Alfalfa and Hay Pellets: How to Make Them With a PTO Mill
To make alfalfa or hay pellets on a farm, start with dry, clean hay, grind it in a hammer mill, adjust the moisture, press it through a flat die pellet mill and let the pellets cool before you bag them. If you own a tractor, a PTO pellet mill is the simplest way to do it: the tractor supplies the power, so you need no engine or three-phase supply. This guide covers each step and how to match the mill to your tractor.
Why pellet your hay?
Pellets take less space than bales, are easier to measure and move, and leave less waste at the feeder. University of Georgia Extension lists hay pellets among the forage alternatives for horses when hay is limited, poor in quality or too expensive. Pelleting also lets you sell a product with more value than a bale, if you follow your state's feed rules.
The tradeoff is work and energy. Grinding and pressing take time, so pelleting pays best when you grow the hay yourself or can buy it cheaply.
What you need
Step | Machine |
|---|---|
Power | A tractor with enough PTO horsepower for the mill |
Grinding | |
Pressing | A PTO flat die pellet mill, or a rotating roller mill for stemmy or hard-to-bind hay |
Cooling | A screen for small batches, or a contraflow cooler for continuous runs |
Storage | Bags or bins in a dry place |
Match the mill to your tractor
Each PTO model lists the tractor power it needs. Check your tractor's PTO horsepower, not engine horsepower, against the product page. Prices at the time of writing, November 2026.
Model | Tractor power | Feed output | Price |
|---|---|---|---|
8 HP | Up to 264 lb/hr | $1,864 | |
See product page | Up to 440 lb/hr | $3,042 | |
22 HP | Up to 880 lb/hr | $3,853 | |
30 HP | 600 to 1,300 lb/hr | $5,377 | |
55 HP | Up to 2,420 lb/hr | $9,718 |
These outputs are for feed. Long-fiber forage usually runs slower, so leave margin when you size the mill. If you have no tractor, our feed pellet machine guide compares the electric models.
Step 1: Start with dry, clean hay
Use hay in good condition. Do not pellet moldy or heated hay, because pelleting does not make it safe to feed. Remove twine, net wrap, stones and any metal before grinding. A bolt or a piece of wire can damage the hammers and the die.
Step 2: Grind it
Hay has to be ground before a pellet mill can pack it. In a 2003 Saskatchewan study on alfalfa pellets, researchers ground alfalfa in a hammer mill through screens of 3.2 mm (1/8 inch) and 1.98 mm (5/64 inch).
For a farm line, start with a screen of about 3 mm and adjust by how the pellets come out. A small mill like the MKH158B hammer mill is rated for straw and other fibrous material.
Step 3: Adjust the moisture
Moisture is what makes the pellet hold together. In the Saskatchewan study, ground alfalfa was conditioned with steam to about 10 to 11% moisture before pelleting. Farm flat die mills have no steam conditioner and rely on friction heat, so the practical method is:
Start with hay in the dry condition used for baling.
Add water in small steps, mix, and test a few pounds at a time.
If pellets crumble, add a little more water or grind finer. If they come out soft and swollen, the mash is too wet.
Step 4: Press
Choose the die for the animal you feed:
Animal | Die hole |
|---|---|
Rabbits and small stock | 3 to 4 mm |
Sheep and goats | 6 mm |
Cattle and horses | 8 mm and up |
Our flat die mills ship with a 6 mm die, and optional dies run from 2.5 mm to 10 mm.
Feed the mill slowly at first. Light, fluffy forage can bridge in the hopper. Stems are the hardest part to bind: in the Saskatchewan study, pellets made from stems alone had low durability. If your hay is very stemmy, grind finer or consider a rotating roller mill, where the rollers are driven and press harder. Read how the R models differ.
Step 5: Cool, screen and store
Pellets leave the die hot and soft, and they harden as they cool. Spread small batches on a screen, screen out the fines and run them through the mill again. Store the pellets cool and dry, and use them within weeks rather than months.
Feeding hay pellets
Change any animal's forage gradually. Weigh pellets instead of measuring them by volume, because a scoop of pellets weighs far more than the same scoop of loose hay. For horses, ask your veterinarian how much pelleted forage to feed and whether to soak it.
Selling hay pellets
Pellets sold as feed are regulated by each state, often through product registration and labels. Check with your state feed control official before you sell. Our animal feed pellet guide lists the U.S. rules to know.
Watch it done
Frequently asked questions
Can I make pellets from grass hay too? Yes. Timothy, orchard grass and other grass hays pellet the same way as alfalfa. Grind them well, because grass stems are tough.
Do I need a binder? Often not, if the hay is ground finely and the moisture is right. Very stemmy hay is harder to bind.
How much can a PTO mill make? The MKFD200P is rated up to 440 lb/hr of feed. Long-fiber forage usually runs slower, so test your own hay.
Can I use the same mill for wood pellets? Yes, with a thorough cleanout between jobs. Flush the die with feed-grade material and discard that batch before you make feed again.
Need help sizing your line?
Tell us your tractor's PTO horsepower, the hay you have and how many tons you want to pellet, and we will help you match the mill and hammer mill. See what to prepare for a quote.
