Executive Summary
This case study describes how a ruminant feed factory in Kostanay, Kazakhstan, modernized its pelleting line with a ring-die pellet mill supplied by Liyang Hongyang Feed Machinery Co., Ltd. (Hongyang Feed Machinery / brand: Hongyang). After the equipment was installed and commissioned with on-site support from the manufacturer, the customer’s line raised throughput from 6.2 tonnes per hour to 8.5 tonnes per hour, improved the pellet durability index (PDI) from 88.7% to 94.2%, reduced energy consumption by 15%, and lengthened die service life from about 600 hours to 880 hours. These figures were recorded at the customer’s plant and published on the company’s official case-study page. The project shows that a combination of well-built equipment and disciplined technical service can produce measurable, verifiable returns for feed producers in competitive markets.
Background: An Industry That Runs on Efficiency
Compound feed production is one of the largest segments of global agriculture. Alltech’s 2025 Agri-Food Outlook, based on its annual survey covering 142 countries and more than 28,000 feed mills, estimated total global feed production at 1.396 billion metric tonnes in 2024, up 1.2% from the previous year. Within this industry, pelletized feed continues to gain ground because pelleting improves feed conversion, reduces ingredient segregation, and lowers waste at the farm level.
Market research published in 2025-2026 places the compound annual growth rate of the animal feed pelleting equipment segment at roughly 4.5% to 7.6% through the early 2030s, with Asia-Pacific accounting for the largest share of demand and several emerging markets expanding fastest.
The Challenge at the Kostanay Plant
The customer operates a ruminant (cattle) feed facility in Kostanay, a region in northern Kazakhstan with a significant livestock sector. The plant’s existing pelleting line was underperforming in three ways:
- Low Output: At 6.2 t/h, the line constrained downstream capacity.
- Inconsistent Quality: Measured PDI around 88.7% led to fines and complaints.
- High Costs: High energy use and quick ring die wear (approx. 600 hours).
Why Hongyang Was Selected
The customer evaluated several equipment options before choosing Hongyang. The company’s HYPM series ring-die pellet mill was selected for three core reasons:
Stability
Design emphasizes stability under continuous load for sustained operation.
Efficiency
Clear advantages in energy efficiency to reduce total production costs.
Support
Commitment to on-site installation, commissioning, and operator training.
Commissioning and On-Site Support
Installation and commissioning were carried out at the customer’s site in Kostanay with Hongyang engineers present. The process included:
Technical Tuning: Equipment alignment, die-roller clearance, and steam conditioning adjusted for local grains and oilseed meals.
Operator Empowerment: Comprehensive training on start-up, shutdown, die changes, and routine maintenance to ensure plant self-sufficiency.
Measured Results After the Upgrade
The throughput increase of 2.3 t/h gave the mill meaningful headroom to satisfy seasonal demand peaks. The improvement in PDI reduced fines at the pellet cooler and during transport. The longer die life meant fewer changeovers and lower wear-part spending.
Industry Context: Efficiency Is the New Competitive Edge
As global feed output grows, competition is shifting from simply producing feed to producing it with lower cost and more consistent quality. Pellet quality is now a purchasing criterion for many livestock and dairy operations. Equipment suppliers that can demonstrate real-world results are better positioned to serve this market.
Conclusion: A Reference Point for Feed Mill Modernization
The Kostanay project illustrates the value of pairing solid equipment with committed technical support. For feed mill operators considering an upgrade, the practical takeaways are straightforward: define bottlenecks, look for documented results, and treat training as essential. The figures from this case provide one concrete data point for that decision.
Post time: Oct-07-2026
