Animal Feed Mixers & Vitamins, Mineral Processors

Animal Feed Mixers – Horse and Dairy

More companies are using the PHLAUER™ dual shaft mixers for horse, race horse, dairy feeds and vitamin and minerals.  The reason is that they get the highest quality at the lowest cost per ton with feed mixers that are predictable, repeatable, and reliable.

The mixers perform consistently at Cv. 5% based on small samples taken directly from the mixer.  The sample only has to be big enough to statistically contain the particles of the smallest ingredient.

Accurate liquid coatings as low as 0.6% can be done on pressurized pellets. Extruded kibble can also be coated as there is no shear in the mixer rotors. Flakes can also be mixed.

Mixing is a randomization process that requires voids for particles to randomly change place, and organized transportation to get ingredients from end to end. Voids are created mechanically using paddles. A high volume of voids is created by the sizing of the paddles with the voids equal to the batch size per rotor revolution in medium sized mixers. Demixing is controlled by the zone size serviced by the paddles which is always less than 10 inches (250 mm).

Low speed dual rotors using these principles mix dry in 30 seconds. Liquid additions vary. Higher coatings, over 5% can be very fast by slug loading the liquid and let the mixing actions wipe it from particles to particle, typically less than a minute. All the ends will be coated.

With low coatings, spraying and after mixing may be required, and times could be as high as 2 minutes. Every job has to be assessed, and if we don’t know how to design the liquid system, we will use our demo equipment to generate data and get the best appearance.

A & J offers a number of options to reduce maintenance. Accelerated wear should be given some consideration. Popular options are AR400 paddles, AR400 housing sides and discharge. UHMW liners are available, a unique feature on PHLAUER™ dual shaft mixers. Also available on single rotor. Heat treated sold to split shaft sleeves under the packings prevent shaft damage.

We recommend that you weigh all fats and oils. The costs will continue to rise, and weighing allows you to sell what you buy. Mineral oil, for example, is purchased by weight and the bulk density varies. Applying by time or volume can give a lot of variance. The payback for weighing is excellent.

Vitamins & Mineral Processors

Our experience in the last few years has been that new ingredients and recipes are harder to mix, particularly to get the end to end transportation. For that reason, we recommend you assess what the dual rotor can do.

We have rebuilt a paddle/ribbon mixer that could not achieve the Cv. ‘s, and have supplied two dual shaft AR400 machines, one with Shearmakers. There are just a few recipes that will have lumps, eg salt and iron oxide. They will not work well if the end user is putting them through a feeder. Shearing for 2 or 3 minutes can radically improve the product. We don’t usually design production to include shear time, and customers are taking lower production on these few items.

Another reason to look at dual shafts it the geometry of the discharge hopper. A long, narrow mixer can have shallow angles on the ends of the hopper causing poor flow. Every job, in our opinion, show be evaluated based upon total performance.

All the options available on animal feed are also available. We also believe attention should be given to accelerated wear. If stainless steel is required, it is softer than carbon steal in the annealed state which gives it chemical resistance. Some options could be to use thicker plate, UHMW, and SO17400 HT900 which has same properties as Tp304, but is heat treatable. It is several times the price of TP304. Teflon Inhibcote impregnation or other coatings could also be looked at.

Demo equipment is available.

Phlauer™ Double Rotor Mixer Lined with UHMW and Sleeves on the Paddle Arms
Optional Teflon Impregnated Removable Paddles

These mixers are lined to make them easier to clean where the mixer had to be scraped. The major industry that has to do this is producers of feeds containing molasses.

The mixer housing is lined above the mixing zone. The sleeves are UHMW tube that is put over the paddle arms. With the sleeves, the paddles cannot be welded on so they are removable. This makes it easy and economical to impregnate the paddles with Teflon.

At this time we are not sure that Teflon is an advantage. We have used them in other industries successfully, but there is no history in the animal feed business. For that reason we are conducting a test with one of our customers. In the attached picture, you will see half are impregnated, and half are not.

UHMW Line Double Rotor Mixer
UHMW Line Double Rotor Mixer

Why is the product unique?

The expansion of UHMW per degree of temperature change is 15.6 times greater than steel. For example, a 70 degree temperature change over 72″ of material, the steel expands 1/32″ and the UHMW 1/2″. A & J has experience with lining and having the lining “float”.

Up until recently this has been with single rotor mixers. The difference with a double rotor is that the paddles are turning upward in the center, so there is potential to have on side expanded far enough to catch the other set of paddles and rip it out.

A & J can prevent this because of our unique center configuration which is 90 degrees. We can fix an angle in the center and create an expansion joint at the start of the sheets.

A & J can prevent this because of our unique center configuration which is 90 degrees. We can fix an angle in the center and create an expansion joint at the start of the sheets.

This option is a 10 to 15% add-on, saves labor, and gets more production of the best quality feed.

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