Feeder Mixer Training
Livestock Farmer: The weight display on the feeder shows a fluctuating number, and the number representing the weight intermittently increases and decreases. On slopes or inclines of the silo, or while the feeder is moving over bumps, the display exhibits jumps and fluctuations. What could be the reason?
Kariz:
The weight display is malfunctioning.
The load cell wires are disconnecting and reconnecting due to vibrations from the feeder.
The feeder chassis is damaged or broken.
The mounting (interface between the load cell and the chassis) is broken or problematic.
Failure to adhere to proper guidelines during extensive welding on the body.
Improper assembly procedures during replacement of the floor or reinforcement of the feeder’s side frames.
Misalignment of the helix, gearbox, and feeder body (The technician might assume that using UCF bearings in the feeder would prevent issues, but misalignment between the helix or auger, gearbox, and feeder body could still cause problems).
There is always oil leakage from the feeder, what should I do? I have oil leakage from the hoses and hydraulic circuit connections, and the hoses are always greasy. Why is this happening?
Generally, overheating of hydraulic oil results in oil leaks in the hydraulic circuit connections.
Why does the oil overheat? The following factors can cause this issue:
The mismatch between the hydraulic tank oil volume and the hydraulic pump.
The mismatch between the size of the hydraulic system hoses and connections with the hydraulic pump.
Failure to replace hydraulic oil on time (every two years, assuming the use of high-quality hydraulic oil).
Using low-quality hydraulic oil.
Tampering with pressure settings in the hydraulic circuit.
Excessive engagement of the feeder gearbox PTO with the tractor (commonly occurring during mixing straw or when the operator forgets to disengage the gearbox rotation from the tractor).
Wear and tear in hydraulic circuit components.
Dear livestock owner, take hydraulic oil and gearbox oil leaks seriously and identify and fix the main cause before more significant problems arise.
The blades should be considered as wear components of the feeder, similar to the lifespan of car tires, which depend on the quality of the tires and the road they are used on.
Factors affecting blade wear:
- Forage fibers: Forage fibers are inherently abrasive and, over time, lead to blade wear.
- Blade position: Blades located near the feeder’s exit door usually wear out twice as fast as the other blades.
- Stones and gravel: Stones and gravel from various sources significantly reduce the lifespan of the blades.
- Type and quality of the blades: A wide range of feeder blades exists in the market. Typically, the feeder manufacturer determines the most efficient type of blade (round, serrated, crescent-shaped, etc.). The quality of the blades depends on the alloy used, machining, and heat treatment. Even with the best alloy available, if proper heat treatment and machining aren’t applied, the blade will lack quality.
- Twine holding forage bundles: If the twine is not removed before inserting the forage bundles into the feeder, the twine can get caught in the auger during TMR production, gradually causing blade wear.
Evaluating blade wear:
Note: The most critical aspect of feeder blades is the distance between the blade and the feeder floor. If the distance is not maintained, even the best available blade will have no effect on producing TMR (Total Mixed Ration).
The best method to evaluate the blades used in the feeder is checking the distance between the blade tips and the feeder floor. Since it might not be feasible for the feeder operator or farmer to measure this directly, the speed of performance (time to achieve the desired feed mix) can be considered as the criterion for replacing or repositioning the blades. If the mixing time increases, the blades should be inspected.
Among various gearboxes, the planetary gearbox boasts the highest efficiency.Planetary gearboxes are used in feed mixers and many agricultural and livestock machinery as power transmitters and speed reducers.
The key factors affecting the performance of gearboxes include the quality of the gear oil used, the alignment of the installation location, and the gearbox’s output axis.
Considering that in standard feeders, the power required for a stationary 12-meter feeder is approximately 35 horsepower, and by utilizing gearboxes with 1.5 times the feeder’s required power, a feeder gearbox should ideally operate without needing service for an average of five years.
Respected livestock owners should keep the following five essential points in mind to ensure the proper functioning of the feeder gearbox:
Install a high-quality breather valve on the gearbox oil cap.
Check the gearbox gear oil monthly.
Address any gearbox leaks (due to neglect of the gearbox oil indicators, the standard oil level is often not maintained).
Ensure smooth rotation of the gearbox without eccentricity (this can be checked with an indicator gauge in a workshop or with a welding rod or solid object in the barn). Eccentricity up to 0.5 mm is permissible.
Verify the proper functioning of the hydraulic pump (excessive heating of the hydraulic pump can transfer heat to the gearbox, leading to issues with seals and bearings).
In a livestock farm, a new feeder replaced an old one, and contrary to expectations of increased milk fat and yield, we noticed a decrease in milk fat while milk yield remained unchanged.
After consultation and discussion with the European manufacturer and experienced feed experts, the conclusion was simple yet surprising:”The feeding habit of the livestock.”
Over time, both milk fat and yield improved, meeting the farmer’s expectations on both fronts. Unfortunately, the milk fat test conducted by the dairy company lacked adequate accuracy.However:A – How do we determine the quality of crushing and mixing feed in different feeders?
Milk fat percentage in the livestock farm.
Milk yield records from the farm.
Expert opinion on feed quality.
Testing using standardized equipment.
B – What is the required time for feed preparation?
Time specified by the feeder manufacturer.
Based on the type of feed required.
Milk fat percentage and yield records.
Trial and error through testing with standardized equipment.
Regarding the first and second questions, given that the quality and weight of initial components like alfalfa and straw can vary, and considering the differences in blade quality, feeder interior design, and augers, the best approach is to test the feed at various stages using different devices to evaluate feed quality.One of the simplest yet most precise methods is the Pennsylvania sieve.
In some cases, two feeders of the same brand and size showed different conditions. It is worth mentioning that the shortest feed preparation time is associated with Trioliet vertical feeders, which take approximately eight minutes.
The Impact of Lubricants on Feeder Performance:
When visiting oil change and repair shops, we are all highly sensitive to the quality of oil and lubricants used in our vehicles.
But do we show the same sensitivity towards the hydraulic oil, gear oil, and grease used in industrial machinery, including feeders?
Unfortunately, due to their busy schedules and considering the cost of these lubricants, many farm owners neglect using high-quality products. This decision, however, leads to substantial expenses in the long run.
It is recommended to use hydraulic oil with a viscosity of 68cSt for hydraulic systems, gear oil with a viscosity of 150cSt for gearboxes, and premium heat-resistant grease for lubrication.