production process.
Two, fuel costs
Some feed plants use natural gas or oil as boiler fuel, the steam cost of oil-fired boiler is more than 3 times higher than coal-fired boiler. When coal-fired boilers are used, feed mills can push for coal payment by steam rather than by weight. Because settle accounts by weight the quality that assures coal hard, easy adulterate. Feed factory in the implementation of coal by steam amount settlement, we should pay attention to the monthly settlement of steam, because steam flow meter data can be adjusted, feed factory needs to prevent boiler workers and coal suppliers have illegal interests transport, theoretically speaking, steam consumption should be less than 5% of the total amount of granulation.
The feed factory also needs to regularly check whether the steam pipeline leaks, whether the soda water separator works normally, whether the burner gives full play to the maximum efficiency, etc. Special attention should be paid to the quality of coal. The poor quality of coal leads to the steam pressure before decompression can not reach 0.6-0.8mpa, and it is difficult to provide dry saturated steam for the pelletizer, which affects the pelletizing efficiency and particle quality, and also leads to the low moisture content of feed conditioning, increasing the loss of raw materials. Regularly check the heat preservation of steam pipelines to minimize heat loss and reduce coal consumption. Feed factory should arrange production reasonably, avoid production link not free. For example, when the steam reaches the service pressure, the steam equipment is not ready; Or the steam equipment is ready, the steam can not meet the requirements for a long time, resulting in the waste of steam and the reduction of production efficiency. In the production arrangement of granular material, it is best to achieve continuous production, to avoid the waste caused by the exhaust and condensate discharge of each particle machine boot.
Iii. Reasonable control of spare parts inventory
Feed factory directly used for production of wear parts are ring mold, roller, hammer, screen, hopper, belt, bearing, motor, sewing machine accessories, gear, sprocket and so on. The factory director should analyze the monthly maintenance expenses, strengthen the whole process management of maintenance parts procurement, and focus on: 1. Formulate reasonable inventory of parts to reduce the backlog of funds. 2. Establish records of receiving and consuming parts. 3. Determine the standard range of normal consumption. 4. Regularly evaluate and examine the quality of accessories provided by suppliers. For example, the same compression ratio, the same caliber of stainless steel ring die although the price is much higher than alloy steel ring die, but stainless steel ring die quality assurance time, ring die service life and wear resistance is alloy steel ring die is incomparable, the use of cost is lower than alloy steel ring die. Even if all are stainless steel ring die, the quality between manufacturers is also uneven. According to 420 stainless steel pressing film 6,500 yuan/unit calculation, if each ring mold can produce 16,000 tons, the pressing film cost is 0.41 yuan /t; If each pressing film can only produce 0.8 million tons, then the pressing film cost is 0.81 yuan. In addition, it should be noted that frequent film changes can have a serious impact on the duration and yield of the film.
Four, reasonable control of maintenance costs
The reasons for the high maintenance cost are as follows: first, they do not pay attention to the repair of equipment and tools, and always buy new ones; Second, the maintenance level is low, resulting in high cost of repeated maintenance, especially in the number of overhaul; Three is the maintenance of accessories loss, including poor quality purchase, shoddy, accessories lost, stolen, damaged, etc.; Four is the feed factory accessories purchase lack of monitoring, resulting in high procurement costs; Fifth, the cost of maintenance auxiliary materials is high (steel, welding rod, oxygen, acetylene, grinding wheel, cutting saw blade, etc.); Sixth, the preventive maintenance of equipment is not enough, resulting in high maintenance costs after the complete breakdown of equipment. The failure of equipment should be prevented primarily and repaired as a supplement. Through sound daily maintenance, the failure rate can be greatly reduced to ensure the normal production.
5. Speed up the upgrading of process equipment
With the development of feed industry, in recent years, China's feed processing equipment upgrading speed up, feed processing equipment professional degree continues to improve, feed equipment manufacturing enterprises to feed factory launched energy-saving professional new processing equipment, for improving production efficiency, reduce production costs, It plays an obvious role in stabilizing the processing quality and increasing the added value of products. Feed mills should actively adopt equipment that can save energy and reduce consumption and low operating cost, especially for those production lines and equipment that have been running for many years, with large energy consumption, low production efficiency and poor safety performance. Efforts should be strengthened to improve technical transformation and reduce the comprehensive cost of the production process.
When equipment replacement, try to consider the full implementation of automation operations. For example, a 5T/h manual feeding, automatic batching and manual product stacking production line compared with a 40T/h automatic feeding, automatic batching and mechanical stacking production line, the latter requires fewer production workers, but there is a significant difference in capacity. Under the premise of producing the same amount of feed, the labor cost of the latter is much lower than the former. The reason for the high labor cost is the production process is limited, the automation of the production line, the degree of mechanization is low, have to use more labor, and the labor intensity of the workers, the loading and unloading process cost is high, the per capita production efficiency is low. Therefore, from the raw material into the workshop to the finished product stacking process, the full implementation of automatic operation, as far as possible to reduce the scope of manual operation, not only can save labor costs, but also can save time, space, safety and other production costs. More importantly, as long as the equipment is normal, the production and quality are stable, while manual operation, affected by people's ability, work enthusiasm, production and quality is unstable. If conditions permit, we can explore and promote the mode of automatic bulk feeding and bulk finished product transportation to save the labor cost and packaging material cost of loading and unloading during feeding and packaging.
Six, feed plant raw material loss
The feed raw material cost of a feed factory accounts for about 70-85% of the production cost. Whether the raw material loss can be controlled at a reasonable level is an important symbol to measure the management level of a feed factory. Feed factory should strictly implement the weighing system and inventory system of raw materials and finished materials, so as to timely find and analyze the cause of abnormal loss every month (or every half month). Reasons for raw material loss in feed processing include: dust loss (unloading, crushing and dust removal, cooling and dust removal, equipment and pipeline sealing is not strict leading to material running and leaking); Moisture loss (unloading, storage, crushing, cooling); Measurement error loss (raw material weighing, batching scale, packaging scale, etc.); Deterioration and other loss (deterioration of raw materials or finished materials, high impurity content of raw materials, scale not cleaned in time, broken bags, rodents, theft, etc.).
Feed mills should attach great importance to the loss of dust. For example, some feed factory corn unloading shed and soybean meal unloading shed is sealed on both sides and ceiling, which can be transformed into three sides and ceiling seal, leaving only one side in and out of the vehicle, so that the convection air volume is greatly reduced, so that the soybean meal and corn dust natural settlement, reduce the dust loss blown away by the wind. It is suggested that feed mills with conditions choose automatic hydraulic unloading platform as far as possible to minimize the dust loss in the unloading process of bulk raw materials
For many feed mills, the water loss in feed processing accounts for more than 50% of the raw material loss. Feed factory should pay close attention to the water content in the finished material, the normal water content is an important index, too high water content will lead to feed easy mildew, too low water will increase the loss of feed factory, and too high or too low water is not conducive to the palatability of finished material. General finished material temperature is not higher than the ambient temperature 5 degrees, moisture is less than 13%. Water loss mainly occurs in storage, crushing and cooling. In the storage link, the feed factory should try to reduce the stock of raw materials in the silo in summer, so as to avoid large evaporation of water due to high temperature. In the process of comminution, excessive comminution should be avoided, the temperature in comminution room should be reduced, the air pressure and suction volume of pulse fan should be controlled, and the water loss of comminution should be controlled by improving comminution efficiency. For example, a feed mill improved its grinding efficiency by 25% after replacing the crusher. According to the normal grinding process water loss 0.5%, after the replacement of the crusher, the yield increased by 25%, conservative estimate, the grinding process water loss decreased by 0.13%. Calculated according to the feed factory produces 10,000 tons of finished materials per month (raw materials to be crushed are calculated according to 80%), loss can be reduced: 10,000 tons *0.13%*80% = 10.4 tons, calculated according to 3,000 yuan per ton of finished materials, loss can be reduced by 31,200 yuan. In the cooling link, the ventilation volume, time, speed and material level device of the cooling tower should be adjusted according to different seasons. Generally, the wind speed in the cooling duct is controlled at 15-20m/s. In addition, it is relatively simple to control the moisture of finished materials by adjusting the height of material leveler in cooling tower, which requires constant attention to the moisture results of finished materials in laboratory for timely adjustment. In addition, an effective way to reduce the loss of raw materials is to monitor and add moisture online during the whole process of production, especially the moisture of the finished material after crushing, mixing and tempering the feed. Under the premise of ensuring safety, water is added in the mixer or modulating cylinder to reduce the loss of moisture of raw materials.
Vii. Comprehensive consideration of raw material costs and processing and manufacturing costs
Considering and balancing the relationship between raw material cost and production cost of feed factory, it may be an important index to evaluate the level of formula technology. For example, viscous raw materials with large sugar content are cheap, but their processing performance is poor. Because of their high sugar content, they tend to stick to the warehouse and equipment, which not only affects the mixing efficiency, but also increases the load of the conveying equipment due to the sticky materials for a long time, leading to the problems of slow material removal and low production efficiency at the bottom of the mixer. In serious cases, the belt of the hoist will break. For example, adding a variety of liquid ingredients in the same formula will lead to prolonged mixing time, reduced batch of ingredients, so that the production cost increases; The more complex the composition of the formula, the longer the compounding cycle, that is, the lower the production efficiency, and therefore the higher the production cost. Therefore, the feed factory should timely communicate the processing performance and processing cost of different raw materials with the formula division, and the formula division should not only consider the raw material cost, but also consider the production and processing performance of raw materials when considering the composition of the formula.
Eight, strengthen the training of feed factory staff and cadres
The quality of feed factory staff determines the cost and quality of feed factory processing. Therefore, on the one hand, it is necessary to strengthen the training of employees in key technical positions, encourage employees to carry out vocational skills identification, encourage employees to participate in various training and learning, and strengthen the management of safety awareness to reduce the occurrence of safety accidents. Key positions such as central control, machine repair, electrician, granulator, boiler worker, etc., the level of these personnel's operation level directly affects the equipment efficiency and feed processing cost, in terms of salary can be appropriately tilted to these key technical positions. On the other hand, we should strengthen the cultivation of employees' loyalty to the enterprise, do a good job in the career planning of employees, stimulate the enthusiasm, initiative and creativity of employees, and formulate a reasonable assessment of employees' production cost process incentive measures.
At present, feed processing cost control involves feed processing technology, equipment, electrical and mechanical control, feed nutrition and production process management, on-site logistics management and so on. Not only requires the feed factory director to have strong management ability, but also requires the feed factory director to have comprehensive professional knowledge, in order to do a good job in the feed production process of on-site management, equipment management, quality management, so as to achieve reasonable scheduling and effective grasp of the production process, so as to control the cost of the production process. To this end, need to feed factory director training and make a professional production manager.
Scientific management
Dirty and messy is the common disease of most feed factories. In the warehouse, the stacking of raw materials is not orderly, different raw materials are mixed with each other, raw materials in stock are not marked, raw materials are scattered all over the ground, running and leaking seriously, and rodents are rampant. There is a lot of garbage in the workshop, raw materials are piled up everywhere, packaging and labels are thrown about, and recycled materials are everywhere and unmarked. Floors, equipment, doors, Windows and roofs are covered with dust, cobwebs, etc. Therefore, feed factory should pay attention to the daily work of the production site for scientific fine management. Only by adopting scientific site management means and mastering the real situation of the site, can we carry out fine management on the feed plant and take measures to reduce costs. Feed plant on-site management system includes: quality control system, energy saving control system, environmental control system, equipment management system, logistics control system, process control system, production operation standardization system, etc. The commonly used on-site management methods of feed plant include 6S management, Lean production management, quality cost management (QCM), TPM and ISO
