Centre technique de la Nutrition Animale Predict the enterobacteriaceae decontamination of feed by...

Centre technique de la Nutrition Animale

Predict the enterobacteriaceae decontamination of

feed by pelleting system

Predict the enterobacteriaceae decontamination of

feed by pelleting system

F. Putier – Manager

www.tecaliman.com

2


Feed-to-Food30 Sept. 09

Context/ObjectivesContext/ObjectivesProgramme context and objectives

Context Regulation EC 2160 2003 zoonosis Discussion between the sector and the

French Ministry of agricultureResearch programme set up

Objectives To demonstrate and validate the impact of

granulation on the bacteriological quality of feeds

Creation of minimum decontamination conditions

Introduction and circulation of a protocol

3



56 trials on pilot press

16 industrial exploratory trials

Validation of decontaminating effect

<3 log in finishing product and of 3 log during process

Set of tables

Protocol proposal to test industrial line effect

84 trials at industrial sites

Validation of protocol and tables

Circulation of protocol

ObjectivesObjectives

Phase 1 Phase 2

4



Phase 1: PrinciplePhase 1: Principle

Creation of granulation trials Four feeds concerned

Pig Laying hen

Ckicken Turkey Granulation according to defined methods

Processor exit temperature Die plate thickness Granulation speed

Samples before and after granulation Enterobacteria analysis (standard NF V08 054 at

37°C) and total flora (NF V08 051)

Related to retention time

in the die plate

5



Phase 1: EquipmentPhase 1: Equipment Feeds

Gondard mixer with twin coils of 224 l Granulation press and pilot coolers

Disinfected sampling equipment

Pig542 µm/65°

Laying hen516 µm/66°

Chicken656 µm/64°

Turkey635 µm/ 59 °

CLM 12 Meccanica press11 kW - 50 at 800 kg/hr

Die plate4/20 4/244/35 4/45

4/50

AcquisitionPower

T° pellets/flourSteam rate

1% pointer waste

Wheat/Barley Maize Oil cakes Carbonate Other

6



Phase 1: MethodPhase 1: Method Composite central plan

Processing T°

45

Compression rates

2

20

24

35

45

50

53 67 83 90

Uses Uses Reduction in number of trials

Entire space scannedAllowance for day effect

Very powerful statistically

14 trials per feed

7



Phase 1: ResultsPhase 1: ResultsRaw data : example on Pig feed

Variations over entire field selected

Strong impact of die sequence

0

1

2

3

4

5

6

20 67° 24 51° 24 83° 35 45° 35 67° 35 90° 45 51° 45 83° 50 67°

Po

pu

lati

on

in e

nte

rob

acte

ria

(lo

g

UF

C/g

)

Hopper entry Processor exit Cooler exit

8



Phase 1: ResultsPhase 1: ResultsRaw data : example on Turkey feed

Variations over entire field selected

Lower impact of die sequence

0

1

2

3

4

5

6

20 67° 24 51° 24 83° 35 45° 35 67° 35 90° 45 51° 45 83° 50 67°Po

pu

lati

on

in e

nte

rob

acte

ria

(lo

g

UF

C/g

)

Hopper entry Processor exit Cooler exit

9



y = 4.5136x + 65.648

R2 = 0.750160

65

70

75

80

85

90

95

100

0 1 2 3 4 5 6

Diminution of enterobacteria (log UFC/g)

Te

mp

era

ture

die

pla

te e

xit

(°C

)Laying HenPigTurkeyChicken

Phase 1: ResultsPhase 1: ResultsRaw data

decontamination with die temperature

To obtain 3 log ≈ 87°C at die exit

10



y = -4.341x + 87.826

R2 = 0.7358

60

65

70

75

80

85

90

95

100

0 1 2 3 4 5

Population in enterobacteria after treatment (logUFC/g)

Tem

per

atu

re d

ie p

late

exi

t (°

C)

Laying Hen

Pig

Turkey

Chicken

Phase 1: ResultsPhase 1: ResultsRaw data

final contamination with die temperature

To obtain <3 log after cooler ≈ 82°C at die exit

11



Introducing tablesIntroducing tables

Example on chicken feed

Computing multilinear regressions and models to predict :

Post-treatment contamination Decontamination

ET-SR =14.65 + 0.054 F-0.54 TSC +0.004 TSC2

enterobacteria via the granulation process

Length of die plate ducts – F (mm)Tem

per

atu

re A

fter

co

nd

itio

nin

g

TA

C (

°C)

ET-AC

3.03.54.04.55.0

20 25 30 35 40 45 5045

55

65

75

85

95

20 25 30 35 40 45 5045

55

65

75

85

95

ET-AC=14.65 + 0.054 F – 0.54 TEC + 0.004 TAC2

Decontamination model adopted 2 curves used to produce :

One table with margin One table without margin

log

12




Chicken and turkey feeds

45

50

55

60

65

70

75

80

85

90

95

2 2.5 3 3.5 4 4.5 5 5.5 6 6.5

Retention time in die plate (s)

T°

at p

roce

sso

r ex

it (

°C)

Chicken with Margin

Chicken without Margin

Turkey with Margin

Turkey without Margin

13




Pig and Laying Hen feeds

45

50

55

60

65

70

75

80

85

90

2 2.5 3 3.5 4 4.5 5 5.5 6 6.5

Retention time in die plate (s)

T°

at

pro

ce

ss

or

ex

it (

°C)

Pig with Margin

Pig without Margin

Laying Hen with Margin

Laying Hen without Margin

14



Phase 2 : PrinciplePhase 2 : PrincipleApplication of table at industrial sites

Samples from entire batchat different points

Counting enterobacteria and total flora

15



Phase 2: Equipment and methodPhase 2: Equipment and method

84 trials at 11 industrial sites 3 trials per feed x 3 feeds

24 pig 12 laying hen 27 chicken 21 turkey

Setting up granulation conditions

Granulation line Ordinary conditioning/ no pre-compression Presses 120 to 260 kW/Steam power from 0.8 to 4 b

Setting up trials

Industrial mixer

2 trials with margin, 1 without

Industrial and pilot coolers

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0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

70 75 80 85 90 95

Temperature die exit (°C)

Flo

ra in

en

tero

bac

teri

a at

co

ole

r ex

it

(UF

C/g

)

Phase 2: ResultsPhase 2: Results Pig and laying hen feeds

Cooler exit / Die exit temperature

Objective <3 log

for enterobacteria with the T° acquired by the feed in the die

Efficient tables

17



0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

50 60 70 80

Temperature conditioning exit (°C)

Flo

ra in

en

tero

bac

teri

a at

co

ole

r ex

it

(UF

C/g

)

Phase 2: ResultsPhase 2: Results Pig and laying hen feeds

Cooler exit/ Die exit temperature

Objective <3 log

Variability of contamination with a conditioning T° of 60°C Variability of T° acquired in the die plate

For T° > 70°C high decontamination

18



0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

70 75 80 85 90 95

Temperature die exit (°C)

Flo

ra in

en

tero

bac

teri

a at

co

ole

r ex

it

(UF

C/g

)

Phase 2: ResultsPhase 2: Results Chicken and turkey feeds

Cooler exit / Die exit temperature

Enterobacteria with the T° acquired by the feed in the die

T° tested between 63 and 85°C at conditioning exit

Objective <3 log

19



ConclusionConclusionGranulation effect demonstratedSufficient effectiveness of table

Chicken/turkey feed High temperatures required Tables with and without margins effective (T°>67°C) Speed less important than T° at conditioning exit

Pig/laying hen feed Little effort required for temperature and speed Retention time often long Table without margin should be sufficient

Allowance for batch start when tables have not yet been reached

Need for bacteriological management of sites

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