Importance of compressed air in feed mills
A general overview of the components of a compressed air system.
By Wilmer Pacheco, Adam Fahrenholz and Charles Stark
Compressed air systems play a vital role in the automation of various processes in feed mills. These systems ensure that ingredients and feed are handled efficiently and reduce labor costs (bin vibrators, automation of equipment, etc.). The purpose of this article is to provide readers with a general overview of the components of a compressed air system. It includes examples of where compressed air is commonly used and offers preventive maintenance tips to help ensure your compressed air system operates efficiently.
A typical compressed air system consists of three main components: the air compressor, the compressed air distribution system, and the equipment that uses compressed air. The compressor takes in ambient air and compresses it to a higher pressure, making it the heart of the system. To maintain optimal performance, it is crucial to check oil levels at least once a week and inspect for any leaks. During air compressor inspections, be sure to clean external filters and remove dust from the radiator. Additionally, clean and blow out electronic cards and variable speed drives. It is also essential to ensure the air dryer is functioning correctly and cycling properly to deliver the driest air possible to the distribution system as moisture can damage both the system and the equipment that uses compressed air. Regularly check operating temperatures and verify that the air compressor room has adequate ventilation to dissipate the heat generated during its normal operation. Inspect the openings of the louvers in the compressor room and if the compressor is in an enclosed space, consider using air extractors to reduce heat buildup. Finally, inspect the air tank and ensure that relief valves are functioning properly. The compressed air distribution system comprises of pipes, hoses, and fittings that transport the compressed air to various points of use. Ensure that air pressure regulators, water separators, and oilers are functioning correctly, as specified by the equipment manual. It is important to note that each piece of equipment may require different air pressures, so always use the air pressure recommended by the equipment manufacturer. The third component of the system includes the equipment that uses the compressed air, such as pneumatic tools, slide gates, and air-driven motors. It is important to regulate the oilers to the correct number of drops per minute according to each equipment manufacturer’s recommendations. Additionally, avoid over lubricating air cylinders as excess of lubricant can clog the mufflers in solenoids’ blocks and cause issues with the cylinders during normal operation.
Compressed air is widely used in batching and mixing processes, where air cylinders operate slide gates under scales and open and close doors beneath drop-bottom mixers. Defective slide gates and cylinders or inadequate air pressure in these areas can lead to manufacturing problems that can affect feed quality, as well as impacting subsequent processes like pelleting and potentially affecting animal performance or producing commercial feeds out of compliance with label guarantees. Additionally, compressed air may be used to atomize liquid ingredients and create a fan pattern during their application in the mixer, which aids in the even distribution of liquid products. During pelleting, compressed air can be used to activate vibrators at the bottom of mash bins, especially when bins are running low on product. This helps to reduce buildup and cross-contamination and serves as a reminder to the pellet mill operator that a bin is running out of mash feed. By-pass or dump chutes are often operated with air, therefore it is important that the chute is operating correctly to avoid sending mash to the cooler.
During your daily walkthrough of the feed mill, pay attention to air leaks, especially during weekends or when the feed mill is not operating. Remember that air leaks increase electricity costs and reduce air compressor capacity. It is important to regularly inspect and fix air leaks and replace worn-out or damaged components of the compressed air systems, such as seals, O-rings, and hoses. Maintaining optimal pressure in the compressed air system can help minimize air leaks, as excessive pressure increases their likelihood. Additionally, installing pressure regulators can help control air pressure in different parts of the feed mill.
Regular inspections, proper maintenance, and timely repairs of air leaks are essential for ensuring the normal operation of the compressed air system and the entire feed mill. By adhering to manufacturer recommendations and promptly addressing issues like leaks, worn components, and incorrect pressure settings, you can optimize energy consumption and maintain smooth feed mill operations. The next time you go around your feed mill, make sure to check your air compressor and ensure that its maintenance is up to date.
