Low Moisture Animal Feed Blocks Using Separator By-Product
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Solution Overview
Problem
Existing animal feed supplement blocks are largely molasses-based, which limits the use of concentrated separator by-product due to palatability and nutritional concerns, and require curing agents or high moisture removal for hardening, increasing costs and energy consumption.
Innovation Solution
Development of low moisture animal feed supplement blocks that use concentrated separator by-product as a molasses-replacement, combined with added sugars and pH adjustment, allowing the blocks to harden without curing agents or high moisture removal, with the by-product accounting for a significant portion of the block's composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molasses is used as the primary component in feed blocks, then the blocks achieve adequate palatability and binding properties, but the use of concentrated separator by-product is limited and manufacturing costs increase
Solution Approach 1:
The patent changes the chemical parameters of the separator by-product through pH adjustment (to alkaline conditions) and concentration (to 90%+ solids content), transforming it from an unsuitable material into an effective molasses replacement that provides both binding properties and palatability
Solution Approach 2:
The patent converts the previously harmful or unsuitable separator by-product (which had limited use due to its properties) into a beneficial ingredient by applying chemical treatment, thereby reducing dependency on molasses and lowering manufacturing costs
2Strength
If curing agents are used to harden poured blocks, then the blocks achieve adequate hardness and structural integrity, but energy consumption and manufacturing complexity increase
Solution Approach 1:
The treated separator by-product self-hardens through its own chemical properties (alkaline pH and high solids content) without requiring external curing agents, thereby reducing both manufacturing complexity and energy consumption while maintaining block hardness
Solution Approach 2:
The patent extracts and eliminates the need for curing agents from the manufacturing process by using the chemically treated separator by-product that inherently provides hardening capability, simplifying the overall process
3Stability of the object's composition
If high moisture removal is applied to harden feed blocks, then the blocks achieve adequate hardness and stability, but energy consumption increases
Solution Approach 1:
The patent changes the moisture content parameter of the separator by-product to 90%+ solids content before use, which allows the material to harden through chemical properties rather than requiring extensive moisture removal, thereby reducing energy consumption while maintaining stability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the creation of feed blocks that are free or low in molasses, with improved palatability and nutritional value, reduced manufacturing costs, and energy consumption, while maintaining hardness comparable to molasses-based products.
Implementation Method 1
pouring the admixture into a vessel; and allowing the poured admixture to cool to ambient temperatures thereby hardening into a feed block
Data Source
AI summary
Low moisture feed blocks deliver supplemental nutrients to animals and are free or substantially free of molasses by using concentrated separator by-product as a molasses replacement. A premixture of concentrated separator by-product and added sugar may be pH-adjusted and concentrated to a high solids content. The premixture may be combined with dry components to form an admixture that is poured into a vessel and allowed to naturally cool and harden into the supplemental feed block.