Method for making a molasses-based animal feed mass

A method of, and apparatus for making hard, dense, vitreous molasses-based animal feed supplement masses, the method comprising heating a molasses composition to a temperature within the range of about 240.degree. F. to about 285.degree. F. to remove all of the water content of the molasses that is necessary to form the desired vitreous masses. A portion of the heating process may be accompanied by an injection of ambient air into the molasses composition being heated. Immediately after heating, the molasses composition is cooled, agitated and de-aerated by directing the molasses composition through a cooler and de-aerator including a conduit in which is positioned an offset beater shaft assembly adapted to separate portions of the composition from the remainder thereof while directing cooling air through the conduit about said portions. After cooling, other animal feed supplements may be mixed with the molasses composition by a utilization of a variable pitch ribbon mixer-auger, further cooled, containerized, and allowed to cure into hard, dense, vitreous masses.

This invention relates to methods of and apparatus for making a 
molasses-based animal feed supplement mass of the type heretofore called a 
block wherein molasses may be mixed with other animal feed supplements and 
formed into a dense, non-porous, vitreous mass. 
BACKGROUND OF THE INVENTION 
Heretofore high energy feed supplements have been used extensively for 
cattle, hogs, sheep and the like, such supplements conventionally being in 
particulate or liquid forms and comprising fat, urea, vitamins, minerals, 
pharmaceuticals and the like. More recently, such supplements have been 
available mixed with molasses and formed into a hard, dense, non-porous, 
vitreous mass, sometimes termed, or mistermed, a "block". In the latter 
regard, the term "block" is presently thought to be inappropriate because 
it implies a solid, and such "blocks" do not exhibit all the 
characteristics of conventional solids. Although it is true that a 
properly formed block of such feed supplement will shatter like glass when 
struck, such blocks exhibit other characteristics that are not like 
conventional solids. For example, if a solid object of any substantial 
weight is placed on the top of even a properly formed non-porous vitreous 
block, in a relatively short period of time, the object will sink 
completely into, and be encased by, the block without any apparent 
softening of the block. In this light, and in light of other similar 
examples indicating block material flowage, such blocks might more 
appropriately be called extremely viscous fluids, or alternately called 
hydroscopic gels transiently in a crystaline form. Nevertheless, for 
consistency with the prior art and economy of description, the term 
"block" will sometimes be used herein. 
Hard, dense, non-porous vitreous molasses-based animal feed supplement 
blocks have met with substantial commercial acceptance because such blocks 
are convenient to handle as compared to particulate or liquid forms of 
feed supplement. Additionally and importantly, these blocks are especially 
convenient to feed by virtue of the hygroscopic characteristic of molasses 
blocks whereby only the surface of a properly formed block is softened 
from a glass-like state to an edible condition upon continued exposure to 
moist air. Because of this characteristic, the contents of such blocks 
become only incrementally available as feed, at a predictable rate, 
thereby inhibiting over feeding. 
A method of making such molasses-based animal feed supplement vitreous 
blocks is disclosed in the U.S. Pat. No. 3,961,081 to McKenzie wherein it 
is presented that to form dense molasses blocks, the water content of the 
molasses has to be reduced to less than 5%. The McKenzie method basically 
comprises a preliminary step of heating a composition of molasses mixed 
with other animal feed supplements to a temperature within the range of 
225.degree. F. to 300.degree. F. to partially reduce the water content of 
the molasses so that the remainder thereof is 5% or greater. Since 
molasses of the type utilized by McKenzie is normally comprised of about 
20% to 25% water content, such water content reduction amounts to removal 
of not more than 75% to 80% of the molasses water content. Of particular 
significance is the fact that McKenzie discloses the requirement that 
after heating, the composition is then subjected to a substantial vacuum 
to further substantially reduce the remaining water content of the 
molasses to about 3% prior to forming the composition into blocks. After 
formation the blocks are allowed to cool and cure at ambient conditions 
until hardened into a dense vitreous form. While this McKenzie patent 
method has met with some success in forming vitreous molasses blocks, it 
is important that during the heating stage of this method, care must be 
taken to avoid development of hot spots in the composition, as well as to 
avoid any substantial expansion and foaming. Such hot spots are considered 
undesirable because they may damage or burn the molasses or other more 
heat-sensitive additives thereby lowering the quality of the resultant 
product. Substantial expansion, which may occur to the extent of as much 
as 600%, and foaming are considered undesirable because such interferes 
with the physical handling of the molasses during processing, reduces 
production, and, unless controlled, also reduces the density of the 
resulting blocks. Reduced block density results in premature and internal 
block softening. Additionally, the McKenzie method requires machinery for 
the practice thereof, particularly the application of vacuum to the 
composition to dehydrate the same, that is relatively complicated, 
expensive and energy intensive and production from such machinery is not 
as great as might be desired. 
SUMMARY OF THE INVENTION 
The present invention overcomes these and other disadvantages and 
shortcomings of the prior art and is embodied in a method of and apparatus 
for making a hard, dense, vitreous molasses-based animal feed supplement 
block or mass, the method comprising heating a molasses composition to a 
temperature within the range of about 240.degree. F. to about 285.degree. 
F. to remove all of the water content of the molasses that is to be 
removed therefrom, and immediately rapidly cooling, agitating and 
de-aerating the composition at ambient pressure to reduce the temperature 
of the composition to at least 200.degree. F. and to remove air entrained 
therein that might otherwise adversely effect block density. The 
composition may then be mixed with other supplements, further cooled, 
placed into open containers, and allowed to cool to ambient temperature 
and cure to an extremely hard, non-porous, dense, vitreous mass. It has 
been found that heating to remove all the water that is to be removed and 
then rapid cooling and de-aerating the molasses obviates any necessity, as 
alleged by McKenzie, for the application of vacuum to remove the final 
increments of water from the composition, all such undesirable water 
content having been removed during the heating step of the instant method. 
Elimination of the need for any vacuum processing to remove water content 
provides substantial economies in energy conservation and machinery cost 
and increases production therefrom without adversely affecting the quality 
of the resultant product. 
To better avoid hot spots developing in the molasses during the 
heating-evaporation process that may damage the composition, to assist and 
accelerate the evaporation process by breaking the surface tension of the 
molasses, and to avoid undesirable extreme expansion and foaming of the 
composition, the present invention further provides for injecting ambient 
air into the composition throughout a substantial portion of the 
heating-water removal process while the molasses is still in a relatively 
thick condition. Such expansion and foaming have been found to be 
undesirable not only because it interferes with the mechanics of the 
heating process but also because it results in less dense final product. 
Blocks that are not sufficiently dense more quickly and more deeply absorb 
water, quickly becoming a sticky glob inconvenient to handle and 
impossible to feed at a controlled rate. However, it has been found that 
by injecting air at a multiplicity of locations evenly dispersed 
throughout the initial heating-evaporation step, the resulting product is 
substantially more dense. It is believed that the injected air not only 
agitates and circulates the molasses being heated to avoid development of 
hot spot therein but also breaks the surface tension of the still 
thickened molasses thereby facilitating water removal by evaporation by 
inducing the passage of steam from the molasses into the atmosphere in an 
open tank wherein this initial heating-evaporation step is performed 
instead of permitting such steam to well-up under the surface of the 
thickened molasses. 
After sufficient cooking to remove by evaporation all of the water content 
that is to be removed (which may be a reduction of the water content of 
the molasses to less than 5%) it is an important aspect of the present 
invention that the molasses composition is then rapidly cooled and 
de-aerated. This is achieved according to the present invention by 
utilization of an flail tube through which a substantial volume of cooling 
air is directed while the molasses composition is beaten, stretched, 
tossed, thrown about and conveyed through the flail tube having an offset 
shaft flail therein. Such extensive flailing action is important not only 
because it aids in rapidly cooling the composition but also because it 
de-aerates the same resulting in a more dense final product. 
It is therefore a principal object of the present invention to provide a 
method of, and apparatus for making a molasses-based animal feed 
supplement block or mass that avoids the disadvantages and shortcomings of 
the prior art. 
More specifically, it is a principal object of the present invention to 
provide a method of, and apparatus for making a molasses-based animal feed 
supplement mass that is particularly and especially hard, dense, 
non-porous and vitreous in form. 
It is another object of this invention to provide such a method by 
utilization of a molasses storage tank heater, a pre-heater, a 
heater-cooker-aerator, a final cooker, a flail cooler-de-aerator and a 
mixer-auger avoiding the shortcomings of the prior art structures. 
It is a further object of the present invention to provide a method of, and 
apparatus for making a molasses-based animal feed supplement vitreous mass 
wherein means are provided to reduce or break the surface tension of the 
molasses while it is being heated to aid in the passage of steam 
therefrom. 
It is a further object of the present invention to provide a method of, and 
apparatus for making a molasses-based animal feed supplement vitreous mass 
wherein air is injected into and dispersed throughout the molasses as it 
is initially cooked to evaporate the water content therefrom. 
It is a further object of the present invention to provide a method of, and 
apparatus for making a molasses-based animal feed supplement vitreous mass 
wherein, after removal of all the water content thereof necessary for 
proper mass formation, the composition is rapidly cooled and de-aerated. 
It is a further object of the present invention to provide a method of, and 
apparatus for making a molasses-based animal feed supplement vitreous mass 
wherein molasses in relatively pure form is heated to remove all of the 
water content thereof necessary to properly form a vitreous mass, the 
molasses is then cooled, and subsequently, other feed supplements are 
added and mixed with the molasses in an efficient manner prior to forming 
a vitreous mass to thereby avoid any heat damage to such other 
supplements. 
It is another object of the present invention to provide a particularly 
efficient and effective means for mixing molasses and other feed 
supplements, or the like. 
It is a further object of the present invention to provide a method of, and 
apparatus for making a molasses-based animal feed supplement vitreous mass 
by cooking the molasses wherein any requirement is avoided for an 
application of a vacuum to the molasses composition to reduce the water 
content thereof, or for any other purpose. 
It is a further object of the present invention to provide a method of, and 
apparatus for making a molasses-based animal feed supplement vitreous mass 
wherein the apparatus therefor is relatively simple and inexpensive, is 
energy efficient, and production therefrom is enhanced.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
Referring in more detail to FIG. 1 of the drawings there is schematically 
and diagramatically illustrated therein apparatus for the practice of a 
method of making a molasses-based animal feed supplement block or mass 
wherein the resultant product is hard, dense, non-porous and vitreous. The 
method basically comprises tapping liquid molasses from a remote storage 
tank 10 through a tank outlet heater 11 wherein the cold, thick molasses 
at the outlet is heated to about 80.degree. F. so it will more readily 
flow out of the storage tank 10. The molasses is directed, preferably 
underground, through a preheater 12 wherein the molasses is heated to 
approximately 140.degree. F. to further thin the same. The somewhat 
thinned molasses is directed to a plant or building 13 (FIG. 1A) and 
pumped through an initial heater-cooker and aerator 14 wherein the 
molasses is heated and cooked to approximately 240.degree. F. to remove by 
evaporation a substantial portion of the water content thereof and air is 
injected therein for purposes that subsequently will be more fully 
discussed. The molasses is then pumped through a final heater-cooker 16 
wherein the molasses is heated and cooked from a temperature of about 
240.degree. F. to between about 260.degree. F. to 285.degree. F. to remove 
most of the remaining water content thereof and all of the water content 
that it is necessary to remove to form the desired vitreous mass. The 
molasses is then moved by gravity through a flail-cooler and de-aerator 
assembly 18 wherein the molasses is rapidly cooled to a temperature of 
between about 180.degree. F.-200.degree. F. and forcefully agitated and 
thrown about to remove air entrained therein. The molasses then falls by 
gravity into a mixer-auger 20 preferably having a variable pitch 
abbreviated screw wherein dry feed supplements from a hopper 21, such as 
plant protein, roughage, fat, urea, vitamins, salt, other minerals, and/or 
pharmaceuticals or the like are mixed with the molasses and conveyed to a 
cooling tower 22. The temperature of the mixed composition may be further 
reduced in the cooling tower 22 or otherwise to preferably between about 
140.degree. F.-150.degree. F. and not more than 170.degree. F. and the 
resultant product is conveyed by a conveyor 24 to a containerizing station 
26 wherein the composition is containerized in any desired size and 
weight. The composition is then permitted to cool to ambient temperature 
and cure to thereby form a hard, dense, non-porous vitreous mass. Of 
particular significance to the present invention is the manner in which 
the liquid molasses is cooked to remove the water content thereof without 
the application of a vacuum thereto and rapidly cooled and de-aerated 
prior to the addition and mixing of other feed supplements. 
Referring in more detail to FIG. 1 of the drawings, liquid molasses of any 
normally employed type, such as sugar cane molasses, having any normally 
encountered specific gravity for raw molasses, such as a Brix number of 
from 80 to 100, flows by gravity from the storage tank 10 through the tank 
outlet heater 11. No attempt is made to heat the entire molasses content 
of the storage tank 10 but rather the gravity flow therefrom is heated 
only as needed. Referring to FIG. 1A of the drawings, the tank outlet 
heater 11 may be of any conventional construction, such as an electric 
heater coil 30 positioned inside the tank 10 about the tank outlet conduit 
32, an inner end 34 of which projects through the heater coil 30 and is 
adapted to receive gravity flow of molasses from the tank 10. An outer end 
36 of the tank outlet conduit 32, which may typically be a pipe of about 3 
inches in diameter, is connected to the preheater 12. The preheater 12 is 
typically formed of a pipe 3 inches in diameter and comprises an outer 
conduit assembly 37 including a first vertical outer conduit 38 connected 
at its upper end at a right angle by an elbow 40 to the outer end 36 of 
the outlet conduit 32. The lower end of the vertical outer conduit 38 is 
connected by a right angle elbow 42 to the left end of a horizontal outer 
conduit 44 positioned below the surface of the ground 46 by a distance of 
about 2 feet. The other end of the horizontal outer conduit 44 is 
connected by a right angle elbow 48 to the lower end of a second vertical 
outer conduit 50, the upper end of which is connected by a right angle 
elbow 52 to a main molasses supply conduit 54 the other end of which is 
connected to the initial heater-cooker and aerator 14. To heat the 
molasses to about 140.degree. prior to passage into the heater-cooker and 
aerator 14, a heat source or steam generator or boiler assembly 60 is 
provided. The steam boiler 60 includes a steam outlet conduit 62 connected 
by a heat exchange medium delivery conduit 64, to an inner conduit 
assembly 65 positioned inside of the outer conduit assembly 37 of the 
preheater 12. The heat exchange delivery conduit 64 is typically a 3/4 
inch diameter pipe and is connected to a like-sized pipe forming the inner 
conduit assembly 65. The inner conduit assembly 65 is directed through and 
sealed within the elbows 52, 48, 42 and 40, and the first and second 
vertical and horizontal outer conduits 50, 38 and 44 of the outer conduit 
assembly 37, and is connected to a steam return conduit 68 connected to 
the boiler 60. The preheater 12 is adapted to receive molasses in the 
space between an inner and outer periphery of the outer and inner conduit 
assemblies 37 and 65 to heat molasses passing therethrough to about 
140.degree. F. Because a majority of the length of the preheater 12 is 
preferably buried beneath the ground surface 46 and insulated by the 
surrounding ground, the heating efficiency thereof is enhanced. A pump 70 
is connected on one side thereof to the main molasses supply conduit 54 
and on the other side to a supply conduit 72 to direct molasses to the 
initial heater-cooker and aerator 14. 
Referring to FIGS. 2-4, the initial heater-cooker and aerator 14 according 
to the present invention comprises a stainless steel tank or receptacle 74 
typically approximately two feet wide by ten feet long and three feet 
deep. The tank 74 comprises front and rear side walls 76 and 78 
respectively connected together by left and right end walls 80 and 82 
respectively, and a bottom wall 84. The tank is divided into a large 
capacity first section 86, and a smaller capacity second section 88 by a 
center partition 90. A molasses inlet opening 92 is provided in the first 
section 86 intermediate the right end wall 82, the inlet opening 92 being 
connected to the conduit 72. The center partition 90 extends from the 
right hand end wall 82 to a point spaced from the left hand end wall 80 to 
form a passage or outlet opening 94 from the first section 86 and an inlet 
to the second section 88. As shown in FIG. 4, the second section 88 of the 
tank 74 is provided with a molasses outlet opening 96 positioned in the 
lower right hand end of the end wall 82. Molasses heated by the preheater 
12 to a temperature of about 140.degree. F. to a less viscous condition is 
pumped through the conduit 72 and through the inlet opening 92 to flow 
through the first section 86 to the passage 94 between the first and 
second tank sections 86, 88 to the molasses outlet 96 as propelled by the 
pump 70. During this flow the molasses in the tank 74 is pumped to 
maintain the depth thereof at about eight to eighteen inches and is heated 
from an inlet temperature of about 140.degree. F. to an outlet temperature 
of about 240.degree. F. to cook the molasses to drive off by evaporation 
more than one-half of the water content thereof. 
To agitate and aerate the molasses being cooked in the tank 74 while it is 
still in a relatively thick, viscous state, an air injection tube assembly 
98, 100 is provided in the first and second tank sections 86 and 88. The 
air injection tube assembly 98 comprises serpentine conduits 102 and 104 
positioned in the lower portions of the first and second tank sections 86 
and 88, respectively, which are supported in the left and right end walls 
80 and 82 immediately above the bottom wall 84 and is connected by a 
conduit 106 to any conventional source of ambient air under pressure such 
as an air blower or impellar 108 adapted to deliver approximately 25 to 50 
cubic feet per minute to the tank 74. The serpentine conduits 102 and 104 
each comprise a series of back and forth extending sections 110 and 112 
connected at angular junctions or apexes 114. Of particular significance 
to one aspect of the present invention is the provision on the underside 
face of each apex 114 of an air injecting nozzle 116 shown in FIGS. 3 and 
4, as totalling nine in number for each serpentine conduit 102 and 104 for 
directing ambient air downwardly towards the bottom wall 84, which air 
bubbles upwardly to agitate the molasses in the tank 74 to reduce hot 
spots therein and to break the surface tension of the molasses to aid in 
ejection of the water-content thereof to atmosphere. It has been found 
that without such means to reduce or break the surface tension of the 
molasses, steam tends to well-up beneath the surface thereby inducing 
undesirable expansion and foaming and retarding the removal of the water 
content thereof. If not otherwise corrected, such conditions would cause a 
less dense, less satisfactory final product. 
To heat and cook the molasses in the tank 74, a source of heat exchange 
fluid of any conventional type, such as the steam generator assembly 60, 
is provided, as schematically indicated in FIG. 1 to direct a heat 
exchange medium such as steam to heat the molasses content of the tank 74 
from about 140.degree. F. to about 240.degree. F. The steam generator 60 
is connected by a conduit 118 to a heat exchanger assembly 120 positioned 
adjacent the bottom of the first tank section 86 spaced above the 
serpentine conduit 102. The heat exchange assembly 120 is shown comprising 
four longitudinal extending conduit runs 122, 124, 126 and 128 connected 
together by three lateral end runs 130, 132, 134, the heat exchanger 
assembly 120 being supported on the left and right end walls 80 and 82 of 
the tank 74 at a height extending upwardly from about two inches from the 
tank bottom 84. The first conduit run 122 is connected by the conduit 118 
to the steam generator assembly 60 and the last conduit run 128 returns 
steam through a return conduit 136 to the steam generator assembly 60. A 
single run heat exchanger assembly 138 is provided for the second tank 
section 88 which is similar in function, position, and support to the heat 
exchanger assembly 120 but is relatively much larger in diameter. The heat 
exchanger assembly 138 comprises a longitudinally extending, single heat 
exchanger run or conduit 140 positioned in the second section 88 of the 
tank 74 and connected to the steam inlet conduit 118 and a second return 
conduit 142 to the steam generator assembly 60. It is important that the 
periphery of the single large diameter conduit 140 extends to within about 
1/4 to 1/2 inch of the adjacent walls 76 and 90, substantially filling the 
width of the second section 88. It has been found that this arrangement 
wherein the heat exchanger conduit 140 is closely adjacent to the walls 76 
and 90 substantially increases the heat transferred to the molasses 
flowing thereabout. Molasses introduced into the inlet 92 of the initial 
heater-cooker and aerator 14 is pumped by the pump 70 at a rate typically 
about 3 gallons per minute to maintain the depth of such molasses in the 
first and second tank sections 86 and 88 of the tank 74 at a depth of from 
about eight to eighteen inches. Such molasses flows about and along the 
two heat exchanger assemblies 120 and 138 to be cooked thereby removing 
about half of the water content thereof. Dwell time of molasses in the 
initial heater cooker-aerator 14 is about 20 to 30 minutes. Air is evenly 
injected throughout the molasses flow from below the level of heat 
exchanger assemblies 120 and 138 through the nozzles 116 in a downwardly 
direction to rise and bubble through the molasses and the surface thereof 
to thereby break the surface tension thereof. It has been found that by 
the injection of air in the manner disclosed, the molasses is not only 
agitated to aid in uniformly heating the same and thereby avoid hot spots 
therein but also that injected air rising to the surface of the molasses 
breaks the surface tension thereof, whereby evaporation and reduction of 
water content is substantially enhanced and accelerated, undesirable 
expansion and foaming is avoided, and a denser final product is achieved. 
From the initial cooker-aerator 14 molasses is pumped upwardly at about 3 
GPM by a liquid pump 144 through conduits 146 and 148 shown in FIGS. 1 and 
1A to the final heater-cooker 16 of a tube and shell type shown in more 
detail in FIG. 5. It should be noted, as shown in FIG. 1A that the final 
heater-cooker 16 is positioned in the plant or building 13 in an upwardly 
inclined orientation and at an elevated position so that molasses pumped 
through the cooker 16 will thereafter flow by gravity to the remainder of 
the processing apparatus. The final cooker 16 comprises an upwardly 
inclined, cylindrical cooking housing or tube 150 having an cylindrical 
inner periphery 151 and is typically approximately ten inches in diameter 
and eighteen feet long. The longitudinal left and right ends of the tube 
150 are closed by circular end plates 152 and 154 and a shaft 156 of a 
paddlewheel assembly 158 is rotatably mounted in the end plates 152 and 
154 and driven by a external electric drive motor 160 for agitating the 
molasses pumped through the final cooker 16 by the pump 144. The left end 
plate 152 of the tube 150 is provided with a molasses inlet opening 162 
connected to the conduit 148 for delivery of liquid molasses from the 
initial heater-cooker-aerator 14. The left end plate 152 is further 
provided with an air inlet opening 164 for purposes that will be 
subsequently discussed. 
The paddlewheel assembly 158 further includes a plurality of circular disks 
166 fixedly mounted, as by keys not shown, in spaced relation along the 
shaft 156. About fifteen disks 166 are provided. As shown in FIG. 5A, each 
disk 166 is provided with a slot 170 cut in the outer periphery 172 
thereof, the slot 170 extending radially inwardly toward a circular 
opening 174 receiving the shaft 156. The fifteen disks are fixed on the 
shaft 156 so that the fifteen slots 170 thereof are angularly staggered 
about the periphery of the shaft 156 to make the molasses flow path 
through the tube 150 unevenly sinusoidal. Each slot 170 is defined by a 
pair of radially extending forward and rearward disk walls 176 and 178. To 
form the disk 166, and as best shown in FIG. 5B, a circular, planar disk 
blank is radially cut to provide the slot 170 and is twisted out of a 
planar or straight condition so that each of the forward and rearward 
walls 176, 178 are sprung away from each other so that when installed on 
the shaft 150 the outer end of the forward wall 176 is nearer the right 
hand end of the final heater-cooker 16 than is the outer end of the 
rearward wall 178 to thereby enlarge the clearance between the walls 176 
and 178. This is important because molasses is conveyed through the 
enlarged slots 170 and the final heater-cooker 16 by pumping thereof by 
the pump 144 pumping against the weight of the molasses in the upwardly 
inclined tube 150, as shown in FIG. 1A. Each adjacent pair of disks 166 
along with adjacent portions of the inner periphery of the housing 150 
define a discrete heating and mixing chamber separated from adjacent 
chambers by disks 166 and connected by the slots 170. Positioned between 
each adjacent pair of disks 166 and pivotally mounted on the outer 
periphery thereof is a longitudinal extending scraper-mixing blade 
assembly 180. The blade assembly 180 comprises a rectangular blade 182 
having a pair of offset, pivot pins 184 on the longitudinal ends of the 
blade 182, the pins 184 being offset to be closer to one flat longitudinal 
side 186 of the blade 182. The flat side 186 is adapted to follow the 
contour of the inner periphery 151 of the tube 150 to remove or scrape off 
any molasses adhering to the periphery 151. The pins 184 extend through 
aligned bores or holes 188 in an adjacent pair of disks 166. Four such 
holes 188 are spaced about the periphery of each disk 166 to permit 
angularly staggering the blade assemblies 180 of the fifteen disks 166 
about the periphery of the shaft 156. Each pin 184 further includes a 
transverse bore 190 adjacent the free end thereof to receive a cotter pin 
192, or the like, to longitudinally fix the blade assembly 180 relative to 
the disk 166. One blade assembly 180 is mounted in each adjacent pair of 
disks 166 so that the blade assemblies are staggered about the periphery 
of the shaft 156 to equalize the rotational load about the shaft 156. On 
rotation of the shaft 156, the blade assemblies 180 are rotated about the 
inner periphery 151 of the housing 150 and are free to pivot relative to 
the disks 166 so that the radially outward longitudinal side 186 of the 
blade assembly 180 scrapes against the inner periphery 151 of the housing 
150 to thereby remove any molasses adhering to the inner periphery 151. 
Further, each blade assembly 180 functions as a mixing blade to mix the 
molasses in the chamber formed by the adjacent pair of disks 166. 
To heat the final heater-cooker 16 and the molasses therein, as best seen 
in FIG. 5, a pair of longitudinally spaced annular shell assemblies 194, 
196 each having left and right annular end closures 198, 200 and steam 
inlet and outlet openings 202 and 204 are provided for directing and 
returning a heat exchanger or transfer medium, such as steam through inlet 
and return steam conduits 206 and 208 from the steam generator assembly 60 
about the periphery of the cooking tube 150 for heating and cooking 
molasses therein. An air conduit 210 for directing ambient air from an 
ambient air blower 212 (FIG. 1) to the air inlet opening (FIG. 5) is 
provided to assist in removal of moisture resulting from evaporation of 
the water content of the molasses being cooked through a pair of 
longitudinally spaced vents 214 and 216 positioned intermediate the length 
and at the right end of the cooker tube 150. The temperature of the 
molasses is raised from an inlet temperature of about 240.degree. F. to an 
outlet temperature of about 260.degree. F. to 285.degree. F. Dwell time in 
the final cooker 16 is about 10 to 15 minutes. Water content of the 
molasses being cooked in the final cooker is reduced to preferably less 
than 5% of the molasses by evaporation and the molasses is pumped through 
the cooking tube 150 and the paddlewheel assembly 158 to a molasses outlet 
218 in the lower periphery of the lower right hand end of the cooker tube 
150 for directing the fully cooked molasses to a conduit 220 to fall by 
gravity to the molasses flail cooler and de-aerator 18. 
The flail cooler and de-aerator assembly 18, as shown in FIGS. 6 and 7, 
comprises a downwardly inclined, steel flail housing, tube or receptacle 
222 preferably ellipical or oval in cross-section, the major and minor 
axes 224 and 226 of the ellipse being typically approximately 26 inches 
and 16 inches, respectively. The tube is typically about 6 feet in length. 
The right and left longitudinal ends of the flail tube 222 are closed by 
right and left end plates 228 and 230 and the tube 222 is provided with 
molasses inlet and outlet openings 232 and 234. Because of the downwardly 
inclined orientation of the flail tube 222, the molasses outlet 234 is 
below the molasses inlet 232 so that gravity aids in movement of molasses 
through the device. A flail shaft assembly 236 is rotatably mounted in the 
right and left end plates 228 and 230 in an offset manner along the major 
axis 224 of the flail tube ellipse by about five inches relative to the 
central longitudinal axis 238 of the flail tube 222. The flail shaft 
assembly 236 comprises a longitudinal extending flail shaft 240 the right 
end of which is drivingly connected to an external electric drive motor 
242 to rotate the same at about 1100 RPM. A plurality of tee-shaped beater 
or flail bars 244 are fixed at right angles in spaced relation along 
approximately the upper two-thirds of the length of the flail shaft 240 in 
perpendicular relationship thereto. Each beater bar 244 comprises a 
radially extending member 246 the inner end of which is fixed to the shaft 
240 and the outer end of which is fixed, at a right angle, to a 
horizontally extending member 248 extending longitudinally of the flail 
shaft 240. The diameter of the flail shaft assembly 236 from the outboard 
edge of a horizontal member 248 of the beater bar 244 to an outboard edge 
of an oppositely disposed beater bar 244 is approximately 16 inches. With 
reference to FIG. 7, it is thus seen that substantial moon-shaped space 
250 is present within the ellipical flail tube 222 beyond the rotational 
circle of the beater bar 244 of the flail shaft assembly 236 to facilitate 
movement of more cooling air therethrough than would be available in a 
cylindrical tube dimensioned to receive the flail shaft assembly 236. 
Molasses in the flail tube 222 is picked up by the horizontal members 248 
from the bottom periphery of the flail tube 222 and thrown through the 
space 250 toward the upper periphery of the tube 222 to de-aerate the 
molasses. To rapidly cool the molasses being thrown about within the flail 
tube 222 the right end plate 228 of the flail tube 222 is provided with a 
cold air inlet 252 for directing cold air from a conduit 254 (FIG. 1) and 
a cold air compressor blower 256 which typically provides about 400 cubic 
feet per minute of cold air through the interior of the flail tube 222 to 
be vented to atmosphere at an air outlet opening and vent 257 and 258. 
Molasses in liquid form is directed through the molasses inlet 232 of the 
flail tube 222 to be tossed, beaten, stretched and thrown about by the 
beater bars 244 within the moon-shaped space 250 and rapidly cooled by the 
flow of cold air directed from the cold air blower 256. As molasses is 
tumbled through the flail tube 222, it is de-aerated and the temperature 
thereof is lowered from an inlet temperature of about 285.degree. F. to an 
outlet temperature of about 180.degree. F. to 200.degree. F., from whence 
it is directed through the outlet 234 and a conduit 260 to fall by gravity 
to the mixer-auger 20. Dwell time for molasses in the flail cooler and 
de-aerator assembly 18 is approximately twenty to thirty seconds. 
The mixer-auger 20, as shown in FIGS. 8 and 9, comprises an upwardly 
inclined mixer-auger cylindrical housing or tube 262 having right and left 
end plates 264 and 266 closing the longitudinal ends thereof. The housing 
262 further includes a pair of inlet openings 268 and 270, for admitting 
the molasses from the conduit 260 from the flail-cooler and de-aerator 18 
and for receiving other feed supplement ingredients such as plant protein, 
roughage, fat, urea, vitamins, salt, other minerals and/or pharmaceuticals 
or the like, delivered by a conduit 272 and a conventional screw or auger 
conveyor 274 and metered from a conventional supplement hopper or storage 
bin 21 (FIGS. 1 and 1A). The housing 262 further includes an outlet 
opening 276 for directing the materials mixed by the mixer auger 20 for 
further processing. The housing 262 is upwardly inclined so that the 
housing 262 adjacent the outlet opening 276 is elevated relative to the 
housing adjacent the inlet openings 268 and 270. Rotatably mounted in the 
end plates 264 and 266 of the housing 262 is an auger assembly 278 
including an auger shaft 280 which is rotatably driven by an electric 
drive motor 281. As best seen in FIG. 9, positioned in fixed spaced 
relation about the periphery of the auger shaft 280 by a plurality of 
spokes 282 is an abbreviated or ribbon screw conveyor 284 comprising a 
helically shaped ribbon 286 of variable pitch coiled about a central 
cylindrical channel or space 290 between the coils of the ribbon 286. By 
pitch is meant the longitudinal distance, as along the shaft 280, between 
the longitudinal ends of the helical ribbon 286 defining one complete 
ribbon revolution about the periphery of the shaft 280. For each 
revolution of the shaft 280, material being conveyed is advanced by the 
ribbon 286 a discrete distance along the longitudinal axis of the shaft 
280. At the right end of the shaft 280, as suggested in FIG. 8, one 
revolution of the shaft 280 results in forward movement of the material a 
distance approximately equal to the diameter of the helical ribbon 286. 
However, adjacent the left end of the shaft 280, as shown in FIG. 8, one 
revolution of the shaft 280 results in forward movement of the material a 
distance approximately equal to one-fourth of the diameter of the helical 
ribbon 286. The pitch of the helical ribbon 286 is evenly graduated from 
right to left along the length thereof. Consequently, the material at the 
right end of the shaft 280 tends to move more quickly than the material 
near the left end of the shaft 280 and therefore the material on the right 
tends to urge forwardly, the material of the left. It should be understood 
that, as the material entering the housing 262 adjacent the right end of 
the shaft 280 is conveyed against the upward incline of the housing 262, a 
portion of the material being moved adjacent the left of the shaft 280 
tends to fall backwardly in the central channel 290 to be picked-up again 
by the ribbon 286 and be advanced with material from the right. By this 
advancing, falling back and advancing again action, the material becomes 
more uniformly mixed. Other supplement ingredients are metered at a 
controlled rate from a supplement storage hopper 21 to be uniformly mixed 
with in appropriate proportions with the molasses delivered to the 
mixer-auger tube 262. The mixture of molasses combined with other 
supplements is directed by gravity through an outlet opening 276 and a 
conduit 292 to the cooling tower 22 for further cooling thereof. 
The cooling tower 22 is of any generally conventional construction and may 
include a rotatable distributor 294 on the upper end thereof to disperse 
materials directed by the conduit 292 to an inlet in the upper end of the 
cooling tower 22 and about the periphery thereof to fall by gravity and to 
be cooled by cold air directed from a conventional cold air blower 296 to 
cool the mixture to about 140.degree.-150.degree. F. Such material is 
directed through the cooling tower outlet 298 to a conventional conveyor 
24 for delivery of the mixture to a containerizing station 26. Depending 
upon ambient conditions, utilization of the cooling tower 22 or equivalent 
cooling device, may or may not be necessary to reduce the mixture 
temperature as desired. Material having a temperature of 150.degree. F. or 
less is currently preferably deposited in masses of about 250 pounds in 55 
gallon steel drums 299 cut in half and further transported on a wheeled 
trolley 300 but any suitable relatively rigid container may be used in 
sizes of up to 500 pounds or more. After containerization the masses or 
blocks are allowed to cool to ambient temperature and cure and harden to a 
vitreous form. 
While the invention has been described with a certain degree of 
particularity, it is manifest that many changes may be made in the details 
of the process, or the construction and the arrangement of the components 
or machinery therefor. For example, a composition of pure molasses or one 
of molasses mixed with certain other ingredients, such as fat or other 
feed supplements may be directed to the initial heater-cooker-aerator 14. 
It is understood that the invention is not to be limited to a specific 
embodiment of the apparatus set forth herein by way of exemplifying the 
invention but that the invention is to be limited only by the scope of the 
attached claims including a full range of equivalency to which each 
element or the apparatus or step of the process is entitled.