Paper 17 - Mr Stefan Vontobel

AFMA 2010 developments in feed processing | Stefan Vontobel | 20101 | © Bühler |

Most recent

developments in

feed processing

Stefan VontobelBühler / Switzerland


Topics

� World meat demand and feed production

� Changes in feed processing – safe feed, safe food

� Thermal process – meal and pelleting

� Pellet quality – energy efficiency


0 10 20 30 40 50 60 70 80 90 100 110 120 130

North America

Developed World

Latin America

World

Developing World

Asia

Africa

Kg/Person/YearSource: United Nations

World situation on meat consumption and production

Per-capita meat consumption

0

20

40

60

80

100

120

140

05 06 07 08 09 10 05 06 07 08 09 10 05 06 07 08 09 10

Source: USDA Livestock & Poultry, World Markets and Trade October 2009

Meat production in Mio T.

Beef & VealCAGR 2005-10

of 0.7%

PorkCAGR 2005-10

of 1.61% BroilerCAGR 2005-10

of 3.16%


Canada

Russia

8%

4%

3%

3%

3%

2%2%

17%22%

21%

15%EU-25

China

US

Mexico

Japan

Brazil

India

Korea

Other

2008: 700 Million Tonnes

Source: IFIF

World Feed Production by Country 2004 vs.2008

7%

4%

4%

3%

2%2%1%

20% 24%

23%

10%

Canada

Russia

China

US

Mexico

Japan

BrazilEU-25

India

Korea

Other

2004: 634 Million Tonnes


Industrial Compound Feed ProductionMiddle East, Africa 2008

2%

5%

3%

2%3%2%

10%

10%

19%

19%

25%

Saudi Arabia

Egypt

South Africa

Iran

Israel

Morocco

Algeria

Tunisia

Nigeria

Zimbabwe

Jordan

7.3

5.5

5.3

2.9

2.8

1.3

1

0.8

0.7

0.5

0.5

0 1 2 3 4 5 6 7 8 9 10

Jordan

Zimbabwe

Nigeria

Tunisia

Algeria

Morocco

Israel

Iran

South Africa

Egypt

Saudi Arabia

Middle East, Africa Industrial Feed Production 2008

� Compound feed Middle East, Africa: Middle East & Africa represents 4.1% of the global compound feed production. Saudi Arabia is the leader with 7.3 mmt of feed production.

� 2.8% growth for Middle East, African Region 2008 over 2007.

Source: Lenz Analysis based on Feed International

154.5

mmt


Factors Affecting Future Production of Compound Feed

• Continuous quality of the

final products

• Price of feed ingredients

• Meat consumption

• Beef production

• Poultry production

• Pig production

Factors Affecting Feed

Production

Factors Affecting Feed

Production Impact for MillersImpact for Millers

• Increasing requirements i.e. EU safety

• Volatile prices �� difficult to hedge against

volatility

• Total meat consumption forecast up in 2010

• Beef production down 1% in 2010 over 2009

• Poultry production up 3% 2010 over 2009

• Pork production up 2% 2010 over 2009

� Despite many hindering factors, such as expensive feed ingredients, disease outbreaks and recession, world feed production continued to grow every year 1999-2009 with a CAGR of 1.75%.

� In 2009 certain regions had negative feed production growth, such as the US and Europe, while other regions, such as Asia, contributed to world feed production growth.


Modern feed plant – change of process with hygienizing

Today and FuturePast

feed plant feed plant

Intake and cleaning

Weighing

Grinding & Mixing

Bagging / Bulk Loadout

Pelleting

Intake and cleaning

Weighing

Grinding & Mixing

Bagging / Bulk Loadout

Hygienizing

Pelleting

Thermal meal

treatment

past today

Retention time [sec.] 10 - 15 max. 240


Aspects for the production of hygienized feed

Feed plant design / concept

� Storage: design & sizing of bins

� Transport: short distance between process

steps

� Production criteria; observe quality

management by following GMP+

� Risk reduction: assessment and

monitoring of risky area and defining

measures according to HACCP

Process lines

� Define process parameters

(temperature & retention time)

� Heating and drying of process steps

prior and after production lots to avoid

condensation / re-contamination

Machines / apparatus

� Hygienic design

� Materials: stainless

steel at critical spots

� Regular cleaning


Hygienizing with steam – what happens to bacteria

Success factors for hygienising:

� Use over-heated steam

� Steam should condensate onto the feed particles

� Knowledge of the initial bacterial count of the raw material

� Define: hygienizing temperature and retention time

� Choose hygienizing systems with a low retention time distribution

0 50 100 150

100‘000

0

bacterial count in cfu/g

Retention time at constant temperature in sec

Increased

temperature

75° C

85° C


What’s important - retention time distribution of

continues systems

long term conditioning

inefficient long term conditioning systems: the retention time distribution can attain 2 min

Optimum flow

FIRST IN – FIRST OUT is only possible in theory

HYTHERM

Very narrow retention time distribution (5 - 10 sec)HYTHERM

HYMIX

HYTHERM

HYTHERM


Effects of hygienizing with steam on the animal feed

Main effects:

� Reduction of micro-organisms (bacteria, mould, yeast)

but also mites, beatles etc.

� Elimination of pathogenic micro-organisms: such as

salmonella, moulds etc.

� Increase of the feed value

� Contribution to a better animal health

� Lower animal mortality

� Reduction of medication use

Side effects:

� Modification of the feed structure of thermal treated

mash, e.g. aggregation, improvement of palatability /

toasting effect (swine), dust reduction

� Degradation of thermo-sensitive substances as

enzymes and vitamins.


How to avoid re-contamination after the

hygienization

� Sufficient cooling and drying of moist product

� Regular cleaning of critical assessed areas of

machines / plant according e.g. HACCP scheme

� Insulation of critical parts (avoid condensation)

� Use spot filters at the specific machines instead of

collecting all aspirating pipes to one filter / cyclone

� Transport

� Short transport distances (vertical process line)

� Dead spots reduced, self-cleaning elements

� Use of pneumatic transports

� Gravity flow with steep spouts (>60°)

� Storage

� Design of the bins

� Short storage time

� Ensure mass flow with the bins.funnel flowrat holing mass flow


Thermal meal treatment – The new generation for the

production of hygienic swine feed

Feature of the new system

� Safe and reliable hygienization process

through HYMIX and HYTHERM

� Very high sanitation standard by the use of

“self-cleaning” pneumatic drying and cooling

stages

� Low manual maintenance and cleaning work

required

� High production flexibility, fast change of

recipes, increase of plant availability

� Can be integrated into existing buildings

HYMIX

HYTHERM


New thermal meal treatment: The product

Raw material: piglet feed

Piglet feed, thermally treated, 85°C, 120 sec

Characteristics of swine feed through thermal treatment

� Significant reduction of bacterial count → better animal health + performance

� Improved flowability

� Less dust / better stable climate

� Improved water solubility and generation of a very homogeneous mash

� Improvement of palatability

� Less diarrheas / higher cleanness within the stables


Discharge

elements

Pellet screen

Feeder

Conditioner

Retentioner

Pellet mill

Cooler

Crumbler

Holding bins

Aspiration

Pelleting: process line with hygienizing / long-term conditioning section


Main influences to the pelleting process / pellet quality

� Raw material, optimized process and equipment are key factors for compacting the

ingredients to a pellet that fulfills the expected requirements

Cooling

5- 10%Machine

15 - 20%

Conditioning

15 - 20%

Preparation

15 - 20%

Formulation

40 - 50%

Source: Kansas State

University


Benefits of compacting animal feed with hygienizing / long-term conditioning section

Feed process benefits

� Improvement of pellet quality

� Lower specific energy consumption

� Higher throughput rates

� Longer life time of dies and rolls

� Improvement of product flow characteristics

Animal benefits

� Reduction of pathogenic germs / salmonellas

� Improved digestability


Parameters for pelleting quality and throughput

Important pelleting parameters

� Die thickness (active length)

� Retention time in die hole

� Throughput pellet mill

� Die hole geometry

� Die speed

� Roll gap

Die

Normal

stress

Press

roll


4 mm pellets for

all animals

Trends for the pellet production – optimizing pellet lines and its benefits

� Production of all products with the same die

� 4 mm pellets develop to be tomorrows

standard for ruminant, pig and poultry feed

� Variations in pellet quality can be controlled

with automatic roll gap adjustments

� One or two stage crumblers will be installed

to adapt particle size for poultry and young

animals

� More often double deck coolers are applied

� Shorter down times between production lots

� Less die changes – less labor involved

� Savings in energy costs - due to crumbling

� Higher flexibility and plant efficiency


Pig feed: influence on specific energy and PDI

0

10

20

30

40

50

60

70

80

90

100

110

120

1 2 3 4 5 6

cond. temp. / °C

retention time / sec

specific energy demandpelleting / kWh/tPDI

6890: pig feed

8

10

12

14

16

1 2 3 4 5 6


Savings in Broiler Production between 6 to 10% with HYSYS

32-34Age (d)

- 6%100%1.7Feed conversion

1500Broiler weight (g)

8.1Stocking / Year

Roller Mill

Long term

conditioning

H‘Mill

Conv.

conditioning

Grinding / Hygenisation /

Pelleting

New

plant

Old

plant

Avg.Broiler production

Savings in feed cost for average farm: Feed savings of 68 tons or 15‘600 €

with apprx. 50‘000 broilers / stocking

in total 45 farms per year Avg. feed savings of 3060 tons or 703’800 €

Feed costs are over 60% of the total costs in broiler production


-50.0

0

50

100

150

200

250

300

350

400

kWh/t Produkt

thermal Energy

electrical Energy

Energy consumption of selected feed mills in Switzerland

N.1 N.2 N.3 N.4 N.5 N.6 N.7 N.8 N.9 N.10 N.11 N.12 N.13 N.14


Key figures of energy consumption by core process

2…3Cooling

Thermal energy25…35Hygienising / Conditioning

40…70Extrusion

Mineral feed...30Pelleting

Cattle feed18...20Pelleting

Swine feed15Pelleting

Poultry feed10Pelleting

Rough estimate for a range

of recipes

3...8Grinding

RemarkskWh/tProcess

data are approx. values


Energy efficiency – potential savings

� Reduce the loss of energy

- Air leakages

- Heat leakages etc.

� Use the best technology

- High efficient drives

- Frequency converters etc.

� Optimize the process

- Control systems

- Modern equipment etc.

Reduce your energy bill without making concessions in terms of performance


Thank you

Documents

Paper 17 - Mr Stefan Vontobel