Before it is transported and shipped to farmers all across America, chicken feed is created at warehouses known as feed mills in a pelletizing procedure, in which soybean and corn powder are mixed to create feed pellets during a heated process. If this process is uninterrupted, farmers can get their feed pellets on time, so they can grow their chickens. But what happens when a feed mill’s stainless steel duct system that processes the feed generates enough condensation that causes a pellet buildup inside the duct? It either slows down the process considerably, or stops it altogether.
In the Georgia-based Columbia Farms feed mill, a $23 million feed plant that produces an average of 10,000 tons of feed per week, the aforementioned buildup problem was a common occurrence. As a temporary solution, the mill workers would go into the ducts through their respective manholes and clean the buildup by hand each time. Over time, the owners of the mill came to the realization that the buildup predicament needed a permanent fix, given it was hindering their business by causing severe down time on chicken feed production, and increasing manual labor by the same token. So, the owners took a different approach to the problem and opted for spray foam insulation as the key material