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Dosing and Mixing of Amino Acids

Amino Acids Supplementation in Feed Mills

Amino acids supplementation in feed

production generally is a batch process.

Two basic process steps are necessary to

get a consistent feed quality:

ÖDosing

ÖMixing

Feed Additives Slide 2

 Amino Acids Supplementation in Feed Mills

Both process steps influence feed

quality directly:

ÖMixing homogeneity determines the

consistency of supplementation within a
given batch.

ÖDosing accuracy determines the

consistency of supplementation from
batch to batch.

Feed Additives Slide 3

Amino Acids Supplementation in Feed Mills

Two questions will be addressed in the following:

1. What are the differences between dry bulk and

liquid additives in both process steps?

2. What is the impact on quality and cost of feed

production?

Feed Additives Slide 4

 Basics of Dry Bulk Mixing
A D

Mixing dry bulk ingredients statistically means

to bring them from a completely de-mixed status
of order into a status of relative (dis-)order
of stochastic homogeneity.
B mixing
A mixture is (mainly) defined by:
Öparticle size (characteristic diameter D)
Önumber of particles N = NA + NB
Öconcentration P = MA / (MA + MB) (M = mass)
ÖCV (coefficient of variation) to qualify its
homogeneity

Feed Additives Slide 5

Mixing Curve Characteristics

CV (%)

120

100

80

60

40
30
25
20
10
5
0
0 50 100 150 70 s 200 250 300
7.8 s Time (s)

CV decrease over mixing time depends on mixer design.

Feed Additives Slide 6

 Basic Statistics of Mixing
1 Sample
Standard Deviation of Sample n-1
Σ (x - P)2
i=1
i
CV = =
Mean of Sample P

Theoretically achievable CV (CVopt):

• representative (number of) samples
• representative size of samples, i.e number of particles
• Gaussian normal distribution
• maximum deviation P ± 2s and confidence interval of 95%

1 1-P 1 1-P
CVopt = or N =
N P CVopt² P

Considering the characteristic particle size D and density ρ, the

minimum sample mass M follows:
π
M = ρ D³ N This mass M may also be interpreted as the
6 amount of feed intake needed to guarantee a
π 1 1-P safe supply of certain supplemented nutrients
M = ρ D³
6 CVopt² P such as amino acids in the feed.
Feed Additives Slide 7

Minimum Sample Size for Particle Size D = 250µm

10.000

1.000
Sample size [g]

425

100
42

10
4.2

1
0.4

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CV [%]
P= 10g/t 100g/t 1kg/t 10kg/t = 1%

Feed Additives Slide 8

 Minimum Sample Size for Dose Rate P = 1kg/t

10.000

1.000
Sample size [g]

198
100

34

10
4.2

1
0.9

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CV [%]
D= 150µm 250µm 500µm 900µm

Feed Additives Slide 9

Mixing Dry Bulk and Liquid Additives

Mixing dry bulk and liquid additives into

the feed matrix is a multi stage process in
the feed mill’s batch mixer
Ö Addition of dry bulk ingredients and
dry mixing
ÖAddition of liquid ingredients by
spraying

Feed Additives Slide 10

 Mixing Dry Bulk and Liquid Additives

Mixing dry bulk and liquid additives into

the feed matrix is a multi stage process in
the feed mill’s batch mixer
Ö Addition of dry bulk ingredients and
dry mixing
ÖAddition of liquid ingredients by
spraying
ÖAbsorption of liquids by dry bulk

Feed Additives Slide 11

Mixing Dry Bulk and Liquid Additives

Mixing dry bulk and liquid additives into

the feed matrix is a multi stage process in
the feed mill’s batch mixer
Ö Addition of dry bulk ingredients and
dry mixing
ÖAddition of liquid ingredients by
spraying
ÖAbsorption of liquids by dry bulk
ÖDry mixing of dry bulk particles with
adsorbed liquids into feed matrix

Feed Additives Slide 12

 Spraying Liquids: a Practical Example
Theoretical surface:
4 t broiler feed
d50 = 0,9mm
covers surface of a
soccer field of 6.000 m²

4 ton mixer
Actual spraying area:
diameter: 1.5 m
Aspray = 16.5 x 30 ≈ 500 m²
length: 3.5 m
compares to penalty room
inner surface:
related to soccer field
A = π x 3.5 x 1.5 = 16.5 m²
n = 30 rpm

Feed Additives Slide 13

Droplet Size of 3l/min Nozzles and Spraying Time

Liquid addition:
no. of nozzles =5
x flow rate = 3 l/min
x spraying time = 30sec
x density = 1.2kg/l
result in = 9kg in 30sec
or = 18kg/min
500
30

25
Liquid addition [kg]

3 20

15

5 nozzles of 3 l/min at 3 bar differential 10

pressure result in varying spraying times 5
of ca. 30sec for 9kg or 60sec for 18kg of
0
liquid additive of 1.2 kg/l density .
0 30 60 90
Spraying time [s]

Feed Additives Slide 14

 Liquid Dosing Increases Batch Time
CV 40
35
Liquids
30
25 Dry components
20
15
10
5
0
0 1 2 3 4 5 6 7 8 9
min
Time to fill the mixer

Time for discharge

Time for mixing Time for spraying

dry components liquids and
incl. additives final mixing
Feed Additives Slide 15

Liquid Dosing Increases Batch Time

Residence time for a dry micro-ingredient
T0 T1 T2 T3
Dry Bulk Dosing: 100
Percentage of
Ts ≈ (T3 - T0) ≈ 180 s
total amount
dosed 0
0 1 2 3
Residence time for last drop of liquid
Liquid Dosing: 100
Percentage of
TL = (T3 - T2 + T3 - T1) / 2 ≈ 145 s
total amount
dosed 0
0 1 2 3
Residence time for first drop of liquid
Assumptions:
T0 = Start of hand adds Dry mixing time
T1 = Start of liquid dosing at T0 + 20s Mixing Time (in minutes)
T2 = End of liquid dosing at T0 + 50s
T3 = End of mixing time at T0 + 180s
Ts, TL : Average mixing time of solid, liquid
Feed Additives Slide 16
 Absorption Time and Viscosity

time (s)
800
660
600 540

400
Absorption of water, choline chloride,
liquid MHA-FA, Lysine base on filter paper 180
With a pipette a droplet of each product was given on filter paper.
200
The time was taken the tissue needed to fully absorb the droplet. 1) 6
1) Degussa FA-AT-PE trial no. MFT 090/04 by W. Polzer 0
Water Cholin chlorid 75%
With viscosity absorption time increases. MHA Lysine base

Feed Additives Slide 17

Absorption, Viscosity and Mixing ctd.

lumping

clustering

This will result in clustering of dry particles.

When liquid particles are large, lumping is promoted.

Feed Additives Slide 18

 Liquid Spraying Systems

Spraying systems need

regular maintenance and
cleaning. Leaking nozzles
affect accuracy, cause
product losses and
promote mold growth
and procrastination.
Feed Additives Slide 19

Inefficient Mixing

over-filling max

min
under-filling

Mixer filling ratio influences efficiency; especially with addition of liquids,

CV is deteriorated dramatically by wrong filling ratio. With under-filling
liquid addition causes incrustations, increases power consumption and
wear and tear of mixing tools.

Feed Additives Slide 20

 Acidic Liquid Additives Enhance Corrosion
A mist of MHA-FA was sprayed on mild steel and two
different types of stainless steel. This layer was covered
with broiler feed powder (<200µm) to simulate the
conditions in the mixer above the mixing tools.
After 3 months, the crust sticking to the metal was
removed. To remove the crust of Methionine based feed
a brush was enough while that of MHA-FA-feed had to
be removed with a spatula. 1)
MHA-FA attacks mild steel, even when mixed with feed,
a behavior not shown by Methionine.

When handling acidic or alkaline additives, according

to Material Safety Data Sheets the following Risk and
Safety Labels apply (Directive 1999/45/EC):
Corrosion2) to liquid MHA-FA DL-M
R41 Risk of serious damage to eyes
S25 Avoid contact with the eyes Mild Steel 0.2 mm/y none
S26 In case of contact with the eyes, rinse SS 321 0.006 mm/y none
immediately with plenty of water and seek SS 316 0.002 mm/y none
medical advice 1) DegussaFA-AT-PE Corrosion Test trial no. MFT 001/94
S 39 Wear eye/face protection by W. Polzer and no. 10, June 2002 by P. Höfler
2) Degussa report no. W326/84 by R. Brüggemann

Feed Additives Slide 21

Liquid Dosing Results in Higher CV

paddle mixer ribbon mixer DL-Met, N=349
CV (%)105 liquid MHA-FA, N=165
50
90
40
% of results

75
IFF report 1.545, 1997
30
60
Prof. Heidenreich
20
45
10
30
0
15
CV: <5% CV: 5- CV: >10%
0
by hand addition by several pipes 10%
by nozzles 11
Mean CV (%) of all batches

Crystalline Additive 10
9
The results of hundreds of mixer profiles 8
of dry and liquid amino acid supplemen- 7
AMIONONews
vol. 03, no. 01
tation assays in our AMINOLab® show: 6
the average CV of dry amino acid supple- 5 March 2003
Dr. J. Fontaine
mented feed mixes was found to be 2% 4
better than those with liquid addition. 3
DL-Methionine liq. MHA-FA
Feed Additives Slide 22
 Dosing of dry bulk versus liquid additives

Liquid additives are mostly

dosed via flowmeter.
A flowmeter detects volume,
not mass.
Accuracy is affected by
5°C
• temperature
• viscosity
20°C • density
Dry bulk is dosed into batch scales.
Bubbles are also detected
The additives’ mass is thus detected
and counted by flowmeter.
and registered by the control system.

Feed Additives Slide 23

Comparison of Typical Technical Data

Dry bulk amino acids Liquid amino acids
transport dosing screw, vibrator, pump
slide gate
measuring scale flowmeter
device
capacity 0 ... 150 kg 3 ... 30 l/min

readability 6,000 – 30,000 digits 52 pulses/l

5 - 25g 20 ml
accuracy ± 1d ± 0.5 - 1%
± 5...25g ±150...300ml
coarse/ yes (range 1 : 10) no
fine dosing

Feed Additives Slide 24

 Consequences of System Differences
Dosing accuracy for both systems is related to nominal
capacity and not to the current amount to be dosed.

Deviations from set points are mainly caused by

Öweighing / metering accuracy

Ötypical system parameters like

Ö diameter/capacity of dosing screw or pump / flowmeter
Ö time delay to shut-off dosing
Ö resulting run-off in coarse and/or fine flow

Feed Additives Slide 25

Consequences of System Differences ctd.

While dry bulk additives are dosed parallel to the the full
batch cycle and added at the beginning of the following
batch, volumetric addition of liquids must fit into a fraction
of the current mixing cycle. Residence time for a dry micro-ingredient
T0 Residence time for last drop of liquid T
3
100

30 0
25
Liquid addition [kg]

20

15
The amount of liquid additives’
10
addition thus is limited by cycle time
and compromises mixing time.
5

0
0 30 60 90
Spraying time [s]

Feed Additives Slide 26

 Impact on Feed Formulation
Typical batch related deviations for dry bulk micro systems -
based on nominal capacities - range from

< 50 ... 100 g / batch

Corresponding deviations of systems for volumetric dosing of

liquid additives typically exceed

> 300 ml / batch.

We see a systematic formulation advantage of ca. 250 g/batch

in favor of dry versus liquid additives dosed volumetrically.
In other words: when based on liquid additives, an additional
safety margin of ca. 250 g/batch should be considered in the
formulation.

Feed Additives Slide 27

Impact on Formulation Costs

Let us consider a feed mill with a yearly production of 100.000t.
The mill’s batch mixer has a capacity of 4 tons, i.e. the mill
produces 25,000 batches per year.
The additional safety margin then is calculated as:
25,000 batches/a x 0.25 kg/batch = 6,250 kg/a

DL-M MHA-FA Biolys Lys-

base 50

supplementation [%] 0.1 0.15 0.2 0.2

nominal consumption [kg/a] 100,000 150,000 200,000 200,000
safety margin [kg/a] 6,250 6,250
actual consumption [kg/a] 100,000 156,250 200,000 206,250

Feed Additives Slide 28

 Conclusions
Dry bulk amino acids have advantages over liquid additives in
the feed mill production process.

Ö Time for mixing dry bulk amino acids into feed matrix is
shorter. More time to increase mixing line performance.

Ö The range of supplementation rates for dry bulk is much

bigger. No spraying time restrictions have to be considered.

Ö Superior mixability of dry bulk amino acids results in better

homogeneity of feed and improved CVs.

Ö Lower safety margins due to superior dosing accuracy

reduce formulation costs in favor of dry bulk amino acids.

Feed Additives Slide 29

Disclaimer
This information and all further technical advice is based on our present
knowledge and experience. However, it implies no liability or other legal
responsibility on our part, including with regard to existing third party
intellectual property rights, especially patent rights. In particular, no
warranty, whether express or implied, or guarantee of product properties in
the legal sense is intended or implied. We reserve the right to make any
changes according to technological progress or further developments. The
customer is not released from the obligation to conduct careful inspection
and testing of incoming goods. Performance of the product described herein
should be verified by testing, which should be carried out only by qualified
experts in the sole responsibility of a customer. Reference to trade names
used by other companies is neither a recommendation nor does it imply that
similar products could not be used.

Feed Additives Slide 30