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Premixtures Fefana Publication Fefana Publication Premixtures Fefana Publication Premixtures Contributors: FEFANA Working Group Premixtures, and in particular: Peter Fidder, Nutreco Philippe Becquet, DSM Cédric Martin, DSM Mario Döpker, Miavit Juan José Mallo, Norel y Nature ISBN 978-2-9601289-0-1 © FEFANA 2013 -03- Table of Contents Preamble 7 b. pH 17 Introduction 9 c. Moisture 18 d. Bulk density 18 e. Reactivity 18 I. THE VARIOUS TYPES OF f. Contaminants 18 PREMIXTURES 10 g. Solubility in water 19 h. Hygroscopicity 19 1. Product forms 11 i. Shelf life 19 2. Product functions 12 j. Flowability 19 3. Different constraints 13 k. Dustiness 19 II. SOURCING AND III. FORMULATION OF PROCUREMENT 13 PREMIXTURES 20 1. Legal, Quality system, 1. Product types 20 Customer requirements 13 a. Pre-dilutions 21 a. Registered and approved b. Specific blends 21 feed business operators 13 c. Complex premixtures 22 b. Legal requirements 14 c. Quality system 15 2. Nutritional aspects 23 d. Customer requirements 15 3. Characteristics of the ingredients 24 e. Sourcing of incoming 4. Choice of carrier(s) 25 materials 15 5. Handling properties 27 6. Safety and quality aspects 27 2. Ingredients specifications 7. Regulatory requirements 28 (feed additives, feed 8. Specific customer requirements 29 materials used as carriers) 9. Logistic aspects 29 and packaging materials 16 10. Conclusions 29 a. Management requirements IV. MANUFACTURING 30 for premixture ingredients 16 b. Specifications for 1. Intake and storage 30 packaging materials 16 2. Suitable equipment 31 3. Conveying 33 3. Specific requirements for 4. Weighing and dosing 34 premix ingredients 17 5. Premixture mixing (types of mixers) 36 a. Particle size 17 6. Mixing procedures 37 -05- 7. Production / dosing sequence 38 VII. SAFETY 62 8. Hygiene and cleaning 39 9. Maintenance and inspection 40 VIII. PHYSICAL AND CHEMICAL CHARACTERISTICS 66 V. PACKAGING AND TRANSPORT 41 1. Homogeneity and segregation 66 1. Packaging types 41 2. Packaging in bags 43 ▪ How to test for segregation 67 3. Packaging in IBC 44 4. Packaging in drums 48 2. Stability in premix 68 5. Packaging should protect 3. Dustiness 69 the premixes during 4. Flowability 69 transport and storage 49 5. Carryover 70 6. Waste management 50 7. Premixtures in bulk 51 Glossary 73 References 79 VI. QUALITY MANAGEMENT 52 Acknowledgements 80 ▪ HACCP purpose 53 Disclaimer 80 1. Finished product specifications 54 2. Quality standards 54 3. Quality manual 55 4. Communication to customers: code of practice for labelling 56 5. Quality Control program for incoming ingredients 57 6. Quality Control program for finished products 58 7. Analytical / Technical tolerances 58 8. Sampling 59 a. Quantitative requirements 60 b. Instructions for taking, preparing and packaging the samples 60 9. Validation of the system 61 -07- Preamble FEFANA is the EU Association of With a unique framework, the as- Specialty Feed Ingredients and sociation is able to draw on the ex- their Mixtures. With more than 100 ceptional knowledge of our mem- members from 28 countries, it rep- bers, bringing together expertise resents feed business operators and science. This is why we are active in the feed chain, such as able to provide you with such a specialty feed ingredients produc- valid publication. ers, premixtures manufacturers, users, importers and distributors. The feed premixture industry has developed greatly over the last Established in 1963, FEFANA has decades. It is regarded as a key represented and served the inter- partner for the compound feed ests of its industry ever since and industry, farmers and other feed it is a recognised partner for na- business operators in handling tional, European and international complexity. Just to mention a few: authorities and fellow organiza- in global sourcing of specialty feed tions in the feed and food chain. ingredients, in managing many formulations, of safe and smooth Specialty Feed Ingredients and handling of ingredients with many their Mixtures are fundamental in different properties. Fefana is a the livestock chain to ensure bal- provider of tailor made solutions anced feed, thus contributing to ani- and a partner to work on conveni- mal health and welfare. Quality and ent and sustainable feed to food safety are at the heart of our busi- solutions. ness and we believe that innovation and sustainability are key concepts In this booklet we would like to that we will continue to focus on. provide the up-to-date information about the role of the premixture industry in the feed to food chain. Didier Jans FEFANA Secretary General -09- Introduction This booklet has been designed In particular we start with a de- and developed by the members of scription of the various types of the FEFANA Working Group Pre- premixtures and go on to explain mixtures. The aim of this working the sourcing and procurement group is to promote, defend and process of premixture ingredients, represent the common and gen- their formulation, manufacturing, eral interests of the European pre- packaging and transport. We then mixture industry. focus on the quality management and safety, and provide informa- The different chapters in this tion on their physical and chemical booklet aim to draw a picture of characteristics. the European premixture industry and are based on EU legislation We hope you will find this booklet at the time of editing. We aim to useful and that it will clarify the land- update the relevant information as scape in which the EU premixture appropriate following changes in industry is operating. legislation. Peter Fidder Chairman Working Group Premixtures Premixtures -10- -11- I. THE VARIOUS TYPES However, manufacturing process- 1. Product forms Liquid premixtures: in general OF PREMIXTURES es of feed are diverse and new these liquid premixtures are in- technologies have become avail- Solid premixtures: these premix- cluded after further processing of In the European Union, premix- able, feeding practices steadily tures in powder form are usually the feed ingredients (e.g. post-pel- tures are defined as “mixtures of change according to the market mixed with the other feed materi- leting / extrusion). It is particularly feed additives or mixtures of one trends, scientific progress and als in the early steps of the feed helpful for feed additives which or more feed additives with feed economic constraints, new feed production, as close as possible may be sensitive to temperature, materials or water used as carri- additives and functional feed in- to the mixer, but before any other moisture or high pressures (e.g. ers, not intended for direct feed- gredients are entering the market treatment (such as pelleting, etc). enzymes). ing to animals”. The terms premix, and the regulatory environment is They represent the vast majority of base-mixes, blends, etc, are com- evolving. Therefore, the premix- premixtures used on the market. This can also be used to apply fla- monly used as synonyms and re- ture industry is constantly adapt- vouring/appetizing substances at flect the large variety of products. ing its offer to the needs of its cus- the surface of the feed and there- tomers. fore provide higher palatability. The use of premixtures is mainly aimed at: Premixtures can take many differ- ent forms according to their use ▪ Reducing the number of ingre- or their specific function(s) in the dients to be supplied, handled feed. and incorporated in the feed mills. ▪ Ensuring proper homogenisa- Picture 1: tion of the feed additives in Manufacturing flowchart of compound feed. Source: IFF, Braunschweig the final feed, especially for those additives that are added in very small quantities or that may present specific risks for the animals if not given in the right amount. ▪ Eventually providing standard- ised products with sustainable quality and safety to the feed industry. Premixtures -12- -13- 2. Product functions l Flavour blends: They are also 3. Different constraints II. SOURCING AND feed additives blends, but fla- PROCUREMENT Premixtures - in either liquid or vouring blends are specifically Depending on the type of products solid form - can contain one or affected by Intellectual Proper- manufactured, the need to oper- 1. Legal, Quality system, more feed additives, with similar ty aspects. The right combina- ate under tight control is increas- Customer requirements or different functions. Basically, tion and balance of the differ- ing and production is becoming the following product types can ent flavouring compounds can more complex due to the following a. Registered and approved Feed be defined according to their func- lead to very different results in factors: business operators tions in the feed: terms of smell or palatability of Feed business operators shall final feed. Flavour blends are ▪ Increasing number of ingredients not operate without a registration ▪ Pre-dilution: They are premix- based on extensive experi- or an approval according the Eu- tures of one feed additive with ence, research and know-how ▪ Possible chemical interactions ropean Feed Hygiene regulation. a carrier or carriers, with the that must be protected. between different types of ad- Feed Business operators can aim to dilute the feed additive ditives leading to only source from registered and / and then better incorporate it ▪ Complex premixtures: Com- or approved establishments. in large amounts of feed ma- plex premixtures contain a va- l Potential stability issues EU Feed Hygiene Regulation re- terials or potentially in another riety of feed additives, which l Potential caking issues quires that sourcing of feed addi- premixture. are aimed to cover the nu- tives as nutritional additives, zoot- tritional needs and the tech- ▪ Possible physical interactions echnical additives, antioxidants ▪ Specific blends: These prod- nological, zootechnical and between the different products with a fixed maximum content in complete feed, colorants as ucts are designed to fulfil spe- sensory objectives linked to leading to: carotenoids and xantophylls, is cific function in feed: the particular feed. They are only allowed from approved feed usually the only supply of feed l Potential lack of homogeneity business operators.
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