This document provides a 3-sentence summary of a feature article on pellet production: Pellet production can save energy, improve feed efficiency, and increase safety. Pelleting feed increases bulk density and consistency while improving digestibility. The use of pellet binders can further reduce energy requirements during pellet production and enhance pellet quality at lower temperatures to achieve benefits like biosecurity while maintaining efficiency and throughput.

1. Digital Re-print -
September | October 2012
Pellet production to save energy, improve
feed efficiency and safety
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2. FEATURE
Pellet production
to save energy, improve feed efficiency and safety
by Murray Hyden C Biol, MSB, Director of
Biosecurity, Kiotechagil, United Kingdom
E
nergy doesn’t get any cheaper, raw subsequently less wastage. All these benefits nutrient utilisation reduces the volume of
material prices continue to climb however depend on pellet quality after the excreta which benefits the environment, so
and margins are squeezed. There cooler. we have less feed being used to improve
is no doubt that pelleting improves If pellet quality is expensive to achieve growth rates and improve to the environ-
efficiency and biosecurity but can it then costs increase and financial benefits ment.
be made more cost effective? are lost and the selection of a low inclusion However, probably the best-known
binder makes sense for so many reasons. indirect benefit of pelleting is biosecurity.
Efficiency of the pelleting process is the Nutritionally, pelleted feeds are more Most of the common pathogens such as
key to feed mill profitability. With 90 percent digestible as a result of starch pregelatinisa- Salmonella, Escherichia and Campylobacter
of animal feed in Europe being pelleted, tion and protein denaturation. The finer are non-spore forming bacteria and are
every feed mill needs to optimise their pel- grist size used in pellets has been found to therefore sensitive to heat. The temperature
leting efficiency. increase digestibility in pigs. required is often not as high as expected
In birds, weight gain and feed efficiency with S. typhimurium being killed after just
Pelleting positives are improved when the pellet quality is good. 10 seconds at 70°C but requiring 7 minutes
Pelleting feed increases the bulk density Even when pelleted diets are re-ground to at 60°C.
of the ration, allowing more tonnage to be the consistency of mash, the performance
delivered per truck, saving costs for the benefits are still found indicating direct ben- Binding benefits
farmer and space in storage. Pelleted feeds efits from the pelleting process. None-the-less, pelleting is a very high
are easy to use in either bulk or bags. Pellets Body weight improvements and mon- cost process (and is becoming more so with
also improve conveying by screw augers, and etary returns are inversely proportional to energy prices increasing). The use of high
discharge from feed bins due to reduced the level of fines in finisher diets. Birds need efficiency pellet binders can reduce energy
bridging. to use less energy to consume the same requirements in three ways:
Pelleted feed is nutritionally consistent level of nutrients in pellets as those fed mash 1: Poor pellet quality results in higher
from pellet to pellet with each pellet con- feeds; in fact birds fed pellets can ingest their fines levels and more returns which is
taining the correct balance of amino acids, total energy requirements in four percent of energetically inefficient.
minerals and vitamins. This means that there the day compared with 15 percent of the 2: Pellet binders help lubricate the die
is no opportunity for ingredient selection day for mash feeds. which reduces energy requirements
during consumption by fussy feeders and In pig production, heat treatment dur- as well as increasing mill throughput.
ing pelleting Lubricating dies minimises wear so they
improves the should last for 25-30,000 tonnes with
digestibility of just one refurbishment. Changing dies
maize which can takes upwards of 2 hours during which
result in a six to time the line cannot operate.
eight percent 3: Pellet quality can be enhanced at lower
improvement temperatures that still permit the
in daily gain and biosecurity benefits but where starch
feed conversion. gelatinisation may not be sufficient to
Reduced fines contribute to pellet quality. This saves
and improved energy and speeds up throughput.
digestibility To achieve good pellets moisture is
lead to further essential; typically 16 percent moisture con-
improvements tent is required in the conditioner to hydro-
that are often lyse the starches. Moisture content and
overlooked. temperature are related because it is the
Figure 1: The effect of temperature on viscosity of a gum For example, steam that provides both the heat and the
and corn starch improved feed water for adequate pellet production.
conversion and Temperature should ideally reach 80°C
16 | September - october 2012 Grain &feed millinG technoloGy

3. FEATURE
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Grain &feed millinG technoloGy September - october 2012 | 17

6. FEATURE
FEATURE
Disrupting bacteria start gut colonisation and invade host to between them. This new information opens
communication
to ensure starch gelatinisation but this is not • Broiler – 1.5 bar / 20 psi to cause damage. cana result concept in the probiotic´s mode of
succeed in host infection new in reduced pellet quality which is
always achieved. the direct gut bacteria modi-
Apart from Consequently the starch in Recommended conditioning temperatures by because the main binding agent, starch, has
In particular, different in vitro trials run action studies.
fication and immune is effect,able to recent
the ration formulation not new con- Rubinum SA products are:
for different in collaboration with CRESA, been Taking this to mind, the use of one probiotic
removed in produce ethanol. Whilst
tribute tohave demonstrated the effect aof
studies pellet quality. By using gums in • Ruminant (fibrous) that B. cereus var. toyoi enzyme this ability may be helpful in some specific
have demonstrated – 50/60°C with systems have been developed to
pellet binder a much faster to Bacillusuptaketo
some bacteria belonging moisture spp. • Pigan 65/70°C
has – effect against the gut colonisation by improve the –in those situations in which pellet
situations digestibility of the DDGS, a we want
isdisrupt bacteria communication, to fact that
achieved at lower temperatures a ensure • Pig creep (milk powder) – 45/50°C such as binder only to reduce theto achieve a suitable
some potential gut enteropathogens, not is often required amount of these specific
higher viscosity in the conditioner of probiotics
can explain some of the effects and better • Broiler – 80/85°C pellet quality from this high fibre ingredient.
based on this bacterium.
heat transfer into the grist. Pelleting larger fibrous materials for rumi- One other important factor of pellet
IfItthe feed is very dry then not only is a
has been described that there is nants requires a different approach to the binders is that they help maintain pellet qual-
there insufficient between gut bacteria, called
communication water for gum hydrolysis smaller broiler pellets where biosecurity is ity during seasonal changes in raw material
but the feed is too dryallows bacteria to get a
‘quorum sensing’ that for the heat transfer paramount. use of one probiotic with The pelletability of may be
"The quality. this ability freshly harvested
necessary to achieve starch intestinal environ-
consensus on whether the gelatinisation. If The thermal processing during pelleting is cereals is often quite different to the last
ment has been effectively colonised before
this is the case it may be necessary to resort helpful in some specific situations –in those situations
not the only cost consideration. It is gener- of the previous harvest grains. So it is likely
to spraying water directly in the mixer to
making the energetic investment required ally accepted that using a roller mill is less that this year’s UK harvest, which has been
add one initiation percent metabolic the mix
for the to two of their water to response expensive that usingwe want not only to reduceabnormal weather pattern,
in which a hammer mill mainly as subjected to an the amount of
to increase pellet temperature in the condi-
to colonize or infect the host (by producing a result of lower maintenance costs. will be reflected in pellet quality.
tioner and get better gum gelatinisation.
toxins, adherence factors). these specific enteropathogens in the gut, but also
Moist feed is generally more palatable and
In particular, some gram-negative bac- Feed formulation issues Improving pellet quality
digestible too.from the gastrointestinal tract
teria typical However, too much water Feed formulation plays a major part in A low inclusion binder, like Kiotechagil’s
increases the risk of moulding so it may be
to avoid the potential of these bacteria to invade
final pellet quality and high protein cereals Mastercube, can really help overcome many
(Yersinia, E. Coli, Salmonella) produce spe-
necessary to check that (N-acyl-homoserine-
cific kinds of molecules the pellets dry to such as wheat will contribute more to pellet of the problems associated with the feed for-
12 – 14 percent MC after the cooler only
lactones). These molecules are not to quality than maize, oats or barley. therefore animal body" overcome some
gut epithelium and Dietary mulation and can also help
minimise the but of moulding.
produced risk also recognised by these fat is known to have an inverse relationship of the engineering shortfalls such as short
bacteria,pressure to them the to be drierto
High giving steam tends possibility with pellet quality, hence the use of post conditioners or poor steam quality.
and does not achieve such high tempera-
know when the population has reached pellet fat spraying for certain rations. When Mastercube is both a binder and a hard-
tures optimal population conditioner, there-
the or moisture in the level to start animal fat is incorporated into the spp by destroying ener and it uses onlythe gut, but alsoingre-
Yersinia and Salmonella feed the added enteropathogens in EU approved to avoid
fore different feedWhen will bethreshold level
host infection. types this more difficult fat coats starch substances cited above.
the chemical granules, and prevents water dients. potential of these bacteria to invade gut
the The primary binder is a gum that
to pellet than enteropathogens start inducing
is reached, others if the pellet binders and uptake, seems therefore that probioticstrans- gelatinises at much lower temperatures than
It which in turn impairs the heat are not epithelium and therefore animal body.
starches do not activate specific genes that
the expression of some fer necessary for gelatinisation. gut specific bac- traditional starches (Figure 1) and provides
only able to directly modify
Recommended pressures for different
express for invasion and infective factors. teria populations anddietary fat are immune higher viscosity and improved lubrication at
When high levels of profile host used,
products are:
In this way, bacteria belonging to this orresponse, but also they can interruptin the theMore inforMation: throughput and
when maize is the primary cereal the way die. The result is faster
group, guarantee the -most suitablepsi
• Ruminant (fibrous) 3.5 bar / 50 time to ration formulation, traditionalto communicate lower fines. www.rubinum.es
used by enteropathogens binders such Website:
• Pig - 2.5 bar / 35 psi as thixotropic bentonite clays or lignosulpho- As the pellet cools the hardener in
nates (the waste Mastercube, a high quality calcium sulphate,
product from the which is approved as a nutrient, has a dual
wood pulping function as a calcium source and a hardener.
Bredol ®
process to man- Pellet breakage during transport and storage
for effective
ufacture paper) due to soft or badly formed pellets is also
have been used wasteful. The hardener increases pellet dura-
feed production
to improve pellet bility to enable pellets to be blown, augured
quality. However, and transported without being crushed.
and nutritional
neither of these The selection of a low inclusion binder
performance
binders provides has the advantage that it minimises the
any substantial impact of nutrient density so feed costs can
nutritional value be maintained.
to the diet. In A feed mill operating efficiently and dust-
WELCOME TO THE TWENTY FIRST EDITION fact, both these free is a pleasant place to work. It is safe for
OF THE INTERNATIONAL MILLING DIRECTORY ingredients are the operators and easier to keep clean.
incorporated at From a biosecurity viewpoint, fines, set-
The premier resource for the global feed and fl our milling industries high inclusion tling as dust on floors and equipment, will
rates and actually soon pick up moisture and will become a
dilute the nutri- habitat for enteropathogens. The require-
ent content of ment today must be for pellet binders
the feed resulting that do not compromise nutrient density,
in more expen- throughput or biosecurity.
sive raw material Genetic selection of meat producing
usage to com- animals that maximise feed intake ensures
pensate. emulsifierthat the response to pelleted diets much
Bredol® technology
opens up a multitude of technical
With cereal more significant than was reported just
opportunities bringing values in feed
prices ever as on the farm.
production as well twenty or thirty years ago.
www.bredol.com
increasing in price Using an effective pellet binder is cost
the temptation effective in so many ways and can be a
to use more co- real benefit in terms of digestibility, biose-
products such curity and mill throughput thus making a
as DDGS from quality pellet binder pay for itself many
bioethanol pro- times over.
duction is much
greater. However, More inforMation:
DDGS inclusion Website: www.kiotechagil.com
&
18 | September - october 2012
Grain feed millinG technoloGy Grain &feed millinG october 2012 | 21
September - technoloGy

7. FEATURE
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