Every feed miller knows the sound of a plant running just right — that steady hum from the pellet press, steam hissing at the right pressure and the feed flowing clean through the cooler. When everything clicks, tons roll off the line, pellets stay strong and energy costs stay under control. But getting there—and staying there—takes more than experience. It takes tracking the right key performance indicators (KPIs) to measure feed production throughput and understand what’s really driving your results.Here are seven essential KPIs every miller should keep an eye on to boost efficiency, protect quality, and push more tons through the gate — safely and profitably.
1. Tons Per Hour (TPH): The Heartbeat of the Mill
Throughput starts here. TPH tells you exactly how many finished tons you’re producing per hour, shift, or day. When it slips, that’s your first sign something’s off. Maybe it’s steam pressure dropping, dies wearing down or a grind that’s a little too coarse.
Field trials across European pilot mills showed that tightening control of conditioning temperature and mash moisture lifted average throughput by 12–35%—without adding horsepower. That’s the power of paying attention to TPH not just as a number, but as a story about how well your system is tuned.
2. Energy Use per Ton: The Hidden Cost Driver
Every kilowatt-hour and pound of steam adds up. Tracking energy consumption per ton shows how much it really costs to make each batch of feed. If energy use climbs but TPH stays flat, you’re burning money somewhere — maybe a dirty die, inefficient cooler or weak steam supply.
3. Pellet Durability Index (PDI): Quality You Can Feel
Research from feed technology trials found that a 3°C drop in conditioner ΔT reduced energy use by 10% but weakened pellets, proving that efficiency is about balance, not shortcuts.
Good throughput means nothing if the pellets fall apart before they reach the feeder. PDI measures how tough those pellets really are after handling, transport and augering.In broiler trials, every 10% increase in fines led to a 3-point rise in feed conversion ratio (FCR)—costing producers up to $1.5 million per million birds. That’s why many mills aim for 90–95% PDI. Strong pellets travel better, feed better and deliver consistent nutrition.
4. Conditioning Temperature and Retention Time: Where Science Meets Art
Conditioning is where feed turns from mash to meal with real performance potential. The sweet spot? About 80–85°C for 30–40 seconds of retention, according to West Virginia University trials.Get it right, and you’ll see smoother throughput, better binding and fewer die blockages. Go too hot or too long, and you risk over-gelatinizing starch and choking the press. Consistent conditioning isn’t luck — it’s a KPI-backed habit.
5. Moisture at Load-Out: The Balancing Act
Feed that’s too wet molds fast. Too dry, and you lose weight, durability and profit. Monitoring moisture at load-out confirms that your conditioning and cooling are working in harmony.Commercial trials showed mills holding post-cooler moisture between 11.5–12.5% achieved up to 20 extra days of shelf life compared to higher-moisture feeds. That’s stability you can count on when feed travels long distances or sits in bins during humid months.
6. Overall Equipment Effectiveness (OEE): Your Mill’s True Potential
OEE ties it all together. It combines availability, performance, and quality into one score that shows how close your mill runs to its maximum capacity.A mill hitting 85% OEE is solid—but that 15% loss often hides hours of unplanned downtime, slow start-ups, or off-spec feed. Tracking OEE helps teams target what’s really limiting throughput—so you’re fixing causes, not symptoms.The best mills don’t chase tons—they manage them. Tracking key performance indicators for measuring feed production throughput gives you a clear picture of how each process step affects the next. From steam pressure to shrink rates, every data point tells a story about consistency, control, and continuous improvement.
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