Chain Conveyor for Feed Mills

An incorrectly sized or poorly integrated system may lead to capacity losses, material accumulation, excessive power consumption, premature wear or bottlenecks in downstream equipment.

Chain Conveyors for Horizontal Material Transfer

In feed mills and grain processing plants, the consistent movement of raw materials and finished products is essential for maintaining an uninterrupted production process.

This becomes especially important in long horizontal transfer lines, where irregular feeding, sudden material surges or insufficient conveyor capacity can affect the performance of the entire plant.

Chain conveyors support reliable horizontal material transfer through their enclosed casing and scraper-chain design. The material is moved continuously between silos, intake points, storage bins and process equipment without relying on manual handling.

The main advantages of chain conveyors in horizontal transfer lines include:

• Continuous and controlled material flow
• Reliable operation in high-capacity applications
• Reduced manual handling requirements
• Lower material loss and limited dust spread
• Flexible layouts with multiple inlet or discharge points
• Custom casing dimensions and conveyor lengths
• Integration with silos, bucket elevators and process equipment

KARDEV evaluates not only the current production capacity but also peak loads, feeding conditions and future capacity increases during the design process.

This approach helps reduce bottlenecks and supports stable, long-term conveyor operation.

Silo Filling, Silo Discharge and Process Transfer

In feed mills and grain storage facilities, chain conveyors are more than stand-alone conveying machines. They form an important part of the overall process flow by connecting storage, production and transfer points.

They can be used to fill silos, discharge stored products into the production line and transfer materials between crushing, grinding, dosing, mixing, pelleting, storage and packaging sections.

Chain Conveyor for Silo Filling

Chain conveyors are commonly used to transfer grain, feed ingredients and other bulk materials to silos through horizontal or slightly inclined conveying lines.

The conveyor can be designed with multiple discharge points according to the silo arrangement. This allows the material to be directed to the selected storage point and helps maintain an organised silo filling process.

The following factors should be considered when determining the required capacity of a silo filling conveyor:

• Product bulk density
• Number and position of discharge points
• Conveying distance
• Feeding equipment capacity
• Peak material flow
• Future plant capacity

The conveyor capacity should always be compatible with the bucket elevator or other equipment feeding the line.

Chain Conveyor for Silo Discharge

Chain conveyors can also be installed beneath silos or storage bins to transfer stored materials into the production process.

Material released from the silo outlets is conveyed through the enclosed casing at a controlled rate. A correctly designed silo discharge conveyor helps reduce irregular material accumulation and provides more consistent feeding to downstream equipment.

Where several silos discharge onto the same conveyor, the number of open outlets, gate operation sequence and maximum possible material flow must be evaluated together.

This prevents the conveyor from being overloaded when multiple silos are discharged simultaneously.

Process Transfer

Chain conveyors can be used between the main process stages of a feed mill or grain handling facility, including:

• Raw material intake
• Cleaning
• Crushing
• Grinding
• Dosing
• Mixing
• Pelleting
• Cooling
• Storage
• Packaging

Corn, wheat, barley, soybean meal, compound feed, pellets and similar bulk products can be conveyed with a system designed according to their physical properties and process requirements.

Inlet and discharge positions, inspection covers, chain tensioning components and the drive assembly should be designed for easy operation, inspection and maintenance.

Capacity Design for Grain, Feed and Pellet Conveying

Many chain conveyor performance problems are caused by incorrect capacity calculations or by selecting the conveyor without considering the full process line.

The required capacity should not be based only on the average production rate of the facility. Short-term flow peaks, product bulk density, operating conditions, feeding behaviour, conveyor filling level and the capacity of connected equipment must also be taken into account.

The main design criteria include:

• Product type and bulk density
• Required and maximum conveying capacity
• Conveyor length and inclination
• Conveyor casing width and height
• Chain type and chain speed
• Scraper flight dimensions and spacing
• Inlet and discharge configuration
• Conveyor filling level
• Motor and gearbox selection
• Wear and corrosion conditions
• Maintenance access
• Future production capacity

Evaluating these criteria together helps ensure stable, reliable and energy-efficient conveying performance.

A conveyor that is too small may cause repeated overloading and production interruptions. An oversized system, on the other hand, may increase investment cost, power demand and mechanical wear without providing a practical benefit.

What Is a Redler Conveyor?

A Redler conveyor is a type of chain conveyor developed for the enclosed handling of bulk materials.

In this system, material is conveyed through the casing by scraper flights attached to a moving chain. This working principle is widely used for the horizontal transfer of grain, feed ingredients, pellets and similar products.

The enclosed casing helps reduce material loss and limit dust spread within the facility. It also allows the conveyor to be integrated into silo filling, silo discharge and process transfer applications.

Redler conveyors are commonly used in:

• Feed mills
• Grain storage and handling facilities
• Silo filling and discharge lines
• Raw material intake systems
• Pellet production plants
• Flour and pulse processing facilities
• Fertilizer plants
• Chemical processing facilities
• Cement and building material plants
• Energy, mining and recycling applications

When the material is particularly abrasive, corrosive, hot or difficult to handle, the casing, chain, scraper flights and wear components must be selected accordingly.

How to Select the Right Chain Conveyor

A chain conveyor should not be selected solely according to motor power or nominal capacity. The entire material flow and the performance of connected equipment must also be reviewed.

For example, if the bucket elevator feeding the conveyor has a higher discharge capacity than the conveyor can receive, temporary overloads and material accumulation may occur.

Similarly, if the equipment downstream of the conveyor has insufficient capacity, the product may build up at the discharge point and eventually block the line.

The following questions should be answered before selecting a chain conveyor:

• What material will be conveyed?
• What is the product bulk density?
• What are the required average and maximum capacities?
• What is the conveying distance?
• Is the conveyor horizontal or inclined?
• How many inlet and discharge points are required?
• Will the system operate continuously or intermittently?
• Which equipment will feed the conveyor?
• Which equipment will receive the product?
• Is future capacity expansion planned?
• Are there any abrasion or corrosion risks?
• Is sufficient access available for maintenance?

A project-specific evaluation based on this information helps prevent the selection of a system that is either undersized or unnecessarily large.

KARDEV Chain Conveyor Solutions

KARDEV designs and manufactures chain conveyor systems according to product characteristics, required capacity and plant layout.

Silo filling conveyors, silo discharge conveyors, Redler conveyors and process transfer lines are configured by evaluating:

• Conveyor casing dimensions
• Chain type and scraper flight design
• Drive system
• Inlet and discharge positions
• Required conveying capacity
• Maintenance and inspection requirements
• Connected equipment capacities
• Plant operating conditions

The objective is not only to achieve the required tonnage. The conveyor must also support consistent material flow, allow practical maintenance and operate reliably as part of the complete production line.

For grain, feed, pellets and other bulk materials, KARDEV provides project-specific chain conveyor solutions for new plants, plant expansions and existing production lines.

Frequently Asked Questions

Where are chain conveyors used?

Chain conveyors are used in horizontal material transfer, silo filling, silo discharge, raw material intake and process transfer lines.

They are widely used in feed mills, grain handling facilities, storage systems, pellet plants and other bulk material processing applications.

Are chain conveyors and Redler conveyors the same?

A Redler conveyor is a type of chain conveyor used to transfer bulk materials through an enclosed casing with scraper flights attached to a moving chain.

In grain and feed handling applications, the terms “chain conveyor” and “Redler conveyor” are often used for similar conveying systems.

What is the difference between a chain conveyor and a belt conveyor?

A chain conveyor moves material through an enclosed casing using scraper flights attached to a chain. A belt conveyor carries the material on a moving belt surface.

Chain conveyors are commonly preferred for enclosed horizontal transfer, silo discharge applications, multiple discharge points and controlled bulk material flow.

Belt conveyors may be more suitable for longer conveying distances or applications where gentler product handling is required.

How is chain conveyor capacity calculated?

Chain conveyor capacity depends on several factors, including:

• Product bulk density
• Conveyor cross-section
• Chain speed
• Scraper flight dimensions
• Filling level
• Conveying distance
• Conveyor inclination
• Feeding arrangement

Motor and gearbox selection should be based on the required capacity, conveyor length, mechanical resistance and expected operating conditions.

Can KARDEV manufacture custom chain conveyors?

Yes. KARDEV can design and manufacture chain conveyor systems according to product type, required hourly capacity, conveyor length, plant layout and process requirements.

Request a Project-Specific Chain Conveyor Solution

A reliable chain conveyor design starts with accurate product, capacity and layout information.

Share the following details with KARDEV:

• Product type
• Bulk density
• Required conveying capacity
• Conveyor length
• Inclination angle
• Inlet and discharge arrangement
• Plant layout or process drawing

Our engineering team can evaluate the operating conditions and determine the most suitable chain conveyor configuration for your production line.