Animal Feed Production Technology - EGAS MONIZ SCHOOL PDF

Animal feed production technology Feed quality and safety Sustainability and innovation in feed production CU: Animal feeding Daniel Murta, DVM, PhD Carolina Ligeiro, DVM www.egasmoniz.com/pt www.egasmoniz.com/pt...

Animal feed production technology Feed quality and safety Sustainability and innovation in feed production CU: Animal feeding Daniel Murta, DVM, PhD Carolina Ligeiro, DVM www.egasmoniz.com/pt www.egasmoniz.com/pt Index Animal feed production technology Feed quality and safety Sustainability and innovation in feed production - Master’s Degree in Veterinary Medicine 2 www.egasmoniz.com/pt Animal feed production technology - Master’s Degree in Veterinary Medicine 1. Contextualization 2. Feed classification 3. Feed processing 4. Animal Feed Industry  Animal feed production technology Contextualization www.egasmoniz.com/pt Feed is of high economic importance, as it has a very large weight in the budget of a farm. In case of a sheep farm this amounts to 55% of all costs and 80% in an aviary - Master’s Degree in Veterinary Medicine Feed quality is extremely important and varies according to: Variety (different nutrition sources) Soil Climate Handling Preservation Storage 4  Animal feed production technology Contextualization www.egasmoniz.com/pt Feed assessment is divides into: Chemical – nutritional composition; Sensory – idea of the hygienic quality of food, taste, texture, odor…; - Master’s Degree in Veterinary Medicine Response from the animal: FCI – Feed Conversion Index – indicates the amount of food required for the animal to gain 1kg of liveweight – FCI = 10kg – for every 10kg of food ingested, the animals gains 1kg of liveweight ADG – Average Daily Gain Cost analysis – according to energy units (€/kcal) 5  Master’s Degree in Veterinary Medicine - www.egasmoniz.com/pt Feed classification Animal feed production technology 6  Animal feed production technology Feed classification www.egasmoniz.com/pt Feed is classified as: Dry forages (e.g., dried pasture, leaves, stems, green chop, and hay) and Roughages (e.g., hay, straws, and hulls with >18% crude fiber); Green pasture, range plants, and freshly fed green forages (e.g., forage feeds); Silages (e.g., ensiled corn, alfalfa, and grass); - Energy feeds (e.g., corn, wheat, barley, and rice); and Protein feeds (e.g., soybean meal, meat and bone meal, blood meal, poultry meal, fish meal, and milk Master’s Degree in Veterinary Medicine replacer). Also, may be included to feeds: synthetic amino acids, mineral supplements, vitamin supplements, other additives (e.g., antibiotics, coloring materials, flavors, phytochemicals, hormones, and medicines) ….to prepare complete diets for animals 7  Animal feed production technology Feed processing www.egasmoniz.com/pt An animal feed is processed to enable it to alter its physical, chemical, microbiological and organoleptic properties, thereby also improving its digestibility - Processing techniques may Master’s Degree in Veterinary Medicine Enhance nutritional characteristics; Extend preservation; Detoxify; Increase consumption; Improve feed manipulation. 8  Animal feed production technology Feed processing www.egasmoniz.com/pt Simple – no concentrate feeds Forage for ruminants Physical treatments Winding and baling; - Crushing; Milling; Master’s Degree in Veterinary Medicine Graining; UV and ozone (microbiological control). Chemical treatments (alkali agents capable of lignin destruction making feed more digestible) Urea is added into the bottom of the bale and urease (enzymes) for NH3 gradual release; NaOH – if liquid, is more difficult to use due to chemical hazards (burns); NH3 – as gas and easy to use; some of it is used by m.o., some remains in the forage and the last quantity is released in a controlled manner. Biological treatments (extend preservation time) Microorganisms; Enzymes 9  Animal feed production technology Feed processing www.egasmoniz.com/pt Simple – no concentrate feeds Hay Preparation of hay: Cutting; Conditioning; - Drying; Turning; Master’s Degree in Veterinary Medicine Baling; Collection and Storage that depends on: forage characteristics; cutting season; climatic conditions; additives Hay quality evaluation Nutrient losses during hay making: Balance moisture: Relative humidity (%) Hay moisture (%) Field losses: 5 -15%; 95 35 Respiration: 5 -15%; 90 30 Over exposure to the sun: 5 -15%; 80 21.5 Fermentation: 5 -10%; 77 20 Leaching: 0 -10%; Manipulation: 0 -5%; 70 16 60 12.5 10  Animal feed production technology Feed processing www.egasmoniz.com/pt Simple – concentrate feeds Physical Cold Treatments of Cereals Dry: Milling/ grinding Friction; - Hammer mill (percussion mill); Mill of dishes or discs (stone and steel mill). Master’s Degree in Veterinary Medicine Fragmentation (very coarse grinding); Roller crushing (e.g., cornflakes); Pressure crushing (less used). Moist Maceration (only wetting); Germination: changes its characteristics (e.g., beer dry wort); Enzyme addition (e.g., yeasts are added in brewing process). 11  Animal feed production technology Feed processing www.egasmoniz.com/pt Simple – concentrate feeds Physical Hot Treatments of Cereals Dry: Bursting: makes the food more desirable, widely used in rations for chicks and piglets (e.g.,popcorn); - Extrusion: heat and pressure treatment, allowing raw material sterilization; Granulation: the goal is formation of granules; Master’s Degree in Veterinary Medicine Micronization: treatment of cereals or protein grains with radiation that lead to the destruction of food molecular bonds, increasing its digestibility. Moist: Expansion: fast heating at high pressure, the volume of the food is even greater than in bursting, there is an increase in digestibility but a decrease in density; Granulation: crumbs – can be dry, but is more used with water vapor having a cooking effect and leading to partial destruction of microorganisms; Floculation: fragmentation followed by maceration with water vapor, and then the crumbled wet grains are passed between rolls to acquire the form of flakes. 12  Animal feed production technology Animal Feed Industry www.egasmoniz.com/pt The feed industry developed after World War II, during a period of population growth and increased food requirements; During the War, there was technology development (machinery) that were further used for food production (e.g., tank factories have started producing - tractors; war industry has started producing ammonia-based fertilizers); Master’s Degree in Veterinary Medicine Simple industry from a technological point of view, but requires robust machinery; Industry with low added value (low profit) which led to its integration, mainly downstream, with other economic activities (their by-products are raw materials for feed industry) 13  Animal feed production technology Animal Feed Industry www.egasmoniz.com/pt Key operations of feed industry (composite feed): 1. Dosing: it is necessary that all nutrients are present in the correct proportions; 2. Milling/Grinding: allows the increase of food digestibility and a greater mixture - homogeneity; 3. Mixing: to obtain the most homogeneous food possible, thus ensuring the Master’s Degree in Veterinary Medicine intake of all nutrients; The food consumed daily by animals must convey the amount of nutrients needed, especially when they are developing animals, which need to have all the necessary nutrients balanced in the little amount of food they ingest per day (e.g.,chicks ingest about 2-3 g of food/day and require 50 nutrients in that portion...) 14  Animal feed production technology Animal Feed Industry www.egasmoniz.com/pt Objectives: To prepare homogeneous mixtures of raw materials in balanced proportions to meet the total or partial needs of domestic animals. This industry fabricates complete and/or complementary composite feeds: - Complete – meet all animal requirements; Master’s Degree in Veterinary Medicine Complementary – fill gaps in the basic-feeds, by completing them in a balanced manner (e.g., minerals, molasses). Minerals Ca provided as calcium carbonate, calcium oxide and dicalcium phosphate; P as dicalcium phosphate; Mg as magnesium oxide and magnesium sulfate 15  Animal feed production technology Animal Feed Industry www.egasmoniz.com/pt Storage in silos; - Milling; Mixing; Master’s Degree in Veterinary Medicine Weighing; Palletisation; Packaging/ bulk; Storage and expedition 16  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Raw materials reception Raw materials are usually exported to the countries where will be used; Long transportation time (usually several producers in the same lot: the raw material is acquired and sold along its route); Chemical analysis are required: often performed 4 to 5 days before the destination arrival of the - ship; Food inspection is legally performed before client delivery; Master’s Degree in Veterinary Medicine After the ship docks, the raw materials are transported by trucks or tank trucks that transport them to feed production plants; Bulk (e.g., cereals, molasses, fats, pomaces, …) Bags/ packages (e.g., corn gluten, salt, mineral correctors (CaPO4, CaCO3), premixes (minerals and vitamins)) Boxes (e.g., vitamins, antibiotics, pigments) 17  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Raw materials reception At feed industry arrival, a new sampling is performed to be analysed, and its quality be confirmed – only then the payment is concretized. - Weighing of the truck; Master’s Degree in Veterinary Medicine Raw material cleaning, if applicable, through taring and magnetic separators; 18  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Raw materials storage Specific for fats Double wall containers for temperature and oxygen control, - to keep fat at liquid state and Master’s Degree in Veterinary Medicine avoid oxydation Over-elevated (possibility of using the gravity factor in our favor) 19 On the ground  Animal feed production technology Animal Feed Industry - Layouts www.egasmoniz.com/pt Same size particles: Mixture of all raw material for - manufacturing feed Master’s Degree in Veterinary Medicine dosing each raw material for manufacturing feed Virtual storage: Product is disposed quickly flour, granules or crumbs Milling after Mixing is more effective (e.g., oats cannot grind well in hammer mills because of its low density, so another cereal or friction should be added) - allows 20 more homogenized mixture.  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt - Master’s Degree in Veterinary Medicine 21  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt - Master’s Degree in Veterinary Medicine 22  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Transportation during processing - horizontal - Master’s Degree in Veterinary Medicine Screw conveyor system Conveyor belts remove raw materials mainly used for transporting closed bags/ boxes From silos (cannot be used vertically) Endless chain system (finished product moved through shovels associated with chains) 23 can be oblique as well as horizontal  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Transportation during processing – vertical - Master’s Degree in Veterinary Medicine Transportation during process can Vertical conveyor system also be oblique: Intermediate Vertical conveyor system (system of between vertical and horizontal wheels and buckets) -allow to lift the food 24  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Raw materials dosing Manual Used for small quantities of feed formulation; Calibrated scales should be used to avoid measurement errors; - Imprecise method – periodic recalibration needed Master’s Degree in Veterinary Medicine Automatic Controlled by computer Scales with a capacity of 1000 to 5000 kg – dose raw materials before mixing; Scales with a capacity of 50 to 100kg – weighing before packing. Some dosing systems might round off the dosages and, in the end, adjust the final weight with the raw material used in greater quantity (if system default),which is an error and can cause nutritional problems for the animals. 25  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Milling Milling (or grinding) is the fundamental operation in the manufacturing process of composite feeds – SIZE REDUCTION. - Advantages: Master’s Degree in Veterinary Medicine Ground product is easier to mix; Risk reduction of segregation (separation by density and weight); Increase of the specific surface of the food: better digestibility; Better pellets consistency if raw materials have lower granulometry. 26  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Milling There are several mills but the most effective for denser and heavier raw materials are the Hammermills (large and heavy steel plates). - Horizontal cylindrical chamber, lined with a toughened steel Master’s Degree in Veterinary Medicine breaker plate; Food is disintegrated mainly by impact forces as the hammers drive it against the breaker plate. Mill sieve controls the desired granulometry – pre calibration of desirable size; Are easily worn when there is contamination of sands in the food (e.g., as beetroot or cassava) – hence the need for a prior selection/cleaning of the food Hammer mill 27  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Milling When the raw materials are light and moist, the grinding efficiency is lower. In this case: - Should be used roller mills or friction mills; Master’s Degree in Veterinary Medicine Moist raw materials must be premixed with denser and drier ones to avoid the need for 2 types of mills (and increase production efficiency) (e.g., grinding corn and oats together). Roller mill 28  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Milling Cylinders with magnet to remove metal products (needles, nails, etc.) from food. Damage/ shatter machinery; - can cause serious sequels in animals! Master’s Degree in Veterinary Medicine Separator sieve Used to separate sands, wire, food, … 29  Animal feed production technology Animal Feed Industry – Fabrication steps www.egasmoniz.com/pt Mixing The purpose of mixing is to associate raw materials ensuring the final product homogeneity. The mixture is easier when the specific size and weight of the particles are similar; - The addition of liquid products (molasses and fats) facilitates homogenization prevents Master’s Degree in Veterinary Medicine or delays “demixing”/disintegration (after a certain time, may occur the separation of the mixture compounds) and the segregation of food; Increasing amounts of micronutrients should be previously mixed (premix) to ensure the good distribution of these throughout the food (e.g. it is initially mixed in hundreds of grams, passing to kilograms, and only then the product resulting from these premixtures, mixed with the total base food); The production capacity of a feed factory is limited by the capacity of the mixer; The optimum mixing time should be determined (coefficient of variation, CV