Kenya’s compound feed industry has an estimated annual capacity of about 1.6 million metric tons, yet production currently runs at only 40 to 60 percent of that capacity, equivalent to roughly 700,000 to 800,000 metric tons per year 1. Poultry feed accounts for about 41 percent of total output, the largest single category 1. At the same time, feed prices have risen by more than 37 percent between 2020 and 2025, and a 50-kg bag of layer mash climbed from about 14 to 32 U.S. dollars over the same period 1, 2. In this cost-sensitive market, feed mills cannot afford the waste that comes from unstable pelleting: fines, rework, and inconsistent pellet quality erode margins and customer trust alike. This case study describes how a mid-sized feed mill in Kiambu County, on the northern edge of Nairobi, stabilized its layer feed line after installing a Hongyang SZLH420 ring die pellet mill with a double-layer conditioner. Over twelve months, the mill held steady throughput on corn-soy layer rations, reduced fines at the cooler discharge, and earned repeat orders from the layer farms it supplies. The project shows how a well-engineered pelleting system, combined with disciplined commissioning and responsive after-sales service, helps a feed manufacturer compete in a difficult market.
The Market Context: A Poultry Feed Industry Under Cost Pressure
Kenya has one of the largest poultry sectors in East Africa, and its commercial layer and broiler segments depend on compound feed. According to the USDA Foreign Agricultural Service, the country’s compound feed industry has an annual production capacity of approximately 1.6 million metric tons but operates at only 40 to 60 percent of capacity 1. The sector is highly fragmented: of 307 registered feed mills, about 90 percent are small-scale, while the two largest producers supply more than half of all poultry feed 1.
The cost environment is unforgiving. The Competition Authority of Kenya (CAK) has noted that feed prices in Kenya are high relative to international benchmarks, driven by the price of maize and soybean meal and by import constraints 2. Between 2020 and 2025, feed prices increased by more than 37 percent, and the price of a 50-kg bag of layer mash rose from roughly 14 U.S. dollars in 2020 to about 32 U.S. dollars in 2024 1. Kenya National Bureau of Statistics (KNBS) data show that the commercial broiler population declined by more than eight percent in 2024, a decline that industry observers attribute substantially to high feed costs 2, 3.
For feed millers, the implication is clear: efficiency is no longer optional. Every ton of fines that cannot be sold as finished feed, every hour of downtime, and every batch that fails to meet specification is a direct loss in a market where margins are already thin. Consistent pelleting capacity and durable, uniform pellets are therefore competitive necessities, not luxuries.
The Customer: A Kiambu Feed Mill Serving Layer Farms
The customer is a family-run feed mill in Kiambu County, one of Kenya’s most densely populated poultry-keeping areas and a major supply hub for the Nairobi market. The mill produces layer mash, chick starter, and broiler finisher for a network of roughly 200 small and medium layer farms, with production running in two daily shifts.
Before the project, the mill operated an older single-conditioning pelleting line. Output fluctuated sharply with ingredient moisture and power supply, fines at the cooler discharge regularly exceeded eight percent, and pellet durability was inconsistent enough that farmers reported broken pellets and dust at the feeder. The mill’s managing director described the situation plainly:
“In this market, our customers compare us on price and on what actually reaches the feeder. When half the bag is dust, they do not complain to us twice — they change supplier.”
The mill needed a pelleting system that could run steadily on standard corn-soy layer formulations, produce durable pellets with low fines, and tolerate the variable raw-material quality common in the Kenyan market.
The Solution: Hongyang SZLH420 with Double-Layer Conditioner
After evaluating equipment from several suppliers, the mill selected the SZLH420 ring die pellet mill with a double-layer conditioner, supplied by Liyang Hongyang Feed Machinery Co., Ltd. The SZLH420 features a 110 kW main motor, a 420 mm ring die inner diameter, a 120 mm effective die width, and a rated speed of 287 rpm 4. For layer feed, the die is matched to the formulation with a moderate compression ratio suited to corn-soy mash.
Two engineering details made the system a good fit for Kenyan conditions:
- Double-layer conditioning. The conditioner provides 90 to 120 seconds of retention time at 90 to 95 degrees Celsius, with steam pressure of 0.2 to 0.4 MPa, raising post-conditioning moisture to 16 to 18 percent 4. Proper conditioning is essential for starch gelatinization, which binds pellets and directly reduces fines 5.
- Heavy-duty ring die and roller assembly. The hardened alloy ring die and matched rollers maintain compression on abrasive corn-soy rations without excessive wear, supporting continuous two-shift operation.
Hongyang’s engineers also matched the die compression ratio to the customer’s actual recipe rather than supplying a generic component, and they recommended die maintenance practices suited to local operating conditions, including rotation schedules and cooling procedures.
Commissioning and After-Sales Support
Commissioning took ten days and included hands-on training for the mill’s operators on conditioning parameters, die and roller gap adjustment, and scheduled maintenance. Hongyang’s service engineers emphasized the process details that determine pellet quality: steam quality and moisture control, conditioning temperature targets, and matching die thickness to the desired pellet durability.
The support continued after handover. In the first month, the mill reported higher-than-expected fines during early-morning runs when steam pressure was unsteady. Hongyang’s team reviewed the settings remotely, recommended a revised steam supply arrangement and a small adjustment to the conditioner paddle configuration, and the problem was resolved within a week. The mill’s production manager later noted:
“What impressed us was not the machine alone, but that the supplier treated our fines problem as their own.”
Results: Stable Capacity, Better Pellets, Satisfied Customers
After twelve months of operation, the mill reported the following outcomes:
- Stable throughput of 5 to 6 tons per hour on layer mash, with minimal variation across ingredient batches, compared with frequent slowdowns on the previous line.
- Fines at the cooler discharge reduced from above eight percent to below four percent, recovering saleable feed that had previously been lost.
- Pellet durability improved to a level that survived bagging, transport, and on-farm handling without excessive breakage.
- Repeat orders from the mill’s layer farm network increased, and the mill added two new customers on the strength of the improved pellet appearance and lower feed waste.
The managing director’s assessment was direct:
“The Hongyang line runs the way we need to run — steady, predictable, and low in waste. When something needs attention, the supplier answers. That is what keeps our customers coming back.”
Why This Matters for Kenya’s Feed Industry
Kenya’s feed industry operates well below capacity, and high input costs will continue to pressure feed millers 1, 2. In such a market, the equipment decision is a margin decision. A ring die pellet mill that holds stable capacity, minimizes fines, and is backed by a supplier willing to support the customer after installation gives a feed mill the reliability it needs to retain farmers and grow.
For Liyang Hongyang Feed Machinery, the Kiambu project reflects a consistent philosophy: sell equipment that work, stand behind it, and treat the customer’s production problem as the company’s own. In a market where trust is rebuilt with every bag of feed, that approach is the most durable product of all.
Post time: Sep-16-2026
