Abstract: A system according to various embodiments can include a source for supplying a material to be treated, an extruder, at least two screws, and a drive coupled to the screws for axially rotating the screws. The extruder includes an inlet for receiving the material, which is fed therein in a controlled manner. The screws are provided within the housing of the extruder. The screws have a plurality of compression and release stages that create mechanical heat which is directly applied to the material to change the mechanical properties of the material thereby facilitating a conversion of a physical state of the material from a non-compactable state to a compactable state as the screws rotate and move the material longitudinally along the screws to produce a final product, for example, a feed tub for use as an animal feed.

Abstract: A process for producing a substantially dry product, according to various embodiments, may include receiving wet grain at a first screw The process includes receiving the wet grain at a second screw from the first screw. The process includes compressing the wet grain between the first screw and the second screw and dehydrating the wet grain when the wet grain is located within at least one zone of the first screw and the second screw to cause a physical property change to the wet grain.

Abstract: A system according to various embodiments can include a source for supplying a material to be treated, an extruder, at least two screws, and a drive coupled to the screws for axially rotating the screws. The extruder includes an inlet for receiving the material, which is fed therein in a controlled manner. The screws are provided within the housing of the extruder. The screws have a plurality of compression and release stages that create mechanical heat which is directly applied to the material to change the mechanical properties of the material thereby facilitating a conversion of a physical state of the material from a non-compactable state to a compactable state as the screws rotate and move the material longitudinally along the screws to produce a final product, for example, a feed tub for use as an animal feed.

Abstract: A device according to various embodiments for preparing wet grain can include at least a first screw configured to receive wet grain. A second screw receives the wet grain from the first screw. At least one of a compressing element and a dehydrating element is included with at least one of the first screw and the second screw to cause a physical property change to the wet grain.

Abstract: A substantially dry product is produced by a process comprising the steps of: removing moisture from a raw material having a first moisture content to produce the substantially dry final product having a final moisture content; (b) advancing the raw material longitudinally along and between at least a first screw and a second screw comprising at least a compression zone and a dehydrating zone which are arranged successively within the first and second screws; and (c) entrapping and removing a predetermined percentage of moisture as the raw material moves through the compression zone and dehydrating zone.

Abstract: A device according to various embodiments for preparing wet grain can include at least a first screw configured to receive wet grain. A second screw receives the wet grain from the first screw. At least one of a compressing element and a dehydrating element is included with at least one of the first screw and the second screw to cause a physical property change to the wet grain.

Abstract: In various embodiments, a device for producing a high density compact livestock feed from a loose granular material according to various embodiment can include a source for supplying a loose granular material to be treated and moving the treated material through a series of successive treatment zones. Rotatable screws are provided within an extruder to compress and transport the treated material a die. The treated material is pressed through the die while a two-dimensional cross-section compression is applied to the treated material. In various embodiments, the high density compact livestock feed is produced having a high protein content, a high fat content, high shipping durability, high quality, and high nutritional value, without the addition of additives.

Abstract: A continuous flow dryer system according to various embodiments can include a source for supplying a material to be treated having a high moisture content, such as a distiller wet grain, a profile screw compression dryer, a profile screw, and a drive coupled to the profile screw for axially rotating the profile screw. The profile screw compression dryer includes an inlet for receiving the material for drying, which is fed therein in a controlled manner. The profile screw is provided within the housing of the dryer. The profile screw has a diameter that increases in dimension in a direction away from the inlet for increasing the compressive force applied to the material to assist with drying as the profile screw rotates and moves the material longitudinally along the profile screw to produce a final product, for example, a distiller dried grain for use as an animal feed.

Abstract: A continuous flow dryer system according to various embodiments can include a source for supplying a material to be treated having a high moisture content, such as a distiller wet grain, a profile screw compression dryer, a profile screw, and a drive coupled to the profile screw for axially rotating the profile screw. The profile screw compression dryer includes an inlet for receiving the material for drying, which is fed therein in a controlled manner. The profile screw is provided within the housing of the dryer. The profile screw has a diameter that increases in dimension in a direction away from the inlet for increasing the compressive force applied to the material to assist with drying as the profile screw rotates and moves the material longitudinally along the profile screw to produce a final product, for example, a distiller dried grain for use as an animal feed.

Abstract: An apparatus and method for processing grain material to generate a consistently high densified grain with a desired length, shape and size. The densified grain processing apparatus comprises a die assembly, a cooling assembly and a break-off assembly. The method includes receiving the grain material by the die assembly and forcing the grain material through an extrusion passageway that evenly distributes the grain material into a plurality of orifices thereby producing a high density shaped grain before the grain material exits the die assembly. A coolant is pumped to a coolant passage by means of an at least one pump and cools the shaped grain by passing the shaped grain through at least one of the cooling tube inside a cooling chamber. The break-off assembly then breaks off a predetermined length of the shaped grain.

Abstract: An animal feed producing system comprises a compression screw assembly. The compression screw assembly includes at least a first screw, a second screw and a plurality of barrels. The first and second screws include a plurality of flights and roots. The plurality of screws is configured such that they include a plurality of sections. Each section comprises a set of plurality of flights and a plurality of roots configured to perform a specific compression function, such as perpendicular compression and lateral compression.

Abstract: A device according to various embodiments for preparing wet grain can include at least a first screw configured to receive wet grain. A second screw receives the wet grain from the first screw. At least one of a compressing element and a dehydrating element is included with at least one of the first screw and the second screw to cause a physical property change to the wet grain.

Abstract: A compression system includes a compression device and a controller. A treated material is pressed longitudinally through a compression chamber by simultaneously applying a lateral pressure and a two-dimensional cross-section compression which includes a pressure applied in a direction traverse to a direction of transport and a pressure applied in a direction parallel to the direction of transport. The controller controls the two-dimensional cross-section compression applied to the treated material such that, during compression, liquids in the treated material migrate to the outer surface of the treated material upon reaching the outlet orifice.

Abstract: A system according to various embodiments can include a source for supplying a material to be treated, an extruder, at least two screws, and a drive coupled to the screws for axially rotating the screws. The extruder includes an inlet for receiving the material, which is fed therein in a controlled manner. The screws are provided within the housing of the extruder. The screws have a plurality of compression and release stages that create mechanical heat which is directly applied to the material to change the mechanical properties of the material thereby facilitating a conversion of a physical state of the material from a non-compactable state to a compactable state as the screws rotate and move the material longitudinally along the screws to produce a final product, for example, a feed tub for use as an animal feed.

Abstract: An apparatus and method for processing grain material to generate a consistently high densified grain with a desired length, shape and size. The densified grain processing apparatus comprises a die assembly, a cooling assembly and a break-off assembly. The method includes receiving the grain material by the die assembly and forcing the grain material through an extrusion passageway that evenly distributes the grain material into a plurality of orifices thereby producing a high density shaped grain before the grain material exits the die assembly. A coolant is pumped to a coolant passage by means of an at least one pump and cools the shaped grain by passing the shaped grain through at least one of the cooling tube inside a cooling chamber. The break-off assembly then breaks off a predetermined length of the shaped grain.

Abstract: An animal feed producing system comprises a compression screw assembly. The compression screw assembly includes at least a first screw, a second screw and a plurality of barrels. The first and second screws include a plurality of flights and roots. The plurality of screws is configured such that they include a plurality of sections. Each section comprises a set of plurality of flights and a plurality of roots configured to perform a specific compression function, such as perpendicular compression and lateral compression.

Abstract: A device according to various embodiments for drying wet grain can include a first screw configured to receive wet grain. A second screw receives the wet grain from the first screw. At least one mechanism is included within at least one of the first screw and the second screw to vaporize water content in the wet grain.

Abstract: A device according to various embodiments for preparing wet grain can include at least a first screw configured to receive wet grain. A second screw receives the wet grain from the first screw. At least one of a compressing element and a dehydrating element is included with at least one of the first screw and the second screw to cause a physical property change to the wet grain.

Abstract: A device according to various embodiments for drying wet grain can include a first screw configured to receive wet grain. A second screw receives the wet grain from the first screw. At least one mechanism is included within at least one of the first screw and the second screw to vaporize water content in the wet grain.

Abstract: A device for producing a high density compact livestock feed from a loose granular material according to various embodiment can include a source for supplying a loose granular material to be treated and moving the treated material through a series of successive treatment zones. Rotatable screws are provided within an extruder to compress and transport the treated material a die. The treated material is pressed through the die while a two-dimensional cross-section compression is applied to the treated material.