Digital Re-print - November | December 2010

New dimension in the production of hygienised feed meal

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New dimension in the
production of hygienised
feed meal
P
athogenic bacteria in feed meal
are a major risk factor for animal
health and performance.
Thermal meal treatment significantly
reduces microorganisms in feed, but requires
a subsequent cooler after the hygienising
section. Difficult to clean, conventional meal
coolers can be a potential source for cross-
and re-contamination.
A new process solution has been devel-
oped by Buhler Group, Switzerland, utilizing
thermopneumatic conveying for drying and
cooling as a smart alternative to meal coolers.
Contaminated raw materials
Agricultural products are a natural source
of microorganisms such as bacteria, yeasts
and molds.
The degree of contamination is subject
to parameters such as type of raw mate-
rial, origin, transport and storage conditions
14 | november - december 2010
by Stefan Hoh, Buhler Group, Switzerland
and the season. Whereas, most of the
microorganisms are harmless, some species
like enterobacteriaceae show pathogenic
potential, with salmonella being the most
common subspecies of enterobacteriaceae
in animal feed.
Infection doses for salmonella are com-
paratively low, with an incubation period of a
few hours to two days, depending on animal
species and age.
Salmonella can cause serious animal dis-
ease like diarrhea, reducing feed digestibility
and conversion, impairing animal growth and
performance.
Hygienising by heat treatment
Sensitive to heat, salmonella are usually
killed at temperatures above 55°C.
However, high concentrations of fat, pro-
tein or starch in formulated feed may form a
protective colloid layer and thus increase the
heat resistance of bacteria.
Feed meal Feature
Hence, a hygienising temperature of
about 85°C has become common practice
in the feed industry to ensure that virtually
all pathogenic bacteria are destroyed. The
temperature is achieved by the addition of
steam into the conditioner and retained
for a certain dwell time in the subsequent
retentioner to guarantee a reliable decon-
tamination process.
Recontamination after
hygienising
After the hygienising process, the hot
and moist feed has to be cooled and dried
to prevent recontamination and growth of
microorganisms.
This usually takes place in conventional
meal coolers utilizing the principle of fluid
bed cooling. Ambient air enters the cooler at
the bottom side, flows through the perfora-
tion and fluidizes the meal.
Even though providing efficient cooling,
Grain &feed millinG technoloGy
Feature Feed meal
meal coolers are often described as a ‘five
star hotel’ for microorganisms: The handling
of hot and moist feed meal can cause con-
densation in the meal cooler, with free water
being a major growth factor for bacteria
which has resist the hygienising process or
airborne bacteria from the high air volumes
applied.
Furthermore, cross- and re-contamina-
tion can occur due to product residues in
the system, which are difficult to remove and
require tremendous cleaning effort.
Thermal meal treatment
The Buhler Group has developed a new
process solution utilising thermopneumatic
conveying for drying and cooling of hygien-
ised feed meal. The thermal meal treatment
process is divided into the sub-processes of
hygienising and thermopneumatic drying/
cooling.
Hygienising is carried out by the HYMIX
and HYTHERM modules.
In the HYMIX, the compound feed
particles can be heated to a temperature
of 80 to 90 degrees C by the addition
Grain &feed millinG technoloGy
of steam. The heated formulated feed is feed enters the Triple Air Control (TAC)
then retained in one or optionally two system for drying and cooling. In the first
HYTHERM modules. stage, pre-heated air is applied for drying and
This allows retention times between 60 cooling, utilising the effect of evaporation.
and 240 seconds to be achieved as a func- Final product temperature is achieved in
tion of the throughput rate. In addition, the the subsequent two pneumatic conveying
HYTHERM system is characterised by its lines, utilizing ambient air for cooling.
very narrow dwell time distribution, thus get- The optimised concept of HYMIX and
ting very close to the ‘first in – first out’ prin- Hytherm ensures low product residues and
ciple, which ensures reliable hygienisation. easy cleaning.
In a second process step, the hygienised Thanks to the high air velocities applied,
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november - december 2010 | 15
 be utilised in the best possible way. Improved feed feed trough.
The system was installed at the Amrein The pig feed produced by the new Last, the heat and steam treatment causes
Futtermühle AG, Switzerland, which pro-
duces hygienised swine feed.
process is characterized by its extremely low
count of microorganisms such as bacteria,
fines to Feed F
mealon coarser eature
agglomerate particles,
which reduces dust generation and improves
Operation of the new facility is fully molds, and yeast fungi. flowability. Choke-ups during discharge from
automated and is controlled exclusively Pathogenic bacteria such as salmonella storage bins and silos are greatly reduced
from the control room. This cuts labour are virtually destroyed, which significantly compared to untreated feed meal.
costs and allows
the TAC system just-in-time
is self-cleaning,production.
which pre- reduces
needs or theadjusted
incidence to and
feedseverity
recipes of
fordiar-
other ability of the feed. Thermally treated swine
Thevents product deposits. Cooling byuptime
new process increases the a ther- rhea disorders in the animals.
animal species, e.g. layer and breeder feed. feed may thus have a positive influence on
ofmopneumatic
the processing lines thanks
conveyor greatlytoreduces
reducedthe Besides
This isimproving the animals’
made possible health,
by the this
following the animal’s appetite and – according to
downtimes when formulationsand are recontami-
changed also enhances feed digestibility, which in turn
risk of cross-contamination options: microfiltration of the air for top More inforMation
feedback :
Amrein received from its custom-
in nation
comparison with hygienising
in comparison to conventional systems
meal hassanitation
a positivestandards;
impact onaddition
the weight
of increase
solid and ers – results in outstanding feed acceptance.
Buhler Group
consisting
coolers. of pellet mills and conventional ofliquid
the animals.
microingredients; post-mixing applica- Moreover, thermal meal treatment
Uzwil, CH-9240 SWITZERLAND
meal Thanks
coolers. to its flexible design, the new Thefor
tion Maillard reactionproduct
unsurpassed occurringhomogeneity;
during the improves the water solubility of the
Website: www.buhlergroup.com
The
thermalnew thermal
meal meal treatment
treatment system hassystem
a small thermal treatment process creates
and monitoring of the steam quality a bundle
and/or feed. Product lumps in the feed slurry
caninstallation footprint. This enablescustomer
be easily tailored to specific the space ofofroast flavours, which
the moisture content. improve the palat- are effectively prevented, as well as
available in existing feed production plants to deposits of high-density particles in the
be utilised in the best possible way. Improved feed feed trough.
The system was installed at the Amrein The pig feed produced by the new Last, the heat and steam treatment causes
Futtermühle AG, Switzerland, which pro- process is characterized by its extremely low fines to agglomerate on coarser particles,
duces hygienised swine feed. count of microorganisms such as bacteria, which reduces dust generation and improves
Operation of the new facility is fully molds, and yeast fungi. flowability. Choke-ups during discharge from
automated and is controlled exclusively Pathogenic bacteria such as salmonella storage bins and silos are greatly reduced
from the control room. This cuts labour are virtually destroyed, which significantly compared to untreated feed meal.

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costs and allows just-in-time production. reduces the incidence and severity of diar-
The new process increases the uptime rhea disorders in the animals.
of the processing lines thanks to reduced Besides improving the animals’ health, this
downtimes when formulations are changed also enhances feed digestibility, which in turn
More inforMation:
in comparison with hygienising systems has a positive impact on the weight increase
Buhler Group
March 9 - 11, 2011
consisting of pellet mills and conventional
meal coolers.
of the animals.
The Maillard reaction occurring during the
Uzwil, CH-9240 SWITZERLAND
Website: www.buhlergroup.com
The new thermal meal treatment system thermal treatment process creates a bundle

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can be easily tailored to specific customer of roast flavours, which improve the palat-

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