Five stars for Egyptian feed mill

09/27/2004 Bühler flour mills supply topclass quality. This quality is also in demand when it comes to animal feed production, a fact borne out by a contract signed with an Egyptian company: In the production of poultry and cattle feeds, Five Star Feed Mills in Suez relies on proven top-quality expertise from Bühler. The Egyptian businessman Mahmoud M. Elshorbagi has a clear goal. His two flour mills in Suez produce the best quality throughout Egypt. That is precisely what he also intends to achieve with the feed he manufactures. The dynamic chairman and managing director of the company established in 1996 therefore commissioned Bühler to design his new feed production facility so that he will easily be able to maintain Five Star quality standards.

Elshorbagi has known Bühler since the time he was involved in flour milling in Oman. Even then, it was important to him to have to deal with a single partner only. Today, the relationship with Bühler has become even closer: From the ship unloader and the complete production plant to the entire infrastructure, Five Star Feed Mills entrusted Bühler with the entire engineering and construction work. No competitor was capable of providing everything from a single source in this form.

Designed with expansion in mind
Not only the external appearance – the color and the architecture – of the feed mill has been matched to the two existing flour mills. The new facility is also linked directly with the flour milling systems. It utilizes the existing grain storage silos through an underground conveyor connection. In addition, the flour mills supply bran and millfeed to the feed production plant through a direct pneumatic conveyor link.

The over 40 meter tall feed mill has been designed with rapid expansion of production in mind. Its main products are poultry and cattle feeds. A high-capacity premix system, which has also been designed to allow easy subsequent expansion, covers the feed mill’s own needs as well as producing premixes for the market. An aquafeed production system is also included, which manufactures specialty feeds for fish and shrimps using a twin-screw extruder. The employees of Five Star acquired their specialized extrusion skills in a course they attended at Bühler headquarters in Uzwil.

Separate production lines
Mahmoud M. Elshorbagi built his feed production facility with the vision of achieving top quality at all times. The feed pellet and meal production lines are therefore completely separated to prevent cross-contamination. All the feed components are accurately blended. The computerized Bühler control system allows fully automatic operation of the entire installation. It also offers another highly signifi cant feature for achieving the quality that Five Star aims at: the retraceability of all components.

The fine raw materials contained in feed pellets are reliably bound as a result of the thermal treatment that the material undergoes in the conditioner before pelleting. In the form of a meal, the feed’s fine ingredients such as vitamins would segregate, failing to provide the optimal nutritional effects in the animals. Steam treatment offers the additional advantage of destroying Salmonellae and other pathogenic germs.

Thermal meal treatment
Not all animal feeding requirements can be satisfied by pellets. Depending on their feeding habits, many animal species may prefer feed in the form of a meal. To ensure a high hygienic standard also of these products, the feed mill infrastructure offers the possibility of installing a Bühler Thermal Meal Treatment system. Though such sanitation systems are not yet widespread in the feed production industry, they are gradually becoming accepted as a standard. This, in any event, is true for Mahmoud M. Elshorbagi, whose declared goal is to ensure top quality and safety of all the products supplied by his Five Star Feed Mills & Animal Production Company.

Bagging of the finished products is one of the final operations in the two completely separated processes for making feed meals and pellets. Bagging of the finished products is one of the final operations in the two completely separated processes for making feed meals and pellets.


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