Olav Fjeld KraugerudNOVA course, June 15, 2009

Department of Animal and Aquacultural Sciences

Lecture 9. Pre-treatment of feed sources and

Lecture 10. Extrusion and nutritive value

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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Pretreatment – where to perform

The pretreatment agents (enzymes, yeast etc.) might be added before the extrusion line (if not it is not pretreatment)

Bioreactor

Place where pretreatment might be performed.

Flexibility-Temperature-Moisture-Pressure-pH-Mixing poss.

Mixer

Incubated material is being mixed with the rest material that is not pretreated

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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Pretreatment of feed sources I

Historical approach

– What is the old fashion way of pretreatment?

Humans has pretreated their food for ages

– Kinema in India (Shrestha and Noomhorm, 2001)

• Boiled

• Addition of wooden ash

• Naturally fermented for 24 – 48 h in bamboo baskets

– Main bacteria causing fermentation: Bacillus subtilis

– Natto in Japan, first reported in 1087 AD (Tripathi and Misra, 2005)

• Fermented by Bacillus natto

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Pretreatment of feed sources II

What is pretreatment

– Additional treatment to the feed mash, or parts of it, than regular milling and conditioning

Why pretreatment

– Increase nutritional quality

• Is being used if extrusion is not increasing nutritional value sufficiently.

• If high processed ingredients are too expensive. (Might be cheaper to do it inhouse)

– If water is added; often cheaper to perfrom it on-line as to avoid cost of drying process.

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Pretreatment – methods I

Biological

– Enzymes

• Singel enzymes

– Phytases

– Proteases

– Carbohydrases

• Enzyme packages

– Pancreatin

– Microbes/yeast – General increasing the nutritional value of the feed

• End-product is a mix of onknown products

Defined end products

Lecture 9 and 10, NO

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al Nutrition , 2009

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Pretreatment – methods II

Biological

– Microbes/yeast/funghis – General increasing the nutritional value of the feed

• End-product is a mix of unknown components

– Some desirable

– Some undesirable

– Key point:

» Wise choice of fermenting agent

• Pretreatment conditions are crucial for obtaining reproducable results

– Monitor and specifye

fermenting agent

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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7

CASE 1

Exp. 1 Exp. 2

Fermentation of rape seed meal and effect on fish performance.

Lecture 9 and 10, NO

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Anim

al Nutrition , 2009

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Digestibility trial with Atlantic salmon

Fermentation of wheat or barley

Inclusion level: 24%

Fermenting agent: Lactobacillus strain (AD2)

16 h @ 30°C, 45% moisture

Chemical composition of diets ~similar

Extruded diets

Fermentation of of whole meal flour (WMF)

Skrede et al., 2001; 2002

Isolated from sourdough

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Fermetation of of whole meal flour (WMF)

● Fermented meal■ Untreated meal

Skrede et al., 2002

Lecture 9 and 10, NO

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al Nutrition , 2009

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Pretreatment – methods III

Biological

– The fermentor itself contributes to the end product

• Changing the chemical composition of the mash

Lecture 9 and 10, NO

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al Nutrition , 2009

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Pretreatment – methods IV

Chemical

– pH

• Often combined with biological to obtain ideal working conditions for the enzymes/microbes/yeast.

– Extractions

– Organic acids

– Mechanical

• Grinding – particle size

Not lectured

Described by Ozren Z. in Lecture 4

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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Pretreatment – physical properties of the feed

An experiment with on-line pretreatment

Aim:

1. Check whether pretreatment itself had any effect on physical properties of the feed

2. Implement the online pretreatment in a regular extrusion line

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Pretreatment Diet Conditoined Incubated s.e.m. P Conditioning Temperature a (°C) 76 76 0.3 0.7522 Extrusion Temperature c (°C) 1st section 62 63 1 0.2909 3rd section 118 b 121 a 0.7 0.0077 4th section 106 b 110 a 0.9 0.0111 5th section 117 116 1 0.4546 Die 106 109 2 0.2009 Pressure 4th section cc (bar) 0.55 b 0.73 a 0.02 0.0176 Die (bar) 28 28 1 0.9239 Screw speed (rpm) 273 273 0.07 0.2328 Torque d (Nm) 359 a 338 a 7 0.0433

SME e (Wh/kg) 42 a 39 b 0.8 0.0319

13

On-line Pretreatment

Processing parameters

Kraugerud & Svihus; accepted for AFST.

Lecture 9 and 10, NO

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al Nutrition , 2009

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On-line Pretreatment

Physical properties

Preatrement Diet Conditioned Incubated s.e.m. c P c

Hardness [N] 34 a 24 b 2 0.0026 Durability [%] 96 93 1 0.0694 Expansion [%] 26 28 2 0.2195

Bulk density [g/l] 519 a 498 b 5 0.0092 Length [mm] 7.7 a 6.5 b 0.1 <0.0001

PDI b [%] 16.3 15.4 0.3 0.1171

Kraugerud & Svihus; accepted for AFST.

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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Pretreatment – CASE 2

Find two practicle challenges/obstacles with pretreatment

Groups: two and two

Two minutes

Group work

– Three groups

– 10 minutes

• Sketch the system (three groups)

• Discuss

– Pros

– Cons

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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Pretreatment – literatureDenstadli et al., 2006. Phytate degradation in a mixture of ground wheat and ground defatted soybeans during

feed processing: Effects of temperature, moisture level, and retention time in small- and medium-scale incubation systems, Journal of Agricultural and Food Chemistry, 54, 5887-5893

Denstadli et al., 2007. A comparison of online phytase pre-treatment of vegetable feed ingredients and phytase coating in diets for Atlantic salmon (Salmo salar L.) reared in cold water, Aquaculture, 269, 414-46.

Gnanasambandam and Proctor, 1999. Preparation of soy hull pectin, Food Chemistry, 65, 461-467

Huth et al., 2000. Functional properties of dietary fibre enriched extrudates from barley, Journal of Cereal Science, 32, 115-128.

Ibrahim, S. S., Habiba, R. A., Shatta, A. A., & Embaby, H. E., 2002. Effect of soaking, germination, cooking and fermentation on antinutritional factors in cowpeas. Nahrung-Food 46, 92-95.

Ito, T., Saito, K., Sugawara, M., Mochida, K., & Nakakuki, T., 1999. Effect of raw and heat-moisture-treated high-amylose corn starches on the process of digestion in the rat digestive tract. J. Sci. Food Agric. 79, 1203-1207.

Kraugerud and Svihus, accepted. A comparison of online pretreatment of plant feed ingredients on processing responses and physical properties of extruded fish feed, Animal Feed Science and Technology.

Martin-Cabrejas, M. A., Sanfiz, B., Vidal, A., Molla, E., Esteban, R., & Lopez-Andreu, F. J., 2004. Effect of fermentation and autoclaving on dietary fiber fractions and anti nutritional factors of beans (Phaseolus vulgaris L.). J. Agric. Food Chem. 52, 261-266.

Phillips, R. D., Chinnan, M. S., Branch, A. L., Miller, J., & Mcwatters, K. H., 1988. Effects of pretreatment on functional and nutritional properties of cowpea meal. J. Food Sci. 53, 805-809.thiamincontent and increased browning of the meal.

Refstie, S., Sahlstrøm, S., Bråthen, E., Baeverfjord, G., & Krogedal, P., 2005. Lactic acid fermentation eliminates indigestible carbohydrates and antinutritional factors in soybean meal for Atlantic salmon (Salmo salar). Aquaculture 246, 331-345.

Skrede, G., Storebakken , Skrede , Sahlstrøm, Sørensen, Shearer, Slinde , 2002. Lactic acid fermentation of wheat and barley whole meal flours improves digestibility of nutrients and energy in Atlantic salmon (Salmo salar L.) diets, Aquaculture, 210, 305-32.

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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Lecture 10. Extrusion and nutritive value

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

www.umb.no 18

EXTRUSION – energy (heat & mechanical)

Conditioner

Bin

Extruder barrel

1.25 meters

Printed with permission from Bühler AG

0

20

40

60

80

100

120

140

1 2 3 4 5

Extruder section Die

Tem

pera

ture

[o C]

0Mash Cutting

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Starch – effect during extrusion process

Showing disintegrated starch granules

Animation by Kraugerud, 2008; Drawings by Tester et al., 2004

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Shear

Tester et al., 2004

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Starch + proteins + extrusion= possible reactions

Starch dextrines and maltose ⇒ sugar with reducing ends

Proteins unfolding

– ⇒ ε-amino group of lysin gets exposed

Reducing end of sugars react withε-amino group of lysin⇒ reduction of available lysin

Camire et al., 1991

Unfolding of proteins.● : hydrophobic AA residues○ : hydrophilic AA residuess-s : disulphide bonds

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Extrusion - effect

Starch

– Expansion as effect of temperature

Hashimoto & Grossmann, 2003

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Extrusion - effect

Starch

– Water stability

10

13

16

19

22

Extruded Pea Raw pea Extruded canola

Ingredient [30% inclusion]

Prot

ein

loss

, 1h,

28

degr

. [%

]

Cruz-Suarez et al., 2001

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Extrusion – whch parameters to concider

Temperature

Moisture

Press

Mechanical energy (shear)

Time

110 – 150°C

15 – 60%

10-50 bar (at thedie)

30 – 150 Wh/kg

10-60s

Lecture 9 and 10, NO

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al Nutrition , 2009

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Extrusion - effect

Digestible

– Starch

• Expansion

• Water stability

Lecture 9 and 10, NO

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Anim

al Nutrition , 2009

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SME & moisture effect on gelatinisation

Bühler AG, 2007

Lecture 9 and 10, NO

VA: Feed Technology and Farm

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al Nutrition , 2009

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Condition temperature effect in extruder

CASE

– Fish feed

– 3 T/h

– 28.5% moisture

– Retention time 30 s

Bühler AG, 2007

Extr

uder

torq

ue[%

]

Temperature, conditioner[°C]

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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Starch: Gelatinisation – T & p

Douzals, 2001; J. Agric. Food Chem

•Low DM (not comparable to extrusion)•Long time (not comparable to extrusion)

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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Gelatinisation – T, % moisture & shear

Cai, 1993; Journal of food science

60

70

80

90

100

80 100 120 140 160 180

Barrel Temperature [C]

Degr

eee

of g

elat

inis

atio

n[%

]

25% 300 rpm

25% 200 rpm

30% 300 rpm

30% 200 rpm

Extrusion of wheat starch

Here at same temperatures (as the T, P graph), the starch is NOT gelatinised!Time and water content is also an important factor!Why the one with higher water content with a lower degree of gelatinisation?ANSWER: Low moisture high shear, hence high degree of gelatinisation)

SME when extruding starch: Increase compared with other materials due to the endotermicnature of gelatinisation.

Lecture 9 and 10, NO

VA: Feed Technology and Farm

Anim

al Nutrition , 2009

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Simple charts = good charts

Bühler AG, 2007

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VA: Feed Technology and Farm

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al Nutrition , 2009

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(PHYSICALEFFECT)

(NUTRITIONAL EFFECT)

SingleTwin

co-rotatingTwin

Counter-rotating

Type of extruder - possibilitiesFôrTek

Lecture 9 and 10, NO

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Anim

al Nutrition , 2009

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Extrusion – literature

Dust et al., 2004. Extrusion conditions affect chemical composition and in vitro digestion of select food ingredients, J. Agric. Food Chem., 52, 2989-2996

General effect of extrusion

Camire et al., 1990. Chemical and Nutritional Changes in Foods during Extrusion, Critical Reviews in Food Science and Nutrition, 29, 35-57

M.D. Drew, Borgeson, Thiessen, 2007. A review of processing of feed ingredients to enhance diet digestibility in finfish, Animal Feed Science and Technology, 138, 118–136

Extrusion and effect on proteins

Areas, J.A.G., 1992. Extrusion of Food Proteins, Critical Reviews in Food Science and Nultritlon, vol. 32, 4, 365-392.

General overview of feed extrusion

Aldrich, Greg, Riaz, Mian N., 2007. Extruders and expanders in pet food, aquatic and livestock feeds, Clenze, Agrimedia GmbH.

-Recommended chapters: 8 and 10.