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