Micro-ingredient

Premixing
Peter R. Ferket
Department of Poultry Science,
College of Agriculture and Life Sciences,
North Carolina State University,
Raleigh, NC 27695-7608

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Module III. Lecture 7
 Purpose of Premixing
Ingredients
● Convenience of handling and storage
● Free up the number of ingredient bins
● Increase batching efficiency and reduce
batching errors
● Optimize micro-ingredient particle distribution
in the feed

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 Evolution of Premix
Composition
Premix Inclusion YEAR
1930 1960 1970 1990 2000
rate, lbs/ton feed 100 10-60 5-20 1-10 0.5-2
Vitamins Yes Yes Separate Separate Separate
Trace Minerals Yes Yes Yes Separate Separate
Macro Minerals Yes Yes Separate Separate Separate
Amino Acids NA Yes Yes Separate Separate
Flavors Yes Yes Yes Separate Separate
Mold Inhibitors Yes Yes Yes Separate Separate
Antioxidants Yes Yes Yes Yes Separate
Pigments Yes Yes Yes Separate Separate
Fats Yes Yes Separate Separate Separate
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 Evolution of form of micro-
ingredient application
Micro-ingredient YEAR
1930 1960 1970 1990 2000
Vitamins Dry Dry Dry Dry Some Liquid
Choline Dry Dry Dry Liquid Liquid
Methionine NA NA Dry Liquid Liquid
Lysine NA NA Dry Dry Liquid
Flavors Dry Dry Dry Dry Liquid
Mold Inhibitors Dry Dry Dry Liquid Liquid
Antioxidants Dry Dry Dry Dry Liquid
Pigments Dry Dry Dry Dry Liquid
Fats Dry Liquid Liquid Liquid Liquid

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 Protein Supplements
● Blend of protein sources
● May contain vitamins, macro minerals, trace
minerals, pharmaceuticals, etc.
● Commonly used in both ruminant and non-
ruminant feeds made on the farm or at small
local mills.
● Specially formulated for a species and feed type.

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 Concentrate
● Blend of protein and concentrated energy
source
● Contains macro minerals, trace minerals,
pharmaceuticals and other feed additives
● Commonly used for ruminants and horses.
● Specially formulated for a species and feed
type

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 Vitamin-Mineral Custom
Premix
● Blend of vitamins, macro- and/or trace
minerals, and other feed additives
● Commonly used for on-farm mixers, and
small feed mills.
● Specifically formulated for a species and
number of feeds.

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 Special Product Premixes
Vitamin Premix
● Specifically formulated for a species
● Feed inclusion level .05 to 1.5 lb/ton

Trace Mineral Premix

● Specifically formulated for a species
● Feed inclusion level of .05 to 2 lb/ton

Feed Additive Premix

● A diluted feed additive
• antibioitics, cocidiostat, mold inhibitor, enzyme, flavor, pigment, antioxidant, etc.
● Can be used in feeds for different species and feed types.

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 Premix Carriers
● a substance that can absorb liquids (take in through
crevices or pores) or adsorb liquids (adhere liquids
through the surface of solids).
● a substance that can accept and hold a fine powder
without segregation or separation over time.
● The type of carrier used in a premix is dependent
upon functionality, physical characteristics, type of
active ingredient, cost, and availability.

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 Typical carriers used
in premixes

Organic Carriers Inorganic Carriers

Ground Rice Hulls Limestone

Wheat Bran Dicalcium Phosphate

Ground Almond Hulls Calcium Propionate

Ground Corn Cobs Verxite/Vermiculite, Zeolite

Soybean Meal Silica

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Functionality of Carriers
Used in Premixes
Functionality Carrier
High absorption Verxite, vermiculite, zeolite
Low adsorption Silica
High adsorption Wheat midds, corn cob meal,
silica
Medium adsorption Rice hulls
Low adsorption Limestone

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 Recommended Carriers for
Micro-ingredients
Micro-ingredient Carrier
Choline Chloride Ground Corn Cobs, Rice Hulls, Silica
Vitamin E Ground Corn Cobs, Rice Hulls, Silica
Trace Minerals Limestone
Dry Vitamins Ground Corn Cobs, Rice Hulls, Wheat bran or midds
Antibiotics Ground Corn Cobs, Rice Hulls, Wheat bran or midds
Enzymes Ground Corn Cobs, Rice Hulls, Wheat bran or midds
Propionic Acid Verxite/Vermiculite, or react with calcium to form
Calcium Propionate
Ethoxyquin Verxite/Vermiculite
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 Qualitative Factors affect
Carrier Functionality
● Particle Size
• Adsorptive surface area increases as particle size decreases
• Particle size should be large enough to produce good flowability and low
dustiness, but small enough to hold the active ingredients without
segregation

● Bulk Density
● Premix handling characteristics improve as bulk density
increases
• Bag faster, stack pallets easier, better flow from bins
• 10-15% limestone often added as a flow/densifying agent

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 Qualitative Factors affect
Carrier Functionality
● Moisture
• Too much moisture in a carrier can cause degradation of
vitamins and drugs by reduction-oxidation reactions
• Premix carriers should have moisture <5%.
• Rice Hulls and limestone have a standard moisture of <5%.
• Other organic carriers, such as wheat bran, wheat midds, and
ground corn cobs have a natural moisture of >12%, so they must
be dried to <5%

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 Qualitative Factors affect
Carrier Functionality
● Fat Content
• Fat oxidation destroys vitamins (esp. vitamins A, D, and E)
and some other active ingredients. Antioxidants, such as
ethoxyquin, are typically added to vitamin premixes to
prevent oxidative damage.
• Carriers should have <4% fat. Inorganic carriers do not
contain fat. Rice hulls contain 2% - 4% fat. Wheat midds
and wheat bran contain 12% fat.

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 Qualitative Factors affect
Carrier Functionality
● Flowability
• Influenced by particle size distribution, particle shape, electrostatic
properties, and hygroscopicity.
• Static charge can be minimized by the use of an anti-static agent, such as
mineral oil. Static charge increases as particle size decreases. Minerals have
high static charge, as do small powder compounds such as riboflavin and
folic acid.
• Flowability can be improved by adding flow agents that have smooth particle
surfaces. Silicon dioxide and hydrophilic silica are common flow agents,
used at inclusion rates of 0.5% to 2% of a premix.
• Caking properties influence flowability, which is dependent upon moisture
(hygroscopicity, pressure, and temperature.

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 Qualitative Factors affect
Carrier Functionality
● Acidity or alkalinity (pH)
• The activity of all biochemicals is critically influenced by the pH of
the medium they are in.
• Extremes in pH (Dicalcium P, which has low pH or limestone,
which has high pH) adversely affect stability.
• Most vitamins are stable in neutral to slight acidity (pH 5.5 - 7.5).
• Vitamins sensitive to low pH: Vitamin A and D; pantothenate;
and folate.
• Vitamins sensitive to high pH: Vitamins E, C and K; thiamin;
riboflavin; and pyridoxine

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 Properties on an
Ideal Carrier
● Particle size similar to the active ingredient
● Low moisture (<5%) and non-hygroscopic
● Low fat (<4%)
● Low electrostatic properties
● Allow adequate adsorption of dry ingredients
and absorption of liquids.

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 Carrier Straight Through Angle of Bulk Density Moisture Absorption of pH
Flow Repose Moisture
mm orifice Degree Lb/ft3 % Day %

Ground Rice Hulls 26 41 18.7 5 1 0.06 6.3

3 0.82
7 2.25
Fine limestone 26 70 62.4 0.2 1 0.02 9.2
3 0.02
7 0.02
Course limestone 7 27 71.2 0.4 1 0.27 9.0
3 0.35
7 0.44
Wheat midds 28 48 20.6 11.3 1 0.30 6.7
3 1.87
7 4.34
Dry Wheat midds 35 47 22.5 5.0 1 5.31 6.9
3 8.94
7 11.70
Ground Corn Cobs 20 50 25.5 5.0 1 2.69 5.4
3 5.66
7 8.13
Dicalcium Phosphate 5 29 58.7 2.8 1 3.84 3.4
3 5.34
7 6.20
Calcium propionate 24 57 33.7 1.3 1 0.27 6.7
3 0.67
7 1.66
Vermiculite 9 28 8.1 5.1 1 0.39 6.3
3 0.48
7 3.37
Silicon dioxide 4 33 14.3 4.4 1 3.50 6.9
3 5.08
7 5.75
 Liquid Binders for Premixes
● Improve the handling characteristics of a premix
• Anti-dust agent, which reduces losses during conveying, odors, irritation,
allergies, and potential dust explosions
• Antistatic agent
• Prevent particles from desegregating and attaching to equipment

● Improves the adsorptive capacity of many carriers

● Binders may include molasses, mineral oil, or vegetable oil.
• Mineral oil is the most commonly used binder.
• Vegetable oil is subject to oxidative rancidity and can destroy vitamins sensitive to
oxidation

● The application rate of the liquid binder in a premix is directly related to

the amount of adsorbing organic carrier present in the premix.

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 Liquid binder Application
Rate to Premixes
Organic Carrier as a Liquid binder as a %
% of Premix of Premix
<15% 0.25%
15 - 25% 0.50%
25 - 50% 1.00%
50 - 75% 1.50%
>75% 2.00%
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 Stress Factors for
Vitamins
● Moisture ● Trace elements
act as catalysts of
● Heat
oxidation or
● Pressure reduction
● Light reactions
● pH
● Chemicals

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 Vitamin Moisture Oxidation Reduction Trace Heat Light Acid Neutral Basic
Minerals pH pH pH

A beadlet S S R S MS MS S R R

D beadlet S S R S MS MS S R R

E acetate R R R MS R R MS R S

K (mpb, msbc) VS R MS VS MS S MS R S

Thiamine HCL S S S MS S R R MS S

Thiamine Mono R MS MS MS MS R R MS S

Riboflavin R R MS R R MS R MS S

Pyridoxine R R R MS R S R MS S

Vitamin B12 R MS S MS MS S MS R MS

Ca Pantothenate S R R R MS S MS R MS

Folic acid R MS MS S MS MS S R MS

Biotin R R R R S R MS R R

Niacin R R R R R R R R R

Niacinamide S R R R R R MS R MS

Vitamin C R VS R VS R MS R R S

Choline Chloride VS R R R R R R R MS

R = RESISTANT; MS = MILDLY SENSITIVE; S = SENSITIVE; VS = VERY SENSITIVE

 Vitamin Stress During Feed
Manufacturing
Stress Factor Vitamin Choline/TM Basemixes Pelleting Extrusion or
Premix Premix Expansion

Heat Low Low Low High Very high

Pressure Low Low Low High Very high

Humidity Low High Low High Very high

Redox Low High High High Very high

reaction

Friction Low High High Very low

high

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 Conveying and Handling
premixed ingredients
● Most carriers are conveyed by either drag chain,
screw auger, or pneumatic system
● Trace minerals are conveyed into storage silos by
pneumatic systems
● Concentrated active ingredients are handled by bag,
tote bags, or bulk bins and are conveyed into the
mixer by gravity to minimize dust losses.

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 Mixer Charging Sequence
for Premixes
1. Carriers is added to the mixer first:
 organic carrier for vitamin or drug premixes or
inorganic carrier for trace mineral premixes.
2. Liquid Binder (mineral oil) is added to the mixer
through spray nozzles and then mixed with the
carrier for at least 1 minute.
3. Inorganic densifier, anti-caking agent, or flow agent
is added
4. Active ingredients are added
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 Mixing Time and Mixer
Type for Premixes
● Varies depending upon type of mixer used.
• Under mixing will cause poor dispersion of active ingredients.
• Over mixing can cause segregation due to the development of
static charge of small pure crystalline products.

● Horizontal double ribbon mixers or Folberg high-speed

paddle mixer is usually used for vitamin or drug
premixes.
● Modified drum mixers are preferred for mixing dense
mineral premixes.
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 Micro-Mineral Nomenclature
and Composition
Element Source Formula % Element Bioavailability1
Cobalt Cobalt Carbonate CoCO3 46 Fair
Cobalt Sulfate (Monohydrate) CoSO4 H2O 33 High
Cobalt Sulfate (Heptahydrate) CoSO4  7H2O 21 High
Iron Ferrous Carbonate FeCO3 40 Fair
Ferrous Sulfate (Monohydrate) FeSO4  H2O 30 High
Ferrous Sulfate (Heptahydrate) FeSO4  H2O 21 High
Zinc Zinc Oxide ZnO 72 Good
Zinc Sulfate ZnSO4  H2O 36 High
Copper Cupric Oxide CuO 75 Fair
Copper Sulfate (Centrahydrate) CuSO4  5H2O 25 High
Copper Carbonate CuCO3 55 Good
Iodine Calcium Iodate CaIO3 64 High
Ethylenediamine Dihydroiodide EDDI 79 High
Potassium Iodate KI 69 High
Manganese Manganese Oxide MnO 60 Fair
Manganese Sulfate (Monohydrate) MnSO4  H2O 28.5 High
Selenium Sodium Selenite Na2SeO3 45 High
1Fair: 65% - 75%; Good: 75% - 85%; High: 95 - 100%
 Sources of Commercial
Vitamins
● Fermentation sources
• Folate, Riboflavin, B12, Biotin,

● Chemically processed
• Niacin, Niacinamide, Vitamin E, Pyridoxine,
pantothenate

● Natural products
• Vitamin E, Vitamin A
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 Classification of Vitamins
● Fat-Soluble:
• Vitamins A, D, E, and K are absorbed in animals
by mechanisms similar to those involved in fat
absorption.

● Water-Soluble Vitamins: All other

vitamins

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Vitamin Coating Technology
● Increase stability in ● Reduce
premixes hygroscopicity
• Vitamins A and D ● Improve solubility
● Reduce electrostatic • Vitamin A, and E
charge
● Improve dispersibility
• Folic acid and
Riboflavin

● Reduce dustiness
• powdered vitamins
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 Types of Spray-dried Coatings
or Carriers
● Gelatin ● Antioxidant-fat
● Carbohydrates: corn • Vitamin C
starch ● Adsorbate
• vitamins A, D, E • Oil adsorbed onto silicon
dioxide, silica, or vermiculite.
● Ethylcellulose
• Vitamin E and Ethoxyquin are
• Vitamin C often delivered as an adsorbate.

● Gelatin-Carbohydrate
combination
• Vitamins A and D

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