Basic Concepts in Feed Manufacture

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• Feed ingredients, (grain, meals, additives) are combined to satisfy nutrient requirements of livestock species and type.

• Feed manufacturers process and deliver compound feeds to livestock producers.

• Livestock products are delivered to food processors and then to the consumer.

A more complicated version of “You are What You Eat!”

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• 800,000 tonnes of chicken meat– Domestic consumption

• 150,000 tonnes of eggs

• 325,000 tonnes of pig meat

• 9,400 million litres of milk– 65% from Victoria

• 2 million tonnes beef – with 60% exported

• Horse industry valued at $6.4 billion

• 76 million sheep

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• Feed processing methods can be chemical, thermal, or mechanical, or any combination, and may include microbial fermentation (such as silage).

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• Processing changes the particle size or physical appearance, separates parts of the seed or plant, improves digestibility or palatability, reduces or prevents spoilage, reduces or inactivates anti-nutritional factors, or improves handling and mixing.

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• Manufacture the right kind of feed for the type of animal to be fed.

• The feed is nutritionally balanced with ingredients that are palatable and digestible for the type of animal.

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• Make the feed in a form that maximizes consumption and minimizes waste.

• For example, pellets are more dense and keep the animal from ‘sorting’ ingredients. The animal may eat more and consume a more balanced ration as a result.

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• Process the feed to enhance digestibility through mechanical, chemical or thermal techniques

• Increased digestibility allows the animal to digest and absorb the feed quicker and more efficiently

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• Measure, monitor and maintain quality control, ensuring that the feeds are not contaminated with bacteria, toxins, unapproved or excess medications or additives, or other unsafe ingredients (such as meat and bone meal in ruminant feeds).

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Truck

Rail

Barge

Other

Ingredient

Receiving

Steam

Pellets to Storage

Bagging

Bulk Shipping

Truck, Rail

Meal/Mash

Grain

Receiving

Grain

Cleaning

Grain

Storage

(Elevator)

Magnetic

Separator Milling

Mixer

Surge Hopper

Storage

Storage

Weigh

Storage

Conditioning

Crumbler/

Granulator

(roller mill)

Screen

Pelleting

Pellet Cooler

Storage

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• Bagged Ingredients

– Label compliance

• Bulk ingredients

– Quality assessment

– Contract compliance

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• Cereal grains

– Hammer mill or Roller mill

– Coarse grind similar to “cookie”

• Soft ingredients

– Usually not pre milled, however some petfood manufacturers will.

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• Batching

– Based on formulation

– Bulk ingredients

– Hand additions

• Mixing

– Various mixers can be used

– Paddle, ribbon

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• Most feedmills use pelletting as primary cook method

– Steam preconditioning

– Pellet press

• Extrusion

– High temperature and pressure

• Expansion

– Pressure

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• Cooling

– To ambient temperature

• Drying

– Remove excess moisture to approx. 12%

Both are used to reduce risks of poor pellet formation and mould growth

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• Finished feed bins

• Bulk delivery to customer

– Dedicated trucks

• Bagging

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• The cost of feed ranges from 50 to 80% of the cost of raising livestock.

• Many of our customers in feed manufacturing and livestock production have developed sophisticated systems for measuring and managing their feed costs.

• Most manufacturers use Least Cost Ration Formulation

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• The nutritional requirements of the target animals (species, genetics, age, weight, sex, function)

• The nutrients in available feedstuffs

• The price of available feedstuffs

From these they can calculate the best/least cost of the required nutrients each commodity supplies.

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• Identify the target animals

• Identify the nutrient requirements for the animals

• Choose the feed ingredients to be used and identify the nutrient content of the feeds

• Calculate how much of each ingredient must be used

• Check the nutrients in the finished feed against the needs of the animal

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• Species

– Monogastics

– Ruminants

• Physiology

– Maintenance

– Growth

– Reproduction

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• Protein

– Amino acids

• Energy

– Lipids, carbohydrates, fibre

• Moisture - water

• Vitamins

– Fat and water soluble

• Minerals

– Trace and Macro

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• But remember no one nutrient is more important than the others

• A balanced and complete diet must contain all the necessary and essential nutrients

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• Most modern feed mills now incorporate a quality management system to ensure:

– Customer satisfaction

– Feed safety

– Continuous improvement

– Third party accreditation

– Regulatory compliance

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