RU2338388C1 - Method of manufacturing complete extruded feed with filling - Google Patents

Abstract

FIELD: agriculture, food products.

SUBSTANCE: method implies preparation of initial mix out of the ground to 0.16...0.63 mm in size grains of corn, wheat and narrow-leafed lupin, then grass meal, sunflower cake, meat and fish meal are added with the specified ratio of components. The mix is aged for 4 hours in a hopper to equalise moisture throughout the total volume, then it is treated in a screw extruder with product temperature before a die equal to 398...433 K, screw rotation speed 1...2 s^-1 and pressure in the before-die extruder zone equal to 5...8 MPa. Fat-vitamin-mineral filling in the amount of 18% to the initial mix weight is introduced prior to withdrawing the mix out of the extruder into the central zone of the extruder cord. The filling is manufactured by mixing sunflower oil sludge, beetroot molasses, feed yeast, feed putrid mud and table salt taken with the specified ratio of components.

EFFECT: invention allows increasing food and biological value of the feed produced.

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Description

The invention relates to the production of animal feed, in particular for pigs, cattle and other animals.

A known method of producing bulk powder feed, including grinding a starchy product (corn and grain) (AS No. 686714 of the USSR, A23K 1/00, 09/25/79), moistening it to 16 ... 18%; extrusion at 1.0 ... 1.4 MPa; cooling; re-grinding and cooling of the finished product.

However, this method does not provide for the possibility of obtaining granular feed.

There is also known a method of producing feed (EP, 0071331, A23K 1/00, 1/18, 09.02.83), including the extrusion of a protein-powdery mixture containing at least 40% powdery component and having the necessary humidity, at elevated pressure and temperature not less than 100 ° C in order to give the mass porosity, fluidity and thermoplasticity, cooling to 37.8 ... 82.2 ° C and subsequent granulation with the formation of a dense elastic structure.

The disadvantage of this method is to obtain durable and flexible granules of feed, which creates difficulties when feeding young animals and birds.

Known feed for rabbits (Kalugin, Yu.A. Feeding rabbits / [Text]. M: Agropromizdat, 1985, p. 71-77, table 27), containing (in wt.%): Grass flour - 20 .. .thirty; straw flour - 10 ... 20; ground oats (wheat) - 14 ... 16; barley - 14 ... 16; wheat bran - 9; oilcake, meal (sunflower, soybean) - 14 ... 18; fish meal (meat meal) - 2; hydrolysis yeast - 1; bone meal - 0.5%, table salt - 0.5; premix - 1.

The disadvantage of this feed is a complex component composition, a high content of straw flour, which, being a roughage, negatively affects the digestibility of feed for young animals. Straw flour has an increased fungal and bacterial contamination, which also negatively affects the sanitary and hygienic condition of the feed, its environmental cleanliness.

A known method of producing feed (A.S. No. 1674769 SU, A23K 1/00, 09/07/91), which includes granulating a feed mixture containing, wt.%; herbal flour - 4; grain mixture of wheat - 30 with corn - 25.3; sunflower meal - 13; fishmeal - 5; yeast - 3; bone meal - 0.6; chalk - 3; shell, limestone - 4.7; salt - 0.4; premix - 1 or protein-vitamin-mineral supplement; cooling, grinding and fractionation of crushed feed into coarse, medium and fine fractions, followed by the withdrawal of grains as a finished product.

A disadvantage of the known compound feed and the method of its production is the low content of fiber-rich component necessary for animals, which reduces its nutritional value and digestibility.

Closest to the proposed technical essence is feed for herbivorous animals and the method for its production (Pat. No. 2148938 of the Russian Federation. IPC ⁷ A23K 1/00. Feed for herbivorous animals and the method for its production. / O.E.Sherbakova. Application No. 98123546 / 12, claimed 28.12.1998, publ. 05.20.2000), according to which feed, containing wt.%: Grass meal 26.5 ... 40.0; wheat bran 9.0 ... 15.0; sunflower meal 13.0 ... 16.0; meat flour 1.0 ... 4.0; fishmeal 2.0 ... 5.0; fodder yeast 1.0 ... 2.0; molasses and / or sapropel 2.0 ... 3.0; common salt 0.3 ... 0.5; premix or protein-vitamin-mineral supplement 0.5 ... 1.0; wheat-based cereal mixture containing 2.0 ... 3.2 wt.% barley, is prepared as follows: herbal flour is mixed with the cereal mixture and extruded at 115 ... 140 ° C and 1.4 ... 3 , 0 MPa, add sunflower meal, meat and fish meal, fodder yeast, common salt, wheat bran and premix or protein-vitamin-mineral supplement to the chilled and ground porous extruded mixture with stirring, granulate the feed mixture with molasses and / or sapropel at 0.28 ... 0.33 MPa to a granule size of 4.7 mm, cooled to a granule they are crushed to a grain 2.0 ... 4.5 mm and fed to animals.

The disadvantages of this method are the low biological value of the resulting product and the limited possibility of its use for various groups of animals.

The technical task of the invention is the receipt of full-extruded extruded feed stuffed with high quality, balanced in composition, increasing their nutritional and biological value, expanding the range of extruded feed stuffed with filling using inexpensive and widespread raw materials.

To solve the technical problem of the invention, a method for the production of full-extruded extruded compound feeds with a filling is proposed, characterized in that a mixture is prepared from pre-crushed to a particle size of 0.16 ... 0.63 mm grain of corn, wheat and narrow-leafed lupine, grass flour is added meal, sunflower, meat and fish meal, with the next choice of the ratio of components, wt.%:

corn grain - 12 ... 15;

wheat grain - 11 ... 13;

narrow-leaf lupine - 20 ... 22;

grass meal - 30 ... 33;

sunflower meal - 14.0 ... 16.0;

meat meal - 1.0 ... 4.0;

fish meal - 2.0 ... 5.0;

moisturize to 18 ... 23%, to equalize the moisture throughout the volume, the mixture is kept for 4 hours in the hopper, and then it is processed on a screw extruder at a product temperature in front of the matrix 398 ... 433 K, screw speed 1 .. .2 s ^-1 and the pressure in the pre-extruder zone of the extruder 5 ... 8 MPa, before the mixture leaves the extruder, the fat-vitamin-mineral-filling filling is introduced into the central zone of the extrusion bundle in the amount of 18% by weight of the initial mixture, for preparation of which the sunflower fuz is mixed , beet molasses, fodder d . Ozhzhi, fodder and food sapropel common salt, the next selection ratio, wt%:

sunflower fuz - 33 ... 35;

beet molasses = 28 ... 31;

feed yeast - 18 ... 20;

feed sapropel - 12 ... 15;

edible salt - 3 ... 5.

The technical result of the invention is to obtain high-quality extruded full-feed compound feeds, stuffed, balanced in composition, with high nutritional and biological value, subject to rational process parameters (temperature in front of the matrix, screw speed, etc.).

To obtain a complete feed, use the following source components in the preparation of the feed mixture.

1. Lupine narrow-leaved cultivar Nadezhda belongs to the legume family and contains 34% protein, 6% fat, 16% water, and is rich in essential amino acids such as leucine, isoleucine, and phenylalanine. It meets the requirements for food legumes (TU 9716-001-11951678-200). Lupine seeds have approximately the same amount of protein as soy (31 ... 33% crude protein), which is similar in composition to animal protein. The fat content in lupine is 5.8 ... 6.0%, which contributes to a more uniform course of the extrusion process and long-term storage of the resulting products. Lupine protein has the highest digestibility among legumes (KP = 80 ... 89%). The content of phytosterol (a component of plant cells that lower blood cholesterol) is 1.6 times higher than that of soy (78.6 mg / 100 g and 50 mg / 100 g, respectively). The content of undesirable compounds (alkaloids) in the seeds of lupine does not exceed 0.04%, which indicates the safety of its use even without preliminary heat treatment.

2. Corn (GOST 13634-90) contains not more than 4% fat, starch - not less than 55%. Corn contains a lot of provitamin A (carotene). The composition of corn includes fiber 1.5%, ash 1 ... 2% and water 14%.

3. Soft wheat of the 5th class (GOST 9353-90) with a crude gluten content of 15 ... 18% and solids content of 82 ... 85%. Protein in wheat contains 8 ... 15%. The limiting acids are lysine, threonine, and leucite. Wheat has a high content of nitrogen-free extractives and nicotinic acid. 1 kg of wheat contains an average of 3.5% fiber, 2% fat, 0.06% calcium and 0.4% phosphorus, as well as vitamins A, D, E and group B.

4. Grass flour (GOST 18691-88), obtained as a result of artificial drying of the green mass of various herbs (legumes, cereals, seeded grasses, grass of natural hayfields, green mass of fodder beans, peas and other crops) on high-temperature drying units. 100 kg of herbal flour contains 12 ... 16% crude protein, 27.4% fiber, 2.7% crude fat. Herbal flour contains in 1 kg 150 ... 350 mg of provitamin A - carotene. 100 g of flour contains 167 kcal of metabolic energy.

5. Sunflower meal (GOST 11246-96) - a by-product of oil extraction production - is the main source of vegetable protein for cattle, its content in the diet is up to 16%. The best for cattle are considered to be protein-rich (38 ... 40%) sunflower and soybean meal. Meal is also rich in phosphorus and iron.

6. Meat and fish meal (GOST 17681-82) - animal feed that contain from 20 to 60% protein and fat from 1.9 ... 2.5% in fish meal and up to 10 ... 14% in meat meal. These foods are rich in calcium and phosphorus.

Since the mixture of the above components has a high content of proteins and carbohydrates, it is advisable to introduce a fat-vitamin-mineral supplement in the form of a filling in the compound feed upon receipt of co-extruded compound feed (compound feed with a filling) for a more complete balance of the composition. [Technology of extruded products: Textbook / A.N. Ostrikov and others. - SPb .; GIORD 2007. - 200 p.: Ill.] The following components were selected as the most suitable fat-vitamin-mineral supplement.

1. Sunflower fuz is a precipitate that forms during the production of vegetable oil and its further filtration and storage [V. Eremchenko The use of vegetable oil waste in feed technology. / V.V. Yeremchenko, A.A. Shevtsov, L.I. Lytkina, E.S. Shentsova // Oil and fat industry. - 2006. - No. 3, - S.58-60.].

The basis of the non-fat complex of the sunflower body is phospholipids, protein and mucous substances of the original oil. Sunflower fuz has a high nutritional and energy value (Table 1).

Table 1 Nutritional and energy value of sunflower seed Indicators unit of measurement Fuze sunflower after self-hydration Hydrofuse one 2 3 four Metabolic energy (bird) Kcal / 100 g 790 380 Crude protein % 15.7 28.1 Crude fat % 70 31.6 Crude fiber % 1,02 0.7 Crude ash % 5,0 5,6 Linoleic acid % 26.49 18.77 Nitrogen-free extractive substances % 21.38 31,0 Dry matter % 88.0 97.0 Amino Acids Digestible Lysine % 0.47 0.85 Methionine % 0.17 0.31 Methionine + Cystine % 0.28 0.50 Threonine % 0.15 0.30 Tryptophan % 0.10 0.30 Arginine % 0.51 1.15 Minerals Calcium % 0.24 0.42 Phosphorus common % 0.32 1,07 Digestible phosphorus % 0.08 0.32 Sodium % 0.06 0.06 Chlorine % 0.09 0.09

Replacing scarce and expensive animal fat with more affordable and cheap vegetable oil waste (sunflower fuser) will significantly reduce the cost of finished products, increase the productivity of farm animals and poultry.

2. Fodder yeast (GOST 28178-89) - products of the microbiological industry, are a valuable protein-vitamin feed, are rich in protein (45 ... 54%), are characterized by high biological value and contain almost all B vitamins (except for B ₁₂ ) Therefore, yeast serves as a complex B-vitamin supplement.

3. Beet molasses (OST 18-385-82) - a by-product of sugar beet production, contains up to 50% carbohydrates in the form of sucrose, which serves as an additional source of energy in animal feed. The nutritional value of 100 kg of molasses is 75 feed. units Molasses is a binder in the granulation of animal feed.

4. Feed sapropel (TU 9291-001-27897610-94) is a unique natural organomineral complex in which the biologically active substances necessary for the animal body are concentrated. It contains macroelements (calcium, magnesium, phosphorus, iron, potassium, sodium), as well as trace elements (manganese, cobalt, vanadium, molybdenum, iodine, bromine, copper, zinc, chromium, nickel), amino acids, carbohydrates, humic acids, vitamins (carotene, B ₁ , B ₂ , B ₃ , B ₆ , B ₉ , B ₁₂ , C, D, E, P), sterols (hormone-like substances) and other biostimulants. The presence of carbohydrates, protein, humic substances and bitumen in the composition of sapropel determines its high adhesive properties, due to which it found application as a binding agent (plasticizer) for granulation of compound feeds. Studies of sapropel for radioactivity showed that heavy metals are within acceptable limits and there are no contraindications for feeding sapropel to animals.

5. Edible salt (GOST 13830-91 E) refers to mineral feed and is an essential component of each diet, include it in the diet of animals and poultry to enrich it with sodium, which should be in a certain ratio with potassium. In animal diets, salt is introduced in an amount of 0.3 ... 0.5% of the total feed mass.

The method is as follows.

Grain components: narrow-leaved lupine of the Nadezhda grade (GOST 11321-89), corn (GOST 13634-90) and wheat (GOST 9353-90), crushed to a particle size of 0.16 ... 0.63 mm and sieved.

Herbal flour is mixed with crushed grain mixture (lupine, corn and wheat), sunflower meal, meat and fish flour in a batch mixer A9-DSG-1.5 until smooth. The components are mixed in the following ratio, wt.%: Narrow-leaved lupine - 20 ... 22, corn - 12 ... 15, wheat - 11 ... 13, grass meal - 30 ... 33; sunflower meal - 14.0 ... 16.0; meat flour - 3.0; fishmeal - 4.0.

Next, the resulting mixture is moistened to 18 ... 23% and kept in a tempering hopper for even distribution of moisture.

After that, the resulting mixture is processed in an extruder KMZ-2U. The mixture through the loading pipe enters the working chamber, where it is moved by a screw to the matrix. As you move the mixture in the mixing zone of the extruder is partially mixed, and in the compression zone there is an abrupt increase in pressure and compaction of the mixture due to a sharp decrease in the size of the screw channel. In the plasticization zone, the mixture is partially converted into a melt due to friction between its particles and the screw turns.

Then there is a further compression of the mixture. In the homogenization zone, the mixture transforms into a homogeneous melt due to an increase in pressure. The melt pressure in the dosing zone reaches 5 ... 8 MPa, the final melting of small inclusions of the mixture is ensured, and a melt is formed, uniform in structure, with a temperature of 398 ... 433 K.

In the stabilization zone, pressure and temperature fields of the product melt are equalized. Then it enters the provided zone and is pressed through the outlet in the matrix in the form of a hollow bundle. A pump for viscous media delivers a fat-vitamin-mineral filling in the amount of 18% to the mass of the initial mixture, consisting of 35% sunflower seed, 30% beet molasses, 18% fodder yeast, 13% fodder sapropel, and 4% food table salt.

Processing is carried out with the following extrusion process parameters: product temperature in front of the matrix 398 ... 433 K, screw rotation speed 1 ... 2 s ^-1 and pressure in the pre-extruder zone 5 ... 8 MPa.

After the product leaves the matrix as a result of a sharp drop in temperature and pressure, moisture instantly evaporates from it, the energy accumulated by the product is released at a rate approximately equal to the rate of explosion, which leads to the formation of a porous structure and an increase in the volume of the extrudate (expansion). Moreover, as a result of the “explosion” of the product (or “decompression shock”), deep transformations of its structure take place: rupture of the cell walls, destruction, hydrolysis [Ostrikov, A.N. Extrusion in food technology [Text] / A.N. Ostrikov, O.V. Abramov, A. S. Rudometkin - St. Petersburg: GIORD 2004. - 288 p.].

The result is a complete extruded feed with high quality filling. Complete extruded feed stuffed with filling is an environmentally friendly product, does not contain growth stimulants, antibiotics, non-toxic. It consists of: micro and macro elements: calcium, phosphorus, sodium, potassium, sulfur, iron, copper, zinc, manganese, cobalt, iodine, selenium; vitamins: A, D ₂ , E, K, B ₁ , B ₂ , B ₃ , B ₄ , B ₅ , B ₆ , B ₁₂ , B _c , H, C; nutrients: crude protein, crude fat, crude fiber, lysine, methionine + cystine, tryptophan. Complete feed stuffed with filling improves the digestibility of nutrients rations; removes toxic digestion products from animals and increases the body's overall resistance; increases the reproductive functions of animals, as well as the growth and development of young animals.

The method is illustrated by the following example.

Lupine, corn and wheat are crushed to a particle size of 0.16 ... 0.32 mm and sieved. Then the feed components are mixed in a screw mixer in the following ratio, wt.%: Narrow-leaved lupine - 21, corn - 14 and wheat - 12, grass meal - 32; sunflower meal - 14; meat flour - 3.0; fishmeal - 4.0, while moisturizing the mixture up to 22%. Then keep the mixture of components in the hopper for 4 hours to evenly distribute moisture throughout the volume of the mixture. Next, the resulting mixture is processed on a screw extruder at a product temperature in front of the matrix 418 K, a screw rotational speed of 2 s ^-1 and a pressure in the prematrix zone of the extruder of 7 MPa.

When substantiating the choice of components and their proportions during dosing, a number of factors were taken into account: the need to obtain high-quality full extruded compound feed with a filling, balanced in nutrition and biological value; maximum enrichment of full feed compound with components oriented to various animal species.

The need to moisten the mixture (up to 18 ... 23%) is due to the following considerations. It is proved that obtaining the active porous structure of the product at the exit from the holes of the extruder matrix is a consequence of the physical properties of the water contained in the extrudate [Ostrikov, A.N. Extrusion in food technology. / A.N. Ostrikov, O.V. Abramov. A.S. Rudometky - St. Petersburg: GIORD 2004. - 288 p.]. At atmospheric pressure of the extruded product at the exit from the matrix, water from a state of superheated liquid instantly turns into steam, releasing a significant amount of energy. Under the influence of vapor pressure, pores are formed in the product, and the remaining whole starch grains break. If the moisture in the mixture is insufficient (less than 18%), then the product at the exit of the extruder did not expand. Conversely, if the moisture content of the product was more than 23%, this led to a decrease in the degree of expansion and the formation of a denser product structure with a rough consistency. The reason for these changes was that with increasing humidity, the plasticity of the mixture of components increased, and this led to a decrease in mechanical stresses in the extrudate. Consequently, the amount of heat released as a result of the work of viscous friction forces was insufficient to obtain an expanded product structure.

Extrusion of the mixture at a pressure in the prematrix zone of 5 ... 8 MPa uniquely determines the temperature of the product processing in the range of 398 ... 433 K, which ensures high quality feed. It was established that the main substances (carbohydrates, proteins, fats, vitamins, etc.) of the feed components have different optimal temperatures necessary for complete and qualitative physicochemical changes in the extrudate [Ostrikov, AN Extrusion in food technology [Text] / A.N. Ostrikov, O.V. Abramov, A.S. Rudometkin - St. Petersburg: GIORD 2004. - 288 p.].

For an efficient and high-quality extrusion process, the proposed regimes made it possible to choose the nature of temperature and pressure changes at which the components of the mixture were subjected, on the one hand, to a complete hydrothermal treatment, and, on the other hand, they had a “soft” (sparing) temperature effect that prevented them thermal decomposition.

A fat-vitamin-mineral filling in the amount of 18% of the mass of the initial mixture, consisting of 35% sunflower seed, 30% beet molasses, 18% fodder yeast, 13% fodder sapropel, 4% food table salt.

It has been experimentally established that it is the screw rotational speed of 1 ... 2 s ^{-1 that} made it possible to ensure the proposed extrusion regimes in which deep physicochemical changes of proteins, carbohydrates and other substances of the feed components occur, giving it the properties most suitable for complete assimilation by animals.

Complete extruded feed stuffed with filling was studied by a set of indicators characterizing its nutritional properties and energy value. The analysis data are presented in table.2.

table 2 Nutrition and energy values of feed. The name of indicators Extruded feed According to traditional technology According to the proposed method Mass fraction, g / kg: Crude protein 170 174 Crude fiber 38,0 43.7 Crude fat 50,0 50,0 Lizina 8.5 8.7 Methionine + Cystine 5.1 5.3 Minerals: Calcium 10.8 11.1 Phosphorus 8.0 8.3 Content: Feed units 1.19 1.20 Metabolic energy, MJ / kg 12.96 13.07

The obtained feed with the specified composition according to the above example was tested in scientific and economic experiments when feeding calves (females and males) and fattening young pigs. Scientific and economic experiments on calves lasted for 6.5 months, on pigs - for 1 month.

As a result of the experiments, it was found that the obtained feed showed high efficiency in raising animals, the best indicators by weight (compared with the control).

Based on the experience on calves, it was found that as a result of feeding the proposed feed, their live weight at 195 days of age was 182 kg, while the weight gain was at least 53%.

The resulting full-extruded stuffed feed with filling had a positive effect on the growth and preservation of the livestock of growing animals. Fungal and bacterial contamination was within the existing norms (Table 3).

Table 3 Sanitary and microbiological indicators of compound feed Name of feed Toxicity Pathogenic, including salmonella BGKF (coliforms) KMAFAiM, CFU / g Extruded non toxic absent absent 1 · 10 ⁵ According to the proposed technology (co-extruded) - // - - // - - // - 1 · 10 ⁴

The safety indicators of full-feed extruded feed stuffed with filling (content of mycotoxins, pesticides, salts of heavy metals, radionuclides) were determined by certified methods in an accredited food testing laboratory of the Voronezh State Technological Academy. The resulting feed was environmentally friendly, characterized by increased nutrition, digestibility and improved sanitary condition.

Thus, the invention will allow;

- to receive full-fledged extruded compound feed with a filling that has high nutritional properties and biological value;

- to use widespread and inexpensive types of raw materials as initial components for the shell and filling of co-extruded animal feed;

- expand the range of manufactured types of co-extruded animal feed, balanced in nutritional value;

- to create environmentally friendly mixed feed with stuffing for animals with increased nutrition and digestibility, as well as improved sanitary condition.

Claims (1)

A method of manufacturing full-extruded extruded compound feeds with a filling, characterized in that a mixture is prepared from pre-crushed to a particle size of 0.16-0.63 mm grain of corn, wheat and narrow-leaf lupine, add grass flour, sunflower meal, meat and fish flour to it the following selection of the ratio of components, wt.%: corn grain  12-15 wheat grain  11-13 narrow lupine  20-22 grass meal  30-33 sunflower meal  14.0-16.0 meat meal  1.0-4.0 fish flour 2.0-5.0 moisten up to 18-23%, to equalize the moisture throughout the volume, the mixture is kept for 4 hours in the hopper, and then it is processed on a screw extruder at a product temperature in front of the matrix of 398-433 K, a screw speed of 1-2 s ^-1 and the pressure in the prematrix zone of the extruder is 5-8 MPa, before the mixture leaves the extruder, the fat-vitamin-mineral filling is introduced into the central zone of the extrusion bundle in the amount of 18% by weight of the initial mixture, for the preparation of which mix sunflower fuz, beet molasses, fodder yeast, crust . Oic sapropel table salt and baking the next selection ratio of components, wt%: sunflower fuzz  33-35 beet molasses  28-31 fodder yeast  18-20 feed sapropel  12-15 edible salt  3-5