Animal Feed Pelleting Process Using Starch Gelatinization
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Solution Overview
Problem
The animal feed pellet industry faces challenges in producing pellets with desired hardness and durability, as existing pelleting processes lack control and flexibility, leading to issues like fines and crumbles during manufacturing, transport, and storage, and traditional methods compromise nutritional value with the use of binders and harsh conditioning.
Innovation Solution
A pelleting process involving separate steps for gelatinizing starch and mixing it with other feed ingredients to form pellets, without high-temperature conditioning, allowing for the production of pellets with enhanced durability and nutritional value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional pelleting process with binders and harsh conditioning is used, then hardness and durability of pellets are improved, but nutritional value deteriorates
Solution Approach 1:
The invention extracts and removes harmful binders (ligninsulfonates, molasses) and harsh conditioning treatments from the pelleting process. Instead, it uses a natural binder system based on feed ingredients themselves (particularly starch and protein components) that are activated through controlled processing to provide adhesion without compromising nutritional value.
Solution Approach 2:
The invention changes the processing parameters from harsh high-temperature conditioning to milder conditions (60-80°C for 1-5 minutes). This parameter change activates the natural binding properties of feed ingredients while preserving their nutritional content, resolving the contradiction between achieving pellet hardness and maintaining nutrition.
2Productivity
If traditional pelleting process is used, then production efficiency is maintained, but pellet durability deteriorates leading to fines and crumbles
Solution Approach 1:
The invention applies preliminary action by pre-cooking or pre-steaming the feed ingredients before pelleting to activate their natural binding properties. This preliminary treatment creates a more durable pellet structure that resists breaking into fines during handling, while the process remains efficient for industrial production.
3Reliability
If binders are added to increase durability, then pellet hardness is improved, but process complexity and cost increase
Solution Approach 1:
The invention applies self-service by enabling the feed ingredients themselves to serve as the binding agent. The natural components (starch, protein) in the feed activate binding properties under controlled processing conditions, eliminating the need for separate binder addition steps and reducing process complexity while maintaining durability.
4Strength
If harsh conditioning is applied to improve pellet quality, then hardness increases, but nutritional value is compromised
Solution Approach 1:
The invention fundamentally changes the conditioning parameters from harsh high-temperature treatments to mild conditions (60-80°C for 1-5 minutes). This parameter change is sufficient to activate natural binding properties and achieve adequate pellet hardness while preserving the nutritional content of temperature-sensitive ingredients.
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
This process results in animal feed pellets that meet industry standards for hardness and durability while maintaining higher nutritional value, reducing the need for binders and minimizing processing-related losses, offering a more economical and flexible production method.
Implementation Method 1
heating the slurry of step (c) or (d) under conditions sufficient to allow the starch to gelatinize
Implementation Method 2
subjecting the feed pellet mixture of step (i) or (j) to a pelleting device to form an animal feed pellet
Data Source
AI summary
The present invention relates to a pelleting process for the production of animal feed pellets having increased nutritional values and meeting or exceeding the industry standards for durability or hardness characteristics. Also provided are animal feed pellets obtainable by the process of the invention, including animal feed pellets having increased nutritional value as well as high or higher durability or hardness characteristics, and which are preferably devoid of molasses and/or lignosulfonates or other disadvantageous ingredients.