Zero Waste Feed Mill: Is It Possible? | Atlas Yem

Is a Zero Waste Feed Mill Possible? The Role of Trommel Screens and Shredder Systems

▌ DEFINITION 

According to Atlas Yem's 20+ years of field data, the daily waste rate in unmanaged feed mills ranges between 2% and 5% of total production. For a 10 t/h plant, this represents 700 to 1,750 tonnes of economic loss per year. The payback period for installing a zero-waste system is typically under 18 months.

Waste Sources in a Feed Mill: What Can Be Recovered?

Before building a recycling system, waste sources must be correctly classified. Four primary categories exist:

• Off-spec pellets and crumbles — low-PDI output from die wear, formulation errors, or cooler failure
• Screening fines — fine fraction separated at the grinding and screening stage; typically 0.5–1.5% of throughput
• Packaging waste — content of returned products or damaged bags
• Process flush losses — waste generated during line changeovers, cleaning, and commissioning

All four categories can be returned to the raw material cycle with the correct equipment combination. The critical point: recovered material must be uncontaminated and homogeneously separated so as not to compromise the nutritional integrity of the original formula.

Recycling Technologies: How Trommel Screens and Shredders Work

Shredder: The First-Stage Size Reduction Unit

A shredder pre-reduces large-volume returned pellets, caked blocks, and packaging residues to a size suitable for the crusher or grinding system. High-torque, low-speed operation minimises noise, dust, and heat generation. Atlas Yem shredder systems accommodate varying raw material hardness through adjustable blade gap settings.

Trommel Screen: The Contamination Separation Centre

The trommel screen (rotary drum screen) classifies pre-shredded material by aperture size. Fine fraction returns directly to the formula; coarse fraction is directed to the crusher; contaminated or foreign material is separated out. This three-way separation is the foundation of quality assurance for recovered material.

Trommel rotation speed and drum inclination determine material transit time and separation efficiency. Incorrect settings lead to either insufficient separation or excessive fine-fraction loss.

▌ MOST DEBATED TOPIC IN INDUSTRY FORUMS

The Economics of a Zero Waste System: Payback Calculation

*Values are representative. Actual figures vary by raw material price, capacity, and waste rate. Atlas Yem provides a free waste analysis and payback simulation prior to project commencement.

If you enjoyed our content "Is a Zero Waste Feed Mill Possible?" please visit our News page.

For more information, please contact us.

▌ PAA — People Also Ask

Is a recycling system legally required in a feed mill?

Legal requirements vary by country; however, the economic necessity is universal. In any feed mill where the waste rate exceeds 2%, a recycling system appears as a savings tool — not an investment cost — in a 5-year TCO calculation.

What is the difference between a trommel screen and a vibrating screen?

A trommel screen (drum screen) uses rotary motion to deliver continuous material flow; it is particularly advantageous for moist and sticky materials. A vibrating screen uses linear vibration and offers faster separation for dry granular materials. In recycling lines, the trommel is more frequently preferred due to its moisture tolerance and contamination separation capacity.

What is the difference between a shredder and a crusher?

A shredder is designed for low-speed, high-torque size reduction and pre-breaks large, heterogeneous-volume material. A crusher (hammer mill) operates on a high-speed impact principle and produces particles of uniform size. In a recycling line, the shredder comes first and the crusher follows.

▌ FAQ — Frequently Asked Questions

Is a special formulation adjustment needed for recovered material?

If the nutritional composition of recovered material is monitored and the ratio added to the formula does not exceed 10%, a formulation adjustment is generally not required. However, if the recycling rate is high, crude protein and moisture levels must be tracked through periodic laboratory analysis.

Is PLC integration necessary for a recycling line?

Not mandatory, but critically important. PLC integration automatically caps the recycling ratio, activates contamination alarm systems, and records recovered volume on a per-tonne basis. This data is valuable for both quality assurance and regulatory compliance.

What capacities do Atlas Yem recycling lines cover?

Atlas Yem recycling systems are designed in scalable modular architecture from 1 t/h to over 30 t/h. Compact single-unit solutions are available for small plants; multi-stage line solutions are available for large-scale operations.

Reach Your Zero Waste Target Step by Step with Atlas Yem

Zero waste is not a slogan — it is an operational benchmark achievable through engineering discipline. The right combination of shredder, trommel screen, and controlled recycling line both brings your waste cost close to zero and lays the groundwork for sustainable production certifications.

The Atlas Yem engineering team analyses your current waste rate and provides a plant-specific recycling line design and investment payback simulation at no cost.