Paper 17 - Mr Stefan Vontobel
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Transcript of Paper 17 - Mr Stefan Vontobel
AFMA 2010 developments in feed processing | Stefan Vontobel | 20101 | © Bühler |
Most recent
developments in
feed processing
Stefan VontobelBühler / Switzerland
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
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%
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
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
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.
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
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
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
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
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.
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
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
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
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
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
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
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
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
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
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
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
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
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
AFMA 2010 developments in feed processing | Stefan Vontobel | 201025 | © Bühler |
Thank you