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Fluctuations in moisture and unwanted components destabilise feed production

Inline measurement solutions for continuous monitoring of quality‑relevant material parameters

Home Measurement Technology Industries Animal Feed Industry

Process deviations develop long before they become visible in the final product

Animal feed production combines raw materials with varying moisture levels, diverse particle structures and thermomechanical process steps. Variations in product moisture directly influence energy consumption, pellet stability, flow behaviour and shelf life. Unwanted components may enter the material flow through raw material fluctuations, storage, conveying or mechanical abrasion. Without continuous inline measurement, deviations often remain undetected until late in the process.

Inline measurement systems make moisture trends and inhomogeneous components visible directly in the material flow, enabling corrective action exactly where the process is still controllable.GreCon Engineering

Lack of transparency in the process – reliable facts from the industry

In many feed plants, key quality parameters are measured only periodically or at the end of production. This creates blind spots in process control.

25 %

Material usage – typical overdosing without inline measurement

> 70 %

most quality deviations occur before final inspection

> 72 h

Time delay between process deviation and laboratory result

Solutions and concepts

In animal feed production, moisture variation and the presence of unwanted components influence energy usage, pellet stability, flow behaviour and downstream processing steps. Inline measurement systems provide the necessary real‑time transparency to detect these deviations early and support stable, reproducible process conditions.

MATCONTROL T installed as a traversing model above a production line

Inline foreign object detection

GreCon MATCONTROL HF provides high‑resolution, full‑surface monitoring of the material flow to detect density deviations, structural irregularities and foreign objects in real time. The measurement data support the stabilisation of upstream cleaning and conveying steps by identifying anomalies before they affect downstream processing.
 

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Inline moisture measurement

GreCon MOISTURECONTROL measures the moisture content of feed components and mixtures continuously and without sampling delays. The real‑time data enable precise control of drying, conditioning and blending, supporting energy‑efficient operation and consistent product characteristics.

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The future of industrial measurement technology

“Rising throughput rates, tighter specifications and increased energy costs heighten the need for precise, real‑time process data. Inline measurement technology is evolving from a monitoring tool into a central decision basis for process control. Continuous measurement enables automated feedback loops, reduced variability and more predictable product quality.”GreCon Engineering
Workers display holographic data in factory hall

Consequences of missing or insufficient measurement – more than just scrap

Production deviations typically develop gradually. Without continuous measurement data, moisture variations, structural inconsistencies or unwanted components often remain undetected until they cause measurable quality losses.

Economic consequences
Increased material consumption, unplanned downtime, rising unit costs.

Operational consequences
Unstable processes, frequent readjustments, overload of quality control.

Strategic consequences
Production performance becomes harder to predict, reduced competitiveness.

The cost of doing nothing is high. Reliable measurement technology is not a convenience option – it is a strategic prerequisite for stable processes.

finger in front of laptop points to holographic statistics

Challenges in the animal feed industry

Animal feed production presents specific measurement challenges due to its material characteristics and process conditions.

Typical challenges

  • wide variation in raw material moisture
  • heterogeneous particle structures within a single material stream
  • thermomechanical influences during conditioning and pelleting
  • limited accessibility for manual sampling points
  • time‑delayed laboratory results for moisture or quality assessment

The result? Processes with high variation and error potential.

These risks are not theoretical – they occur daily, often go unnoticed and lead to significant costs.
That is why industrial measurement technology is not optional, but essential.
And this is exactly where Fagus‑GreCon comes into play.

GreCon Product overview

Everything at a glance: our measurement technology solutions

The measurement data obtained through GreCon systems provide the information required to operate feed production lines efficiently, reproducibly and with reliable process stability. Measurements are carried out inline, continuously and directly within the process — exactly where deviations occur and remain controllable.

Supported measurement and optimisation tasks

  • Moisture measurement
  • Detection of unwanted components / foreign objects
  • Density and structural monitoring
  • Monitoring of bulk material distribution
  • Homogeneity and formulation control

The systems can be combined modularly, integrated into existing plants and adapted to new line concepts. At the centre is a robust, process‑integrated measurement approach that forms the foundation for stable processes and reliable decision‑making.

We look forward to hearing from you.

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