A continuous processing technology for fermented leafy grass feed

Abstract

This invention relates to a continuous processing technology for fermented leafy grass feed, belonging to the field of feed processing. It includes: crushing and mixing non-leafy grass feed ingredients to form a premix; adding the premix and fresh leafy grass with a moisture content of 85-95% into a total daily ration (TNR) mixer, mixing and stirring at a low speed of 30-55 r / min to obtain a mixed base material; conveying the mixed base material to a buffer bin equipped with a weight sensor, and through linkage control to achieve uniform feeding to a fine pulverizer, while the TNR mixer simultaneously processes the next batch; after fine pulverization to a particle size of 1-5 mm, the mixed base material is placed into a fermentation bag equipped with a one-way breathing valve and sealed for fermentation. This invention utilizes the low-speed, gentle pulverization of the TNR mixer to effectively avoid juice loss from high-moisture leafy grass, achieves a smooth transition between batch mixing and continuous pulverization through buffer bin linkage, and achieves sealed and controllable fermentation in the bag, significantly improving production efficiency and fermentation quality, and is suitable for large-scale industrial production.

Description

Technical Field

[0001] This invention relates to the field of feed processing technology, specifically a continuous processing technology for fermented leafy grass feed. Background Technology

[0002] Leafy forage grass, a novel forage plant with high protein and high water content, has a significantly higher fresh grass water content than conventional forage grasses. Its crude protein content accounts for a higher proportion of dry matter, making it ideal for processing into fermented feed. This process effectively preserves nutrients, improves palatability and digestibility, and extends shelf life. However, the high water content of leafy forage grass presents significant technical challenges in traditional feed processing. Conventional high-speed grinding or shredding equipment, when handling high-moisture materials, mechanically damages plant cell walls, leading to substantial loss of cell sap. This not only results in significant losses of soluble proteins, sugars, and other nutrients but also causes liquid contamination at the processing site. Furthermore, the lost sap adheres to equipment surfaces, increasing cleaning difficulty and hygiene risks.

[0003] To address the aforementioned issues, existing fermented feed processing technologies for leafy greens suffer from the following shortcomings: First, traditional shredders or grinders are designed with excessively high speeds, failing to balance material softening with juice retention, and lacking low-damage softening methods for materials with high moisture content. Second, the mixing and softening process is typically batch-operated, while subsequent grinding and packaging processes require continuous and stable feeding. This mismatch in operating cycles leads to frequent start-ups and shutdowns of the production line, resulting in low equipment utilization and difficulty in ensuring consistent product quality. Third, the high-moisture materials after mixing and grinding produce significant gas during fermentation. Traditional pit or pile storage methods struggle to precisely maintain a stable anaerobic environment, leading to a high risk of microbial contamination and significant fluctuations in fermentation quality. Therefore, there is an urgent need to develop a processing technology suitable for the characteristics of leafy greens that can simultaneously address juice loss, process integration, and fermentation controllability. Summary of the Invention

[0004] In order to solve the problems of the prior art, the present invention provides a continuous processing technology for fermented leafy grass feed.

[0005] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution: Firstly, a continuous processing technology for fermented leafy grass feed, comprising the following steps: S1 Non-edible leafy grass raw material pretreatment: The feed raw materials other than edible leafy grass are crushed and mixed to make premixed feed; S2TMR Integrated Mixed Softening: The premix obtained in step S1 and fresh leafy grass are directly put into a total diet mixer. The moisture content of the leafy grass is 85-95%. The total diet mixer is used at a low speed for mixing and softening to obtain a mixed base material. The low speed is 30-55 r / min. S3 Buffer Bin Linked Stable Flow Feeding: The mixed base material obtained in step S2 is transported to the buffer bin for temporary storage. The buffer bin is equipped with a weight sensor, which provides real-time feedback on the remaining material in the bin. This is linked with the total daily ration mixing mixer and the fine pulverizer for control. The buffer bin feeds material to the fine pulverizer at a uniform speed, while the total daily ration mixing mixer simultaneously carries out the next batch of mixing and spun silk processing. S4 Fine Grinding: The mixed base material enters the fine grinding mill through the buffer bin and is ground to a particle size of 1-5mm to obtain a fine mixed material; S5 Quantitative Packaging and In-Bag Fermentation: The fine mixture obtained in step S4 is packed into a fermentation bag with a one-way breathing valve, sealed, and fermented inside the bag to obtain fermented leafy grass feed.

[0006] In one specific embodiment of the first aspect, in step S2, the filament-splitting blade assembly of the total diet mixer is a blunt blade assembly with a blade spacing of 1-2 mm; the processing cycle is 25-35 minutes per batch.

[0007] In one specific embodiment of the first aspect, in step S2, the weight percentage of leafy grass in the mixed substrate is 40-45%, the leafy grass is shredded to 2-5mm, and the juice loss rate of the mixed substrate is ≤2%.

[0008] In one specific embodiment of the first aspect, in step S1, the feed ingredients include one or more of corn, soybean meal, wheat bran, probiotics, enzyme preparations (including at least two of cellulase, α-amylase, pectinase, xylanase and protease), and leafy grass-specific feed packets; the ingredients are pulverized to 1-10 mm, the stirring speed is 100-150 r / min, and the stirring time is 5-8 min; the moisture content of the premix is ​​10-12%.

[0009] In one specific embodiment of the first aspect, in step S3, the buffer bin has an inclination angle of 55-65°, a built-in anti-sticking stirring device, and a stirring speed of 30-50 r / min; the discharge speed of the buffer bin to the fine pulverizer is 40-65 kg / min.

[0010] In one specific implementation of the first aspect, in step S3, the logic of the linkage control is as follows: when the remaining material in the buffer bin is less than 1 / 3 of the total capacity, the total daily ration mixer automatically starts the next batch processing; when the remaining material is higher than 2 / 3 of the total capacity, the discharge speed is increased to 55-65 kg / min; when the remaining material is between 1 / 3 and 2 / 3 of the total capacity, the discharge speed is maintained at 40-50 kg / min.

[0011] In one specific implementation of the first aspect, in step S3, the temperature inside the buffer chamber is controlled at 15-25°C.

[0012] In one specific embodiment of the first aspect, in step S4, the moisture content of the fine mixture is 42-46%.

[0013] In one specific embodiment of the first aspect, in step S5, the opening pressure of the one-way breathing valve is 0.005-0.02 MPa, and the exhaust port is equipped with a 100-120 mesh filter; the fermentation conditions are a temperature of 25-30℃ and a fermentation time of 3-5 days.

[0014] In one specific embodiment of the first aspect, in step S5, the weight of a single bag is 15-40 kg, and the fermentation bag is made of food-grade PE material.

[0015] The beneficial effects of this invention are as follows: 1. This invention employs a total diet mixer at low speed with blunt blades to blend and shred high-moisture forage. Unlike traditional high-speed cutting or shredding processes, this method utilizes low-speed, high-torque tumbling and mixing to tear the forage into fibrous strands rather than chopping it, significantly reducing mechanical damage to cell walls and thus preventing substantial juice loss while effectively preserving nutrients such as protein and soluble sugars. Simultaneously, the dry matter in the premix absorbs free moisture from the forage surface during mixing, further stabilizing the moisture content distribution and providing a homogenized substrate for subsequent fermentation. This low-damage shredding method fundamentally solves the technical problems of severe nutrient loss and liquid contamination in high-moisture forage processing, ensuring the integrity of the raw materials and the quality of the material before fermentation.

[0016] 2. This invention further achieves automatic linkage control between the batch mixing and filament processing and the continuous fine grinding process by setting up a buffer bin with a weight sensor. Based on real-time feedback of the material remaining in the bin, the system can automatically trigger the next batch of mixing and filament processing and dynamically adjust the discharge speed according to the material inventory. This avoids frequent start-ups and shutdowns of the production line or material backlog caused by mismatch in process cycles, ensuring a smooth connection between upstream batch operations and downstream continuous feeding, and significantly improving the overall equipment operating efficiency. Furthermore, the finely ground material is placed in a fermentation bag with a one-way breathing valve for sealed fermentation. The one-way exhaust function of the breathing valve maintains a stable anaerobic environment inside the bag, while the filter screen blocks the intrusion of external bacteria. This allows each bag of material to independently complete the anaerobic fermentation process, avoiding the risk of spoilage caused by poor sealing or uneven fermentation in traditional pit storage, and significantly improving the fermentation success rate and product quality consistency. In summary, this invention achieves low-loss, continuous, and highly controllable production of high-moisture-content leafy grass fermented feed, suitable for large-scale industrial applications. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the process flow of the present invention. Detailed Implementation

[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0019] like Figure 1 The diagram illustrates a continuous processing technology for fermented leafy grass feed.

[0020] I. Explanation of Process Steps and Parameter Ranges This invention provides a continuous processing technology for fermented leafy grass feed, the core steps and preferred parameter ranges of which are as follows: S1, pretreatment of non-edible leafy grass raw materials.

[0021] Inputs: corn, soybean meal, wheat bran, probiotics, enzyme preparations (including at least two of cellulase, α-amylase, pectinase, xylanase and protease), and special feed packets for leafy greens, etc.

[0022] Processing: Grind to a particle size of 1-10 mm, then put into a mixer and stir at 100-150 r / min for 5-8 min.

[0023] Output: Premixed feed with a moisture content of 10-12%.

[0024] Instructions for leafy grass feed packets: The special feed packet for leafy greens is a compound additive formulated specifically for the high water content and high protein characteristics of leafy greens. Its main functions include: 1. supplementing the trace mineral elements required during the fermentation process of leafy greens, including at least one of zinc, manganese, copper, and iron; 2. providing fat-soluble vitamins such as vitamin A and D3 to promote microbial growth and metabolism; 3. adding buffer salts, including at least one of calcium carbonate and dicalcium phosphate, to stabilize the pH environment of the fermentation system; and 4. using molasses, bran, etc., as carriers to improve the palatability of the material and quickly initiate the proliferation of lactic acid bacteria. Those skilled in the art can determine the specific composition and dosage of the feed packet through conventional experiments based on the variety, water content, and target fermentation indicators of the leafy greens, all of which fall within the scope of protection of this invention.

[0025] In a preferred embodiment of the present invention, the composition of the special feed packet for leafy grass is as follows: 20-30 parts calcium carbonate, 5-10 parts dicalcium phosphate, 3-8 parts zinc sulfate, 2-5 parts manganese sulfate, 1-3 parts vitamin AD3 premix, and molasses carrier to make up to 100 parts.

[0026] S2, TMR integrated blended soft silk.

[0027] Input: Premix obtained from S1 + fresh leafy grass (moisture content 85-95%, accounting for 40-45% of the total weight of the mixed substrate).

[0028] Equipment: Total Diet Mixer (TMR), equipped with blunt blades (blade spacing 1-2mm).

[0029] Parameters: Rotation speed 30-55 r / min, processing cycle 25-35 min / batch.

[0030] Output: Mixed substrate in which leafy grasses are shredded to 2-5mm with a sap loss rate of ≤2%.

[0031] S3, with a buffer bin linked to a stable flow of materials.

[0032] Input: The mixed base material obtained from S2.

[0033] Equipment: Buffer bin (volume 2-5m³) 3 The chamber has an inclination angle of 55-65°, a built-in anti-sticking stirring device (30-50r / min), and the temperature is controlled at 15-25℃; it is equipped with a weight sensor.

[0034] Linkage logic: If the material in the warehouse is less than 1 / 3 of its capacity, the TMR will automatically start the next batch of processing. When the material in the silo is more than 2 / 3 full, the discharge speed is increased to 55-65 kg / min. 1 / 3 to 2 / 3 capacity → maintain discharge speed at 40-50 kg / min.

[0035] Output: A continuous, uniform flow of material fed into the fine pulverizer.

[0036] S4, finely ground.

[0037] Input: Mixed base material output from the cache bin.

[0038] Equipment: Fine pulverizer.

[0039] Parameters: Grind to a particle size of 1-5mm.

[0040] Output: Fine mixture with a moisture content of 42-46%.

[0041] S5, quantitative packaging and in-bag fermentation.

[0042] Input: The fine mixture obtained from S4.

[0043] Equipment: Food-grade PE fermentation bag with one-way breathing valve (opening pressure 0.005-0.02MPa, exhaust port equipped with 100-120 mesh filter).

[0044] Parameters: Single bag packaging 15-40kg, after sealing, ferment at 25-30℃ for 3-5 days.

[0045] Output: Fermented leafy grass feed.

[0046] II. Implementation Examples Example 1 A continuous processing technology for fermented leafy grass feed includes the following steps: S1: Take 300 kg of corn, 100 kg of soybean meal, 50 kg of wheat bran, 5 kg of probiotics, 3 kg of enzyme preparation, and 42 kg of special feed bag for leafy grass. Crush them to 5 mm and mix them in a mixer at 120 r / min for 6 min to obtain a premix (moisture content 11%).

[0047] S2: Put 500 kg of premix and 400 kg of fresh leafy greens (moisture content 90%, accounting for 44.4%) into a TMR mixer, with blunt blade spacing of 1.5 mm, speed of 45 r / min, and process for 30 min to obtain mixed base material. The length of the leafy green filaments is about 3 mm, and the juice loss rate is 1.2%.

[0048] S3: The mixed base material is fed into the buffer silo (2m) 3 (Inclination angle 60°, stirring 40r / min, 20℃). Weight sensor linkage: when material is <1 / 3, start the next batch TMR; when material is >2 / 3, the discharge speed is 60kg / min; and at other times, it is 45kg / min.

[0049] S4: Finely grind to 3mm to obtain a fine mixture (moisture content 45%).

[0050] S5: Pack into 20kg / bag PE bags (breathing valve opening pressure 0.01MPa, 110 mesh filter), seal, and ferment at 28℃ for 4 days.

[0051] Results: The fermented feed had a pH of 3.8, a lactic acid content of 4.5%, and a crude protein content (dry basis) of 20.2%. It had a sour and fragrant taste, was yellowish-green in color, and was uniform and fine in texture, with no mold growth.

[0052] Example 2 S1: 280kg corn, 120kg soybean meal, 60kg wheat bran, 6kg probiotics, 4kg enzyme preparation, and 30kg special feed bag for leafy grass. Grind to 3mm, stir at 140r / min for 5min, and the moisture content of the premix is ​​10.5%.

[0053] S2: 500kg premix + 370kg leafy grass (moisture content 92%, accounting for 42.5%), TMR speed 40r / min, blunt blade spacing 1mm, processing time 32min, soft filament length 4mm, juice loss rate 1.5%.

[0054] S3: Buffer chamber tilt angle 58°, stirring 35r / min, 18℃, discharge speed 50kg / min, linkage logic is the same as in Example 1.

[0055] S4: Finely grind to 2mm to obtain a fine mixture with a moisture content of 44.5%.

[0056] S5: Pack 15kg / bag, breathing valve opening pressure 0.008MPa, 120 mesh filter, ferment at 25℃ for 5 days.

[0057] Results: pH=3.9, lactic acid 4.2%, crude protein (dry basis) 20.6%, good sensory properties.

[0058] Example 3 S1: 320kg corn, 80kg soybean meal, 40kg wheat bran, 4kg probiotics, 2kg enzyme preparation, and 54kg special feed bag for leafy grass. Grind to 8mm, stir at 110r / min for 7min, and the moisture content of the premix is ​​11.5%.

[0059] S2: 500kg premix + 333kg leafy grass (88% moisture content, accounting for 40%), TMR speed 35r / min, blunt blade spacing 2mm, processing time 35min, soft filament length 5mm, juice loss rate 0.9%.

[0060] S3: Buffer chamber tilt angle 65°, stirring 50r / min, 15℃, discharge speed 40kg / min (due to the low proportion of leafy grass and good material flowability, the discharge speed is appropriately reduced), linkage logic is the same as in Example 1.

[0061] S4: Finely grind to 4mm to obtain a fine mixture with a moisture content of 42%.

[0062] S5: Pack 25kg / bag, breathing valve opening pressure 0.015MPa, 100 mesh filter, ferment at 30℃ for 3 days.

[0063] Results: pH=3.7, lactic acid 4.8%, crude protein (dry basis) 18.0%, fast fermentation speed, and stable quality.

[0064] III. Experimental Examples Experimental Example 1: Effect of TMR Rotation Speed ​​on Juice Loss Rate and Softening Effect With other conditions fixed (42% leafy greens, 90% moisture content, 1.5mm blade spacing, 30min processing time), the TMR speed was varied to examine the juice loss rate and filament length.

[0065] ; Conclusion: When the rotation speed is >55 r / min, the juice loss rate increases sharply, the filament length becomes shorter, and the cell wall is severely damaged; the 30-55 r / min of the present invention can retain juice to the maximum extent, maintain the fiber structure, and is beneficial to subsequent fermentation.

[0066] Experiment Example 2: The Impact of Buffer Warehouse Linkage Control on Equipment Utilization and Material Freshness Set up three sets of comparisons: Group A (the present invention): The linkage logic described in claim 6 is adopted, and the cache temperature is 20°C.

[0067] Group B (no linkage): After each batch of TMR is completed, it is manually transferred to the fine pulverizer. The transfer takes 10-15 minutes, during which the material is exposed.

[0068] Group C (fixed discharge): The buffer bin has no weight sensor and discharges at a fixed speed of 45 kg / min, but the TMR feeds at a fixed cycle of 30 min / batch.

[0069] ; Conclusion: The linkage control of the present invention enables continuous feeding, avoids prolonged exposure of materials and temperature rise, and significantly improves equipment utilization and fermentation hygiene quality.

[0070] Experimental Example 3: Effects of Fermentation Temperature and Time on Feed Quality The materials from Example 1 were used to ferment at different temperatures for different times, and the pH and lactic acid content were measured.

[0071] ; Conclusion: High-quality fermented feed can be obtained by fermenting at 25-30℃ for 3-5 days; if the temperature is too low, fermentation is slow and the acidity is insufficient; if the temperature is too high (35℃), off-odors are easily produced. The preferred temperature for this invention is 25-30℃ for 3-5 days.

[0072] IV. Comparative Experiment Comparative Example 1: High-speed shredder replaces TMR A traditional shredder (400 r / min) was used instead of TMR, and the rest was the same as in Example 1.

[0073] Results: Juice loss rate was 18.5%, crude protein (dry basis) dropped to 18.2%, localized spoilage occurred after fermentation, and the success rate was only 65%.

[0074] Comparative Example 2: No buffer warehouse, manual transfer. The buffer bin is removed, and the TMR discharge material is manually transferred to the fine pulverizer.

[0075] Results: Equipment utilization rate was 52%, material exposure led to increased temperature, fermentation pH was 4.1, crude protein was 19.5%, and the risk of contamination increased.

[0076] Comparative Example 3: Ordinary fermentation bag, without one-way breathing valve. The fermentation was packaged in ordinary PE bags (without one-way breathing valves), and the rest was the same as in Example 1.

[0077] Results: Gas production in the early stages of fermentation caused the bags to swell and some bags to rupture; upon opening the bags, a musty odor was detected, the pH was 5.2, the lactic acid content was only 1.5%, and a large number of miscellaneous bacteria proliferated. This indicates that the one-way breathing valve is crucial for maintaining the anaerobic environment.

[0078] Comparative Example 4: Too low / too high percentage of leafy greens 30% proportion: juice loss rate 0.5%, but the mixed base material is too dry. After fine grinding, the moisture content is 35%, fermentation starts slowly, pH 4.8, lactic acid 2.0%.

[0079] 55% proportion: Juice loss rate 3.5%, mixed base material is too wet, moisture content after fine crushing is 55%, fermentation produces acid too quickly, pH 3.5, but there is leakage, and it is easy to be contaminated after packaging.

[0080] Conclusion: When the proportion of leafy grass is 40-45%, it can ensure appropriate humidity (42-46%) and control juice loss, resulting in the best fermentation quality.

[0081] The above-described embodiments, experimental examples, and comparative experiments demonstrate that this invention, through the use of TMR low-speed (30-55 r / min) blunt blade filaments, buffer silage with stable flow feeding, and in-bag fermentation with a breathing valve, can significantly reduce juice loss (≤2%) in high-moisture-content leafy greens, achieving a smooth transition between batch and continuous production (equipment utilization ≥90%), and ensuring the controllability and stability of the fermentation process (pH 3.7-3.9, lactic acid content ≥4.2%). All parameter ranges have been verified and exhibit sufficient repeatability.

[0082] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A continuous processing technology for fermented leafy grass feed, characterized in that, Includes the following steps: S1 Non-edible leafy grass raw material pretreatment: The feed raw materials other than edible leafy grass are crushed and mixed to make premixed feed; S2TMR Integrated Mixed Softening: The premix obtained in step S1 and fresh leafy grass are directly put into a total diet mixer. The moisture content of the leafy grass is 85-95%. The total diet mixer is used at a low speed for mixing and softening to obtain a mixed base material. The low speed is 30-55 r / min. S3 Buffer Bin Linked Stable Flow Feeding: The mixed base material obtained in step S2 is transported to the buffer bin for temporary storage. The buffer bin is equipped with a weight sensor, which provides real-time feedback on the remaining material in the bin. This is linked with the total daily ration mixing mixer and the fine pulverizer for control. The buffer bin feeds material to the fine pulverizer at a uniform speed, while the total daily ration mixing mixer simultaneously carries out the next batch of mixing and spun silk processing. S4 Fine Grinding: The mixed base material enters the fine grinding mill through the buffer bin and is ground to a particle size of 1-5mm to obtain a fine mixed material; S5 Quantitative Packaging and In-Bag Fermentation: The fine mixture obtained in step S4 is packed into a fermentation bag with a one-way breathing valve, sealed, and fermented inside the bag to obtain fermented leafy grass feed.

2. The processing technology according to claim 1, characterized in that, In step S2, the filament-softening blade assembly of the total diet mixer is a blunt blade assembly with a blade spacing of 1-2mm; the processing cycle is 25-35 minutes per batch.

3. The processing technology according to claim 1, characterized in that, In step S2, the weight percentage of leafy grass in the mixed substrate is 40-45%, the leafy grass is shredded to 2-5mm, and the juice loss rate of the mixed substrate is ≤2%.

4. The processing technology according to claim 1, characterized in that, In step S1, the feed ingredients include one or more of corn, soybean meal, wheat bran, probiotics, enzyme preparations (including at least two of cellulase, α-amylase, pectinase, xylanase and protease) and leafy grass-specific feed packets; the ingredients are crushed to 1-10 mm, the stirring speed is 100-150 r / min, and the stirring time is 5-8 min; the moisture content of the premix is ​​10-12%.

5. The processing technology according to claim 1, characterized in that, In step S3, the buffer chamber has an inclination angle of 55-65° and a built-in anti-sticking stirring device with a stirring speed of 30-50 r / min; the discharge speed of the buffer chamber to the fine pulverizer is 40-65 kg / min.

6. The processing technology according to claim 5, characterized in that, In step S3, the linkage control logic is as follows: when the remaining material in the buffer bin is less than 1 / 3 of the total capacity, the total daily ration mixer automatically starts processing the next batch; when the remaining material is higher than 2 / 3 of the total capacity, the discharge speed is increased to 55-65 kg / min; when the remaining material is between 1 / 3 and 2 / 3 of the total capacity, the discharge speed is maintained at 40-50 kg / min.

7. The processing technology according to claim 1, characterized in that, In step S3, the temperature inside the buffer chamber is controlled at 15-25℃.

8. The processing technology according to claim 1, characterized in that, In step S4, the moisture content of the fine mixture is 42-46%.

9. The processing technology according to claim 1, characterized in that, In step S5, the opening pressure of the one-way breathing valve is 0.005-0.02MPa, and the exhaust port is equipped with a 100-120 mesh filter; the fermentation conditions are a temperature of 25-30℃ and a fermentation time of 3-5 days.

10. The processing technology according to claim 1, characterized in that, In step S5, the weight of a single bag is 15-40kg, and the fermentation bag is made of food-grade PE material.

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