Livestock husbandry has undergone great changes in the past two decades and is changing rapidly. The improvement of the genetic basis of livestock and poultry compels feed producers to produce high-quality feeds to meet the higher nutritional requirements of high-quality livestock and poultry breeds. An in-depth understanding of nutrition knowledge, environmental issues, and ethical relationships requires feed producers to change their production processes. The use of new additives such as enzymes requires feed producers and equipment suppliers to consider the use of processing designs with low feed content. This article reviews recent advances in feed production technology, equipment and operations and looks forward to the 21st century feed mill.
There must be innovation. There are many reasons why the feed industry is innovating. In some cases, economically weak competition requires producers to adopt more effective technologies. In other cases, new regulations in government agencies force producers to make changes. In any case, new concepts and technologies are required in competitive industries or businesses, and the feed industry itself requires few changes.
The factors that require innovations in feed production include government regulations, regulations, and public concerns about food safety; the use of feed additives and growth promoters; residues of pesticides and other chemicals in feed and its products. Feed additives used for growth promotion may be banned at some point in the future. Although there is a lack of scientific evidence for the antibacterial properties that result from the use of additives, public awareness may be sufficient to eliminate the use of current additives.
The feed industry may have to use a heat sterilization process to eliminate microbiological contamination of feeds shipped, which has been implemented in all European countries, and the United States will adopt this policy in the coming years. Heat sterilizing process can not disappear fungal fungus, but diagnostic techniques improve quickly. Reducing the effects of mycotoxins is technically expected to make feeds safer. Another factor that promotes technological improvements in the feed industry is environmental issues, including atmospheric and water pollution, animal waste disposal and odor control. It is widely believed that environmental pollution can be reduced by increasing the use of feeds. Kansas State University studies have shown that simple techniques like proper comminution can cause drastic reductions in dry matter and nitrogen content in pig manure. The use of enzymes such as phytase, cellulase and beta-glucanase can increase the digestion of nutrients in animals and reduce the difficulty of waste treatment. Some processing, such as bulking, pressing, extruding, and hydrothermal treatment can increase the use of nutrients. The normal requirement for feed mills is to control dust and storm pollution. Almost any state should consider the contamination of the tank farm. Some states are stepping up control of gas leaks and these controls will not be reduced in the future. Structural changes in the industrial structure feed processing industry have also led to changes in production methods. Industrial mergers have led to an increase in the production capacity and international status of established feed companies. Feed producers began specializing in production. For the production of feed selenium, which has low or no potential benefits, it is replaced by locally required feed. Aquatic feeds and pet feeds are also produced as needed. Vertical integration in agriculture leads to an increase in the production of feed for a single livestock breed. The quality of a feed plant depends more on the environmental conditions than the traditional livestock breeding density. The merger will continue to exist in the feed industry. Old or inefficient feed mills will stop production. Feed production is increasingly concentrated on high-efficiency plants. Many people do not want to merge, but vertical coalitions will continue. Another phenomenon is that many commercial feed companies quietly self-associate to ensure that their feed mills sell well. Many companies often check Their production line determines each feed mill produces the most profitable mix. To be profitable, it is impossible for a feed mill to produce all the feed that meets all consumers, but must cut off some inconsequential products from the mix. Although farm feed processing is not an outdated thing, many producers have found that centralized management can earn more profits while allowing some people to do what they can do. The impact of the combination of feed producers on feed purchases has caused pure producers to disappear. This trend will inevitably continue. The expansion of production scale helps producers to sell his products at a lower price. Process control/automation Process control and automation facilitate a series of changes that occur in the feed industry. Effective technology has made it possible for feed plants that are not operated on the job. The question is whether it is necessary to do so, enter the next century, we will have more and better choices for automation, which requires managers with clear goals and superior intelligence to determine the appropriate level of automation. In many cases, managers determine the degree of automation of the process based on labor savings. In fact, managers took over the most secular jobs in the feed mills, but the arguments were growing more and more about the quality and consistency of the feed. Computers can perform well with repetitive tasks, such as weighing, and can achieve very high precision. The computer can also monitor the entire process and make control decisions. A typical employee assigned to multiple jobs rarely makes the machine reach its limit of use. There is no doubt that with the automatic increase in the degree of feed plants, the level of managers and employees should be increased. Although the feed processing plant is operated by a small number of employees, the cost of retaining employees with a high level will increase, which is in contrast to saving labor costs. Many feed mill employees today cannot be automated and need to be retrained or replaced. The biggest advantage of automation may be the ability to generate reports. It covers the status of processing parameters per minute, inventory and daily usage reports, incoming and outgoing reports, financial statements, and preventive maintenance projects, schedules, and other transactional work. We are in the information age, and managers with low levels will be overwhelmed by information. In some feed companies, there is no feed production experience to the executive for feed production management. There are also business managers who have outstanding performance in other areas to participate in management. In many cases, they are experts in managing information. In fact, companies that produce feed, food, or cars rarely have a connection. Button production lines require people who want to retain management positions to learn to manage information and processing processes and people. In the coming century, a large number of additional projects will affect how feed plants are built and how they are managed.
Feed ingredients We have all heard of genetically modified organisms (GMOs). At the end of the century, the biggest problem facing many feed mills was the processing of two sources of cereals, which had to be acquired, stored, crushed and used separately. In the future, up to four or five types of GMO cereals and conventional grains that are required to be certified for protection can be used in the feed industry. You can imagine the chaotic scenes of acquisition, crushing, storage space allocation, and quality identification. Now it is the feed mill manager who considers how to deal with this issue. Once it is necessary to wait until it is confirmed that the protected grain has been transported out of the train, chaos is inevitable. There is no easy solution to the current feed mill and it may be necessary to increase the storage and crushing space. When adding new facilities, they should be designed to be flexible from the beginning. For example, the U.S. feed industry often crushes grains before they are used for ingredients and blends, while Europe often uses them after crushing. If crushed after weighing, the problem is solved. The new feed mill should be built both before and after smashing. In addition to GMOs cereals, new by-products are increasingly being used as feed. Some come from the food processing industry, and therefore their ingredients are unique. In the acquisition and storage of raw materials, fast unloading and cargo segregation will be necessary in the future. If the feed mill receives bulk raw materials through trains, 100 effective compartments are required. The detention period of the vessel is 15 hours later than the train transportation, resulting in a rise in freight rates. In many cases, the company has begun construction of an additional storage and fast unloading system for immediate access to raw materials. Segregation effectively allows a dramatic drop in the nutrient content of a particular batch of raw materials. Current analytical techniques can detect certain ingredients in raw materials in a very short period of time. According to a key component such as protein, fat and moisture content stored in isolation, so that the formulated feed closer to the nutrition needs of a given animal, avoid nutrient waste. Obviously this requires a great deal of flexibility in the feed plant storage system, as well as the requirements for specific raw materials.
The smashing is not very particular about grain smashing, but the smashing results have a dramatic effect on feed shrinkage, mixing performance, pelleting quality, and animal performance and health (ulcer). Although the drum mill has become a trend, the situation is somewhat sluggish, and the hammer mill won't disappear in a short time. In Europe, the vertical axis hammer crusher replaces the horizontal axis hammer chip. It is reported that the former has the advantage that it does not require air assistance, and the runner can produce a fan effect, forcing air to pass through the screen from the crushing chamber. In addition, the vertical axis hammer mill is poor in feed mixing (such as smashing). Feed crushing is almost completely automated. It must be considered when selecting the right raw material package and automatically opening and closing the logistics, even when unattended. The crushing process should also consider proper detection and control.
The usual batch weighing system technology of the distribution system is very good, but sometimes it is difficult to maintain, and some aspects need to be improved. One of them is online innovation, and instruments that measure the composition of proteins, certain amino acids, fats, humidity, cellulose, and starch should be frequently tested. It is possible to test each batch of feed, which can greatly improve the accuracy of feed ingredients.
Weighing accuracy is another aspect. There is a constant weighing system that uses weightlessness instead of net weight in each batch. This can include ingredients in shipping bags or shipping cans. With the weight loss system, 10 or 15 parts can be weighed at the same time, which can shorten the cycle time between batches, provide a continuity report, and weigh more accurately than usual. Batch cycles of 1.0 to 1.5 minutes are required and can be matched with future short mixing cycles.
It is difficult to say whether there is a tendency to increase the individual mixing capacity (12 to 15 tons) for a new single-animal feed plant. I personally believe that small (2 to 4 tons) short-cycle agitation will have a place because of its flexibility and high output per hour. For example, a 3-ton blender, 1.5-minute cycle, and 1-hour production of 120 tons of compound feed, is now possible, and is expected to reach a cycle of 1 minute in the future. Pelletizing and other hydrothermal processing granulations are irreplaceable in the foreseeable future, but can also be improved in terms of granulation efficiency and granulation quality. Some reforms were effective at the time, but they were rarely suitable for existing feed mills. The following are some trends in conditioning, granulation, and cooling.
Each conditioning time of the quenching and tempering time controller is not suitable for all feeds. After the improvement, the conditioning time can be changed into a controllable variable, which can be controlled by using the shaft speed and/or picking angle. The conditioning time can be adjusted according to the type of feed or the desired particle quality. For a long time, it has been considered that the quenching and tempering residue time has an effect on the quality of refining and the quality of pellets. In the past year, European equipment suppliers have made some innovations in this regard, including the angle of the tuner, the adjustment of the angle of prey, and the steam or smash Wiers. Conditioners are basically mounted on a horizontal platform. A hinge is attached to the rear of the conditioner to elevate its front end to facilitate the flexible use of the inlet and outlet nozzles, which may result in infinite control of the residual time. Under normal circumstances, the conditioner is leveled when the conditioning is started. Once stabilized, it can be tilted to the desired level. The prey angle can be adjusted during the operation of the new model conditioner. In this case, the adjusting rod is hollow and can be rotated at any time. When the pulp angle reaches the standard value, the granulation starts. After the stabilization, the pulp angle can be adjusted to increase or decrease. Residual time. A relatively simple and effective improvement to the conditioner is to install a flat plate to prevent the escape of steam and powder. The top plate prevents the steam from flowing out of the conditioner without coming into contact with the powder. The bottom plate forces the predator nozzle to raise the finished powder. In this case, the drug residue is very serious because there are 50 to 200 pounds of feed left in the conditioner every time, but there are two technologies to solve this problem.
Humidity Control It is well known that granulation quality and productivity depend on comminution of moisture and temperature, humidity, and humidity detection and control systems that are effective but require increased precision and resistance. It is now as easy to adjust the moisture content of the powder as it is to adjust the humidity.
Pellet quality The industry can now adjust the particle quality in formulas just as it regulates amino acids, minerals, energy, etc. The particle quality does not change linearly with the material composition, which is more difficult. As the data increases, the particle quality should be predictable.
Online roll adjustment This is an effective but costly way of regulation. Recent experience with pellet machines shows that this is not the case. As with the conditioning time, the single scroll setting does not have the best effect on all materials, and online scrolling can solve this problem.
The granulation pressure is slightly increased by the steam pressure of the new pelletizer designed by PCI, and the crushing temperature can be increased above Z12F. The preliminary results of granulation quality and broiler production performance are encouraging. Now production machines can be installed in broiler feed mills in the same way as prototypes.
The Universal Granulator (UPC) The concept of universal granulator was proposed by the Wenger manufactory. Compared with particle machines, it is closer to the extruder. But its products are granular. Using UPC can get a very good granulation effect, have a wide range of application prospects in aquatic animals, raw materials and pet feed.
The essentials of expander high temperature and short-term heat conditioners are acceptable in the United States, although they may change. The quality of the pellets has improved, but the animal's production performance has not improved, and the maintenance and processing costs are high. Another problem is the use of swelled feeds to affect pig health (ulcers). Some companies are exploring the possibility of heat expansion without granulation. There is still a problem with bulk density and flow, but animal production is equivalent to pellets.
Cooling machine reverse cooling machine is very common in the new feed mill, but the problem of finished product humidity control has not been solved. I think that in the future, the chiller should be equipped with a humidity sensing control system that can dry the material to a safe level just like the cooling material. This requires two hot and cold bands and airflow control.
The challenge for post-granulation extra application granulation is to add phytase and other heat per sensor additives to the feed. Another challenge is to uniformly add 25 to 50 grams of active material to a ton of feed. We cannot simply add it in the same way that we add 20 to 80 pounds of fat to 1 ton of feed. Many existing technological innovations are expensive and cannot be applied to existing equipment. This should be considered in new designs and new construction. Loss-of-weight systems, weigh-belt feeders, control particle flow rates and give signals to add an accurate amount of additives.
Phytase is the basis for low levels of heat-sensitive additives. Other enzymes, drugs, vitamins and biological agents require similar or better accuracy. We should now be prepared.
There are many contradictions between unloading and transporting feed mill managers and nutritionists. Nutritionists want to prepare 12 to 20 different feeds for pigs and turkeys, and 8 to 12 broilers. Most feed mill managers want to prepare a feed for each animal. This is a dilemma. The more formulas, the lower the production efficiency and production volume of feed mills. Some companies produce two or three basic feeds and then mix them at the outlet in different proportions to produce feeds that meet the animal's production stages. This is theoretically possible, but it is actually difficult. Mixing requires additional weighing and additional formulation. Accuracy is a problem, and particle quality degradation can occur. The homogeneity of the finished product should be at least consistent with that of the basal feed, which is beneficial to solve the problems between the efficient production of the feed mill and meeting the nutritional needs of the animal.
Summary It is difficult to predict what feed mills will have in the 21st century, but there are many alternatives. The more you grasp the situation, the easier it is to choose. There is no doubt that feed mills will be more connected with food safety, environmental issues, livestock farm production efficiency and economics. The feed mills that can survive are necessarily feed mills with a wide range of sources. They can make logical decisions based on information that is useful in journals, weekly magazines, trade fairs, and newspapers. They also predict the future based on European trends. .
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