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We Challenge Ourselves To Progress And Strive To Continually Improve

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OUR PROCESS

Achieving Operational Excellence…

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Davidsons Feeds has invested significantly in its manufacturing facilities to ensure that it has the latest technology to produce the high performance feeds required by its customers. Our state of the art mill has been designed to deliver the highest quality feed. As a result of these investments, Davidsons are proud to supply high performance animal nutrition solutions throughout Scotland and the North of England. By maximising value from our people and assets we are able to achieve operational excellence.

We Believe In Sustainable Farming Because We Value The Future

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Davidsons Process Infographic

Please click on any area in the below infographic for further details about each stage of our process…

Davidsons Process Infographic
Raw Material Intakes Mineral Bins Raw Material Weighing Grinding Mixing Boa Conditioning Pelleting Press Cooling Sieve Fat Coating Final Product Bins Packing Bulk Out Loading Raw Material Weighing Raw Material Weighing Mixing Mixing Raw Material Intakes Raw Material Intakes

Raw Material Intakes

Over the 2 raw material Intakes, each can tip 2 – 3 trucks per hour, with each raw material having a specific identification number which is recognised by the computerised system. The driver (company employee or contractor) upon being weighed is given a “Card” that included all load details. It is scanned by the driver at the intake and this starts up the route for the product that is being tipped. The system is fully alarmed so if at any point a fault happens during the tipping process, the computer system automatically shuts the route down to avoid any possible cross contamination, the route will only start again when the fault has been sorted. Upon the end of tipping, the system runs a full clean out-period to ensure all of the routes are clear of materials to prevent cross contamination for the following load.

Mineral Bins

There are 14 mineral bins that are filled by bulk blower vehicles. Vehicles are weighed on a weighbridge and given a unique tipping number. The vehicle then makes its way around to the mineral intake blow lines.

Raw Material Weighing

There are are 4 raw material weighers at Davidsons, with each having a maximum capacity of 2.5 tonnes. The required ingredients are weighed out and recorded by a computer system, as the material is weighed and used. Between each batch being weighed, we have a full clean-out to stop any possible cross contamination. The raw material weighers are checked and calibrated regularly to ensure correct measurements.

Grinding

We have 2 grinders that are used to reduce the raw materials down to a Grist (or flour like material). Both grinders have magnets fitted above each machine to catch any ferros metal. In the grinder, beaters smash the raw material and a 3.5mm screen is used to pass the material through.

Mixing

At this point of the process, we add to the mixer the Grist from the Grinders, minerals and oils (if required). Paddles in the mixer ensure an even mix of all included items. The mixer runs for a mix time of approx 1 minute and then discharges. The mix quality is checked often to ensure an even and good mix of all added materials. The batch is then sent to the press lines if pelleting is required, or to the meal bins.

Boa Conditioning

The Boa Conditioner is a machine that adds the following: steam, molasses and mechanical heat by way of friction. The material goes into the Boa as a loose meal and as it exits, the machine reaches temperatures of around 76oC and the meal is then transformed into a “Bread crumb” form. The main purpose of the Boa is to condition the meal and improve pellet quality.

Pelleting Press

Compounds can be formed into 3 different sizes which are manufactured on 3 different lines:

3mm pellets run approx 10 tonnes per hour

6mm nuts run approx 18 tonnes per hour

12mm rolls run approx 12 tonnes per hour

Cooling

There are 3 coolers to ensure products are cooled to ambient air temperature to prevent salmonella and mould growth. Just before discharge, samples are taken of each production run. Products are tested for hardness, durability and are scanned for nutritional content and all results are stored on the company database.

Sieve

All 3 press lines are sieved after leaving the coolers to remove dust and fines.

Fat Coating

At this stage, the product is weighed and put inside the fat coater. The cold product is sprayed with hot fat, which cools on the product and makes the product more durable and also gives a shiny appearance. The product now leaves the fat coater after being mixed for 10 seconds.

Final Product Bins

The final product is then sent to one of our  final product bins. There are 62 final product bins in total, which allows us to rotate the bins to keep the products fresh and made-to-order. There are a variety of  finished product bins, larger bins (holding 50 tonnes) for regular, popular products, and smaller bins (10 tonnes) for smaller bespoke products.

Packing

The packing plant has a storage capacity of 500 tonnes, meaning over 30 different products can be stored. All products are sieved,weighed, bagged, labelled, bag stitched and then palletised onto 1 tonne pallets (40 by 25kg bags). The pallets are then shrink wrapped and stored before delivery to our customers.

Bulk Out Loading

There are 2 bulk out loading weighbridges at Davidsons, taking only around 20-30 minutes to load each vehicle. After each compartment is loaded, the nearby printer prints a delivery note with all required information which is then given customer. As products are taken from each finish product bin, the stock levels are adjusted as required. Bulk out loading 1 out loads 6mm nuts, meals, and coarse blends. Bulk out loading 2 out loads 3mm pellets, 12mm rolls and rough mix products.

Raw Material Weighing

There are are 4 raw material weighers at Davidsons, with each having a maximum capacity of 2.5 tonnes. The required ingredients are weighed out and recorded by a computer system, as the material is weighed and used. Between each batch being weighed, we have a full clean-out to stop any possible cross contamination. The raw material weighers are checked and calibrated regularly to ensure correct measurements.

Raw Material Weighing

There are are 4 raw material weighers at Davidsons, with each having a maximum capacity of 2.5 tonnes. The required ingredients are weighed out and recorded by a computer system, as the material is weighed and used. Between each batch being weighed, we have a full clean-out to stop any possible cross contamination. The raw material weighers are checked and calibrated regularly to ensure correct measurements.

Mixing

At this point of the process, we add to the mixer the Grist from the Grinders, minerals and oils (if required). Paddles in the mixer ensure an even mix of all included items. The mixer runs for a mix time of approx 1 minute and then discharges. The mix quality is checked often to ensure an even and good mix of all added materials. The batch is then sent to the press lines if pelleting is required, or to the meal bins.

Mixing

At this point of the process, we add to the mixer the Grist from the Grinders, minerals and oils (if required). Paddles in the mixer ensure an even mix of all included items. The mixer runs for a mix time of approx 1 minute and then discharges. The mix quality is checked often to ensure an even and good mix of all added materials. The batch is then sent to the press lines if pelleting is required, or to the meal bins.

Raw Material Intakes

Over the 2 raw material Intakes, each can tip 2 – 3 trucks per hour, with each raw material having a specific identification number which is recognised by the computerised system. The driver (company employee or contractor) upon being weighed is given a “Card” that included all load details. It is scanned by the driver at the intake and this starts up the route for the product that is being tipped. The system is fully alarmed so if at any point a fault happens during the tipping process, the computer system automatically shuts the route down to avoid any possible cross contamination, the route will only start again when the fault has been sorted. Upon the end of tipping, the system runs a full clean out-period to ensure all of the routes are clear of materials to prevent cross contamination for the following load.

Raw Material Intakes

Over the 2 raw material Intakes, each can tip 2 – 3 trucks per hour, with each raw material having a specific identification number which is recognised by the computerised system. The driver (company employee or contractor) upon being weighed is given a “Card” that included all load details. It is scanned by the driver at the intake and this starts up the route for the product that is being tipped. The system is fully alarmed so if at any point a fault happens during the tipping process, the computer system automatically shuts the route down to avoid any possible cross contamination, the route will only start again when the fault has been sorted. Upon the end of tipping, the system runs a full clean out-period to ensure all of the routes are clear of materials to prevent cross contamination for the following load.

YOUR FARM TELLS A STORY

Davidsons Feeds Makes It A Happy One

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CONTACT

Davidson Brothers (Shotts) Ltd
Gray Street, Shotts ML7 5EZ

Envelope

GENERAL

+44 (0)1501 820 048
contact@davidsonsfeeds.co.uk

Phone

SALES

+44 (0)1501 820 473
sales@davidsonsfeeds.co.uk

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