Layer Feed Crusher

Purpose-built for poultry layer nutrition, the Bellaex Layer Feed Crusher combines differential toothed/serrated rolls with a uniform feeding module to deliver tight, repeatable particle-size distributions at low fines. Three flow-path modes—Bypass 1st, 1st Only, Dual Continuous—enable rapid recipe changeovers without stopping, so you can match target coarse/fine ratios for pre-layer, grower and layer diets.

The process concept “pellet larger first → controlled post-crushing” reduces die restriction, often lifting pellet-mill throughput significantly versus direct pelleting through small die holes, while lowering specific energy and protecting thermally sensitive nutrients. A hinged access door, sampling port and optional digital gap indication make on-line checks fast and maintenance predictable.

Applications

• Dedicated layer feed plants and integrated poultry feed mills
• Pre-pelleting optimization lines for corn/soy layer diets
• Controlled post-crushing after cooler to achieve coarse/fine targets
• Retrofits on older lines to increase pellet-mill tons/hour and reduce kWh/t
• Grain-based rations for small to medium feed plants and contract mills
• Materials
• Corn / maize (whole or cracked)
• Soybean meal and full-fat soy
• Rapeseed/canola meal
• Wheat, sorghum and other mixed grains
• Cooled pellets for post-crushing

Bellaex’s Layer Feed Crusher have Six capacity points from ≈4 to 20 TPH with staged roll counts let you scale output and select single or dual-stage crushing as required. See Models for full specs.

• Dual-stage differential rolls (selectable) for shear + compression with low fines
• Three flow modes via internal flaps for instant recipe change
• Precision handwheel roll-gap (optional digital readout) for staged particle profiles
• Differential speed pairing to reduce over-crushing and amp spikes
• Uniform feeding roll for stable load and consistent PSD
• Direct whole-corn or cooled-pellet crushing capability
• Enclosed housing with end-blocking, guards and E-stop
• Sampling port + sight window for on-line verification
• Hinged service door for fast cleaning and roll swaps
• Options: magnetic iron removal, gap sensors, vibration & temperature monitoring, PLC/HMI

• Intermeshing toothed/serrated rolls with differential speed for efficient shear + compression.
• Chamber and roll geometry tuned for corn and soybeans, not a generic stone crusher.
• Achieves uniform, controllable particle size; in grain applications it supports high soybean cracking rates and very stable corn PSD with minimal over-grinding.

• Rolls are centrifugally cast Ni–Cr–Mo alloy with a 15–20 mm wear layer and hardness up to approx. HS65–69 after heat treatment.
• Tough, wear-resistant surface handles high-throughput corn and soy with less roll regrinding.
• Double-layer design (hard outer alloy + ductile iron core) balances hardness and impact strength, reducing roll cracking risk.

• Cylinder-actuated internal flap between upper and lower roll pairs.
• Single-stage mode: only the upper roll pair runs; material bypasses the lower rolls for coarser layer feed and higher throughput.
• Dual-stage mode: material passes through both roll stages for tighter PSD and finer control.
• Mode switch can be completed within seconds, and the lower roll motor can be turned off in single-stage mode to save energy.

• Heavy-duty digital or scaled handwheel drives a threaded shaft and preloaded compression springs to move the floating roll precisely.
• Operators can adjust the roll gap online without stopping the feed crusher, quickly matching different diet specifications.
• Preloaded springs maintain constant crushing pressure and act as a safety buffer: if stones or metal contaminate the feed, the roll can open slightly and then automatically return to its original position.

• Dedicated feed roll with grooved surface meters material evenly across the entire roll length.
• Prevents surges and under-feeding, stabilizing motor load and increasing the fraction of product within your target particle band.
• Supports better mixing, conditioning and pellet quality downstream.

• High-intensity magnetic bars ahead of the nip remove tramp iron and hard ferrous contaminants.
• Protects roll surfaces from impact damage and reduces bearing failures.
• Drawer-style design makes routine cleaning fast, keeping magnetic efficiency high.

• Rectangular tube welded base, stress-relieved for high rigidity and low vibration; anchored with four foundation bolts for stable 24/7 operation.
• Split, bolted housing modules (feed hopper, upper/lower roll housings, discharge) avoid welding distortion and make transport, installation and later upgrades easier.
• Observation windows and vented side panels allow quick visual checks and heat dissipation.

• Compact drive with energy-efficient motor, reducer and taper-bushed pulleys for easy removal.
• Dual-sided V-belt with spring-loaded tension device keeps belt tension constant, preventing slip and extending belt life.
• Motor is mounted directly on the housing—no separate motor foundation required—simplifying installation and alignment.

• Separate guards for motor and belt drive, bolted to the housing for quick removal.
• Integrated cooling/vent holes in guards promote airflow, lowering temperatures around belts and bearings and reducing slip or premature failure risk.

The Bellaex layer feed crusher is a grain-specific feed crusher for corn and soybeans, delivering ≥98% soybean cracking and tight corn particle control for more consistent poultry layer performance.

Core Advantages

• Gain-specific chamber and roll profile optimized for corn and soybean kernels in poultry feed
• Soybean cracking rate up to ≥98% and tightly controlled corn particle-size distribution with fewer unbroken kernels
• More predictable PSD entering the mixer, supporting gizzard development, feed intake and stable egg production

The Bellaex feed crusher uses Ni–Cr–Mo chilled alloy rolls with HS65+ hardness, extending roll life by 20–50% versus ordinary cast-iron feed crushers and cutting downtime and spare-parts cost per ton.

Core Advantages

• Centrifugally cast Ni–Cr–Mo alloy rolls with HS65+ hardness and 15–20 mm wear layer
• 20–50% longer roll life versus standard cast-iron rolls under similar working conditions
• Longer intervals between roll regrinding/replacement, reducing downtime and spare inventory
• Improved sealing around bearing blocks keeps dust out, extending bearing life and long-term reliability

The Bellaex layer feed crusher offers flexible single- and dual-stage feed crushing modes, so one machine can cover starter, grower and layer PSD targets with fast recipe changeovers.

Core Advantages

• Cylinder-actuated internal diverter for fast switching between single-stage (coarse) and dual-stage (fine) modes
• One feed crusher can serve starter, grower and layer diets by combining mode selection with roll-gap adjustment
• No tools or manual re-routing required, minimizing changeover time between formulations
• Avoids purchasing multiple machines for different particle-size ranges and reacts quickly to nutritionist PSD changes

The Bellaex feed crusher features online roll-gap adjustment, modular construction and accessible drives, making a roller feed crusher that is easy to operate, install and maintain in modern layer feed plants.

Core Advantages

• Online roll-gap adjustment via handwheel or digital display—no shutdown required for PSD fine-tuning
• Roll, bearing and belt assemblies designed for straightforward removal with standard tools
• Integrated motor base and four foundation bolts simplify installation and alignment
• Modular housing design speeds cleaning and inspection, supporting preventive-maintenance routines

The Bellaex layer feed crusher combines a rigid base, precise drive and selectable second-stage operation to keep feed crushing stable 24/7 and cut specific energy by up to 15–20% versus fine pelleting alone.

Core Advantages

• High-precision drive and rigid base reduce vibration and misalignment for 24-hour continuous operation
• Ability to shut down the second roll stage when not needed to avoid unnecessary power consumption
• "Pellet larger first → controlled post-crushing” process concept reduces die restriction and pellet-mill motor load
• Combined with efficient motors, trials indicate potential 15–20% lower specific energy versus fine pelleting alone under comparable conditions

• Enclosed housing with modular, bolted sections; large hinged access doors and observation windows
• Dual-stage crushing chamber with primary & secondary differential toothed/serrated rolls
• Cylinder-actuated diverter and 3-mode internal flow system
• Bypass 1st / 1st Only / Dual Continuous
• Online roll-gap adjustment with scale; spring-protected floating roll
• Grooved stainless-steel feeding roll with adjustable feed rate
• Integrated magnetic separator at the inlet
• Robust welded base with four anchor points
• Belt drive with spring-loaded tensioner and taper-bushed pulleys
• Industrial plummer-block bearings and reducer (e.g. Guomao or equivalent)
• Local push-button controls with E-stop, guard interlock-ready
• 380 V / 50 Hz standard electrical package
• Carbon-steel industrial coating with vented protective guards

• Digital roll-gap display and/or gap sensors for recipe memory and repeatability
• PLC/HMI with recipe storage, remote monitoring and data logging
• Upgraded high-intensity magnetic separators
• Vibration and temperature condition-monitoring sensors
• Rapid particle-size screening interface for on-line PSD verification
• Remote diagnostics gateway
• Premium/imported bearings and reducers
• Stainless steel or enhanced wear protection for product-contact surfaces
• Non-standard voltage/frequency packages
• Spare-parts kits (extra roll pair, bearings, seals, belts)
• CE and regional conformity documentation

Power(kw):7.5

Feeding Power(kw):0.75

Capacity(TPH):4-6

Roller Size(mm):220*800*2

Power(kw):7.5*2

Feeding Power(kw):0.75

Capacity(TPH):6-10

Roller Size(mm):220*800*4

Power(kw):11

Feeding Power(kw):0.75

Capacity(TPH):8-12

Roller Size(mm):220*1200*2

Power(kw):22

Feeding Power(kw):0.75

Capacity(TPH):10-16

Roller Size(mm):220*1600*2

Power(kw):15*2

Feeding Power(kw):0.75

Capacity(TPH):12-18

Roller Size(mm):220*1200*4

Power(kw):15*3

Feeding Power(kw):0.75

Capacity(TPH):14-20

Roller Size(mm):220*1200*6

A: In single-stage operation, only the upper roll set works; material bypasses the lower rolls for a coarser PSD and higher throughput with lower energy. In dual-stage operation, material passes through both roll sets, giving a tighter PSD with fewer fines. You switch modes quickly via the cylinder-actuated internal diverter, without opening the housing.

A: Yes. The feed crusher handles whole corn and other grains directly, as well as cooled pellets for post-crushing. This allows you to pellet through larger die holes (reducing die restriction) and then post-crush to your nutritionist’s target coarse/fine ratio.

A: You record and reuse:

• The roll-gap setting (via scale or digital display),
• The mode (single or dual stage),
• The motor speeds and material feed rate.
• Operators simply dial the handwheel or input the stored value on the HMI; the feed crusher’s stable feed roll and differential-speed rolls keep PSD consistent batch to batch.

A: By pelleting “larger first” and then post-crushing, you:

• Reduce die restriction and pellet-mill motor load,
• Increase tons/hour through your existing pellet mill,
• Use the feed crusher’s efficient differential-roll crushing to reach the final PSD, often with 15–20% lower specific energy than fine pelleting alone under the same conditions.

A: Rolls are centrifugally cast Ni–Cr–Mo alloy with a thick wear layer and hardness around HS65+, giving long life in abrasive grain applications. A magnetic separator is standard to protect the rolls; high-intensity versions are available. Controls range from local push-buttons to PLC/HMI with remote monitoring and condition-based maintenance options. Standard power is 380 V / 50 Hz; other voltages/frequencies are available on request.