Problems with feed formulation

Problems with feed formulation

1. Ignore recipe space as nutritional needs

The initial limit in the feed formula system is usually the default (set to 100%). This is important both for understanding recipe space costs and for warning when errors occur. If the weights are set only for maximum or minimum nutrient requirements, and several ingredients are provided, the software will choose the cheapest ingredient to meet 100% of the maximum-minimum weight setting.

The formula space also affects the final formula cost and the shadow price of the raw materials used to formulate the feed. Shadow price refers to the unit value of each ingredient or nutrient in the optimal formulation. In general, when preparing a formula that is rich in nutrients and has a high concentration, raw materials with a high concentration of nutrients should be selected, and vice versa. Raw material supply is just a simple nutritional issue, such as lysine. The content of different raw materials will have an important impact on the final cost of the formula and the value (shadow price) of the raw material. In most cases, raw materials are purchased solely based on their nutritional content per unit, rather than the shadow price in the feed formulation. Taking lysine as an example, 78% lysine is better and has greater value in high nutrient concentration feeds, while 40% lysine or 50% liquid lysine may be more popular in low concentration formulas . The evaluation of feed ingredients is not limited to the cost per unit of nutrition, but also considers their final value, impact on final feed cost, and space for manufacturing feed.

2. Establish conflict suppression

Conflict suppression does not mean feed formulations that result in infeasibility. They can be subtle and may improve performance but at the same time increase feed costs. For example, set a minimum relationship between amino acids and crude protein. Operators must be aware of amino acid limits that meet their minimum requirements and minimize costs and their impact on crude protein levels. Understand the relationship between related nutrients or ingredients and know how to limit their impact on the cost of the final product and its formulation.

3. Advanced recipe functions

Given the same data, all formulation software should produce the same results. However, the speed, flexibility, and ease of operation of each software are quite different. The system must be able to produce at least the lowest cost recipe for each product, given the nutrient requirement table and available raw materials.

The real difference between formula systems is the ability to provide additional functions as a management tool. If the formula has been determined, the amount of each raw material required to produce several tons of products can be given. The cost of raw materials often accounts for 70% to 80% of the selling price of feed. A slight improvement in the efficiency of raw material procurement can have a greater impact on profitability.

For functions such as research, development, procurement and production, formulation technology can be a valuable decision-making tool. In addition, advanced models using linear programming can help determine whether raw materials purchased and distributed from different origins at different prices should be considered, rather than one production location. When there is a surplus or shortage of raw materials, these models can even highlight the allocation of raw materials to produce special products to save costs. More specialized models have emerged based on the operating principle of maximizing benefits rather than minimizing costs.

4. Precautions for good feed formulation design practices

All feed factories must comply with GMP standards and must also comply with HACCP rules. Good formula designs are produced in research laboratories. Control the initial review and then review it periodically to build up the recipe database. Remember this adage: your output is actually determined by your input.

5. Establish nutritional content standards for each raw material

Published data can provide good guidance for establishing feed dosage levels, but the maximum and minimum dosage of raw materials still need to take into account the following aspects:

(1) Quality assurance/control procedures: The nutritional composition analysis data of each raw material used and the detailed description of the raw material specifications determine the amount of each raw material used in the diet. If some or all of the control procedures are missing, the maximum use standards will be lower than the published ranges; conversely, for good software with good nutrient data, wider maximum limits may be available.

(2) Time factor: Various raw materials and feed products must circulate efficiently during the feed production and transportation process. Reduced feed production efficiency due to purchased ingredients can offset the cost savings achieved through formulation design. Likewise, while feeds with high fat additions store well in warmer climates, they can create extreme problems during the colder seasons, such as during handling, transportation and in feed tanks. The amount of raw materials added and the nutritional standards should change with the seasons.

(3) Feed type/production stage: Raw materials such as cereals and animal proteins should have certain limits, so that extreme changes in diet composition will not occur and impact on animal production performance. The particle size of the same raw material in different feed products is allowed to be different, otherwise it will affect animal health and production performance.

(4) The relationship between raw materials and nutrients: Do not set limits for raw materials containing only one nutrient, otherwise it will cause nutrients such as salt and sodium to be lower or higher than the standard requirements.

(5) Shadow price: The shadow price of a raw material indicates its value under a given dietary limit. The lower shadow price limit refers to the maximum amount of the raw material available at this price; the higher shadow price limit refers to the maximum amount of the raw material available at this price; the higher shadow price limit It refers to the lowest quantity of the original quantity available at that price. When the actual cost is lower than the upper limit of the shadow price, setting the maximum amount of a raw material added will increase the feed cost. At this time, it is necessary to consider relaxing the limit (such as raising the maximum limit of poultry by-products from 5% to 8%). Manufacturers should be aware that shadow prices and limits can affect final feed costs.

(6) Multiple optimization programs: Today’s commonly used feed formula software can adjust the dosage of each raw material in the formula to achieve the best feed. It is not only important to pay attention to the limits of nutritional ingredients in a single diet, but also in all diet formulations. Apply the above principles to find the optimal limit based on shadow prices and final feed costs.

6. Determine the recipe with the lowest cost and least controversy

Determining the production quantities of a given feed product and the frequency of formula changes requires good communication between nutrition, marketing, production, purchasing and production personnel. Changes in each of the above aspects need to take into account the needs and requirements of other aspects. Changes in formulas not only depend on reducing the cost of raw materials, but also require careful consideration of raw material supply, forecasting the demand for raw materials, the cost of feed mills changing new formulas, etc.

7. Formula software and its design

Today’s computers are reliable, but the computers themselves are far less important than the software. The software provides reasonable cost, high productivity and reliability. However, perfect software does not exist. Software was invented by humans, and humans themselves are not perfect, so the software they design is not perfect either. A few problems with software usually mean that the designers are working on improving the product with new features and staying on the cutting edge of technology.

The most important quality of a software designer is the ability to respond to changing technologies and consumer needs. As mentioned earlier, the development of recipe software requires a combination of technology and knowledge from different fields. All software designers have the ability to write programs. However, not all formulation software companies have the ability to develop and maintain the mathematical operation of linear planning. While this technology serves the smallest production formulations, it has very limited adaptability for growth and more efficient use. As functional improvements and additional capabilities are recognized in feed formulations, they have the ability to respond without relying on external resources for R&D and assistance.

More informations about feed pellet machinery