Patent Application
20120301598
The subject disclosure relates to pelletized animal feed products and to systems and methods for generating pelletized animal feed products.
The demand for pelletized feed is driven by weather patterns that cause traditional forage shortages both in winter snow conditions and summer drought conditions. However, there is limited availability in the market for feed pellets or cubes containing a near complete ration of energy, protein, nutrients, and roughage. Traditional feed of this type is generally made from alfalfa and offered in pellets or cubes as an economical way to transport and physically feed to livestock. Feed pelletizing is, as conventionally practiced, an extrusion type thermoplastic molding operation in which finely divided particles of a feed ration are formed into compact, easily handled pellets.
Dried Distiller's Grains with Solubles (DDGS) and Dried Distiller's Grains (DDG) are regarded as a good source of protein and energy but can be difficult to transport and physically feed to livestock. Challenges exist in achieving efficient weight limits on certain modes of transportation and DDGS/DDG is known to “brick-up”, which can make unloading a challenge. Attempts have been made to densify DDGS in the form of pellets but due to challenges related to DDGS composition, the attempts do not add value above using DDGS in loose form.
Producers using DDGS in loose form, with or without loose forms of corn stover/cob and other forages, also contend with various challenges. Waste is caused from livestock trampling DDGS. Additionally, animals tend to consume the most palatable feed, therefore the animals may selectively consume one feed over another when loosely provided. Further, loose feeds tend to physically separate according to size and density, which may be undesirable.
Utilizing corn stover/cobs as a loose feed is a well understood and practiced standard. There also exists documented research indicating variances in nutritional values within the dead corn plant. These variances may lead to inconsistent uptake of nutrients by livestock being fed loose stover/cob. Corn stover/cobs is not a complete feed in itself and is generally supplemented with other forms of protein and nutrients from such feeds as distillers grains, alfalfa, corn, or other cereal grains. Again, the problem of selective feeding can be apparent with these feeding programs. The loose and low density of corn stover and cobs combined with its specific and limited nutritional value can create high transportation costs and can limit its use.
A number of attempts have been made to resolve these feeding challenges. For example, Scott Landers (U.S. Patent Publication No. 20080290548), entitled “PELLET MILL DIE AND PELLETIZING PROCESS”, discusses pelleting 100% DDG material. The resulting composition does not provide a complete feed solution, the size possible to generate with 100% DDG is generally too small for range pellets, and no PDI (pellet durability index) is provided, which is likely due to the tendency of 100% DDG pellets to have low durability.
Additionally, U.S. Pat. No. 4,996,065, entitled “MOLASSES-FREE CHEMICALLY REACTIVE BINDER FOR ANIMAL FEED”, discusses a feed pellet composition with binders to replace molasses binders. In this patent, the use of corn cob, distillers grains and distillers solubles, are mentioned as examples for possible pellet ingredients. However, the resulting pellets obtained have a PDI of less than 90%, which may be too low for range feed purposes.
The subject disclosure relates to a formulation of an animal feed pellet, which yields an animal feed pellet composition. Such a formulation and resulting pellet can provide high quality nutritional needs to farms in an easily transported medium.
The disclosed aspects relate to a composition of feed pellets and methods for the production of the feed pellets. In some embodiments, biomass can be milled to less than about ⅜ inch in size. Biomass may include corn cobs and corn stover in equal or substantially equal proportions, or may include a minimum of around 20% corn cobs. Alternate biomass sources, such as alfalfa can also be utilized in some embodiments.
The biomass, dried distiller's grains with solubles, distillers solubles, and binders may be mixed together. In some embodiments, the ratio of ingredients can be as follows: about 30-50% milled biomass on a w/w dry matter basis, about 45-65% dried distillers grains on a w/w dry matter basis, less than around 6% distillers solubles on a w/w dry matter basis, and about less than about 2.5% binder on a w/w dry matter basis.
Once mixed, the ingredients may be conditioned using steam. In some embodiments, steam conditioning may include providing steam at approximately 175 pounds per square inch for about 30 seconds. After steam conditioning, the ingredients may be extruded through a die of between about ¼ inch and about 3.5 inches in size. The pellets are then cooled.
The binder used to make the pellets includes at least one of molasses, lignin sulfate, and sodium bentonite. The final pellets include about 13-21% protein, about 4-9% fat, about 25-45% neutral detergent fiber, and about 5-20% moisture. Further, the pellets possess a pellet durability index of greater than around 94%.
In order that the disclosed aspects may be more clearly ascertained, some embodiments will now be described, by way of example, with reference to the accompanying drawings, in which:
TABLE 1 lists the composition of the feed pellet on a dry matter basis according to exemplary and representative embodiments; and
TABLE 2 lists the feed pellet characteristics according to exemplary and representative embodiments.
The disclosed aspects will now be described with reference to several embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of various embodiments. It will be apparent, however, to one skilled in the art, that embodiments may be practiced without some or all of these specific details. In other instances, well known process steps and/or structures have not been described in detail in order to not unnecessarily obscure the disclosed aspects. The features and advantages of embodiments may be better understood with reference to the drawings and discussions that follow.
The various aspects relate to a composition of a feed pellet and methods for producing the feed pellet. The composition can meet nutritional and durability standards. Further, the composition and methods for production of the composition can provide enhanced nutritional delivery to farm animals, a reliable feed source for farm owners, and a more readily handled feed for distributors. In addition, the composition and the methods of its production can enable consistent nutritional quality regardless of local weather, can discourage selective eating by livestock, and can provide for ease of handling.
Referring to
As shown in
An advantage of co-locating a corn ethanol plant with the biomass ethanol plant is that, for the purposes of generating feed pellets, the infrastructure for two of the main ingredients, DDG and biomass, are present at the ethanol production facilities. The feed pellet production facility may be collocated with a biorefinery to capitalize on these efficiencies. Of course, it is within the scope of this disclosure that the ingredients utilized for the generation of feed pellets are generated at discrepant, remote locations and are shipped to the feed pellet processing location as needed.
Referring to
Referring to
Additional nutritional additives 402 may mirror, or be substantially similar to, the guidelines presented in Nutrient Requirements of Beef Cattle, Seventh Revised Edition, 1996. In some embodiments, the nutritional additives may include the following nutrients: copper, iron, manganese, zinc, selenium, cobalt, iodine, Vitamin A, Vitamin D, and Vitamin E. The final pellets may, in some embodiments, provide between around 10-70% of the animal requirements for these nutrients dependent upon addition levels, animal intake, stage of production, and type of animal.
From the mixer 406 the homogenized pellet ingredients can be processed by a conditioning chamber 408 which may receive steam 410 and subject the pellet ingredients to elevated temperatures and moisture for a set period of time. In some embodiments conditioning may be anywhere from around 15 seconds to about 10 minutes but, in some particular embodiments, approximately a 30 second conditioning time can be sufficient. The moisture from the steam can increase lubrication, and partially gelatinize starches. The temperature of the ingredients may be raised to between about 120 and 230° F., dependent upon process conditions. In some embodiments, the lignin within the prepared biomass acts as a plasticizer as it is heated by steam conditioning. This effectively “glues” the pellet together and increases the final product's Pellet Durability Index (PDI). Further, in some embodiments syrup may be added to the ingredients to assist in lubrication of the ingredients through the pellet die.
The steam conditioned ingredients may be supplied to a pellitizer (i.e. pellet mill die chamber) 412 where the steamed ingredients are extruded through the die to generate the feed pellets 414. The hot extruded pellets are cooled, typically with forced air through vertical cooling systems.
An discussed herein, a feed pellet can be provided that includes about 30-50% biomass on a w/w dry matter basis, about 45-65% dried distillers grains on a w/w dry matter basis, less than about 6% distillers solubles on a w/w dry matter basis, and about less than 2.5% binder on a w/w dry matter basis.
In an implementation, the dried distillers grains include at least one of dried distillers grains with solubles, low fat dried distillers grains, and high protein dried distillers grains. In some implementations, the biomass includes corn cobs and corn stover. According to some implementations, the biomass includes a ratio of about 50% corn cobs and about 50% corn stover. In a further implementation, the biomass includes at least about 20% corn cobs, and the remainder can be corn stover. In some implementations, the binder includes at least one of molasses, lignin sulfate, and sodium bentonite.
In some implementations, the feed pellet includes about 13-21% protein, about 4-9% fat, about 25-45% neutral detergent fiber, and about 5-20% moisture. In another implementation, the feed pellet can comprise a pellet durability index of greater than 94%. In still another implementation, the feed pellet can comprise a densification improvement of greater than about 28% dried distillers grains with solubles and greater than about 100% corn stover.
The mixed pellet ingredients can be conditioned with steam (at 506). In an implementation, conditioning the mixed pellet ingredients can include supplying steam at about 175 pounds per square inch. In another implementation, conditioning the mixed pellet ingredients can include supplying steam for about 15 seconds.
The conditioned pellets can be extruded through a die (at 508) to generate pellets. The die can be between ¼ inch and 3.5 inches in size. The pellets can be cooled (at 510).According to some implementations, the pellets can comprise about 17% protein, about 6.8% fat, about 35% neutral detergent fiber, and about 12% moisture. In another implementation, the pellets can comprise a pellet durability index of greater than 94%.For suitable range feed pellets, a die of between ¼ inch and 3.5 inches may be particularly well suited. A pellet of less than ¼ of an inch may be lost through trampling. Pellets larger than 3.5 inches may be difficult for an animal to consume. Of course, alternate pellet sizes, and an array of pellet geometries, as can be dictated by the market, are considered within the scope of this disclosure.
A series of limited examples were conducted according to an exemplary embodiment of the system (as shown in
In the example production of feed pellets, the ingredients according to Table 1 were combined in a mixer to ensure homogeneity. The ingredients listed in Table 1 are provided in w/w percentage of dry matter basis. The majority of the material includes DDGS and prepared corn biomass. The corn biomass may include corn cobs and corn stover. In this example, the biomass included roughly 50% cob material, and the remaining material corn stover. The nutrient additions include mandated and market driven nutrition supplementation.
All of the ingredients are milled via a hammer mill to maximum of ⅜ inch particle size. After mixing, the ingredients are subjected to steam conditioning for 30 seconds. Steam is supplied at 175 psi in this example. Following conditioning, the conditioned ingredients are extruded through dies sized between ⅜ inch and 3.5 inches. Generally, per die between 500 and 600 pounds of pellets may be generated per hour. The pellets are cooled and subjected to testing for nutritional content and durability.
The results of the testing are provided in example Table 2. For the samples generated, the PDI was greater than 94%, which is significantly higher than previously known feed pellets. Additionally, the feed pellets included a favorable nutritional content with 13-21% protein, 4-9% fat, 25-45% neutral detergent fiber (non-detergent fiber or NDF), and 5-20% moisture. Further, the densification improvement of the pellets is 28% greater than DDGS and over 100% greater than stover
The embodiments as disclosed and described in the application (including the FIGURES and Examples) are intended to be illustrative and explanatory of the various aspects. Modifications and variations of the disclosed embodiments, for example, of the apparatus and processes employed (or to be employed) as well as of the compositions and treatments used (or to be used), are possible; all such modifications and variations are intended to be within the scope of the disclosed aspects.
The word “exemplary” is used to mean serving as an example, instance, or illustration. Any embodiment or design described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Rather, use of the word exemplary is intended to present concepts in a concrete fashion, and the disclosed subject matter is not limited by such examples.
The term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” To the extent that the terms “comprises,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, for the avoidance of doubt, such terms are intended to be inclusive in a manner similar to the term “comprising” as an open transition word without precluding any additional or other elements.
This application claims the benefit of U.S. Provisional Application Ser. No. 61/490,229 filed May 26, 2011, and entitled “COMPOSITION OF FEED PELLET AND METHODS FOR PRODUCTION”, the entirety of which is expressly incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61490229 | May 2011 | US |
