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World meat demand and feed production Changes in feed processing safe feed, safe food Thermal process meal and pelleting Pellet quality energy efficiency
Pork
CAGR 2005-10 of 1.61%
Broiler
CAGR 2005-10 of 3.16%
80 60 40 20 0
05 06
07
08 09
10
05
06 07
08
09 10
05
06
07 08
09
10
Source: USDA Livestock & Poultry, World Markets and Trade October 2009
Developed World North America 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Kg/Person/Year
17%
22%
US
23%
21% 8% 15%
EU-25
China
Source: IFIF
154.5
Compound feed Middle East, Africa: Middle East & Africa represents 4.1% of the global compound feed production. Saudi Arabia is the leader with 7.3 mmt of feed production. 2.8% growth for Middle East, African Region 2008 over 2007.
Source: Lenz Analysis based on Feed International
5 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010
Factors Affecting Feed Factors Affecting Feed Production Production Continuous quality of the final products Price of feed ingredients Meat consumption Beef production Poultry production Pig production
Total meat consumption forecast up in 2010 Beef production down 1% in 2010 over 2009 Poultry production up 3% 2010 over 2009 Pork production up 2% 2010 over 2009
Despite many hindering factors, such as expensive feed ingredients, disease outbreaks and recession, world feed production continued to grow every year 1999-2009 with a CAGR of 1.75%. In 2009 certain regions had negative feed production growth, such as the US and Europe, while other regions, such as Asia, contributed to world feed production growth.
Past
Pelleting
feed plant
7 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010
feed plant
Weighing
Weighing
Feed plant design / concept Storage: design & sizing of bins Transport: short distance between process Process lines steps Define process parameters Production criteria; observe quality (temperature & retention time) management by following GMP+ Heating and drying of process steps Risk reduction: assessment and prior and after production lots to avoid monitoring of risky area and defining condensation / re-contamination measures according to HACCP
8 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010
Machines / apparatus Hygienic design Materials: stainless steel at critical spots Regular cleaning
75 C
Increased temperature
85 C
0 50 100 150 Retention time at constant temperature in sec
Success factors for hygienising: Use over-heated steam Steam should condensate onto the feed particles Knowledge of the initial bacterial count of the raw material Define: hygienizing temperature and retention time Choose hygienizing systems with a low retention time distribution
Optimum flow
HYTHERM
HYTHERM
inefficient long term conditioning systems: the retention time distribution can attain 2 min
Thermal meal treatment The new generation for the production of hygienic swine feed
Feature of the new system Safe and reliable hygienization process through HYMIX and HYTHERM Very high sanitation standard by the use of self-cleaning pneumatic drying and cooling stages Low manual maintenance and cleaning work required High production flexibility, fast change of recipes, increase of plant availability Can be integrated into existing buildings
E RM HYTH
HYMIX
Characteristics of swine feed through thermal treatment Significant reduction of bacterial count better animal health + performance Improved flowability Less dust / better stable climate Improved water solubility and generation of a very homogeneous mash Improvement of palatability Less diarrheas / higher cleanness within the stables
Holding bins
Crumbler
Machine 15 - 20%
Cooling 5- 10%
Formulation 40 - 50%
Feed process benefits Improvement of pellet quality Lower specific energy consumption Higher throughput rates Longer life time of dies and rolls Improvement of product flow characteristics
Press roll
Die
Throughput pellet mill Die hole geometry Die speed Roll gap
Trends for the pellet production optimizing pellet lines and its benefits
Production of all products with the same die 4 mm pellets develop to be tomorrows standard for ruminant, pig and poultry feed Variations in pellet quality can be controlled with automatic roll gap adjustments One or two stage crumblers will be installed to adapt particle size for poultry and young animals More often double deck coolers are applied
Shorter down times between production lots Less die changes less labor involved Savings in energy costs - due to crumbling Higher flexibility and plant efficiency
cond. temp. / C
16 14 12 10 8 1 2 3 4 5 6
Savings in feed cost for average farm: with apprx. 50000 broilers / stocking
Feed costs are over 60% of the total costs in broiler production
kWh/t Produkt
N.2
N.3
N.4
N.5
N.6
N.7
N.8
Remarks Rough estimate for a range of recipes Poultry feed Swine feed Cattle feed Mineral feed Thermal energy
Reduce the loss of energy - Air leakages - Heat leakages etc. Use the best technology - High efficient drives - Frequency converters etc. Optimize the process - Control systems - Modern equipment etc.
Thank you
25 | Bhler | AFMA 2010 developments in feed processing | Stefan Vontobel | 2010