Vijay anand p e; ussec animal feed milling - pondering on strategic check points
description
Transcript of Vijay anand p e; ussec animal feed milling - pondering on strategic check points
1
ANIMAL FEED MILLING PONDERING ON STRATEGIC CHECK POINTS
Dr. P E Vijay Anand
Director
India – Feed / Meal Program, USSEC
2
Marketing
FEED MILLING IN THE VALUE CHAIN?
Raw Material and Input
Management Feed Milling Technology
Animal Production
So its important
Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
Animal feed milling - Pondering on strategic check
points
3
WHY SHOULD FEED MILLING IMPROVE IN
INDIA?
Most of it is not OK
Some - thinking of improving
Very few practice GMP Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
Animal feed milling - Pondering on strategic check
points
4
FOOD VALUE CHAIN – WHY IS FEED MILLING IMPORTANT
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Raw material
Feed Manufacture
Animal production
Human food
Lower most step
All the more attention is needed because of this position; what goes wrong here gets passed throughout
Animal feed milling - Pondering on strategic check
points
5
THE SWING IS HIGHLY VARIABLE
Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
Degrees of modernization vary - There is a lot of room for modernization and improvement immaterial of size of the mill
Animal feed milling - Pondering on strategic check
points
6
INTER-LINKAGES IN FEED MILLING
Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
Genetics
Nutrition
Performance
PUSH
Animal feed milling - Pondering on strategic check
points
7
PRESENT DAY DRIVER?
Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
Animal feed milling - Pondering on strategic check
points
Genetic improvements are placing constant pressure on feed
manufacturers to produce quality feeds that match the increased
requirements of improved breeds without creating additional physiological or health
stress
8
HOW MUCH FEED WAS PRODUCED IN 2013?
Commercial broiler – 10 MMT
Commercial layer – 11 MMT
Poultry breeders – 1.74 MMT
Aquaculture – 1.25 MMT
Dairy – 7 MMT
TOTAL – 30.99 MMT Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Animal feed milling - Pondering on strategic check
points
9
HOW MUCH FEED WILL BE PRODUCED BY 2020?
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
31 40.00 29%
Obvious - Some good attention is needed
Animal feed milling - Pondering on strategic check
points
10
NEW FEED MILL BUSINESSES IN THE LAST 6
MONTHS
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
24 Mills 1.27 MMT Rapid expansion
Animal feed milling - Pondering on strategic check
points
11
NEW SOY MEAL BUSINESS
CG-Nil
OR- Nil
BH(2) 72/15
MP-Nil
PB(1) 48/10
HR(3)144/31
MH(1) 60/15
KA (0) Nil
KL(0) Nil
AP(6) 444/123
WB(2) 108/28
JH - Nil
RJ (2) 96/21
TN(1)
21
Feed capacity 1.11 MMT SBM potential 0.274 MMT
Poultry 13 Aqua 8
2013
UP(2) 144/31
Animal feed milling - Pondering on strategic check
points
12
NEW FEED MILL BUSINESSES IN THE LAST 5 YEARS
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Year New animal feed
businesses
New feed milling
capacity
New soybean
requirement
2009 39 2.5 0.500
2010 29 1.08 0.235
2011 29 1.04 0.254
2012 25 1.16 0.270
2013 51 2.10 0.403
TOTALS 173 7.88 MMT 1.66 MMT
Animal feed milling - Pondering on strategic check
points
13
PEOPLE ON CONTROLS
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Feed Mill
Formulator
Production
Procurement QC and inventory
Engineering
Check Points
Animal feed milling - Pondering on strategic check
points
14
PROCUREMENT – FIRST STEP
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Feed mills cannot have direct control on raw material
Material is diverse in terms of production methodologies used, geographies, quality, quantity, processing and handling
Purchase based on moral guarantee?
Animal feed milling - Pondering on strategic check
points
15
PROCUREMENT – CHANGE STYLE
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Verbal agreements and phones are in great use
Contracts are not honored
Depending on guarantee has to set in
Analytical reports will decide; not phone calls
Animal feed milling - Pondering on strategic check
points
16 Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
LAB ANALYSIS? Majority don’t have labs
Advanced rapid analysis is helping take decisions; saves money
Choice of analytical labs is a matter of striking a balance between buyers and sellers
Animal feed milling - Pondering on strategic check
points
17
PRODUCTION Animal feed milling - Pondering on strategic check
points
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Head of production
Preventive maintenance
House keeping
Attention to every functioning part
Manpower on shop floor; training
18 Vijay Anand; Aqua India 2014; 23-24 January, Vijayawada, India; Advocating a path forward for freshwater fish farming
THREE MAJOR COSTS THAT FEED MILLS HAVE TO FIGHT
Fuel for transport and in-plant
operation
Increasing electricity cost
Increasing raw material cost
Animal feed milling - Pondering on strategic check
points
External factors not in
control of feed mills
3
19 Vijay Anand; Aqua India 2014; 23-24 January, Vijayawada, India; Advocating a path forward for freshwater fish farming
ELECTRICITY
Grinding Mixing
Fines Pelletting
Cooling Moisture
Animal feed milling - Pondering on strategic check
points
20
DIESEL DOUBLE PINCH
Material in Material out
FEED MILL Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Animal feed milling - Pondering on strategic check
points
21 Vijay Anand; Aqua India 2014; 23-24 January, Vijayawada, India; Advocating a path forward for freshwater fish farming
DIESEL IN THE LAST DECADE Animal feed milling - Pondering on strategic check
points
22
RISING RAW MATERIAL
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Surely a major combat area – cant afford to keep mill efficiency low
Animal feed milling - Pondering on strategic check
points
23 Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
CASH FLOW
Capital advance for input management
Capital blockage due to market vagaries
Animal feed milling - Pondering on strategic check
points
24
IMPORTANT CHECK POINTS (INDIA)
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Feed Mill
Grinding
Mixing
Fines
Moisture Pest
control
Storage
Pelleting
Animal feed milling - Pondering on strategic check
points
25
GRINDING
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Big cost in a feed mill
Selection of equipment
Strong maintenance
Optimizing particle size saves cost
Particle size – linked performance
Increase in particle size is known to increase digestion specially in the upper tracts of young animals
Animal feed milling - Pondering on strategic check
points
26
MIXING
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Nutrient uniformity
Mix time; diet uniformity; ingredient segregation co-relation is not available
Mixer testing procedures?
Diet uniformity critical in younger
animals as compared to older animals
Animal feed milling - Pondering on strategic check
points
27
PELLETING
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Pelleting
Reduces wastage
Minimizes selective feeding
Reduces ingredient
segregation
Less time and energy for
prehension
Destroys pathogens
Thermal modification of
starch and protein
Improved palatability
Animal feed milling - Pondering on strategic check
points
28
PELLETING
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
40% Formulation
20% Grinding
20% Conditioning
15% Die section
5% Cooling/Drying
60% of pellet quality can be
determined before it
reaches the pellet mill
Animal feed milling - Pondering on strategic check
points
29
WHAT ELSE DOES THE FORMULA DO?
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Animal requirements
Pellet quality
Animal feed milling - Pondering on strategic check
points
30
WHAT ELSE DOES THE FORMULA DO?
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
Least cost formulations/Best cost formulations – can they be made to predict pellet quality too?
Charts are available on pelletablity of common ingredients
Animal feed milling - Pondering on strategic check
points
31
FINES
Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
Fines
Pellet cooling
hindrances
Fat coating hindrance
Selective feeding
Segregation
Usually generated due to low pellet quality
Lower pellet quality
More fines
More recycling efforts/cost
Reduced through put of mill
Animal feed milling - Pondering on strategic check
points
32
MOISTURE
Vijay Anand; Global Milling Conference 2014; 23-24 March 2014, Pondering on strategic feed milling check points
25 kg feed bag 10% moisture Equals 2.5 l water
2.5 l water is evenly distributed in a normal course
Animal feed milling - Pondering on strategic check
points
33
MOISTURE MIGRATION
Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
Feed Bag Stacked against a wall Cooler surface
15 kg feed 2.5 l water
=16% moisture
Animal feed milling - Pondering on strategic check
points
34
WHAT ELSE DOES MOISTURE DO TO A MILL?
Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
Animal feed milling - Pondering on strategic check
points
High raw material moisture = production loss due to in plant shrinkage
Higher finished product moisture = marketing problems
Procurement Manufacturing
35
SUMMARY
Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points
Animal feed milling - Pondering on strategic check
points
Milling is a weak link
Genetics is driving milling
Feed business growing
New Business in India
Feed’s position on value chain
Three major external costs
People on controls
Cash flow
Pelleting
Fines
Formulation
Mixing
Grinding
Moisture
36
LETS THINK AND PLAN
BETTER MILL EFFICIENCY
Animal feed milling - Pondering on strategic check
points Thank You
Vijay Anand; Global Milling Conference 2014; 23-24 April 2014, Pondering on strategic feed milling check points