3 Proven Ways to Reduce Waste in Pellet Coating

Oils and fats are among the most expensive yet essential ingredients in animal feed. They enhance nutrition, improve palatability, and enhance the quality of the final product.

However, these benefits can quickly turn into hidden losses when dosing and coating are inaccurate. Even small errors in pellet coating can lead to significant “invisible waste” that reduces your profit margins.

In order to reduce this invisible waste, you need to focus on three essential areas: precision dosing, coating uniformity, and intelligent control. Together, these principles create a foundation for accurate liquid application, consistent feed quality, and greater cost efficiency.

Let’s see how:

Proven Way 1: Adopt Hyper-Accurate Differential Dosing

Traditional dosing systems often fail to account for variations in material flow, leading to inconsistent application and wasted raw materials. This oversight can result in higher costs and inefficiencies in the coating process. Inconsistent flow can occur due to changes in material density, moisture content, or variations in environmental factors. These fluctuations make it difficult to maintain precise dosing and can lead to under- or over-application of expensive ingredients.

Solution

In order to solve this issue, use Dual Weighing Systems combined with Differential Weight Algorithms. These advanced technologies continuously monitor and adjust material flow, which ensures precise dosing despite any variations.

By factoring in real-time changes, the system delivers exactly the right amount of material with every application. The system tracks both material flow and weight, dynamically adjusting the output to maintain consistency, which is critical for high-quality pellet coating.

Benefits

This method results in immediate cost savings by reducing raw material waste. It maximizes your return on investment by improving dosing accuracy and operational efficiency.

Proven Way 2: Achieve Near-Perfect Uniformity

Inconsistent pellet coating leads to wasted nutrients and uneven product quality. When the coating is not uniform, some pellets may lack essential nutrients, affecting both their effectiveness and appeal. This can also result in variations in texture, affecting how the pellets are consumed or processed. Inconsistent pellet coating can also impact the digestibility of the feed, leading to health complications in animals.

Solution

The key to solving this issue is to use an Independent Continuous Spraying Chamber with optimized nozzles that ensure precise, controlled atomization. This setup guarantees that the coating is applied evenly to every pellet, regardless of size or shape.

Benefit

Achieving near-perfect pellet coating uniformity ensures that every pellet delivers the intended nutritional balance. Consistent application enhances digestibility, improves feed performance, and maintains the product’s visual quality. The result is a stable output that meets strict quality standards across batches. Uniformity also helps minimize waste, lowers the rate of rejected material, and builds long-term trust in product consistency.

Proven Way 3: Implement Intelligent Closed-Loop Control

Manual adjustments in the pellet coating process often lead to errors, inconsistencies, and operational instability. These issues can disrupt production and negatively affect product quality. Operators must constantly adjust settings such as temperature, pressure, and coating levels, which can easily lead to human error.

Solution

Implementing a Smart Electric Control System with real-time data visibility addresses this challenge. The system automatically monitors and adjusts parameters such as temperature, pressure, and coating levels, thus ensuring precise control and minimizing human error.

The integration of sensors and smart controls allows for a more intuitive system that makes real-time adjustments without operator input.

Benefit

This intelligent control system boosts operational efficiency by maintaining stable, reliable production parameters. It ensures consistent product quality, reduces downtime, and optimizes the overall production process.

Wrapping-Up

The FAMSUN SLPS260 Continuous Coater is a powerful example of how advanced engineering can bring all three waste-reduction strategies together in one system. Designed specifically for coating high-density pellets with moderate grease additions, this pellet coating system delivers consistency and precision across every batch.

Equipped with an independent coating chamber and four individually controlled grease spraying lines, this pellet coater ensures every pellet receives a uniform coating layer. Its dual-screw rotor system promotes even mixing and stable material flow, which helps achieve consistent coating quality.

Its precision weighing and dosing system reduces measurement errors by 2.2% compared to conventional equipment. In a 20-ton-per-hour production line, this precision can save more than 300,000 RMB annually in raw material costs only. Moreover, the system maintains cumulative oil accuracy within ±1%, offering both reliability and efficiency.

Backed by FAMSUN’s intelligent control platform, the SLPS260 continuously monitors operating conditions and adjusts automatically to maintain stability. The result is lower waste, higher quality, and a smoother, more profitable coating process.