New dimension in the production of hygienised feed meal

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Digital Re-print - November | December 2010New dimension in the production of hygienised feed meal

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Pathogenic bacteria in feed meal

are a major risk factor for animal

health and performance.

Thermal meal treatment significantly 

reduces microorganisms in feed, but requires

a subsequent cooler after the hygienising

section. Difficult to clean, conventional meal

coolers can be a potential source for cross-

and re-contamination.

A new process solution has been devel-

oped by Buhler Group, Switzerland, utilizing

  thermopneumatic conveying for drying and

cooling as a smart alternative to meal coolers.

Contaminated raw materialsAgricultural products are a natural source

of microorganisms such as bacteria, yeasts

and molds.

The degree of contamination is subject

  to parameters such as type of raw mate-

rial, origin, transport and storage conditions

and the season. Whereas, most of the

microorganisms are harmless, some species

like enterobacteriaceae show pathogenic

potential, with salmonella being the most

common subspecies of enterobacteriaceae

in animal feed.

Infection doses for salmonella are com-

paratively low, with an incubation period of a

few hours to two days, depending on animal

species and age.

Salmonella can cause serious animal dis-

ease like diarrhea, reducing feed digestibility 

and conversion, impairing animal growth and

performance.

Hygienising by heat treatmentSensitive to heat, salmonella are usually 

killed at temperatures above 55°C.

However, high concentrations of fat, pro-

 tein or starch in formulated feed may form a

protective colloid layer and thus increase the

heat resistance of bacteria.

Hence, a hygienising temperature of 

about 85°C has become common practice

in the feed industry to ensure that virtually 

all pathogenic bacteria are destroyed. The

 temperature is achieved by the addition of 

steam into the conditioner and retained

for a certain dwell time in the subsequent

retentioner to guarantee a reliable decon-

 tamination process.

Recontamination afterhygienising

After the hygienising process, the hot

and moist feed has to be cooled and dried

 to prevent recontamination and growth of 

microorganisms.

This usually takes place in conventional

meal coolers utilizing the principle of fluid

bed cooling. Ambient air enters the cooler at

 the bottom side, flows through t he perfora-

 tion and fluidizes the meal.

Even though providing efficient cooling,

New dimension in theproduction of hygienisedfeed meal by Stefan Hoh, Buhler Group, Switzerland

Gain&fd illinG thnlGy14 | november - december 2010

FeatureFeed meal 

meal coolers are often described as a ‘five

star hotel’ for microorganisms: The handling

of hot and moist feed meal can cause con-

densation in the meal cooler, with f ree water 

being a major growth factor for bacteria

which has resist the hygienising process or 

airborne bacteria from the high air volumes

applied.

Furthermore, cross- and re-contamina-

  tion can occur due to product residues in

 the system, which are difficult to remove and

require tremendous cleaning effort.

Thermal meal treatment

The Buhler Group has developed a new

process solution utilising thermopneumatic

conveying for drying and cooling of hygien-

ised feed meal. The thermal meal treatment

process is divided into the sub-processes of 

hygienising and thermopneumatic drying/

cooling.

Hygienising is carried out by the HYMIX

and HYTHERM modules.

In the HYMIX, the compound feed

particles can be heated to a temperature

of 80 to 90 degrees C by the addition

of steam. The heated formulated feed is

  then retained in one or optionally two

HYTHERM modules.

This allows retention times between 60

and 240 seconds to be achieved as a func-

 tion of the throughput rate. In addition, the

HYTHERM system is characterised by its

very narrow dwell time distribution, thus get-

 ting very close to the ‘first in – first out’ prin-

ciple, which ensures reliable hygienisation.

In a second process step, the hygienised

feed enters the Triple Air Control (TAC)

system for drying and cooling. In the first

stage, pre-heated air is applied for drying and

cooling, utilising the effect of evaporation.

Final product temperature is achieved in

  the subsequent two pneumatic conveying

lines, utilizing ambient air for cooling.

The optimised concept of HYMIX and

Hytherm ensures low product residues and

easy cleaning.

Thanks to the high air velocities applied,

Gain&fd illinG thnlGy november - december 2010 | 15

Feature Feed meal 

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ability of the feed. Thermally treated swine

feed may thus have a positive influence on

  the animal’s appetite and – according to

feedback Amrein received from its custom-

ers – results in outstanding feed acceptance.

Moreover, thermal meal treatment

improves the water solubility of the

feed. Product lumps in the feed slurry 

are effectively prevented, as well as

deposits of high-density particles in the

feed trough.

Last, the heat and steam treatment causes

fines to agglomerate on coarser particles,

which reduces dust generation and improves

flowability. Choke-ups during discharge from

storage bins and silos are greatly reduced

compared to untreated feed meal.

needs or adjusted to feed recipes for other 

animal species, e.g. layer and breeder feed.

This is made possible by the following

options: microfiltration of the air for top

sanitation standards; addition of solid and

liquid microingredients; post-mixing applica-

 tion for unsurpassed product homogeneity;

and monitoring of the steam quality and/or 

of the moisture content.

Improved feedThe pig feed produced by the new

process is characterized by its extremely low

count of microorganisms such as bacteria,

molds, and yeast fungi.

Pathogenic bacteria such as salmonella

are virtually destroyed, which significantly 

reduces the incidence and severity of diar-

rhea disorders in the animals.

Besides improving the animals’ health, this

also enhances feed digestibility, which in turn

has a positive impact on the weight increase

of the animals.

The Maillard reaction occurring during the

 thermal treatment process creates a bundle

of roast flavours, which improve the palat-

 the TAC system is self-cleaning, which pre-

vents product deposits. Cooling by a ther-

mopneumatic conveyor greatly reduces the

risk of cross-contamination and recontami-

nation in comparison to conventional meal

coolers.

Thanks to its flexible design, the new

 thermal meal treatment system has a small

installation footprint. This enables the space

available in existing feed production plants to

be utilised in the best possible way.

The system was installed at the Amrein

Futtermühle AG, Switzerland, which pro-

duces hygienised swine feed.

Operation of the new facility is fully 

automated and is controlled exclusively 

from the control room. This cuts labour 

costs and allows just-in-time production.

The new process increases the uptime

of the processing lines thanks to reduced

downtimes when formulations are changed

in comparison with hygienising systems

consisting of pellet mills and conventional

meal coolers.

The new thermal meal treatment system

can be easily tailored to specific customer 

More inforMation:

Buhler Group

Uzwil, CH-9240 SWITZERLANDWebsite: www.buhlergroup.com

Gain&fd illinG thnlGy16 | november - december 2010

FeatureFeed meal 

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