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

2. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 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. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 3 56 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

4. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 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. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 5 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

6. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 6 Phase 1: Method  Composite central plan Processing T° 45 Compression rates 22 20 24 35 45 50 536783 90 Uses Reduction in number of trials Entire space scanned Allowance for day effect Very powerful statistically 14 trials per feed

7. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 7 Phase 1: Results Raw data : example on Pig feed Variations over entire field selected Strong impact of die sequence 0 1 2 3 4 5 6 20 67°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

8. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 8 Phase 1: Results Raw data : example on Turkey feed Variations over entire field selected Lower impact of die sequence 0 1 2 3 4 5 6 20 67°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

9. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 9 Phase 1: Results Raw data  decontamination with  die temperature To obtain  3 log  ≈ 87°C at die exit

10. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 10 Phase 1: Results Raw data  final contamination with  die temperature To obtain <3 log after cooler  ≈ 82°C at die exit

11. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 11 Introducing tables Example on chicken feed Computing multilinear regressions and models to predict :  Post-treatment contamination  Decontamination ET-SR =14.65 + 0.054 F-0.54 TSC +0.004 TSC 2  enterobacteria via the granulation process Length of die plate ducts – F (mm) Temperature After conditioning TAC (°C) ET-AC 3.0 3.5 4.0 4.5 5.0 20253035404550 45 55 65 75 85 95 20253035404550 45 55 65 75 85 95 ET-AC=14.65 + 0.054 F – 0.54 TEC + 0.004 TAC2 Decontamination model adopted 2 curves used to produce :  One table with margin  One table without margin log

12. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 12 Introducing tables Chicken and turkey feeds Chicken with Margin Chicken without Margin Turkey with Margin Turkey without Margin

13. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 13 Introducing tables Pig and Laying Hen feeds Pig with Margin Pig without Margin Laying Hen with Margin Laying Hen without Margin

14. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 14 Phase 2 : Principle Application of table at industrial sites Samples from entire batch at different points Counting enterobacteria and total flora

15. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 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 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

16. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 16 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 707580859095 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

17. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 17 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 50607080 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

18. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 18 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

19. Centre technique de la Nutrition Animale Feed-to-Food 30 Sept. 09 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