Poultry feed manufacturers rely on consistent fat application to ensure pellet quality and performance. In this case study, APEC worked with a large poultry feed manufacturer to replace a spray-based coating process with a more reliable poultry feed coating system designed to improve uniformity, reduce downtime, and eliminate common maintenance challenges.
Challenges in Poultry Feed Processing
Clogging and Inconsistent Fat Application
The customer experienced frequent clogging issues with their existing spray coating machine used to apply fat to poultry pellets. These clogs resulted in spotty pellet coverage, inconsistent coating quality, and increased downtime for cleaning and maintenance.
Maintenance and Equipment Reliability Issues
Excessive wear on pumps caused by the spray nozzle system led to frequent pump rebuilding and replacement. This increased maintenance costs and disrupted production schedules, highlighting the limitations of the existing poultry feed processing equipment.
Automated Poultry Feed Coating Solution
Mistcoater Poultry Feed Coating System
APEC provided a Mistcoater poultry feed coating system to replace the existing spray nozzle equipment. The Mistcoater was designed to operate within the existing footprint, minimizing installation costs while improving coating performance and reliability.
Nozzle-Free Design for Reduced Downtime
The Mistcoater utilizes a nozzle-free liquid application design, eliminating the risk of clogged spray nozzles. This approach improved coating consistency and reduced maintenance requirements compared to traditional poultry feed processing equipment.
Results of Upgrading Poultry Feed Coating Equipment
Improved Coating Uniformity and Reduced Maintenance
By eliminating spray nozzles, the Mistcoater delivered consistent fat application across poultry pellets while significantly reducing downtime. Maintenance requirements were reduced, and the need for frequent pump rebuilding was minimized.
Reliable Performance Within Existing Operations
The upgraded poultry feed coating system improved overall process reliability without requiring major changes to the production line, supporting efficient operation within the customer’s existing feed manufacturing facility.
This project demonstrates how upgrading poultry feed processing equipment with a reliable, nozzle-free poultry feed coating system can improve coating uniformity, reduce downtime, and enhance overall production efficiency.
Explore additional APEC resources for product sheets, guides, and case studies related to feed automation, or contact APEC today to learn more about improving poultry feed coating performance.
