Quality Control Measures that Affect Feeds

Click here to view a video that explains animal feed production: feed quality and safety.

Click here to view a video that explains factors affecting feed pellet quality.

Quality control in feed production is of utmost importance in the overall success and profitability of animal enterprises. There is no other factor, directly or indirectly related to the proper nutrition and high performance of animals that is more critical than feed quality control and ration consistency. The degree of quality is the consistency in which feed is formulated, processed, mixed and delivered as compared to what is expected. Animals thrive on a routine and respond better if the feed is low in nutrient variation as offered to them; and is similar in moisture content, texture and rate of energy availability.

Quality has been defined as "any of the features that make something what it is" and "the degree of excellence which a thing possesses". Either definition may be acceptable if one recognizes that quality control means knowing the quantitative amounts of all components, good and bad, in a feed. Usually, quality is verified by comparison with a known standard. However, relative values of quality over time is extremely valuable and useful in many situations.

The relationship between feed quality and animal performance is important and encompasses not only the quantitative amounts of all feed components, but also the digestibility and metabolism of those components. Thus, the challenge for nutritionists and others involved in animal feed production is to consistently monitor all aspects of the feed production system being used and measure those variables that are good indicators of quality control. For the feed industry, a quality control system is the responsibility of management and involves personnel being properly trained to ensure a high level of organization, documentation, and the policing of various procedures and processes necessary to guarantee the basic quality of feedstuffs and feeds.

How to Sample and Evaluate Animal Feeds

Quality control of incoming ingredients is crucial to predicting the quality of a complete feed, supplement, premix, etc. An important first step is accurate sampling and complete examination of the ingredient prior to unloading. Sampling and inspection procedures need to be in writing and kept in a Quality Control Procedures Manual. The goal in sampling any lot of ingredients or finished feed is to obtain samples that are representative of the lot in question. A wrong answer -- which may arise from incorrect sampling, incorrect handling of samples, analytical error, etc -- is worse than no answer. Thus, it is our responsibility to know proper procedures and techniques for sampling to be sure that correct formulations can be made.

Sampling

Below are some suggested sampling procedures for bulk ingredients and mixed feeds, bagged ingredients and mixed feeds, hays, and syrups and fats.

Bulk Ingredients and Mixed Feeds

Take a minimum of three, 2 kg samples.

Each 2kg sample should be the composite of several cores taken randomly from the delivery truck, bull storage bin or feed bunk, as applicable.

Duplicate determinations are recommended for all variables measured.

Bagged Ingredients and Mixed Feeds

Use slotted feed tier for sampling and take one kg samples.

For lots of one to ten bags, sample all bags.

For lots of eleven or more, sample ten bags.

Analyse a minimum of three samples and average the results.

Click here to view a video that explains sampling of bulk bags.

Hays

For chopped hay, take ten samples per lot.

For cubes, take forty cubes from a given population.

For bales, take one 30cm to 50cm core from the end of forty bales in a given population.

Syrups and Fats

Use a continuous flowing sampling procedure at the point of delivery, or a core liquid sampler.

Evaluation

Establishment of a retention schedule is recommended for all ingredients and mixed feed samples. Separate analytical analyses should be routinely performed on samples of the following for quality.

• Water
• Grains
• Roughages
• Silages
• Protein supplements
• Mineral mixtures
• Vitamin premixes
• Molasses and fat
• Specific feed additives

As a starting point for insuring quality in feedlot rations, all incoming feed ingredients should be quality checked for the following:

• Moisture
• Colour
• Off odour
• Presence of foreign material
• Texture and uniformity
• Evidence of heating
• Deterioration due to biotoxins

More detailed analyses are performed on individual feed ingredients for the purpose of feed formulation, and sometimes before the purchasing of commodities if the seller does not provide this information. Analyses that usually are considered to be routine for the different feed ingredients include:

Grains - grade, moisture, protein, ash.

Grain by-products - moisture, protein, ash.

Dry roughages - moisture, protein, ash, and acid detergent fibre.

Silages - moisture, ph, temperature, protein, ash.

Protein supplements - moisture, protein, ash, non-protein nitrogen.

Mineral mixtures - moisture, specific nutrients.

Molasses - moisture, ash.

Fats - moisture, free fatty acids, impurities, unspecifiable.

Determining the variation in the four major areas that affect feed consistency can derive an overall evaluation of feed quality delivered. They are:

• Variation of incoming ingredients.
• Variation in feed mixing efficiency.
• Variation in efficiency of delivery of mixed feed from mixing point to the animals.
• Variation in analytical procedures.

Maintaining Feed Quality Through the Application of Good Manufacturing Practices

Click here to view a video about a Canadian feed mill tour.

The management of a feed mill has an obligation to uphold Current Good Manufacturing Practices. The use and endorsement of appropriate and proper procedures and practices in the production of feeds do not cost the feed industry, they pay dividends. The feed mill manager is a key individual involved in the daily activities associated with the management of people, facilities and resources, that ensure the procedures appropriate for the production of feed in his/her feed mill are enforced. The feed mill manager, as his/her supervisors and the people working under their direction, have an obligation to the animal food industry to maintain high quality standards in the production of feeds for animals -- to produce meat, milk, eggs, etc. for the consumer.

Good Manufacturing Practices deal specifically with the manufacturing of any feed containing one or more feed additives. If any feed obtains a feed additive, it is a medicated feed. The feed mill management should have written instructions that cover GMP's and quality assurance programs. Good Manufacturing Practices cover all areas involved in the production of feeds including personnel, facilities, feedstuffs, quality assurance checks, inventory control checks, processing methods, mixing procedures, finished feeds, and feed delivery. Although commercial feed mills that produce and sell a complete line of feeds to the general public have a somewhat greater task in assuring quality and prevention of cross contamination of feed additives, the obligation and importance in all feed mills are still great. Outlines, checklists and procedures relevant to feed mill operations are presented below.

Personnel training are essential and should be conducted periodically to assure compliance with procedures and insure quality of feed produced. These meetings usually are helpful in establishing and maintaining good morale and teamwork among employees.

The feed mill and adjacent buildings must be of suitable construction to minimize access to rodents, birds, insects and other pests, and located in an area that will allow proper drainage. The building and grounds should be maintained as needed to assure a clean work place for employees and for the production of feeds. Litter, refuse, improperly stored equipment and supplies are hazards and should be removed. The building must also provide sufficient space for facilities and personnel to perform their job properly. Examples for the production of medicated feeds include:

• Appropriate area for receiving and storing of ingredients and feed additives
• Adequate space for grain processing, etc.
• Appropriate space for feed mixing
• Reserved area for equipment maintenance

Equipment must meet safety standards and be properly installed. All scales and metering devices must be tested for accuracy upon installation and at least once per year thereafter. Equipment must be constructed and maintained to prevent lubricants and coolants from contaminating ingredients or feeds. Excessive spills, leaks and dust problems must be prevented.

Ingredients should be systematically monitored for quality factors throughout the entire process of purchasing, receiving, sampling and handling. All ingredients should be inspected for any abnormality that may result in a quality risk when added to the feed, and representative samples taken for assays. During this handling of ingredients, care must be taken to prevent contamination.

Feed additives and premixes require special handling and record keeping. Records on feed additives received must show the following information:

• Name of feed additives, including potency.
• Date received.
• Amount in kilograms.
• Supplier's name.
• Supplier's code for feed additives (if applicable).
• Supplier's lot or code number.
• Return of any damaged or unacceptable feed additives.

Other procedures that must be followed in the storage, handling and use of feed additives include:

• Check each feed additive for identification. Do not accept unless properly identified.
• Keep all feed additives and premixes stored in a neat and orderly manner for easy identification. It is preferable to store feed additives in a separate room.
• Each bag or feed additive container must be coded with the supplier or company code for that feed additive.
• Packaged feed additives in the storage area must be stored in their original closed containers.
• Check bags for tears and any other abnormalities. Do not accept any feed additives that are not in good condition.
• Feed additives in the mixing area must be properly identified, stored, handled and controlled to maintain their integrity and identity.
• Clean up any spilled feed additives immediately, dispose of properly and record in the Feed Additives Inventory Record.
• Use a separate scoop for handling each feed additive.
• Feed additives and premixes must be used on a first received basis.

A daily inventory of feed additives and premixes is required. The Feed Additives Inventory Record should be completed at the end of each 24-hour period. One should check usage of each feed additive against medicated feeds produced. The feed additives container should be weighed before it is opened, and every kilogram of feed additive must be accounted for in usage or adjustment. (If a 20kg bag was purchased but the feed additives amount to 19kg, then list 1.0 adjustment). Other adjustments could be due to improper weighing and spillage.

• Cleaning processing and mixing of feed ingredients requires that personnel involved by thoroughly trained and properly supervised. Considerations for proper GMP's include the following.
• Screening of grains and use of magnets
• The grind should be as uniform as possible
• Flaking of grain should be accomplished with proper amount of steam, temperature and roll tolerance
• Mixing directions should be standard for a feed mill. (Certain mixed feeds may require specific directions)
• Prevention of contamination
• Checking for accuracy of all scales used for weighing ingredients (including feed additives) at least once per year.