A TECHNICAL REPORT
ON
STUDENT INDUSTRIAL WORK
EXPERIENCE SCHEME (S.I.W.E.S)
Oracle farms limited
BY
ASEN STEPHE
JOESEPH SAAWUAN
TARKAA
UNIVERSITY MAKURDI BENUE
STATE
NIGERIA.
SUBMITTED IN PARTIAL
FULFILMENT OF THE
AWARD OF BACHELOR OF
ENGINEERING (B.ENG) IN
MECHANICAL ENGINEERING
CHAPTER ONE
1.0 INTRODUCTION
This report is a brief description of my six
months internship carried out as compulsory
component of the B.Eng. MECHANICAL
Engineering under ITF’S SIWES Program
the internship was carried out at ORACLE
FEEDMILL INDUSTRAIL LAYOUT, NAKA
ROAD BENUE STATE. I was posted to the
maintenance and repairs department where I
participated actively as an intern.
I sought to get fieldwork experience in an
environment unknown to me, which involved
taking note of skills I would need to work in a
professional
environment.
This
report
contains my activities that have contributed to
achieving my desired goal.
The following chapter contains an outline of
the history, aims and objectives of SIWES and
a
description
of
ORACLE
FEEDMILL
INDUSTRAIL LAYOUT, NAKA ROAD BENUE
STATE. and its activities. And after is a
reflection of my functioning, the unexpected
circumstances and the learning goals achieved
in the course of my industrial training.
Conclusively, my whole industrial training
experience is viewed in relation to my
learning goals
1.1 Brief history (SIWES)
The Student Industrial Work Scheme (SIWES)
was initiated by the industrial training fund (ITF)
in 1973, to serve as a medium through which
theoretical and practical experience could be
combined to better the Nigerian educational
system. It is a tripartite Program involving the
students, the Universities and Industries. It is
funded by the Federal Government of Nigeria
and jointly coordinated by the ITF and the
National Universities Commission (NUC). It is
a skill training Programme designed to expose
and prepare students of tertiary Institutions for
the industrial work situation they are likely to
meet after graduation. The scheme also affords
the students the opportunity of familiarizing and
exposing themselves to the needed experience in
handling equipment and machinery.
1.2 Aims and objectives of SIWES
The objectives of the programme are:
1.To expose students to actual working culture
and industrial practice
2.To allow students to extend their theoretical
knowledge into practice
3.To motivate students to practice the right
working attitudes and professionalism to
increase their employability potential.
4.To facilitate students to potential employers.
The three vital experiences to be provided by any
Industrial Training centre shall include but not
limited to:
1.Basic skills of technical staff
2.Application skills of engineers
3.Management skills
CHAPTER TWO.
2.0 TRAINIG ORGANISATION
Oracle farms limited is a Nigeria owned
company, incorporated under the laws of the
Fedreal Republic of Nigeria in the year 2001.
We redefined our standard and practices of
work through our stock of sound equipment,
state of the art machinery and pool of
experience professionals.
ORACLE FARMS LIMITED is a conglomerate
of various companines which include: oracle
agro feed mill, oracle star shea butter company,
oracle rice mill, oracle corn mill, and oracle
yam/cassava mills.
2.1 Organisational Chart For oracle farms
limited
Below is the organisational chart for oracle
farms limited
Fig 1
2.2 Feed mill safety and maintenace safety
Feed mill operation precautions
1. First choose the installation location of
the crusher and power machine. For longterm fixed operations, the unit should be
fixed on the concrete base. The unit must
be installed firmly and without looseness;
the pulleys of the two machines should be
in a straight line and should not be skewed.
2. After the base is fully solidified, repeat
the system to statically check the unit
thoroughly, and then carry out the dynamic
empty load test run for 3 to 5 minutes. If
there is no abnormality, it can be officially
put into operation.
3. If you use electricity for power, you
should find a reasonable layout of the line
by a professional (electrician). The electrical
lines and facilities should be neatly
arranged and must not be installed and
used in private.
4. When the pulverizer is put into operation
for about 10 days, the cover should be
opened, and the running parts such as the
rotor and the hammer should be inspected.
The bolts should be tightened to check
whether the bearings are well lubricated. If
there is stuck or rubbing, Eliminate in time.
5. Carefully check the processed materials
during work, and remove hard objects such
as nails, stones, and iron wires to avoid
injury or damage.
6. The operator is strictly forbidden to wear
gloves. When feeding materials, they should
stand on the side of the crusher to avoid
rebounding debris and damage the face.
Do not hold too tight when smashing long
stalk crops to prevent accidents.
7. During the operation process, pay close
attention to the working condition of the
pulverizer. If vibration, abnormal noise,
excessive temperature of the bearing and
the machine parts or external spraying are
found, stop the inspection immediately and
continue working after troubleshooting. .
8. When the blockage occurs and the load is
too heavy, stop it immediately. It is strictly
forbidden to use a wooden stick or hand to
force the feed to avoid injuring the arm and
damaging the machine. After each shift is
completed, the unit should be inspected
and maintained to ensure that the unit is in
good condition.
2.3 Introduction to Feed Mill Industry
Feed manufacturing refers to the process of
producing animal feed from raw agricultural
products. Fodder produced by manufacturing is
formulated to meet specific animal nutrition
requirements for different species of animals at
different life stages. According to the American
Feed Industry Association (AFIA),[1] there are
four basic steps:
Receive raw ingredients: Feed mills receive raw
ingredients from suppliers. Upon arrival, the
ingredients are weighed, tested and analyzed for
various nutrients and to ensure their quality and
safety.
Create a formula: Nutritionists work side by
side with scientists to formulate nutritionally
sound and balanced diets for livestock, poultry,
aquaculture and pets. This is a complex process,
as every species has different nutritional
requirements.
Mix ingredients: Once the formula is
determined, the mill mixes the ingredients to
create a finished product.
Package and label: Manufacturers determine the
best way to ship the product. If it is prepared for
retail, it will be "bagged and tagged," or placed
into a bag with a label that includes the
product's purpose, ingredients and instructions.
If the product is prepared for commercial use, it
will be shipped in bulk.
2.4 Feed preparation and quality
The quality of the prepared feed ultimately
depends on the quality of the material such
as the grain or grass used; the raw material
should be of very good quality. Commercial
feed manufacturing is an industrial process,
and therefore should
follow HACCP procedures. The Food and
Drug Administration (FDA) defines HACCP
as "a management system in which food
safety is addressed through the analysis
and control of biological, chemical, and
physical hazards from raw material
production, procurement and handling, to
manufacturing, distribution and
consumption of the finished product".
The FDA regulates human food and animal
feed for poultry, livestock, swine, and fish.
Additionally, the FDA regulates pet food,
which they estimate feeds over 177 million
dogs, cats, and horses in America. Similar
to human foods, animal feeds must be
unadulterated and wholesome, prepared
under good sanitary conditions, and
truthfully be labeled to provide the required
information to the consumer.
2.5Feed formulations
For swine
Feed makes up approximately 60% to 80%
of the total cost of producing hogs.
Manufactured feeds are not merely
for satiety but also must provide animals
the nutrients required for healthy growth.
Formulating a swine ration considers the
required nutrients at various growth stages
in creating an appropriate feed. Three basic
methods are used to formulate swine diets:
Pearson square, algebraic equations and
linear programs (computers). In recent
times, microcomputer programs are
available that will balance a diet for many
nutrients and assist with economic
decisions.
The basic nutrients required are crude
protein, metabolizable energy, minerals,
vitamins and water. The formulation
procedure has both fixed and variable
portions. Swine rations are generally based
on a ground cereal grain as a carbohydrate
source, soybean meal as a protein source,
minerals like calcium and phosphorus are
added, and vitamins. The feed can be
fortified with byproducts of milk, meat byproducts, cereal grains; and "specialty
products." Antibiotics may also be added to
fortify the feed and help the animal's health
and growth.
Distillers dried grains with solubles (DDGS),
which are rich in energy and protein, have
been used in place of corn and soybean
meal in some livestock and poultry feeds
and corn DDGS have become the most
popular, economical, and widely available
alternative feed ingredient for use in U.S.
swine diets in all phases of production. The
U.S. Grain Council reported that corn
DDGS is used primarily as an energy
source in swine diets because it contains
approximately the same amount of
digestible energy (DE) and metabolizable
energy (ME) as corn, although the ME
content may be slightly reduced when
feeding reduced-oil DDGS.
A 2007 study highlighted the recent trends
in the use of DDGS, as many producers are
including 20% DDGS in diets of swine in all
categories. Although 20% is the
recommended level of inclusion, some
producers are successfully using greater
inclusion rates. Inclusion rate of up to 35%
DDGS has been used in diets fed to
nursery pigs and finishing pigs.
For fish
Farmed fish eat specially formulated pellet
feeds containing the required nutrients for
both fish health and the health of humans
who eat fish. A fish feed should be
nutritionally well-balanced and provide a
good energy source for better growth.
Commercially farmed fish are broadly
classified into herbivorous fish, which eat
mostly plant proteins like soy or corn,
vegetable oils, minerals, and vitamins; and
carnivorous fish, which are given fish
oils and proteins. Carnivorous fish feed
contains 30-50% fish meal and oil, but
recent research suggests finding
alternatives to fish meal
in aquaculture diets.
Among the various feeds
investigated, soybean meal appears to be a
better alternative to fishmeal. Soybean
meal prepared for the fish industry is
heavily dependent on the particle sizes
contained in the feed pellets. Today
technology to process these types of feed is
based on fish feed extruder machines. Fish
feed extruder is essential for vegetable
protein processing. Particle size influences
feed digestibility. The particle sizes of fish
pellet feed are influenced by both grain
properties and the milling process.
Properties of the grain include hardness
and moisture content. The milling process
affects particle size based on the mill
equipment type used, and some properties
of the mill equipment (for example
corrugations, gap, speed, and energy
consumption)
For poultry
As reports have indicated, feeding makes
up the major cost in raising poultry animals
as birds in general require feeding more
than any other animals, particularly due to
their faster growth rate and high rate of
productivity. Feeding efficiency is reflected
on the birds' performance and their
products. According to National Research
Council (1994), poultry requires at least
38% components in their feed. The ration of
each feed components, although differing
for each different stage of birds, must
include carbohydrates, fats, proteins,
minerals and vitamins. Carbohydrates,
which are usually supplied by grains
including corn, wheat, barley, etc. serves as
a major energy source in poultry feed. Fats,
usually from tallow, lard or vegetable oil are
essentially required to provide important
fatty acid in poultry feed for membrane
integrity and hormone synthesis.
Proteins are important to supply the
essential amino acids for the development
of body tissues like muscles, nerves,
cartilage, etc. Meals from soybean, canola,
and corn gluten are the major source of
plant protein in poultry diets.
Supplementation of minerals are often
required because grains, which are the
main component of commercial feed
contain very little amounts of these.
Calcium, phosphorus, chlorine, magnesium,
potassium and sodium are required in
larger amounts by poultry. Vitamins, such
as vitamin A, B, C, D, E, and K, on the
other hand, are the components that are
required in lower amounts by poultry
animals
Fanatico (2003) reported that the easiest
and most popular way to feed birds is to
use pelleted feeds. Aside from the
convenience to the farmer, pelleted feeds
enable the bird to eat more at a time. In
addition, some researchers also found
improvement of feed conversion, decreased
feed wastage, improved palatability and
destruction of pathogens when birds were
fed with pellet feed as compared to birds
fed with mash feed.
Commercial manufacturing of pelleted feed
usually involves a series of major
processes including grinding, mixing and
pelleting. The produced pellets are then
tested as to pellet durability index (PDI) to
determine quality. To enhance good health
and growth, antibiotics are often added to
the pelleted feed.
Researchers have concluded that smaller
particle-sized feed will improve digestion
due to the increased surface area for acid
and enzyme digestion in the gastrointestinal
tract. However, some researchers have
recently brought to our attention the
necessity of coarse particles for poultry
feed to complement the natural design and
function of the gastrointestinal tract
(GIT). Hetland et al (2002) and Svihus et al.
(2004) discussed that the GIT retention
time decreased due to lack of gizzard
function that eventually gave a negative
impact on live performance. Zanotto &
Bellaver (1996) compared the performance
of 21-day-old broilers fed with different feed
particle size; 0.716 mm and 1.196 mm.
They found that the subject fed with larger
particle size feed showed better
performance. Parsons et al. (2006),
evaluating different corn particle sizes in the
broiler feed found that the largest particle
size (2.242 mm) gave better feed intake
than the other particle sizes tested (0.781,
0.950, 1.042 and 1.109 mm). Nir et al.
(1994), however, argued that the
development of broilers was influenced by
changing particle sizes. However, variation
in particle size between 0.5–1 mm usually
did not have any effect on the broilers. Very
fine particles (<0.5 mm) may impair the
broilers performance due to the presence of
dust that cause respiratory problems,
increased water intake, feed presence in
the drinkers and increased litter moisture.
Chewning et al. (2012), in their recent
study, concluded that although fine particle
sizes (0.27 mm) enhanced broilers live
performance, the pelleted feed did not.
All of this data shows that both fine and
coarse particle sizes do have different
functions in poultry feed. Appropriate
proportions of these two ingredients must
be used with respect to the live
performance of the broilers. Xu et al.
(2013) compared the performance of nonpelleted feed to pellets with fine particles
and found that the addition of coarse
particles improved feed conversion and
body weight. Similar results were also
obtained by other researchers
like Auttawong et al. (2013) and Lin et al.
(2013).
For livestock
Livestock includes beef cattle, dairy
cattle, horses, goats, sheep and llamas.
There is no specific requirement of feed
intake for each livestock because their feed
continuously varies based on the animals'
age, sex, breed, environment, etc.
However, basic nutrient requirements of a
livestock's feed must consist of protein,
carbohydrates, vitamins and minerals.
Dairy cattle need more energy in their feed
than other types of cattle. Studies have
shown that energy supplied by feed is
provided by various carbohydrate sources,
including non-fiber carbohydrates (NFC)
such as fermentable feeds or neutral
detergent fiber (NDF) such as forage.
Feeds with high NDF are good for rumen
health, however, they provide less energy
and vice versa. Fats are added in the
livestock feed to increase energy
concentration, especially when the NFC
content is already too high since excessive
NFC lessens the NDF fraction, affecting the
rumen digestion. In ruminants, most
proteins consumed are broken down by
microorganisms and the microorganisms
later get digested by the small intestine.
The National Research Council suggested
that the crude protein required in livestock
feed should be less than 7%. Lactating
ruminants, especially dairy cattle require
the highest amount of protein, especially for
milk synthesis. Minerals including calcium,
phosphorus and selenium are required by
livestock for maintaining growth,
reproduction and bone health.
Like other animals, livestock also require
appropriate proportions of fine and coarse
particles in their feed. Theoretically, finer
particles will be easier to digest in the
rumen, however the presence of coarse
particles might increase the amount of
starch entering the small intestine, thus
increasing energetic efficiency.
Livestock could be fed by grazing on
grasslands, integrated or non-integrated
with crop production. Livestock produced in
stalls or feedlots are landless and are
typically fed by processed feed containing
veterinary drugs, growth hormones, feed
additives, or nutraceuticals to improve
production. Similarly, livestock consume
grains as the main feed or as a supplement
to the forage based feed. Processing grains
for feed is aimed at getting the easiest
digestible grains to maximize starch
availability, thus increasing the energy
supply.
Hutjens (1999) reported that milk
performance was significantly better when
the cattle were fed with ground corn. A
study compared the digestibility of various
corn particle sizes and distribution and
concluded that to have 80% digestibility, a
particle size of 0.5 mm should be used (for
16 hr incubation).
A research team from the University of
Maryland and the USDA studied the
development, fermentation in rumen and
starch digestion sites in dairy cow feeding
on corn grain from different harvests and
differently processing, and concluded that
digestion, metabolism and heat energy
were higher for high moisture corn
compared to dry corn. Grinding increased
DMI and resulted in increased yields of
milk, protein, lactose and non-fat solids.
2.6Feed manufacturing process
Depending on the type of feed, the
manufacturing process usually start with the
grinding process. Figure 1 illustrates the
workflow for general feed manufacturing
process. Grinding of selected raw material
is to produce particle sizes to be optimally
and easily accepted by the animals.
Depending on the formulation, feed could
contain up to 10 different components
including carbohydrate, protein, vitamins,
minerals and additives. The feed ration can
be pelleted by
proportionally homogenizing the specific
compositions. Pelleting is achieved by
various methods, but the most common
means is by extrusion. Formula and feed
making machine are very important during
the entire process of the feed production to
ensure quality feed.
2.7 Grain milling for feed preparations
Corn, sorghum, wheat and barley are the
most used cereals in the preparation of
feed for the livestock, poultry, swine, and
fish industry. Roller and hammer mills are
the two types of processing equipment
generally used to grind grains into smaller
particle sizes.
Milling cereal grains by mechanical action
involves several forces like compression,
shearing, crushing, cutting, friction and
collision. The particle size of the ground
cereal is very important in the animal feed
production; smaller particle sizes increase
the number of particles and the surface
area per unit volume which increase access
to digestive enzymes. Other benefits are
increased ease of handling and easier
mixing of ingredients. The average particle
size is given as geometric mean diameter
(GMD), expressed in mm or microns (µm)
and the range of variation is described by
geometric standard deviation (GSD), with a
larger GSD representing lower uniformity.
According to Lucas (2004), GMD and GSD
are accurate descriptors of particle size
distribution when the particle size
distribution is expressed as log data, and
are distributed log normally. Studies have
shown that grinding different grains with the
same mill under similar conditions results in
products with different particle sizes. The
hardness of a grain sample is related to the
percentage of fine particles obtained after
grinding, with a higher percentage of fine
particles from lower hardness grains.
Rose et al. (2001) discussed that
hard endosperm produces irregularlyshaped larger particles, while soft
endosperm produces smaller size particles.
The correlation between particle size and
energy consumed is although not positive
but, to obtain very fine particle sizes require
higher energy which reduces the rate of
production. Moreover, a very fine grind of
grain has no impact on the efficiency of
pelleting, nor on the power consumed
during pelleting. Amerah et al.
(2007) discussed the availability of more
data suggesting grain particle sizes are
very important in mashed diets than in
pelleted diets
2.8 Introduction of feed mill machines and
equipment.
1.0 FEED PALLET MACHINE.
feed pellet machine is a feed processing
machine that directly compresses powdery
grains such as corn, soybean meal, straw, hay,
rice husk into pellets. It is widely used in large,
medium and small aquaculture, grain and feed
processing plants, livestock farms, poultry
farms, individual farmers and small farms.
Working Principle
The feed pellet machine is to extrude the mixed
powder feed once. It doesn’t need to add water
or drying during the granulation process. When
the temperature rises to about 70 degrees
naturally, the starch can be gelatinized and the
inside of the granule is deeply matured. The
surface of granules is smooth and high
hardness, which can be stored for a long time. It
is an ideal equipment for small or medium feed
processing plants and farmers who raise rabbits,
fish, chickens, pigs, sheep, cattle etc.
Working steps:
Step 1: Prepare raw material and mix
Step 2: Adjust machine
Step 3: Pour in the material and start
granulation
Step 4: Screen the granules
FIG2: feed pallet machine.
2.0 WOOD HAMMER MILL MACHINE
wood hammer mill machine is a special
equipment for producing wood powder
(sawdust), which is used for cutting wood, logs,
branches, leftovers, etc. The machine adopts
double feeding ports. It has the characteristics
of reasonable design, compact structure, safety
and durability. It is widely used in
papermaking, edible fungi, machine-made
charcoal, particle board, sawdust board, high
density board, MDF and other industrial
production material preparation section and
single wood powder (sawdust) production base.
It is also an ideal equipment for biomass
burning pellets making.
Working Principle
It adopts blade cutting and high-speed airflow
impact and collision, that is double crushing
functions. And it can complete the micromaterial sorting process at the same time. In the
process of blade cutting and pulverization, the
rotor generates high-speed airflow, which
rotates with the cutting direction of the blade.
The material is accelerated in the airflow and
repeatedly hit. The raw materials are doublepulverized at the same time, which accelerates
the pulverization rate of the material.
Product Details
1. Moving blade
The cutting blade is made of high-quality alloy,
which has the characters of tough, wearresistant, sharp in cutting, not easy to rust,
corrosion-resistant and long service life. And it
can improve the capacity.
2. Main partof the machine
The main part of the machine is processed by
dynamic balancing equipment, and the weight
error in all directions of the machine is not
more than 15g, which has the benefits
of running smoothly, low noise,
improving efficiency, prolonging the service
life. It’s low cost and high capacity, which is a
mature wood processing machinery.
3. Cutterhead
The cutter head is made of thickened steel,
which changes the original characteristics of
fragile and increases the service life of the
machine. The fan blade design not only
improves the running speed of the wood, but
also accelerates screening of the wood from the
machine. The cutter head operates stably and
plays the role of secondary crushing.
4. Hammer
The hammer is made of carbon steel, which can
crush the wood chips for many times, thereby
improving the crushing rate. And the hammer
can be used on both sides. After one side is
damaged, the user can replace the hammer, but
the hammer can only be replaced in the same
position. It can not be exchanged with each
other, so as not to affect the dynamic balance of
the machine. The double-sided use reduce the
cost.
FIG 3 wood hammer mill machine.
3.O Grass Crushing and Cutting
Machine
The grass cutting and crushing machine can
turn corn stalks, wheat stalks, rice stalks, peanut
stalks and other agricultural crops and pastures
into softer filamentous feeds through the
principles of cutting, shattering, kneading, and
crushing, which improves the utilization rate
and palatability of feed and grass.
Product Usage
The new cutting and crushing machine is a new
type of multi-functional feed machine
developed by our company according to market
demand and feedback. It can guillotine and
knead grass at the same time. Compared with
the ordinary guillotine machine, this machine
adds a triangular blade, cutterhead
and triangular dead knife. After the forage is
cut, it is smashed by the triangular blade again
to make the material finer. It is mainly used for
cutting various dry and wet crop straw and
pasture, such as corn stalks, rice stalks, which
are used to raise cattle, sheep, horses, deer and
other animals. This machine is suitable for
pastures and farmers, and is the preferred bestselling model for farmers.
Work principles
This machine is a kind of an agricultural and
pasturage machinery which is used for cutting
green (dry) corn stalks, straws and other crop
stalks and pastures. The working principle of
the cutting machine: the motor is used as the
supporting power. The power is transmitted to
the main shaft, and the gear at the other end of
the main shaft transmits the speed-adjusted
power to the grass press through the gearbox,
universal joint, etc.
When the material to be processed enters
between the upper and lower grass presses, it is
clamped by the grass presses and sent to the
cutting mechanism at a certain speed. After the
material is chopped by the high-speed rotating
cutter, it is smashed again by the high-speed
rotating upper and lower triangular blades
(hammers) of the grass crushing system, and
finally thrown out of the machine through the
grass outlet. This crushing machine has a
beautiful appearance, adopts an all-steel body,
thickened steel, and the coating adopts a baking
paint process, with bright colors, good
durability, corrosion resistance and durability.
FIG 4.0 Grass Crushing and Cutting
Machine
4.0 TCXT Series Permanent Magnet
Sleeve
TCXT Series Permanent Magnetic Drum
is mainly used for separating magnetic
metal impurities, such as screws, bolts,
nuts, washers and iron chippings and
shavings, etc. from the raw materials.
Product features：
◆High magnetic intensity, powerful iron
removal performance;
◆No power consumption, made with
stainless steel.
MECHINE FEATURES
1. High magnetic intensity, powerful iron
removal performance;
2. No power consumption, made with
stainless steel.
APPLICTIONS
TCXT SERIES PERMANENT MAGNETIC
DRUM is mainly used for separating magnetic
metal impurities such as screw, blot , nuts,
washers and iron chippings and shavings, etc.
from the raw materials.
FIG5.0 Permanent Magnet Sleeve
. KDVM SERIES VACUUM COATING
SYSTEM.
MACHINE FEATURES:
1. Horizontal
structural
with
horizontal area brings the
larger
the
materials into
contact with the spraying liquid.
2. Three rows of nozzles uniformly distributed
on the rotor axial make spraying more
uniform high accuracy and uniformity of liquid
spraying.
APPLICATIONS
1.
It is used for spraying liquid additives,
such as oil,liquid fat, etc. to extruded pellets
directly after drying section.