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CHALLENGES IN FEED
MANUFACTURING IN THE
21st CENTURY
Food Safety and
Other implications
Keith Behnke
Kansas State University
Manhattan, Kansas
The Feed Manufacturing Industry
Is a Critical and Highly Visible
Part of the Food Industry
FOOD SAFETY AND RELATED
ISSUES
WILL BE THE DRIVING FORCE
FOR THE NEXT SEVERAL
DECADES
HOW WILL
FOOD SAFETY
IMPACT
FEED MANUFACTURING?
THE WAY WE DESIGN,
BUILD AND MANAGE
NEW FEED MILLS
WILL CHANGE!!
Answer 1.
HOW WILL
FOOD SAFETY
IMPACT
FEED MANUFACTURING?
Answer 2.
SOCIAL AND ECONOMIC
ISSUES, AS ALWAYS, WILL
CONTINUE TO DRIVE
CHANGE
Companies that avoid change and innovation
will not survive!!!!
FACTORS BRINGING ABOUT
CHANGE
Public Safety, Laws and
Regulations
* Food Safety-Microbiological
* Feed Additives/Growth Promotants
* Pesticide and Chemical residues
FACTORS BRINGING ABOUT
CHANGE
Microbiological Contamination
* Current U.S. Regulations on
Meat and Bone Meal use.
* Heat Sterilization Policies
of the EEC.
•HACCP Programs that will
include feedmills.
Microbiological
Contamination
Development of strategies to
reduce or eliminate microbiological
contamination.
*Chemical
*Thermal
*Radiation?
FACTORS BRINGING ABOUT
CHANGE
Environmental Concerns
* Air Pollution
*Water Pollution
*Animal waste Disposal
*Odor Control
HOW WILL
FOOD SAFETY
IMPACT
FEED MANUFACTURING?
ANSWER 3.
Process Control and Automation
Will become part of HACCP
Programs.
* Complex Process-e.g. Expanders
* Labor Replaced by Automation
* Feed Quality/Consistency
* Information Management
HOW WILL
FOOD SAFETY
IMPACT
FEED MANUFACTURING?
ANSWER 4.
CONSUMMER POWER
AND
ACTIVISM.
PERCEPTION OFTEN BECOMES
REALITY!!
If we are perceived to be part of the problem,
we are part of the problem.
“We live in an age where
CONSUMER POWER
frequently outweighs
SCIENTIFIC PERSUASION”.
Feedstuffs 72:3, 1999
THE FUTURE!
“The Future Ain’t What It Used To Be” Yogi B.
FACTORS BRINGING ABOUT
CHANGE
Feed Industry Structure
* New Equipment Availability
* Mergers, Acquisitions and Divestments
* International Ownership
* Marketing Structure
* Vertical Integration
FOOD SAFETY ISSUES
INGREDIENTS
Current Global Population of 6.0 Billion
“87 Million People Added Annually”
“Conventional technology alone will not
allow food, feed, and fiber production
to be increased sufficiently to meet the
needs of the 10 billion global
population of the 21st century”
Biotechnology is the only Significant
Means to Increase Food, Feed, and
Fiber Production
Currently 5 billion tons of food is produced
annually.
30% (1.5 billion tons) is lost to pests
Loss of cultivable land (0.44 ha/capita in
1961; only 0.26 ha in 1997).
Number of Transgenic Crop Field
Trial Sites in the USA
1987-1997
44%
4%1%11%3%
11%
4%2%
8%
12%
Corn
Sugar beat
Tomato
Cotton Canola
Melon/squash
Potato
Others Soybean
FOOD SAFETY ISSUES
INGREDIENTS
Genetically Modified Organisms (GMO’s)
Must be Identity Preserved
May Have 4 to 6 GMO’s Plus Commodity
Grains in a Single Feed Mill
Bin Space, Grinding, Inventory, and QA?
DO TRANSGENIC CROPS
PRESENT A FOOD SAFETY
CONCERN?
PERCEPTION BECOMES
REALITY!!
FOOD SAFETY ISSUES
RECEIVING AND STORAGE
High-Speed Unloading
Ingredient Segregation
Inbound Analysis and QC QUICK MICROBOILOGICAL
TESTS ARE BECOMING
AVAILABLE
High Speed Infrared Instrument
FOOD SAFETY ISSUES
Proportioning Systems
* On-line Reformulation
* Weighing Accuracy
Loss-in-Weight Systems
* Short Cycle Batching
1.0-1.5 Min. Cycles
FOOD SAFETY ISSUES
Mixing and Mixing Equipment
* Trend is Toward Large
(12-16 Ton) Mixers.
Concern with Uniformity!
* Smaller, Short-Cycle Mixers
-1.0 to 1.5 Min.Mixing Cycles
-High Flexibility
IMPROVED RIBBON DESIGN
H&S
TR Mixer
Pelleting?
FOOD SAFETY ISSUES
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
Pelleting Will Not Go
Away!!!
FOOD SAFETY ISSUES
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
Is the pelleting system an
asset or liability in
microbiological control??
FOOD SAFETY ISSUES
PELLETING-CONDITIONING
Conditioning Time Control for
pellet quality and microbial
control
-Variable Shaft Speed
-Pick Angle Control
-Steam Block Panels
-Conditioner Angle
FOOD SAFETY ISSUES
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
On-Line Moisture Control
“MOISTURE MANAGEMENT”
FOOD SAFETY ISSUES
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
EXPANDERS
FOOD SAFETY ISSUES
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
Compactors
FOOD SAFETY ISSUES
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
UNIVERSAL PELLET COOKER
The “UPC”
from
Wenger Manufacturing
FOOD SAFETY ISSUES
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
Pressure Pelleting
PRESSURIZED CONDITIONING PCI, Inc. Wichita, Ks.
Coolers are often a
significant source of
microbiological contamination!
FOOD SAFETY ISSUES
COOLERS AND COOLER DESIGN
FOOD SAFETY ISSUES
COOLERS AND COOLER DESIGN
Counter Flow Coolers
Are Here To Stay!
FOOD SAFETY ISSUES
COOLERS AND COOLER DESIGN
Future Designs Will
Include Drying Capability
FOOD SAFETY ISSUES
Post Pellet Additive Application
*Low Inclusion Liquids
-Enzymes
-Drugs
-Vitamins
-Biologicals
-Antimicrobiological agents
FOOD SAFETY ISSUES
Load Out System Design
Designed to maintain
the cleanest feed possible
SUMMARY (ADVICE!!)
Stay Informed!!!
* Consider the Economics
* Consider the Alternatives
*Make Logical, Rational Decisions
*Watch Related Developments
Recommended