The FlexMill is AGI's solution for feed production on medium to large size farms or retail applications. The FlexMill has the adaptability to be applied to new or renovated facilities. For a complete solution, the FlexMill can also be incorporated with the AGI overhead bin system and AGI's full line of grain and meal storage tanks. The FlexMill system components are designed for bolt-together rapid installation with no need for specialized construction techniques. AGI can design and plan an entire feed mill manufacturing facility around the FlexMill.
Grains and other feed ingredients are delivered by truck and unloaded through the receiving drag conveyor. The metering inlet in the receiving pit regulates the product flow going into the receiving system. Material moves along the bottom chamber of the drag conveyor.
Ingredients are discharged into a bucket elevator that elevates the product to the top of the facility. The product discharges from the bucket elevator that is designed specifically for feed mill applications and the wide range of ingredient characteristics common in feed mills. Product is then routed by the two-way valve to either the bulk storage system or to the distributor above the overhead ingredient bin pack.
This allows for loading ingredient bins directly from the truck for grains, minerals, and other soft stock ingredients. or loading the bulk storage bins for future mill demands. Bulk storage bins are filled by a drag conveyor with gates at the inlets of each bin. Bulk storage bins can be used for grains and other high usage ingredients.
Based on client requirements, condition monitoring can be installed. Screw feeders at the bottom of the bulk storage bins meter the product into a reclaimed drag conveyor. The reclaimed drag delivers the product back to the receiving bucket elevator, which then routes the ingredients to the overhead bin pack distributor and into the overhead bins. Overhead ingredient bins have internal smooth walls with chamfered corners to prevent product hang-up. At the base of the bin, are hopper cones with large openings.
The combination of smooth bin walls and large openings provides mass flow, which results in the first-in, first-out flow of product and prevents bridging of difficult flowing products. The FlexMill is designed as a low-profile feed processing system with the features of a commercial feed manufacturing facility. The FlexMill has several compelling features, such as a fully automated control system, which allows the entire process to operate with minimal operator intervention which improves weighing accuracy and increases the throughput of the system. It also maintains detailed records for all operations and ingredient usage to provide traceability and quality assurance.
AGI has partnered with one of the world's leading feed mill automation specialists to bring a feature-rich and expandable platform as well as global 24-7 service and support. AGI can also incorporate its industry-leading CMC hazard monitoring platform to protect the equipment and facility for dust explosion prevention and equipment protection to improve operating uptime. The FlexMill contains multiple scales for grain, micro, and protein ingredients to allow for the simultaneous weighing of three ingredients.
Surge hoppers for each of the three scales and one in front of the mixer minimize filling and transfer times for ingredients. Macro ingredients such as grains that do require grinding are metered into the grain scale from overhead bins. Macro ingredients that do not require grinding are metered into the soft stock scale from overhead bins.
The micro dosing system provides highly accurate weighing of low inclusion products and is constructed of stainless steel components to allow for flowability and increased lifespan and therefore is suitable for commercial applications. The FlexMill includes a HammerMill with 40 to 75 horsepower options. The variable speed capabilities on the HammerMill allows grain particle size to be adjusted on a per-formula basis.
AirAssist dust collection on the HammerMill improves grinding efficiency by pulling small particles through and away from the HammerMill screen area. and provides dust control on the entire system. The FlexMill mixer is a horizontal paddle style engineered for rapid and complete mixing of ingredients and the capability of liquid inclusion.
Transfer Loop Drag Conveyor allows for a low profile design and superior clean out of any product. The FlexMill system is designed to process batches of 1000 kg. However, throughput is dependent on the specific ingredient recipe. Therefore, throughput of the FlexMill ranges from 8 to 12 batches per hour or a capacity of 8 to 12 tons per hour. During batch 1, feeders are activated for grain, meals, and micro-ingredients at the same time.
As soon as ingredient requirements are met, each scale is discharged into the surge hopper below it. During the weighing of batch 2, batch 1 grain is held in the surge hopper above the hammer mill. As soon as the scales for batch 1 have been discharged, the feeders are again activated for the weighing of batch 2. The hammer mill pocket feeder is activated. to begin the grinding of the grain ingredients, providing even flow and distribution across the hammer mill width. Ground grain is delivered to a surge above the mixer using a loop conveyor.
Batch 1 micro-ingredients and meals are transferred directly to the surge hopper above the mixer and held. When all of the batch one ingredients are collected in the surge above the mixer, the ingredients are discharged into the mixer for mixing and if required the addition of liquid ingredients is sprayed over the feed inside the mixer. When batch one ingredients discharge from the mixer surge, batch two ingredients are immediately discharged from the scales and begin their grinding and transfer process. Batch three weighing begins immediately after after batch 2 has been discharged from the scales. Ingredients are thoroughly mixed and then discharged into the loadout drag conveyor.
The process will continue until the total production requirement is complete. Finished feed is delivered to the overhead loadout bins via drag conveyor and loadout bucket elevator where it can be stored for customer pickup. AGI's intelligent FlexMill system can be designed with repeat batching automation to provide optimal weight and mix accuracy, ensuring the right mix from start to finish.
Repeat systems highly accurate measuring weighs each ingredient to its target. weight, producing fast, accurate batches. As one batch is routed out, the next batch is being weighed.
The dynamic ECO, or early cutoff system, increases accuracy and minimizes waste by providing predictive and adaptive weighing control. The result is increased precision and output while decreasing waste and risk of feed contamination. It supports regulatory compliance and commercial risk mitigation. Repeat's batching system is modular in design and can allow the customer to expand in the future. The AGI FlexMill provides a cost-effective solution for feed production requirements that are more than simple on farm grind and mix but not not the capacity of a commercial feed mill.
The owners achieve the quality and efficiency of a commercial mill and the ability to utilize all available ingredients. Built to the standards for a commercial feed mill, the FlexMill will be a value-add investment for the long term.