Soybean Excellence Center SEC Feed Manufacturing Track Basic Level PDF

Soybean Excellence Center SEC Feed Manufacturing Track Basic Level Supported by: Statement on Intellectual Property The materials in this lecture fall under the protection of all intellectual property, copyright and trademark laws of the U.S. The digital materials included here come...

Soybean Excellence Center SEC Feed Manufacturing Track Basic Level Supported by: Statement on Intellectual Property The materials in this lecture fall under the protection of all intellectual property, copyright and trademark laws of the U.S. The digital materials included here come with the legal permissions of the copyright holders. These course materials should be used for educational purposes only; the videos should not be distributed electronically or otherwise beyond the confines of this online course. Any usage of the videos or course materials outside of USSEC’s SEC Digital Platform, should be previously authorized by USSEC, Kansas State University, and the lecture’s authors. Supported by: 2  Basic Feed Manufacturing Overview Part 1 Carlos Campabadal, PhD IGP Institute Department of Grain Science and Industry Kansas State University Supported by: 3 Learning Objectives Understand how feed manufacturing connects to the food value chain. Understand the basic feed manufacturing process. Supported by:  Introduction Production of animal and fish feed requires several important processing and quality control steps. Quality feed ingredients will produce quality feed. Each step-in feed manufacturing uses specific equipment in each of its processes. Supported by: Objective of Manufacturing Feed Fulfill nutritional-physiological requirements Competitive price ($/lb or $/kg feed) Profitable cost level ($/ lb or $/kg meat) Fulfill statutory demands Fulfill regulations Control, reduce or eliminate potential hazards associated with feed Supported by: Connection of Agriculture to the Human Food Chain Animal waste Feed additives Animal Nutrition Meat By-products Milk Food processing Feed Animal Eggs Plant breeding Miscellaneous Breeding & Crop production Feed storage animal products management Supported by:  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU Business Objectives in Feed Manufacturing Commercial feed mills –Sell feed for profit –Customer service Integrated feed mills –Delivery nutrients to animals for optimal performance or meat production –Low-cost high volume On-farm –Utilize grain grown on the farm to raise animals –Minimize feed input costs Supported by:  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU Feed Ingredients Cereal Grains: – Corn – Sorghum – Wheat – Barley Soft Stock: – SBM – Animal Protein (Fish Meal) – Calcium – Salt Supported by:  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU  Feed Ingredient Receiving Ingredient receiving in bag –Additives –Fish Meal, SBM Ingredient receiving in bulk or bags –Cereal, soft stocks Supported by: Source: Photos of Carlos Campabadal 13  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU Feed Ingredient Storage Storage –Cereal grains in metal and concrete silos –Soft Stocks in bags, hoppers or flat storage –Additives in bags Supported by: Source: Photos of Carlos Campabadal  This concludes Part 1 of Overview of Feed Manufacturing. Please continue with Part 2. Supported by: 16  Acknowlegement The development of this lecture was made possible through the funding from: U.S. Soybean Export Council (USSEC) The development of this lecture was made possible through support from: Dr. Carlos Campabadal International Grains Program (IGP) Institute of Kansas State University Supported by: Disclaimer This is a lecture intended for educational use and professional development. It is not intended nor does it necessarily represent enforceable standards, industry consensus, mandatory requirements, nor all possible solutions or ideas to resolve your safety and health needs. This course has been developed to share information on potential topics associated with animal nutrition and production. In most cases, there are many solutions or combinations of solutions to problems. Use only those sections that apply to your operation; but first evaluate each section and suggestion based on its economic and operational feasibility and application. Mention of trade names, commercial products or organizations does not imply or express endorsement by Kansas State University or USSEC, its members, employees, or cooperating companies and individuals. Supported by: Soybean Excellence Center SEC Feed Manufacturing Track Basic Level Supported by: Statement on Intellectual Property The materials in this lecture fall under the protection of all intellectual property, copyright and trademark laws of the U.S. The digital materials included here come with the legal permissions of the copyright holders. These course materials should be used for educational purposes only; the videos should not be distributed electronically or otherwise beyond the confines of this online course. Any usage of the videos or course materials outside of USSEC’s SEC Digital Platform, should be previously authorized by USSEC, Kansas State University, and the lecture’s authors. Supported by: 20  Basic Feed Manufacturing Overview Part 2 Carlos Campabadal, PhD IGP Institute Department of Grain Science and Industry Kansas State University Supported by: 21  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU  What is Grinding? Reduces particle size of feed ingredients (cereal grains) Increases nutrient absorption by the animal increasing digestibility Better mixing effect Increases pelleting and extrusion process efficiency Supported by:  Grain Grinding Supported by: Source: Diagrams from CPM Hammer Mills Contact Point "Flow Director" Primary Destruction Zone Full Hammer Tip Speed Impact Zone Acceleration Zone "Regrind Chamber" Attrition Supported by: Source: Diagrams from CPM Location of Hammers in Rotor Supported by: Source: Diagram from KSU and photo from Carlos Campabadal Roller Mills Supported by: Source: Diagrams from CPM  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU Batching and Weighting System Supported by: Source: Photo from KSU and Jaramillo, Colombia  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU  What is Mixing? Process to obtain maximum mixing of the feed ingredients (liquids and solids) No damage to ingredients Shortest possible mixing time Supported by: Source: Photo from KSU  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU What is Pelleting? It is the process of agglomerating ingredients into compress and dense pellets. It has the following advantages: –Less feed waste –Reduces animal selection of feed –Improves feed efficiency –Degrades some microorganisms –Increases density of the feed Supported by: Source: Diagrams from CPM  Feed Pellet Conditioning Entrance Objective of Conditioning: Add heat, moisture and mix ingredients Forward Neutral Backwards Feed Exit Fill Level Supported by: Source: Diagrams from KSU Roll and Die Supported by: Source: Photos from KSU  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU  Pellet Cooling Pellets come out hot, need to be cool down for proper storage. Usually cooling until 2°C above ambient temperature Uses ambient air Several types of cooling systems Measure pellet quality after cooling Supported by: Fuente: Fotos de KSU  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU Pellet Crumbling Rolls to reduce size of the pellets so small chickens can eat them. Sizes will depend on the chicken age. Supported by: Source: Diagrams from CPM 39  This concludes Part 2 of Overview of Feed Manufacturing. Please continue with Part 3. Supported by: 40  Acknowlegement The development of this lecture was made possible through the funding from: U.S. Soybean Export Council (USSEC) The development of this lecture was made possible through support from: Dr. Carlos Campabadal International Grains Program (IGP) Institute of Kansas State University Supported by: Disclaimer This is a lecture intended for educational use and professional development. It is not intended nor does it necessarily represent enforceable standards, industry consensus, mandatory requirements, nor all possible solutions or ideas to resolve your safety and health needs. This course has been developed to share information on potential topics associated with animal nutrition and production. In most cases, there are many solutions or combinations of solutions to problems. Use only those sections that apply to your operation; but first evaluate each section and suggestion based on its economic and operational feasibility and application. Mention of trade names, commercial products or organizations does not imply or express endorsement by Kansas State University or USSEC, its members, employees, or cooperating companies and individuals. Supported by: Soybean Excellence Center SEC Feed Manufacturing Track Basic Level Supported by: Statement on Intellectual Property The materials in this lecture fall under the protection of all intellectual property, copyright and trademark laws of the U.S. The digital materials included here come with the legal permissions of the copyright holders. These course materials should be used for educational purposes only; the videos should not be distributed electronically or otherwise beyond the confines of this online course. Any usage of the videos or course materials outside of USSEC’s SEC Digital Platform, should be previously authorized by USSEC, Kansas State University, and the lecture’s authors. Supported by: 44  Basic Feed Manufacturing Overview Part 3 Carlos Campabadal, PhD IGP Institute Department of Grain Science and Industry Kansas State University Supported by: 45  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU What is Extrusion? It is a continuous process where the feed ingredients are cook to form a plasticized shape by using temperature, pressure, mechanical force and, water. Its advantages: – Cooks the starches making feed more digestible – Can produce different shapes and forms – Sterilizes the feed ingredients with the high temperatures – Increases feed efficiency Supported by:  Extrusion Process Steam Lines Feeder Conditioner to Boiler to produce steam mix steam, water, and feed Barrels and screw (shorter length for producing FFSBM) Drying and cooling Product outlet Supported by: Source: www.Andritz.com and Carlos Campabadal  Animal Feed Manufacturing Soft Stock Cereal (SBM) Grains Receiving Storage Grinding Bulk/Bag Batching/Mixing Load Out Extrusion Pelleting Processes Processes Drying Cooling Cooling Crumbling Bulk/Bag Supported by: Load Out Source: Photo from KSU Bag and Bulk/Load Out Supported by: Source: Photos from KSU  Conclusions It is important to develop your feed manufacturing process based on your needs, logistics, and economical conditions. Feed mills can be developed as combination of manual and automatic systems when needed. Feed manufacturing processing is fairly simple and is the same to everybody, but all feed mills are different. Supported by:  This concludes the lecture of Overview of Feed Manufacturing. Please continue with the corresponding quiz. Supported by: 52 Thank you for your attention! Carlos Campabadal, PhD Email: [email protected] Phone: +1-217-721-1025 Supported by: 53  Acknowlegement The development of this lecture was made possible through the funding from: U.S. Soybean Export Council (USSEC) The development of this lecture was made possible through support from: Dr. Carlos Campabadal International Grains Program (IGP) Institute of Kansas State University Supported by: Disclaimer This is a lecture intended for educational use and professional development. It is not intended nor does it necessarily represent enforceable standards, industry consensus, mandatory requirements, nor all possible solutions or ideas to resolve your safety and health needs. This course has been developed to share information on potential topics associated with animal nutrition and production. In most cases, there are many solutions or combinations of solutions to problems. Use only those sections that apply to your operation; but first evaluate each section and suggestion based on its economic and operational feasibility and application. Mention of trade names, commercial products or organizations does not imply or express endorsement by Kansas State University or USSEC, its members, employees, or cooperating companies and individuals. Supported by: