Forage Processing and Pelletizing Technology Shaping Feed Production

Introduction

Forage processing deals with the conversion of raw agricultural materials such as alfalfa, grasses, straw, and mixed forages into compacted formats that are suitable for the nutritional needs of livestock. Apart from making the feedstock more compact and uniform, pelletizing also makes the pellets more convenient to store, transport, and feed. Besides that, better pellet quality also leads to improved digestibility and nutrient uptake by animals, which makes going through a process innovation a key feed producer topic on the global stage.

There are several stages involved in the pelletizing process of forage. After that, the materials are ground to suitable sizes, heat and moisture are added before pressing through the dies to create equal sized pellets. Counting the stages, advanced pelletizing equipment can perform grinding, conditioning, pelleting, and cooling in a seamless operation that yields high-quality output while maintaining production efficiency. With the rising trend of demand for uniform and premium quality feed, such technological features will be key across the dairy, beef, poultry, and small ruminant sectors.

Automated pelletizing technology, digital tracking, and modular manufacturing have been emphasized in the technologies' recent progress. System manufacturers and solution providers aim to equip their products with features that allow precise control over parameters such as moisture level, die pressure, and rate of production. Besides, integrated features help to reduce human interference, improve the consistency of the process, and facilitate the implementation of quality assurance protocols, wherein feed outputs are aligned with expected animal performances. For instance, in April 2025, industry expansion was reflected when ANDRITZ secured an order to supply a complete, high-efficiency feed plant to Alwadi Poultry Farms Company in Saudi Arabia, reinforcing capacity expansion through advanced processing solutions. The order is for a complete feed mill system that not only covers the manufacture of feed pellets for poultry and ruminants with features such as hammer mills, mixers, and pellet mills, but also includes automated controls to ensure the system runs efficiently and with flexibility. This plant, which is planned to be operational in the first half of 2026, shows a trend of using turnkey processing solutions to improve pellet quality and output.

Similarly, in November 2025, an Indonesian livestock producer installed a 5-ton-per-hour feed pellet processing machine to set up a local facility for manufacturing forage pellets, strengthening in-house production capacity. The line consists of high-end grinding, mixing, pelletizing, and packaging equipment that is ideal for this sort of forage feedstock. This endeavor is an example of how medium-sized enterprises and regional producers are increasingly interested in adopting pelletizing technologies to raise feed quality and increase local supply capabilities.

Innovation in forage processing technologies is profoundly influenced by advances both in automation and digital process control. The latest systems, for instance, equipped with sensors, programmable logic controls, and integrated software platforms, allow for the measurement of crucial parameters such as temperature, moisture, and pellet density in real time. Also, such systems make it possible to foresee the maintenance needs and optimize the production process, which means there is less downtime, lower energy consumption, and less wastage during the production runs. Studies confirm that the digital monitoring and variable control systems contribute significantly to increasing the reliability of operations and, hence, help maintain the consistent quality of output across the different batches.

Another significant trend the industry witnessed is modular and scalable pellet plant solutions that can be easily adapted to various operational requirements. Compact pelletizing lines with output volumes that are just large enough for local producers keep investment costs down and thus make processing at the farm or cooperative level feasible. Huge integrated plants, usually run by well-known technology suppliers, are aimed at high-volume production and have a very close connection with distribution systems. Both styles of the plants are to be credited with further extending forage pellet technology to a wider range of livestock feed production scales.

Nevertheless, there are still some difficulties with the acceptance of new technologies. High initial expenditure, the need for technical training, and integrating production runs are factors that can make smaller producers reluctant. On the other hand, modular designs and the option to finance purchases are facilitating the adoption process for a wider spectrum of producers. Moreover, greater awareness of sustainability and feed quality is leading to pelletizing systems that are resource-efficient and, at the same time, capable of delivering measurable performance benefits.

Check out the Global Alfalfa Pellet Market report for detailed information about the major growth drivers.

Major drivers explained

The demand for consistent pellet quality and production efficiency is a key driver of innovation in forage processing. Automation and digital control systems play a major role in reducing variability, improving throughput, and delivering feed output that meets the performance expectations of different livestock classes. Another factor is economic optimization. Top-of-the-line pelletizing machinery reduces energy consumption, uses resources more efficiently, and lowers operating costs by reducing waste and downtime. Therefore, producers can maintain consistent quality output at lower unit costs, which is good for their competitive standing.

Lastly, the need for scalable solutions that can support varying operational sizes is prompting technology providers to offer modular and turnkey systems. These platforms enable producers to obtain advanced pelletizing systems without making large capital investments.

Table of Contents

1. Overview of forage processing fundamentals
2. Pelletizing technology and methods
3. Grinding and size reduction systems
4. Conditioning and moisture control approaches
5. Automation and digital process control
6. Quality monitoring and assurance
7. Modular pellet plant solutions
8. Economic considerations and cost analysis
9. Regional implementations and case studies
10. Future trends and technology outlook

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