Case Study: Better animal nutrition through reliable process technology in biotechnology
Modern agriculture is facing the task of feeding a growing world population while at the same time optimizing the health and performance of livestock. A key aspect in this context is the continuous improvement of animal nutrition. And this is where reliable process technology in biotechnology plays a decisive role. Lactic acid bacteria improve intestinal health and promote digestive function in livestock. Starter cultures are also used in the food industry, particularly in the production of dairy products and other fermented foods. These cultures initiate the process leading to the finished food and contribute to quality and flavor development. They therefore have an indirect but important influence on the nutrition of animals based on such foods. The production of these bacteria in turn requires not only precision, but also innovative process technologies to ensure the highest standards of purity and quality.
A complex production process
The sophisticated production of lactic acid bacteria is subject to careful control and monitoring to guarantee the desired properties of the end product.
The starting point is a fermentative process in which lactic acid bacteria, in particular Lactobacillus and Streptococcus, are used. These bacteria convert milk sugar (lactose) into lactic acid. Fermentation takes place in special fermentation containers under controlled conditions such as temperature, pH value and nutrient content.
The specific introduction of microorganisms capable of growth, known as inoculation of the milk, begins with a suitable quantity of lactic acid bacteria cultures. Before the main fermentation, the bacteria can be pre-propagated to increase the number of viable cells. These cultures can be obtained from previously successful fermentations.
The duration of fermentation varies depending on the product and the desired texture. It can range from a few hours to several days. During this process, the lactic acid bacteria multiply and produce lactic acid, which leads to acidification of the milk.
Fermentation is stopped when the desired acidity is achieved, or the product has the desired consistency and taste. This can be accomplished by cooling or increasing the pH value.
Pioneers in agricultural lactobacilli
An Austrian company following this approach is a leading player in the field of lactic acid bacteria production. Since its foundation, the agricultural biotechnology company has been offering lactic acid bacteria as probiotics and starter cultures for silage, farms and animal feed producers. The original product range of two items has grown into a broad portfolio of about 600 products, which is distributed in over 50 countries worldwide. These include special products based on live lactic acid bacteria for the ensiling of fresh plant material, animal feed or energy crops for biogas production.
The variety of products allows livestock farmers and feed manufacturers to choose from different options to meet the specific needs of their animals. As a result, the company now has a significant influence on the global pet food industry.
The challenge, however, is to keep up with the increasing demand while meeting the highest quality standards. Investments in state-of-the-art research and development laboratories as well as an in-house fermentation plant demonstrate the company's will to innovate. The large-scale production of biocatalytic enzymes offers the opportunity to use advanced technologies in animal nutrition and feed production.
This is where the collaboration with Hecht Technologie begins. HECHT, known for its innovative solutions in special system construction and advanced systems in the field of containment and powder handling, was selected as a partner to plan and implement parts of a new production facility.
A groundbreaking partnership
This successful collaboration is intended to serve as an outstanding example of process technology in biotechnology and to illustrate the importance of reliable components in the production side. Not only ease of operation should be guaranteed, but also high safety standards in the containment area. This is especially important to avoid contamination of starting materials and end products.
Even in the run-up to the event, the process technologist from Pfaffenhofen a. d. Ilm was able to distinguish itself through various tests on site. Through tests in the company's own technical center, which simulated the subsequent operation, the reliability of the powder handling and the conveying by HECHT components could be demonstrated. The good preparation and impressive execution of the tests formed the basis for the later commissioning of the plant production. The entire system integrates several HECHT components, including from the process steps of discharging, conveying, dosing and filling, and underlines the versatility of HECHT's technologies.
An extensive and challenging project
In addition to the criteria for safe and easy operation of the system, other outstanding features were in the areas of containment and cleanability. The production machinery was designed to meet the high requirements, as these aspects are crucial for the quality of the lactic acid bacteria. In total, the order consisted of five lines and included components such as Big Bag discharging stations, pneumatic conveyor systems, weighing containers and Big Bag filling stations. The description as "extensive and challenging" did justice to the project and gave an idea of the technical and logistical task. However, due to the preliminary tests at HECHT and the professional cooperation of all those involved, no critical decisions were made, which made the entire course of the undertaking noiseless.
Innovative process technologies from Hecht
The expansion of production capacities not only enables greater efficiency in existing products, but also opens new business areas, such as the production of biocatalytic enzymes for industrial biotechnology. At this point, the central role of reliable process technology must be mentioned. The functions of the system can be represented in five systems.
In a mixer line, raw materials are fed either via one of two Big Bag discharging stations with Solivalve system or via drums and one of three suction lances. The conveying is carried out by means of HECHT ProClean Conveyor (PCC 200), by means of an on-site screening machine, which is equipped with a false air addition. The PCC 200 is filled in a defined way through a scale. The filled weight is ejected into the weighing container when filled correctly. If incorrect dosing has occurred, the product can only be discharged into the downpipe and removed from the filling process by a smaller pneumatic conveyor (PCC 100) and a continuous liner filling head. The weighed product is then filled from the weighing container into an on-site mixer. Parallel to the weighing hopper with pneumatic conveying, products can be fed via a bag hopper with a sieve insert and with a downstream weighing hopper. A Big Bag filling station is used to fill the end product.
In the pickling line, the materials are conveyed via one of two weighed Big Bag discharging stations by means of a PCC 300 with two inlet connections and discharged into a downstream on-site container. A vapor barrier is installed between the PCC 300 and the on-site tank to prevent vapors from rising from the tank.
In the can filling line, products are fed via a Big Bag discharging station with Solivalve. The conveyance takes place using a PCC 200 through an on-site screening machine, which is equipped with a false air inlet. The conveyed product is discharged into a downpipe, which serves as a buffer tank for a downstream on-site filling system. The filling capacity of the system is approx. 250 kg in 6 h.
In the crushing line, products are extracted from one of two mixers via a suction shoe by means of a PCC 200 and fed into a mixer. From this mixer, the products are filled into Big Bags at the Big Bag filling station.
In addition, the harvest tank line includes three Big Bag filling station, with identical design and function. The operator feeds products into an on-site container via the Big Bag hopper. A vapor barrier prevents vapors from rising from the on-site container into the drop line.
Overall, the system can be cleaned and dried completely automatically step by step after some modification work. Depending on the line, cleaning is done selectively or several times a week.
Conclusion
This success story of the collaboration between the biotechnology company and Hecht Technologie highlights the importance of reliable process technology in biotechnology to produce animal nutrition.
The use of innovative technologies not only increases efficiency, but also ensures the quality and purity of the products. The partnership between these companies helps to ensure sustainable and high-quality food production for animals that meets ever-increasing quality standards.
