Download - Paper 17 - Mr Stefan Vontobel
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AFMA 2010 developments in feed processing | Stefan Vontobel | 20101 | © Bühler |
Most recent
developments in
feed processing
Stefan VontobelBühler / Switzerland
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AFMA 2010 developments in feed processing | Stefan Vontobel | 20102 | © Bühler |
Topics
� World meat demand and feed production
� Changes in feed processing – safe feed, safe food
� Thermal process – meal and pelleting
� Pellet quality – energy efficiency
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AFMA 2010 developments in feed processing | Stefan Vontobel | 20103 | © Bühler |
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%
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AFMA 2010 developments in feed processing | Stefan Vontobel | 20104 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 20105 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 20106 | © Bühler |
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.
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AFMA 2010 developments in feed processing | Stefan Vontobel | 20107 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 20108 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 20109 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201010 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201011 | © Bühler |
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.
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201012 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201013 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201014 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201015 | © Bühler |
Discharge
elements
Pellet screen
Feeder
Conditioner
Retentioner
Pellet mill
Cooler
Crumbler
Holding bins
Aspiration
Pelleting: process line with hygienizing / long-term conditioning section
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201016 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201017 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201018 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201019 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201020 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201021 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201022 | © Bühler |
-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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201023 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201024 | © Bühler |
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
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AFMA 2010 developments in feed processing | Stefan Vontobel | 201025 | © Bühler |
Thank you