Centre technique de la Nutrition Animale
Predict the enterobacteriaceae decontamination of
feed by pelleting system
Predict the enterobacteriaceae decontamination of
feed by pelleting system
F. Putier – Manager
www.tecaliman.com
2
Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Context/ObjectivesContext/ObjectivesProgramme context and objectives
Context Regulation EC 2160 2003 zoonosis Discussion between the sector and the
French Ministry of agricultureResearch programme set up
Objectives To demonstrate and validate the impact of
granulation on the bacteriological quality of feeds
Creation of minimum decontamination conditions
Introduction and circulation of a protocol
3
Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
56 trials on pilot press
16 industrial exploratory trials
Validation of decontaminating effect
<3 log in finishing product and of 3 log during process
Set of tables
Protocol proposal to test industrial line effect
84 trials at industrial sites
Validation of protocol and tables
Circulation of protocol
ObjectivesObjectives
Phase 1 Phase 2
4
Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Phase 1: PrinciplePhase 1: Principle
Creation of granulation trials Four feeds concerned
Pig Laying hen
Ckicken Turkey Granulation according to defined methods
Processor exit temperature Die plate thickness Granulation speed
Samples before and after granulation Enterobacteria analysis (standard NF V08 054 at
37°C) and total flora (NF V08 051)
Related to retention time
in the die plate
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Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Phase 1: EquipmentPhase 1: Equipment Feeds
Gondard mixer with twin coils of 224 l Granulation press and pilot coolers
Disinfected sampling equipment
Pig542 µm/65°
Laying hen516 µm/66°
Chicken656 µm/64°
Turkey635 µm/ 59 °
CLM 12 Meccanica press11 kW - 50 at 800 kg/hr
Die plate4/20 4/244/35 4/45
4/50
AcquisitionPower
T° pellets/flourSteam rate
1% pointer waste
Wheat/Barley Maize Oil cakes Carbonate Other
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Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Phase 1: MethodPhase 1: Method Composite central plan
Processing T°
45
Compression rates
2
20
24
35
45
50
53 67 83 90
Uses Uses Reduction in number of trials
Entire space scannedAllowance for day effect
Very powerful statistically
14 trials per feed
7
Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Phase 1: ResultsPhase 1: ResultsRaw data : example on Pig feed
Variations over entire field selected
Strong impact of die sequence
0
1
2
3
4
5
6
20 67° 24 51° 24 83° 35 45° 35 67° 35 90° 45 51° 45 83° 50 67°
Po
pu
lati
on
in e
nte
rob
acte
ria
(lo
g
UF
C/g
)
Hopper entry Processor exit Cooler exit
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Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Phase 1: ResultsPhase 1: ResultsRaw data : example on Turkey feed
Variations over entire field selected
Lower impact of die sequence
0
1
2
3
4
5
6
20 67° 24 51° 24 83° 35 45° 35 67° 35 90° 45 51° 45 83° 50 67°Po
pu
lati
on
in e
nte
rob
acte
ria
(lo
g
UF
C/g
)
Hopper entry Processor exit Cooler exit
9
Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
y = 4.5136x + 65.648
R2 = 0.750160
65
70
75
80
85
90
95
100
0 1 2 3 4 5 6
Diminution of enterobacteria (log UFC/g)
Te
mp
era
ture
die
pla
te e
xit
(°C
)Laying HenPigTurkeyChicken
Phase 1: ResultsPhase 1: ResultsRaw data
decontamination with die temperature
To obtain 3 log ≈ 87°C at die exit
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Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
y = -4.341x + 87.826
R2 = 0.7358
60
65
70
75
80
85
90
95
100
0 1 2 3 4 5
Population in enterobacteria after treatment (logUFC/g)
Tem
per
atu
re d
ie p
late
exi
t (°
C)
Laying Hen
Pig
Turkey
Chicken
Phase 1: ResultsPhase 1: ResultsRaw data
final contamination with die temperature
To obtain <3 log after cooler ≈ 82°C at die exit
11
Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Introducing tablesIntroducing tables
Example on chicken feed
Computing multilinear regressions and models to predict :
Post-treatment contamination Decontamination
ET-SR =14.65 + 0.054 F-0.54 TSC +0.004 TSC2
enterobacteria via the granulation process
Length of die plate ducts – F (mm)Tem
per
atu
re A
fter
co
nd
itio
nin
g
TA
C (
°C)
ET-AC
3.03.54.04.55.0
20 25 30 35 40 45 5045
55
65
75
85
95
20 25 30 35 40 45 5045
55
65
75
85
95
ET-AC=14.65 + 0.054 F – 0.54 TEC + 0.004 TAC2
Decontamination model adopted 2 curves used to produce :
One table with margin One table without margin
log
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Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Introducing tablesIntroducing tables
Chicken and turkey feeds
45
50
55
60
65
70
75
80
85
90
95
2 2.5 3 3.5 4 4.5 5 5.5 6 6.5
Retention time in die plate (s)
T°
at p
roce
sso
r ex
it (
°C)
Chicken with Margin
Chicken without Margin
Turkey with Margin
Turkey without Margin
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Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Introducing tablesIntroducing tables
Pig and Laying Hen feeds
45
50
55
60
65
70
75
80
85
90
2 2.5 3 3.5 4 4.5 5 5.5 6 6.5
Retention time in die plate (s)
T°
at
pro
ce
ss
or
ex
it (
°C)
Pig with Margin
Pig without Margin
Laying Hen with Margin
Laying Hen without Margin
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Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Phase 2 : PrinciplePhase 2 : PrincipleApplication of table at industrial sites
Samples from entire batchat different points
Counting enterobacteria and total flora
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Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
Phase 2: Equipment and methodPhase 2: Equipment and method
84 trials at 11 industrial sites 3 trials per feed x 3 feeds
24 pig 12 laying hen 27 chicken 21 turkey
Setting up granulation conditions
Granulation line Ordinary conditioning/ no pre-compression Presses 120 to 260 kW/Steam power from 0.8 to 4 b
Setting up trials
Industrial mixer
2 trials with margin, 1 without
Industrial and pilot coolers
16
Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
70 75 80 85 90 95
Temperature die exit (°C)
Flo
ra in
en
tero
bac
teri
a at
co
ole
r ex
it
(UF
C/g
)
Phase 2: ResultsPhase 2: Results Pig and laying hen feeds
Cooler exit / Die exit temperature
Objective <3 log
for enterobacteria with the T° acquired by the feed in the die
Efficient tables
17
Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
50 60 70 80
Temperature conditioning exit (°C)
Flo
ra in
en
tero
bac
teri
a at
co
ole
r ex
it
(UF
C/g
)
Phase 2: ResultsPhase 2: Results Pig and laying hen feeds
Cooler exit/ Die exit temperature
Objective <3 log
Variability of contamination with a conditioning T° of 60°C Variability of T° acquired in the die plate
For T° > 70°C high decontamination
18
Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
70 75 80 85 90 95
Temperature die exit (°C)
Flo
ra in
en
tero
bac
teri
a at
co
ole
r ex
it
(UF
C/g
)
Phase 2: ResultsPhase 2: Results Chicken and turkey feeds
Cooler exit / Die exit temperature
Enterobacteria with the T° acquired by the feed in the die
T° tested between 63 and 85°C at conditioning exit
Objective <3 log
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Centre technique de la Nutrition Animale
Feed-to-Food30 Sept. 09
ConclusionConclusionGranulation effect demonstratedSufficient effectiveness of table
Chicken/turkey feed High temperatures required Tables with and without margins effective (T°>67°C) Speed less important than T° at conditioning exit
Pig/laying hen feed Little effort required for temperature and speed Retention time often long Table without margin should be sufficient
Allowance for batch start when tables have not yet been reached
Need for bacteriological management of sites
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