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Victam International Feed and Food Industries Show Aquafeed Horizons Vacuum Coating pelleted feed

Victam International Feed and Food Industries Show Aquafeed Horizons Vacuum Coating pelleted feed May 9 & 10, 2007, Utrecht, The Netherlands By Dr. Aliro Borquez, Aquaculture Engineer – Catholic University of Temuco, Chile

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Victam International Feed and Food Industries Show Aquafeed Horizons Vacuum Coating pelleted feed

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  1. Victam International Feed and Food Industries Show Aquafeed Horizons Vacuum Coating pelleted feed May 9 & 10, 2007, Utrecht, The Netherlands By Dr. Aliro Borquez, Aquaculture Engineer – Catholic University of Temuco, Chile Mr. Eduardo Perez, MA, MBA Ag. Eng. – Norwegian University of Life Sciences

  2. Today’s discussion: Target market for vacuumed coated pelleted feed Difficulties experienced in coating pelleted feed Equipment available to the industry for coating pelleted feed with fat 4. Research accomplished by adding fat to pelleted broiler feed by means of vacuum infusion

  3. Fat levels in diets (%) 1. Target market for vacuumed coated pelleted feed Courtesy of: Dr. S.J. Kaushik, INRA, France

  4. Amazonian spesiesBrazil - Peru Pelleted Feed El Dorado "Tigre de río" (Salminus maxillosus) Dorada – Cat Fish Brachyplatystoma flavicans Courtesy of : Dr Jose Rainuzzo – SINTEF, Norway

  5. Amazonian spesiesBrazil - Peru Pelleted Feed Common Name: Gamitana, Tambaqui Colossama macropomun Common Name: Red Pacu Piaractus brachypomus Courtesy of : Dr Jose Rainuzzo – SINTEF, Norway

  6. 2. Difficulties experienced in coating pelleted feedA pellet must make many passes in order to get fully coated! (90 sec. cycle) Pellet passes by the nozzles 40-50 times Courtesy of: Forberg International AS, Norway

  7. These are the consequences of incorrect liquidaddition or wrong equipment when adding fat! Courtesy of : FeedTech Services, Norway

  8. 3. Equipment available to the industry forcoating pelleted feed with fat Fat at the die by Purina Intenational Drum coater by Dinnissen bv Mist coater by APEX Spraying system by Andritz Sprout Ribbon mixer by Dinnissen bv Disc coater by Kahl

  9. Where to apply the liquids?Before or after the extruder/pellet press? Post Processing Extruder or Pellet Press location Courtesy of: Andritz Sprout, Denmark

  10. Truck Loadout? Post Process Liquid Application at Loadout/Bagging The vacuum coating concept! Possible Location of a vacuum coater! Courtesy of: Andritz Sprout, Denmark

  11. Molasses Fats Flavors / Digests To what type of pelleted feed could we add liquids by means of the vacuum coater? Liquid vitamins? Fat / vitamins Fat / vitamins

  12. Pellet durability and adding fat at the mixer Added fat or fat levels over 5% in a mixed meal formula, will in all instance, lubricate the flow of material through the die, thereby reducing resistance and reducing quality or PDI. (Leaver, R. 1977).

  13. 4. Research accomplished by adding fat to pelleted broiler feed by means of vacuum infusion This report analyzes the results of tests conducted at Forberg International AS, Larvik, Norway by personnel from the Norwegian University of Life Sciences, Ås, Norway and by FeedTech Services Tønsberg, Norway. Later the same tests were conducted in Chile by personnel from Catholic University of Temuco, Chile and FeedTech Services, Tønsberg, Norway.

  14. Main objectives of the trails • To study the possibility of adding lipids to animal pellets, mainly broiler, turkey and pig, via vacuum infusion as it has been previously applied to salmon feed. • If vacuum infusion of lipids to animal diets was feasible, what would be the upper limit that would be possible to be added and preserving good quality. • To determine the integrity of the pellets (durability of the pellets or PDI) of the diets, that would be subjected to vacuum infusion of lipids.

  15. The diets • Group I diets with low over all fat content originating from the raw materials used in the diet (3% total lipids). Finding the upper level of fat addition to pelleted diets and still maintain good pelletability index. • Group II diets with high overall fat content originating from the raw materials used in the diet plus formulated fat (5% total lipids). Finding the upper level of fat addition to pelleted diets and still maintain good pelletability index.

  16. Composition of the diets for broiler feed Composition Diet 3%Diet 5% (%) (%) Protein 18.6 19.0 Ether extract 3.0 5.0 Calcium 0.8 0.8 Phosphorus 0.6 0.6 Sodium 0.16 0.16

  17. Sample preparation • Total pellet samples 112 (200 g each) (56 samples in Norway and 56 samples in Chile). • The oil used in the test corresponds to oil of sunflower with density of 900g/l. • The corresponding oil amount for each treatment, previously determined, was weighed and deposited in plastic recipients (heated to 40ºC), separated and identified by treatment.

  18. Vacuum infusion procedure Vacuum pressure was applied for 30 seconds which was the standard time used for all treatments. The sample was then shaken manually to mix the oil and pellets homogenously. Finally, pressure was released slowly during 40 seconds. The sample was mixed again manually. Each sample was placed inside the corresponding plastic bag

  19. How vacuum infusion occurs! Courtesy of : Dinnissen bv, The Netherlands

  20. RVC 6 A Forberg F-6 rotating vacuum coater for laboratory testing and Hand Held vacuum coater were used for the “vacuum coating pelleted feed tests” Forberg Hand held vacuum coater Equipment for the tests was provided by Forberg International AS, Norway Courtesy of: Forberg International AS, Norway

  21. Why is pellet durability measured? Pellet Durability Index (PDI), according to “Feed Manufacturing Technology IV” is a test developed by The Department of Grain Science and Industry of Kansas State University to measure the relative ability of the feed pellet to resist breaking in the bulk handling system. (Fogo, William, 1994).

  22. Hardness or PDI determination After treatment of the fat the hardness of every sample was determined following the corresponding procedures described by the methods of Amandus Kahl and Holmen Tester. Courtesy of : Borregaard Lignotech, Norway Courtesy of : Amandus Kahl, Germany

  23. P.D.I. by Kahl Tester (all) The diet with 5% initial fat and 7% added fat at 500mb had the best durability

  24. P.D.I. by Kahl Tester - Chile The diet with 3% initial fat and 9% added fat at 500mb had the best durability

  25. P.D.I. by Kahl Tester - Norway The diet with 5% initial fat and 7% added fat at 500mb had the best durability

  26. P.D.I. by Holmen Tester (all) The diet with 5% initial fat and 7% added fat at 500mb had the best durability

  27. P.D.I. by HolmenTester - Chile The diet with 3% initial fat and 9% added fat at 500mb had the best durability

  28. P.D.I. by Holmen Tester - Norway The diet with 5% initial fat and 7% added fat at 500mb had the best durability

  29. The experimental broiler feed Trial 100mb pressure 500mb pressure * Also in Norway with the Holmen tester

  30. Conclusions of the tests • The initial level of lipid in the pellet plays a determining role in the hardness of pellet when a greater lipid level is incorporated by means of vacuum pressure. • In pellets that are made with high lipid levels (5%) and with low initial hardness (4.3 Kg.) the additional increment of the lipid level (8 and 12%) by vacuum pressure produce an increment of its hardness that do not surpass 5.1 Kg. • Pellets that are made with low lipid levels (3%) preserve its hardness levels when a greater oil amount is incorporated to them by means of vacuum pressure (8 or 12%).

  31. Conclusions of the tests (cont.) 4.It is possible to increase the energy level in chicken pelletized diets, incorporating greater levels of lipids by means of vacuum coating. • It is possible to reach lipid levels of 8% and 12% in pelletized diets with initial levels of 3% and 5%, using vacuum pressure at 100 and 500 mb. • A combination of pellets with an initial level of lipids of 3% and a vacuum pressure of 500mb gave the best P.D.I. when a total of 12% lipids was reached.

  32. Why use vacuum infusion to coat pelleted feed • Fat may be added to cold pellets. • Fat addition levels of up to 12% are possible under some conditions. • Fat, once added to the pellet, does not leak out of it. • The vacuum coater equipment can be cleaned in a simple “washing step”, thus allowing for quick de contamination of the equipment when certain ingredients are used. • The quality or PDI of the pellet improves thanks to an improved elasticity of the pellet. • A cocktail of liquids may be added together with fats, eliminating the need to over supplement vitamins at the mixer due to heat losses at the pellet press. • Pelleting through put and quality can be improved when the mixed meal of a diet no longer need to have fat levels over 4%.

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