CA1300421C - Animal feed block and packaging method - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

A method of preparing an animal feed supplement in solid block form. An aqueous feed solution containing aqueous solutions of sugars or proteins or mixtures thereof and mixed with solidifying and nutrient ingre-dients to prepare an aqueous supplement liquid which con-tains from 10 to 35 weight percent water. A plastic bag formed of a water soluble plastic film having a thicness from 0.5 to 10 mils and formed of polyvinyl alcohol, polyvinyl acetate, ehtylene-vinyl acetate copolymers or alkyl cellulose eaters is placed into a vertical-walled form. The aqueous feed supplement liquid mixture as poured into the plastic bag. The mold containing the feed supplement is stored to permit its contents to soli-dify. The vertical-walled form is stripped from the resultant solid block to recover a solid block entirely covered by said plastic film.

Description

:~3U~421 ANIM~L FEED BLOC~ ~ND PAC~GING METROD

This ln~entlon relates to an animal feed supplement and, ln particular, to a preser~ati~e coating for a solid anioal feed supplement, and a method of packaglng the solid supple~ent.

Molasses has been used for man~ yesrs ss an ani~sl feed suppleDent together vlth additi-es such as phosphoric acid and feed nutrlents auch as urea, fats, and the like. Solid aterisls such as cottonseed ~eal hs~e al80 been ~uspended in the olasses; ho~e~er, difficulties ha~e been e~perienced ~ith aintslning a stable suspension of solld ~sterials. The liquld supplements ha~e been fed b~ application to fodder or b~ free choice feeding on lic~-~heels.
Feed supplements have also been Danufactured and marketed as solid blocks. The earliest blocks were pressed blocks which were formed by compressing Dixtures of molasses and dry in8redients. Poured blocks, in which the ingredient~ sre mixed with molasses and poured into containers where they 2~ solidify, are more recent de~elopments. The earliest commercisl poured block was prepared bg evaporati~e heating of molasses similar to candy manufacturing as described in U.S.
Patent 3,961,081. Thls block lacked water resistance, and melted at ele~ated storage temperatures.

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13(~4Zl The ~o~t recent ad~ance~ ln ~upplement blocks have been the poured chemlcal blocks, ln ~hlch addltl-es are used to gel olasses and form ~ater-reslstance ~ollds. Large a~ounts of calcium oslde or sgnesium oslde ha~e been added to Dolasses and the DiStures ha~e been heated to form aolld Aupplements in the oanner described ln New Zealsnd Pstent Speclflcstlon No.
170,505.
Entirelg chemlcall~ gelled and hardened poured blocks and their ~Isnufacture are described in U.S. Patents 4,027,043, 4,160,041 and 4,431,675. These blocks are prepared b~ the reaction of Dolasses, a soluble phosphate ant the oside or aoluble aalt of calclu~ and/or agneslu~. No heatlng 18 re-qulred and the liguid ~isture is poured lnto cardboard contalners for solldiflcatlon. Ma~lmum hardne~s 18 attalned lS bJ uslng both calclu~ and oagneslum osldes.
~nother ~ethod of anufscture of a poured block is described ln U.S. Patents 4,171,385 and 4,171,386 in ~rhich the oolssses is gelled with clay which is added with high shear egitatlon. Magneslum oxlde ls sdded to the llquid mixture and the hardness of the block can be increased bg the addition of ferrous sulfate, as described in U.S. Patent 4,265,916.
These prior products ha~e been used for free choice feeding of cattle on ranges or in pastures and are too hard for feeding cows in a dairy or to beef cattle in a feed lot.
Also feed lngredients guch as godium carbonate or bicarbonate cannot be included ln these blocks without affectin~ their qualitg.

13004Zl Vnfortunatel~, all the afore-~entloned ~upplement blocks are affected to so~le degree b~ the en-lron-lent. Usuall~ the blocks lose from 1 to about 5 welght percent Dolsture ln the few ds~s l~medlatel~ followlng thelr rlanufacture. In hot, dr~
cllulates, further 1088 of water can occur, to the estent that the block~ shrink end crack, resultlng ln an unattractlve appearsnce. ~lhen e~posed to elevated storage temperatures snd hlgh huDldlt~, mold can also de~relop on the 6urface of the blocks, usuall~ startlng at the surface interface bet ~een the 1~) cardboard bo~ ~nd the block.

Thla lD-entlon co-prlses pourlng aqueous, liquid block lngredlents lnto a contalner for-led of a thln fllD of 8 water soluble plastic. Surprlsingl~, lt ha6 been found that the llquld feed ni~ture can be poured directl~ into a container of a wster soluble plastic film and the container will retain the llquid until lt solldlfles.
The container of H water soluble plastic is a preformed ba8 with a w811 thickness from 0.5 to about 10 mils, preferably from 1 to about 5 mils. The liquid mixture of in8redient6 i8 poured into the plastic bag ~hich can be supported in A surrounding mold that i6 removed after the ingredients ha~e solidified. The size of the mold can be ~aried o~rer wide limi ts, from 1 to about 750 pounds, to prepare the most con~enient feeding size for the particular application. Small, individual blocks, each weighing from 1 to about 5 pounds can be prepared for a ~ingle day feedin8 of 13UC)421 an indlvldal anl-al. ~lternatl-el~, large block~ frorl 20 to about 750 pouds can be prepared for free-cholce feedlng by a nu~ber of anirlals. The block larket 18 tJplc~llJ aupplied wlth blocks of 40 to 60 pounds, 250 pounds, and 500 pounds, esch, and such sizes are also preferred when uslng the plastlc fllm packaglng of thls ln~entlon.
Thls lnventlon also lncludes preparstlon of a buf fer-containing, solld, animal feed supplement vhich has the proper hsrdness and palatlbilit~ to achie~le a dail~ anlmal consu-ption of 0.2 - 0.5 pound of sodiun csrbonate or bicarbonste and 0.07 - 0.15 pound of agnesluo o~ide ~ith free cboice feedlng. The feed supplement is a solldified nisture of arlous feed lngredients ~ith a feed solutlon of sugsrs or proteins, end oistures thereof. The supplement 18 solldified b~ sodium carbonate, bicarbonaee, or a ~1%ture thereof, and agneslu~ oside. The l~tter additl~es thus serve the dusl purposes of solidlf~ing the feed supplement and pro~riding the desired buffer for the animal. The concentration of these additive6 i6 from 8 to 25 weight percent sodium carbonate, blcerbonate, or 0i%tures thereof, and from 2 to about 5 weight percent msgnesium oxide. Other feed ingredients can also be included, such as from 1 to about 35 weight percent natural protein feeds or equivalent proteins such as urea, biurea and ammonium salts. Fat from either animal or plant sources can be lncluded in an amount from 1 to about 20 weight percent.
Calclum and/or phosphorus addltives can be included such as cslcium carbonate, dicalcium phosphate, defluorinated 13~)()4~1 phosphate rock, etc., ln amount~ ~ufflclent to pro-lde fro~
0.5 to 1.5 velght percent calclum and from 0.5 to 1.5 velght percent phosphorus ln the flnal product. Vlta~lns and trace ninerals can also be lncluded.
~hen the buffered supplement block is pro~lded to anlmals vhich are not fed a hi8h volume grsin and forage diet, lt may be necessar~ to increase the hardness of the block to li01t consumption. The hardness of the block can be ad~usted to any desired ~alue b~ the inclusion of either, or both, phosphoric acid and li-e (or calcium h~dro~ide) in amounts from O.S to 5 ~ei8ht percent, each.
Other feed ingredients can be lncluded ln the liquld lrture before it is poured into the plastic filD container.
~ ples of these feed lngredients lnclude ~ ~ource of protein ln an amount from 1 to about 35 veight percent. Protein aources include natural protein feeds such as so~bean ~eal, cottonseed eal, rape seed meal, sunflower seed ~eal, corn gluten meal, etc. vhich contain proteins at relativel~ high concentratlons, e.g., from 10 to about 35 weight percent.
2~ Lower grade protein source6 such as ground rice hulls, ground oat hulls, ground almond shells, ground walnut shells, etc.
can also be used, as well as ground or cracked grains, e.g., cracked corn, oats, etc. For ruminants, equivalent protein sources can be used such as urea, biurea, and ammonium salts, alone, or in admi~ture vith the aforementloned naturfll proteins. Also, products rich in "by-pass~ protein can also be used such as bloodmeal, feather meal, etc. These are relati~el~ hi8h in protein content, from about 75 to 90 .

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percent proteln and are used at lo~er content~ ln the block mixture, e.g., from ~bout 1 to About 10 welght percent.

THE FEED SUPPLEMENT
The feed supplements which are used for pr~ctlce of thic ~n~ention, in genersl, hsve the composltlon set forth ln the followin~ tsble:
Table 1 In8redient Concentration ln Final Product (Weight Percent) Brosd Preferred Feed Solution 30-90 50-80 Sodium carbonate(l) 8-25 12-18 Magnesium oside 2-5 3.5-5 Protein or non-protein nitrogen(2) 1-35 5-20 Fat 1-20 2-8 Vitamins 0-3 0.1-2 Minersls 0-4 0.1-2 Phosphorus source 0-8 1-3 C~lcium source 0-8 1-3 Hsrdenlng sgents(3) 0-10 0-6 (l)sodium csrbonste, bicsrbonate,or mi%ture thereof ~23~expressed ~8 equlYslent pro~ein Jcalcium oxide or hydroxide, snd/or phosphoric scid These supplements contain from 10 to 35 percent water, 2~ preferably from 15 to 28 percent water. Water is a component of the above ingredients such as the feed solutions. Where necessary, water can also be sdded as an ingredient to obtain the desired wate content in the final supplement.
The content of minerals, phosphorus snd calcium, as well as other in8redients such as drugs, Yitamlns, etc., can be varied as desired for specific applications. Examples of 13~)4Zl various minerals are manganese, iodine, zinc, copper, cobalt and iron compounds. In some specific applications, a high content mineral supplement iB desirable, e.g., containing from 6 to 10 percent phosphorus, 5 to 8 percent calcium and from 0.1 to 2 percent of mineral salts, added as finely divided powders. These salts can be water insoluble salts such as dicalcium and tricalcium phosphate or can be water soluble salts such as monammonium phosphate. Examples of vitamins include Vitamin A, Vitamin D, and Vitamin E.
Examples of useful drugs are: growth promoting food additives or drugs such as monensin and sodium monensin, commercially available under the trade mark Rumensin from Eli Lilly Co.; chlortetracyline and sulfamethiazine; and mixtures of chlortetracycline and sulfamethiazine; etc.
Other useful drugs include antiblat and antihelmintic agents as well as insect control agents. The aforementioned materials are used in effective concentrations for the desired result, e.g., drugs are used at concentrations from 0.5 to about 1.0 weight percent.
The minerals are usually used in similar concentrations, but are often expressed in amounts from 3 to about 500 milligrams per pound and vitamins are frequently expressed from 10 to about 50,000 units per pound.

THE FILM COATING
The blocks are surrounded by a film of a water soluble plastic such as polyvinyl alcohol, polyvinyl acetate, ethylene-vinyl acetate copolymers and alkyl cellulose esters. These films are edible. Of the aforementioned, films of 13(t~421 polyvinyl alcohol are preferred ~8 these are generally recognized as safe packaglng materlals for food products. ~s desired, or necesssry, the polyvlnyl alcohol can be strengthened by the inclusion of from 5 to about 40 weight percent glycerol. Films of poly~lnyl alcohol ~/ill slowly dissol~e in weter at ambient temperatures and ~111 rapldly dissolve st temperstures of 150-F or greater. Desplte this solubility, ~e have found that the equeous oisture of ingredients can be poured into and retained ln contsiners of the plastic at elevated terlperatures. This permits the use of these contsiners to package the supplements vhlch are poured lnto the contsiners at the elevated teoperstures esperienced during their preparation, ~hich for ost auppleoent formulations, is from 110- to 135F. Althought the ~upplement oistures are aqueous suspensions and are poured into the pla~tlc containers at such elevated temperatures, the plastic containers will retsin the supplements. After the supplements solidify, the plastic film containers protect the supplement by retaining moisture and preventing growth of mold.
2~J A microcide and/or insecticide in8redient csn be included in the plastic fi lm. This can be an in8redient having a specific activity for the particular microorganism which is to be controlled, including bactericides and fungicides. The microcide is included at an effective concentration which is preselected for each gpecific microcide and is generally from about 0.0001 to about 2 weight percent.
The plastic film has a thickness from about 0.1 to about 10 mils, preferably from about 0.5 to about 5 mils, and most 130 (1421 preferabl~ from 1 to a~out 3 all~. Thla fllo ls preformed lnto a ba8 and the ba8 i8 preferabl~ supported in a rlgld mold to impsrt uniform slze and shape to the finlshed block product 8 .

THE FEED SOLUTION
The animal feed supplement 18 preared froo a commerclal aqueous feed solution. Generall~, thls will be a sugar solution, and a variety of sugar solutions can be used;
however, ~olasses i8 a preferred source. The feed solution should be present in the feed supplement at a concentration of from 30 to about-9S, preferabl~ from 50 to about 80, ~ei8ht percent. The preferred ~olasses ~ource is com~ercially available ~ith a sugar content from about 65 to 85 Bri~ and a consistenc~ that varies from a thin to 8 thick s~rup. The ~ater content of these solutions is from 5 to about 30 weight percent. The colasses can be an~ sugar containing molasses such as cane or Blackstrap Molasses, beet molasses, conYerted molasses wood sugar mola6ses, hydrosyrup, cltrus colasses snd the llke.
2() ~nother 6ugsr solution that can be used is ~hey, 8 by-product of the dairy industrg. The whey is a dilute sulution of lactoalbumin, lactose, some fats, and the 601uble inorganlcs from the parent milk. This whey solution is condensed and spray dried to a powder or is condensed to about 40 to 60 percent 601ids and preserved. ~ typical analysis is as follows:

130~Zl Table 2 Compositlon of a T~plcal Drled Whey Proteln 12.0%
Fat 0 7%
Lactose 60.02 Phosphorous 0.79~
Calclum 0.87%
Ash 9 7%

~ third source of a useful sugar solutlon ls the pulp and paper industry which produces large quantities of by-product lignin sulfonates from wood during the sulfite pulpin~

process. After the separation of lignln, the scidit~ of the resultant solution is neutraliYed ~ith sn ammonlum or alkali etal bisulfite compound or base to form the follo~lng organic ~alts:
Ammonium lignin sulfonate;

Sodium lignin sulfonate; and Magnesium lignin ~ulfonate.

A tgpicsl analysis of a commercially available ammonium lignln sulfonate solution is as follows:

Table 3 .
2~ T~pical Anal~sis of Ammonium Li8nin Sulfonate Percent Solids 50~
Specific gravity 1.237 pH, 102 solution 3.5 Sugars - e~pressed as glucose16.0Z
-Tannin content 45.0%
Available ammonia 3.0 Sulfur 6.0 Ash 1 ~

~3V~)4Zl The ~ug~r solutlon 1~ the energ~ lngredlent of the ~uppleoent. Sources of other etabollz~ble org~nlc alues can be used to replace a portlon of the sugar solutlons. ~samples of ~uch other useful energ~ lngredlents sources lnclude con-densed and deh~drated molasses solubles whlch are obtained from the fermentation of molasses to produce chemlcals such ss ethanol, cltric acid, glutsmlc scld, etc. A materl~l rich ln etabollzable ~alues, known as condensed molasses solubles, ls obtained b~ evaporatlon of the residue from this fermentation.
This msterial can also be deh~drsted to dr~ness and the resul-tsnt dr~ solld 18 also A useful addlti-e. Another er~ useful feed solutioD is a coDdensed or concentrated fer~ented corn e~tract, ~hlch is aonetlmes referred to as corn ~teep llquor or azoferm. This aterlal is obtslned br concentratlng the liquid remalnlng after steeplng corn in an aqueous sulfur dlo~ide solutlon and allowing it to fernent. These materials can hsve from 40 to 100 percent solids and contain, on a dr~
weight bssls, from 1 to 15 percent sugar and contain signi-ficant contents of proteln, e.g., from 5 to sbout 25 percent.
~11, or sn~ portlon of the aforementioned sugar solutions can be replsced with these feed solutions, depending on the smount of nstural protein which is desired in the finsl supplement.
THE BUFFER INGREDIENTS
The buffer ingredients, which also serve to solidify the feed supplement, sre sodium csrbonate, sodium bicarbonste and mixtures thereof, and magnesium oxide. The carbonate i6 the preferred csrbonate source ss it is readil~ availsble and less costly than the bicarbonate. ~lso, the alkaline carbonate 13~)Q42~

neutrallres the aclds commonly present ln nolasses and 18 thereby converted to 8 ml~ture of bicarbonate and carbonate.
Other sources of the buffer lnclude sodlum sesquicarbonate, ~hich is a hydrated cerbonate snd bicarbonate double salt.
C~rbonate ores such as trona ore, whlch can contaln up to 25 weight percent impurities, can 81BO be used provided they 0re of sufficient concentration and do not contsln any toxic lmpurities. The carbonate/bicarbonate ingredient i6 used in sn amount from 8 to 25, preferably from 12 to 18, weight percent of the supplement.

The secoDd buffer ingredient which can be used is agnesium oxide. Preferably the agnesium oxide has a ~oderate to high reactivity, aB ~easured b~ the time required to neutralize 8 standsrd citric acid solution. ~cceptable ~agnesium oxides exhibit neutralization times in this standard test which are from 10 to about 150 seconds, preferably from 10 to about 90 seconds. The magnesium oxide can be used in an amount from 2 to 5, preferably from 3.5 to 5, welght percent of the supplement. It ls also preferred that the weight proportion of magnesium oxide to the carbonate/bicarbonate be from 1/4 to 1/2, preferably about 1/3. When used in these proportions, the buffer ingredients have the most desirable pH
value, and are the most effective as a rummen buffer.
THE PHOSPHATE AND CALCIUM INGREDIENTS
When the supplement blocks are free-choice fed to animals on a hi8h volume diet, their hardness as measured by a laboratory durometer should be about 20 to 45 units. ~hen the upplement l~hould al~o contaln dletarJ a-ount~ of pho~phoruR
and/or calclum, ~ultable eources are dlcalclum phosphste, defluorinated phosphate rock, calclum carbonste, g~psum, etc., all havlng llmlted water eolublllty. When the blocks should hs~e ~ hardness of 60 unlts or greater (as nay be required ~hen fed to snlmals on low to r~oderate ~olu-le dlets whlch vould o~erconsume the softer block), water soluble snd reac-tl~/e 60urces of phosphate snd/or cslclum csn be used 8Shsrdening sdditi~es.
The phosphstes vhich csn be employed as hardenlng a8ents lo the feed ~upplelDent block can be phosphoric acid or any soluble eslt thereof, ~ith the acld belng preferred. Examples of useful phoaphates lnclude the slksli n~etal snd a-lnonlum salts, e.g., eodlum phosphate, potassium phosphate, or anr~onlum phosphate. The preferred hardenlng a8ent 18 phosphorlc acid vhlch can be of any commerclall~ a~allable 8rsde from 50 to 98 percent acid. When necesssry to lncrease hsrdness, the phosphste 1B emplo~ed ln the 6upplement st a concentration from about 0.5 to about 5.0, preferably from O.S
23 to about 3.0 weight percent, expressed ss P205 Calcium sources ~hich can be used ss hardenin8 agents can be cslcium o%ide or hydroxide. Commercially available lime, calcium oxide, i8 useful ln finely subdivided form, typically 90 weight percent or more ps6sing a 125 mesh screen. The more 2~ finely subdi~ ided the lime, the fsster that it will hydrste and participate ln the solldlflcatlon of the supplement. The llme csn be slaked by mixing with water prlor to addltlon to the sugar solution, or if desired, can be added directly to 4Zl the aqueous sugar solutlon, dependlng on the proce~s equlpment snd controls. When necessnry to increase hardness, the amount of the calclum o~lde or h~dro~lde lngredlent ~/hich is employed can be from 0.5 to about 5.0 /eight percent, e~pressed as the oside, and preferabl~ ls from sbout 0.5 to about 3.0 welght percent based on the weight of the sugar solutlon.

THE PROTEIN SOURCE
The feed supplement can al80 contain a nitrogen source for the snllDsl's protein requirements. The nitrogen can be in proteins ~/hich are commonl~ found in srious sources such ss:
trled blood and oeat meal froo renderlng plsnts, cottonseed esl, ~o~ Deal, rspe seed oesl, sunflower seed neal, dehydrsted alfslfs, drled and sterilized snimal snd poultry oanure, fish ~eal, liquid or powdered egg, fish solubles, cell creaD ~Ind rabbit pellets. When the feed supplement is lntended for consumption by rumlnants, 8 non-proteln nltrogen compound such as ammonlacal compounds, e.g., urea, biuret or mono- or di- ammonium phosphates can be used to supplement the protein reguirements The preferred non-protein nitrogen source is 2~1 urea ~hich can be ~dded in an amount from 2 to about 15 weight percent, preferablg from 5 to 12 weight percent, based on the supplement. In some applications, it is preferred to use all natural protein, and in such instances, a vegetable meal such as cottonseed meal, soy meal, rape seed meal, corn gluten meal, etc. can be used.

``` 13Q04Zl The follovlng exaaple~ lllu~trate prdctlce of the lnventlon snd vlll serve to demonstr~te results obtalnable therevith.

Exsmple 1 Buffer-contalning feed supplement samples are prepsred b~
mi~ing together the follovlng ingredlents:
Content (Weight Parts) In~redient No 1 No 2No.3 No 4 No 5 .
1. Molssses 470 470 470 470 470 2. Ures 20 20 20 20 20 3. ~ster 100 100 100 100 100 10 4. Sodlum Carbonste150 ~ __ 150 5. Sodium Sesgulcarbonate -- 150 -- -- --6. Sodlu- Blcarbonate -- -- 150 -- --7. ~agneslu- o~lde 50 50 50 50 --8. Corn gluten 80 80 80 80 80 9. Feather eal 50 50 50 50 50 10. Dicalciu- phosphste50 50 50 50 50 11. Fat (ao~ oll) 30 30 30 30 30 The supple~ents are prepared by stlrring the misture of molasses, vster and ures and addlng the selected csrbonste buffer (Ingredlent 4, 5 or 6) vhile contlnuing to stlr the 0ixture. ~fter the csrbonste iB completely dispersed, the msgnesium oxide iB sdded snd the mixture is stirred. ~he remsining ingredients are then sdded, the mi~ture is stirred 2~ to disperse these ingredients, and the liquid mixture is poured into smsll csrdbosrd boxes.
~11 of the mlxlng of the ingredients is done st smbient tempersture (70-F.). ~ slight increase in temperature is observed and the temperatures of the final mi~ure, before pouring, are also recorded snd presented belo~. The bo~es are plsced in a laborstor~ o~en msintained at 120-F. to simulste the temperature expected in plant prsctice of the in~ention~

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After 24 hours, the samples are removed froo the oven and the following hardness values are observed, when measurlng the surface hardness wlth a durometer havlng a small dlameter pln:

No.l No 2 No.3 No.4 No.5 Pour Temperature (-F) 108 106 100 90 86 Rardness 60 40 20 12 <2 Samples 4 and 5 were too soft for spplication as even well-fed cattle would be e~pected to overconsume supplement blocks having these hardness values. These blocks were sufficiently soft that one could easil~ push one's fin8ers lnto the product.
Saople 2 had acceptable hardDess for free choice feedin8.

Sample 1 vould be acceptable, hovever, it ~a~ have llDited consumptinn lf fed to anl~als on a high volume diet of other feeds. Sample No. 3 vould be Darginsll~ acceptable, however, over-consumption could be e~pected in ~an~ applications.

The dlrect relatlonship between hardness and percent of the carbonate added as bicarbonate, which is apparent from a comparison of Samples 1-3, provides a control useful for final adjustment of the hardness to fit a particular feedin8 2'J situation. Thus, if the animals do not consuoe sufficient quantities of the block formulated with sodium carbonate as ssmple No. 1, some of the sodium carbonate can be replaced with sodium bicarbonate, softening the block.

Example 2 ~5 The procedure of E~ample 1 was repeated to prepare se~en addltional samples. These samples had the following compositions:

13~Q4Zl Content (Welght Parts) No. No. No. No. No. No. No.
Ingredlent 7 8 9 10 11 12 13 Molasses 470 470 470 470 470 470 470 Water 100 100 100 100 100 100 100 ~rea 20 20 20 20 20 20 20 Sodlum carbonate150 150 100 100 75 75 50 Magnesium o~ide 40 30 50 35 50 25 30 Di Calcium phosphate 50 50 50 50 50 50 50 Corn gluten 80 80 80 80 80 80 80 Feather oeal 50 50 50 50 50 50 50 Fat 30 30 30 3 The pour teoperatures, contents of sodium carbonate and lU magnesiuo oside, snd the hardness alues of the blocks after 24 hours storage at 120-F. sre as follows:
No. No. No. No. No. No. No.
Ss-ple 7 8 9 10 11 12 13 Pour temperature, F: 95 96 103 106 96 93 92 Sodiuo Carbonate 15 15 10 10 7.5 7.5 5 Magneslu~ oslde 4 3 5 3.5 5 2.5 3 Hardness 40 30 40 20 25 <2 <2 Samples 12 and 13 are unacceptable, snd sample6 10 and 11 are marglnally acceptable for free choice feeding.

13V~42~

~sa-ple 3 The procedure ~as repested vlth the formulatlon of Sample No. 13, howe~er, llolted ~00unt6 of llDe and phosphorlc Hcld ~ere lncluded. The for0ulatlon ~as as follovs:

Content (Welght Parts) Ingredlent No 14 water 100 ll~e 10 ~olasses 470 urea 20 phosphoric acld 20 sodium carbonate 50 agnesius o~ide 30 eorn gluten 80 feather oeal 50 dlcalcium phosphate50 fat 30 The wster and li-e are i~ed to h~drate the line, and the olasses and urea are then added. ~fter these ingredlents are oi~ed b~ stirring, the phosphoric acid 18 added and after it 18 neutrsllzed, sodlum carbonate i8 added and the 0i~ture ls stirred. Magne~iu~ o~lde is then sdded. ~fter stirrin8 the oagne~ium o%ide lnto the llquld, the reoaining ingredlents are added. The pour temperature of the liquld is 106F.

~fter 24 hours at 120F. the laboratory sample is 2() lnspected and obser~ed to ha~e a hsrdness value of 20, thus lndlcsting that the lime snd phosphoric acid significantly increased the hsrdness from that obser~ed for sample No. 13.

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Ex~sple 4 A feed ~upplement i8 produced ln commerclal quantltles ln a conmerclal plant olxer. The followlng lngredlents are l~ed lnto the supplement:
InRredientContent (~elRht Percent) Water 10 0 Molasses 47.6 Urea 1.3 Sodlum Carbonate15.0 Magnesium Oxlde5.5 Corn gluten 8.0 Feather nesl 5.0 Dicalclum phosphate 5.0 Fat (So~ oil) 2.5 ~ita-ln ix 1.0 The foroulation provided the followlng nutrients:

Crude Protein 14.0 NPN not ore than 3.8 Calcium 1.2 Phosphorus 1.1 Carbonate buffer~ 17.0 ~agneslum oxide 5.5 Fat _ 2.5 ~a oi~ture of carbonate-bicar~bon~a~të hydrated salt The ingredlent6 were mi~ed ln a plant batch lxer uslng the procedure of addltlon of Example 1. After 811 the lngredlents had been added, the temperature of the final 2~ mixture wa~ 102F. The ml~ture was poured into 250-pound cardbosrd molds which were lined with bags of polyvinyl alcohol film having a thickness of 0.002 inch. After filling, the plastic film was folded across the top surface of the supplement, and the molds were covered and moved into a ware-house. During storage ovrnlght, the temperature of the supplement mixture ln the molds reached a maximum value of 165F After overnlght storage, the cardboard molds were removed and the solid supplement block was entlrely ~ealed in ~o~

ehe pla6tic fllm. The solld supplement had a hardness value of 35.
The resultant blocks were fed, free-choice, to a test group of hlgh producing Holstein COW6, milked three tlmes daily and on a full feedlng progrHm. Si~ pens of cows were provided with the supplement block; one pen contained 80-90 fresh cows; another pen contalned 100 cows with at least 100 days ln lactation; three pens contalned 78 mature milking cows each; and two pens contained 78 firat-cslf-helfers each. A
~ooden fruit bin 4 feet ~ 4 feet and 3 feet high was placed in each pen and four to fi~e supplement blocks vere placed ln each bin, and replenishet as consumed.
The cows consumed the supplement blocks at a rate adequate to supply from 0.2 to 0.3 pounds of the buffer lngredients per day to each cov. The lowest consumption vas by the fresh cows which consumed the block at an average rate of 0.84 pounds per head per day. This was e~pected, as during the progress of the test cows were moved from thls pen to the other test pens, and fresh cows, unfamiliar with the 2() supplement, were added to the fresh cow pen. The three pens of mature COW6 consumed the supplement block at a rate of 1.44 pounds per head per day; the pen of 100-lactation-day cows consumed the supplement block at the rate of 1.36 pounds per head per day, and the cows in the remaining pens consumed the supplement blck at a rate of 1.21 pounds per head per day.
The feedin8 test vas continued for one month.
Since the cows were under a full feedlng program wlth an ,, ,, ~ .

:13~ 4~:1 a~erage of elght fe~dlngg per da~ of ellage, hay and gr~ln, lt wa8 not e~pected that they would consume the block At the necessary rate of about 1.2 to 1.6 pounds per head per dey.
Contrar~ to e~pectations, the aforementioned consu-ptlon rate vas une~pectedl~ high and vas sufficlent to suppl~ the COWB
with the necessary quantity of buffers. The daily feedlng regimen W88 as follows:
Time RationQuantit~ Per head 0600 - 0630 grain mi~12.5 pounds corn silage 15.0 0730 - 1200 alfalfa 4.5 n 1400 - 1700 8rain nls12.5 n corn silage 15.0 n 2100 alfalfs 4.5 n ~ilageto e~cess of consumptlon The 8rain mi~ contained cottonseed meal, vhole lS cottonseed, shretded beet pulp, wet corn gluten, liquid oupple-ent and mineral mi~.
In addltion to the abo~e feedings, the cows were also fed a total of 10 pounds of steam rolled bsr1ey, consumed during the three mllkings each day. The sverage daily conQumption of 2u these feeds was 79 pounds per cow per day.
The formulation and hardness of the suppe~ent block pro~ided the proper pslatability to insure adequate consumption on a free-choice bssis under the most critical situation, l.e., with cows which were fed all they could est of other feeds - ~3(~(~4Zl ExamDle 5 ~ feed supplement 1B prepared by prehestlng nolasses to a teoperature of 150-F. The preheated molas6es 18 introduced into a ol~lng ~essel snd stlrred while addlng urea, magnesium oslde, calclum phosphste, ~alt and corn gluten meal ~t the following proportlons:
Table 6 Welght Ingredlnet Percent Holasses 70 Calcium Phosphate 5 l~ S~lt 3 Corn gluteD meal lo Magneslum oslde l2 The supplement 1B maintalned at 150F durlng nl~lng of the in8redients and 1B then poured dlrectly into bottomless c~llndrlcal molds llned ~ith plastlc bsgs formed from a film ~lth a thickness of 0.002 inch.
Each mold i8 formed of two hal~e6 whlch ~oin along the longitudlnal midllne of the assembled form. The ~oined edges ha~e contlnuous ed8e flanges whlch are clamped together to assemble the form. The forms are made of fiberglass reinforced plastic and are surrounded by an outer jacket of polystyrene fam insulation approximately I inch thick.
The forms rest on a smooth surface pallet snd the plastic ba8s are placed, one each within each form, with the top of each bag extending above the top of its form. Four molds are plsced on each pallet and the psllet is moved to the packaging statlon of the block plsnt.
After each bag is filled, the upper end of each bag is folded closed, against the top surface of the liquld contents ~ 3~a4zi ln the bag, and an adheslvl~ backed label 1~ applled over the folds.
Each pallet, vhlch ~upports four fllled ~olds, each contalnlng 500 pounds of block ingredients, is ~oved lnto a S heated stor0ge room, nalntained at 135-F. The Dext oornlng, the blocks are ~oved lnto the varehouse, the mold clamps sre released and the nolds are remo~ed, leavlng four glossy surfaced ~olasses blocks, each weighing 500 pounds, on each pallet. The blocks are co~pletel~ finlshed and read~ for ahlp~ent.

Example 6 ~ feed ~uppleDent la prepared b~ in8 vater and ll-e to prepare a slurr~ containlng 33 weight percent calcium, e~pressed as llDe. The h~dration of the line raises the alurr~ te~perature to 190F., and cane Dolasses iB then added to prepare a ~lxture ontslnlng about 84 percent cane molasses.
Dr~ urea and salt are then added, followed by magnesium oxide, corn gluten, and fat. The mixture is stirred for ten minutes 2~ and 1B then poured into bottomless molds llned with plastic bags ha~lng a 2 0il thickness. The molds have an octagonal cross section. The molds are approIimatel~ 20 inches tall and 22 inches in width, and each mold is filled with 250 pounds of supplement The molds are stacked on a pallet vith four ~olds on the pallet, filled and the top edges of the plastic ba8 in each mold are folded against the surface of the liquid contents and an adheslve label ls placed over the folded edges. A plywood dlvlder is placed over the molds and a ` 13UQ4Z~

second la~er of plastlc-bag-llned olds 18 ~tacked on the pl~ood dl-lder and fllled ln the aame manner.
The psllets are mo~ed lnto an unhested ~arehouse and the temperature of the supplements monltored. When the temperatures of the supplements ln the molds reflch 165-F, the lnsulalng ~ackets are remo~ed fromthe molds. The follo~lng mornlng the molds sre remo~ed, lesving pallets, each supportlng two la~ers of ~upplement blocks, four blocks ln eacb la~er. The blocks ha~e a gloss~ appearance and appear dark brown through the transparent plastic co~erlng.
The blocks ha~e the follo~ing lngretients:
Table 8 Welght Ingredient Percent Cane Molas~es 54.2 Corn Gluten Meal 14.0 ~ater 6.0 Ures 5.0 Fat 4.6 Salt 4 5 Magnesium 0%ide 4.5 Phosphorlc acld (75%) 4.0 Llme 3.0 Vitamins and Trace Mlnerals 0.2 The blocks are resdy for ~hipment into the feed distribution system wlthout any further treatment. Theg are supplled for free cholce feeding by placing one or more blocks at 6elected locations on catte range6, and the outer plastic fil~ is stripped from the blocks when they are placed on the range.
Since the blocks are hlghly ~eather resi~tsnt, they ~ithstand rslns ~ithout any significant loss.
The blocks also ha~e an extended storage life in the "` 13(~C)4Zl distrlbutlon ~stec. The plastlc outer co~erlng 18 lmpermesble to osygen Mnd the blocks can be stored under hlgh humldlt~ conditlons wlthout developlng an~ 001d. Slnce the plastlc outer co~erlng also reslsts ~olsture transfer, partlcularly at low humldlt~ condltlons, the blocks can also be stored under hot and/or dry condltlons wlthout esperlencing an~ ~lgniflcant loss of moi~ture and wlthout cracklng.
The lnvention ha6 been described with reference to the presentl~ preferred and lllustrated embodl~ents. It is not intended that the ln~entlon be undul~ llmlted b~ the dlsclosure of the preferred embodlments. Instead, lt ls inteDded that the ln-ention be deflned b~ the method steps, and lngredlents, and thelr ob~ious equl~alents set forth ln the followlng clalms:

Claims (27)

1. The method of preparing an animal feed supplement in solid block form which comprises:

(a) admixing an aqueous feed solution selected from aqueous solutions of sugars, proteins and mixtures thereof, with solidifying and nutrient ingredients to prepare an aqueous feed supplement liquid which contains from 10 to 35 weight percent water;

(b) placing a plastic bag formed of a water soluble plastic film having a thickness from 0.5 to 10 mils and formed of a plastic selected from polyvinyl alcohol, polyvinyl acetate, ethylene-vinyl acetate copolymers and alkyl cellulose esters, into a vertical-walled form;

(c) pouring the aqueous feed supplement liquid mixture into the plastic bag;

(d) storing the form containing the feed supplement to permit its contents to solidify; and (e) stripping the vertical-walled form from the resultant solid block to recover a solid block entirely covered by said plastic film.

2. The method of claim 1 wherein said feed supplement is poured into said plastic bag at a temperature from 43° to 57°C.

3. The method of claim 1 wherein said film also includes a microcide in an effective concentration from 0.0001 to about 2 weight percent.

4. The method of claim 1 wherein said mold is bottomless and is placed on a pallet and said plastic bag is placed within said mold.

5. The method of claim 1 wherein said mold is a cylindrical mold with a longitudial split and is joined along the longitudinal split into said vertical-walled form, and said step of stripping said form from said solid block comprises the steps of separating the joined longitudinal edges to spread the cold and remove it from the block.

6. The method of claim 1 wherein said plastic is polyvinyl alcohol.

7. The method of claim 1 wherein said plastic has a thickness from 0.001 to about 0.005 inch.

8. A method of feeding ruminants which comprises:

(a) preparing a solid feed supplement in block form having a total water content from 10 to 35 weight percent and consisting essentially of from 30 to 95 weight percent of a feed solution containing 40 to 95 percent solids of sugar, protein, or mixtures thereof and, solidifying and buffering ingredients consisting essentially of sodium carbonate, sodium bicarbonate, and mixtures thereof in an amount from 8 to 25 weight percent of said supplement, and from 2 to 5 weight percent magnesium oxide of said supplement;

(b) feeding said solid feed supplement to the ruminant for free choice consumption; and (c) controlling the free choice consumption of the feed supplement at a level from 1 to about 4 pounds per day by maintaining the quantities of said solidifying and buffering ingredients at the amounts sufficient to impart a preselected hardness to said solid feed supplement.

9. The method of claim 8 including the step of incorporation from 3.5 to 5 weight percent magnesium oxide in said supplement.

10. The method of claim 8 wherein said sodium carbonate, sodium bicarbonate or mixtures thereof are added in an amount from 12 to 18 weight percent of said supplement.

11. The method of claim 8 wherein a mixture of sodium carbonate and sodium bicarbonate is added in proportions from about 4/1 to 1/4 weight parts carbonate to bicarbonate, and said step of controlling the consumption of the feed supplement is practiced by adjusting the proportions of carbonate to bicarbonate which is added to said feed solution.

12. The method of claim 8 including the step of incorporating a nitrogen source in said feed supplement solid in an amount from 1 to 35 weight percent, expressed as protein.

13. The method of claim 8 wherein the non-protein-nitrogen content of said protein source is no greater than 90 weight percent of the total protein source, expressed as equivalent protein.

14. The method of claim 8 wherein said protein source comprises a ruminent by-pass protein.

15. The method of claim 8 wherein said by-pass protein is feather meal.

16. The method of claim 8 wherein said by-pass protein is blood meal.

17. The method of claim 8 wherein said by-pass protein is a mixture of corn gluten meal and feather meal.

18. A water resistant, solid, animal feed supplement in block form containing from 10 to 35 weight percent water, and consisting essentially of:

(a) from 30 to 90 percent of an aqueous syrup containing from 40 to 95 percent solids comprising a feed nutrient selected from the group consisting of sugar, protein, and mixtures thereof; and (b) solidifying and buffering ingredients consisting essentially of:
(i) from 2 to 5 weight percent magnesium oxide;
and (ii) from 8 to 25 weight percent sodium carbonate, bicarbonate, or mixtures thereof, whereby said supplement has sufficient hardness to permit free choice feeding.

19. The feed supplement of claim 18 wherein said magnesium oxide is added to said supplement in an amount from 3 to 5 weight percent.

20. The feed supplement of claim 18 wherein said sodium carbonate, sodium bicarbonate or mixtures thereof are added in an amount from 12 to 18 weight percent of said supplement.

21. The feed supplement of claim 18 wherein a mixture of sodium carbonate and sodium bicarbonate is added to said supplement in proportions from about 4/1 to 1/4 weight parts carbonate to bicarbonate.

22. The feed supplement of claim 21 wherein said protein source contains non-protein nitrogen in an amount no greater than 90 weight percent of said protein source, expressed as equivalent protein.

23. The feed supplement of claim 18 wherein a protein source is added to said feed supplement solid in an amount from 1 to 35 weight percent, expressed as protein.

24. The feed supplement of claim 22 wherein said protein source comprises a ruminant by-pass protein.

25. The feed supplement of claim 24 wherein said by-pass protein is feather meal.

26. The feed supplement of claim 24 wherein said by-pass protein is blood meal.

27. The feed supplement of claim 24 wherein said by-pass protein is a mixture of corn gluten meal and feather meal.