Executive Summary
Tanzania’s poultry sector is experiencing rapid expansion, with commercial broiler production growing at over 13% annually. In this competitive landscape, feed represents 60–70% of total production costs, making feed mill efficiency a critical factor for profitability. This case study examines how a medium-scale broiler integrator in the Dar es Salaam region successfully reduced ring die procurement costs by approximately 15% while maintaining—and in some metrics improving—pellet quality, by switching from a European ring die supplier to Hongyang (Liyang Hongyang Feed Machinery Co., Ltd.).
Over a six-month evaluation period, the customer tested Hongyang ring dies on two CPM 7726-series pellet mills running broiler finisher feed formulations. The results demonstrated consistent pellet durability index (PDI) above 93%, stable hourly throughput, and significantly lower die-related downtime compared with their previous European-sourced ring dies.
Tanzania’s Poultry Industry Context
According to Tanzania’s Ministry of Livestock and Fisheries 2024/2025 budget speech, the country produced and distributed 95.58 million chicks in the 2023/2024 fiscal year, a 13.9% increase from the previous year. Of these, 73.48 million were broiler chicks, reflecting the dominance of meat production in the sector. With approximately 72 million chickens across the country and an estimated 2.5 million metric tons of annual feed demand, the pressure on feed manufacturers to deliver consistent quality at competitive prices has never been greater.
The establishment of Aviagen East Africa Limited in Kilimanjaro—producing grandparent stock for the regional market—has further raised quality expectations across the value chain. Feed mills serving commercial broiler operations must meet exacting standards for pellet durability, feed conversion ratio (FCR), and production consistency.
Customer Background and Challenge
The customer is a privately owned poultry integrator operating a feed mill, slaughterhouse, and contract-growing network near Dar es Salaam. The mill processes approximately 8,000–10,000 metric tons of broiler feed per month, with two CPM 7726-series pellet mills running 16–18 hours daily on a six-day schedule.
Prior to engaging with Hongyang, the customer exclusively used ring dies sourced from a well-known European manufacturer. While the European dies delivered acceptable pellet quality, the customer faced three persistent challenges:
1. Procurement Cost: European ring dies carried a significant price premium, driven by higher labor and energy costs in the manufacturing country.
2. Delivery Lead Time: Standard delivery times of 8–12 weeks created inventory management difficulties and occasional production bottlenecks.
3. Limited After-Sales Support: The geographical distance limited the supplier’s ability to provide timely technical consultation on die selection and troubleshooting.
Seeking to optimize production costs without compromising quality, the customer’s procurement team began evaluating alternative ring die suppliers in early 2025. Hongyang was shortlisted based on its track record of supplying ring dies compatible with CPM, Andritz, and Van Aarsen pellet mills to markets across Southeast Asia, the Middle East, and Africa.
Hongyang Ring Die Solution
Hongyang’s technical team conducted a detailed review of the customer’s production parameters before recommending a tailored ring die specification:
Pellet Mill Model: CPM 7726-12
Ring Die Inner Diameter: 762 mm
Effective Width: 190 mm
Hole Diameter: 3.0 mm
Effective Thickness: 60 mm
Compression Ratio: 1:10
Material: High-grade alloy steel (vacuum degassed)
Heat Treatment: Vacuum furnace + continuous quenching
The recommended die featured several key technical attributes that distinguished it from standard alternatives:
Material Selection: Hongyang sourced vacuum-degassed alloy steel billets, reducing inclusions and ensuring uniform material properties throughout the die blank. This metallurgical consistency is essential for maintaining hole geometry under sustained high-pressure pelleting conditions.
Precision Drilling: Die holes were drilled using imported German gun drills on CNC multi-spindle machines, achieving smooth bore surfaces and tight diameter tolerances. The single-pass drilling process ensured consistent hole finish from inlet to outlet, reducing the risk of hole plugging during initial run-in.
Vacuum Heat Treatment: The die underwent heat treatment in a vacuum furnace followed by continuous quenching, resulting in uniform hardness distribution across the die body with minimal surface oxidation. This process contributed to extended die service life and reduced premature wear in high-tonnage broiler feed applications.
No-Flush Start-Up: A distinctive benefit of the Hongyang die was the ability to begin producing saleable pellets immediately upon installation, without the standard 20–30 minute flush-in period required by many competitor dies. This translated directly to reduced feed waste and faster return to full production.
Production Results
The customer installed the first Hongyang ring die in mid-2025 on Pellet Mill #1, which was dedicated to broiler finisher feed (corn-soybean meal base, 18% crude protein). Key performance indicators were tracked over a 90-day evaluation period:
Metric: Pellet Durability Index (PDI) – Previous Supplier: 92.5% – Hongyang: 93.8% – Change: +1.3%
Metric: Throughput Rate (t/h) – Previous Supplier: 10.2 – Hongyang: 10.5 – Change: +2.9%
Metric: Fines Return Rate – Previous Supplier: 8.2% – Hongyang: 6.5% – Change: -20.7%
Metric: Die Changeover Time – Previous Supplier: 2.5 hours – Hongyang: 2.5 hours – Change: Equivalent
Metric: Die Service Life (estimated) – Previous Supplier: 2,200-2,400 hours – Hongyang: 2,300-2,500 hours – Change: Comparable
Metric: Procurement Cost – Previous Supplier: Baseline – Hongyang: ~15% lower – Change: -15%
The PDI improvement, while modest in absolute percentage terms, had a meaningful impact on downstream operations. Lower fines return reduced the re-processing load on the grinding and mixing sections, while improved pellet integrity during pneumatic conveying and bucket elevator transfer reduced in-house feed waste.
Perhaps most significant from an operational perspective was the stability of throughput. The customer reported that the Hongyang die maintained consistent output rates throughout its service life with minimal die face dressing required, contributing to predictable production scheduling and reduced labor intervention.
Customer Feedback
After six months of operation with Hongyang ring dies across both pellet mills, the mill manager provided the following observations:
“We were cautious when first considering a Chinese ring die supplier. Our previous experience with other Asian manufacturers had been mixed. But Hongyang’s technical team approached our requirements professionally, asked the right questions about our formulation and target PDI, and delivered a die that performed from day one. The cost savings are real, but what impressed me more is that pellet quality actually improved. Our birds are performing well and we haven’t seen any negative impact on FCR.”
The procurement manager added:
“The lead time is typically four to five weeks compared to eight to twelve from our previous supplier. This alone gives us much more flexibility in inventory planning. When we had a question about compression ratio optimization for a new broiler starter formulation, Hongyang’s technician responded with a detailed recommendation within 24 hours.”
How Hongyang Ensures Quality Consistency
Behind these results lies Hongyang’s systematic approach to ring die manufacturing, developed since the company began ring die production in 2006. Key elements of their quality assurance framework include:
- Raw Material Traceability: Every die blank is traceable to its heat number, with mill certificates verifying chemical composition and mechanical properties.
- In-Process Inspection: Hole diameter and pitch are verified by optical measurement at multiple stages during drilling.
- Post-Heat-Treatment Hardness Testing: Hardness is measured at multiple points across the die face and inner bore to confirm uniformity.
- Final Dimensional Inspection: Inner diameter, concentricity, and mounting flange dimensions are verified against the specified pellet mill model before shipment.
Liyang Hongyang Feed Machinery Co., Ltd. holds ISO certification and supplies ring dies and roller shells compatible with all major pellet mill brands, including CPM, Andritz, Buhler, Van Aarsen, Famsun, and Muyang. The company’s products are exported to over 30 countries across Asia, Africa, the Middle East, Europe, and the Americas.
Conclusion
This case study demonstrates that high-quality ring dies from specialized Chinese manufacturers like Hongyang can match or exceed the performance of established European suppliers while offering meaningful cost and lead time advantages. For Tanzanian feed millers operating in a price-sensitive, fast-growing market, the combination of reliable pellet quality, reduced procurement cost, and responsive technical support represents a compelling value proposition.
The key takeaway is not simply about cost reduction—it is about achieving production stability with equipment that performs consistently over its service life. Hongyang’s ability to deliver that stability, backed by genuine metallurgical and manufacturing expertise, is what distinguishes the company in an increasingly crowded global marketplace.
Post time: Jun-06-2026
