12/05/2022

In line quality control in

Feed Manufacturing

Budi Tangendjaja, PhD

Technical Consultant, USSEC ID

Agenda

• Introduction
• Feed Business and Formulation
• Updated Data Base
• In-Time and In-Line Quality Measurement
• Application in Feed Production
• Conclusion

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Purpose of Feeding Broiler
Maximize Performance:
• Broiler Index (IP) > 400
• FCR 1.5 to reach 1.8 kg
• Days to market 1.8 Kg
Feed is Major Cost in Broiler Production
As 10 Apr 22
12/05/2022
Lowest Cost of Production
• Cheapest cost to produce 1
kg live weight
• Lowest cost 1 kg carcass
• Total income from parting:
breast meat, leg quarter,
by-products (ovals, feet
etc.)
• Feed contribute 72%
of broiler cost
• 20% is from DOC
To reduce cost:
- More ingredients
choice
- Precision nutrition
- Review un-necessary
additives
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Volatility of Ingredients Price (Corn and SBM)

Role Nutrition in Feedmill Business

Nutrient
Purchasing spec

Finance
and Production
Accounting
Quality Choice of
Feedmill Assurance Formulation Ingredients
Business

Marketing Nutrition
Formula Cost Price
84-94% of total cost (shadow)

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Development of Feed Formulation

Synthetic Amino Acids Advance in Genetics
Nutrient requirements based on AA Commercial Enzymes
Vitamins discoveries Antibiotic restriction
Early Nutrition

>1950 >1960 >2000 >2020

Linear programing using computer Precision Nutrition

Amino Acids Requirement
Concept of Metabolizable Energy
NIR for quality measurement
Formulation based on in time data base
Cloud computing, Formulation any time any
where
Performance prediction and intime monitoring

Formulation based on in time data base

• Formulation is Question
mathematical calculation  How often you formulate a
• Use correct data input ration?
• Incorrect Data resulted in  Is your formula based on
Incorrect Formula
correct ingredient data?
• All use “Linear Programing”
 How do you manage
• Software: Excel, Academic,
Commercial (Brill, Format, variability of ingredients?
BestMix, CFC, Mixit,
FeedLive)

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Data requirement for linear program

 Raw materials nutrient composition

 Constraint or limitation divide into 2:
1. Targeted nutritive value of the diet to be
formulated
2. Limitation of raw materials usage
 Price of raw materials
“garbage in garbage out”

Raw Material/Ingredients composition

 Book Value? NRC, Brazil,

ARC, CVB
 Ingredients data obtained
from Adisseo, Evonik, Novus,
Ajinomoto, local publication
etc.
 If not available, self
generated data from
Laboratory analyses and
predicted nutrient using
published equations

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Nutrient contents of soybean meal by origin

Critical Nutrients:

• AMEn (Meteos, 2021)

• Digestible EAA

• Protein Quality
KOH Prot. Solubility,
Urease Activity
Heat Damage Index

Ibanez et al., 2020

Book value or result of analysis

 Average of published analysis
 There is a variation in the result
 For safety margin, mean value
deducted by ½ Std Dev.
 Is it the correct way to run Least Cost
Feed Formulation? Or use Stochastic
Formulation
 Real value from the current ingredient
use to be more precise
 Require NIR to estimate nutrient and
the result is transferred to Formulation
data base

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Corn grading
in a Feedmill
 Chicken will perform
differently when fed corn
Grade A and Grade D.
 Require Quality Control
system to differentiate
quality of Ingredients
 Segregation or
separation in warehouse
or silo to improve quality
consistency of final ration

Soybean meal quality differences

Country of origin: India vs. Brazil vs. Argentina vs. USA

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AME and Amino acids of different SBM

Evonik, March 2022 from >5500 samples

SID Lys of SBM from different origin

in the last 4 years

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Possible errors in feedmill affecting quality

• Raw materials
• Formulation
• Processing
• Delivery and storage in farm

Know your raw materials

Nutrient content

Method to measure nutrients in feed

Nutrient Matrix
Proximates
Wet Chemistry

Protein
Total amino calculation AMEn MJ/kg
HPLC analysis
acids
Dig Lys, %

Calo. bomb
Dig Met + Cys, %
Energy Dig P, %

Zhang, 2022

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How do solve the problem?

§ Analyze an ingredient to be
used in feed production
§ Use result of analysis to revise
the data base in Feed
formulation
§ Run Feed Formulation in-time
the ingredients are used
§ Require quick and reliable
method for nutrient
measurement. NIR is a choice

Near Infra Red (NIR)

Spectroscopy Technology
 Apply thermal radiation to sample

 Absorption of C-H, O-H, N-H, C-C, C=O

bonds, wavelenth1100 - 2500 nm

 Measure reflected light with detector

Sample

 Apply measured spectrum to

NIR light
calibrations
 Able to measure damaged products Light source
(SBM, DDGS) for Digestibility, ME
Reflection
Detector
Analysis within minutes!

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Several companies develop hand-held NIR (BASF

Trinamix, Evonik, Trouw etc.)

Complete Nutrients can be estimated by NIRS

• Proximate composition: Moisture, • Digestible amino acids

protein, Fat, ash, Fiber)
• Carbohydrate fractions: Nitrogen
Free Extract (NFE), Neutral
Detergent Fiber (NDF), Starch,
sucrose, Non-Starch Polysaccharide
(NSP),
• Total Amino Acids, Biogenic Amine
• Phytate, Non-Phytate Phosphorus
• Fatty Acids
(poultry and pig)
• Metabolizable Energy (ME)
for poultry, ME for layer and
ME for broiler.
• Toxicants: Trypsin Inhibitor,
Urease Activity, Protein
Solubility in KOH
• Damaged protein
22

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Benefit in using NIRS

Benefit and Pitfall in Using NIR system

• Why Use NIR and Formulation Services?
But there are Pitfalls:
– NIR gives up to the minute analytical data
– Data should be linked to the Formulation • Callibration using Wet
Program as closely as possible Chemistry, if Kjeldahl result is
– High priced ingredients should be carefully not accurate
used
– Trend towards precision formulation with
• Require continuous
frequently corrected data updates improvement, need
standardized laboratory
• Small differences in nutrient content can • Prediction from Biological
make a big difference to feed cost in the System, estimating ME or
current market Digestible Nutrients
• Data needs to be leveraged to take • Equation vs animal trials?
economic advantage
(Clark, 2022) • Not the single or only technique

Quick Test is
still useful

• Can be quick
method
• Detection of hull in
rice bran
• Visual
measurement

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Adjustment of Data Base from Complete

Nutrients Analysis
 Result of NIR measurement can
be transferred easily to the
formulation data base using
Interface
 Formulation software is available
not only in computer but also in
Cloud Computer, so you can
formulate a ration every where
and any time
 Formulation will be more precise
based on actual ingredient
measurement

Application Online
QC at Feedmill

Feedmill can produce good

feed?

Can they produce all the time?

Major problem with Feedmill
Can not control variability

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Process Variation in Feed Manufacturing

•Blue Line = individual results

•Red Line = moving average of 5 results
•Lab results indicating stable process!
Elholm (2021)

Error in Quality Measurements

• Sampling (equipment,
scheme, personnel's)
• Laboratory Analysis
(method, chemicals,
equipment's, analyst)
• Presentation or
processing of Samples

https://www.forecast.app/
Source:Edvotek

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Use In-Line Quality Measurement

• NIR can be installed in several

locations of Production Line
• Measurement is fast (2 seconds),
accurate, and the result can be
connected digitally and the
results can be used for automatic
adjustment of formula or process
• Result to more consistent quality
and reduce cost REAL-TIME Information on
moisture, fat, protein and
other basic components Elholm (2021)

2
Mixer
control

Final product
1 4 quality control

Feed formulation Drying and 3

coating control

Elholm (2021)

30

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Foss suggestion on Re-formulation On-Line

1

•
Soybean meal

Wheat In-line NIR installed after raw material silos. May be installed with a
Maize

Other • bypass system to be used on different raw material streams

• NIR quality date transferred to feed formulation software which
• recalculates recipe
• Protein the controlling parameter
• New set-points for dosage is transferred to PLC/SCADA system for
continuous reformulation
• Savings can amount to up to 1 USD / ton of feed produced or
~50,000 USD per year for a feed mill producing 50,000 tons/year
Feed
Formulation
software

Elholm (2021)

31

Similar On-Line Quality Measurement for

grains and oilseed at Export Terminal

Sample is
analyzed to grade
the grains

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Conclusion
• Feed is major cost in broiler production
• Feed formulation play important role to reduce cost
• Formulation require correct nutritional data of ingredients and
should be done based on actual analysis of nutrient
• NIR can be used to estimate complete nutrients content required
for formulation
• In-Line NIR can be installed during feed production and formula
can be adjusted accordingly
• In-line quality control can improve consistency of quality and
reduce cost of feed production

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Thank you
btangendjaja@ussec.org

USSEC.ORG | USSOY.ORG

While the U.S. Soybean Export Council (USSEC) does not guarantee the forecasts or statements of USSEC Staff or Contractors, we have taken care in selecting them to
represent our organization. We believe they are knowledgeable and their presentations and opinions will provide listeners with detailed information and valuable insights
into the U.S. Soy and U.S. Ag Industry. We welcome further questions and always encourage listeners to seek a wide array of opinions before making any financial
decisions based on the information presented. Accordingly, USSEC will not accept any liability stemming from the information contained in this presentation.

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