Digital Re-print May | June 2013

Adding value to feed milling with profit-oriented feed formulation

Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. Copyright 2013 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

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Innovative extrusion processes without limits. Bhler is the global technology partner for companies producing breakfast cereals, snack foods, or food ingredients on a commercial scale. With its extensive extrusion know-how and its passion for customized solutions, Bhler is always in a position to generate added value and success for any product idea. Bhler offers an integral range of products and services for all process stages from correct raw material handling, cooking and shaping through extrusion to drying of the extruded products. And this for all market segments from breakfast cereals and snack foods to modified flours and starches, texturized proteins, or vitaminized rice. In short: extrusion processes without limits.
extrusion@buhlergroup.com, www.buhlergroup.com/extrusion

Innovations for a better world.

FEATURE

Adding value to feed milling with profit-oriented feed formulation

by Bea van Deynse, marketing manager, Adifo, Belgium
ormulation software has become a commonly used tool in the feed industry. Almost all feed mills use some application or other to calculate their least-cost formulas. But can such a formulation software tool mean more for a feed producer? We asked Karel Vervaet, BESTMIX product owner, Adifo, Belgium, what to expect from a feed formulation tool and how it can really add value to a feed mills business process.

The BESTMIX feed formulation system for example, exploits the computer power to the highest degree. This software can handle an unlimited number of mathematical solving algorithms.

Multiblend is making a big difference

When you have lots of data to manage, optimising recipe per recipe is no longer feasible in this demanding business. Having a powerful tool like Multiblend allows you to manage and optimise hundreds or even thousands of recipes in one go. This is a real time and money saver. An example to illustrate the power of multiblend feed formulation: it takes less than seven seconds for a Multiblend with 1,500 products and a total of 400 ingredients to reach a new optimisation result. These powerful processes enable the user to have real-time what-if? scenarios. The break down functionality is enormous and the user is guided smoothly from the global view to the smallest detail.

The Multiblend functionality in feed formulation software enables formulators to change things on the fly in their products and work very productively in an interactive way. So the real value of using multiblend lies in an optimal raw material allocation.

Integration with central administration software: a direct impact on profit

The feed formulation department is the heart of the feed mill. Being in the centre of the organisation, a close connection with the central administration software (ERP) is of the highest importance to get the best results. Being able to link up your feed formulation software with your ERP offers enormous advantages. Lets take BESTMIX as an example here. A Multiblend run will add the highest value, when working with the most accurate, up to date figures from ERP. Price information, stock amounts and forecast figures are managed in ERP. Using web services, these figures are automatically processed and made available to the BESTMIX user.
Grain

Always more data to manage and to use

Better performance, handling large quantities of data and controlling it in one central database are the key challenges for every feed formulation and optimisation software. That is why your formulation software needs to be constantly updated to meet the fast growing market demands, says Vervaet. Make sure to ask your supplier how the formulation software is adapted to todays technical capabilities.
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FEATURE But it goes further than that. Risk management, which means having the right raw materials available at the right moment in the correct production location, has become the key challenge for every purchase manager. Todays techniques allow a Multiblend based upon live raw material contract figures from the ERP. The full ingredient position from ERP is downloaded into the BESTMIX feed formulation database and using Multiblend, the most optimal allocation of these contracts in time and place is calculated. These allocations are then sent back to the ERP where the position monitor for raw materials is instantly updated and purchase decisions can be made or changed with these updated figures. designer tool, the graphical labels are created during the formulation, allowing for a last minute change on the label when needed. In most cases however, the formulation software cannot create the label completely, as information such as batch number or production date is not available at the moment of the creation. Software designer Adifo has created an add-on solution on top of Dynamics AX. The content of the labels is supplied by BESTMIX and the Dynamics AX add-on generates the labels, combining relevant formulation and production information on the label. As such, the business content stays the responsibility of the formulation department, where it should be, whilst the complete label can still be created in an automated process. plement feeds matching their homegrown or local ingredients. Only the best end result is good enough and the modern feed plants nowadays are equipped for these quick changes. Vervaet says, More complex multilevel-level compounds can be defined with more detailed constraints at all levels. This leads to direct profits,

Advanced labeling essential

In the last couple of years, labeling legislation has changed constantly. Having a flexible labeling solution that allows users to anticipate these changes is of the highest importance. Any modern feed formulation software is expected to offer a labeling solution. In BESTMIX for instance, all European and US legislation on declaration is implemented in a user friendly way. All components of the label; composition, guaranteed analysis values, conditional texts, health and safety information, barcodes and so on, are set up separately. With an easy to use

Software as a service and cloud computing are todays buzzwords. And the feed industry is not left behind.
as all includes are optimised. The price of the mean compound is kept as low as possible. This also means that the included compounds can be changed more often. This increased functionality enables the management of a larger number of specifications, compounds and products. BESTMIX Feed Formulation Software stores all data in powerful databases, where they can be organised, managed, secured and archived for many years.

Best end result needed for a demanding market

Farmers have a growing understanding of nutrient requirements and digestibility systems and always require the best feed. They ask for special concentrates or com-

innOVaTiOn DisTinguishes BeTween a leaDer anD a FOllOwer.

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FEATURE ity is a major success factor in professional confirm this percepleast cost formulation. tion. Other emulsifiers End (and half) product nutritional content strongly interact with is computed by the formulation Once the starchtool. delaying retapproved, the content of rogradation formulated recipes is and staling delivered to the quality platform and used as referand thus provide bread ence value. Products are sampled in production with improved and and analysis results are compared to the reference prolonged softness and values and evaluated againstfreshness. outliers. Sample data is Some have used to generate the Certificates of Analysis. potent foaming ability One of the key factors for success in manbecause of their suraging quality data is the amount of resources face-active nature and Figure 1: Effect of reducing agents on the dough consistency required for running theare operations. is used as That whipping why BESTMIX LIMS comes multiple agents with for sponge cake andThey data ease workflow automation, and the like. the mixing of water in the final product. Figure 1 compares the connectors the hence manual handling ofdispersion data and in and fat and improve fat effect of cysteine and inactive yeast on the minimizing like: importing intake transactions from of Use full potential of quality data bakery products that contain larger amounts extensibility and resistance towards exten- results, production software, the as A feed should also consider the qual- ERP fat, or such as biscuits, or in liquid updating systems such sion in amill standard wheat flour dough. ingredient matrix of BESTMIX ity data and turn them into real value. Formulation, wafer batters. They also decrease the amount Quality Control (QC) is the result of the importing analysis from to NIR instruof necessary fat, results contributing cholesterol, Emulsifiers implementation of the quality monitoring plan. ments and from external laboratories. Emulsifiers are polar molecules that can calorie and cost reduction. QC is not with a goal in itself; it is a service to mulinteract many constituents of Emulsifiers tiple processes and departments. vision is Tracking that interact with gluten during This mixing process Lecithinand tracing: how to go the blueprint for LIMS, the platform it? is an emulsifier which has been strengthen theBESTMIX bonds between protein chains, about Lecithin developed Adifo for collecting quality data All feed mills products feel the increasing pressure but they by also provide a lubricating effect that used in bakery for a long time. Once and transforming the into value for the feed andwas food safety No one can allows the chains to data slide over each other eas- of egg yolk used as audits. the source of lecithin, company. risk of not being able to track and LIMS is used for monitorily. TheyBESTMIX are involved in the stabilisation of the take butthe nowadays concentrated lecithin obtained the entire production. all available inggas internal and external processes. bubbles in dough by binding to the bound- trace from soy beans, canola or So sunflower seeds must The be easily retrievable. Databases The quality materials is used for ary layers. As of a raw result, dough elasticity, oven data is used. most obvious benefit of lecithin not store lots of data of but also make updating ingredient matrix. rise and the volume increase, and theBESTMIX crumb pore is only to lower the stickiness the dough and that these are available for auditing. LIMS thisbakers process, an sure size facilitates reduces. The will leading note an to increase improve its data machinability. Other than this, In Adifos each and increased frequency of absorption, updating. In the end, in the practical water although the lecithin softenssoftware, the crumb due to its every interacchange is triggered and made visible. New is mastering the variation of raw material qualdough rheological measurements may not tion with starch. But its effect on volume

FEATURE functions like Audit Trail make counterparts. it easy for less than that of its synthetic the user to of track all is modifications. The dosage lecithin about 30-150The g per controller disposes of all data%). from a dosages single 100 kg of flour (0.03 0.15 Low source andthe noprocessing longer needs to of search for increase quality the dough, native files spread around, says Vervaet. whereas high dosages increase dough stability and fermentation tolerance, improve crumb What about formulation structure and prolong shelf life. in the todays buzzwords. And feed by industry is These molecules arethe formed breakingnot behind. Adifo recently offleft fatty acids from edible fats launched and oils. its The formulation asare a service platform, enabling all forms that preferred as flour improver parties in feed formulation including nutritionare the ones that prevent staling best. This ists, advisors, and farmers to share property isformulators, found in linear saturated fatty acids their knowledge via the cloud. This way, that interact best with starch, and thefeed most formulation is entering collaborative era. effective of them all the is glycerol monostearate. The dosage starts at 0.05 percent and may Dare totoask go up onemore percent, especially in high-fat If you are a specialist in feed producproducts. tion, make sure to work with a partner who understands youresters business. to Diacetyl tartaric of Dare monoask more from your software. Especially in and diglycerides (DATEM) termsDATEMs of technical performance, integration currently are the most effective with ERP, data and volume. service They sharing with emulsifiers for bread are various customers, labeling, lab data usage, tracking molecules formed by esterification of monoand tracing possibilities, concludes Vervaet. and diglycerides (obtained from edible oils) with mono- and diacetyl tartaric acid. Some of these molecules are more active than the More (Khler, inforMation : but the effect of the others 1999), mixture is www.adifo.com better than any single type of pure Website: www.formulation-as-a-service.com emulsifier. DATEM is rather used in bread improvers. The optimum dosage is about 400 g per 100 kg,

cloud? Software and as a service, cloud computing are Monodiglycerides

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18 GRAIN | may - June 2013 FEED MILLING TECHNOLOGY

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The optimum dosage is about 400 g per 100 kg, FEATURE

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This digital Re-print is part of the May | June 2013 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on www.docstoc.com.
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In this issue:
Additives for flour standardisation
Part II: Additives other than enzymes

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Adding value to feed milling

with profit-oriented feed formulation

Kill step validation of low-moisture extrusion

High efficiency elevator buckets: modern vs traditional design Feed focus

Poultry

Pest control
across the supply chain

Assessing nutritional value with NIR

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