3-3 Thr - Keith Behnke - Feed Milling Milestones - ANC 2010

8/18/2019 3-3 Thr - Keith Behnke - Feed Milling Milestones - ANC 2010

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Future Advances

Where did we come from

Where are we going???

Keith Behnke

Kansas State Universityan a an, ansas

THE FUTURE!

“The Future Ain’t What It Used To Be” Yogi B.


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THE FEED INDUSTRY

A Brief Histor

FEEDING STANDARDS

1864 German Chemist Emil Wolff published first

Feeding Standards based on Digestible Nutrients.

1898 FEEDS AND FEEDING First Addition

1912 Vitamins (“Vital Amines”) first discovered

1944 NRC/NAS published first series of feeding

s an ar s or commerc a ves oc an pou ry.


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EVOLUTION OF THE

FEED INDUSTRY

Early 1800’sorses an mu es prov e ra wor

– Oats and other grains provided by livery

stables

– Little science available regarding nutrition

* Calf feed for dairy farms was needed.

EVOLUTION OF THEFEED INDUSTRY

• 1866 H.K. Webster, Lawrence, Mass-Horse Feed

• 1875 Blatchfords Wauke en Il. Calf Feed

• 1879 O. A. Cooper

• 1885 Mooreman Manuf.• 1894 Ralston Purina (Robinson-Danforth, St. Louis)

• 1895 Albers Milling (Carnation, Co.-1929)

• 1920 Nutrena Mills (Cargill, Inc.)


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• 1850 Molasses first used in horse and cattle feed

• 1885 Cotton Seed Meal

• 1888 Corn gluten feed and meal

• one mea

• 1903 Dried beet pulp introduced

• 1910 Dried buttermilk

• 1915 Soybean cake imported from Asia for feed

• 1922 First U.S. soybean meal

• 1943 Urea used as NPN source for ruminant diets

• 1954 Animal fat first used in poultry diets

•

• 1848 Cotton bags replaced wooden barrels

• 1886 Jute imported from India for bags

• 1895 Hammermill patent issued

• 1909 Horizontal batch mixer-S. Howes Co.

• 1924 High molasses pelletmill

• 1931 CPM introduced the first steel die- flat bed

•

• 1942 First Bulk Truck developed

• 1948 Paper bags first used for feed

• 1950 Horizontal ellet cooler-Wen er Manuf.

• 1955 First “punch-card” batching system introduced

• 1957 Drop-bottom mixer

• 1962 Pellet Durability Tester developed-Pfost, KSU


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Late 1800’s to 1950’s

• Increased growth in new firms entering the

feed industry

• New in redients were bein introduced to the

market place

• The nutritional value of co-products wereecom ng recogn ze

1960’s to 1980’s

• Livestock production was growing at a pace

.

• New livestock buildings were being built.

• Feed manufactures were making good profits


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1960’s to 1980’s

• The feed industry was growing by leaps and

• New feed mills were going up in every state

• ngre ent p ants were e ng u t to meet t e

needs of the feed industry

• Existing Feed mills were being expanded

1980’s to 2000’s

• The livestock industry reached a pointmeetin the demand of customers.

• Chan in Livestock/Poultr Production – Number of U.S. Farms

• 1950: 5.6 million

• Today:


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Structure of the Feed Industry

Changing Livestock/Poultry ProductionChanging Livestock/Poultry Production

1980’s to 2000’s

SpeciesGrou Number Producers1 50 Toda

PoultryPoultry Vertical integrationVertical integrationunderwayunderway

Virtually 100Virtually 100

percent integratedpercent integrated

SwineSwine 3.0 million3.0 million 65,00065,000

Beef/CowBeef/Cow 2.8 million2.8 million 971,000971,000

Source: USDA/NASSSource: USDA/NASS

a rya ry . m on. m on ,,

• Some Impacts of Livestock and Poultry

n egra on onso a on, s- o ay:

– Livestock and poultry producers became major

ee manu ac urers

• Construction of large feed mills to produce complete

feed – 500 000+ tons er ear

• Mills located to optimize logistical issues; ingredient

procurement, finished feed transportation

• Mills designs are extremely efficient, targeted for

minimal number of feed formulations


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1980’s to 2000’s

• The feed industry matured

the demand.

• e ee n ustry eg n to conso ate

• Small town feed mills were replaced by

regional mills

140

100

120

n s n s

60

80

l l

i o n T

l l

i o n T

20

40 M i M i

0

1 9 1 9 1 9 1 9 2 0 2 0 2 0 3 5 7 9 1 3 5

Source: Feedstuff sSource: Feedstuff s


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U.S. Feed Production b S ecies

Layers 6%Layers 6%

25%25%Horse 2%Horse 2%

Dairy 17%Dairy 17%

OtherOther

(pet, etc.)(pet, etc.) Aquaculture 1% Aquaculture 1%a ea e3%3%

Source: informa economicsSource: informa economics

Feed Mill Operations – ChangingTimes

.

FDA:

- amen e to a ress

animal drugs

- rs

AAFCO: 1957 - established model state feed bill

-

OSHA - established in 1971


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Feed Mill Operations –

ang ng mes• EPA: Growth of Federal Environmental Regulations

1820

14

16

P a g e s

P a g e s

8

10

s a n d s o f

s a n d s o f

2

4 T h o

T h o

7 2 7 4 7 6 7 8 8 0 8 2 8 4 8 6 8 8 9 0 9 2 9 4 9 6 ' 0 0 ' 0 2

' 0 4 ' 0 6


• OSHA: Examples of Required TrainingExamples of Required Training

• Bin Entry• Bloodborne Pathogens• Com an Vehicles

• Manlifts• Lockout and Tagout• Personal Protective

• Confine Space• Electrical Work Practices

• Emergency Action

Equipment

• Pesticide Application• Emergency

• xposure o as es os, ea ,other chemicals asappropriate

• Fall Protection Equipment

• Respiratory Protection• Truck Dumper Operation• Rail Operations Safety

• First Aid• Employee Orientation• Use of Fire Extinguishers

• Welding/Cutting/ Hotwork• Grain Handling Equipment• Planned Maintenance

• • Front-end Loader/Bobcat• Hazard Communication

• • Storage and handling of LP

Gases


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ang ng mes2. Growing Emphasis on Feed Safety

Increasing Demands by Consuming Public

Removed from farming and animal production practices

Declining personal responsibility

September 11, 2001

Bioterrorism Response and Preparedness Act of 2002

USDA, FDA, DHS, FBI Strategic Partnership Program

Agroterrorism (SPPA) Initiative

Impacts on the Mill:

Increased interest in HACCPncrease emp as s on ac y secur y ssues

Feed Mill Operations – ang ng mes

.

Renewable Fuels Mandate - Energy Policy

7.5 billion gallons by 2012

121 existing biorefineries: 6.332 billion

allons

84 under construction/expansion: 6.245

billion gallons

Source: Renewable Fuels Assoc iationSource: Renewable Fuels Assoc iation


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The Impact of BiofuelsDistiller’s Dried Grains wi thDistiller’s Dried Grains wi th

Solubles (DDGS) ProductionSolubles (DDGS) Production

28

32

T o n

s

T o n

s

20

24

0 S h o r t

0 S h o r t

8

12

1 , 0

0 0 , 0

1 , 0

0 0 , 0

0

4

8 0 8 5 9 0 9 5 0 0 0 3 0 5 0 6 0 7 0 8 0 9 1 0

Sources: USDA; The ProExporter Network®, 2007Sources: USDA; The ProExporter Network®, 2007-- 2010 Projected2010 Projected

THE FUTURE:

It’s all about food safety!!


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to

Chan e???

or some o us n

August 16, 1977


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August 16, 1977

The day ELVIS died!!

or mos :

September 11, 2001

The day terrorists attacked the

World Trade Center


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u , or e

ee n us ry:

Late Fall, 1987

For the World

Late Fall, 1987

The first confirmed case of BSE on

,


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SEQUENCE OF EVENTS

1987: BSE Confirmed in England

1990: “European Beef Scare” began in earnest-Lots of

media hype. Beef consumption dived.

SEQUENCE OF EVENTS


1990: “European Beef Scare” began in earnest.

1996: British government stated that: “contaminated beef”

was t e e y cause o t e nv reutz e - aco

disease attacking younger people. Death toll


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SEQUENCE OF EVENTS



1996: “Contaminated beef” caused “nv CJD”: . . react on - mp emente regu at ons

designed to prevent the use of ruminant protein

.

The regulations were to serve two purposes

1. Sto the otential s read of BSE

2. Maintain confidence in the U.S. meat

supply

SEQUENCE OF EVENTS



1996: “Contaminated beef” caused “nv CJD”

: . . react on - mp ement rum nant

protein regulations

case of BSE in the U.S.


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SEQUENCE OF EVENTS

December 23,2003, 5:30pm Eastern time:

F rst con rme case o BSE n t e U.S. announce

Secretar of A riculture

Ann Veneman

SEQUENCE OF EVENTS

December 23,2003, 5:00pm Eastern time:

rst con rme case o BSE n t e U.S.

- It was the evening before Christmas Eve Day

-

-Futures trading was going to stop at noon, Dec 24

Secretary of Agriculture

Ann Veneman


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SEQUENCE OF EVENTS

First confirmed case of BSE in the U.S (2002).

What Happened?

SEQUENCE OF EVENTSFirst confirmed case of BSE in the U.S(2002).

a appene

Domestically-Not much, really!

-Live beef prices took a hit for a few months.

-Beef consumptions stayed essentially level.


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What Happened?

Domestically-Not much, really!

Why?

Consumer Confidence!!

In the U.S., citizens actually trust FDA!!

SEQUENCE OF EVENTS

First confirmed case of BSE in the U.S(2002).

What Happened Internationally?

-Beef Exports decreased

-U.S. Ex orts Banned b several countries


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a s e o n o a s

at s t e o nt

fact that the FEED industry is a critically

.


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a s e o n o a s

e ongo ng ssue roug t ome t e

fact that the FEED industry is a criticallympor an par o e n us ry.

WE MUST ACCEPT THAT

REALIZE HOW IMPORTANT

.

The biggest issue that animal

agriculture will face in the future?

FOOD SAFETY


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“

requent y outwe g s

SCIENTIFIC PERSUASION”.

Feedstuffs 72:3, 1999

The Future

What else is coming??


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The Future of Biotech

Ingredients

Designer Grains/Oilseeds

- “ ”

grains/oilseeds.

-concerning phosphorus buildup in soils.

FEED MILL DESIGN-

The evolution of mill design


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PELLETING

HACCP

Microbial Control in Feed Mills

e as tr e or years to raw

a line from the feed mill to the dinner

p ate o ar, w t tt e success.


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THERMAL PROCESSING

Temp Number EntrobacteriaºC Samples Log10 CFU/gm


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On-Line Reformulation

possible to reformulate rations in real time.

• Nutrient overage would be cut to near zero

•

• Ingredient changes more easily managed.

SUMARY

•The Feed Industry has come a long way in 150 years.

•Food safety is the most important issue

to be dealt with by the feed industry.

•Perception becomes reality. If we are perceived

as bein art of the roblem we are.

•Respond quickly and openly to any challenge

•Technology (Bio Ingredients) will be here soon


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“Some eo le look at the wa thin are and ask WHY? I would rather look at the way things

could be and ask WHY NOT?”- George Bernard

Shaw

THANK YOU

Documents

3-3 Thr - Keith Behnke - Feed Milling Milestones - ANC 2010