Feed additive processing technology represents an innovative field that has emerged from the integration of feed processing and pharmaceutical chemical technologies. This advanced method emphasizes efficiency, low energy consumption, contamination-free production, and continuous operation. The process is designed to ensure high-quality, consistent, and safe feed additives for animal nutrition.
1. **Process Overview**
The production flow of a feed additive premix is illustrated in the figure below. The general steps are as follows:
Premixed Additive Process
Thinner
↓
Dilution ↠Dissolve ↠Measure ↠Iodine, Cobalt, Selenium, etc.
↓
Carrier and Additive Raw Materials → Drying → Crushing → Sieving → Measuring → Mixing → Finished Product
2. **Key Process Points**
2.1. **Raw Material Selection**
The selection of raw materials is crucial for ensuring the effectiveness and safety of the final product. Ideal additive ingredients should meet the following criteria:
- High absorption rate by animals and strong biological activity
- Low levels of harmful heavy metals, within regulatory limits
- Good palatability with no unpleasant odor
- Resistance to moisture absorption and clumping
- Stability against oxidation and decomposition
- Minimal electrostatic charge, good flowability
- Particle size suitable for uniform mixing
- High purity, meeting feed-grade standards
- Easily available and cost-effective
- No residual effects in animals and safe for human consumption
2.2. **Carrier Selection and Processing**
Carriers are essential for diluting trace elements and improving their handling properties. They should have a good surface structure and water-absorption capacity, allowing micro-additives to adhere effectively. The carrier must also exhibit good dispersibility, fluidity, and chemical stability. Common choices include fine powders, cake powder, and steamed bone powder. The moisture content should be below 10%, and the particle size should range between 30 and 80 mesh.
2.3. **Selection and Processing of Diluent**
The diluent must be chemically stable and not react with or antagonize the trace elements it is meant to dilute. It should have a similar bulk density to both the diluted components and the carrier to ensure even mixing. Calcium carbonate (CaCO₃) is often used due to its low cost, wide availability, and compatibility with animal nutrition. Its bulk density is approximately 2.7 g/cm³, making it an effective choice.
2.4. **Treatment of Toxic Trace Elements**
Trace elements such as selenium, cobalt, and iodine can be toxic if not handled properly. To minimize risks, these elements are typically pre-treated through hydration. They are dissolved in warm water, sprayed onto refined thinners, mixed thoroughly, dried, and then ground into a fine powder for use in the final mix.
2.5. **Drying**
Many additive raw materials contain excess moisture, which can affect storage and processing. A temperature-controlled electric oven is commonly used for drying. This step helps extend the shelf life of the product and makes subsequent grinding more efficient.
2.6. **Crushing**
All raw materials must be crushed to the appropriate fineness. Specialized grinders are used for sensitive components like selenium, cobalt, and iodine. After crushing, the material is sieved, and any oversized particles are returned for further processing.
2.7. **Weighing and Measuring**
Accurate measurement is critical in the formulation of feed additives. Manual weighing is often used, with trained personnel responsible for the task. Precision scales or electronic meters may also be employed to ensure accuracy.
2.8. **Mixing**
A high-speed, sealed mixer is used to ensure thorough blending. The mixer should leave no more than 0.3% residue after each batch. The process typically involves adding the carrier first, followed by the trace elements, with a mixing time of 10–15 minutes per batch.
2.9. **Packaging**
Once the additive is mixed, it is measured and packaged. The packaging must meet strict quality standards, with a precision of at least 1/500. The bags should be tightly sealed to prevent leakage, and each package should include a quality inspection certificate detailing the intended use, dosage, and application instructions.
This comprehensive approach ensures that feed additives are produced efficiently, safely, and consistently, meeting the needs of modern animal nutrition systems.
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