Distiller grain production device

• US 9,480,281 B1
• Filed: 09/03/2015
• Issued: 11/01/2016
• Est. Priority Date: 04/15/2011
• Status: Active Grant

• Current Assignee: Nationwide 5 LLC
• Original Assignee: Nationwide 5 LLC
• Inventors: Thomas, Michael R.
• Primary Examiner(s): Malekzadeh, Seyed Masoud
• Application Number:
  US14/845,079
• Time in Patent Office: 425 Days
• Field of Search: 426/516, 426/454, 426/512, 426/518, 425/144, 425/382.4, 425/143, 425/145, 425/149, 425/207, 425/208, 425/209, 425/378.1, 425/404, 425/379.1, 425/382.R
• US Class Current: 1/1
• CPC Class Codes: A23K 10/38 from distillers' or brewers' waste
• CPC Class Codes: A23N 17/005 for shaping by moulding, extrusion, pressing, e.g. pellet-mills processes A23K40/00; presses in general B30B
• CPC Class Codes: A23P 10/20 Agglomerating; Granulating; Tabletting
• CPC Class Codes: A23P 10/25 Agglomeration or granulation by extrusion or by pressing, e.g. through small holes, through sieves or between surfaces
• CPC Class Codes: A23P 10/28 Tabletting; Making food bars by compression of a dry powdered mixture
• CPC Class Codes: A23P 30/20 Extruding
• CPC Class Codes: B29C 2948/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 2948/92019 Pressure
• CPC Class Codes: B29C 2948/92209 Temperature
• CPC Class Codes: B29C 2948/92428 Calibration, after-treatment, or cooling zone
• CPC Class Codes: B29C 2948/9259 Angular velocity
• CPC Class Codes: B29C 2948/926 Flow or feed rate
• CPC Class Codes: B29C 2948/92638 Length
• CPC Class Codes: B29C 2948/92704 Temperature
• CPC Class Codes: B29C 2948/92923 Calibration, after-treatment or cooling zone
• CPC Class Codes: B29C 48/04 Particle-shaped making granules B29B9/00
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/06 Rod-shaped
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/32 with annular openings, e.g. for forming tubular articles
• CPC Class Codes: B29C 48/345 : Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
• CPC Class Codes: B29C 48/395 : using screws surrounded by a cooperating barrel, e.g. single screw extruders
• CPC Class Codes: B29C 48/402 : the screws having intermeshing parts
• CPC Class Codes: B29C 48/53 : having a varying channel depth, e.g. varying the diameter of the longitudinal screw trunk
• CPC Class Codes: B29C 48/872 : characterised by differential heating or cooling
• CPC Class Codes: B29C 48/875 : for achieving a non-uniform temperature distribution, e.g. using barrels having both cooling and heating zones
• CPC Class Codes: B29C 48/90 : with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
• CPC Class Codes: B29C 48/904 : using dry calibration, i.e. no quenching tank, e.g. with water spray for cooling or lubrication
• CPC Class Codes: B29C 48/911 : Cooling
• CPC Class Codes: B29C 48/9135 : of flat articles, e.g. using specially adapted supporting means
• CPC Class Codes: B29C 48/919 : using a bath, e.g. extruding into an open bath to coagulate or cool the material
• CPC Class Codes: B29C 48/92 : Measuring, controlling or regulating
• CPC Class Codes: F26B 17/20 : the axis of rotation being horizontal or slightly inclined
• CPC Class Codes: F26B 5/14 : by applying pressure, e.g. wringing; by brushing; by wiping

Abstract

A device for producing a high density compact livestock feed from a loose granular material according to various embodiment can include a source for supplying a loose granular material to be treated and moving the treated material through a series of successive treatment zones. Rotatable screws are provided within an extruder to compress and transport the treated material a die. The treated material is pressed through the die while a two-dimensional cross-section compression is applied to the treated material.

Claims

1. A device for producing a dense compact livestock feed from a loose granular material, comprising:

a source for supplying a loose granular material to be treated;

an extruder comprising an elongated housing having an inlet end and a discharge end, the inlet end in communication with the source and to receive the loose granular material to be treated and the extruder arranged to compress the treated material within the extruder, wherein the extruder includes;

rotatable screws provided within the housing and extending between the inlet end and the discharge end for compressing and transporting the treated material, the screws apply a compressive force to the treated material as the screws rotate and move the treated material longitudinally along the screws;

at least one drive coupled to the screws for axially rotating the screws; and

at least one heater disposed along a portion of the housing for heating the treated material moving along the screws;

a controller comprising a computer control loop which controls a plurality of temperature sensors embedded within at least one wall of the elongated housing and are connected in the computer control loop, wherein the plurality of the temperature sensors are configured to monitor a temperature as the treated material moves through the elongated housing and wherein the computer control loop is configured to control individual heater output regulators, a rotatable screw motor speed regulator, and a distiller grain feed flow controller to adjust and regulate a heater output, a rotation rate of the rotatable screws, and a feeding rate of the treated material respectively, to maintain the treated material within a temperature range along one or more treatment zones of the elongated housing as the treated material travels along the elongated housing, and a die located at tips of the screws at the discharge end of the extruder for creating a substantial pressure for compacting the treated material, wherein the die includes;

a chamber having a through hole which extends longitudinally through the chamber and provides a restricted passageway for compressing the treated material, the through hole includes an inlet orifice for receiving the treated material from the discharge end of the extruder and an outlet orifice for discharging the treated material, and pressing the treated material in a modulus state longitudinally through the restricted passageway;

at least one wall of the chamber is structurally configured to apply a pressure applied in a direction transverse to a direction of transport and a pressure applied in a direction parallel to the direction of transport such that a two-dimensional cross-section compression is applied to the treated material passing through the chamber forcing liquids in the treated material to migrate to an outer surface of the treated material upon reaching the outlet orifice.

2. The device of claim 1, wherein the dense compact livestock feed is shaped to form at least one of a pellet, a cube and a tub.