High-Energy Feed Pellet Vacuum Fat Incorporation
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Solution Overview
Problem
Existing feed pellets with high fat content have low digestibility and high density, leading to non-optimum feed conversion and storage issues, as increasing fat content compromises swelling capacity and sedimentation value.
Innovation Solution
The development of high-energy feed pellets with a total fat percentage over 15% using the Universal Pressure Cooking (UPC) method, where fat is added in a vacuum-coating device to maintain low density and optimal digestion, involving a method that includes mixing starch-containing compositions, extrusion, and introducing a fat-containing composition under vacuum to achieve a high-energy feed pellet with improved transport and storage properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If compression is used to produce feed pellets, then the feed pellets have high density, but this results in non-optimum digestion and reduced feed conversion
Solution Approach 1:
The invention changes the production method from compression to UPC (Universal Pressure Cooking) processing, which fundamentally alters the physical and chemical parameters of the feed pellets. This parameter change allows achieving low density (at most 700 g/l) while maintaining high digestibility through the specific UPC process conditions that preserve natural material properties without compacting them into dense structures
Solution Approach 2:
The invention uses composite materials by combining natural feed ingredients with binding agents in a specific formulation that enables the UPC process to create pellets with optimized density and digestibility characteristics. The composite structure allows the feed to absorb water and swell properly during digestion while maintaining pellet integrity
2Use of energy by moving object
If fat content is increased to raise energy value, then the energy value increases, but the density increases and swelling capacity decreases
Solution Approach 1:
The invention applies parameter changes by using the UPC process to incorporate high fat content (more than 15 wt.%) into the feed pellets without the usual density increase. The UPC method allows fat to be integrated into the pellet matrix in a way that maintains porosity and swelling capacity, unlike conventional mixing and compression methods where fat adds weight and reduces volume expansion
Solution Approach 2:
The invention utilizes porous material structure by maintaining a loose, non-dense pellet configuration through UPC processing. The porous structure allows high fat content to be accommodated while preserving the spaces needed for water absorption and swelling, preventing the pellets from becoming too dense despite the added fat mass
3Use of energy by moving object
If fat content is increased to raise energy value, then the energy value increases, but the swelling capacity decreases
Solution Approach 1:
The UPC process parameters (temperature, pressure, time) are optimized to allow high fat incorporation while maintaining the hydrophilic properties of the feed ingredients. This parameter optimization ensures that even with more than 15 wt.% fat, the pellets retain their ability to absorb water and swell to at least 40 ml after 30 minutes
Solution Approach 2:
The feed formulation uses a composite of hydrophilic binding agents and fat sources that work together in the UPC process. The binding agents create a matrix that can accommodate fat while maintaining water-absorbing capacity, resulting in a composite material that achieves both high energy value and high swelling capacity
4Quantity of substance
If compression is used to produce feed pellets, then the feed pellets have high density, but they adhere to one another during storage and transport
Solution Approach 1:
The invention changes from compression to UPC processing, which fundamentally alters the surface properties and internal structure of the pellets. The UPC process creates a less compact, more porous structure that reduces inter-pellet adhesion during storage and transport, eliminating the sticking problems associated with densely compressed pellets
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 feed pellets achieve better feed utilization, reduced manure production, and improved animal health by maintaining low density and high energy value while ensuring optimal digestion and storage, with a swelling capacity of at least 40 ml and sedimentation value of at most 60 ml, enhancing farm and environmental efficiency.
Implementation Method 1
introducing a fat-containing composition under vacuum to achieve a high-energy feed pellet with improved transport and storage properties
Data Source
AI summary
The present invention relates to a high-energy feed pellet based on natural materials having a total fat percentage of more than 15 wt.%. The present invention also relates to a method for the preparation of the high-energy feed pellet based on natural materials in which the starting materials are mixed and processed to obtain a feed pellet, which method comprises the following steps: a) providing a starch-containing composition having an average particle size of 200-650 µm; b) bringing the composition of step a) into contact with a certain amount of supplementary components; c) extruding the product obtained in step b) to obtain a feed pellet; d) introducing a fat-containing composition into the feed pellet obtained in step c) in a vacuum; and e) bringing the feed pellet obtained in step d) to atmospheric pressure in order to obtain the high-energy feed pellet having a total fat percentage of more than 15 wt.%.