Production Processes

Pelleting

1. Reviews: Operation of the pelleting system.

 Job descriptions, critical task procedures and protective equipment. Review
video "Pellet Mill Critical Task Procedures.”
 Product Integrity Manual for pelleting.
 Safety Manual - safety devices in pelleting system.
2. Pellet Mill Certification Manual: Reads before performing any duties; completes
review at end of each chapter. Reviewed by plant manager.
3. Pellet Durability Test:
 Reviews section in Product Integrity Manual.
 Taught how to perform test.
 Conducts PDI test during on job training.
 Reviews the locations PDI requirements
4. Read the operations and maintenance manuals for the pellet mill(s), cooler(s),
screener(s), molasses meter(s), and crumble rolls.
 Review the maintenance check points in Maintenance Manager (oils, lubes, &
inspections) for each major piece of equipment.
 Compare the operator’s manual’s schedule of maintenance to the location
Maintenance Manager. Look for any deviation between the two schedules;
discuss your findings with the location maintenance team and plant manager.
5. Describe the Pellet Mill steam harness and understand the science for the CAN
steam harness arrangement.
6. Complete liquid meter calibrations for the fat/oil at the die and the molasses in
the conditioner. Compare the calibrations to existing calibrations and make the
necessary adjustments.
7. On-the-job experience: Performs all jobs associated with pelleting, including
changing screens, rolls, dies, and lubrication. The associate should be able to
run a pellet mill without any supervision.
8. Technical Issues: (This information can be found in the P&E Library)
 What is the minimum conditioner retention time?
 What is your die speed in ft/min?
 What should the die speed be for pellets and cubes?
 What is the percent open space in your die?
 What should it be?
 What is your die friction?
 How does this value affect die open space?
 Calculate your die compression ratio (L/D)
 Calculate pellet "die retention time”
 What is the CFM of air being utilized through your locations cooler(s)?
 What is the target temperature for pellets when they are discharged from the
cooler?
 How does your location’s cooler fire protection operate?
  What is the purpose of a steam trap?
9. Pelleting unit capacities:
 Prepare a flow diagram
 Determine the capacities of all coolers, crumble rolls, screeners, and pellet
mills.
 Conduct time studies and compare them to the location Model Mill standards.
 Make a recommendation for improvement in regards to safety and efficiency.
10. Measure cooler efficiency using both moisture and temperature analysis on
pellets and cubes.
 What is the depth of product in the cooler and what should it be?
 Will the bed depth very between pellets and cubes, if so why?
11. How do you determine if a die is worn out?
 What were the average pelleted tons per die for your location’s last three
dies?
12. List some examples of different types of dies and rolls.
 What style of die and rolls does your location utilize?
13. Determine the optimum conditioner temperature for the top ten products pelleted
at your plant.
14. Calculate the direct pelleting cost per ton using Model Mill.
15. Work with the plant manager when placing orders for dies and rolls.
 Who is your plant’s Tradico contact?
 Which suppliers are approved vendors for dies and rolls? (See the approved
vendor listing)
16. Determine screen size for your locations pellet screens.
 For cubes
 For pellets
 For crumbs
17. Reports at least one near miss in a high risk area of pelleting and complete the
investigation.
18. Identify at least two limiting factors (bottlenecks) which affect pelleting
productivity.
19. Determine your locations average pelleting rate (throughput).
20. What are the scheduling or flushing requirements for running a medicated feed
in front of a non-medicated feed (i.e. running a ionophore feed before a horse
feed).
21. Review and critique the process improvement sheets for all shifts while complete
the pelleting training.
22. Complete the pelleting certification.
23. Reference the CAN Plant Operations Talent Development Competencies for
relevant details.
24. Reference World Class Management Model for relevant Accountability and
Competency Statements.
25. Refer to relevant Model Mill process screens and reports.
26. Understand related LRT screens and functions.
27. Reviews and signs off on all related SOP’s for this area.
 Formal review with plant manager upon completion of training.

The above questions should be answered on a separate sheet and reviewed with the
plant manager. If something is found to be incorrect or vague the associate should
revisit the area and schedule a second follow up with the PM.