HydroMix. Computer-controlled liquid feeding system

Transcription

1 HydroMix Computer-controlled liquid feeding system

2 HydroMix the liquid feeding system for the future! Today, liquid feeding systems are an integral part of modern pig management. These systems are especially recommended if inexpensive alternative feed products such as whey or wet co-products from food industries can be used. The HydroMix system developed by Big Dutchman stands for: state-of-the-art technology for fully-automated feeding of sows, piglets and fattening pigs for any size of production. The name HydroMix not only stands for reliable liquid feed supply to all animals, but also for a high-quality system. To meet our customers existing and future demands, our engineers are constantly working on further developments. We are able to supply a liquid feeding system to suit literally any customer s system be it large or small so as to meet their special requirements regarding different on-farm circumstances. We therefore offer several different systems under the brand name HydroMix : ) HydroMix-Standard ) HydroMix-residue-free feeding with pipe rinsing ) HydroMix-Synchron ) HydroMix-Compact ) HydroMix-multi-phase feeding ) HydroMix-Sensor From this list, both customer and consultant can select the appropriate system as they discuss the situation together. ESF system CALLMATIC 2 in combination with HydroMix Areas of application In the sow house, HydroMix can be used for various types of housing and management. Including: ) gilt rearing in group housing; ) empty and pregnant sows; ) to supply the electronic sow feeding system (ESF) CALLMATIC 2 for pregnant sows in group housing; ) individual feeding of sows with piglets in farrowing pens. In the finishing house, the pigs can be supplied with liquid feed both at length and cross troughs or at the sensor monitored trough. In the piglet house HydroMix-Sensor is used. This way the piglets always receive fresh feed, as required by precise sensor measurement. View into a finishing compartment with cross troughs HydroMix advantages ) fully automatic preparation of feed formulae adapted to the animal s requirements from individual ingredients; ) use of low-priced by-products helps to reduce feed costs; ) ability to vary nutrient intakes; ) entirely computer-controlled feeding management via MC 99 NT; ) distribution of many feed formulae or water possible via one feed pipe; ) automatic feed supply even over long distances; ) high metering precision at every feed valve; ) flexible modular construction for large and small units, low-priced expansion of systems possible; ) suitable for feeding groups or individual animals; ) low operating cost, long service life.

3 HYGIENE basic prerequisite for improved feed conversion Liquid feed is a favourable nutrient medium for microbes. Big Dutchman has carried out intensive research in this field to create optimum hygienic conditions for liquid feeding. Our hygiene package includes: ) pneumatic intake flap ) residue-free feeding with pipe rinsing ) tank cleaning with rotating cleaning heads ) acid fogger. Residue-free feeding with pipe rinsing The entire quantity of feed prepared is distributed each feeding time. After feeding is finished, the entire system, including all valves, drop pipes, piping as well as the mixing and rinse water tanks, are rinsed with fresh water. between feeding times, only fresh water remains in the pipeline. This water is passed into the rinse water tank at the next feeding time and is then used for the next preparation. Advantages ) several feed mixes can be fed from one ring circuit; ) between feeding times, fresh water can be metered out at the individual valves; ) automatic cleaning of all parts of the system coming into contact with feed. Tank cleaner The tank cleaner allows thorough, fully automatic cleaning of mixing and rinse water tanks. This is achieved by applying rotating cleaning heads with specially-designed variable nozzles. These nozzles can be adapted to the respective water pressure as well as the quantity of water required. Consequently a very small quantity of water can still achieve optimum cleaning throughout the entire tank. A separate water pipe preferably with a separate fresh water pump supplies the cleaning heads with water. This tank cleaning system can also be attached to any existing liquid feeding system. To ensure trouble-free operation, the tank has to be completely water-tight and it must be possible to close the component intake opening with a pneumatic flap. Acid fogger The acid fogger is ideally suited for disinfecting mixing and rinse water tanks. Several times a day, this system distributes very small quantities of disinfection solution in the tank. This allows the dirt film to be removed without residues occurring on the inside of the tank after long operational use even with the tank cleaning system being applied. The fog penetrates every corner of the mixing tank, so ensuring optimum disinfection and hygiene. The acid fogger starts rotating by compressed air at 8 bar. At the same time, negative pressure is used to suck the acid/lye directly from the can (possible distance: 2.5 m; 8 ft) without the need for a pump. The system is controlled by a feeding computer. Under observance of the required safety measures, the acid fogger can also be retrofitted into any existing liquid feeding system keeping the system clean.

4 Main components of a HydroMix liquid feeding. Mixing tank with agitator and tank cleaner You can choose: ) square or rectangular tanks made of stainless steel (V2A) in sizes of 500 to 2000 litres (32 gal up to 370 gal) capacity (larger tanks upon request); ) round or rectangular tanks made of acid-resistant glass-fibre reinforced plastic (GRP) in segmental style from 500 to 0000 litres (396 gal up to 2642 gal) capacity (larger tanks upon request). 2. Electronic weighing system According to their construction, mixing tanks are equipped with an electronic -, 3- or 4-point weighing system. Weigh bars are mounted below the feet of the mixing tank. They record the change in weight during metering of feed components as well as during the discharge of the ready-mixed feed and transmit the corresponding data to the MC 99 NT feeding computer. The computer can be set to calibrate whether the weigh bars are supposed to be working with a resolution of kg or 00 g (2.2 lb or ¼ lb) this is valid up to 6 t (3 230 lb) total weight! 3. Feed pump Depending on the feeding method, the pipeline length and the kind of feed used, either centrifugal pumps or positive displacement pumps (also frequency-controlled) with different capacities are used. Centrifugal pump Positive displacement pump

5 4. The intelligent feed valve and pipes The feed is transported from the mixing tank to the feed valve via acid-resistant plastic pipes (Ø 50 or 63 mm; 2 or 2.5 ). The intelligent Big Dutchman feed valve is equipped with state-ofthe-art BUS technology => flexible, more reliable and faster data transfer in all directions. Thanks to the use of a two-wire line the electric installation of the feed valve is simple and fast (50 % less cost than comparable systems). The sensor electronics is already included in the valve, so that sensor-controlled feeding can be carried out very simply The small programmable circuit board which is installed at the valve is responsible for precise feeding. The valve itself is a reliable, durable, pneumatically-driven diaphragm valve. It is designed for very precise metering and flexible installation options. The intelligent Big Dutchman feed valve 5. Feeding computers MC 99 NT and MC 99 NT-Economy Successful pig finishing requires high precision in all sectors, from feed mixing through to data gathering. Therefore, Big Dutchman liquid feeding systems are essentially computer-controlled. The MC 99 NT creates a sound basis to achieve even the most demanding tasks. Thanks to its modular construction from the individual computer to a network tailor-made concepts can be put into practice for all possible requirements. In such a network, the MC 99 NT acts as a distribution centre. It supports other BD components such as different scale types, hand-held terminal, valve and relay cards. It is also possible to run several programs at one time. For example, the MC 99 NT can mix and feed at the same time. Data input and control operations can be carried out directly using the MC 99 NT with its large LCD-Display, at the hand terminal or at a PC. Users are easily guided through the program. Additionally, running processes can be graphically depicted on the PC => process visualisation. Future program updates can be carried out safely and easily by simply replacing the userfriendly miniature flash cards. If MC 99 NT is connected to a modem, it is possible to send alarm messages to your mobile phone, either via autocaller or as SMS via Internet. Moreover, Big Dutch man service staff can dial into your computer via modem for remote service. MC 99 NT MC 99 NT-Economy frequency converter with analogue card control unit with relay card and valve card weigh bar animal scale largescale indicatitruck weigher WA 99 scale network network TM Windows process visualisation process visualisation TM Windows PC in the house PC at home BD servicehotline printer modem modem modem telephone network via Internet telephone telephone alarm provider autocaller SMS mobile phone MIT-99 hand terminal network

6 HydroMix-Standard ring circuit 2 6 stub pipe Key 3 4 water 2 feed 3 mixing tank 5 4 electronic weighing system 5 feed pump 6 feed valve 7 sensor 7 HydroMix-residue-free feeding with pipe rinsing Key feed bin 2 feed auger 3 fresh water tank 4 rinse water tank 5 mixing tank 6 electronic weighing system 7 feed pump 8 compressor 9 feed valve... and with weighed fresh water and/or rinse water tank Key feed bin 2 feed auger 3 weighed fresh water tank 4 weighed rinse water tank 5 mixing tank 6 electronic weighing system 7 feed pump 8 compressor 9 feed valve

7 HydroMix-Synchron rapid feeding of large animal numbers Operating principle HydroMix-Synchron allows mixing and feeding at the same time with only one computer. To do this, the respective feed components are mixed in the mixing tank, passed to the feeding tank and, from there, pumped to the individual feed valves. The computer at once starts the next feed formula so that mixing starts anew. Large numbers of animals can thus be fed with many different rations, but without too long waiting times. HydroMix-Synchron can also be run as residue-free feeding with pipe rinsing Key feed bins 2 rinse water tank 3 mixing tank 4 feeding tank 5 electronic weighing system 6 foreign matter separator 7 fresh water tank 8 feed valves HydroMix-Compact the space-saving liquid feeding system In this system, two small tanks are simultaneously used as mixing and feeding tanks. For this purpose, the required feed quantity is divided into several portions and, while feed is being mixed in one of the tanks, the content of the second tank is metered out. Thus, with HydroMix-Compact you are able to mix and feed at the same time. The advantage of this is that large numbers of animals can be supplied with many different rations very rapidly. In between feed distribution times there is no waiting time. The second important advantage is its compact design, which allows you to install it even in small service rooms or feed kitchens. Operating principle Upon starting the feeding process, the respective feed components are transferred into a mixing or feeding tank and mixed there. The finished ration is metered out while the next ration is already prepared in the second mixing tank. This process is repeated until the entire feed quantity has been mixed or metered out to all animals. HydroMix-Compact can also be designed as a residue-free feeding system with pipe rinsing. 2 Key feed bins 2 rinse water tank 3 mixing/feeding tank 4 electronic weighing system 5 fresh water tank 6 feed valves

8 Multi-phase feeding nutrient supply to animals depending on their requirements If more than one feed formula is used during the finishing period, this is called phase feeding. If a different feed formula is distributed every day, however, this is called multi-phase feeding. It provides any number of animals with the exact nutrients each one needs per day. Operation principle The components necessary for a multi-phase feeding system: at least 2 (max. 4) mixing tanks for the respective basic mixes, 2 feed pumps with frequency converter, 2 feed pipes and 2 feed valves per trough. When feeding starts, the computer evaluates the required quantities of the different basic mixes for preparing the individual daily delivery for each valve. MC 99 NT controls the performance of the feed pump and the valve opening time per valve. Both valves at one trough have the same opening time. A frequency converter ensures that small feed quantities are then metered out for as long as large quantities. This system allows the feed to be supplied according to the animals requirements every day Sensor feeding optimum use of feed intake capacity Big Dutchman customers are successfully feeding their pigs with HydroMix-Sensor feeding. In the last couple of years, this system has been gaining popularity as it allows to feed based on animal appetite and consumption of feed and helps to achieve an animal: feeding place ratio of 3: at short troughs. This results in a better use of floor space and more advantages when using large group pens. The principle is as follows: a sensor is installed 2 to 3 cm (approx. ) above the bottom of the trough so that the MC 99 NT feeding computer can check at regular inter - vals whether the trough is empty. Whenever required, fresh feed can be dispensed. This increases the incentive to eat. The animals determine their own daily routine by their feed consumption behaviour => significantly better use of genetic feed consumption capacity. The sensor registers the feed level in the trough Advantages Large group pen with sensor feeding => small investment costs ) animal : feeding place ratio of 3 : => improved utilisation of floor space; ) feeding curve adapted to the needs of the animals; ) frequent supply with small, freshly mixed rations; ) flexible pen shape, particularly important in case of renovated house; ) only a small mixing tank required => saving investment costs; ) simple, clear system layout with dead-end pipes possible.

9 Fermentation improved feed digestibility thanks to fermented grain Fermented liquid feed has some distinct advantages such as an increased concentration of lactic acid, a low ph-value (approx. 4.5) and predigested starch. These three essential aspects greatly improve the digestibility of the feed in the pig s stomach. The livestock producer also highly benefits from the effects of fermentation by: ) improved feed utilization ) improved energy utilization ) increased weight gain ) increased profitability compared to conventional feeding without fermented grain components (see test results). Fermentation process Fermentation is the process of breaking down carbohydrates by means of micro-organisms in the absence of air. These micro-organisms produce enzymes, which in return transform the starch contained in the grain into glucose. Glucose is then converted into 2 Lactate (a salt of lactic acid). The feed is thus preserved naturally a process comparable to the making of silage. It goes without saying that such a process has to be controlled and monitored. For instance it is necessary to permanently check the ph-value and the temperature. Advantages of fermented feed Fermentation is a kind of predigestion process and thus greatly increases the digestibility of the feed. Consequently the pigs need less energy to digest it. The nutrient absorption is much improved, which in return results in a better feed utilization. Moreover, the low ph-value considerably reduces the content of harmful bacteria within the feed. Advantages for the pig Thanks to the quicker ph reduction within the pig s stomach, less pathogens can settle there. Lactic acid bacteria greatly improve the intestinal flora in the pig s small intestine, thus stabilising the animal s health status. Moreover, the increased concentration of lactic acid bacteria results in an improved energy utilization. In this way, less indigestible feed gets into the large intestine, so that the pigs suffer less from diarrhea. Test results by the «Landsudvalget for Svine» in Denmark Feed without Feed with fermented grain fermented grain Number of groups Feed units/day (barley equivalent) Daily weight gain (g) 924 (2.04 lb) 957 (2. lb) Feed units/kg weight gain Lean meat percentage (%) Profit contribution in Index in % 00

10 MediSystem the ideal medicating system The MediSystem offered by Big Dutchman enables you to supply your animals with precise dosages of medication, vitamins or other agents all fully automatic and absolutely reliable! The additives are metered per valve, directly into the drop pipe of the trough, which means they do not get into the feed line. This way there is no danger of an unwanted carry-over of additives. In case of dead-end lines, metering can be carried out over injectors into each individual dead-end => inexpensive solution. The MediSystem is equipped with a mobile pumping and mixing station which can be used for multiple houses. Since the additive mix is continuously pumped over, the use of difficult water-soluble substances, which are often less expensive, is possible without problems. After medication metering is finished, the Medi ring circuit is emptied by means of compressed air and then automatically cleaned with water. The MediSystem can be retrofitted in all fully-automatic feeding systems. A new product which is now available in our product range is the inexpensive mobile MediSystem for dead-end feed lines. The required components are all installed on a portable board. This includes: ) an acid resistant diaphragm pump; ) a flow meter; ) a timer and ) a canister (2.5 l; 3.3 gal) with agitator. The system can easily be connected to the required dead-end: hang up the board at the desired location, connect to compressed air system and Medi-hose and establish a power connection. Mobile MediSystem for medication in dead-end lines

11 MIKROS for metering of liquid additives into the mixing tank The use of minerals, vitamins and other additives in feed mixes is becoming increasingly important. The MIKROS system developed by Big Dutchman permits to precisely meter small amounts of liquid additives into the mixing tank of liquid feeding systems. The indiviual ingredients are added one after the other into the weighed metering receptacle by means of pumps. From there, they are pumped into the mixing tank of the liquid feeding system. Before the next ingredient is metered out, the receptacle is rinsed with water. MIKROS operates with hose pumps which tolerate the use of concentrated acids with a ph value of approx.. The piping and the weighing hopper are also acidproof. The entire system is controlled by a MC 99 NT feeding computer. MIKROS works with high precision (scale resolution ± g; ± oz) and can weigh and meter amounts from 30 g up to 8 kg ( oz up to 39.6 lb). CCM hopper for CCM metering direktly into the mixing tank The CCM hopper offered by Big Dutchman is optimally suited for long-term storage and subsequent precise metering of CCM, high moisture grain, brewer s grains or other feedstuffs to the liquid feeding system. The hopper is made of stainless steel and is available in different sizes (up tp 8 m 3 ; 282 ft 3 ). The circular bottom is equipped with a blade which is driven by a gear motor. The blade rotates and causes the feed to fall down on a horizontal auger which is also driven by a gear motor. The blade also prevents feed bridging in the hopper. A slope auger (available up to 4 m; 46 ft) transports the feed to the mixing tank.

12 Efficient technical accessories Foreign matter separator for safe and trouble-free transport of feed For safety reasons, a foreign matter separator should always be installed in a modern liquid feeding system. It is made of stainless steel and has a centrally arranged inlet and outlet. The feed mix hits a deflector which slows down the flow rate and causes foreign matter, such as stones to drop. The installed magnet serves as separator for metal pieces. The foreign matter separator can be emptied and cleaned over of an easy-to-open hinged lid. There are no special tools required. HELMIX stops pipe blocking caused by feed sedimentation Big Dutchman s newly developed pipe installation module HELMIX can easily be installed in dead-end and circular pipelines of liquid feed systems, especially in places that are prone to feed sedimentation. This can occur: ) if the feed has a high solids to liquid ratio, especially when the majority of the ingredients have low water absorptive properties; ) if the metering rates and flow rates are especially low, as is the case in farrowing pens and piglet rearing; ) if feed ingredients have a very high content of solids; ) if the pipeline is very long; ) in feeding facilities without rest feed. Through the spiral inner structure of HELMIX the feed is put into rotation and can enjoy a more regular flow. The feed has a more even consistency at all feed troughs, which is especially important in long pipe - lines. We recommend installing the module every 50 to 00 m (64 to 328 ft). It can easily installed in already existing facilities. Big Dutchman Pig Equipment GmbH Postfach Vechta Germany Tel. +49(0) Fax +49(0) big@bigdutchman.de Technical details subject to change. e 7/2007