Executive Summary
In 2024, a mid-sized goat feed manufacturer based in Johor, Malaysia, completed a year-long evaluation of the HYPM420 ring die pellet mill supplied by Liyang Hongyang Feed Machinery Co., Ltd. The results demonstrated consistent throughput of approximately 3.5 metric tons per hour, a marked improvement in pellet durability index (PDI), and ring die service life exceeding the client’s prior benchmark. This case study documents the operational context, technical challenges, and the measurable outcomes achieved through Hongyang’s equipment and on-site technical support.
Customer Background
The client, Gemilang Ternakan Feedmill Sdn. Bhd. (name anonymized at customer’s request; “Gemilang” is a placeholder), operates a dedicated ruminant feed production facility in the Kluang district of Johor, Malaysia. Established in 2017, the company initially served local goat farms with mash-form complete feed before transitioning to pelleted feed in 2020 in response to growing demand from commercial Boer and Katjang goat operations across Peninsular Malaysia.
Malaysia’s goat population was estimated at approximately 430,000 head in 2023, with the government targeting increased self-sufficiency in mutton and chevon production under the National Agro-Food Policy (NAFP) 2.0. [Note: Specific livestock data to be verified against the latest annual report of the Department of Veterinary Services Malaysia.]
Johor, Perak, and Kedah are among the states with the highest concentration of small- to medium-scale goat farms, creating a steady regional demand for quality pelleted goat feed.
The client’s production line prior to 2023 consisted of a second-hand pellet mill of non-specialist origin, which proved increasingly inadequate as order volumes grew.
The Challenge
The client faced three interconnected production bottlenecks:
The existing pellet mill, rated at a nominal 2.5 TPH, frequently operated below 2.0 TPH when processing goat feed formulations. Goat feed differs from poultry feed in several critical ways: it typically contains higher crude fiber levels (12–18%), a broader inclusion of fibrous by-products such as palm kernel cake (PKC), and coarser grind specifications. These characteristics place greater mechanical demand on the pellet mill’s drive train and die-roller interface.
The client struggled with fluctuating Pellet Durability Index (PDI) readings. Target PDI for pelleted goat feed is generally above 95%, as excessive fines lead to feed refusal, sorting behavior, and respiratory irritation in goats — particularly in intensive housing systems with automatic feeding lines. The client’s outgoing pellets exhibited PDI values ranging between 89% and 93%, with fines accumulating noticeably during bulk transport and silo discharge.
The non-OEM ring dies in use were achieving only 2,500–3,000 metric tons of throughput before requiring replacement. Given the abrasive nature of high-fiber goat feed formulations — where silica from roughage and abrasive PKC particles accelerate die wear — this short lifespan represented a significant per-ton operating cost burden.
Hongyang’s Solution
After a technical consultation and site visit by Hongyang’s engineering team in early 2023, the following solution was proposed and commissioned:
Equipment Configuration
| Parameter | Specification |
|---|---|
| Pellet Mill Model | HYPM420 Ring Die Pellet Mill |
| Main Motor Power | 90 kW (inline drive) |
| Ring Die Inner Diameter | 420 mm |
| Effective Die Width | 120 mm |
| Die Hole Diameter (Goat Feed) | 4.5 mm |
| Compression Ratio (L/D) | 1:9.5 (optimized for goat feed with PKC inclusion) |
| Roller Assembly | Twin-roller, shell-type, with eccentric adjustment |
| Conditioner | Double-shaft differential conditioner (retention time: 45–90 seconds, adjustable) |
Key Technical Decisions
Hongyang supplied a ring die forged from high-chromium alloy steel (Cr content approximately 18–20%), vacuum-hardened to a surface hardness of HRC 58–62. The die hole geometry featured a multi-stage inlet relief taper, which reduces the peak compressive stress at the die entry and promotes uniform material flow — a critical factor when pelleting fibrous goat feed with variable particle size distribution. [Note: Specific alloy grade and hardness range to be verified against Hongyang's current product technical specifications.]
The 1:9.5 compression ratio was selected after trial runs using the client’s actual production formulation (comprising approximately 45% energy concentrate, 25% PKC, 15% soybean hulls, 10% mineral-vitamin premix, and 5% molasses binder). This ratio provided sufficient compaction to achieve target PDI without excessive energy consumption or undue die wear — a balance that required iterative fine-tuning. [Note: Formula proportions are approximate; the client's actual formula is commercially confidential.]
The double-shaft differential conditioner was configured to maintain a mash temperature of 78–84°C at the conditioner discharge, with steam addition at 2.5–3.0 bar(g). This conditioning regime gelatinizes starch fractions, activates the binding properties of molasses, and softens fibrous particles — collectively improving pellet durability while reducing frictional load on the ring die.
Hongyang dispatched a senior commissioning engineer for a 7-day on-site installation, alignment, and trial-run period. The engineer conducted training sessions for the client’s mill operators covering die break-in procedures, roller gap adjustment protocols, steam quality management, and daily wear inspection routines.
Results & Customer Feedback
After 12 months of continuous operation (January–December 2024), the following data was recorded:
Performance Metrics Comparison
| Metric | Before | After |
|---|---|---|
| Average Throughput | ~1.8–2.0 TPH | ~3.4–3.6 TPH |
| Pellet Durability Index (PDI) | 89–93% | 96–98% |
| Fines Content (post-cooling) | 7–11% | 2–4% |
| Ring Die Service Life | ~2,500–3,000 tons | ~7,200+ tons (still in service) |
| Roller Shell Life per Set | ~800–1,000 tons | ~2,200–2,500 tons |
| Specific Energy Consumption | ~28–32 kWh/ton | ~24–26 kWh/ton |
The ring die installed in January 2024 had accumulated over 7,200 metric tons of throughput by December 2024 and remained in service — approximately 2.4 to 2.9 times the lifespan of the client’s previous ring dies. The roller shells were replaced once during the year, at around 2,400 tons, representing a roughly 2.5x improvement.
Customer Feedback (paraphrased from technical review meeting minutes):
“The pellet quality consistency has been the most noticeable improvement. Our farm customers previously complained about high fines in each bulk delivery; those complaints have virtually disappeared since switching to the Hongyang-equipped line. The energy savings alone — roughly 4–6 kWh per ton — have contributed meaningfully to our margin. Most importantly, Hongyang’s engineer stayed with us until every parameter was dialed in. That level of commitment is something we had not experienced with other suppliers.”
Conclusion
The Gemilang Ternakan Feedmill case demonstrates that a properly specified ring die pellet mill — coupled with application-specific die engineering and diligent on-site commissioning — can deliver substantial and sustained improvements in goat feed production efficiency. For Hongyang, this engagement reinforces the company’s capability to serve the Southeast Asian ruminant feed sector, where high-fiber formulations and tropical operating conditions place unique demands on pelleting equipment.
The HYPM420 ring die pellet mill has proven to be a dependable workhorse in this application, offering a compelling total cost of ownership proposition through reduced energy consumption, extended wear-part life, and superior pellet quality.
The client has since placed a repeat order for a second HYPM420 unit to support expanded production capacity in 2025.
Post time: Jun-02-2026
