Most recent developments in feed processing

Stefan Vontobel Bhler / Switzerland

1 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Topics

World meat demand and feed production Changes in feed processing safe feed, safe food Thermal process meal and pelleting Pellet quality energy efficiency

2 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

World situation on meat consumption and production

Meat production in Mio T.

140 120 100

Pork
CAGR 2005-10 of 1.61%

Broiler
CAGR 2005-10 of 3.16%

Per-capita meat consumption

Africa Asia Developing World World Latin America

Beef & Veal

CAGR 2005-10 of 0.7%

80 60 40 20 0

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
Developed World North America 0 10 20 30 40 50 60 70 80 90 100 110 120 130

Source: United Nations

Kg/Person/Year

3 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

World Feed Production by Country 2004 vs.2008

2004: 634 Million Tonnes

Other
20%

2008: 700 Million Tonnes

Other US
24%

India Korea Russia Canada Japan Mexico Brazil China

1% 2% 2% 3% 4% 4% 7% 10%

India Russia Korea Canada Japan Mexico EU-25 Brazil

2% 2% 3% 3% 3% 4%

17%

22%

US

23%

21% 8% 15%

EU-25

China

Source: IFIF

4 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Industrial Compound Feed Production Middle East, Africa 2008

Middle East, Africa Industrial Feed Production 2008
mmt
Jordan Zimbabwe Nigeria Tunisia Algeria Morocco Israel Iran South Africa Egypt Saudi Arabia
0 1 2 3 4 5 6 7 0.5 0.5 0.7 0.8 1 1.3 2.8 2.9 5.3 5.5 7.3 8 9 10

2%2% 2% 3% 3% 5% 10% 25%

Saudi Arabia Egypt South Africa Iran Israel Morocco Algeria

154.5

10% 19% 19%

Tunisia Nigeria Zimbabwe Jordan

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
5 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Factors Affecting Future Production of Compound Feed

Factors Affecting Feed Factors Affecting Feed Production Production Continuous quality of the final products Price of feed ingredients Meat consumption Beef production Poultry production Pig production

Impact for Millers Impact for Millers

Increasing requirements i.e. EU safety Volatile prices volatility difficult to hedge against

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.

6 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Modern feed plant change of process with hygienizing

Past

past Retention time [sec.] 10 - 15

today max. 240

Today and Future

Bagging / Bulk Loadout

Hygienizing Pelleting Thermal meal treatment

Pelleting

feed plant
7 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

feed plant

Bagging / Bulk Loadout

Intake and cleaning

Intake and cleaning

Grinding & Mixing

Grinding & Mixing

Weighing

Weighing

Aspects for the production of hygienized feed

Feed plant design / concept Storage: design & sizing of bins Transport: short distance between process Process lines steps Define process parameters Production criteria; observe quality (temperature & retention time) management by following GMP+ Heating and drying of process steps Risk reduction: assessment and prior and after production lots to avoid monitoring of risky area and defining condensation / re-contamination measures according to HACCP
8 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Machines / apparatus Hygienic design Materials: stainless steel at critical spots Regular cleaning

Hygienizing with steam what happens to bacteria

100000 bacterial count in cfu/g

75 C

Increased temperature

85 C
0 50 100 150 Retention time at constant temperature in sec

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

9 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Whats important - retention time distribution of continues systems

FIRST IN FIRST OUT is only possible in theory
HYMIX HYTHERM HYTHERM

Optimum flow

HYTHERM

Very narrow retention time distribution (5 - 10 sec)

HYTHERM

inefficient long term conditioning systems: the retention time distribution can attain 2 min

long term conditioning

10 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

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.

11 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

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.
rat holing funnel flow mass flow

12 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

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
E RM HYTH
HYMIX

13 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

New thermal meal treatment: The product

Raw material: piglet feed

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

Piglet feed, thermally treated, 85C, 120 sec

14 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Pelleting: process line with hygienizing / long-term conditioning section

Pellet screen

Holding bins

Aspiration Discharge elements Feeder Conditioner Retentioner Pellet mill Cooler

Crumbler

15 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

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

Machine 15 - 20%

Cooling 5- 10%

Formulation 40 - 50%

Conditioning 15 - 20% Preparation 15 - 20%

Source: Kansas State University

16 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Benefits of compacting animal feed with hygienizing / longterm 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

17 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Parameters for pelleting quality and throughput

Press roll

Die

Important pelleting parameters

Die thickness (active length) Retention time in die hole
Normal stress

Throughput pellet mill Die hole geometry Die speed Roll gap

18 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

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

4 mm pellets for all animals

Shorter down times between production lots Less die changes less labor involved Savings in energy costs - due to crumbling Higher flexibility and plant efficiency

19 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Pig feed: influence on specific energy and PDI

120 110 100 90 80 70 60 50 40 30 20 10 0

cond. temp. / C

6890: pig feed

retention time / sec specific energy demand pelleting / kWh/t PDI

16 14 12 10 8 1 2 3 4 5 6

20 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Savings in Broiler Production between 6 to 10% with HYSYS

Broiler production Avg. Old plant Grinding / Hygenisation / Pelleting HMill Conv. conditioning Age (d) Stocking / Year Broiler weight (g) Feed conversion 32-34 8.1 1500 1.7 100% - 6% New plant Roller Mill Long term conditioning

Savings in feed cost for average farm: with apprx. 50000 broilers / stocking

Feed savings of 68 tons or 15600

in total 45 farms per year

Avg. feed savings of 3060 tons or 703800

Feed costs are over 60% of the total costs in broiler production

21 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Energy consumption of selected feed mills in Switzerland

400 350 300 250 200 150 100 50 0 -50.0 N.1

thermal Energy electrical Energy

kWh/t Produkt

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

22 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Key figures of energy consumption by core process

Process Grinding Pelleting Pelleting Pelleting Pelleting Hygienising / Conditioning Cooling Extrusion
data are approx. values

kWh/t 3...8 10 15 18...20 ...30 2535 23 4070

Remarks Rough estimate for a range of recipes Poultry feed Swine feed Cattle feed Mineral feed Thermal energy

23 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Energy efficiency potential savings

Reduce your energy bill without making concessions in terms of performance

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.

24 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010

Thank you
25 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010