January | February 2010

Feature title: Least cost formulation in aquafeed

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The International magazine for the aquaculture feed industry

 Least-cost
formulation in
aquafeeds
by Peter De Letter, Consultant BESTMIX® feed formulation software email: peter.deletter@adifo.be, Adifo NV, Belgium
and Jean Broers, Product Manager BESTMIX® feed formulation software email: jean.broers@adifo.be

A
quafeed formulation is a in agrifeed. The nutritionist manages his availability per plant, the software creates a
fast growing business, yet set of ingredients by setting the measured least cost formula that fulfils the ingredient
relatively new. Growing and calculated nutrient values. Then, taking and nutritional requirements of the diet.
world population, pressure into account the ingredient prices and the However, the quality and ‘real world’ cost
on the use of marine ingredients,
price volatility of raw materials, better
availability of nutritional knowledge Figure 1: Data integration of formulation data
and difficulties in the production of
aqua diet make aqua diet formulation
a challenging business. A professional
and state of the art least cost for-
mulation software, like BESTMIX®
Dry with 20-50% less energy
(a product by software specialist
Adifo) is essential to develop sustain-
able, cost effective and nutritionally
complete feeds.

Data management
and integration Geelen Counterflow / T +31-475-592315
The general principles of least cost Geelen Counterflow USA Inc. / T +1-772-559-4338
formulation for aquafeed are the same as
Geelen Counterflow América Latina / T +54-9-2362-418899
E info@geelencounterflow.com / I www.geelencounterflow.com
14 | InternatIonal AquAFeed | January-February 2011

F: Feed formulation
effectiveness of the
aqua diet stands or
falls with the quality
of the available data.
Import wizards and
special data manage-
ment tools help the
nutritionist to gain
time and have a reli-
able database where
prices, stock data,
nutritional data and
quality constraints
are up to date.
BESTMIX® feed for-
mulation software
offers the possibility to exchange informa-
tion with ERP and production systems and
to import nutritional data and calculation
rules from external ingredient suppliers or
research institutes. In addition, the software into account antinutritional factors of
is able to use online data coming from
NIR apparatus filtered through a special
lab module called BESTMIX® LIMS (see
figure 1).
Fulfilling nutritional and
ingredient constraints
Aqua diets contain a high concentra-
6 | InternatIonal
tion of protein and fat. This adds extra
10
complexity to aqua diet formulation.
Aqua feed nutritionists are challenged by
the need to reduce reliance on marine
protein and lipid sources offering new
"Using BESTMIX® multiblend, feed producers can
reduce raw material costs by more than 1%.
This way, the limited and more expensive
resources will be divided amongst all aqua diets
in the most cost effective way"
alternative protein sources. BESTMIX®
helps searching for nutritionally valid
alternatives by getting the most out of
the nutritional potential of all ingredients.
When setting a maximum constraint on
marine oil and protein sources, or in case
prices and availability are not favourable,
the software will search for a valid and
cost effective alternative formula. Such
an alternative mixture could consist of
vegetable oil and protein (or algae based)
16 | InternatIonal AquAFeed | January-February 2011
Figure 2: use lot optimization to cope with
changing ingredient qualities assuring a stable
end product quality
sources combined with additives like
lysine, methionine, enzymes to increase
essential nutrient availability from these
sources and phosphate additives taking
phytic acids for example.
Gut physiology and development vary
widely between the different aquaculture
species and life stages. Therefore it is
important to be able to set up aqua diets
per species and life stage. The nutritionist
can create constraint frameworks and
calculate specific
nutrient
AquAFeed availability2011
| January-February for
larvae
and adult AquAFeed
| InternatIonal animal types. This con- 2011 A second control mechanism is the
| January-February
cept has already proven to maximize cost
effectiveness in agrifeed.
Developing fish feed is a phased
research and development project. In the
final stage, when the production is defined
and set, the diet should not change too
drastically in order to guarantee the
defined R&D characteristics. Still, the
guaranteed nutritional values must be met
at all times. Small quality changes of these
ingredients will result in large deviations
of the quality in the end-product. The
production formulator must take this
into account to deliver feed with stable
quality. Developments are available to
seminar has been a huge success Email: sales@meriden-ah.com
and wesignificant increase
look forward of the toxic potency of
to working and above can affect fish performance and dis- group, and yellowing of the tilapia surface was
Website: www.meriden-ah.com
AFB1 (Centoducati et al., 2009). ease resistance
The hapatoxicity of AFB1 was also con-
firmed by Spahdari et al. (2010) in a study
which confirms
previous obser-
Are you sure
T IatNlevels
T O ofD0,R25, E 75, and vation
looking at the impacts of AFB1 on Beluga
I N(Huso
S E Rhuso) I V50, by (Phuoc
et al., 2004) who I‘m not missing
100ppb AFB1/kg of diet during a three- reported that a key essential
months period. FOR ADDED MAR G Icontaining
diet N nutrient?
In this case, results showed that the vari- 60 – 300 ppb l Large range and inventory
ous levels of AFB1 did not significantly affect AFB1 can signifi- of many sizes
the specific growth ratio (SGR) (P<0.05) of cantly reduced l Higher capacity for existing
fish in different treatments. performance of elevators
However, weight gain and food conver- tra catfish 16.59 l Durable, long life designs
sion ratio (FCR) varied significantly (P<0.05) ± 0.2 g after 10 l Free elevator design service
between control and treatments with diets or 22 weeks of
contaminated with 75 and 100ppb AFB1/kg feeding.
after 90 days. These findings Watchdog Elite
Histopathological studies showed that dif- seem to suggest VANNAGEN ®
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ferent level of AFB1 can cause broad range that Pangasius Elevators and Conveyors!
of change in liver tissue, including progressive catfish is more l Bearing Temperature, Belt Misalignment,
naturally supports…
Underspeed, Belt Slippage, Blockage Detection
fat deposition, hepatocyte degeneration and sensitive to
… Per formance
l Fully programmable to optimize elevator operation
necrosis, particularly at concentration of 75 AFB1 than other
and 100ppb AFB1/kg of diets after Format’s
60 days catfish species
… Health l LED displays for speed and set-up
powerful l Simple, reliable, consistent
assure this quality. BESTMIX® contains (Spahdari et al., 2010). such as channel … Stress management
a lot optimization module to take the
formulation and resource Elevator Bolts
catfish (Ictalurus
real-time ingredient quality in account at optimization software Cold Forged for Highest Quality!
Recent studies in Vietnam punctatus) and l Euro Bolts (DIN15237), Original
moves feed businesses
www.chemoforma.com
production time. Each lot of an ingredi- In a recent study in Vietnam, Tu (2010) walking catfish Ref 70, Fang Bolts & Easifit Bolts
ent has a specific quality. This quality forward to improved
conducted a comprehensive study on the sen- margins.
(Clarias batra- l Available in steel / stainless / zinc
can be registered and controlled online plated
sitivity of Tra catfish (Pangasionadon hypoph- chus). The study l Wide range available from stock
upon the intake of each lot by using thalmus) to AFB1, analyzing the Format International
impacts of alsoLimited,
evaluated the
BESTMIX® LIMS, Adifo’s Lab Management Format House, Poole Road,Woking,
feeding AFB1 contaminated diets on growth application of an We have your per for mance in mind
Information System software. BESTMIX® Surrey GU21 6DY, England.
performance, physiological response, histo- Aflatoxin binder
will help the nutritionist and production Tel: +44 1483 726081 Fax: +44 1483 722827
logical changes and disease resistance of Tra (Mycofix®Secure)
Website www.formatinternational.com
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manager to optimize the usage of each catfish. to counteract
Chemoforma Ltd. CH-4302 Augst Switzerland
Tel +41 61 811 33 55 Fax +41 61 811 28 03 Email: 4b-uk@go4b.com
lot, guaranteeing an optimal production
process and a stable quality (Figure 2). January-February 2011 | InternatIonal AquAFeed | 7
January-February 2011 | InternatIonal AquAFeed | 11
Revised Buckets C2 half page 2.indd 1 21/09/2010 11:37:09
use of swing values: tolerances are set
for minimum and maximum deviations on
ingredient percentages determined in the
R&D formula.
Adjusting to the market
using multiblend tools
Theoretically, it is possible to create
the ideal formula: being both nutrition-
ally fulfilling as well as cost effective at
a certain point in time. Yet, ingredient
resources and prices are very volatile
and can change drastically in the short
term. Using multiblend tools, the least
cost formulation program will take into
account ingredient availability and prices
of stock, contracts and the market.
Nutritionists and purchasers can sit
together and create the most economi-
cal overall solution for the whole plant
for a certain defined period. The moment
of stocks and contracts usage can even
be optimized: it can be cheaper to keep
your current stock for a later period and
buy an alternative lot of this ingredient
at current market conditions (Figure
3). Using BESTMIX® multiblend, feed
producers can reduce raw material costs
by more than 1%.
This way, the limited and more expen-
January-February 2011 | InternatIonal AquAFeed | 17
 F: Feed formulation

sive resources will be divided amongst all
Fourth International Feed Regulators Meeting
aqua diets in the most cost effective way.
Coping with production
GROWiNG iS
Aqua News
has to consider other production-related Conclusion
parameters as well. One ingredient can
be dosed on different scales, while each
20" x 10" CC-XD
The different parameters can be chal-
lenging for the team that is responsible
of these scales has a certain precision and elevator bucket
for developing and producing aquafeed.

beautiful
challenges in aqua diets

T
minimal dosing capacity. In some situations, This means that the nutritionist, the feed
he International Feed will offer a wide variety of topics, event, “It is a unique event for

T
Producing aqua-feed is different from the amount of silos is limited. The formula- engineer, the logistic planner, the produc-
I n d u s t r y F e d e r a t i o n including: industry and global feed regula- apco has
producing compound feed. Most fish feeds tor can set up these parameters in his tion manager and the sales manager must
(IFIF) in cooper ation A presentation on regula- tors to come together to discuss i n t r o -
formulation software tool to optimize the all work together in one formulation
with the Food and Agriculture tor y developments of feed issues of mutual interest.” duced a 20"
formula, taking into account the production system in such a way that the information
Organization of the United labeling; Government feed regulators may x 10" Xtreme Duty
"Only
Nations (FAO)thewill most host advanced
the
process parameters of the plant.
The newly reestablished Codex attend this event at no fee. For
is passed from one step to the next step.
(CC-XD) elevator bucket
Afterwards, the diet information must be
four th I n t e r n a t i o n a l F e e d Feed Task Force, hosted by Swiss industry and trade association repre- to accompany its existing 7" and
formulation software Keep your labels up to date
Regulator s Meeting (IFRM) authorities, - an outlook on the sentatives, the cost is $275 USD.
automatically updated when new informa-
8" projection sizes.
tools
January 24-25,such 2011 inasAtlanta,
BESTMIX ® plans and
Task Force
The aqua feed world
a discussion The is aIFRM
highlyiscompeti- tion comes up or when new parameters
being held prior The Tapco CC-XD operates at
tive world. Feed manufacturers have to dif- have been measured. Only the most
USA. The Amer ican Feed of risk assessment methods and to the International Feed Expo/I up to 940 feet per minute. The
guarantee an added
Industr y Association (AFIA) value to tools;
is management
ferentiate themselvesnternational
from the averagePoultrylevel.
advanced formulation software tools such
Expo which is bucket is reinforced with a 5/8"
A good presentationon of January
the aqua-feed diets as BESTMIX® guarantee an added value
assisting with the organization of The IFIF Feed Regulator y 26-28, 2011. For more thick front lip and has 1056.6
aqua diet manufacturers"
the event.
is a must for every producer. Generated
Comparison Repor t for Feed details on the largest annual feed
to aqua diet manufacturers, who focus
cubic inches of capacity. CC-XD
specifications must have a highly commercial on delivering to their customers exactly
Delegates from over 20 coun- Additives will compare and industry tradeshow, visit www. buckets are molded with
value, whilst the information presented must what they ordered.
tries are expected to attend contrast the approval processes in ife11.org or www.ipe11.org. 35-50% more resin than the
are extruded and pelletized.This means that be complete, 100 percent correct, customer
the two-day event, held in the Canada, the USA and the EU; CC-HD. The CC style buckets’
the formulator has to pay extra attention to friendly and fulfilling all legal specifications. So
Georgia World Congress Center, FAO/WHO will provide an More inforMation: distinctive “breaks” on the
controlling the starch content, the humidity, how to keep reports and labels up to date
to discuss topics relevant to the outlook on the possible emer- AFIA bottom of the
More inforMation : bucket provide an
the density and the high fat contents. To be when formulas and ingredients vary in time?
feed and pet food industry. gency notification mecha- 2101 Wilson Boulevard ideal product trajectory. Tapco
Adifo N.V.
able to achieve a certain quality and density And how to keep labels up to date according Industrielaan 11 B is available in polyeth-
IFRM offers a chance for inter- nisms; Suite 916 CC-XD
for optimal pelletizing, the nutritionist or to changing feed policies?
Arlington Adjusting
VA 22201 these Maldegem, B-9990
national regulators to come A report on of the Safe Supply ylene, nylon and urethane and is
production manager can adjust the dry mat- data one by one would be extremely time- Belgium
together and gain greater under- of Affordable Food Everywhere USA ideal for demanding, super high
ter and density parameters in BESTMIX® consuming. ThereforeTel:it+1is703 5241921
essential to be Tel: +32 50 303211
standing of the global issues project. Fax: +1 703 5241921 Fax: +32throughput
50 711193 applications. For
as to start the pelletizing process in ideal able to set up labels in the software in such
affecting the feed industr y IFIF chairman of the board, Email: afia@afia.org Website:more information visit www.
www.adifo.com
conditions. a way, that they are ‘refreshed’ automatically
around the world. The meeting Dave Cieslak, Cargill, said of the Website: www.afia.org tapcoinc.com.
When formulating diets, the formulator when needed.

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38 | InternatIonal AquAFeed | January-February 2011

18 | InternatIonal AquAFeed | January-February 2011 contact@aquativ-diana.com - www.aquativ-diana.com
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