Energy-Saving Techniques in Feed Milling: Capacity, Moisture, and Efficiency Insights

Energy savings in feed milling go beyond simply reducing kilowatt-hours; the key is optimizing throughput capacity to achieve the lowest energy consumption per ton of feed produced. Understanding and addressing production bottlenecks in the plant enables feed mills to maximize capacity and minimize energy intensity, especially when shifting between floating and sinking feed types.

One critical factor influencing capacity and energy efficiency in producing sinking feeds is the extrusion die design. Historically, dies limited throughput for sinking feeds, resulting in lower production rates and higher energy per ton compared to floating feeds. However, advances in die technology have largely overcome this challenge, enabling sinking feed production rates nearly equal to floating feeds. Designing dies that push capacity to match the dryer’s ability to effectively remove moisture is essential to avoid bottlenecks and improve energy utilization.

Dryer performance itself plays a crucial role in energy savings. Efficient drying prevents product override or uneven drying, which can cause feed losses and energy waste. Careful control of drying ensures that energy input translates directly into feed quality and consistent moisture content.

Extrusion Moisture vs. Operating Cost and Feed Performance in Feed Milling

The attached chart vividly illustrates how extrusion moisture percentage impacts operating cost, energy consumption, and feed performance. Key points from the chart include:

• Drying and steam costs increase linearly with moisture content, reflecting the energy required to remove water.

• Operating load or extruder energy cost decreases as extrusion moisture rises, showing that more moisture reduces resistance and energy needed in the extruder.

• Feed performance, measured presumably by growth or feed conversion metrics, peaks in an optimal "sweet spot" of about 22-32% extrusion moisture.

• Together, these trends indicate the most energy-efficient and productive operation occurs within this moisture range where drying cost is balanced by reduced extrusion energy and maximal feed results.

By optimizing moisture in extrusion processes, feed mills can simultaneously reduce drying energy, lower extrusion load, and attain improved feed performance.

In summary, feed mills aiming for energy savings should focus on these interrelated factors:

• Identify and address plant bottlenecks to maximize throughput capacity rather than just cutting raw energy use.

• Utilize advanced extrusion die designs suited for sinking feeds to enable higher production rates with lower energy intensity.

• Optimize dryer operations to achieve consistent, even drying and avoid energy loss from product override.

• Target extrusion moisture levels in the approximate 22-32% range to achieve a balanced cost-to-performance sweet spot.

  
  

Implementing these strategies not only reduces energy consumption on a per-ton basis but also leads to higher quality feed and better farm performance. Understanding the trade-offs between moisture, energy costs, and feed outcomes empowers feed mill operators to make smarter, data-driven decisions.

true energy savings in feed milling are achieved by strategically optimizing throughput capacity, adopting advanced die designs, and managing extrusion moisture to hit the perfect performance-cost sweet spot. To master these data-driven strategies and gain hands-on expertise, consider attending the In-Person AgriSchool Aqua Feed Milling Management training course. Hosted by Progressus, this program runs from November 18-21, 2025, in Bangkok, Thailand. Take this opportunity to learn from industry experts and make smarter, more sustainable decisions for your operation. You can learn more and register at https://www.progressus.asia/agrischool-inperson-afm.