Executive Summary
Nigeria’s animal feed industry, with an estimated market volume of 15.18 million tonnes in 2024 and a projected CAGR of 1.80% through 2034, faces persistent capacity constraints that force the country to import approximately 5 million tonnes of feed annually at a cost of N4.54 trillion ($2.75 billion) [1]. Against this backdrop of supply-demand imbalance, local feed manufacturers are actively investing in production capacity upgrades.
This case study examines the deployment of a Hongyang Feed Machinery SFSP-series hammer mill at a family-operated poultry feed mill near Ibadan, Oyo State. The implementation delivered:
These gains enabled the mill to expand its market reach while maintaining consistent product quality.
Introduction: Nigeria’s Feed Industry Landscape
Nigeria operates the largest animal feed market in West Africa, driven by a population exceeding 220 million and rapidly growing demand for poultry protein. The domestic feed sector, however, struggles with structural constraints: limited production capacity, aging equipment infrastructure, and heavy reliance on imported feed materials. Local feed costs approximately N2.4 million per tonne, nearly 2.5 times the global average of N970,000 ($550) per tonne, reflecting chronic inefficiencies in domestic manufacturing [1].
The southwestern region, centered around Ibadan in Oyo State, has emerged as a critical feed production hub serving the extensive poultry farming networks of Lagos, Ogun, and Ondo states. Mills in this corridor supply compound feed to broiler and layer operations that, in turn, serve Nigeria’s urban protein markets.
Within this competitive environment, grinding efficiency—specifically the ability to produce uniform particle sizes at scale—directly determines both feed quality and production economics.
The Client: A Growing Ibadan Feed Mill
The subject of this case study is a family-owned feed milling operation located on the outskirts of Ibadan, which has been producing compound poultry feed for approximately 15 years. The mill originally served smallholder layer farms in the surrounding region with mash feed, but as commercial broiler operations expanded across southwestern Nigeria, the facility pivoted toward higher-volume broiler feed production.
By early 2025, the mill was operating at near-maximum capacity with its existing grinding equipment—a decade-old hammer mill that had become the primary bottleneck in the production line. Despite operating extended shifts, the facility struggled to meet contractual delivery schedules during peak demand periods.
Management identified three core problems:
- Insufficient grinding throughput
- Inconsistent particle size distribution contributing to variable pellet quality downstream
- Escalating maintenance costs as the aging equipment required increasingly frequent repairs
Technical Challenges: Grinding as a Bottleneck
Prior to the equipment upgrade, the facility’s grinding stage exhibited several measurable deficiencies:
These constraints not only limited current production but prevented the mill from pursuing contracts with larger commercial poultry integrators who demanded consistent feed quality specifications.
Solution Design: Hongyang SFSP-112×40 Hammer Mill
Equipment Selection Rationale
Following a technical evaluation of multiple equipment suppliers, the mill selected Hongyang Feed Machinery’s SFSP-112×40 wide-chamber hammer mill. The selection was based on Hongyang’s demonstrated expertise in customizing grinding solutions for tropical-region feed mills and the SFSP series’ reputation for high throughput with low energy intensity.
Technical Specifications
The deployed equipment configuration included:
| Parameter | Specification |
|---|---|
| Model | SFSP-112×40 Hammer Mill |
| Rotor Diameter | 1,120 mm |
| Chamber Width | 400 mm |
| Main Motor Power | 90 kW |
| Rotor Speed | 1,480 rpm |
| Hammer Arrangement | 6 rows × 16 hammers (96 total) |
| Screen Area | 1.35 m² |
| Screen Hole Diameter | 3.0 mm (primary), 2.5 mm (finishing) |
| Rated Capacity | 4.5–5.5 tons/hour (maize, 3.0 mm screen) |
Customization for Local Conditions
Hongyang’s engineering team conducted pre-installation analysis that informed several customizations:
Installation and Ramp-Up
The installation followed a structured four-week timeline:
Hongyang deployed a two-person technical support team who remained on-site through the first week of commercial production to monitor performance parameters and train the mill’s operational staff on maintenance protocols and troubleshooting procedures.
Performance Results
Quantitative Improvements
After six weeks of stabilized commercial operation, the facility recorded the following performance metrics:
| Performance Indicator | Pre-Upgrade | Post-Upgrade | Change |
|---|---|---|---|
| Grinding Throughput (maize, 3.0 mm screen) | 2.8 t/h | 4.8 t/h | +71% |
| Average Sustained Throughput (mixed formulation) | 2.5 t/h | 3.4 t/h | +35% |
| Particle Size CV (sieve analysis) | 18.3% | 7.1% | -61% |
| Specific Energy Consumption | 22 kWh/t | 17.1 kWh/t | -22% |
| Screen Cleaning Interval | 4–5 hours | 18–20 hours | +350% |
| Hammer Replacement Interval | 300–350 h | 800–850 h | +150% |
Operational Impact
The throughput improvement eliminated the grinding bottleneck, allowing the downstream pelleting line to operate at full rated capacity for the first time in the facility’s history. Production scheduling shifted from extended 14-hour shifts to standard 10-hour shifts while still achieving higher total daily output.
The 61% reduction in particle size variability translated directly into improved pellet quality. With more uniform grind, the conditioner achieved more consistent moisture and temperature penetration, and pellet durability index rose from an average of 86% to 93% across broiler formulations.
Economic Benefits
The operational improvements delivered measurable economic returns:
Customer Feedback
Before the Hongyang hammer mill, grinding was our constant headache. We were running the old machine 14 hours a day and still falling behind orders. The new equipment has completely changed our operation. We now finish grinding by early afternoon and the particle consistency has noticeably improved our pellet quality. Our customers have commented on the better feed—less dust, more uniform pellets. Hongyang’s team understood our local conditions and didn’t just sell us a machine; they designed a solution that works with Nigerian raw materials and our climate.
The mill has subsequently ordered a second Hongyang SFSP hammer mill for a planned expansion line, and has recommended the equipment to two other feed mills in the Oyo State region.
Conclusion
This Ibadan-based case study illustrates that targeted investment in modern grinding technology can deliver transformative efficiency gains for West African feed manufacturers operating under challenging local conditions. The 35% sustained throughput improvement, combined with enhanced particle uniformity and reduced operating costs, demonstrates that equipment customization for regional raw material characteristics yields superior outcomes compared to generic solutions.
For Nigeria’s feed industry—which must bridge a 5-million-tonne annual production gap to reduce import dependency—deployment of efficient, locally-adapted processing equipment represents a practical pathway toward greater self-sufficiency.
Hongyang Feed Machinery’s approach, which integrates pre-installation analysis, equipment customization, and sustained technical support, provides a replicable model for similar upgrades across the West African feed sector.
References
- New Telegraph Nigeria. (2025). Poultry: Nigerian Merchants To Import Animal Feeds With N4.54tr. [1]
- Expert Market Research. (2025). Nigeria Animal Feed Market Report and Forecast 2025–2034.
- Performance data collected during on-site monitoring period (Q1–Q2 2025).
About Hongyang Feed Machinery Co., Ltd.
Hongyang Feed Machinery specializes in the design, manufacturing, and technical support of advanced feed processing equipment, with particular expertise in grinding, pelleting, and complete feed mill solutions. With over 20 years of industry experience serving clients across more than 30 countries, Hongyang combines precision engineering with deep regional market knowledge to deliver customized solutions that enhance productivity, product quality, and operational profitability for feed producers worldwide.
Post time: May-29-2026
