Advances in Feed Milling Technology
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Advances in feed milling technology and the development of SPF eggs and organic foods are summarized. Feed milling involves processing, preparation, quality control and storage of animal feed. Key equipment includes hammer mills, roller mills, mixers and pellet mills. SPF eggs are produced in isolator or FAPP facilities to be free of specific pathogens. Strict protocols govern feed, housing and testing to maintain SPF status. Organic foods are grown without synthetic chemicals and use alternative soil fertility methods.
Advances in Feed Milling Technology
- 1. Advances in Feed Milling Technology
- 2. Feed milling technology Animal feed technology deals with Processing of feeds, fodders Preparation of formula feeds Quality control of the feed ingredients Feed plant management Storage of the feed ingredients
- 3. Feed industry came into existence in India in1961 with the establishment of a feed plant in Ludhiana, Punjab. CLFMA was formed on 8th June, 1967. It is the sole, national, representative body of compound animal manufacturers in India.
- 4. 1.Intake hupper 2.bucket elavator 3.surge hopper(raw feed ) 4.separator 5.surge hopper(feed for grinding) 6. Feeder and magnet 7.Hammer mill 8.Bucket elavator 9.Surge hopper(ground material for mixing) 10.Molasses service tank 11.Molasses dosing tank 12. Horizontal mixer 13.Surge hopper(finished mash feed) 14.Magnet 15.Feed packer(gunny bag) 16.Dust bag
- 5. Mills commonly used Hammer mills Consists of a cylinder or rotor made up of several plates keyed to the main shaft or axel. Pins through these plates near the edge carry the hammers which are attached to them. Outside the rotating cylinder is a perforated steel screen. The holes in these screen may be as small as 1/32 inch or as large as 2-3 or more inches. The hammer tip is travelling at a minimum of 5000 to 7000m/min. Most common grinder used in feed industry
- 6. Hammer mills can be single, double or triple reduction type with either rigid or swinging hammers. The double or triple reduction type have knives or blunt disc on one side of the rotor to chop the longer stemmed materials into smaller materials before they come in contact with the hammers. The fan or blower is usually used for product transfer after a grinding . The fan requires about 25-30% of horse power of mill.
- 7. The production of hammer mill depends upon different factors Horse power Diameter & shape of screen opening Screen area Moisture content Peripheral speed Kind of grain Location of feed intake Hammer tip and screen clearance No of hammers Hammer width & design Air flow through the mill
- 9. Roller mill Several potential advantages of a roller mill over a hammer mill when grinding a mash type of feeds. More energy savings Produce 15-40% more tonnes per hr at a given hp than full circle hammer mills, when producing the same finished particle size.
- 10. Feed mixing Feed mixers are mainly of two types Vertical batch mixer Horizontal mixer
- 14. Attribute Vertical mixer Horizontal mixer Cost Relatively inexpensive & do a good job of dry mixing Expensive & do a good job of dry and liquid mixing Use Not used in larger feed mills Used in small mills as well as larger feed mills Floor space Less more Time 20 mins or more time per batch to obtain maximum mixing efficiency. & slower 3-5min per batch and faster Power req. Consumes less power More power Discharge of mixed feed Opening at one place Opening at several places along the bottom to aid in more discahrge Clean out Lesser extent 100% generally Liquid addition Molasses, fats cant be mixed Can be mixed efficiently Mixing effiiciency Lower Approaches 99%
- 15. Feed pelleting technology Pelleting can be defined as the agglomeration of smaller particles into larger particles by means of a mechanical process in combination with moisture, heat and pressure. Pelleted feeds are agglomerated feeds resulting from extruding either individual or feed mixture by compacting and forcing through die openings by any mechanical process and subsequent cooling.
- 16. Pelleting system 1.Storage bin 2.Pellet mill 3.Cooler 4.Crumbler 5.Elavating system 6.Pellet scalper(screen) 7.Steam supply
- 17. Storage bin Store mixed mashed feed for pelleting in adequate quantity to ensure continuous operation of the pellet mill. This means a minimum of two beans each with a capacity of not less than one and half times the capacity of the batch mixer used to supply conditioned feed to the pellet mill.
- 18. Pellet mill Are available in wide ranges of sizes: 20 to 40 hp to 700hp. The inside diameter of the pellet die on the large mill is 37 inches versus 12inch on the small mill. Parts of the pellet mill Feeder Conditioning chamber Pelleting device Speed reduction device Prime mover Base
- 20. Feeder Generally screw type with some variation in flight arrangement such as single flight, double flight, full pitch or one half pitch Feeder is equipped with some type of speed control such as a variable speed electric valve or a ratchet speed control device. purpose of the feeder is to provide a constant even flow of feed to the mixing and pelleting operation.
- 21. Conditioning chamber Is accomplished by addition of controlled amounts of steam A mixer, low speed (up to 125 rpm) or high speed (125 to 500 rpm) model, is provided in order to properly condition the feed. Further this mixer can be used for the the addition of molasses up to 15% without special attatchments and up to 30% when properly equipped. The optimum conditions for pelleting are 13-17% moisture and 170-190̊F (77-88̊C) as the feed enters the die. The normal moisture of the mass is 10%. 1% moisture will be added to the feed as the temperture is raised 20 ̊F by steam addition
- 22. The conditioned mash is forced through holes in the die by roller pressure. Die thickness is a factor in the production of high quality pellets and production rates. The die should be as thin as possible to increase production efficiency. The difficult to pellet ingredients, such as fibre , urea etc are normally produced on a thin die as compared to high grain products which would normally produced on a thicker die. A thick die produce a better quality pellet than a thin die but also reduce production rates.
- 23. Prime over most pellet mills are installed with an electric motor as the prime mover Base The pellet mill and motor are usually mounted on a common base to maintain alignment of the pellet mill and motor. Coolers Vertical or horizontal The cooler type will often decided by the plant layout and the product mix
- 24. Where the floor space is limited, the vertical cooler is preferred. where height is limited horizontal cooler is preferred. Vertical coolers are prefered for small diameter pellets. Its design is simpler with lesser maintenance and energy cost. Horizontal coolers are particularly used when sticky feeds are manufactured. Best for fragile pellets and cubes.
- 25. Crumblers The objective of crumbling is not merely to reduce the size of the pellets but to control the reduction to a specific particle size with a minimum of fines. In this process pellets of 10/64 inch or 12/64 inch diameter are ground on corrugated rolls and the resultant product is graded by shifting over appropriate screen sizes.
- 26. Pellet elavating systems Pellets are usually elavated either by standard bucket elavators or by air. Bucket elavators are exclusively used for cold pellets as these are less expensive to install Pneumatic conveyors are generally used for hot pellets. Pellets are most vulnerable to damage before being cooled. Conveying equipment between the pellet mill and the cooler creats fines. Conveying equipment should be operated as slowly as possible. Belt conveyers and drag conveyers will normally
- 27. Shifting device Some type of shifting is necessary to remove fines produced during pelleting and crumbling and while passing through the cooler. Fines are returned to the pellet mill for reprocessing.
- 28. Steam supply An adequate well regulated supply of steam is a must for any efficient pelleting operation. As a general rule 5% moisture is accepted as a maximum though in some cases this may b exceeded.
- 29. Newer developments Feed pelleting technology made rapid strides in 1990s incoorporating advances upstream in super conditioning as well as downstream in post conditioning, cooling and micro liquid application. Systems for the automatic or remote adjustment of the pelleting rolls or rollers can be considered as a major advance. These system offers many advantages including reduced labour requirements, faster start-ups, increased capacity, more consistent pellet quality and improved die and roller life
- 30. Expander technology Expanding , pressure conditioning and HTST conditioning all describe a general technique of super conditioning which can kill salmonella more efficiently than pellet alone In super conditioning high temperatures above 90̊C and moisture contents are applied for 15-20 secs prior to pelleting. Expander is one type of super conditioner that is a specially designed screw press in which the pressure and temperature of a feedstuff or feed mixture increases through friction and optional steam injection.
- 31. The expander is now a common equipment in Northern-Europe primarily in order to satisfy demands for better pellet durability and for greater flexibility in the inclusion of liquids and difficult to pellet ingredients. It is a method ensuring manufactured feed contains very little salmonella or other pathogenic organisms.
- 32. The most serious challenges of expander processing Expanded crumbles have a lower bulk density and different flow behaviour. These characteristics may result in higher transport cost. Less suitable for broiler or turkey finisher feed
- 33. Micro time conditioning and pelleting or pellet cooker technology Pellet cooker technology was designed by Wenger Manufacturing Company, USA to exceed the performance of expander pelleting system. Feed is subjected to a very high temperature of 125-150̊C for only 3-4 secs to minimize the destruction of valuable nutrients while feed gets pasturized.
- 34. Pellet sizes are in the range of 2-18 mm Change over down time is less than 15mins. A rotary cutter on the pellet head cuts pellets to a specified length, depending on its adjustable rotation speed. Faster rotation produces shorter pellets.
- 35. SPF EGGS
- 36. The term SPF has been defined by the international committee on the labarotary animals (ILCA) as those animals free from specific micro-organisms and parasites but not necessarily free from others not specified.
- 37. Facilities for SPF flock production Two types of facilities are currently in use for the production of research flock for spf flock. The first type consisting of isolators was developed by the Houghton poultry research station in England. The second type is based on the concept of filtered air positive pressure houses.
- 38. Isolators Each isolators requires eggs to be hatched in the isolators and birds to be maintained for at least 18 months within the isolators. The units are made up of fibre glass or plastic Each unit can accomodate 12 hens with 1 male Each isolator has its own ventilation unit consisting of prefilters and high efficiency particulate air filter.
- 40. FAPP House The use of FAPP house differs from isolators regarding the role of animal caretaker. In FAPP house the caretaker has direct contact with the chickens unlike isolators. It is important to have walls and floors completely sealed with a washable sealer to facilitate cleaning. Entrance to the either house is through a shower facility and the care taker need to shower including scrubbing under the finger nails and washing his/her hair prior tp entry into the clean area. Materials such as syringes, tubes, clean clothing etc are placed in air lock and fumigated with formaldehyde and potassium permanganate prior to entry into the clean area. There is no direct contact between the mechanical room and clean room.
- 44. Feed for SPF flock Feeds are delivered to the departmental storage facility in bags using departmental personnel and the departmental truck. The truck is disinfected with sodium hypochlorite solution prior to recieving the feed. The bags are entered through the feed room, placed on slats, fumigated, turned around and fumigated again. Pelleted feed are used for all the birds except the chicks which recieves crumbled chick starter.
- 45. Ventilation system Both houses have prefilters which are changed once a month and HEPA filters are changed in every 4 months. It is important to change the filters to maintain the pressure. Frequent changing of prefilters will change the functional period of the more expensive HEPA filters.
- 46. Development of SPF flock Long and costly procedure Eggs obtained from a flock without the possibility of testing individual hens prior to receiving eggs, are fumigated or disinfected at the outside on arrival and dipped in a solution containing tylosin or erythromycin to reduce the mycoplasma contamination. Albumin sample is tested for presence of ALV and those eggs free from viruses are allowed to hatch. The presence of all known chicken viruses are tested. Sera are collected at 8wks and frequently afterwards and tested for the presence of antibodies. Fertile eggs of these birds are transferred into the SPF FAPP house after fumigation and dipping in the antibiotic solution.
- 47. Problems of SPF flocks Successful maintenance of SPF flock depends on number of factors. The main risk is Introduction of pathogen Reduced reproduction caused by inbreeding
- 48. Introduction of pathogen Dalton catagorised the risk factors associated with the introduction of pathogens into SPF flock Animal care taker(60%) Food (20%) Water (10%) Airborne pathogens (8%) Insects/ vermins(1%) Egg transmission(1%)
- 49. SPF Eggs most be free from following pathogens: Avian Adenovirus Group 1&2, Avian Encephalomyelitis, Avian Leucosis, Avian Nephritis, Avian Rhinotracheitis, REO disease, Chicken Anaemia, Egg Drop Syndrome’76, Fowl Pox, Infectious Bronchitis Infectious Bursal Disease, Infectious Laryngotracheitis, Influenza Virus Type-A, Marek’s disease, Newcastle disease, gallisepticum, Mycoplasma synoviae).
- 50. Turkey Viral Rhinotracheitis (Avian pneumovirus), Avian Reticuloendotheliosis, Salmonella pullorum, Salmonella gallinarum, Salmonella enteritidis, Avian Paramyxovirus Type 2&3, Mycoplasmosis (Mycoplasma)
- 51. Importance in testing and manufacturing poultry vaccines Three kinds of “substrate” derived from SPF-eggs are used for virus production: Embryonated and pre-incubated SPF-eggs, Primary cells (e.g. chicken embryo fibroblasts) derived from pre-incubated embryonated SPF- eggs Chickens hatched from SPF-eggs.
- 52. Organic food
- 53. Organic farming can be defined as an approach to agriculture in which the aim is to create integrated, humane, environmentally and economically sustainable agricultural production system.
- 54. Organic foods are grown without synthetic pesticides, growth hormones, antibiotics, modern genetic engineering techniques(including genetically modified crops), chemical fertilizers, or sewage sludge. Organic farming uses various methods to enhance or maintain soil fertility, such as crop rotation, tillage and cultivation practices, cover crops, and natural products (such as natural fertilizers, pesticides,and so on).
- 55. The use of synthetic materials is not allowed in organic farming unless the materials are on the Natl. List of Allowed and Prohibited Substances. It takes several years to convert a field from conventional farming to organic farming since land can have no prohibited substances used on it for 3 y before the harvest of an organic crop. Animal herds can be converted to organic by feeding them 80% organic feed for 9mo, followed by 3mo of 100% organic feed.
- 56. Animals must consume only 100% organic feed for their products to be sold as organic, but the animals can receive vitamin and mineral supplements. Preventive management practices such as vaccinations can be administered when absolutely necessary to keep animals healthy, but those animal products cannot be sold as organic. Antibiotics cannot be used on products to be sold as organic.
- 58. The United States Department of Agriculture (USDA), in cooperation with accredited certification agencies, regulates the production and labeling of organic poultry products under the Organic Foods Production Act of 1990 and the National Organic Program (NOP) In order to be sold as organic, NOP Final Rule Section 205.236 requires that poultry or edible poultry products must be from poultry that has been under continuous organic management beginning no later than the second day of life.
- 59. Feed & feed additives All agricultural components of the ration must be certified organic. Fields, including pastures used for organic poultry and lots used for outdoor access, must be certified Non-synthetic (natural) substances, such as oyster shells, calcium carbonate or fish meal; and synthetic substances that appear on the National List, may be used as feed additives and supplements
- 60. The only specific synthetic feed additive on the National List for poultry is DL-methionine. FDA-approved trace minerals and vitamins are allowed in poultry rations, so long as they are not derived from slaughter byproducts and do not contain any genetically engineered ingredients, which are referred to as "excluded methods" in the NOP Final Rule. No synthetic colorings, flavorings, dust suppressants, or flowing agents are allowed, since none appear on the National List.
- 61. Feed used for organic poultry production must not contain: Animal drugs, including hormones, to promote growth; Feed supplements or additives in amounts above those needed for adequate nutrition and health maintenance; Plastic feed pellets; Urea or manure; Mammalian or poultry slaughter byproducts fed to mammals or poultry; Feed, additives, or supplements in violation of the Food and Drug Administration; or Feed or forage to which any antibiotic, including ionophores, has been added.
- 62. Health care Selection of species and types of poultry that are suitable for site-specific conditions and resistant to prevalent diseases and parasites; Provision of a feed ration sufficient to meet nutritional requirements, including vitamins, minerals, protein and/or amino acids, fatty acids, and energy sources; Establishment of appropriate housing, pasture conditions, and sanitation practices to minimize the occurrence and spread of diseases and parasites; Conditions that allow for exercise, freedom of movement, and reduction of stress appropriate to the species (no caged laying hens); Physical alterations as needed to promote the poultry's welfare, performed in a manner that minimizes pain and stress; and Administration of vaccines and other veterinary biologics.
- 63. Interestingly, mortality may be higher in large- scale organic production than in conventional production because medications are not permitted. Necrotic enteritis is a common health problem in large organic broiler flocks. Approved materials that are used for disinfection and sanitation of the premises and equipment include chlorine materials, iodine, hydrogen peroxide, peracetic acid, phosphoric acid, and alcohol.
- 64. Housing NOSB recommendation advises the NOP to establish the following avian minimum space requirements: Laying hens and breeders: 2.0 sq ft/bird indoors, 2.0–5.0 sq ft/bird outdoors Pullets: 2–3 lbs/sq ft indoors, 2–3 lbs/sq ft outdoors Broilers: 1–5 lbs/sq ft indoors, 2–5 lbs/sq ft outdoors
- 65. The NOSB has also recommended that: (a) ammonia levels should be less than 10 ppm and must be less than 25 ppm indoors; (b) the confinement of birds in cages is not permitted under any circumstance; and (c) minimum indoor and outdoor space requirements be established for organic poultry.
- 66. References Nutrition and feeding of organic poultry by Robert Blair The Experimental Animal in Biomedical Research: Care, Husbandry ..., Volume 2By Bernard E. Rollin Organic Foods ,CARL K.WINTER AND SARAH F. DAVIS, Vol. 71, Nr. 9, 2006—JOURNAL OF FOOD SCIENCE CONSUMER DEMAND FOR ORGANIC FOODS: WHAT WE KNOW AND WHAT WE NEED TO KNOW GARY D. THOMPSON , Amer. J. Agr. Econ. 80 (Number 5, 1998): 1113-1118