Improving the efficiency of pig feed manufacturing and application of additives

261 Pages·2013·3.47 MB·English

Improving the efficiency of pig feed

manufacturing and application of
additives
4B-104

Prepared for the
Co-operative Research Centre for High Integrity Australian Pork

By

Peter Sopade1, Brenton Hosking2, Cherie Collins3, Simon Diffey4, Glen Fox1,
David Henman3, Chris Brewster5, Andrew Philpotts3, Annette Tredrea6, Hugh Rodrigues7,
Danny Singh7, Aaron Cowieson8, Mike Gidley1 and John Black9

1Centre for Nutrition and Food Sciences, Queensland Alliance for Agriculture & Food
Innovation, The University of Queensland St Lucia, Qld 4072
2Formerly of Better Blend Stockfeeds (Rivarina (Australia) Pty. Ltd.), Oakey, Qld 4401
3Rivalea (Australia) Pty. Ltd., Corowa, NSW 2646
4National Institute for Applied Statistics Research Australia, School of Mathematics and
Applied Statistics, The University of Wollongong, Wollongong, NSW 2522
5Formerly of Ridley AgriProducts Pty. Ltd., Corowa NSW 2646
6Plant Breeding Institute, University of Sydney, Narrabri, NSW 2390
7Formerly of Wacol Pig Research Centre, DEEDI, Wacol, Qld 4076
8Formerly of Poultry Research Foundation, The University of Sydney, Camden NSW 2570
9John L Black Consulting, PO Box 4021, Warrimoo, NSW 2774

June 2013
CRC for

Established and supported under
the Australian Government’s
Cooperative Research Centres
Program
Table of Contents

Executive Summary 9

A. Introduction 13

Part One – Commercial feed processing 15

B. Survey of Commercial Pig Feeds 16
B.1 Methods 16
B.2 Results 18
B.3 Conclusions 25

C. Variation to Processing Conditions in Commercial Mills 26
C.1 Background 26
C.2 Methods 27
C.2.1 Treatments 27
C.2.2 Laboratory procedures 28
C.2.3 Mill characteristics 29
C.2.4 RVA and in vitro assays 29
C.3 Results 29
C.3.1 Mill and physical pellet characteristics 29
C.3.1.1 Effects of sorghum inclusion 29
C.3.1.2 Effects of conditioning temperature 31
C.3.1.3 Effects of adding surfactants 32
C.3.1.4 Effects of grind size 33
C.3.1.5 Effects of sorghum inclusion and processing on pellet 33
size and hardness
C.3.1.6 Effects of processing on particle size distribution 35
C.3.2 Nutritional characteristics 35
C.3.2.1 Effects of processing on nutritional quality 35
C.3.2.2 Effects of processing on pellet composition 40
C.3.3 Grain composition and physical characteristics 41
C.4 Conclusions 42

D. Processing Conditions and Animal Performance 43
D.1 Effects of processing temperature, time and sorghum inclusion 44
D.1.1 Background 44
D.1.2 Methods 44
D.1.3 Results 45
D.1.3.1 Mill and pellet physical characteristics 45
D.1.3.2 Laboratory assessment of nutritional quality 45
D.1.3.3 Effects of processing on chemical composition 47
D.1.3.4 Results of animal studies 47
D.1.3.5 In vitro starch digestion and feed conversion rate 50
D.2 Effects of particle size and steam pelleting 52
D.2.1 Mill and physical characteristics 52
D.2.2 Results of particle size analysis 53
D.2.3 Chemical analyses and mill characteristics of ground grains 53
and fractionated mixtures
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D.2.4 Animal studies 57
D.2.4.1 Methods 57
D.2.4.2 Results 57
D.3 Conclusions 58

E. Development of NIR Calibrations 61
E.1 Background 61
E.2 Methods 61
E.3 Results 61
E.3.1 Effects of processing on NIR scans 61
E.3.2 Preliminary NIR calibrations 64
E.4 Conclusions 65

Part Two – Pilot-plant feed processing 67

F. Grain and Diet Formulation 68
F.1 Background 68
F.2 Methods 68
F.2.1 Wheat 68
F.2.2 Feed formulation 68
F.2.3 Physicochemical property 68
F.3 Results 69

G. Manufacture of pellet diets 74
G.1 Background 74
G.2 Methods 74
G.2.1 Milling 74
G.2.2 Particle size distribution 74
G.2.3 Experimental design 74
G.2.4 Process parameters 76
G.3 Results 77

H. Proximate composition of the pellet diets 80
H.1 Background 80
H.2 Methods 80
H.3 Results 80

I. Pellet quality: Hardness and durability 82
I.1 Background 82
I.2 Methods 82
I.3 Results 82

J. Pasting properties of the pellets 84
J.1 Background 84
J.2 Methods 84
J.3 Results 84

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K. In vitro starch digestion of the pellets 91
K.1 Background 91
K.2 Methods 91
K.3 Results 91

L. Starch gelatinisation characteristics of the pellets 94
L.1 Background 94
L.2 Methods 94
L.3 Results 94

M. In vitro protein digestion of the pellets 101
M.1 Background 101
M.2 Methods 101
M.3 Results 101

N. Fourier transform infra-red spectroscopy (FTIR) on the state of starch and 103
protein in the Pellets
N.1 Background 103
N.2 Methods 103
N.3 Results 103

O. Animal performance – Feed efficiency with weaners 108
O.1 Background 108
O.2 Methods 108
O.2.1 Animals and treatments 108
O.2.2 Husbandry and management 108
O.3 Results 109

P. Enhancement of the NIR calibrations 113
P.1 Background 113
P.2 Methods 113
P.3 Results 113
P.3.1 Effects of processing on NIR scans 113
P.3.2 Preliminary NIR calibrations 113

Q. Research needs and recommendations 117
Q.1 Further research 117
Q.1.1 Processing model 117
Q.1.2 Enhancing NIR calibrations 117
Q.2 Recommendations 118

References 118

Acknowledgements 121

Publications 121

Appendix 123

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List of Figures

1 An approximation to the processing that is carried out each mill 17

2 Pasting properties of the flaked and raw barley and sorghum 21

Starch digestograms of the flaked and raw barley and sorghum with the model 21
3
parameters

4 Pasting properties of the mixtures of grains from mills A and B 22

5 Starch digestograms for several diets from two mills 23

Progressive changes in the pasting properties (RVA) of typical samples – A (mill 24
6
A), B (mill B).

Particle size distribution of barley, sorghum and wheat grains used in the 36
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manufacture component

Particle size distribution of ration mixtures containing nil, 40% or 60 % sorghum 37
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as used in the manufacture component

Starch digestion parameters of the mash and pellets from the diet common across 38
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the three mills

Difference between mash and pellets in the variables describing starch digestion 39
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for the three mills

Effects of process conditions and formulations on RVA parameters (PV = peak 46
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viscosity, FV = final viscosity and IV = initial viscosity)

Effects of process conditions and formulations on in vitro starch digestibility 48
12
parameters

Relationship between animal performance and in vitro digestion parameter (H = 51
13
high, L = low, T = temperature, C = conventional conditioning, E = extended

conditioning, S = sorghum inclusion)

Particle size distribution after a first hammer milling through a 4 mm screen and 54
14
after re-grinding (3.2 mm screen) those particles captured on 1.8 mm (barley) and

0.9 mm (sorghum) screens

Particle size distribution of milled and fractionated grains and feed mixtures, 55
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GA104

Effect of re-grinding large particles fed either as mash or conventional pellets on 60
16
feed conversion ratio for weaner and grower pigs

17 Spectral variation between manufacturing processes 62

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18 Spectral differences within an individual processor (QAF) 62

19 Example of spectral differences between two processors including all processing 63
stages (BBS – white; QAF – green)

20 Loading plot of spectral regions associated with pellet quality 63

21 A schematic diagram of a ripple mill 75

22 The pellet mill 75

23 Particle size distributions and parameters 78

24 The measured temperature of the conditioned samples against the set temperature 79

25 Typical viscograms of the pellets showing grain effects 85

26 Dependence of the changes (mash-pellet) in pasting parameters of the mash on the 89
grain, and conditioning temperature and time

27 Typical starch digestograms of the pellets showing the temperature effects 92

28 Typical thermograms of the pellets and corresponding mash 95

29 Gelatinisation characteristics of the pellets showing the grain and conditioning 96
temperature main effects, and the grain x conditioning temperature x conditioning
time interaction effects

30 Flowchart of the procedure for degree of starch gelatinisation by the amylose 98
solubility method

31 Grain x conditioning temperature x conditioning time interactions (nominal 99
values) on degree of starch gelatinisation by the amylose solubility method

32 Typical protein digestogram of the pellets 102

33 Grain x temperature effects on in-vitro protein digestibility of the pellets 102

34 Typical spectra of the pellet diets 104

35 Effects of grain x conditioning temperature x conditioning time on the FTIR 106
absorbance ratios

36 Animal performance parameters of the pellet diets as affected by the processing 111
condition

37 PCA showing new samples (circled) clustering away from the previous samples 114
used in the calibrations

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List of Tables

1 Description of samples for the project 19

2 Changes in pasting properties along the processing chain as indicated by RVA 25
variables

3 Ingredient inclusions (%) for rations manufactured under protocol BBS 27

4 Manufacturing component (BBS, QAF, RAP) - Mill processing conditions 28

5 Milling equipment and capacities 30

6 Variables used to calculate retention time at the mixer conditioner 31

7 Processing conditions and responses to increasing sorghum inclusion at the BBS, 31
QAF and RAP mills

8 Effect of conditioner temperature on mill and pellet characteristics at the BBS mill 32

9 Processing conditions and responses to the inclusion of surfactant (Kemzyme W, 32
BBS)

10 Processing conditions and responses to the inclusion of surfactant (Bredol, RAP) 33

11 Processing conditions and responses to grind size, QAF 33

12 Particle size of feed mixtures before (mash) processing and pellet characteristics 34
in response to increasing sorghum inclusion and temperature, BBS

13 Particle size of feed mixtures before (mash) processing and pellet characteristics 34
in response to increasing sorghum inclusion and 2 grind sizes, QAF

14 Particle size of feed mixtures before (mash) processing and pellet characteristics 35
in response to increasing sorghum inclusion and the use of a surfactant (Bredol),
RAP

15 Processing effects on the chemical composition of a pig grower feed 40
manufactured at BBS

16 Processing effects on the chemical composition of a pig grower feed 41
manufactured at QAF

17 Processing effects on chemical composition of a pig grower feed manufactured at 41
RAP

18 Chemical and physical characteristics of grains used in the manufacture of a pig 42
grower feed at the mills

19 Processing conditions for experiment 44
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20 Physical characteristics of feed components before (mash) and after processing 45
(pellet)

21 Chemical components of the mash 49

22 Chemical components of the pellet 49

23 Predicted mean values for feed conversion ratio (feed:gain) over 0-28 days for the 49
interaction between conditioning temperature (temp) and conditioning time
(conditioning)

24 Predicted mean values for feed conversion ratio (feed:gain) over 7-28 days for the 49
interaction between conditioning temperature time

25 Predicted mean values for feed conversion ratio (feed:gain) over 7-28 days for the 50
interaction between conditioning temperature and sorghum inclusion in the diet

26 Processing conditions for conventional and fractionated ration mixtures 52

27 Physical components of conventional and fractionated ration mixtures before 53
(mash) after (pellet) processing

28 Chemical and physical characteristics of grains and grain fractions 56

29 Chemical components of conventional and fractionated ration mixtures after 56
processing

30 Rivalea weaner pig experiment. Effects of grain type, particle size and diet form 57
on average daily intake (ADI), rate of gain (ROG) feed conversion ratio (FCR) of
pigs from 0-28 days

31 Wacol grower pig experiment. Effects of grain type, particle size and diet form 58
on average daily intake (ADI), rate of gain (ROG) feed conversion ratio (FCR) of
pigs from 0-28 days

32 Criteria used to assess the value of NIR calibrations 65

33 Statistics for NIR calibrations established for variables measured on final 66
processed pellets

34 Physicochemical (laboratory and NIR) properties of the wheats 70

35 Diet formulation for soft wheat 1894 71

36 Diet formulation for hard wheat 1895 72

37 Diet formulation for sprouted wheat 1896 73

38 Processing and replicated conditions for the pellets 76

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39 The main effects of the processing conditions on the specific mechanical energy 79
(SME)

40 Proximate composition of the pellet diets 81

41 Predicted hardness and durability of the 18 pellet treatments 83

42 Summary of statistical analysis (p-values) of the RVA parameters as affected by 86
the processing conditions

43 Predicted RVA parameter values of the three-level interactions 87

44 Predicted RVA parameter values of the four-level interactions 88

45 Predicted starch digestion parameters for the 18 pellet treatments using the 93
modified first-order kinetic model

46 Summary of statistical analysis (p-values) of the animal performance parameters 110
as affected by the processing conditions

47 Pearson’s correlation analysis of the key parameters of the pellets 112

48 Comparison of calibration statistics from previous calibrations and the new 115
calibrations

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List of Appendices

These appendices relate to part two of the project

I Experimental design codes for part two of the project 123

II Statistical report on moisture content of the pellet diets 124

III Statistical report on starch content of the pellet diets 138

IV Statistical report on protein content of the pellet diets 150

V Statistical report on fat content of the pellet diets 162

VI Statistical report on ash content of the pellet diets 174

VII Statistical report on pasting behaviours of the mash and pellets 186

VIII Statistical report on in vitro starch digestion of the pellet diets 198

IX Statistical report on differential scanning calorimetry of the mash and pellets 214

X Statistical report on in vitro protein digestion of the pellet diets 225

XI RIVALEA ethic approval 11N093C – Influence of grain and processing conditions on 237
pig growth

XII Statistical report on weaner feeding trials 240

XIII MINITAB output on hardness and durability of the pellets 260

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