Process optimization in poultry feed mill

The poultry feed industry is pretty much active in a lot of countries and it is achieved market acceptance. The final products are supposed to meet certain specifications to fulfill the nutritional need of animals at different life periods. The final product for poultry is shipped in the form of pelleted feed for the convenience of consumption. One of the major challenges of poultry feed production is the principal complement of equipment necessary for the local production. Imported poultry pellets are quite expensive and unaffordable for many poultry feed industries. Hence, the need to be able to produce poultry feed at lower cost yet achieve the objective of quantity and quality expected of pelleted feeds is critical to the viability of the enterprise. The study aims to investigate the effects of some operating parameters (pressure and temperature of the compounded feed) and die hole size on the pelleting efficiency, throughput capacity, and to optimize the conditions. The improvement approach is conducted by observing the main operating parameters of productivity; statistical analysis is conducted to observe the effect of those parameters on the production rate and the quality of the product. Comparison between parameter levels is done through analysis of variance to determine the significance of the tested parameters. The optimization of parameters was applied with Minitab and designed expert software to determine the best operating conditions. The obtained results showed that the downtime decreased by 77% monthly and productivity increased by 32.5% per hour and the pellet durability index increased by 1.23%. The total sales increased by 6,750,600 LE/Month.

Tuning Thermostability and Catalytic Efficiency of Aflatoxin-Degrading Enzyme by Error-prone PCR

In our previous work, a recombinant aflatoxin-degrading enzyme derived from Myxococcus fulvus (MADE) was reported. However, the low thermal stability of the enzyme had limitations for its use in industrial applications. In this study, we obtained an improved variant of recombinant MADE (rMADE) with enhanced thermostability and catalytic activity using error-prone PCR. Firstly, we constructed a mutant library containing over 5000 individual mutants. Three mutants with T₅₀ values higher than the wild-type rMADE by 16.5 °C (rMADE-1124), 6.5 °C (rMADE-1795), and 9.8 °C (rMADE-2848) were screened by a high-throughput screening method. Additionally, the catalytic activity of rMADE-1795 and rMADE-2848 was improved by 81.5% and 67.7%, respectively, compared to the wild-type. Moreover, structural analysis revealed that replacement of acidic amino acids with basic amino acids by a mutation (D114H) in rMADE-2848 increased the polar interactions with surrounding residues and resulted in a threefold increase in the t_1/2 value of the enzyme and made it more thermaltolerate. KEY POINTS: • Mutant libraries construction of a new aflatoxins degrading enzyme by error-prone PCR. • D114H/N295D mutant improved enzyme activity and thermostability. • The first reported enhanced thermostability of aflatoxins degrading enzyme better for its application.

Effect of the Pellet and Mash Feed Forms on the Productive Performance, Egg Quality, Nutrient Metabolism, and Intestinal Morphology of Two Laying Hen Breeds

Simple Summary

Although there is an established understanding of the nutritional requirements for poultry production, the evaluation of the feed form for chickens still needs to be further examined. It is generally believed that a pellet diet has a positive effect on chicken growth, but there are some studies that have reported no difference between pellet and mash on chicken’s performance. The present study indicated that pellet diets improved the production performance and nutrition metabolism through positive changes in the laying rate, feed intake, egg albumen quality and apparent digestibility of laying hens.

Abstract

One of the most important factors that determine feed utilization by chickens is the feed form. Although it is generally believed that pellet diets have a positive effect on chicken growth, there are some studies that have indicated no difference between pellet and mash on chickens performance. This study was conducted to assess the effects of feed form on production performance, egg quality, nutrient metabolism and intestinal morphology in two breed laying hens. Two hundred and sixteen 25-week-old Hy-Line brown (n = 108) and Hy-Line grey (n = 108) hens were selected. Each breed was randomly allocated into two treatments with 6 replications (9 birds in each replication), which were fed mash and pellet diets, respectively. Production performances were recorded daily and egg quality traits were measured every two weeks. At 42 weeks of age, one bird per replication from each experimental group was selected for metabolism determination and intestine morphology observation. Compared with mash diets, pellet diets improved laying rate (p < 0.05), ADFI (average daily feed intake, p < 0.05), egg weight, shell strength, yolk proportion and Haugh unit (p < 0.05) in both breeds and reduced the FCR (feed conversion ratio, p < 0.05) in Hy-Line grey. The apparent digestibility of DM% (dry matter) and CP% (crude protein) were significantly higher (p < 0.05) in both breed laying hens fed pellet than those fed mash. The apparent digestibility of P% (phosphorus) and Ca% (calcium) was higher in Hy-Line grey fed pellet and was higher in Hy-Line brown fed mash. Compared to mash diets, pellet diets increased the VH (villus height), CD (crypt depth) and VCR (ratio of villus height to crypt depth) of the small intestine of Hy-Line grey, and increased the VH and CD of duodenum and ileum of Hy-Line brown. Overall, pellet diets improved production performance and nutrition metabolism through positive changes in the laying rate, feed intake, egg albumen quality and apparent digestibility of laying hens. The current findings provided support for the advantages of feeding pellets during the peak egg laying period for the two popular laying hen strains, Hy-Line brown and Hy-Line grey.

Thermal processing of corn and physical form of broiler diets

This study aimed to assess the effect of preprocessing of corn and of physical form of diets on growth performance, carcass yield, and nutrient digestibility in broilers and also the influence of corn processing on pellet quality. A total of 1,080 male Cobb chicks from 1 to 35 D were evaluated. Birds were distributed according to a completely randomized design in a 3 × 2 factorial arrangement, with 3 types of corn processing (unprocessed, pelleted, or expanded), and 2 diet physical forms (mash or pelleted), totaling 6 treatments and 9 replicates with 20 birds. The data were submitted to ANOVA, and means were compared by Tukey's test (P < 0.05). There was no interaction between the physical form and preprocessing of corn for any of the studied variables (P > 0.05). The use of expanded corn in the diets before pelleting resulted in higher pellet durability index and lower amount of fines (P < 0.05) when compared with unprocessed corn. Broilers fed pelleted diets had higher feed intake (FI) and weight gain (WG; P < 0.001), higher amounts of abdominal fat (P < 0.05), and lower ileal digestible energy (IDE, P = 0.05) than those fed mash. There was no effect of the feed form on nutrient digestibility (P > 0.05). Broilers fed diets with unprocessed corn had higher FI when compared to those fed diets with expanded or pelleted corn (P < 0.001). The use of pelleted corn resulted in lower WG than the other processing methods (P < 0.01). The corn expansion process improved feed conversion ratio and adjusted feed conversion ratio (P < 0.001). Inclusion of expanded corn improved the coefficient of apparent ileal digestibility of DM, CP, starch, and IDE (P < 0.05) in comparison with unprocessed corn. It is concluded that pelleted diets improve broiler performance. The corn expansion can be used to improve physical quality of the diets and broilers growth performance and nutrient digestibility.

Effect of dietary coarse corn inclusion on broiler live performance, litter characteristics, and ammonia emission

Ammonia (NH3) emission from nondigested nutrients in poultry creates additional adverse environmental impacts on soil, water, air, and health. Mitigating NH3 emission has become vital for the poultry industry to remain sustainable. As the presence of large particles in the feed stimulates the broiler gizzard to retain ingesta in the gastrointestinal tract longer and improve digestive efficiency, the inclusion of large particles in feed may lead to less nitrogen (N) and moisture content (MC) in feces such that lower NH3 production would be expected. This chamber study investigated the effects of dietary coarse corn (CC) inclusion on broiler live performance, litter characteristics, and NH3 emission. One hundred eighty female broilers (Ross 344 × 708 strains) at day 21 were randomly placed in 6 chambers with 2 dietary treatments (0% CC and 50% CC), with 3 chambers per treatment and 30 birds per chamber for 3 wks. The results showed that the 50% CC inclusion (1) decreased broiler feed intake and BW without affecting mortality-adjusted feed conversion ratio from day 21 to 42; (2) increased gizzard weight and decreased proventriculus weight; (3) decreased N content and MC in litter; and (4) decreased NH3 concentrations in the chambers, as well as NH3 emission from the chambers. Dietary CC inclusion could be an effective way to mitigate broiler litter N content and MC as well as NH3 emission.

Effects of feed form and energy levels on growth performance, carcass yield and nutrient digestibility in broilers

Feed form is well recognized to improve broiler performance, specially by increasing feed intake (FI). However, when different diet energy levels are used, the results differ in the literature. Therefore, this experiment was conducted to evaluate the influence of feed form and dietary metabolizable energy (ME) levels on broiler performance, carcass yield and on the digestibility of DM, CP, starch and gross energy. In total, 1152 male Cobb 500 broilers were evaluated between 35 and 47 days. The birds were distributed according to a completely randomized design in a 2 × 4 factorial arrangement, consisting of two feed forms (mash or pellet) and four ME levels (12.73, 13.06, 13.40 or 13.73 MJ/kg), totaling eight treatments with eight replicates of 18 birds. Broilers fed the lowest ME level presented the lowest weight gain (WG) and worst feed per unit gain (P < 0.01). Metabolizable energy intake increased (P < 0.01) with progressive increments of ME, which, however, did not affect caloric conversion (CC, P > 0.05). Pelleted diets promoted higher FI, WG, ME intake (P < 0.01) and better feed per unit gain and CC (P < 0.05) compared with mash. In mash diets, increasing dietary ME levels promoted a linear increase in WG (P < 0.01) and reduced feed per unit gain (P ≤ 0.05), but did not affect FI (P > 0.05). In pelleted diets, on the other hand, increasing ME levels linearly reduced FI (P < 0.05) and feed per unit gain (P < 0.01). Broilers fed pelleted diets presented higher abdominal fat deposition than those fed mash (P < 0.05). Increasing ME levels reduced the coefficients of ileal apparent digestibility of DM (P < 0.01) and total starch (P < 0.05) but did not affect the digestibility of other evaluated nutrients. The digestibility of all nutrients was lower when pelleted diets were fed compared with mash. Increasing inert material inclusion in the diets at the expense of soybean oil to reduce dietary ME levels promoted higher pellet durability index values (P < 0.05) and the percentage of fines (P < 0.01). Overall, the results suggest that pelleted diets promote better broiler performance because they increase FI, since the digestibility of dietary fractions is reduced. Chickens consuming low-energy pelleted diets may increase FI to compensate for energy deficit. In contrast, broilers fed mash diets may have reached their maximum intake capacity and did not regulate FI by changing feed energy density. When feeding pelleted diets, dietary energy reduction should be considered to reduce feed costs and to improve the carcass quality of broilers.

Effect of pelleting and different feeding programs on growth performance, carcass yield, and nutrient digestibility in broiler chickens

This experiment was conducted to study the effect of different feeding programs and pelleting on performance, nutrient digestibility, ileal digestible energy (IDE); and carcass yield of broilers from 21 to 35 d of age. In total, 768 male broilers were distributed according to a completely randomized design with 6 treatments and 8 replicates of 16 birds each. The treatments were mash and pelleted diets provided ad libitum, or pelleted and supplied at the same rate (100%) or restricted at 95, 90, and 85% (P100, P95, P90, and P85) of the amount consumed by the birds fed mash diet ad libitum. When supplied ad libitum, the pelleted diet had the highest feed intake and weight gain (WG), better feed conversion ratio (FCR), better feed conversion adjusted for 2.3 kg (AdjFCR, P < 0.001) and caloric conversion (P < 0.001); and higher amount of abdominal fat (P < 0.001) when compared to the control (mash ad libitum). However, there were no effects on nutrient digestibility (P > 0.05). When the pelleted feed was provided in the same amount as in the control group, there were no differences in any of the evaluated parameters (P > 0.05). Limiting pelleted diet to 95, 90, and 85% of free choice mash diet resulted in lower WG (P < 0.001). P90 and P95 treatments resulted in higher dry matter and crude protein digestibility and IDE in relation to the others (P < 0.001). Carcass yield was reduced (P < 0.05) in the birds fed P85 diet. The regression analysis between P100, P95, P90, and P85 showed a linear reduction in WG when restriction was increased (P < 0.01); however, there was a linear increase in the nutrient digestibility (P < 0.001). It is concluded that pelleting improves broiler performance, but these results depend on feed intake. The higher intake provided by pelleting can increase the amount of abdominal fat. Feed intake reduction can result in lower performance and lower carcass and cuts yield in broilers.

Effect of different types and levels of fat addition and pellet binders on physical pellet quality of broiler feeds

Two experiments were conducted to evaluate the effects of different types and levels of mixer-added fat (soybean oil: SO and calcium fat powder: CFP) and pellet binders (PBs: calcium lignosulfonate (CaLS) and bentonite (Ben)) on physical pellet quality (PPQ) parameters. PPQ included pellet durability index (PDI), pellet hardness, and pellet length of broiler diets processed under short-term conditioning. The first experiment had 4 treatments arranged as a 2 × 2 factorial with 2 types (SO and CFP) and 2 levels (1.5 and 3%) of mixer-added fat. In the second experiment, 22 treatments, combinations of 2 types of mixer-added fat (SO and CFP) at 3 levels (0, 1.5 and 3%) and 2 types of PB (CaLS = 0, 0.5, and 1% and Ben = 0, 1, and 2%), were arranged by a completely randomized design. PDI was measured by 2 devices: Pfost Tumbling box (PDIT) and Holmen NHP tester (PDIH). The results showed that the diets containing 1.5% CFP without PB had significant differences in all PPQ parameters. The results revealed that adding 0.5% CaLS to the 3% SO diets significantly enhanced PDIH, pellet hardness, and pellet length compared to other treatments. Moreover, 1.5% CFP diets with 2% Ben had significantly higher PDIT, PDIH, and pellet hardness among the treatments. Based on contour plots, different levels of Ben in the diets containing SO failed to create optimum PDIT values (>96%). However, 1.5 to 2.50% CFP diets without Ben had the optimum PDIT values. The optimum PDIT value was achieved by the diets containing 3% SO in the range of 0.21 to 0.56% CaLS. Furthermore, adding 0.5% CaLS to the diets containing less than 2.86% SO resulted in suboptimal PDIT values (<96%). The diets containing 1.5 to 2.50% CFP without CaLS had the optimum PDIT values. However, increasing CaLS levels more than 0.38% led to suboptimal PDIT values. Overall, these results indicated that the selection of appropriate PBs should be based on type and level of mixer-added fat.

Influence of feed ingredients with pellet-binding properties on physical pellet quality, growth performance, carcass characteristics and nutrient retention in broiler chickens

The influence of inclusion of pellet binder on physical pellet quality, growth performance, carcass characteristics and total tract apparent retention of nutrients was examined. Broiler starter (Days 1–21, pellet diameter: 2.5 mm) and finisher (Days 22–42, pellet diameter: 4 mm) diets were formulated and then allocated to one of the seven treatments including control diet, and diets including sodium bentonite (10 and 20 g/kg), wheat gluten (10 and 20 g/kg) and wheat (100 and 200 g/kg). All ingredients used as a pellet binder significantly (P &lt; 0.05) increased the pellet-durability index compared with control diet. Wheat gluten and wheat at both inclusion rates were significantly (P &lt; 0.05) more efficient than was sodium bentonite in improving pellet hardness. From Day 1 to Day 42, chickens fed 10 g/kg wheat gluten and 100 and 200 g/kg wheat gained significantly (P &lt; 0.05) more weight than did control. During starters, birds fed 200 g/kg wheat showed the highest feed intake (P &lt; 0.05). On Day 42, all the pellet binders resulted in a heavier heart weight than in the control (P &lt; 0.05). At Day 21, the length of ileum was significantly (P &lt; 0.05) higher in birds fed 10 and 20 g/kg sodium bentonite, 10 g/kg wheat gluten and 200 g/kg wheat, but at Day 42, it was greater in birds fed 20 g/kg wheat gluten and 200 g/kg wheat than in those fed the control diet. Inclusion of wheat gluten (10 and 20 g/kg) and wheat (100 and 200 g/kg) increased (P &lt; 0.05) fat apparent retention. Birds fed 20 g/kg wheat gluten had a significantly (P &lt; 0.05) higher total tract apparent retention of crude fibre, also calcium apparent retention improved by wheat gluten inclusion at concentrations of 10 and 20 g/kg compared with control (P &lt; 0.05). Overall, inclusion of 10 g/kg wheat gluten, and 100 and 200 g/kg of wheat improved physical pellet quality and weight gain in broilers.

The effect of manipulation of pellet size (diameter and length) on pellet quality and performance, apparent metabolisable energy and ileal nutrient digestibility in broilers fed maize-based diets

A 2 by 2 factorial arrangement of treatments was used to evaluate the effect of pellet diameter (3 and 4.76 mm) and pellet length (3 and 6 mm) on pellet quality and performance, apparent metabolisable energy and ileal digestibility of nitrogen and starch in broilers. From 0 to 9 days of age, all birds were offered a common starter diet. Broiler grower (Days 10–21) and finisher (Days 22–42) diets, based on maize, were formulated and then allocated to the four different treatments. All diets were steam-conditioned at 60°C before pelleting. In grower diets, increasing pellet diameter and pellet length reduced (P < 0.001) the gelatinised starch content of the diets. In finisher diets, gelatinised starch content of pellets was not influenced (P > 0.05) by main effects or the interaction. In grower and finisher diets, increments in pellet durability index and pellet hardness with increasing pellet length were greater in pellets with a 3-mm diameter than those with a 4.76-mm diameter. During the grower period (Days 10–21), birds fed the 3-mm-diameter pellets had lower (P < 0.01) feed per gain than those fed pellets with a 4.76-mm diameter. During the finisher (Days 22–42) and whole trial (Days 10–42) periods, neither main effects nor the interaction were significant (P > 0.05) for weight gain, feed intake and feed per gain. Increasing pellet diameter from 3 to 4.76 mm decreased (P < 0.001) apparent metabolisable energy values. Neither main effects nor the interaction were significant (P > 0.05) for the coefficient of ileal apparent digestibility of nitrogen. Increasing pellet length from 3 to 6 mm decreased (P < 0.05) relative weight of gizzard in 3-mm-diameter pellets but not in the 4.76-mm-diameter pellets (P > 0.05). Overall, when low conditioning temperatures are used to optimise nutrient availability, small diameter die holes and longer pellet lengths can favour creating high physical quality pellets. The present study also showed that feeding lower diameter pellets to broilers during the grower period (Days 10–21) only improved feed per gain, a response which disappeared as the birds grew older.