Bentoli
Issue: August 2013
connect
Issue:
Issu
Is
sue:
e: August
Augus 2013
Tip of the month
Learn from yesterday, live for today,
hope for tomorrow. The important
Industry Update
Understanding of Steam Preconditioning
in Pelleting Systems
Solutions
®
Our Moisture Optimization Solution: Recitol
thing is to not stop questioning.
Bentoli Inside News
Albert Einstein
Industry Update
Understanding of Steam Preconditioning in Pelleting
Systems
Eugenio Bortone, Ph.D., P.A.S., Dpl. ACAS
Quality of any animal pelleted feed is measured by
the Pellet Durability Index (PDI). The latter depends
largely on the ingredients present in the formulation
such as corn (starch sources), synthetic binders and
also by the processing conditions. In this article we
will focus on one element of the process that is
critical in the production of pelleted feeds. This is the
Preconditioning step where steam is applied to
moisten and elevate the temperature of the meal with
the main objective of improving PDI. Even today,
with new advances in processing technology,
pelleting continues to be the most popular and
economical method of producing animal feeds. To
obtain pellets with high PDI, it is recommended that
the mash be preconditioned for more than 30
seconds at temperatures higher than 85° C. Longer
residence time in the conditioner permits more
penetration of the moisture and better distribution of
heat to increase starch gelatinization, activation of
synthetic binders, which in turn results in better
binding of the feed particles, hence increasing PDI.
Starch: Gelatinization and Damage
Starch is a biopolymer found in all cereal grains. Most
animal feed formulations have corn, sorghum, and
rice which provide an excellent source of starch.
Starch is biopolymer that acts as a natural binder in
www.bentoli.com
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ent
n ol
olii.co
com
co
com
Memberships & Certifications
pelleted feeds but before
it can act as such it must
be subjected to heat
treatment and exposed to
moisture to be gelatinized.
The term gelatinization
has been widely used in
connection with the
pelleting process, and
more so in relation to the
production of high-quality
or very durable pellets
(PDI). Starch gelatinization
is defined as the loss of
birefringence, or as the
irreversible rupture of the
native secondary bonds in
the crystalline region of the
starch granule. According to Hoseney (1986), the
loss of birefringence occurs under continuous
heating and excess moisture, which can lead to
increased viscosity and increased swelling (water
uptake) of the starch granules. If we want to measure
the actual degree of cooking (starch gelatinization)
caused by steam conditioning, we must first
consider the starch damage caused by grinding and
the damage caused during pelleting. Starch damage
occurs during grinding as well as in the pelleting
process and these can be wrongly interpreted as
gelatinized starch. During pelleting, damage is mainly
caused by friction as the mash is compressed and
extruded through the working area of the die, and
has been well documented by several authors
Page 1/3
Pa
Bentoli
connect
(Skoch 1979; Stevens 1987; Bortone at al. 1995).
One advantage of the starch damage caused in the
grinding process is the exposure of greater surface
area, which in turn can increase the water absorption
of the mix and this can increase the starch
gelatinization.
steam, and wet steam contains vapor with free
water. In the pelleting process, steam is used to
increase the temperature and moisture of the mash.
This is accomplished when saturated steam
condenses back to water, transferring its energy to
the shrimp feed mash.
Steam Conditioning
The process of adding steam to the mix meal is
known as preconditioning or steam conditioning.
During this process, the mixed meal is exposed to
saturated steam to increase its moisture and
temperature, which will eventually result in starch
gelatinization and activation of other binding agents
found in the mix. The conditioning is achieved in a
continuous mixing chamber.
Steam Quality
Steam used in the process of heating must be as dry
as possible. The dryness fraction of steam describes
its quality and is defined as the proportion of water
droplets in suspension present in the steam. Reimer
and Beggs (1993) reported that when steam of 80%
quality (dryness fraction) was used, mash feed
entering the conditioning chamber at 12% moisture
and 18° C, exited the conditioner chamber at 16%
moisture and 84° C. However, at 100% steam
quality, the conditioned mash reached 91° C. The
latter can be explained by looking at steam tables,
which show that wet steam has heat content
substantially lower than that of dry saturated steam
at the same pressure. Therefore, it is very important
to ensure the quality of steam being delivered to the
pelleting system. This can be accomplished by
proper insulation of the steam lines and having
adequate steam traps and steam separators. Poor
maintenance of the steam traps and separators will
severely affect steam quality. In the case that steam
traps do not properly work water and steam can be
injected into the preconditioner chamber causing
clumps of very high moisture mash and when these
clumps drop into the pelleting chamber can cause
stoppages and down time.
Preconditioning Equipment
The preconditioner is made up of a screw feeder that
takes the meal from the holding bin to the
conditioner, the paddles (Figure 1), which convey and
expose the meal to the steam being injected, and the
exit port which drops the meal into the chute or
feeding port of the pellet press. The residence time in
the preconditioner can be increased by reducing the
rotational speed of the paddles (frequency converter)
or changing the pitch angle of the paddles. The
configuration should be one that allows the mash to
fill half the preconditioner. This is accomplished by
setting some of the paddles with reverse, some with
Figure 1. Pre-Conditioning Chamber Showing Paddle Configuration
neutral, and some with forward pitch angles.
Immediately after the reverse and closer to the exit
port, the paddles should have a forward pitch to
allow the mash to flow out of the conditioner. Too
many paddles in the reverse position can plug the
conditioner.
Figure 2. Starch gelatinization is a time dependent process.
Conclusion
Proper pellet durability of feeds requires gelatinization
of starch and activation of other natural or synthetic
binders present in the formulation. This cooking
process occurs largely in the preconditioner, where
the mixed meal is exposed to saturated steam. Best
results are achieved by preconditioning at
temperatures in excess of 85° C for most animal
feeds. Find grinding and use of low pressure steam
with dryness factor greater than 80% can improve
the efficiency of preconditioning.
Solutions:
Our Moisture Optimization Solution:
Recitol®
For more information about this and other Bentoli solutions,
please contact your local representative.
P
Page 2/3
Bentoli
connect
Bentoli Inside News
Steam Condensation and Molecule Binding
When steam condenses (adds moisture) on the
mash feed, it simultaneously transfers its energy.
During this time-dependent process, the starch
granules (Figure 2) swell up until they gelatinize.
Similarly, proteins will start changing their molecular
structure, in some cases becoming more fluid. It is
during this process that the binding of molecules
starts, which is responsible for producing tight
matrix. Because it is a time-dependent process,
most of the steam conditioners used in feeds should
have long enough dwell times to allow proper steam
conditioning of the mash meal.
Steam
Steam can be classified as saturated, superheated,
or wet. Saturated steam is vapor only at a given
temperature and pressure, while superheated steam
is vapor at temperatures greater than saturated
www.bentoli.com
ww.
w.be
bentol
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oli.co
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.co
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m
Issue: August 2013
www.bentoli.com
Bentoli is a Texas based company
and is very proud to announce its
membership and alliance with “GO
TEXAN”. Through the Texas
Department of Agriculture, the GO
TEXAN program represents Texas
agribusiness on a state, national and
international level, and we are delighted to be
included as part of the comprehensive campaign to
promote Texas agriculture products. There’s no
denying Lone Star Pride!
On a global scale, Bentoli is committed to
continuously evaluating and improving quality and
process standards through compliance and
certification programs such ISO: 9001-2008.
Consistent with this philosophy, Bentoli Asia has
recently completed the final stage of the FAMI-QS
certification process, and we are very pleased with
this achievement.
The FAMI-QS Code addresses safety, quality and
regulatory compliance of specialty feed ingredients
and their mixtures. FAMI-QS is a pioneer in its field as
it is the only certifiable code specifically aimed at
specialty feed ingredients and their mixtures. It was
also the first Community Guide to Good Practice to
obtain official recognition from the European
Commission as foreseen in the Feed Hygiene
Regulation. An exclusive program for the feed
industry, the FAMI-QS code is designed for
international validity, with participants found around
the globe.
Better feed. Better food
Page 3/3
Bentoli
Issue: August 2013
connect
Issue:
Issu
Is
sue:
e: August
Augus 2013
Tip of the month
Learn from yesterday, live for today,
hope for tomorrow. The important
Industry Update
Understanding of Steam Preconditioning
in Pelleting Systems
Solutions
®
Our Moisture Optimization Solution: Recitol
thing is to not stop questioning.
Bentoli Inside News
Albert Einstein
Industry Update
Understanding of Steam Preconditioning in Pelleting
Systems
Eugenio Bortone, Ph.D., P.A.S., Dpl. ACAS
Quality of any animal pelleted feed is measured by
the Pellet Durability Index (PDI). The latter depends
largely on the ingredients present in the formulation
such as corn (starch sources), synthetic binders and
also by the processing conditions. In this article we
will focus on one element of the process that is
critical in the production of pelleted feeds. This is the
Preconditioning step where steam is applied to
moisten and elevate the temperature of the meal with
the main objective of improving PDI. Even today,
with new advances in processing technology,
pelleting continues to be the most popular and
economical method of producing animal feeds. To
obtain pellets with high PDI, it is recommended that
the mash be preconditioned for more than 30
seconds at temperatures higher than 85° C. Longer
residence time in the conditioner permits more
penetration of the moisture and better distribution of
heat to increase starch gelatinization, activation of
synthetic binders, which in turn results in better
binding of the feed particles, hence increasing PDI.
Starch: Gelatinization and Damage
Starch is a biopolymer found in all cereal grains. Most
animal feed formulations have corn, sorghum, and
rice which provide an excellent source of starch.
Starch is biopolymer that acts as a natural binder in
www.bentoli.com
be
ent
n ol
olii.co
com
co
com
Memberships & Certifications
pelleted feeds but before
it can act as such it must
be subjected to heat
treatment and exposed to
moisture to be gelatinized.
The term gelatinization
has been widely used in
connection with the
pelleting process, and
more so in relation to the
production of high-quality
or very durable pellets
(PDI). Starch gelatinization
is defined as the loss of
birefringence, or as the
irreversible rupture of the
native secondary bonds in
the crystalline region of the
starch granule. According to Hoseney (1986), the
loss of birefringence occurs under continuous
heating and excess moisture, which can lead to
increased viscosity and increased swelling (water
uptake) of the starch granules. If we want to measure
the actual degree of cooking (starch gelatinization)
caused by steam conditioning, we must first
consider the starch damage caused by grinding and
the damage caused during pelleting. Starch damage
occurs during grinding as well as in the pelleting
process and these can be wrongly interpreted as
gelatinized starch. During pelleting, damage is mainly
caused by friction as the mash is compressed and
extruded through the working area of the die, and
has been well documented by several authors
Page 1/3
Pa
Bentoli
connect
(Skoch 1979; Stevens 1987; Bortone at al. 1995).
One advantage of the starch damage caused in the
grinding process is the exposure of greater surface
area, which in turn can increase the water absorption
of the mix and this can increase the starch
gelatinization.
steam, and wet steam contains vapor with free
water. In the pelleting process, steam is used to
increase the temperature and moisture of the mash.
This is accomplished when saturated steam
condenses back to water, transferring its energy to
the shrimp feed mash.
Steam Conditioning
The process of adding steam to the mix meal is
known as preconditioning or steam conditioning.
During this process, the mixed meal is exposed to
saturated steam to increase its moisture and
temperature, which will eventually result in starch
gelatinization and activation of other binding agents
found in the mix. The conditioning is achieved in a
continuous mixing chamber.
Steam Quality
Steam used in the process of heating must be as dry
as possible. The dryness fraction of steam describes
its quality and is defined as the proportion of water
droplets in suspension present in the steam. Reimer
and Beggs (1993) reported that when steam of 80%
quality (dryness fraction) was used, mash feed
entering the conditioning chamber at 12% moisture
and 18° C, exited the conditioner chamber at 16%
moisture and 84° C. However, at 100% steam
quality, the conditioned mash reached 91° C. The
latter can be explained by looking at steam tables,
which show that wet steam has heat content
substantially lower than that of dry saturated steam
at the same pressure. Therefore, it is very important
to ensure the quality of steam being delivered to the
pelleting system. This can be accomplished by
proper insulation of the steam lines and having
adequate steam traps and steam separators. Poor
maintenance of the steam traps and separators will
severely affect steam quality. In the case that steam
traps do not properly work water and steam can be
injected into the preconditioner chamber causing
clumps of very high moisture mash and when these
clumps drop into the pelleting chamber can cause
stoppages and down time.
Preconditioning Equipment
The preconditioner is made up of a screw feeder that
takes the meal from the holding bin to the
conditioner, the paddles (Figure 1), which convey and
expose the meal to the steam being injected, and the
exit port which drops the meal into the chute or
feeding port of the pellet press. The residence time in
the preconditioner can be increased by reducing the
rotational speed of the paddles (frequency converter)
or changing the pitch angle of the paddles. The
configuration should be one that allows the mash to
fill half the preconditioner. This is accomplished by
setting some of the paddles with reverse, some with
Figure 1. Pre-Conditioning Chamber Showing Paddle Configuration
neutral, and some with forward pitch angles.
Immediately after the reverse and closer to the exit
port, the paddles should have a forward pitch to
allow the mash to flow out of the conditioner. Too
many paddles in the reverse position can plug the
conditioner.
Figure 2. Starch gelatinization is a time dependent process.
Conclusion
Proper pellet durability of feeds requires gelatinization
of starch and activation of other natural or synthetic
binders present in the formulation. This cooking
process occurs largely in the preconditioner, where
the mixed meal is exposed to saturated steam. Best
results are achieved by preconditioning at
temperatures in excess of 85° C for most animal
feeds. Find grinding and use of low pressure steam
with dryness factor greater than 80% can improve
the efficiency of preconditioning.
Solutions:
Our Moisture Optimization Solution:
Recitol®
For more information about this and other Bentoli solutions,
please contact your local representative.
P
Page 2/3
Bentoli
connect
Bentoli Inside News
Steam Condensation and Molecule Binding
When steam condenses (adds moisture) on the
mash feed, it simultaneously transfers its energy.
During this time-dependent process, the starch
granules (Figure 2) swell up until they gelatinize.
Similarly, proteins will start changing their molecular
structure, in some cases becoming more fluid. It is
during this process that the binding of molecules
starts, which is responsible for producing tight
matrix. Because it is a time-dependent process,
most of the steam conditioners used in feeds should
have long enough dwell times to allow proper steam
conditioning of the mash meal.
Steam
Steam can be classified as saturated, superheated,
or wet. Saturated steam is vapor only at a given
temperature and pressure, while superheated steam
is vapor at temperatures greater than saturated
www.bentoli.com
ww.
w.be
bentol
nttoli
oli.co
ol
.co
com
m
Issue: August 2013
www.bentoli.com
Bentoli is a Texas based company
and is very proud to announce its
membership and alliance with “GO
TEXAN”. Through the Texas
Department of Agriculture, the GO
TEXAN program represents Texas
agribusiness on a state, national and
international level, and we are delighted to be
included as part of the comprehensive campaign to
promote Texas agriculture products. There’s no
denying Lone Star Pride!
On a global scale, Bentoli is committed to
continuously evaluating and improving quality and
process standards through compliance and
certification programs such ISO: 9001-2008.
Consistent with this philosophy, Bentoli Asia has
recently completed the final stage of the FAMI-QS
certification process, and we are very pleased with
this achievement.
The FAMI-QS Code addresses safety, quality and
regulatory compliance of specialty feed ingredients
and their mixtures. FAMI-QS is a pioneer in its field as
it is the only certifiable code specifically aimed at
specialty feed ingredients and their mixtures. It was
also the first Community Guide to Good Practice to
obtain official recognition from the European
Commission as foreseen in the Feed Hygiene
Regulation. An exclusive program for the feed
industry, the FAMI-QS code is designed for
international validity, with participants found around
the globe.
Better feed. Better food
Page 3/3
Bentoli
Issue: August 2013
connect
Issue:
Issu
Is
sue:
e: August
Augus 2013
Tip of the month
Learn from yesterday, live for today,
hope for tomorrow. The important
Industry Update
Understanding of Steam Preconditioning
in Pelleting Systems
Solutions
®
Our Moisture Optimization Solution: Recitol
thing is to not stop questioning.
Bentoli Inside News
Albert Einstein
Industry Update
Understanding of Steam Preconditioning in Pelleting
Systems
Eugenio Bortone, Ph.D., P.A.S., Dpl. ACAS
Quality of any animal pelleted feed is measured by
the Pellet Durability Index (PDI). The latter depends
largely on the ingredients present in the formulation
such as corn (starch sources), synthetic binders and
also by the processing conditions. In this article we
will focus on one element of the process that is
critical in the production of pelleted feeds. This is the
Preconditioning step where steam is applied to
moisten and elevate the temperature of the meal with
the main objective of improving PDI. Even today,
with new advances in processing technology,
pelleting continues to be the most popular and
economical method of producing animal feeds. To
obtain pellets with high PDI, it is recommended that
the mash be preconditioned for more than 30
seconds at temperatures higher than 85° C. Longer
residence time in the conditioner permits more
penetration of the moisture and better distribution of
heat to increase starch gelatinization, activation of
synthetic binders, which in turn results in better
binding of the feed particles, hence increasing PDI.
Starch: Gelatinization and Damage
Starch is a biopolymer found in all cereal grains. Most
animal feed formulations have corn, sorghum, and
rice which provide an excellent source of starch.
Starch is biopolymer that acts as a natural binder in
www.bentoli.com
be
ent
n ol
olii.co
com
co
com
Memberships & Certifications
pelleted feeds but before
it can act as such it must
be subjected to heat
treatment and exposed to
moisture to be gelatinized.
The term gelatinization
has been widely used in
connection with the
pelleting process, and
more so in relation to the
production of high-quality
or very durable pellets
(PDI). Starch gelatinization
is defined as the loss of
birefringence, or as the
irreversible rupture of the
native secondary bonds in
the crystalline region of the
starch granule. According to Hoseney (1986), the
loss of birefringence occurs under continuous
heating and excess moisture, which can lead to
increased viscosity and increased swelling (water
uptake) of the starch granules. If we want to measure
the actual degree of cooking (starch gelatinization)
caused by steam conditioning, we must first
consider the starch damage caused by grinding and
the damage caused during pelleting. Starch damage
occurs during grinding as well as in the pelleting
process and these can be wrongly interpreted as
gelatinized starch. During pelleting, damage is mainly
caused by friction as the mash is compressed and
extruded through the working area of the die, and
has been well documented by several authors
Page 1/3
Pa
Bentoli
connect
(Skoch 1979; Stevens 1987; Bortone at al. 1995).
One advantage of the starch damage caused in the
grinding process is the exposure of greater surface
area, which in turn can increase the water absorption
of the mix and this can increase the starch
gelatinization.
steam, and wet steam contains vapor with free
water. In the pelleting process, steam is used to
increase the temperature and moisture of the mash.
This is accomplished when saturated steam
condenses back to water, transferring its energy to
the shrimp feed mash.
Steam Conditioning
The process of adding steam to the mix meal is
known as preconditioning or steam conditioning.
During this process, the mixed meal is exposed to
saturated steam to increase its moisture and
temperature, which will eventually result in starch
gelatinization and activation of other binding agents
found in the mix. The conditioning is achieved in a
continuous mixing chamber.
Steam Quality
Steam used in the process of heating must be as dry
as possible. The dryness fraction of steam describes
its quality and is defined as the proportion of water
droplets in suspension present in the steam. Reimer
and Beggs (1993) reported that when steam of 80%
quality (dryness fraction) was used, mash feed
entering the conditioning chamber at 12% moisture
and 18° C, exited the conditioner chamber at 16%
moisture and 84° C. However, at 100% steam
quality, the conditioned mash reached 91° C. The
latter can be explained by looking at steam tables,
which show that wet steam has heat content
substantially lower than that of dry saturated steam
at the same pressure. Therefore, it is very important
to ensure the quality of steam being delivered to the
pelleting system. This can be accomplished by
proper insulation of the steam lines and having
adequate steam traps and steam separators. Poor
maintenance of the steam traps and separators will
severely affect steam quality. In the case that steam
traps do not properly work water and steam can be
injected into the preconditioner chamber causing
clumps of very high moisture mash and when these
clumps drop into the pelleting chamber can cause
stoppages and down time.
Preconditioning Equipment
The preconditioner is made up of a screw feeder that
takes the meal from the holding bin to the
conditioner, the paddles (Figure 1), which convey and
expose the meal to the steam being injected, and the
exit port which drops the meal into the chute or
feeding port of the pellet press. The residence time in
the preconditioner can be increased by reducing the
rotational speed of the paddles (frequency converter)
or changing the pitch angle of the paddles. The
configuration should be one that allows the mash to
fill half the preconditioner. This is accomplished by
setting some of the paddles with reverse, some with
Figure 1. Pre-Conditioning Chamber Showing Paddle Configuration
neutral, and some with forward pitch angles.
Immediately after the reverse and closer to the exit
port, the paddles should have a forward pitch to
allow the mash to flow out of the conditioner. Too
many paddles in the reverse position can plug the
conditioner.
Figure 2. Starch gelatinization is a time dependent process.
Conclusion
Proper pellet durability of feeds requires gelatinization
of starch and activation of other natural or synthetic
binders present in the formulation. This cooking
process occurs largely in the preconditioner, where
the mixed meal is exposed to saturated steam. Best
results are achieved by preconditioning at
temperatures in excess of 85° C for most animal
feeds. Find grinding and use of low pressure steam
with dryness factor greater than 80% can improve
the efficiency of preconditioning.
Solutions:
Our Moisture Optimization Solution:
Recitol®
For more information about this and other Bentoli solutions,
please contact your local representative.
P
Page 2/3
Bentoli
connect
Bentoli Inside News
Steam Condensation and Molecule Binding
When steam condenses (adds moisture) on the
mash feed, it simultaneously transfers its energy.
During this time-dependent process, the starch
granules (Figure 2) swell up until they gelatinize.
Similarly, proteins will start changing their molecular
structure, in some cases becoming more fluid. It is
during this process that the binding of molecules
starts, which is responsible for producing tight
matrix. Because it is a time-dependent process,
most of the steam conditioners used in feeds should
have long enough dwell times to allow proper steam
conditioning of the mash meal.
Steam
Steam can be classified as saturated, superheated,
or wet. Saturated steam is vapor only at a given
temperature and pressure, while superheated steam
is vapor at temperatures greater than saturated
www.bentoli.com
ww.
w.be
bentol
nttoli
oli.co
ol
.co
com
m
Issue: August 2013
www.bentoli.com
Bentoli is a Texas based company
and is very proud to announce its
membership and alliance with “GO
TEXAN”. Through the Texas
Department of Agriculture, the GO
TEXAN program represents Texas
agribusiness on a state, national and
international level, and we are delighted to be
included as part of the comprehensive campaign to
promote Texas agriculture products. There’s no
denying Lone Star Pride!
On a global scale, Bentoli is committed to
continuously evaluating and improving quality and
process standards through compliance and
certification programs such ISO: 9001-2008.
Consistent with this philosophy, Bentoli Asia has
recently completed the final stage of the FAMI-QS
certification process, and we are very pleased with
this achievement.
The FAMI-QS Code addresses safety, quality and
regulatory compliance of specialty feed ingredients
and their mixtures. FAMI-QS is a pioneer in its field as
it is the only certifiable code specifically aimed at
specialty feed ingredients and their mixtures. It was
also the first Community Guide to Good Practice to
obtain official recognition from the European
Commission as foreseen in the Feed Hygiene
Regulation. An exclusive program for the feed
industry, the FAMI-QS code is designed for
international validity, with participants found around
the globe.
Better feed. Better food
Page 3/3