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1、Click to edit Master title styleClick to edit Master subtitle style11SURF*ACEClick to edit Master title styleClick to edit Master subtitle style22What are the Major Concerns of the Feed MillerKeep high Quality of feed Less Moulds and Less Microbial CountsGood Pellet QualityLess FinesMore through put
2、 per hourDecrease Power ConsumptionLess Process LossEfficient utilization of steamEfficient Cooling of feed before baggingOptimum Moisture in the feedClick to edit Master title styleClick to edit Master subtitle style33IMPORTANCE OF MOISTURE IN FEED Huge Variations in the Feed Moisture throughout th
3、e year Recover the Process Loss Better penetration of the steam better anti-microbial effects Better Starch Gelatinization Better Pellet Quality Better Pellet Durability Index Less machinary wear and tear Save Energy Consumption Increase Throughput of the Feed MillClick to edit Master title styleCli
4、ck to edit Master subtitle style44Variations in MoistureAll the Feed Formulations are based on 88% Dry matter which means 12% should be the moisture but the variation in our feed moisture ranges from 8 12%If the feed is too much dry Poor Palatability and DigestibilityClick to edit Master title style
5、Click to edit Master subtitle style55Process Loss RecoveryA process loss of 0.5 to 3% can occur during the feed productionMain Reasons Loss as Moisture & dust Huge Economic Impact:If 0.5% Process Loss= Loss of 5 Kg feed in a 1 ton batchIf Cost of 5 Kgs Feed= USD 2.00If the feed prodcution of a feed
6、mill is 10,000 tons per monthLoss= USD 20,000.00Loss per Annum because of process Loss = USD 240,000.00Click to edit Master title styleClick to edit Master subtitle style66Better Steam PenetrationMoist Steam penetrates better than Dry Steam and have a better anti microbial effectThis can help reduce
7、 the pelleting temperature by around 5% whichWill help to protect the nutrientsLow fungal and bacterial growth leads to lower production of toxinsClick to edit Master title styleClick to edit Master subtitle style77Improvement of the Starch Gelatinisation Index4 to 7% more; 20% and close to 30%Bette
8、r PDI (Pellet Durability Index) - up to 3% higher:Higher pellet bindingLower proportion of finesBetter uptake of Metabolisable Energy because of higher destruction of fibrous cover of starch particles / access to CP /access to lipidic depotsBetter Starch Gelatinisation & Pellet QualityClick to edit
9、Master title styleClick to edit Master subtitle style88Better Production ParametersWhen Moisture added with a Surfactant,Generation of a thin aqueous film andemulsion of dietary fat and the addedWater takes placeBetter general lubrication of machineryLower energy consumption (kWh/ Tm) - about 10 to
10、15% orHigher production yield (as Tm/ h) without increasingEnergetic consumption- up to 10 to 15%*depending on the kind of dietClick to edit Master title styleClick to edit Master subtitle style99Advantages in ANIMAL by Hydration programsBetter use of ME Starch/CP/ FatLower generation of finesLower
11、Feed WasteTotal microbiological control- production cycleLower ME losses by fungiLower mycotoxin incidenceLower incidence of coliforms /Salmonella / ClostridiumHigher biosafety levelsHigher Pellet PalatabilityImproved Feed Conversion RatioClick to edit Master title styleClick to edit Master subtitle
12、 style1010?Favours mould growth?Favours oxidation?Caking and lumping of feed?Favours building up of heat?Very high level favours bacterial growth LIMITATIONS OF HIGH MOISTURE IN FEEDHow to we Add Moisture?Click to edit Master title styleClick to edit Master subtitle style1111SUR FACE.A Synergistic b
13、lend of Organic Acids and Surfactants to optimize the moisture content in feed without increasing the risk of mould growth & Bacterial Loadby control of the water activityClick to edit Master title styleClick to edit Master subtitle style1212Target:To bind water to the feedProportions:1 to 3% (depen
14、ding on initial moisture)10 to 30 liters per ton(around 30 to 90 liters per batch generated at the mixer)Application of product:SURF ACE (0.2 kg per ton plus 10 l of water for 1% moistureincrease)Pump specifications:Depending on total hydrating solution to be appliedfrom 6 l/ min to 30 l/ minHow to
15、apply the Moisture with SURFACEClick to edit Master title styleClick to edit Master subtitle style1313SprayWaterSurfAce1200 lSurfAce1000 lDosatronD45 REIE8Surf Ace - lnea4 a 7.5 mContadorelectromagnticoaplicacina 2%SeguroantiretornoDesconectorcon dos segurosSeguroantiretorno100 /200 lIncorporacin500
16、 g/ 10 lBomba2 a 4 inyectoresP = 2 barsngulo = 90d = 16.1 l/ minelectrovlvulaManmetroSonda denivelSeguridad a sobrepresinTubos y juntas armados y resistentes a cidosIBCrecambiableIBCfijoSurface Applicator SystemClick to edit Master title styleClick to edit Master subtitle style1414Mechanisms of acti
17、on of SURF ACEClick to edit Master title styleClick to edit Master subtitle style1515Surfactant Short-chainfatty acidsActivity as surfactant Applied in water due to its amphotericstructure(lipophilic andhydrophilic)EmulsifierSalts ofalimentary fatty AcidsActivity as emulsifier due to its ability to
18、create a mixedcommon layer between the added water and the fatphase in the feedSURF ACEClick to edit Master title styleClick to edit Master subtitle style1616The addition of the emulsifier to the water favors the creation of a new phase with the total incorporation of the added water to the fat phas
19、e of the feedWater is incorporated in an structural way to the feed, so it cannot get lost during processing. Pelleting machine identifies the new phase as a higher volume of “fat” and the press yield improvesDurability is not affected (as it happens with extra fat addition), but enhanced as more cr
20、ystal starch becomes gelatinizedEmulsifier activityClick to edit Master title styleClick to edit Master subtitle style1717Surface TensionWater: 72 dynas / cmWater + SURF ACE: 45 dynas / cmMechanisms to decrease the water surfacetension with SURF ACEAt right,Water withSURF ACEWaterSURF ACE decreases
21、the surface tension of the water dropsClick to edit Master title styleClick to edit Master subtitle style1818Consequences of decreasing the surfacetension with SURF ACESURF ACE added at 2% in water allows:Better distribution of the liquid added andbetter fixation to feed particlesRetention of liquid
22、 higher than 80%The increase in moisture is not reflected in a higher WaterActivity Aw - reduction of hazard by fungal growthClick to edit Master title styleClick to edit Master subtitle style1919WATER ACTIVITY - DEFINEDWater Activity (Aw) of feed or raw materials is a measure of degree or amount of
23、 free water available for microbial growth or chemical activity.It is measured as the ratio of the partial pressure of water vapour in the feed/raw material sample to that of pure water at the same temperature.PBAw= Always between 0 and 1PFWhere:Awis water activityPBis the partial pressure of water
24、above the test sample.PFis the partial pressure of water above an open dish.Click to edit Master title styleClick to edit Master subtitle style2020Does The Program Causes Nutrient DilutionsDilution is offset by the following factors:1. Digestibility is improved because of better Starch Gelatinizatio
25、n2. Better digestibility due to faster rehydration after consumption of feed3. Pathogen Reduction in the feedClick to edit Master title styleClick to edit Master subtitle style2121TRIALS WITHSURF*ACEClick to edit Master title styleClick to edit Master subtitle style2222Experimental designT0 - Feed w
26、ithout addition of waterT1 - Feed with 1,5% Hydrating solution + Comp A actual use (2.5%)T2 - Feed with 1,5% Hydrating solution + 2.5% SURF ACEEach treatment consisted of 3 batches with 2,000 kg each, of ruminant feedThe application of the hydrating solution was carried out directly as solution in t
27、he mixer by means of an already implemented pump devicePelleting temperature was set at 40, while throughput was set as 4 t/h.Amperage was free to evaluate the improvement experimented by pelleting yieldCustomer wanted to have the same dosage rates in both treatmentsClick to edit Master title styleC
28、lick to edit Master subtitle style2323Recorded parameters and analysesAmperagePellet Production yield (t / h)Total time to produce the batch with 6,000 kgPelleting temperature (C)(Determinations monitored every 4 minutes at the Control Room)Humidity (%)Microbiology (fungal counts) at days 0, 14 and
29、30 after sampling5 samples of 500 g each per experimental batch, for treatments Controland T2 plus 2 samples from Competitor batch(12 samples in total)Click to edit Master title styleClick to edit Master subtitle style2424Click to edit Master title styleClick to edit Master subtitle style2525Click t
30、o edit Master title styleClick to edit Master subtitle style2626TratamientoSolucinAditivotiempoHongosHongosHongos(%)(%)identufc / gufc / gufc / gda 0da 14da 30T11017:23901607017:33509010017:43601807066.7143.380.0T21218:09505030Surf Ace18:1750701018:2540903018:32701105018:22901202060.088.028.0Tabla 4
31、. Datos evolucin microbiolgicaTratamientoSolucinAditivotiempoHongosHongosHongos(%)(%)identufc / gufc / gufc / gda 0da 14da 30T11017:23901607017:33509010017:43601807066.7143.380.0T21218:09505030Surf Ace18:1750701018:2540903018:32701105018:22901202060.088.028.0Tabla 4. Datos evolucin microbiolgica(Con
32、trol)With SurfaceFEED MICROBIOLOGYClick to edit Master title styleClick to edit Master subtitle style2727TRIAL WITH THE BIGGEST FEED PRODUCER IN THE REGION AT THEIR FEED PLANT IN TURKEYClick to edit Master title styleClick to edit Master subtitle style2828Evaluation of the effect of SURF*ACE on: Fee
33、d quality (moisture, mould level) Parameter of production (total production, press energy) Evaluation with two different feeds (beef/chicken)CONTROL without added waterObjectivesClick to edit Master title styleClick to edit Master subtitle style29291 trial day, 6th november 2007Two feeds:BEEF FEEDCH
34、ICKEN FEEDTreatments:T0 control treatmentT1 with Surf*Ace, diluted at 2% in water, and then the hydrating solution applied at 1% in the feedProtocolClick to edit Master title styleClick to edit Master subtitle style3030Evaluation of Surface on Production Parameters14.6800.1400.7605.2900.0008.621Surf
35、ace6.830105.95380.70080.700278.80016.00015.5172.5001.000T17.830111.86680.80081.300294.40016.00014.2860.0000.000T0Poultry - 15 tons14.720-0.1609.3100.1404.1706.329Surface6.57074.90270.400197.10015.90019.20011.3922.5001.000T17.54080.81370.300212.70016.00020.00010.7140.0000.000T0Beef - 15 tonskwh/tK Wa
36、ttsTemp.Press 2(oC)TempPress 1(oC)AmpPress(A)Mealt/hSteam%Recorded t/hAdditive %Hydr.Sol (%)TreatmentClick to edit Master title styleClick to edit Master subtitle style3131Evaluation of Surf*ace Differences in tons per hour (t/h)10.7111.410.210.410.610.81111.211.4T0T114.2915.5113.613.81414.214.414.6
37、14.81515.215.415.6T0T1BeefChicken6.30 % MoreThroughput8.60 % MoreThroughputClick to edit Master title styleClick to edit Master subtitle style3232Evaluation of Surf*ace Differences in Amperage (A)212.7197.1185190195200205210215T0T1294.4278.8270275280285290295T0T17.30 % LessEnergy5.30 % LessEnergyBee
38、fChickenClick to edit Master title styleClick to edit Master subtitle style3333Evaluation of Surf*ace Differences in kwh/ ton7.546.5766.26.46.66.877.27.47.6T0T17.836.836.26.46.66.877.27.47.67.88T0T114.7% LessKWH/ ton14.7% LessKWH/ tonClick to edit Master title styleClick to edit Master subtitle styl
39、e3434Evaluation of Surf*ace Feed Quality0.00-4.000.800.72Surface10.0010.0088.0012.002.501.00T110.0014.0087.2011.280.000.00T0Chicken0.00-18.000.400.74Surface10.0050.0097.2012.162.501.00T110.0068.0096.8011.420.000.00T0BeefYeast Day 0Mouldscfu/gDay 0DurabilityDay 0 (%)MoistureDay 0 (%)Additive(%)Hydr.
40、Sol(%)TreatmentClick to edit Master title styleClick to edit Master subtitle style3535Evaluation of Surf*ace Economical Evaluation Beef Feed$2.88Net Gain per ton of feed =$1.00 If Cost of Surface is $ 4.00 250 gms$3.88 Gross Gain =$2.59 Hydrating Process (0.74%) $ 350.00$0.19 Steam decreased by 4.17
41、%$1.10 Press Energy decreased by 14.72%Savings after using Surf*ace$12.00 Total =$4.50 Steam$7.50 Press EnergyProduction Cost StandardsClick to edit Master title styleClick to edit Master subtitle style3636Evaluation of Surf*ace Economical Evaluation Chicken Feed$2.63 Net Gain per ton of feed =$1.00
42、 If Cost of Surface is $ 4.00 250 gms$3.63 Gross Gain =$2.52 Hydrating Process (0.72%) $ 350.00$0.01 Steam decreased by 0.17%$1.10 Press Energy decreased by 14.68%Savings after using Surf*ace$12.00 Total =$4.50 Steam$7.50 Press EnergyProduction Cost StandardsClick to edit Master title styleClick to
43、edit Master subtitle style3737CONCLUSIONSOptimizes Moisture in the feedKeep high Quality of feed Less Moulds and Less Microbial CountsGood Pellet QualityLess FinesMore through put per hourDecrease Power ConsumptionLess Process LossEfficient utilization of steamEfficient Cooling of feed before bagging
