Feed Mixer Upgrade Cuts Dust by 90% at Cumbria Mill

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For nearly twenty years, ISF has been the go-to partner for a top manufacturer and supplier of ruminant feed and blends in Cumbria, catering to farmers all over the UK. Their latest project tackled two common issues that many feed mills face: excessive material handling and pesky airborne dust.

By installing a larger mixer and enhancing the discharge, conveying, and dust control systems, ISF helped the client boost production efficiency, eliminate unnecessary handling, and create a safer work environment.

Tackling Double Handling and Airborne Dust

The existing process relied on a bucket loader to feed raw ingredients into the mixer, resulting in a rough blend for animal feed formulations. Once mixed, the product was discharged onto the blending shed floor, where the loader would scoop it up again for transfer to storage bays or the weigh hopper.

Each extra handling step added to processing time, increased vehicle movements, and released harmful airborne dust. Therefore, the project needed a well-coordinated strategy for material transfer and dust control, rather than just swapping out the mixer.

Installing a 13-Tonne Mixer and Upgrading Material Transfer

The customer had procured a new 13-tonne mixer from Keenan. ISF was brought on board to install the equipment and enhance the surrounding processes to cut down on handling time and manage airborne dust.

After conducting a site survey, ISF’s design team created detailed 3D renderings of the proposed upgrades. The plan included a new discharge and conveying system, modifications to the holding bin, and a new dust unit designed to capture airborne dust and reintegrate it into the process.

ISF also extended the holding bin to fit the larger mixer and fully enclosed it to minimize dust. The upgraded discharge and conveying system now efficiently transfers the mixed product from the mixer onto the conveyor and into the bin, all set for the wet mix process.

The 13-ton mixer is a powerhouse, handling the equivalent of an entire bulk vehicle load in just one batch. By weighing and mixing everything at once instead of in smaller portions, production speeds up significantly.

ISF Feed Mixer Upgrade In Cumbria Cuts Dust By 90%

Creating a Dedicated Discharge Route for Dry Blends

To effectively manage dry mix formulations, ISF crafted and installed an intermediate outlet slide complete with discharge bellows. This setup allows for the product to be removed before it even hits the holding bin, sending it straight to a separate storage area.

The bellows gently lower the product to the ground, which greatly minimizes dust escape compared to discharging from a height.

All the new equipment was manufactured at ISF’s York workshop, and it was delivered and installed during a planned shutdown. This strategy ensured that the upgraded system could be introduced safely and with minimal disruption to ongoing production.

Boosting Production Efficiency and Cutting Down Dust

ISF reports that this upgrade has automated the customer’s process, ramped up efficiency and production by 40%, and slashed airborne dust by an impressive 90%. Plus, double handling has been eliminated, making the workplace safer and more efficient.

With the added capacity, there’s now dedicated time in the workday for dry blends. Previously squeezed in around a busy wet mix schedule, these can now be planned and processed more smoothly through the discharge bellows, giving the customer better control over their production timeline.

This project showcases how thoughtful improvements to discharge equipment, conveying systems, bin design, and dust control can really enhance daily operations. Instead of relying on just one change, the benefits came from a series of interconnected engineering upgrades.

The customer is thrilled with the finished installation, and ISF is already collaborating with them on their next project.

Reach out to ISF to chat about your next upgrade project at isfyork.com.