Effi cient feed processing


for profi table and safe feed with Kemin’s millSmArt programme


By Carmen Coetzee, Product Manager, Kemin Animal Nutrition and Health


Feed processing is a complex operation, and feed manufacturers are continuously seeking ways to improve efficacy and profitability while ensuring feed safety. This drives the need for innovation in feed processing to meet the increasing demands for food of animal origin, including fish, meat, milk and eggs.


The options to improve feed manufacturing are countless, and it is noted that advancements made in feed processing are impacting productivity, pellet quality, feed safety and profitability. Incorporating sustainable practices to mitigate the impact on the environment has gained more focus over the years. Kemin’s feed processing and feed safety programme with


process optimisation practices such as millSMART has been adopted in the feed industry has gained attention due to its beneficial effects seen in productivity, feed quality and safety. The variability of moisture in feed raw materials, in processing feed has seen to increase cost by up to 50%. Practices implemented to monitor process fluctuations, and reduce their variability brings benefits for the feed mill manager to ensure a uniform product, and quality of feed is produced, while ensuring safety. Moisture targets for feed materials in the mixer are reached


with the millSMART programme. The pre-conditioning solution, is a solution with a reduced surface tension, known as Opti CURB which contains either Sal CURB, Myco CURB or KEM WET products. The science behind the surfactants responsible for improving the pre- conditioning solutions capillarity, and therefore its movability within the feed matrix, ensures uniform penetration and dispersion of the solution throughout the batch of feed treated. Moreover, feed safety is ensured, as the surface-active solution contains either anti-microbial and mould inhibitor compounds and controlling moulds and pathogens is achieved by covering the full surface area of the feed. The Opti CURB solution is added with engineering application technology to ensure maximum efficacy in feed processing improvements. This pre-conditioning step ensures the feed particles are saturated and ready for steam conditioning and compaction. Pre-conditioning of the mash feed in the mixer followed by steam conditioning, has therefore formed a synergy, which ensures the


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current objectives and benefits of conditioning are further maximised. Saturated steam is applied to the feed matrix, with the assumption that the steam is absorbed fully and uniformly. Technically this is seen in both the transfer of moisture and heat into the feed particles in the conditioner. The speed at which heat, and moisture are transferred is different, this is due to the different behaviours of both and to the limited retention time of the feed particles in the conditioner, as they pass through. Conditioning is one of the most important steps in feed processing. The advantages of steam conditioning are not only preparing feed for compaction, but ensuring pathogen kill-off with other effects seen on nutrient digestibility improved due to starch gelatinisation, plasticised proteins and overall feed quality. The cooking of these nutrients creates a type of natural adhesive with positive effects seen on the PDI, which is an indicator of pellet quality and how effectively that pellet will endure transport and handling before final consumption. The quality of steam is often overlooked or not fully understood


in its effects on compaction and the final pellet quality. Saturated steam or dry steam versus wet steam and super-heated steam is the desired quality of steam required for optimum conditioning practices. Heat transfer for saturated steam is more efficient compared to wet steam.


During pelleting, the feed material is compacted to form good


quality pellets. It is essential that frictional heat is minimised as the mash is rolled and the newly formed pellets moves through the die holes. Feed throughput and energy consumption are important key performance indicators. In the millSMART programme, the mash feed matrix is well conditioned, ensuring smooth transfer through the pellet die, as feed particles are well lubricated. This reduces the frictional heat generated, feed throughput is improved, and energy consumption is reduced. It is essential as part of feed hygiene that conditioning and


pelleting temperatures required to kill pathogenic moulds and bacteria such as Salmonella are reached. Depending on the diet type, the temperatures may exceed 85°C, or be as low as 60°C. Excessive temperatures may have detrimental effects on essential nutrients or bioactive compounds. Temperatures which are too high give rise to a higher risk of condensation thereafter and therefore a risk of


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