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AP42 Chapter 9 Reference AP-42 Section Number: 9.9.1 Reference Number: 14 Title: Feed Manufacturing Technology 111 American Feed Manufacturers Association, Arlington, VA 1985 Reference & Repolt Sect. __ Reference __ ' Feed Manufacturing Technotogy I11 TECHNICAL EDITOR Robert R. McEllhiney Professor Department of Grain Science and Industry Kansas State University a ASSOCIATE EDITORS Charles G. Olentine, Jr., Watt Publishing Company Raymond J. Lunemann, International Multifoods Corp. Jim Rempe, ACCO Feeds Division, Anderson, Clayton & Company Keith C. Behnke, Kansas State University Wallace D. Bees, Format Pharm-Tech. LaDell R. Swiden, Consultant Carl Stevens, Kansas Stete University Roy Schultz, Hubbard Millin Company John R. Pedersen, Kansas tl tate University Eugene F. Morneau, Cargill, Inc. K. v. Lensmeyer, Ralston Purina Company Robert R. McEllhiney, Kansas State University ... 111 Table of Contents Chapter Page SECTION I. INTRODUCTION TO THE FEED INDUSTRY 1 1 History of the Formula Feed Industry ........ ................... 2 2 The U.S. Formula Feed Industry Today ...... .............. 9 3 Feed Manufacturing: An International Perspective ................... 13 SECTION II. PLANT FEASIBILITY, DESIGN, AND CONSTRUCTION 21 4 Plant Feasibility ... ..................... 22 5 Feed Plant Layout and Design . ................ 27 6 Construction of a Feed Plant ........ ................ 59 7 Pressurizing Feed Mills ........................... .... 63 SECTION Ill. BULK MATERIALS HANDLING AND STORAGE 65 8 Conveyors. 9 Bucket Elev 10 Bins ....... 11 Pneumatic Conveying . ....................................... 93 12 Liquid Ingredients ....................................... 99 13 Dust Collecti SECTION IV. MANUFACTURING OPERATIONS 123 14 Receiving Cost Center ........ ...................... 125 15 Material Processing Cost Center ....... 137 16 Proportioning and Mixin 17 Pelleting Cost Center .............. ....................... 167 18 Blocking ............................ ................... 191 19 Extrusion Cooking Systems .............. ...... 195 20 Feed Packaging .......................... 21 Warehousing an .............. 22 Drying and Aeration of SECTION V. SPECIALTY FEEDS 221 23 Production of .... ... 222 24 Liquid Feeds . .............. ................. 238 25 Microingredie ............................... 242 SECTION VI. COMPUTER SYSTEM APPLICATIONS 247 26 Planning the Components of an Integrated System . ....... 252 27 Implementing the Integrated System ... ............................ 260 28 Justifying the System ........... ............................ 262 SECTION VII. UTILITIES AND MAINTENANCE 265 29 Maintenance Programs ............ ............................. 266 30 Boiler Water Treatment ............. .............................. 273 31 Boilers and Associated Equipment ... 32 Steam Traps 33 Compressed ....... 298 34 Plant Electric 35 Electric Motors . ....................................... 314 36 Special Purpose ................................ chapter Page SECTION VIII. QUALITY ASSURANCE 335 37 Sampling .. 336 38 Feed Microscopy: Premier Quality Co .347 39 Laboratory Testing . , . 350 40 In-Plant Quality Assurance , , . 354 41 Controlling Drug Carryover and Other Additives . 369 42 Product Liability . ..................................... 372 SECTION tX.-SANITATIONAND PEST MANAGEMENT 379 43 Sanitation and Pest Management.. .:. 380 SECTION X. MODERN SAFETY AND LOSS CONTROL MANAGEMENT 391 44 Managing a Safety and Health/Loss Control Program . 392 45 Micro-Premix Operation .................... ......................... 402 46 Control of Fire and Explo n in Feed Plants.. 403 47 Managing Work Related Employee Disability . ............... 408 SECTION XI. ENERGY MANAGEMENT 41 1 48 Organizing an Energy Management Program ......................... 412 49 Energy Cost Center.. , . 41 4 50 Feed Plant Energy Audit . 41 9 51 Utility Rate Schedules and lnvoi 424 SECTION XII. ENVIRONMENTAL MANAGEMENT 429 52 Environmental Assessment . 43 1 53 Air Pollution Control . , , . , 434 54 Wastewater Management . 440 55 Solid and Hazardous Waste , . , , . 454 56 Spill Control . , , . .' .......................... ........... 459 SECTION XIII. PLANT MANAGEMENT 463 57 The Plant Manager's Job . , , . 465 58 Planning and Budgeting . 470 59 Manufacturing Cost Contr 477 60 Product Costing .............................. 486 61 Feed Mill Proces 491 62 Operating Standards and Analysis . 498 63 Production Planning and Scheduling . 508 64 Inventory Control , , , , . , , , . 512 65 Shrink Control in Feed Manufacturing . 522 XIV. PROCESSING EFFECTS 529 66 Processing Effects on Nutrition . 529 67 Fish Food Formulation and Processing . 534 APPENDIX Page A . ....................... ............................. 541 B. Plant Feasibility .Site Visit Check List .................................. 546 C. Determining and Expressing Particle Size ... 549 D. Test Procedure for Solids .Mixing Equipmen 552 E. Properties of Saturated Steam and Water ..... 556 F. Physical Properties of Feed Ingredients .................................. 558 G. Wafers. Pellets. and Crumbles .......................................... 563 H. A Procedure for Estimating Degree of Gelatinizations of Cooked Grains ...... 566 I. Package Weight Control ................................................ 567 J . Typical Sewer Use Ordinance Lim 569 K . Calculation of Stormwater Runoff 570 L. Characteristics of Hazardous Waste 570 M . General Construction Specificatio 571 N. Electrical Data ................ 585 0. Basic Statistical Concepts ...... 587 P. Formulas for Geometric Figures . 595 Q . Conversion Factors ............. 598 FOR YOUR INFORMATION Feed Plant Short Courses ........................................................ 20 Truck Management ............................................................. 166 Feed Science and Management at KSU ........................................... 246 INDEX ........................................................................ 605 I . Chapter 2 1. The U.S. Formula Feed Industry Today Wayne Anderson Feedstuffs Senior Editor The one sure statement that can be made about the formula mately ?on pounds or more per ton to make a balanced feed industry in the U.S. today is that it will not be the same ration. tomorrow. Change has always been a pati of feed manufacturing. 0 B~ISPm;.wslwper cniicciiirules differ from supplements in a:, with niost other industries. and that is as true now as it has ever that they contain only pan of the animal's protein re- been. New customers. new markets. new technology. and different quirements. It is added with grain and other high prolein economic conditions all play roles in causing that change. ingredients at the rate of 100 pounds (or more) per tun to The U.S, feed industry of the 1980s is basically a mature make a balanced ration. industry. Overall. per capita consumption of animal products has 0 Preriiirrs are formulations of one or more rnicroingredients. generally plateaued and population growth in the U.S. has sta- such as vitamins. minerals. trace minerals. or drugs mixed bilized at an annual rate of about I&. Livestock and poultry with a carrier ingredient. They do not contain any significant producers continue to decline in numbers while increasing in unit amount of protein. A premix is usually added at a rate of less size. The growth of various forms of venical integration. contrac- than 100 pounds per ton with grain and other protein in- tual arrangements and. more recently. on-farm feed mixing. all gredients to make a balanced ration for nonruminant ani- have combined with fewer customers to cause a decline in the mals. For beef. it may be mixed (or top-dressed) with grains nuniherof manufacturers and dealers in the traditional (hrmula feed andlor roughages to make a complete ration. industry in the U.S. The feed industry has traditionally been an ouilet for a number of mill by-products and oil extraction products. Table 2-1 Defining the Industry illustvales how cenain by-product ingredients have increased in When doing any survey of the feed industry. it is necessary usaseoverthepast ISyears. Compiled by USDA.thetableshou,sa to set up definable parameters to which the feed ntanuiacturers and dramatic increase in demand for soybean meal while other protein their products can be compared. The United States Depanment of ingredients have either held steady or have declined. Additionally. Agriculture has periodically conducted surveys of the feed indus- the quantity of high-protein feeds consumed by livestock and try. In those studies the follou,ing definitions fur feed manufactur- poultry has increased greatly. ing haw been used: Corn is the primary grain used in animal feeds in the U.S.. b Fwd.!n;ll;q rsroDlihmctir is usually a slalionary mill opera- comprising ahout 75%> of the Seed grain market for domestic tion st a single location together with any mobile niills hased consumption (Table 2-21, In terms of corn equivalents. feed con- at that location. sumed by livestock and poultry showed little growth in the early e I'riiiuir~/cki/ niiintfitcruriq is the processing ;ind mixing of 1980's: in Pact. consumption has not grown to a great degree over individual feed ingredients. sometimes with the addition of a the last IS years (Table 2-3). premix at a rate of less than 100 pounds per ton of linished Iced. e Sc~.oriil~tr\.~rds~rt~~rif~~cruri~~g is the processing and mixing Changes in the Industry of me or more ingredients with formula feed supplements. The commercial feed industry. which ranks anions the top SupplemenLs are usually
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