POULTRY FEED MILL - CRITICAL CONTROL POINTS TO QUALITY

PROCESS
SNO ACTIVITY CONTROL POINTS SET VALUES TIME LINE RESPONSIBILITY
STORAGE OF CORN SHOULD BE KEPT AS COOL AS POSSIBLE 5 DEG TEMP LESS THAN AMBIENT DAILY SILO OPERATOR
OPERATE AERATION FANS DURING COOL TIME only DAILY SILO OPERATOR
FUNGAL FREE
1 GRAIN STORED FOR LONG TERM- ROTATE THE GRAIN EVERY
SILO STORAGE
15 DAYS FORTNIGHT SILO OPERATOR
DURING WINTER OPERATE THE AERATION AFTER SUN SET DAILY SILO OPERATOR
PREVENT VEVILS ENTER FROM WARE HOUSE TO SILO REGULARLY
RIGHT FORMULA ENTRY IN TO PLC /
ZERO FORMULATION ERROR PHYSICAL INSPECTION RANDOM CHECKING PRODUCTION MANAGER
RM FILLING / BIN ALLOTMENT / ASSIGNED MATERAIL
FILLED IN ASSIGNED BIN/ NO CONTAMINATION SHIFTWISE/ CONTINOUS CONTROL ROOM OPERATOR
ERROR FREE PER BATCH / HOURS PER BATCH / CROSS CHECK
2
BATCHING BATCHING TIME - SET VS ACTUAL DESIGN CAPACITY SHIFT WISE CONTROL ROOM OPERATOR
DOSING BINS- SET WEIGHT VS ACHIEVED WEIGHT - BIN
ACCURACY 0.05% - 0.1% CONTINOUS MONITORING/ CONTROL ROOM OPERATOR
WEIGH HOPPER / SCALES- ACCURACY 0.05%- 0.1% CONTINOUS MONITORING/ CONTROL ROOM OPERATOR
CALIBRATION OF WEIGH HOPPER AS PER SOP/ SUPPLIER RECOMMENDATION FORT NIGHT CONTROL ROOM OPERATOR
CHECK FOR SIEVE DIA & OPENING % AS RECOMMENDED PRODUCT WISE/SHIFT WISE CONTROL ROOM OPERATOR
PARTICLE SIZE DISTRIBUTION/ POWDER % 600- 700 MICRONS PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
DELTA' T'- temperature of feed before( AMBIENT) & after
grinding 3-5 DEG SHIFT WISE QA - PROCESS CHEMIST
EFFICIENT MEASURE MOISTURE OF GROUNDED FEED VARIABLE DATA PRODUCT WISE/SHIFT WISE CONTROL ROOM OPERATOR
3
GRINDING
CHECK FOR SIEVE DAMAGE PHYSICAL INSPECTION/ CHANGE AT RIGHT TIME CONTINOUS MONITORING/ CONTROL ROOM OPERATOR

RIGHT TIME SIEVE , BEATER & MOUNTING ROD CHANGE PHYSICAL INSPECTION/ CHANGE AT RIGHT TIME SHIFT WISE CONTROL ROOM OPERATOR
CHECK THE GROUNDED BATCH MATERIAL FILLING 75 TO 80
OF RIBBON TOP LEVEL 75- 80% OF RIBBON TOP LEVEL WEEKLY ONCE QA - PROCESS CHEMIST
MIXER CV % LESS THAN 5% WEEKLY ONCE QA - PROCESS CHEMIST
CHECK PREMIX / RIGHT PREMIX FOR RIGHT FEED PHYSICAL INSPECTION SHIFT WISE QA - PROCESS CHEMIST
HOMOGENEOUS
4 CHECK FOR MIXING TIME - DRY MIZ, LIQUID FILLING & WET
MIXING
MIX AS RECOMMENDED WEEKLY ONCE QA - PROCESS CHEMIST
CHECK FOR MIXER DOOR LEAKAGE 0% LEAK CONTINOUS MONITORING/ CONTROL ROOM OPERATOR
MIX FEED MOISTURE 11-12% PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
PHYSICAL CLEANING OF MIXER AND FUMIGATION PHYSICAL INSPECTION WEEKLY ONCE PRODUCTION MANAGER
CHECK STEAM PRESSURE 1.5 TO 3 Kg/cm2 SHIFT WISE PELLET OPERATOR
MEASURE RETENSION TIME IN SECS 60-90SECS WEEKLY ONCE QA - PROCESS CHEMIST
PERFECT
5 MEASURE MOISTURE OF CONDITIONED HOT MASH 14-15% PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
CONDITIONING
MEASURE TEMPERATURE OF HOT MASH 70 - 85 EVERY HOUR PELLET OPERATOR
CHECK CONDITIONER PADDLE & ADJUST IF NECESSARY AS RECOMMENDED WEEKLY ONCE MAINTENANCE INCHARGE
 DIE & PRESS ROLL SETTING PHYSICAL INSPECTION/ CHANGE AT RIGHT TIME SHIFT WISE PELLET OPERATOR

DIE & PRESS ROLL CHANGE TIME NECESSITY PHYSICAL INSPECTION/ CHANGE AT RIGHT TIME SHIFT WISE PELLET OPERATOR

DIE ROTATION NECESSITY PHYSICAL INSPECTION/ CHANGE AT RIGHT TIME WEEKLY ONCE PRODUCTION MANAGER
WHEN DIE HOLE HOLE REACHES 0.5MM OVER &
OPTIMAL
6 ABOVE DIE ACTUAL DIA BEFORE TOUCHES NEAR
PELLETING
CHECK DIE HOLE SIZE BY HOLE , CHANGE THE DIE WEEKLY ONCE
PELLET OPERATOR/
MEASURE TEMPERATURE OF HOT PELLET 70 -85 EVERY HOUR/DAILY QA PROCESS CHEMIST
MEASURE MOISTURE OF HOT PELLET 14-15 PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
MEASURE FINES AT PELLETING LESS THAN 1% PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
MONITOR KNIFE CONDITION / CHANGE TIME AS RECOMMENDED SHIFT WISE PELLET OPERATOR

MEASURE COOLING TIME 12- 15 MIN WEEKLY ONCE PRODUCTION MANAGER

MEASURE TEMPERATURE AFTER COOLING AMBIENT +5DEG PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
MOISTURE OF FEED AFTER COOLING 11 -12% PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
7 COOLING
CLEANING OF COOLER WEEKLY WEEKLY ONCE PRODUCTION MANAGER
BLOWER PIPE CONDITIONS WEEKLY WEEKLY ONCE PRODUCTION MANAGER
CYCLONE BLOCKAGES WEEKLY WEEKLY ONCE PRODUCTION MANAGER
FINES AFTER CRUMBLING 20% PRODUCT WISE/SHIFT WISE PELLET OPERATOR
ACCURATE
8
CRUMBLING CHECK CRUMBLER ROLL WEAR AND CHANGE TIME PHYSICAL INSPECTION/ CHANGE AT RIGHT TIME WEEKLY ONCE PRODUCTION MANAGER
CHECK FEED TEXTURE & EVENESS AS PER STD PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
.
FINISHED FEED
9 MEASURE PELLET LENGTH 4-5 MM PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
PELLET
MEASURE PDI STD VS ACT 85% PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
MEASURE FINES % 5%
PBS- BELOW 2MM- 50-55%, 1-2MM 40-45%BS-
9A
FINISHED FEED MEASURE FEED PARTICLE SIZE DISTRIBUTION BELOW 2MM- 60-65%, 1-2MM - 20-25% PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST
CRUMBLE MEASURE FINES % PBS 10% , BS 8% PRODUCT WISE/SHIFT WISE QA - PROCESS CHEMIST

FIND OUT FINES AFTER STORAGE( 1, 2, 3 DAYS) MEASURE & COMPARE WITH BEFORE STORAGE RANDOM SAMPLING WEEKLY QA - PROCESS CHEMIST
FEED STORAGE LOT HEIGHT AS RECOMMENDED SHIFT WISE PRODUCTION MANAGER
10
AT WAREHOUSE

PDI (STD VS ACT ) MEASURE & COMPARE WITH BEFORE STORAGE RANDOM SAMPLING WEEKLY QA - PROCESS CHEMIST
11 FEED AT FARMS
FINES AT FARM MEASURE & COMPARE WITH BEFORE STORAGE RANDOM SAMPLING WEEKLY QA - PROCESS CHEMIST
SWAP TEST FOR MICRBIOLOGY / FEED / RAW MATERIAL /
WEEKLY RANDOM SAMPLING WEEKLY QA - PROCESS CHEMIST
WARE HOUSE/
12 BIO SECURITY MILL INSIDE & OUTSIDE PREMISE HOUSE KEEPING & ALL ROADS AND LOADING &
SPRINKING BLEACHING POWDER WHERE EVER NECESSARY/ DAILY UN LOADING POINTS, QA - PROCESS CHEMIST
MEDICINAL SPARY DRAINAGES