Demonstration of the pelleting plant at the machine ring Arnstein
Mobile pelleting plant
Farmers have pellets pressed as bedding and for heating
MR Arnstein eV has been organizing the use of a mobile straw pelleting system for four years - first in its own ring area, then in the whole of Lower Franconia. Farmers use the pellets here as bedding and fuel.
Ever since Herbert Krückel started laying hens on his organic farm, he has been using straw pellets for bedding. 'The absorbency of the material and the practical handling impress me,' he says. Once a year, he has his own straw, low-quality hay or spelled husks pelletized in a mobile system. This is organized by MR Arnstein.
“Several interested members asked me about straw pelleting years ago. With Franz-Josef Tradt from Regiopell in Wolpertshausen, Baden-Württemberg, we were able to find a competent contractor. We bundle the orders and then he'll be with us in Lower Franconia for a good four weeks, ”says Gebhard Karch, Managing Director of MR Arnstein eV.
It is important to have suitable locations for the mobile straw pelleting plant. After all, the machine, with a length of over 12 meters, requires an enormous amount of space. But not only the system should be on firm ground, there must also be sufficient space for the delivery of the straw bales to be processed and for the bagging of the pellets in big bags or the filling of containers or trailers. The spatial conditions for this are not available on every farm. However, Herbert Krückel is lucky that his immediate neighbor in Schleerieth also uses the mobile system and has enough space. A total of four locations at which the plant could be used with at least 50 tons each were ultimately available.
Pellets from dry stalks
In addition to grain straw, rapeseed straw, hay, husks, miscanthus or reeds can be pelletized in the plant. It is important that the starting material is dry and, if possible, pre-shredded. Then the system runs smoothly. “It is a great challenge for the technology to process the different raw materials in a stable and trouble-free manner. With dry, short-cut straw in square or round bales, you are on the safe side, ”confirms Praktiker Krückel. Then, he continues, the machine can compact up to a ton of material per hour into pellets. Service provider Franz-Josef Tradt expects an average daily output of 10 tons.
Sometimes it is also advantageous to mix different types of straw. “You cannot set a general rule, but winter barley straw is sometimes difficult to process. The plant, on the other hand, copes best with wheat straw. If you mix the two, it is very clever, ”advises Franz-Josef Tradt.
Practical handling and high absorbency
Herbert Krückel needs around five to six BigBags, i.e. almost five tons of pellets, for the litter of his 3,000 laying hens. At home, he stores the material in containers, where he can easily remove it using a slide. “Before the installation, I distribute a BigBag with the wheel loader in the empty barn. Then the animals come and, depending on the season, I only have to litter again after weeks. The handling of the pellets is extremely practical, ”he reports. This justifies the additional effort compared to straw.
The organic farmer is also enthusiastic about the absorbency of the bedding material. 'The pellets can absorb 400 times their own weight and thus significantly more moisture than long straw,' he explains. This has a positive effect on the house climate. The high temperatures during production also reduce the germ and spore load.
“Many horse owners are also very taken with the litter with pellets. They report fewer respiratory diseases and mainly use wheat, triticale or spelled straw, ”adds Gebhard Karch, managing director of MR Arnstein. In addition, the consumption of box litter is significantly lower compared to long straw. If a horse needs an average of about four to five bales per month, this is reduced to about one ton for bedding with pellets. To do this, however, dirty litter and horse apples should be removed regularly
Well thought-out structure of the system
Back to the modern pelleting system from PCM Green Energy. This is transported in a 45-foot container with a special semi-trailer by an authorized freight forwarder. All important components - the preparation with mixer and hammer mills, the conditioning, the pelleting press and the pre-cooling section with discharge conveyor are integrated. A 200 kw generator, which is driven by a diesel generator, provides the power supply.
The straw is introduced into the 10 cbm mixer from above, foreign substances such as stones or metal are separated. Then two hammer mills break up the material further. Water can optionally be added to the conditioner. Finally, the shredded material is pressed through a ring die at a pressure of approx. 600 bar. The pellets thus obtained are finally filled via an external conveyor and cooling belt. As a rule, they are bagged in big bags with a content of 600 to 800 kg.
Entrepreneur Franz-Josef Tradt controls and operates the plant while another force - usually the client - loads the machine with straw and transports the pellets away. Please note a filling height of 3.80 m for the mixer. That is why working with a telescopic loader makes sense. This device can also be conveniently conveyed by the machine ring.
Around € 120 / t net will be charged for the production of one ton of pellets. 'Sometimes it gets cheaper, sometimes a little more expensive - depending on the starting material and thus performance and depending on travel and set-up costs,' explains Franz-Josef Tradt.
Feeding and heating
Customers are satisfied with the process and, above all, with their product. Many, like farmer Krückel, use straw pellets to litter poultry or horses. In addition, some sow farmers use straw pellets to add raw fibers to their feed. This is particularly interesting for self-mixers and pig farmers who feed liquid. 'It is clear that the straw must be of perfect quality,' adds the operator.
Georg Keller from Eßleben near Werneck in turn heats his home with straw pellets. Four years ago, he had to invest in a new heating system and opted for a heating system that copes well with the renewable energy source. 'I find the idea simply appealing. As a farmer, I am now self-sufficient. And by returning the ashes to the field, I have a closed cycle, ”he argues. With the straw of three hectares of grain, i.e. around eight tons, it covers its annual needs. However, the farmer points out that straw pellets have other burning properties, such as wood pellets. Therefore, interested parties must take great care that their firing is designed accordingly.
There are many possible uses for straw pellets. Gebhard Karch, Managing Director at MR Arnstein, is seeing a growing demand from his members for use in their own company. “While we initially only pressed XXX t of pellets, this year it was a good 270 tons. I am sure that we will achieve this brand again next year and continue working with Franz-Josef Tradt, ”he summarizes.
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