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8/18/2019 3-3 Thr - Keith Behnke - Feed Milling Milestones - ANC 2010
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Future Advances
Where did we come from
Where are we going???
Keith Behnke
Kansas State Universityan a an, ansas
THE FUTURE!
“The Future Ain’t What It Used To Be” Yogi B.
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THE FEED INDUSTRY
A Brief Histor
FEEDING STANDARDS
1864 German Chemist Emil Wolff published first
Feeding Standards based on Digestible Nutrients.
1898 FEEDS AND FEEDING First Addition
1912 Vitamins (“Vital Amines”) first discovered
1944 NRC/NAS published first series of feeding
s an ar s or commerc a ves oc an pou ry.
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EVOLUTION OF THE
FEED INDUSTRY
Early 1800’sorses an mu es prov e ra wor
– Oats and other grains provided by livery
stables
– Little science available regarding nutrition
* Calf feed for dairy farms was needed.
EVOLUTION OF THEFEED INDUSTRY
• 1866 H.K. Webster, Lawrence, Mass-Horse Feed
• 1875 Blatchfords Wauke en Il. Calf Feed
• 1879 O. A. Cooper
• 1885 Mooreman Manuf.• 1894 Ralston Purina (Robinson-Danforth, St. Louis)
• 1895 Albers Milling (Carnation, Co.-1929)
• 1920 Nutrena Mills (Cargill, Inc.)
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• 1850 Molasses first used in horse and cattle feed
• 1885 Cotton Seed Meal
• 1888 Corn gluten feed and meal
• one mea
• 1903 Dried beet pulp introduced
• 1910 Dried buttermilk
• 1915 Soybean cake imported from Asia for feed
• 1922 First U.S. soybean meal
• 1943 Urea used as NPN source for ruminant diets
• 1954 Animal fat first used in poultry diets
•
• 1848 Cotton bags replaced wooden barrels
• 1886 Jute imported from India for bags
• 1895 Hammermill patent issued
• 1909 Horizontal batch mixer-S. Howes Co.
• 1924 High molasses pelletmill
• 1931 CPM introduced the first steel die- flat bed
•
• 1942 First Bulk Truck developed
• 1948 Paper bags first used for feed
• 1950 Horizontal ellet cooler-Wen er Manuf.
• 1955 First “punch-card” batching system introduced
• 1957 Drop-bottom mixer
• 1962 Pellet Durability Tester developed-Pfost, KSU
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Late 1800’s to 1950’s
• Increased growth in new firms entering the
feed industry
• New in redients were bein introduced to the
market place
• The nutritional value of co-products wereecom ng recogn ze
1960’s to 1980’s
• Livestock production was growing at a pace
.
• New livestock buildings were being built.
• Feed manufactures were making good profits
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1960’s to 1980’s
• The feed industry was growing by leaps and
• New feed mills were going up in every state
• ngre ent p ants were e ng u t to meet t e
needs of the feed industry
• Existing Feed mills were being expanded
1980’s to 2000’s
• The livestock industry reached a pointmeetin the demand of customers.
• Chan in Livestock/Poultr Production – Number of U.S. Farms
• 1950: 5.6 million
• Today:
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Structure of the Feed Industry
Changing Livestock/Poultry ProductionChanging Livestock/Poultry Production
1980’s to 2000’s
SpeciesGrou Number Producers1 50 Toda
PoultryPoultry Vertical integrationVertical integrationunderwayunderway
Virtually 100Virtually 100
percent integratedpercent integrated
SwineSwine 3.0 million3.0 million 65,00065,000
Beef/CowBeef/Cow 2.8 million2.8 million 971,000971,000
Source: USDA/NASSSource: USDA/NASS
a rya ry . m on. m on ,,
• Some Impacts of Livestock and Poultry
n egra on onso a on, s- o ay:
– Livestock and poultry producers became major
ee manu ac urers
• Construction of large feed mills to produce complete
feed – 500 000+ tons er ear
• Mills located to optimize logistical issues; ingredient
procurement, finished feed transportation
• Mills designs are extremely efficient, targeted for
minimal number of feed formulations
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1980’s to 2000’s
• The feed industry matured
the demand.
• e ee n ustry eg n to conso ate
• Small town feed mills were replaced by
regional mills
140
100
120
n s n s
60
80
l l
i o n T
l l
i o n T
20
40 M i M i
0
1 9 1 9 1 9 1 9 2 0 2 0 2 0 3 5 7 9 1 3 5
Source: Feedstuff sSource: Feedstuff s
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U.S. Feed Production b S ecies
Layers 6%Layers 6%
25%25%Horse 2%Horse 2%
Dairy 17%Dairy 17%
OtherOther
(pet, etc.)(pet, etc.) Aquaculture 1% Aquaculture 1%a ea e3%3%
Source: informa economicsSource: informa economics
Feed Mill Operations – ChangingTimes
.
FDA:
- amen e to a ress
animal drugs
- rs
AAFCO: 1957 - established model state feed bill
-
OSHA - established in 1971
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Feed Mill Operations –
ang ng mes• EPA: Growth of Federal Environmental Regulations
1820
14
16
P a g e s
P a g e s
8
10
s a n d s o f
s a n d s o f
2
4 T h o
T h o
7 2 7 4 7 6 7 8 8 0 8 2 8 4 8 6 8 8 9 0 9 2 9 4 9 6 ' 0 0 ' 0 2
' 0 4 ' 0 6
Feed Mill Operations –
• OSHA: Examples of Required TrainingExamples of Required Training
• Bin Entry• Bloodborne Pathogens• Com an Vehicles
• Manlifts• Lockout and Tagout• Personal Protective
• Confine Space• Electrical Work Practices
• Emergency Action
Equipment
• Pesticide Application• Emergency
• xposure o as es os, ea ,other chemicals asappropriate
• Fall Protection Equipment
• Respiratory Protection• Truck Dumper Operation• Rail Operations Safety
• First Aid• Employee Orientation• Use of Fire Extinguishers
• Welding/Cutting/ Hotwork• Grain Handling Equipment• Planned Maintenance
• • Front-end Loader/Bobcat• Hazard Communication
• • Storage and handling of LP
Gases
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Feed Mill Operations –
ang ng mes2. Growing Emphasis on Feed Safety
Increasing Demands by Consuming Public
Removed from farming and animal production practices
Declining personal responsibility
September 11, 2001
Bioterrorism Response and Preparedness Act of 2002
USDA, FDA, DHS, FBI Strategic Partnership Program
Agroterrorism (SPPA) Initiative
Impacts on the Mill:
Increased interest in HACCPncrease emp as s on ac y secur y ssues
Feed Mill Operations – ang ng mes
.
Renewable Fuels Mandate - Energy Policy
7.5 billion gallons by 2012
121 existing biorefineries: 6.332 billion
allons
84 under construction/expansion: 6.245
billion gallons
Source: Renewable Fuels Assoc iationSource: Renewable Fuels Assoc iation
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The Impact of BiofuelsDistiller’s Dried Grains wi thDistiller’s Dried Grains wi th
Solubles (DDGS) ProductionSolubles (DDGS) Production
28
32
T o n
s
T o n
s
20
24
0 S h o r t
0 S h o r t
8
12
1 , 0
0 0 , 0
1 , 0
0 0 , 0
0
4
8 0 8 5 9 0 9 5 0 0 0 3 0 5 0 6 0 7 0 8 0 9 1 0
Sources: USDA; The ProExporter Network®, 2007Sources: USDA; The ProExporter Network®, 2007-- 2010 Projected2010 Projected
THE FUTURE:
It’s all about food safety!!
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to
Chan e???
or some o us n
August 16, 1977
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August 16, 1977
The day ELVIS died!!
or mos :
September 11, 2001
The day terrorists attacked the
World Trade Center
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u , or e
ee n us ry:
Late Fall, 1987
For the World
Late Fall, 1987
The first confirmed case of BSE on
,
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SEQUENCE OF EVENTS
1987: BSE Confirmed in England
1990: “European Beef Scare” began in earnest-Lots of
media hype. Beef consumption dived.
SEQUENCE OF EVENTS
1987: BSE Confirmed in England
1990: “European Beef Scare” began in earnest.
1996: British government stated that: “contaminated beef”
was t e e y cause o t e nv reutz e - aco
disease attacking younger people. Death toll
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SEQUENCE OF EVENTS
1987: BSE Confirmed in England
1990: “European Beef Scare” began in earnest.
1996: “Contaminated beef” caused “nv CJD”: . . react on - mp emente regu at ons
designed to prevent the use of ruminant protein
.
The regulations were to serve two purposes
1. Sto the otential s read of BSE
2. Maintain confidence in the U.S. meat
supply
SEQUENCE OF EVENTS
1987: BSE Confirmed in England
1990: “European Beef Scare” began in earnest.
1996: “Contaminated beef” caused “nv CJD”
: . . react on - mp ement rum nant
protein regulations
case of BSE in the U.S.
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SEQUENCE OF EVENTS
December 23,2003, 5:30pm Eastern time:
F rst con rme case o BSE n t e U.S. announce
Secretar of A riculture
Ann Veneman
SEQUENCE OF EVENTS
December 23,2003, 5:00pm Eastern time:
rst con rme case o BSE n t e U.S.
- It was the evening before Christmas Eve Day
-
-Futures trading was going to stop at noon, Dec 24
Secretary of Agriculture
Ann Veneman
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SEQUENCE OF EVENTS
First confirmed case of BSE in the U.S (2002).
What Happened?
SEQUENCE OF EVENTSFirst confirmed case of BSE in the U.S(2002).
a appene
Domestically-Not much, really!
-Live beef prices took a hit for a few months.
-Beef consumptions stayed essentially level.
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What Happened?
Domestically-Not much, really!
Why?
Consumer Confidence!!
In the U.S., citizens actually trust FDA!!
SEQUENCE OF EVENTS
First confirmed case of BSE in the U.S(2002).
What Happened Internationally?
-Beef Exports decreased
-U.S. Ex orts Banned b several countries
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a s e o n o a s
at s t e o nt
fact that the FEED industry is a critically
.
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a s e o n o a s
e ongo ng ssue roug t ome t e
fact that the FEED industry is a criticallympor an par o e n us ry.
WE MUST ACCEPT THAT
REALIZE HOW IMPORTANT
.
The biggest issue that animal
agriculture will face in the future?
FOOD SAFETY
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“
requent y outwe g s
SCIENTIFIC PERSUASION”.
Feedstuffs 72:3, 1999
The Future
What else is coming??
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The Future of Biotech
Ingredients
Designer Grains/Oilseeds
- “ ”
grains/oilseeds.
-concerning phosphorus buildup in soils.
FEED MILL DESIGN-
The evolution of mill design
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PELLETING
HACCP
Microbial Control in Feed Mills
e as tr e or years to raw
a line from the feed mill to the dinner
p ate o ar, w t tt e success.
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THERMAL PROCESSING
Temp Number EntrobacteriaºC Samples Log10 CFU/gm
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On-Line Reformulation
possible to reformulate rations in real time.
• Nutrient overage would be cut to near zero
•
• Ingredient changes more easily managed.
SUMARY
•The Feed Industry has come a long way in 150 years.
•Food safety is the most important issue
to be dealt with by the feed industry.
•Perception becomes reality. If we are perceived
as bein art of the roblem we are.
•Respond quickly and openly to any challenge
•Technology (Bio Ingredients) will be here soon
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“Some eo le look at the wa thin are and ask WHY? I would rather look at the way things
could be and ask WHY NOT?”- George Bernard
Shaw
THANK YOU