quality control manual for cattle feed plants

228 Pages·2017·3.68 MB·English

QUALITY CONTROL MANUAL FOR
CATTLE FEED PLANTS
M R Garg, P L Sherasia and B M Bhanderi
Animal Nutrition Group,
National Dairy Development Board, Anand-388 001

National Dairy Development Board, Anand
FOREWORD
Apart from locally available feed resources, compounded cattle feeds and strategic feed
supplements are important source of nutrients for growing and lactating animals. To ensure
that these feeds and feed supplements are manufactured in a cost effective manner and in
accordance with standard specifications, various aspects related to least cost feed formulation,
raw material quality testing, storage, production etc. need to be taken into consideration. It
is essential that, feed milling plants have a qualified and trained animal nutritionist.
I am happy to note that NDDB’s Animal Nutrition group has put in a great deal of effort to
prepare a Quality Control Manual for Cattle Feed Plants based on research from authoritative
sources, to serve as a practical guide on the subject, which would be useful not only for
officers currently involved in quality control but also for those interested in knowing about
systems for ensuring quality in feeds.
The manual has been carefully organized in numbered parts, chapters and sections for
quality control in production, storage and common analytical procedures of feeds. The part
on cattle feed production and storage includes recommended practices on a number of
aspects such as sampling, spot tests for feed ingredients, rodent/pest control, production
operations, feed formulation methods, pelleting, process for production of bypass protein
and mineral mixture production.
The part on commonly used analytical procedures has useful information on laboratory
practices, proximate analysis, analysis of fibre fractions, molasses, minerals, vitamins,
bypass protein and fat supplements, aflatoxins, pesticide residues as well as procedures
for measurement of methane emissions. The description of analytical procedures generally
include relevant information on principle, apparatus, reagents/materials, procedure,
calculation and reference source, along with photographs and/or illustrations where ever
applicable. The appendices contain useful information on BIS standards for feed and feed
supplements, glossary of terms, conversion factors etc. which would aid the readers.
I am sure that this manual will prove to be a valuable reference tool for animal nutrition
officers involved in quality control in cattle feed plants as well as others who are interested
in the subject.
January, 2013 Amrita Patel
Chairman, NDDB

CONTENTS
Sr. No. Title Page No.
Flowchart for quality control in a cattle feed plant ......................................... xii
Typical flow diagram of 150 MTPD cattle feed plant....................................... xiii
Introduction .......................................................................................................... 1
PART – I
QUALITY CONTROL IN A CATTLE FEED PLANT
1.0 Quality control of raw materials and finished products ............................... 3
1.1 Sampling ................................................................................................ 3
1.1.1 General requirements of sampling ..................................................... 4
1.1.2 Scale of sampling ................................................................................. 4
1.1.3 Preparation of individual samples ....................................................... 5
1.1.4 Preparation of composite samples ..................................................... 5
1.1.5 Referee samples ................................................................................... 5
1.1.6 Testing of samples ................................................................................ 5
1.1.7 Criteria for conformity .......................................................................... 5
1.2 Evaluation of feeds and feed ingredients for quality ........................ 5
1.2.1 Physical evaluation ............................................................................... 5
1.2.1.1 Common adulterants in feeds ............................................................. 6
1.2.1.2 Spot tests for detection of various types of adulteration ................ 7
1.2.1.3 Urea spot test ....................................................................................... 8
1.2.1.4 Identification of plant and animal protein in feed ............................. 8
1.2.1.5 Spot tests for minerals in finished feed ............................................. 8
1.2.1.6 Spot tests for toxic constituents ......................................................... 10
1.2.1.7 Other tests ............................................................................................. 11
1.2.2 Chemical evaluation.............................................................................. 13
1.2.2.1 Analysis of feed and feed ingredients................................................ 13
1.2.3 Quality control of finished product ..................................................... 14
2.0 Quality control during storage .......................................................................... 15
2.1 Control measures .................................................................................. 15
2.1.1 Rodent and pest control ...................................................................... 17
2.1.2 Insect infestation and its control ......................................................... 17
2.2 Quality changes in stored food grains ............................................... 19
2.2.1 Physical changes................................................................................... 20
2.2.2 Chemical changes ................................................................................. 20
3.0 Quality control during production .................................................................... 21
3.1 Quality check points during production ............................................. 21
3.1.1 Bulk receiving operation ...................................................................... 22
3.1.2 Intake of raw materials at the dumping hopper ............................... 22
3.1.3 Batch preparation operation ................................................................ 22
3.1.4 Grinding operation ................................................................................ 24
3.1.5 Mixing operation-Dry ............................................................................ 24
3.1.6 Molasses mixing operation .................................................................. 25
3.1.7 Pellet mill operation .............................................................................. 26
3.1.8 Pellet cooling operation ....................................................................... 27
3.1.9 Moisture control operation .................................................................. 28
3.1.10 Bagging section .................................................................................... 28
3.1.11 Bin sampling.......................................................................................... 29
3.1.12 Premix section ...................................................................................... 29
3.1.13 Aspiration section ................................................................................. 29
3.2 Determining excess or short usage of raw materials....................... 29
3.3 Quality commitment and points to evaluate ..................................... 30
3.4 Computerized least cost feed formulation (LCF) ............................... 31
3.4.1 Dynamic production and procurement system ................................. 31
3.4.2 Required information for computerized feed formulation ................ 32
3.4.3 LCF within a given number of bins .................................................... 34
3.4.4 LCF for various classes and physiological functions ........................ 34
3.4.5 Addition or deletion of ingredients in LCF ........................................ 34
3.5 Losses in feed weight .......................................................................... 34
3.6 Improving pellet quality and efficiency .............................................. 35
3.6.1 Pellet quality issues .............................................................................. 35
3.6.2 Factors affecting pellet quality ............................................................ 35
3.6.2.1 Formulation ............................................................................................ 35
3.6.2.2 Conditioning .......................................................................................... 35
3.6.2.3 Grinding ................................................................................................. 36
3.6.2.4 Die/ roller ............................................................................................... 36
3.6.2.5 Cooling ................................................................................................... 36
3.6.3 Advantages of pelleted feeds .............................................................. 37
3.6.4 Pellet durability index (PDI) ................................................................. 38
3.7 Contamination/ cross-contamination ................................................... 38
3.8 Plant design ........................................................................................... 39
3.9 Future trends ......................................................................................... 39
Bypass protein plant layout ................................................................................ 40
4.0 Bypass protein supplement production process............................................. 41
4.1 Nutritional properties of formaldehyde treated protein meals ........ 42
4.2 Production process for bypass protein feed supplement ................ 42
4.3 Operational and safety guidelines for bypass protein plant ............ 43
4.4 Operational health and safety aspects ............................................... 44
4.5 Benefits of feeding bypass protein feed ............................................ 44
Mineral mixture plant layout ............................................................................... 45
5.0 Mineral mixture production process ................................................................ 46
5.1 Mineral mixture production process ................................................... 47
5.2 Functions of different minerals ............................................................ 47
5.3 Major equipments of mineral mixture plant ...................................... 48
5.4 Start up and shut down procedure .................................................... 49
PART – II
COMMONLY USED ANALYTICAL PROCEDURES
6.0 Good laboratory practices ................................................................................. 53
6.1 Laboratory safety .................................................................................. 54
6.2 Laboratory safety techniques .............................................................. 57
6.3 Safe handling of special chemical hazards ........................................ 59
6.4 Washing and cleaning of laboratory glassware ................................. 61
6.5 Preparation of standard solutions ....................................................... 62
7.0 Proximate analysis .............................................................................................. 67
7.1 Determination of moisture ................................................................... 67
7.2 Determination of total ash ................................................................... 68
7.3 Calculation of organic matter .............................................................. 69
7.4 Calculation of nitrogen free extract .................................................... 69
7.5 Determination of acid insoluble ash ................................................... 69
7.6 Determination of crude protein-Kjeldahl method .............................. 70
7.7 Determination of crude protein- Automated Kjeldahl method ........ 73
7.8 Estimation of ether extract using Soxhlet apparatus ........................ 75
7.9 Estimation of ether extract using Soxtec system ............................. 76
7.10 Determination of crude fibre-Muslin cloth method ........................... 77
7.11 Determination of crude fibre using Fibertec system ........................ 79
7.12 Determination of crude fibre using Ankom technology ................... 80
7.13 Determination of urea-Distillation method ......................................... 82
7.14 Determination of urea in animal feed-Colorimetric method ............ 84
7.15 Determination of serum/ plasma urea ................................................ 84
7.16 Estimation of urea in milk-DMAB method ......................................... 85
7.17 Analysis using near infrared analyser (NIR) ....................................... 86
8.0 Analysis of fibre fractions .................................................................................. 89
8.1 Determination of neutral detergent fibre ............................................ 89
8.2 Determination of neutral detergent fibre-Fibertec system. ............... 91
8.3 Neutral detergent fibre and neutral detergent insoluble
nitrogen estimation using Ankom 220 Fiber analyzer ...................... 91
8.4 Determination of acid detergent fibre ................................................ 93
8.5 Determination of acid detergent fibre-Fibertec system .................... 94
8.6 Acid detergent fibre and acid detergent insoluble nitrogen
estimations using Ankom 220 fiber analyzer ..................................... 94
8.7 Determination of cellulose-Fibertec system ....................................... 95
8.8 Determination of acid detergent lignin ............................................... 96
8.9 Determination of acid detergent lignin-Fibertec system ................... 97
8.10 Determination of acid detergent lignin-Ankom 220 fiber analyzer ..... 97
9.0 Analysis of molasses .......................................................................................... 98
9.1 Determination of density in degree brix ............................................ 98
9.2 Determination of sulphated ash .......................................................... 101
9.3 Determination of total reducing matter .............................................. 101
10.0 Mineral analysis ................................................................................................... 106
10.1 Determination of moisture ................................................................... 106
10.2 Determination of total ash ................................................................... 106
10.3 Determination of calcium, copper, iron, magnesium, manganese,
potassium, sodium and zinc - using Atomic Absorption
Spectrometry ......................................................................................... 107
10.4 Determination of calcium – Precipitation method ............................. 111
10.5 Determination of phosphorus – Precipitation method ...................... 112
10.6 Determination of phosphorus – Photometric method ...................... 113
10.7 Determination of available phosphorus .............................................. 114
10.8 Determination of iron – Colorimetric method ................................... 115
10.9 Determination of copper– Colorimetric method ................................ 116
10.10 Determination of manganese– Colorimetric method ........................ 117
10.11 Determination of cobalt– Colorimetric method ................................. 118
10.12 Determination of zinc– Colorimetric method ..................................... 120
10.13 Determination of fluorine – Distillation method ................................ 122
10.14 Determination of fluorine - Ion selective electrode method ............ 123
10.15 Determination of iodine - Titration method ....................................... 124
10.16 Determination of iodine - Ion selective electrode method .............. 125
10.17 Determination of sulphur ..................................................................... 126
11.0 Analysis of bypass protein and fat supplements ........................................... 127
11.1 In vitro determination of degree of protein protection in
bypass protein supplement ................................................................. 127
11.2 In sacco digestibility determination .................................................... 128
11.3 Determination of protein-bound formaldehyde ................................. 129
11.4 Amino acid analysis by hydrolysis method ....................................... 131
11.5 Total fat extractions using acidic chloroform: methanol (2:1 v/v)
method ................................................................................................... 132
11.6 Fatty acid analysis of feed ................................................................... 133
11.7 Fatty acid analysis of milk ................................................................... 134
11.8 In vitro determination of degree of protection in bypass fat
supplement ............................................................................................ 135
11.9 Determination of acid value ................................................................ 137
11.10 Determination of saponification number ............................................ 137
11.11 Determination of free fatty acids ........................................................ 137
12.0 Estimation of gross energy in biological samples using bomb calorimeter ..... 138
12.1 Gross energy of feed and faeces ....................................................... 139
12.2 Gross energy of urine .......................................................................... 140
12.3 Gross energy of milk ............................................................................ 140
13.0 Analysis of strained rumen liquor (SRL) .......................................................... 143
13.1 In vitro gas production technique ...................................................... 143
13.2 Estimation of volatile fatty acids ......................................................... 146
13.3 Estimation of total volatile fatty acids by GC .................................... 147
13.4 Determination of total nitrogen in SRL .............................................. 148
13.5 Determination of TCA precipitable nitrogen ...................................... 150
13.6 Determination of lactic acid in SRL .................................................... 150
14.0 Urine analysis ...................................................................................................... 152
14.1 Determination of allantoin - Colorimetric method............................. 152
14.2 Determination of uric acid by uricase method .................................. 154
14.3 Estimation of creatine and creatinine ................................................. 155
15.0 Estimation of Aflatoxin B in feed .................................................................... 156
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15.1 Estimation of Aflatoxin B - HPLC method ......................................... 156
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15.2 Estimation of Aflatoxin B - Elisa kit method .................................... 157
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15.3 Estimation of Aflatoxin B - TLC method ........................................... 162
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15.4 Estimation of Aflatoxin B - Modified Romer's method .................... 163
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16.0 Vitamin analysis .................................................................................................. 165
16.1 Determination of vitamin A - using HPLC ......................................... 165
16.2 Simultaneous estimation of vitamins A & E – HPLC method .......... 168
16.3 Estimation of vitamin D – HPLC method ........................................... 169
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17.0 Estimation of organochlorine pesticide residues – GC method.................. 171
18.0 Estimation of methane emission in ruminants by sulfur hexafluoride
tracer technique ................................................................................................... 173
References ............................................................................................................ 178
PART – III
APPENDICES
Appendix - I Compounded feeds for cattle – specification
(Fifth Revision; IS 2052 : 2012) .......................................................... 179
Appendix - II Mineral mixtures for supplementing cattle feeds – specification
(Fourth Revision; IS 1664 : 2002) ....................................................... 180
Appendix - III Specification for compounded feeds for young stock
(IS 5560 : 1970; Reaffirmed 1980; Reaffirmed 2004) ....................... 181
Appendix - IV Bypass protein feed for cattle – specification
(First Revision; IS 14325 : 2012) ......................................................... 182
Appendix - V Urea molasses block as ruminant feed supplement – specification
(IS 13451 : 1992) .................................................................................. 183
Appendix - VI Specification for cane molasses (IS 1162 : 1958) ............................. 184
Appendix - VII Specification for livestock feed ingredients ....................................... 185
Appendix - VIII List of cattle feed plants under dairy cooperatives .......................... 187
Appendix - IX Abbreviations ........................................................................................ 193
Appendix - X Glossary of terms ................................................................................. 194
Appendix - XI Conversion factors used in general analysis work ........................... 199
Appendix - XII Weight-unit conversion factors ............................................................ 201
Appendix - XIII Weight and other measurement equivalents ..................................... 202
Appendix - XIV Atomic weights ..................................................................................... 203
Appendix - XV O.D. conversion table ........................................................................... 206
LIST OF FIGURES
Fig No. Figure Name Page no.
1.0 Cattle feed plant ................................................................................................... 3
1.1 Sample storage room .......................................................................................... 4
1.2 Generation of analysis report ............................................................................. 14
1.3 Finished products should be tested before delivery ....................................... 15
2.1 Finished product .................................................................................................. 15
2.2 Lesser grain borer ................................................................................................ 18
2.3 Rice weevil............................................................................................................ 18
2.4 Warehouse beetle ................................................................................................ 18
2.5 Flat grain beetles ................................................................................................. 18
2.6 Grain moth ............................................................................................................ 18
2.7 Confused flour beetle .......................................................................................... 18
2.8 Grain storage silo ................................................................................................. 20
3.1 Controlling a plant operation .............................................................................. 21
3.2 Dumping of maize grain...................................................................................... 22
3.3 Computerized batching ........................................................................................ 23
3.4 Pre-weighing bins ................................................................................................ 23
3.5 Hammer mill ......................................................................................................... 24
3.6 Batch mixer .......................................................................................................... 24
3.7 Homogeneity is function of mixing time ........................................................... 25
3.8 Molasses storage tank ......................................................................................... 25
3.9 Molasses mixing .................................................................................................. 25
3.10 Better the pellet, better the performance .......................................................... 26
3.11 Pelleting improves digestibility of feed.............................................................. 26
3.12 Pellet mill .............................................................................................................. 27
3.13 Cyclone ................................................................................................................. 27
3.14 Filling of cattle feed in a bag ............................................................................. 28
3.15 Aspiration system ................................................................................................ 29
3.16 Computerized control using LCF ........................................................................ 31
3.17 Factors affecting pellet quality ............................................................................ 35
3.18 Uniform pelleting should be desirable .............................................................. 36
3.19 Compound cattle feed ......................................................................................... 37
3.20 Pellet durability tester .......................................................................................... 38
3.21 Moisture meter installed in a conveyer ............................................................. 39
4.1 Ruminal degradation of protein .......................................................................... 41
4.2 Bypass protein feed manufacturing plant ......................................................... 42
5.1 Mineral mixture manufacturing plant ................................................................. 46
5.2 Ball mill ................................................................................................................. 48
5.3 Ribbon mixer ........................................................................................................ 48
5.4 Storage silo .......................................................................................................... 49
6.1 Animal nutrition laboratory ................................................................................. 53
6.2 Commonly used laboratory safety signs ........................................................... 55
6.3 Chemical rack ....................................................................................................... 57