Distiller grain production device

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

a source for supplying the granular material to be treated;

a controller in communications with a plurality of sensors for monitoring temperature conditions of the treated material moving through a series of successive treatment zones;

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

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

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

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

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

a chamber having a through hole which extends longitudinally through the chamber and provides a passage 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 to a cooling zone, in the modulus state, the treated material is pressed longitudinally through the 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 two-dimensional cross-section compression is applied to the treated material such that liquids in the treated material migrates to an outer surface of the treated material upon reaching the outlet orifice; and

the cooling zone comprising a cooling unit including a die extremity tubing and a heat exchanger for cooling the treated material received from the die to form a dense compact body, wherein:

the heat exchanger comprises a cooling conduit provided between a heat exchanger inlet and a heat exchanger outlet; and

the die extremity tubing comprises a first opening in direct communication with the outlet orifice for receiving the treated material from the die and a second opening for discharging the treated material from the device as the dense livestock feed, the die extremity tubing extends through the cooling conduit such that the heat exchanger surrounds the die extremity tubing to cool the treated material using conductive heat transfer and the heat exchanger is controlled to cool the treated material to a second predetermined temperature which is below a boiling temperature of the at least one oil and liquid within the treated material.

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