Predict the enterobacteriaceae decontamination of feed by pelleting system

Centre technique de la Nutrition Animale

Predict the enterobacteriaceae decontamination of

feed by pelleting system

F. Putier – Managerwww.tecaliman.com

2


Feed-to-Food30 Sept. 09

Context/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 press16 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

ObjectivesPhase 1 Phase 2

4



Phase 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: 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

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Phase 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: 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°

Popu

latio

n in

ent

erob

acte

ria (l

og

UFC

/g)

Hopper entry Processor exit Cooler exit

8



Phase 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°Popu

latio

n in

ent

erob

acte

ria (l

og

UFC

/g)

Hopper entry Processor exit Cooler exit

9



y = 4.5136x + 65.648R2 = 0.7501

6065707580859095

100

0 1 2 3 4 5 6

Diminution of enterobacteria (log UFC/g)

Tem

pera

ture

die

pla

te e

xit (

°C)

Laying HenPigTurkeyChicken

Phase 1: ResultsRaw data

decontamination with die temperature

To obtain 3 log ≈ 87°C at die exit

10



y = -4.341x + 87.826R2 = 0.7358

6065707580859095

100

0 1 2 3 4 5

Population in enterobacteria after treatment (logUFC/g)

Tem

pera

ture

die

pla

te e

xit (

°C)

Laying HenPigTurkeyChicken

Phase 1: ResultsRaw data

final contamination with die temperature

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

11



Introducing tablesExample 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

pera

ture

Afte

r con

ditio

ning

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



Introducing tables Chicken and turkey feeds

4550556065707580859095

2 2.5 3 3.5 4 4.5 5 5.5 6 6.5Retention time in die plate (s)

T° a

t pro

cess

or e

xit (

°C)

Chicken with MarginChicken without Margin

Turkey with MarginTurkey without Margin

13



Introducing tables 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 6.5Retention time in die plate (s)

T° a

t pro

cess

or e

xit (

°C)

Pig with MarginPig without Margin

Laying Hen with MarginLaying Hen without Margin

14



Phase 2 : PrincipleApplication of table at industrial sites

Samples from entire batchat different points

Counting enterobacteria and total flora

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Phase 2: Equipment and method

84 trials at 11 industrial sites 3 trials per feed x 3 feeds24 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)

Flor

a in

ent

erob

acte

ria a

t coo

ler e

xit

(UFC

/g)

Phase 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

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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)

Flor

a in

ent

erob

acte

ria a

t coo

ler e

xit

(UFC

/g)

Phase 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

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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)

Flor

a in

ent

erob

acte

ria a

t coo

ler e

xit

(UFC

/g)

Phase 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

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ConclusionGranulation 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

Predict the enterobacteriaceae decontamination of feed by pelleting system

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