Premix production is a highly precise and standardized process. Its core lies in the uniform dilution and dispersion of trace components (vitamins, minerals, amino acids, medications, etc.) within a carrier to ensure the nutritional balance and animal safety of the final feed product.
The following is a detailed process of premix production, which can be divided into several key stages:
I. Pre-Production Preparation Stage
Formulation Design:
Animal nutrition experts scientifically calculate the precise addition ratios of various trace components and carriers based on the nutritional needs of the target animal, raw material characteristics, production processes, and regulatory requirements.
Raw Material Procurement and Inspection:
Trace Components: Procuring high-purity vitamins, minerals (sulfates, oxides, etc.), amino acids, enzyme preparations, and pharmaceutical additives.
Carriers and Diluents:
Commonly used carriers include maifanite, zeolite powder, rice husk powder, and defatted rice bran. Requirements include low moisture content (generally <10%), moderate particle size, chemical stability, and good flowability.
Strict Incoming Inspection:
All raw materials must undergo testing to confirm that their effective ingredient content, purity, and hygiene indicators (heavy metals, microorganisms, etc.) meet standards.
Production Order Issuance:
A production list is generated based on the formulation, specifying the batch number, raw material type, feed quantity, production sequence, and process parameters.
II. Core Production Process
The production process typically takes place in a closed, dust-free, and cross-contamination-free environment, following the principle of "large quantities first, then small quantities."
Step 1: Carrier Pretreatment
The carrier may contain impurities and excessive moisture. It must first be cleaned and crushed, then dried in a dryer to control the moisture content within the standard range (usually 8-10%).
After drying and cooling, the carrier enters the mixing chamber.
Step 2: Precise Batching
This is the most critical step, directly determining the quality of the premix.
Large proportion raw materials (such as carrier, dicalcium phosphate, salt, etc.) are usually weighed using a large scale.
Trace raw materials (vitamins, trace elements, drugs, etc.) must be weighed on a separate, high-precision micro-ingredient scale, often in a dedicated "micro-ingredient room" to avoid cross-contamination. Many modern factories use automated batching systems to reduce human error.
Step 3: Mixing
Put all weighed raw materials into the mixer.
Mixer Type:
High-efficiency twin-shaft paddle mixers or horizontal ribbon mixers are commonly used to ensure high mixing uniformity.
Mixing Sequence:
Usually, most of the carrier is added to the mixer first.
Then, trace components are added (following the principle of adding components with better stability first, then those with poorer stability).
Sometimes a small amount of grease (usually 1-3%) is added for "grease coating," which reduces dust, prevents stratification, and stabilizes vitamins.
Mixing Time:
Strictly adhere to the optimal time determined by equipment performance testing. Insufficient time will result in uneven mixing, while excessive time may lead to stratification or electrostatic adsorption.
Step 4: Finished Product Packaging and Labeling
The uniformly mixed finished product is conveyed to the finished product hopper via pneumatic conveyor or scraper conveyor, and then enters the automatic packaging machine.
Packaging materials must be moisture-proof and light-proof (e.g., multi-layer laminated woven bags).
The packaging bag must clearly indicate: product name, product number, main ingredients, proportions, target users, production date, batch number, shelf life, and manufacturer information.
III. Key Post-Production Steps
Quality Inspection:
Mixing Uniformity Inspection: Ensure CV ≤ 5% by testing the coefficient of variation (CV) of a tracer (e.g., salt content, specific minerals) in the sample.
Active Ingredient Content Inspection: Sampling and testing key vitamins, minerals, and other indicators to ensure consistency with label values.
Sampling Retention: Samples of each batch of product must be retained for a period after the expiration date for quality traceability.
Storage and Transportation: Finished products should be stored in a cool, dry, and well-ventilated warehouse, avoiding contact with toxic or harmful substances. Protect from sunlight, rain, and damage during transportation.
IV. Core Elements for Ensuring Premix Quality
Accuracy: Absolute precision in ingredient formulation.
Uniformity: Highly uniform mixing, ensuring each small portion of feed contains equal amounts of trace components.
Stability: Minimizing the loss of active ingredients (especially vitamins) during production and storage.
Safety: Eliminating cross-contamination (especially with pharmaceutical additives) and ensuring compliance with hygiene standards.
Traceability: Clear records throughout the entire process from raw materials to finished product, allowing for tracing any issues back to their source.
V. Special Precautions in Production
Cross-contamination control: After producing medicated premixes, the production line (mixer, conveying pipelines, silos) must be thoroughly cleaned before producing the next batch of non-medicated or different medicated premixes. Many factories have established independent production lines.
Static electricity and dust control: Trace amounts of raw materials can easily generate dust and static electricity, affecting mixing and adsorption. Factories need a good dust removal system and process control.
Personnel training: Operators must undergo rigorous training to understand the importance of precision and standardized operation.
premix production is a process of transforming "precise science" into "standardized industrial products." It may seem simple, but it has a high technical threshold and is the most technologically advanced link in the feed industry, often referred to as the "heart" and "chip" of feed.
