Sanitized Feed for Chicks

NEW COBB-VANTRESS MILL SERVES BREEDING OPERATIONS IN KENTUCKY, TENNESSEE

Cobb Vantress Inc.
Siloam Springs, AR • 479-549-6009
Founded: 1916
Feed production: 104,000 tpy at two locations
Number of employees: 2,700
Key personnel at Albany:
• Matt Ferguson, feed mill manager
Supplier List
Air compressor .....................Kaeser
Batch control system ...Tyson Foods Inc.
Bearing sensors ....Maxi-Tronic Inc.
Bin level monitors ....BinMaster Level Controls
Boiler ......................Cleaver Brooks
Bucket elevators ...Hayes & Stolz Ind. Mfg. Co. Inc.
Contractor ......Todd & Sargent Inc.
Conveyors (drag) ...............Tramco
Conveyors (screw) ...Conveyors Inc.
Distributor ..Hayes & Stolz Ind. Mfg. Co. Inc.
Dust collection system ................... AIRLANCO
Elevator buckets ......Maxi-Lift Inc.
Engineering ....Todd & Sargent Inc.
Gates/diverters .....................Vortex
Hammermill ...Mill Technology Co.
Liquid tanks ........................ Fastec
Manlift .....Schumacher Elevator Co.
Microingredient system .................InterSystems
Mixer ...Hayes & Stolz Ind. Mfg. Co. Inc.
Pellet cooler ....Geelen Counterflow
Pellet crumbler ..................... CPM Roskamp-Champion
Pellet mill.............................. CPM Roskamp-Champion
Scales .. Rice Lake Weighing Systems
Speed reducers .....................Dodge

Cobb-Vantress, Inc., a leading broiler genetics company, began manufacturing at its new 80,000-tpy feed mill in January 2015 to meet the special nutritional needs of young birds. The mill, located on the outskirts of Albany, KY (606-387-0625), was built to serve two Cobb- Vantress parent chick hatchery complexes in Monticello, KY and Lafayette, TN.

“It was good to have control over our own feed,” says Feed Mill Manager Matt Ferguson, who came to Albany in the fall of 2013 after working at the Cobb-Vantress mill in its headquarters city of Siloam Springs, AR.

To build the mill, Cobb-Vantress hired Todd & Sargent Inc., Ames, IA (515-232- 0442). Ferguson notes that Todd & Sargent built the mill at Siloam Springs, as well. “[The Albany mill] is a copy of the older mill, with some improvements,” he says.

The main improvement, Ferguson explains, is the addition of a CPM hygieniser to the product flow between the steam conditioner and the pellet mill. The hygieniser is a long steamjacketed auger that maintains mash feed at its steam-conditioned temperature, preventing bacterial growth prior to pelleting. Sanitized feed is critical for raising Cobb’s breeder stock.

Todd & Sargent began construction2013. Ferguson says the project went relatively smoothly in spite of extremely bad winter weather in 2014-15.

Mill Specifications
Todd & Sargent constructed a slipform concrete mill on a 56-x-60-foot footprint and standing 175 feet tall. The structure includes 14 overhead ingredient bins holding an average of 1,400 tons, two mash bins holding 96 tons, and 10 finished feed bins holding 700 tons.

Ferguson says there are no whole grain storage tanks on site, since most of the corn used is sourced from producers locally or, if necessary, from grain elevators at Franklin or Owensboro, KY.

The mill receives grain and soymeal at 100 tph. Whole grains are ground on a 200-hp Mill Technology cutter plate hammermill at 30-40 tph. Ferguson says the variable-speed drive allows operators to control the granulation without having to change screens.

Mill operations are under control of a customized automation program developed by Tyson Foods, Cobb’s parent company.

Ingredients are mixed in a three-ton, 50-hp Hayes & Stolz twin-screw mixer. Mixing time currently averages four to five minutes per batch. Microingredients are added at the mixer through an Intersystems 16-bin system utilizing loss-in-weight bins. Liquids and fats also are added at the mixer.

Following the steam conditioning and hygenising steps mentioned above, mash feed is pelleted using a 500-hp CPM Model 7932 pellet mill. Pellets then are treated with a Geelen counterflow cooler and an Apec fat coater. Virtually all of the pellets are crumbled in a CPM crumbler for feeding to young birds.

Cobb-Vantress operates a fleet of six feed trucks out of Albany. Trucks are loaded while parked on a 70-foot Rice Lake Weighing Systems truck scale using a Tramco loadout conveyor. Loading time averages 10 minutes.

Ed Zdrojewski, editor