M Tech Industrial Engineering & Management 2011-13 Semester III
CHAPTER III
PROCESS STUDY
3.1 KSE Ltd. Production Process
The process of cattle feed manufacture is comparatively a simple process once the
formulation of feed mixture is arrived at. The main aim of the process is to ensure that the
final mixture contains uniformly same proportion of the ingredients even in smallest possible
sample of, say, one gram is originally intended. Obviously, to attain uniformity in
concentration, a mixture of ingredients is to be ground to fine mesh and mixed thoroughly.
This mixed power can be used directly for feeding. Alternatively, the mixed ground material
can be pelletized. In brief, various steps in the processing of cattle feed manufacture can be
enumerated as follows
Material receiving and proportioning,
Material grinding
Mollassifying and mixing
Pelletizing and cooling
Packing
Production is carried out by new technology using computers to increase the quality of
the product. This may avoid the presence of harmful things such as urea in the cattle feed.
3.12 The various Steps Included in the Production Process are:
STEP: 1
16 bins are used to keep the different types of raw materials. When specific raw materials are
needed, then the lid of the bin will open and the materials pass through the conveyer belt.
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M Tech Industrial Engineering & Management 2011-13 Semester III
STEP: 2
Chief nutritionist formulates the formulae for the feed and perfect programming is done in the
control room by the computer to get the best feed.
STEP: 3
Production is done in batches of 1000 Kg. each. The number of batches to be produced for
each brand should be determined by the concerned engineer.
STEP: 4
The materials send to the lopper is automatically weighted and raw materials are put to
hammer mills.
STEP: 5
There are to hammer mills which powder the ingredients to produce a batch by rotating each
other.
STEP: 6
To enhance the quality and homogeneity of the products, the proper mixing is done in the
mixing unit.
STEP: 7
To increase the taste and smell of the feed, molasses is sprayed. Molasses is used to give
palatability to the feed an also as a source of energy.
STEP: 8
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M Tech Industrial Engineering & Management 2011-13 Semester III
Final stage is the packing of the product in various quantities and pasting of labels for each
quantity product.
RAW MATERIAL RECIEPT
QUALITY CHECK
RAW MATERIAL FEEDING
BATCH WEIGHING
BATCH GRINDING
BATCH MIXING
MOLASSES MIXING
PELLETISING
MASH
BAGGING
QUALITY CHECK
DESPATCH
Fig. 3.1 Production Process
3.2 Machinery
Since its inception, the plant is under continuous modernization to ensure quality and
efficiency in production. Some of the machineries in the plant are:
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M Tech Industrial Engineering & Management 2011-13 Semester III
Table 3.1 Major Machines
[Link]. Machines Specification Nos.
1 Hammer mills 40 HP 4
2 Batch mixer 20 HP 1
3 Pellet Mill 150 HP 2
4 Steam Boiler 1 TN/Hr 1
5 Bagging Machine 1 HP 1
6 Diesel Generator 350 KVA 2
7 Air Compressors 10 HP 3
3.3 MMCP-Technology
MILLING- Milling technology is being used for ensuring that all the granules are grinded and
screened by 3mm sieve.
MIXING-The raw material will be mixed thoroughly by using horizontal mixer of capacity.
COOCKING-The steam for the cooking is produced using 1MT Boiler at a temp. of 80 degree
Celsius.
PELLETIZING-Two Pellet Mills of the capacity 15 T/Hr each is used.
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M Tech Industrial Engineering & Management 2011-13 Semester III
3.4 Computerized Production
The most sophisticated feature of the unit is computerized system for the production.
The microprocessor controls the overall production procedure. A computerized control room
is situated near the plant. Then the experts can operate the production from the control room.
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