EFFECT OF DIET FORMULATION AND MANUFACTURE TECHNIQUE ON PELLET PRODUCTION, NUTRIENT AND EXOGENOUS ENZYME RETENTION, BROILER PERFORMANCE AND INTESTINAL HEALTH

• Sponsoring Institution: National Institute of Food and Agriculture
• Project Status: COMPLETE
• Funding Source: HATCH
• Reporting Frequency: Annual
• Accession No.: 0217499
• Project Start Date: Mar 1, 2009
• Project End Date: Feb 28, 2014
• Program Code: [(N/A)]- (N/A)

Recipient Organization
WEST VIRGINIA UNIVERSITY
886 CHESTNUT RIDGE RD RM 202
MORGANTOWN,WV 26505-2742

Performing Department
Animal & Veterinary Science

Non Technical Summary
Poor pellet quality leads to suboptimal growth and loss of profit in broiler (meat-type chicken) production. Pellet quality is defined as the ability of a pellet to maintain its structural integrity through stressors associated with transport and conveyance of feed. High quality pellets improve broiler growth by allowing increased feed intake, improved productive energy, decreased feed wastage, and reduced ingredient segregation. Feed and feed manufacture contribute 60-70% of total costs associated with broiler production. However, up to 72% of pellets will lose their structural integrity before reaching the feed pan. Increasing the number of structurally sound pellets will increase broiler growth and decrease the total amount of feed needed to produce a market weight bird. Diet formulation and manufacturing technique directly affect pellet quality. In current industry practices, pellet quality is poor due to the utilization of least-cost diet formulations and high feed volume requirements. More importantly, there is a lack of information available to both poultry nutritionists and feed mill managers linking diet formulation and manufacturing technique to pellet quality. Therefore, there is an important need to understand what components of feed and feed manufacture have the potential to increase pellet quality and how variation in feed formulation and manufacturing technique will affect the growth and health of broiler chickens. Our long-term goal is to create a feed formulation program that will enable poultry nutritionists to formulate diets that will accurately predict pellet quality and improve broiler growth and health. Our objective in this proposal is to evaluate the effect that altering diet formulation and manufacturing technique will have on pellet quality, broiler growth, and intestinal health. This study will be the first step in the career-long creation of an altered and improved feed formulation program. A critical need for research involving pellet quality is evidenced by the fact that almost all commercial broilers are fed pelleted diets yet little research exists coinciding diet formulation and manufacturing technique. Our central hypothesis is that diet formulation and manufacturing technique are correlated and a proper combination of both techniques will optimize pellet quality. Our rationale for this study is that increasing pellet quality would allow maximum meat yield in a shorter period of time with less feed and directly increase profit for commercial agriculture. Only three universities in the United States are equipped with research-producing pilot feed mills - Kansas State University, North Carolina State University, and West Virginia University. The laboratory involved in this proposal has been, or is, affiliated with Kansas State University and West Virginia University and has studied pellet quality extensively and therefore are well-qualified and capable of successfully completing this proposal.

Animal Health Component

(N/A)

Research Effort Categories

Basic

(N/A)

Applied

(N/A)

Developmental

(N/A)

Classification

Knowledge Area (KA)	Subject of Investigation (SOI)	Field of Science (FOS)	Percent
302	3910	1010	15%
302	3220	1010	25%
302	3260	1010	10%
501	3220	1010	25%
501	3260	1010	10%
501	3910	1010	15%

Knowledge Area
302 - Nutrient Utilization in Animals; 501 - New and Improved Food Processing Technologies;

Subject Of Investigation
3220 - Meat-type chicken, live animal; 3910 - Cross-commodity research--multiple animal species; 3260 - Poultry meat;

Field Of Science
1010 - Nutrition and metabolism;

Keywords

feed manufacture

pellet quality

broiler performance

broiler metabolism

Goals / Objectives
Specific Aim #1: Evaluate the effects that altering diet formulation and/or manufacturing technique will have on pellet quality. Our working hypothesis, based upon strong preliminary data obtained at West Virginia University, is that altering diet formulation and manufacturing technique will optimize pellet quality. Moreover, understanding the interaction that exists between diet formulation and manufacturing technique will aid in optimizing pellet quality. Specific Aim #2: Evaluate the effects that altering diet formulation and/or manufacturing technique will have on broiler growth and feed conversion. Our working hypothesis is varying diet formulation and manufacturing technique alters nutritional value of feedstuffs and will affect broiler growth and feed conversion. Specific Aim #3: Evaluate the effects that diet formulation and manufacturing technique will have on broiler intestinal health. Our working hypothesis is that altering nutritional value of feedstuffs via diet formulation and manufacturing technique will result in alterations in intestinal morphology and gene expression.

Project Methods
Planned Studies/Activities/Approach. Formulation of Poultry Diets: Feed manufacture and pellet quality is heavily influenced by the ingredient profile of a poultry diet. A poultry ration will be formulated using least-cost ingredients and industry nutrient recommendations. Additionally, a research-based diet will be formulated based on the results of a comprehensive feed ratio study conducted at West Virginia University. Both diets will be isocaloric and formulated based on digestible amino acids using a commercial feed formulation program (Brill Feed Ration Balancer). It is necessary to use digestible amino acids because these diets will be fed to broiler chickens. If formulation based on digestible amino acids is not used, improvements in growth may be attributed to changes in amino acid digestibility instead of treatment differences. All diets will be considered nutritionally balanced according to the Brill Feed Ration Balancer Program. The research-based diet will contain higher, predetermined inclusions of protein and moisture because these components have been shown to increase pellet quality. All diets will contain common industry utilized feedstuffs, including corn, soybeans, dried distiller's grains with solubles, wheat middlings, and animal fat. Manufacture of Experimental Treatments: Variation in pellet quality is highly influenced by production variables associated with feed manufacture. Two manufacturing techniques - a thin die utilizing a production rate of approximately 1.25 ton/hr and a thick die utilizing a production rate of approximately 0.83 ton/hr - will be utilized. A 2x2 factorial design [diet formulation (least-cost vs research-based) x manufacturing technique (thin-fast vs thick-slow)] will comprise the experimental treatments. Evaluation of Thermomechanical Disruptions in Experimental Treatments: The additions of hot steam and the pressure of pelleting may result in thermomechanical changes in feed ingredients. For example, the amount of starch gelatinization and the amount of protein denaturation are factors that may improve pellet quality. The extent of alteration may be influenced by retention time in the conditioner and residence time in the die. Additionally, we expect variation in nutrient profile (the ratio of protein to other ingredients) and variation in moisture content to highly influence thermomechanical changes in feed ingredients. Statistical Evaluation: All production variables, pellet quality variables, and analyses of pellet samples will be analyzed using a latin square design. Multiple comparisons will be performed to explore differences between treatments. Significant differences will be explored using Fischer's Least Significant Difference (LSD) test. A diet formulation x manufacturing technique factorial will be used to determine main effects and the interaction. Statistics will be calculated using the GLM analysis of variance procedure of the Statistical Analysis System (SAS).

Progress 03/01/09 to 02/28/14

Outputs
Target Audience: The target audience for this final report would include poultry integrators, feed mill managers, and non-ruminant nutritionists. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided? This project has provided a basis for numerous graduate students to be trained. These students have done an outstanding job in presenting data at national meetings that has led to recognitions of excellence by way of meeting awards. All speaking invitations provide professional development. How have the results been disseminated to communities of interest? Abstracts presented at national and international meetings. Peer-reviewed journal articles. Proceedings from meetings associated with invited presentations. Extension presentations throughout West Virginia and surrounding states. Invited industry presentations. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? Support for exploring these specific aims was used to generate additional funding to expand research opportunities. The aforementioned hypotheses were tested and data generated contributed to numerous abstracts presented at scientific meetings, proceedings papers associated with invited seminars, and 19 peer-reviewed publications. The impact of these accomplishments was great, evidenced by invitations to speak at very prestigious national and international meetings. For example, this past year I was a key note speaker at the Arkansas Nutrition Conference that many would describe as the most pretigious poultry nutrition conference in the US. J.S. Moritz. Pellet Quality Performance Tests: Milling to Bird Performance. Arkansas Nutrition Conference. September 3-5, 2013. Rogers, AR. In addition, I was asked to speak at the European Symposium for Poultry Nutrition in Cesme, Turkey. J.S. Moritz. Effects of feed manufacture on nutrient requirements of poultry. Proceedings of the 18th European Symposium on Poultry Nutrition. October 31- November 4, Cesme, Turkey.

Publications

• Type: Journal Articles Status: Accepted Year Published: 2013 Citation: Wamsley, K.G.S., and J.S. Moritz. Resolving poor pellet quality and maintaining amino acid digestibility in commercial turkey diet feed manufacture. 2013. J. Appl. Poult. Res. 22:439-446.
• Type: Journal Articles Status: Accepted Year Published: 2013 Citation: Wamsley, K.G.S., and J.S. Moritz. The use of practical diets and regression analyses to determine utilization of lysine and phosphorus in corn distillers dried grains and solubles using Cobb 500 male broilers. 2013. J. Appl. Poult. Res. 22:279-297.
• Type: Journal Articles Status: Awaiting Publication Year Published: 2013 Citation: Evans, A.M., B.N. Swiger, K.P. Blemings, M.S. Lilburn, and J.S. Moritz. Effect of Strain and Finisher Diet Non-Phytate Phosphorus Level on Performance and Litter Composition in Large Tom Production. International Journal of Poultry Science. Accepted.

Progress 01/01/12 to 12/31/12

Outputs
OUTPUTS: The results of this project in the year 2012 have been disseminated through peer-reviewed abstracts and publications as well as popular press articles. In additiion, data generated from this project has been presented in several invited research presentations. J.S. Moritz. Temperatures: Processing Quality vs. Nutritional Quality. Poultry Protein and Fat Seminar. US Poultry and Egg Association. October 3-5, 2012. Nashville, TN. J.S. Moritz. Pellet Quality. Feed Mill Management Seminar. US Poultry and Egg Association. March 20-22, 2012. Nashville, TN. J.S. Moritz. Maintaining Feed Quality. Virginia State Feed Association Conference and Nutrient Management College. February 15-17, 2012. Roanoke, Virginia. J.S. Moritz. Virginia State Feed Association Conference (Feed mill managers dinner). February 15th, 2012. Roanoke, Virginia. Maintaining Feed Quality in Poultry Feed Mills. PARTICIPANTS: Graduate students - Staci Loop, Kala Beaman, Kelley Wamsley, Curran Gehring, Laurel Shires, Leonel Mejia Industry collaborators - Eddie Fontanna, Mosaic Feed, Mike Persia, Syngenta College Collaborators - Phil Turk, Department of Statistics University Collaborators - Alex Corzo, and Chris McDaniel, Mississippi State University TARGET AUDIENCES: Poultry Integrators Feed manufacture companies Producers Researchers PROJECT MODIFICATIONS: Not relevant to this project.

Impacts
Inorganic feed phosphates are often incorporated into commercial feed formulations to meet nutritional requirements and enhance feed manufacture; however, peer-reviewed publications supporting the enhancement of manufacture are limited. The inclusion of TCaP decreased energy consumption of the pellet mill in both experiments. The inorganic feed phosphate source affected pellet durability; however, overall feed quality differences were minimal and would likely not affect bird performance upon feeding. Feed ingredient price has influenced nutritionists to improve diet nutrient availability through the use of exogenous enzyme cocktails (EEC). This experiment indicated no benefit from the EEC on 4- to 21-d broiler chick performance. Experiment 2 used increased mixer-added fat and similar conditioning temperatures relative to experiment 1, but with no benefit. Experiment 3 used similar diet formulations as experiment 2, a thinner pellet die, conditioning temperatures of 71, 77, and 82 degree C, and the inclusion of an unconditioned mash treatment. Benefits from the EEC were demonstrated for BW gain and FCR for the unconditioned mash treatment. Overall, on the basis of these studies, future evaluations of EEC efficacy postpelleting should consider several manufacturing variables. It has been shown in previous studies that older broilers can be affected by feed form, particularly as it relates to the pellet quality not allowing these birds to express their full growth potential. lysine and feed form interacted for effects on BW gain and feed conversion, resulting in birds fed Ma attaining BW gain and feed conversion values similar to those in chicks fed CM and PC, but only when lys was fed at the highest level. Based on regression analysis, BW gain and feed consumption of chicks fed the PC diets responded much quicker to increasing dietary lys levels than did BW gain and feed consumption of chicks fed the Ma and CM diets, and chicks achieved greater BW gain and feed consumption at similar lys concentrations. Furthermore, chicks fed the PC diets achieved their optimal response with less dietary lys. overall, there is a need to achieve optimal pellet quality as a way to avoid excessive dietary lys concentration, in turn allowing broiler chicks to express their full growth potential. Most commercial broilers are fed pelleted diets containing an exogenous phytase. Various techniques exist to prevent denaturation of phytase during pelleting, but the potential remains for phytase to lose efficacy in liberating phytate-bound phosphorus. Seven out of 9 enzymes resulted in BW gain similar to that of the positive control diet. Five of those enzymes resulted in decreased FCR by an average of 8 points compared with the other 2. Tibia measures demonstrated additional differences among enzyme treatments. Phytase activity did not positively correlate with performance or bone mineralization measures. Therefore, evaluations of phytase may need to include in vivo bird testing beyond in vitro activity assays to fully assess efficacy.

Publications

• Wamsley, K.G.S., C. K. Gehring, A. Corzo. E.A. Fontana, and J.S. Moritz. Effects of inorganic feed phosphate on feed quality and manufacturing efficiency. 2012. J. Appl. Poult. Res. 21: 823-829.
• Beaman, K.R., K.G.S. Lilly, C.K. Gehring, P.J. Turk, and J.S. Moritz. 2012. Influence of pelleting on the efficacy of an exogenous enzyme cocktail using broiler performance and metabolism. J. Appl. Poult. Res. 21: 744-756.
• Loop S.A., K.G.S. Lilly, L.K. Shires, C.K. Gehring, K.R. Beaman, M.E. Persia, and J.S. Moritz. 2012. Phytase analytical activity of pelleted diets may not adequately describe efficacy in the bird. J. Appl. Poult. Res. 21: 492-501.
• Corzo, A., L. Mejia, C. D. McDaniel and J.S. Moritz. 2012. Interactive effects of feed form and dietary lysine on growth responses of commercial broiler chicks. J. Appl. Poult. Res. 21: 70-78.
• Shires, L.K., S. A. Loop, C. K. Gehring, K. G. S. Lilly, K. R. Beaman, P. J. Turk, and J. S. Moritz. 2012. Justifying phytogenic feed additive matrix values in conjunction with exogenous feed enzymes. J. Appl. Poult. Res. 21: 39-47.

Progress 01/01/11 to 12/31/11

Outputs
OUTPUTS: Valuable information was discovered and reported in peer-reviewed abstracts, papers, symposia, and invited presentations. In general, we found that pellet quality has an economic effect on poultry production and nutrients can be altered due to the manufacture process. PARTICIPANTS: The Virginia Poultry Grower's COOP was instrumental in generating data concerning feed manufacture effects on commercial turkey strains. TARGET AUDIENCES: All poultry professionals. PROJECT MODIFICATIONS: Not relevant to this project.

Impacts
The facilities at West Virginia University were key to acheiving our research conclusions. Our feed mill is one of three "research active" University feed mills in the U.S. The main impact was publication of results that likely resulted in proceedural changes in the poultry industry.

Publications

• K. G. S. Lilly, C. K. Gehring, K. R. Beaman, P. J. Turk, M. Sperow, and J. S. Moritz. Examining the relationship between pellet quality, broiler performance, and bird sex. J. Appl. Poult. Res. 2011, 20: 231-239.
• J.S. Moritz. Manipulating amino acid and phosphorus in male turkey diets to optimize performance and reduce environmental impact. Proceedings of the Multi-State Poultry Feeding and Nutrition Conference. May 24-26, 2011, Indianapolis, IN. (refereed proceedings) Invited Speaker
• J.S. Moritz. 2011 Effects of feed manufacture on nutrient requirements of poultry. Proceedings of the 18th European Symposium on Poultry Nutrition. October 31- November 4, Cesme, Turkey. (refereed proceedings) Invited Speaker
• K.G.S. Lilly and J.S. Moritz. Feeding broilers high-quality pellets shows positive economic return. Watt Poultry USA. August 2011. P 26-29. (refereed trade journal)
• J.S. Moritz and L.K. Shires. Poultry litter ash as a pelleting aid and mineral source. Feedinfo News Service. March 21, 2011. (refereed trade journal)
• J.S. Moritz. Manipulating amino acids and phosphorus in male turkey diets to optimize performance and reduce environmental impact. Feedinfo News Service. May 31, 2011. (refereed trade journal)
• C. K. Gehring, K. G. S. Lilly, L. K. Shires, K. R. Beaman, S. A. Loop, and J. S. Moritz. Increasing mixer-added fat reduces the electrical energy required for pelleting and improves exogenous enzyme efficacy for broilers. J. Appl. Poult. Res. 2011, 20: 75-89.

Progress 01/01/10 to 12/31/10

Outputs
OUTPUTS: Least-cost diet formulations and pellet mill operating techniques vary widely. As a result, pellet quality is often inconsistent. Past research has associated pellet quality changes with feed formulation and manufacturing techniques. However, the interaction between the 2 factors has rarely been explored. The objective of the current study was to evaluate the effects of altering a least-cost diet (LC) formulation and altering manufacturing techniques on pellet processing variables and quality. Optimizing the diet formulation and manufacturing technique improves pellet quality. However,high pellet quality must equate to improved broiler performance to justify the increased cost output. The objective of the current study was 2-fold: 1) to assess broiler performance based on changes in pellet quality obtained by altering the diet formulation and manufacturing technique, and 2) to assess broiler performance when using pelleted diets including andexcluding antibiotics. The price of fat and diet formulation with exogenous enzymes have reduced the amount of fat added to broiler diets. Although diets may be cheaper to produce, there is potential for nutrient and exogenous enzyme destruction with low inclusions of fat (0.5-1%) because of frictional heat and shear forces produced in the pellet die. Additionally, much of the added fat may be applied using post-pellet spray application and the amount of fat added in the mixer may become negligible. Thermal inactivation of exogenous enzymes and occurrence of unfavorable reactions (e.g., Maillard reaction, protein cross-linking, etc.) may be abated by increased levels of fat included at the mixer prior to pelleting, i.e., mixer-added fat (MAF). Pelleted feed increases BW gain and FE in broilers when compared with mash feed. However,the improvement in broiler performance may rely on pellet quality. At the West Virginia University pilot feed mill and broiler housing facilities, 2 experiments were conducted. In experiment 1, pellets were produced through varying pelleting techniques to create 5 diets unique in feed form. These diets were fed to male Cobb 500 broilers for performance evaluation. The expected broiler performance was not observed, perhaps because the nutrient availability of the diets was affected by altering the pelleting technique. Experiment 2 was designed to explain variations in feed form on broilers of varying sex categories, with consistent nutrient availability among treatments. PARTICIPANTS: Not relevant to this project. TARGET AUDIENCES: nutritionists feed mill managers researchers PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.

Impacts
We conclude that diet formulation and manufacturing technique are, in fact, linked and must be considered when attempting to optimize pellet quality. In conclusion, to maximize broiler performance, the diet formulation and manufacturing technique must be considered. It is likely that increased MAF improved exogenous enzyme retention and nutrient utilization by broilers. Subject to current fat prices, increasing MAF may reduce the total cost of broiler production, particularly when reduction of electrical energy usage is considered. Males had improved feed conversion and were larger than females, and those in the group with an equal male:female ratio were intermediate. Whole pellets in the diet improved FCR compared with ground pellets. Broilers fed high-quality pellets exhibited the greatest carcass weight. An economic model based on intake, 2 scenarios of feed costs, and carcass weight was created using the data obtained from experiment 2.

Publications

• K. G. S. Lilly, C. K. Gehring, K. R. Beaman, P. J. Turk, M. Sperow, and J. S. Moritz. 2010. Examining the relationship between pellet quality, broiler performance, and bird sex. J. Appl. Poult. Res. Accepted.
• C. K. Gehring, K. G. S. Lilly, L. K. Shires, K. R. Beaman, S. A. Loop, and J. S. Moritz. 2010. Increasing mixer-added fat reduces the electrical energy required for pelleting and improves exogenous enzyme efficacy for broilers. J. Appl. Poult. Res. doi:10.3382/japr.2009-00082.
• N. P. Buchanan, K. G. S. Lilly, and J. S. Moritz. 2010. The effects of diet formulation, manufacturing technique, and antibiotic inclusion on broiler performance and intestinal morphology. J. Appl. Poult. Res. 2010 19: 121-131.
• N. P. Buchanan, K. G. S. Lilly, C. K. Gehring, and J. S. Moritz. 2010. The effects of altering diet formulation and manufacturing technique on pellet quality. J. Appl. Poult. Res. 19: 112-120.

Progress 01/01/09 to 12/31/09

Outputs
OUTPUTS: Much work has been conducted on feed manufacture effects on enzyme and nutrient retention. Several abstracts have been published and presented at national meetings and several papers have been submitted for publication. PARTICIPANTS: Not relevant to this project. TARGET AUDIENCES: feed mill managers, nutritionists, researchers PROJECT MODIFICATIONS: Not relevant to this project.

Impacts
MAIN EFFECTS AND INTERACTIONS OF VARYING FORMULATION PROTEIN, FIBER, AND MOISTURE ON FEED MANUFACTURE AND PELLET QUALITY Conclusions and Applications 1. A 5% inclusion of soy protein isolate or cellulose improves pellet quality without negatively affecting pellet manufacture variables. 2. Supplemental protein (2%) in the form of soybean meal and supplemental moisture (2 and 4%) in the form of tap water improve pellet quality. 3. Supplemental fiber (2 and 4%) in the form of oat hulls negatively affect pellet manufacture variables and pellet quality. 4. Significant nutrient interactions did not exist between fiber, protein, and moisture for pellet manufacture variables and pellet quality. However, increased moisture retention in the stored pellet indicates a possible increase in thermomechanical reactions.

Publications

• Buchanan, N.P. and J.S. Moritz, 2009. Main effects and interactions of varying protein, fiber, and moisture on feed manufacture and pellet quality. J. Appl. Poult. Res. 18:274-283