dry extrusion of full fat soybeans principles

7/22/2019 Dry Extrusion of Full Fat Soybeans Principles

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Adoption of the Full Fat

Soybean Meal by the

Romanian Feed

Industry

Iani CHIHAIA, USSEC South

East Europe


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Dry Extrusion of Full Fat Soybeans

Process Principles

Dr. Iani Adrian CHIHAIA

USSEC South East Europe


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Dry Extrusion of Full Fat SoybeansProcess Principles

Figure: Pieterse H. 2002

Extrusion Cooking of Soybeans: a continuous, HTST(High Temperature Short Time) process by whichlow moisture or steam moisturized, high proteinaceous , high oil bearing and fibrouscontaining raw

material is texture changed and cooked by a combination of moisture, pressure, temperature, and

mechanical shear.


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Dry Extrusion of the Full Fat Soybean Meal

Due to the unique combination of the high-shearing, friction, high temperatures, short

time and pressure during the extrusion process results the rupture of the soybeans cell

tissue, which liberates the oil from the sub cellular structures, thereby improving the

lipids digestibility and energy values for the animals.

High Shear Ruptured Beans Cells Walls and Released Oil after Extrusion

Source: Insta Pro 2002

Oil Vacuoles inside of Raw Beans Cells


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Dry Extrusion Full Fat Soybeans ProcessBrief Description

Source: Said N. 2010

Dry extrusion of the full fat soybeans is a widely used technology by today feedindustries in many countries.The processing is very simple and quality parameters are

easy to asses.

Dry Extrusion Process Parameters Unit ValueSoybeans initial moisture % 11,0

Extrusion processing time sec 15-21

Temperature at the nose cone point C 154-156

Extruder barrel pressure bar 40-60

Dry Extrusion Full Fat Soybean meal Processing Flow


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Full Fat Soybean Meal Dry Extrusion Plant


7/38Correct Monitoring of the Soy Extrusion Plant


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Dry Extrusion of the Full Fat Soybean Meal

Pictures: Chihaia I. 2005


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Properly Processed

Dry Extruded Full FatSoybean Meal

Poor Processed

Extruded Full FatSoybean Meal


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Dr. Mian RIAZ of TAMU discussingCorrect Dry Extruder Setup with the staff of an

Extrusion Plant from Romania


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Dry Extruded

Full Fat Soybean Mealas a

Novel Feed Ingredient


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Dry Extruded Full Fat Soybean Meal

as a Novel Feed Ingredient

Lack of knowledge regarding this

ingredient.

Variability in beans chemicalcompositions

Variability in processing parameters

Variability in FFSBM Quality

Soybeans availability

High Feed Costs

Challenges Opportunities

Updating the professional level of the

nutritionists.

Implementation of NIR.

Hiring more skilful operators / people.

Fine tuning of the feed formulas.

Sourcing # 1 soybeans from the US

Cutting feed costs


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Dry Extruded Full Fat Soybean MealProcessing and Quality Control Essentials

Source: Said N. 2010

Under proper processing conditions with high temperature (over 150C), short time

(15 20 seconds) and high pressure (40 -60 bars) the anti nutritional factors are

deactivated and optimum nutritional quality extruded full fat soybeans is obtained. By

achieving the optimum processing parameters during the extrusion process, the trypsin

inhibitors, lipase and lypoxidase enzymes will be deactivated and the amino acids

availability will be improved as well as.

However, any change from the optimum processing parameters should will negatively

affect the quality of the final product and jeopardize the animal performances.

The extruder operators usually verify the quality of the cooking process by using the

Soy Chek, which is a color test and measures the same urease activity as does pH rise. Itis a stabilized and accelerated reagent that is particularly sensitive between 0.05 and

0.20 pH rise units recommended for soybean feeds by the American Feed Industries

Association. In 5 minutes you can determine if your extruder or other equipment is set

properly for high quality FFSBM production.


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Dry Extruded Full Fat Soybean MealProcessing and Quality Essentials

Optimum Processing Temperature taking in to accountthe Beans Moisture and Crude Fat levels

Source : Insta Pro, 2002

SpecificationsNormal Moisture Level

Beans

Low Moisture Level

Beans

Moisture 10-12 % < 10 %*Crude Fat 16-18 % 16-18 %Crude Protein 32-36 % 32-36 %Trypsin Inhibitors Units

(before extrusion)40.000-100.000

TIU/gram 40.000-100.000TIU/gramOptimum Trypsin Inhibitors Level(after extrusion)

< 15.000 TIU/gram < 15.000 TIU/gramProcessing Temperature for

Dry Extrusion149-160C 160C


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Influence of Heat Treatment on

Trypsin Inhibitor Activity and Protein Quality

Figure: Chihaia I. 2011


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Relation between

the temperature of extruding

and the in vivo assessment of the

degree of FFSBM processing

Source : Insta Pro, 2002

Globally accepted relation

between the degree of FFSBM

processing and urease activity

Degree of FFSBM

Processing Temperature ofExtusion (C)Under - Processed 145

Degree of FFSBM

Processing UreaseActivityUnder - Processed


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FFSBM Quality Parameters Unit Value

Moisture % 7,0-7,5

Crude Protein % 34,0-36,0

Crude Fat % 18,5-19,0

Urease Activity mgN2/min 30C 0,1

Soy-Chek color 4,5

Example of Full Fat Soybean Meal Processing & Quality Parameters

Courtesy of a Romanian Soy Extrusion Plant


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Dry Extruded Full Fat Soybean Meal

Nutritional ProfileRomania 2010

Specifications Per Average Values

DM % 93,56

CP % 37,43

Methionine % 0,51

Cystine % 0,56

M+C % 1,27

Lysine % 2,24

Threonine % 1,41

Triptophane % 0,50

Arginine % 2,49

Isoleucine % 1,57Leucine % 2,70

Valine % 1,66

Histidine % 0,94

Phenylalanine % 1,74

Dry Extruded Full fat soybean meal

Courtesy of Evonik Romania, 2010

Wet Expanded Full Fat Soybean Meal

Specifications PerAverage Values

Total Digestible P

DM % 89,89

CP % 34,08

Methionine % 0,49 0,40Cystine % 0,55 0,41

M+C % 1,04 0,81

Lysine % 2,18 1,81

Threonine % 1,35 1,07

Triptophane % 0,47 0,38

Arginine % 2,50 2,18

Isoleucine % 1,50 1,20

Leucine % 2,57 2,00

Valine % 1,59 1,24

Histidine % 0,91 0,76

Phenylalanine % 1,68 1,36


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Dry Extrusion of Full Fat SoybeansAmino Acids and Metabolizable Energy Equations

Source: NRC 1994

The metabolizable energy values ofthe different full fat soybean meal

products are usually estimated by

the Romanian nutritionists from

proximate composition based on

the prediction equation available

from National Research Council orother prestigious animal nutrition

companies and research institutes

around the world :

Full-fat soybeans (feeds in meal form)MEn = 2,769 - 59.1 CF + 62.1 EE

Full-fat soybeans (feeds in pellet form)MEn = 2,636 - 55.7 CF + 82.5 EE

Alternatively to Amino NIR, the nutritionistsshould use the amino acids (total and digestible)

regression equations available from Evonik.


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Other Mechanically Processed Soybeans Products

By adding a Press System and a Dehuller to the existing Extrusion system, the flexibility of

processing soybeans is increasing. In addition to the dry extruded full fat soybean meal, shouldbe produced :

Undehulled Expelled Soybean Meal,

Dehulled Expelled Soybean Meal

Expelled Soy Oil

Soy Hulls

To produce expelled soybean meal, the extruded full fat soy is conveyed from the dry extruder to a

continuous horizontal press (expeller) in which up to 75% of the oil can be removed from the

extruded full fat soybean meal. The resulting expelled soybean meal will average 46% protein and

6% to 8% oil.

Undehulled Expelled Soybean Meal Process Flow

Source: Riaz M. 2004


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Other Mechanically

Processed Soybeans Products


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Soybeans

Extruded Full fatSoybean Meal

Soybeans

Soy Hulls

Low FiberExtruded FullFat Soybean

Meal

Soybeans

UndehulledEx-Press SBM

CrudeSoy Oil

Soybeans

Dehulled LowFiber Meal

Ex-Press SBM

CrudeSoy Oil

Extruded Full Fat Soybean Meal Products Extruded & Expelled Soy Products

Soy Hulls

Other Mechanically Processed Soybeans Products

Source: Riaz M 2004


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Undehulled ExtrudedExpelled SBM

Press System

Soy Oil

Other Mechanically Processed Soybean Products

Pictures: Chihaia I, 2004


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Extruded - Expelled

Undehulled Soybean Meal

Nutritional Profile

(Source: Said N, 2000)


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Extruded - Expelled

Dehulled Soybean Meal

Nutritional Profile

(Source: Said N, 2000)


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Proximate Analysis Values

for the Soy Extruded - Expelled Products and Derivatives

(Source: Said N & Pieterse H., 2000)

Specifications FFSBM DehulledFFSBM UndehulledExPress SBM DehulledExPress SBM Soy Hulls(cold dehulled)min max min max min max min max min max

Dry Matter (%) 93,0 96,0 93,0 96,0 93,0 96,0 93,0 96,0 88,00 92,00Crude Protein (%) 34,0 39,0 36,5 40,5 43,0 46,0 46,0 48,0 11,00 15,81Crude Fat (%) 18,0 19,5 20,0 22,0 7,0 10,0 7,0 10,0 1,30 3,64Crude Ash (%) 4.0 4,5 3.5 4.0 5,5 6,3 5,0 5,5 3,78 7,80Crude Fiber (%) 5,2 6,0 3,2 3,7 5,2 6,0 3,3 3.7 36,40 28,0

Inclusion levels of the soy extruded expelledProducts in farm animals diets :

Non Ruminants : 540 %

Ruminants : up to 25 %

REMBER : Animals do not require feed ingredients or

formulas, but rather the nutrients which are part of thechemical composition of these ingredients and feed

formulas. Therefore, a feed formula is meaningless if we

dont understand the ingredients nutritional profile,

functional properties and the nutritional & functional

principles involved in formulating the feed.


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Soy Extruded - Expelled Products and DerivativesTypical Inclusion Rates

Source: Insta Pro, 2010


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ExtrusionExpelling

a Versatile Technology

E t i E lli


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ExtrusionExpellinga Versatile Technology

The Extrusion Expelling technologyallows a great versatility and flexibility in

approaching different oilseeds or feedstuffs

processing with the same plant.

With small adjustments or investments,

the initially soy designed plant should

process: sunflower seeds, rapeseeds, corn

germ meal or any other oil bearing seeds

ready available in the market.

Beside the soybeans, other oil seeds such

as canola and sunflower are processed with

the Extrusion - Expelling /Pressing systems

in Romania and several other countries from

North, South America, Europe and Asia.

Sunflower seedsCanola seedsCorn Germs

Sunflower cakeCanola cakeCorn Germs Meal

(Source: NutriCom Magazine, 2009)


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ExtrusionExpelling

a Versatile Technology

(Source: NutriCom Magazine, 2009)

OilseedCrude FatContent

(%)

CrudeProtein

Content

Oil RemovalEfficiency

(%)

Press

ExPressMeal Crude

Fat Content

(%)

Press-

ExPress

Meal Crude

Protein

Content

(%)

Canola35-40 22-26 72-75 8-11 32-37

Sunflower 35-45 16-2 72-75 10-13 22-27

Oil removal efficiency and meals produced from high oil bearing seeds


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Adoption of

the Full Fat Soybean Mealby the Romanian Feed Industry

Impacts and Achievements

Ad ti f th F ll F t S b l


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Adoption of the Full Fat Soybean Meal

by the Romanian Feed Industry

By turning the theory in to practice, the very first commercial size soy extrusion

expelling plant was succesfully established in 2002 year by Suinprod Roman (one of the

leading integrations in the country) just 3 months after the first ASA-IM Soy Extrusion

Seminar in Bucharest, Romania. Few months later, AviTop the poultry division of Kosarom

group invested in a 4,5 tons / hour soy extrusion plant,equipped with a soy oil expellingunit as well.

Gradually, the livestock integrated companies undestood the advantages of producing

their own full fat soybean meal, pressed soybean meal and soy oil and started to invest in

soy processing facilities.

At this stage, there are over 22 Romanian companies owning extruders or large size soy

extrusion units and having a processing capacity of 87,000 to 100,000 (2 swifts / day, 5

days /week and 8 months/ year).

Impacts and Achievements (I)


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Extrusion Plant 2000 year

i l


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Extrusion Plants 2010 year

Ad ti f th F ll F t S b M l


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Dry extrusion is the dominant technology used at this stage to process full fat soybeans

in Romania.

There are 19 companies using dry extrusion technologies from different equipmentsuppliers. Is estimated that over 65% of the full fat soybean meal is produced by large size

integrated companies using U.S. original extrusion - expelling technology.All the large dry

extrusion plants are equipped with large soy dehulling and ex-presses systems to squeeze

the oil out from the beans and produce high quality soybean meal cake.

Three companies (a pig integrated company and two independent feed manufacturers)

invested in wet expanders units to produce full fat soybean meal as well. Since the steam

(used in wet expanders to cook the beans) moisture interferes with the expulsion of the oil

which makes impossible the production of the soybean meal cake.

Impacts and Achievements (II)

d i f h ll b


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On site soy processing reduces feed costs, allows home oilseed feedstuffs to be used.

Most of the soy extrusion plants from Romania can be easily configured to

simultaneously produce: full-fat soy, partially de-fatted soybean meal (ExPress soybean

meal), and chemical-free, virgin soy oil.

It allows for formulation of higher energy diets without recourse to high levels ofsupplemental fats.

Impacts and Achievements (III)

d i f h ll S b


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In a pelleted broiler diets supports chick performance equal or superior to that of

dehulled solvent extracted soybean meal, and the extrudedexpelled soybean meal couldpartially or completely replace solvent soybean meal without any adverse effects on body

weight, feed conversion, mortality, dressing percentage, or abdominal fat content provided

as long as the diets are nutritionally balanced.

Under current market conditions, with high prices for the vegetal oils, the inclusion of the

FFSBM in broiler ratios is generating big savings : over 16 Euros / MT of feed, especially forthe broiler grower and finisher diets. Vegetable oil consumption dramatically decreased in

grower and finisher diets since the use of FFSBM and for the broiler starter diets there is no

even need for oil addition.

Impact and Achievements (IV)


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THANK

YOUfor your

attention

Iani Adrian CHIHAIA

USSEC Consultant

dry extrusion of full fat soybeans principles

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