Centre technique de la Nutrition Animale Predict the enterobacteriaceae decontamination of feed by pelleting system F. Putier – Manager

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Context/Objectives Programme context and objectives  Context  Regulation EC 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

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept trials on pilot press 16 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 Objectives Phase 1 Phase 2

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept 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 V at 37°C) and total flora (NF V08 051) Related to retention time in the die plate

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Phase 1: Equipment Feeds Gondard mixer with twin coils of 224 l Granulation press and pilot coolers Disinfected sampling equipment Pig 542 µm/65° Laying hen 516 µm/66° Chicken 656 µm/64° Turkey 635 µm/ 59 ° CLM 12 Meccanica press 11 kW - 50 at 800 kg/hr Die plate 4/20 4/24 4/35 4/45 4/50 Acquisition Power T° pellets/flour Steam rate 1% pointer waste Wheat/Barley Maize Oil cakes Carbonate Other

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Phase 1: Method  Composite central plan Processing T° 45 Compression rates 2 Uses Reduction in number of trials Entire space scanned Allowance for day effect Very powerful statistically 14 trials per feed

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Phase 1: Results Raw data : example on Pig feed Variations over entire field selected Strong impact of die sequence °24 51°24 83°35 45°35 67°35 90°45 51°45 83°50 67° Population in enterobacteria (log UFC/g) Hopper entryProcessor exitCooler exit

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Phase 1: Results Raw data : example on Turkey feed Variations over entire field selected Lower impact of die sequence °24 51°24 83°35 45°35 67°35 90°45 51°45 83°50 67° Population in enterobacteria (log UFC/g) Hopper entryProcessor exitCooler exit

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Phase 1: Results Raw data  decontamination with  die temperature To obtain  3 log  ≈ 87°C at die exit

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Phase 1: Results Raw data  final contamination with  die temperature To obtain <3 log after cooler  ≈ 82°C at die exit

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Introducing tables Example on chicken feed Computing multilinear regressions and models to predict :  Post-treatment contamination  Decontamination ET-SR = F-0.54 TSC TSC 2  enterobacteria via the granulation process Length of die plate ducts – F (mm) Temperature After conditioning TAC (°C) ET-AC ET-AC= F – 0.54 TEC TAC2 Decontamination model adopted 2 curves used to produce :  One table with margin  One table without margin log

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Introducing tables Chicken and turkey feeds Chicken with Margin Chicken without Margin Turkey with Margin Turkey without Margin

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Introducing tables Pig and Laying Hen feeds Pig with Margin Pig without Margin Laying Hen with Margin Laying Hen without Margin

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Phase 2 : Principle Application of table at industrial sites Samples from entire batch at different points Counting enterobacteria and total flora

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept 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 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

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Temperature die exit (°C) Flora in enterobacteria at cooler exit (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

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept Temperature conditioning exit (°C) Flora in enterobacteria at cooler exit (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

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept 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

Centre technique de la Nutrition Animale Feed-to-Food 30 Sept 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