Distiller grain production device

1. A device for producing a dense compact livestock feed from a loose granular material, comprising:

a source for supplying a loose granular material to be treated;

a controller in communications with a plurality of sensors for monitoring temperature of at least one zone as the treated material moves through a series of successive treatment zones;

an extruder comprising an elongated housing having an inlet end and a discharge end, the inlet end in communication with the source and to receive the loose granular material to be treated and the extruder arranged to compress the treated material therein, wherein the extruder includes:

rotatable screws provided within the housing and extending between the inlet end and the discharge end for compressing and transporting the treated material, the screws configured to apply a compressive force to the treated material as the screws rotate and move the treated material longitudinally along the screws;

at least one drive coupled to the screws for axially rotating the screws;

at least one heater disposed along a portion of the housing for heating the treated material moving along the screws to a first predetermined temperature which causes at least one of an oil and a liquid to boil within the treated material and changes physical properties of the treated material into a modulus state;

at least one treatment zone provided within the extruder, wherein the at least one treatment zone comprises at least one non-heating zone provided in the housing such that no heater applies additional heating to the treated material; and

a die located at tips of the screws at the discharge end of the extruder for creating a substantial pressure for compacting the treated material, wherein the die includes:

a chamber having a through hole which extends longitudinally through the chamber and provides a restricted passageway for compressing the treated material, the through hole includes an inlet orifice for receiving the treated material from the discharge end of the extruder and an outlet orifice for discharging the treated material, pressing the treated material in the modulus state longitudinally through the restricted passageway by applying a two-dimensional cross-section compression which includes a pressure applied in a direction tranverse to a direction of transport and a pressure applied in a direction parallel to the direction of transport; and

the controller configured to monitor the pressure and use the pressure to control the two-dimensional cross-section compression applied to the treated material, wherein creating the pressure inside the die results in at least one liquid in the treated material migrating to its outer surface during one or more times when the treated material is, at least one of, inside the die, at the outlet orifice, and after exiting the outlet orifice.

2. The device of claim 1 , wherein the dense compact livestock feed is shaped to form at least one of a pellet, a cube and a tub.

3. The device of claim 1 , wherein, in the chamber, the pressure applied in the traverse direction onto the treated material is substantially equal to the pressure applied in the parallel direction.