Predict the enterobacteriaceae decontamination of feed by pelleting system

1. Predict the enterobacteriaceae decontamination of feed by pelleting system F. Putier – Manager www.tecaliman.com

2. Context/Objectives • Programme context and objectives • Context • Regulation EC 2160 2003 zoonosis • Discussion between the sector and the French Ministry of agriculture • Research 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 84 trials at industrial sites 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  Validation of protocol and tables Circulation of protocol Objectives Phase 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. Chicken 656 µm/64° Turkey 635 µm/ 59 ° Pig 542 µm/65° Laying hen 516 µm/66° Phase 1: Equipment • Feeds • Gondard mixer with twin coils of 224 l • Granulation press and pilot coolers • Disinfected sampling equipment  Wheat/Barley Maize Oil cakesCarbonate Other 1% pointer waste CLM 12 Meccanica press 11 kW - 50 at 800 kg/hr Acquisition Power T° pellets/flour Steam rate Die plate 4/20 4/24 4/35 4/45 4/50

6. Compression rates 50 45 2 90 53 67 35 83 24 20 Phase 1: Method • Composite central plan 14 trials per feed Processing T° 45 Uses Reduction in number of trials Entire space scanned Allowance for day effect Very powerful statistically

7. 6 5 4 Population in enterobacteria (log UFC/g) 3 2 1 0 20 67° 24 51° 24 83° 35 45° 35 67° 35 90° 45 51° 45 83° 50 67° Hopper entry Processor exit Cooler exit Phase 1: Results • Raw data : example on Pig feed Variations over entire field selected Strong impact of die sequence

8. 6 5 4 UFC/g) 3 Population in enterobacteria (log 2 1 0 20 67° 24 51° 24 83° 35 45° 35 67° 35 90° 45 51° 45 83° 50 67° Phase 1: Results • Raw data : example on Turkey feed Hopper entry Processor exit Cooler exit Variations over entire field selected Lower impact of die sequence

9. Phase 1: Results • Raw data  decontamination with  die temperature To obtain  3 log  ≈ 87°C at die exit

10. Phase 1: Results • Raw data final contamination with  die temperature To obtain <3 log after cooler  ≈ 82°C at die exit

11. Introducing tables  enterobacteria via the granulation process • Example on chicken feed log ET - AC 95 95 3.0 85 85 3.5 4.0 75 75 4.5 5.0 Temperature After conditioning TAC (°C) 65 65 ET-SR =14.65 + 0.054 F-0.54 TSC +0.004 TSC2 ET-AC=14.65 + 0.054 F – 0.54 TEC + 0.004 TAC2 55 55 45 45 20 20 25 25 30 30 35 35 40 40 45 45 50 50 Length of die plate ducts – F (mm) • Computing multilinear regressions and models to predict : • Post-treatment contamination • Decontamination • Decontamination model adopted 2 curves used to produce : • One table with margin • One table without margin

12. 95 90 85 80 75 T° at processor exit (°C) 70 65 60 55 50 45 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 Retention time in die plate (s) Turkey with Margin Chicken with Margin Turkey without Margin Chicken without Margin Introducing tables • Chicken and turkey feeds

13. 90 85 80 75 70 T° at processor exit (°C) 65 60 55 50 45 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 Retention time in die plate (s) Pig with Margin Laying Hen with Margin Pig without Margin Laying Hen without Margin Introducing tables • Pig and Laying Hen feeds

14. Phase 2 : Principle • Application of table at industrial sites Samples from entire batch at different points Counting enterobacteria and total flora

15. Phase 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 Setting up trials 2 trials with margin, 1 without Industrial mixer Granulation line  Ordinary conditioning/ no pre-compression  Presses 120 to 260 kW/Steam power from 0.8 to 4 b Industrial and pilot coolers

16. 4.5 4.0 3.5 3.0 Flora in enterobacteria at cooler exit 2.5 (UFC/g) 2.0 1.5 1.0 0.5 0.0 70 75 80 85 90 95 Temperature die exit (°C) Phase 2: Results • Pig and laying hen feeds • Cooler exit / Die exit temperature Objective <3 log Efficient tables for enterobacteria with the T° acquired by the feed in the die

17. 4.5 4.0 3.5 3.0 Flora in enterobacteria at cooler exit 2.5 (UFC/g) 2.0 1.5 1.0 0.5 0.0 50 60 70 80 Temperature conditioning exit (°C) 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

18. 4.0 3.5 3.0 2.5 Flora in enterobacteria at cooler exit (UFC/g) 2.0 1.5 1.0 0.5 0.0 70 75 80 85 90 95 Temperature die exit ( °C ) Phase 2: Results • Chicken and turkey feeds • Cooler exit / Die exit temperature Objective <3 log Enterobacteria with the T° acquired by the feed in the die T° tested between 63 and 85°C at conditioning exit

19. Conclusion • Granulation effect demonstrated • Sufficient 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