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.
- 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.
- 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 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
