YEDENT AGRO GROUP OF COMPANIES PROCESSING OF SOY BASED PRODUCTS FOR HUMAN FOODS AND POULTRY FEEDS

Transcription

1 YEDENT AGRO GROUP OF COMPANIES PROCESSING OF SOY BASED PRODUCTS FOR HUMAN FOODS AND POULTRY FEEDS

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3 1. SOYA EXTRUSION AND PRESSING PROCESS EQUIPMENT 1. The Pre Cleaner 2. The Course Mill 3. The Extruder 4. The Oil Press 5. The Counter Flow Cooler 6. The Final Mill

4 THE PRODUCTION PROCESS 1. SOYA PRE CLEANING Equipment used for the pre-cleaning includes an aspirator fan which draws dust and lighter matter / chaff out of the flowing grain and a vibratory screen unit which has two screens; the larger scalps larger particles and stones into a collecting trough and a smaller screen which allows broken particles, sand and dust to fall through leaving the clean and whole soya grain to be received at the bagging end. 2. COURSE MILLING The Soya grains are conveyed from a hopper into a stainless steel hammer mill rated at 1mt/hr by a screw auger for a course milling to reduce the soya grains into a course flour

5 .3. EXTRUSION The coarsely milled soya is fed into the extruder which extrudes the soya at high temperature (140 C) and pressure 4. PRESS AND COOLING The hot extruded product is conveyed through a vented screw auger into the press where the oil is squeezed out of the meal. The crude oil is pumped into a reservoir whiles the pressed soya cake is transported into the counter- flow cooler for cooling before final milling 5. MILLING The cooled product is then fed into the final mill for fine milling and then bagged.

6 2. CEREAL BLENDS PROCESSING LINE EQUIPMENT 1. The Pre Cleaner 2. Sorting Line 3. The Roaster 4. The Mixer 5. The Primary Mills 6. The Sifting Unit 7. The Final Mill 8. The fortification and Disinfestation unit 9. The Packaging Unit

7 THE PRODUCTION PROCESS 1. GRAINS CLEANING Equipment used for the cleaning process includes an aspirator fan which draws dust and lighter matter / chaff out of the flowing grain through a cyclone and a vibratory screen unit which has two screens; the larger screen scalps larger particles and stones into a collecting trough and a smaller screen which allows broken particles, sand and dust to fall through, leaving the clean and whole soya grain to fall unto the sorting table. Magnets are placed at vantage positions to remove ferrous metal pieces. The targeted yield of cleaned maize is 99.5 % of the lot introduced.

8 2.SORTING As a food grade manufacturing entity, grains meant for production must be of impeccable quality and within the specification and standards established. The raw material is discharged from the cleaner onto a belt conveyor for manual picking of unwanted matter such as stones, cobs, or any other foreign material other than the grain been sorted. Grains sorted are weighed at 50kg before being sent for roasting.

9 4. ROASTING Raw maize and soybeans are roasted by a continuous flow roaster which burns liquefied petroleum gas (LPG) for heat. Raw grain of known weight is fed into an inclined screw conveyor which feeds the roaster. The grains are admitted onto the moving belt of the roaster which takes them through drying, roasting and cooling sections of the roaster. The purpose of this heat treatment is to improve the digestibility of the proteins and the starch components of the cereals, and act as a pasteurization stage against the presence of undesirable microorganisms. For maize, roasting temperature is 150 C, at a residence time of 20 minutes and grain depth of 10cm, while for soybeans; roasting temperature is 160 C, residence time of 25 minutes and grain depth of 8cm. Roasting rate is 1mt/hr. Roasted products are bagged and weighed

10 5.MIXING Roasted grains are weighed in accordance with product formulation ratios. These are then introduced into a 0.5mt- capacity-horizontal mixer as a batch to be blended. The mixing process, after the introduction of the grains, takes 5 minutes into a homogeneous matrix before milling commences..

11 6. MILLING AND SIFTING Mixed grains are conveyed from the mixing hopper into a stainless steel hammer mill rated at 0.75mt/hr by a screw auger for an initial milling. The milled meal is transferred to the rotary sifter by aid of a pneumatic conveyor. Meal that goes through a predetermined micron screen in the sifter is moved by a pneumatic conveyor into a 1mt stainless steel holding bin for subsequent weighing and bagging. Oversized milled meal is fed by a screw conveyor to the secondary mills to the required granulation.

12 7. MIXING (FORTIFICATION AND DISINFESTATION The required quantity of micronutrients (premix vitamins and minerals that are designed to compensate for low levels of these nutrients in the diet) for a ton of milled meal is added to a part of the meal and fed into the vertical mechanical- batch-mixer simultaneously with the rest of the milled meal to make a total of 1ton. The vertical mixer is left to run for another 30 minutes after all of the 1ton meal is introduced. The mixed meal is then discharged into lined sacks ready for the disinfestation process. Losses should not exceed 1% of the lot introduced The fortified meal is fed at a rate of 0.5mt/hr into a stainless impact finisher which employs high speed fans (3000rpm) to generate impact to destroy any live insect eggs that might remain in the product for the purpose of prolonging the products shelf life. Heat is applied at a point to raise the temperature of the product running through the finisher to between 50 C and 55 C as a further measure to destroy any insects or eggs before it is cooled finally for bagging

13 8. PACKING A form-fill-seal equipment is used to pack the finished product in laminated printed foils. Packaging rate varies from 0.20mt/hr for 100g sachets to 3mt/hr for 5kg cathedral bags. Production and expiry dates as well as product batch numbers are printed during packaging. The product is fed into the packaging machine by a screw auger into the holding bin. The machine forms the foil, fills in the product and seals finally. The sealed sachets from the machine are manually packed into paper cartons and released to the finished products warehouse.