Toaster (full fat soybean)
One of Agrotechnology's unique technologies is the Toaster (rotary oven), which has been designed for various purposes within the processing of raw materials for animal feed use: toasting, drying, gelatinisation, sterilisation.
Toasting
Making raw materials digestible and editable for animal feed.
Raw materials such as soya beans and pulses cannot directly be used as animal feed without prior processing due to the presence of biologically active inhibitors, such as trypsin, urea and other known allergy inducing agents.
Those inhibitors make the raw materials inedible by the animals and as a consequence unsuitable to feed. Amongst others those bacteria and inhibitors can cause inflamations in the stomach of the animal (eg. poultry) and hence reduce the digestibility. This in return has a strong negative impact, shown through scientific studies, on the development (growth and health) of the animals.
Processing those raw materials with the Toaster and hence exposing them short term to high temperatures reduces the bacteria and destroys inhibitors to a level which makes them suitable to feed to animals. For detailed information on the nutritional and inhibitor level see the table below.
Furthermore, in contrast to soya bean meal and cake, soya beans processed with the Toaster are full fat and contain its full oil level. The oil in soya beans is highly nutritious, posesses a high level of energy and carries various essential vitamins which all together foster the development of the animal fed with full fat soya, both in terms of growth and health. This is shown through scientific studies and is confirmed by our customers who use our technology.
Another advantage is the low processing cost. Comparing it to other technologies i.e. extruding and pressing, which also have the goal of making the raw material editible, require a heavy energy input. Therefore, processing large quantities leads to a strong cost benefit.
Lastly, due to the heat treatment of the raw material and the subsequent lower humidiy level, it makes the raw material long lasting and storable. As in the example of toasted soya beans they can be stored for several months up to about a year as they have a low humidity level, are still in its original form (not pressed) yet made digestible for animal feed. Therefore, our customers can achieve hedging of commodity prices, buying at low market prices, processing the raw material and subsequently storing it.
In short, processing raw materials such as soya beans with the Toaster provides 3 main advantages:
- Higher nutritional value as commonly used processing methods eg. soya cake/ meal
- Faster animal growth
- More healthy
- Lower (processing) cost
- Long storage capabilities (hedging of raw material prices)
Drying
The Toaster is designed to dry and toast grain and similar free-flowing products such as wheat, barley, soya beans, pulses and oilseeds, and also for thermal processing of eggshell. It is well suited to dry products with a high water content or a consistency which makes them unsuited to drying in a column dryer. Energy efficient drying is achieved when the rotary oven is deployed together with a Counter-flow cooler:
Gelatinisation
Wheat, oats, barley and maize for animal feed
Infra-red radiation penetrates cereal husks creating high internal temperatures and efficiently breaking down complex starches thus increasing digestibility and adding to the nutritional value of the treated product without a long destructive heating process.
Sterilisation
The Toaster can be used to sterilise cereals for consumer products and animal feed.
Exposure to temperatures between 100 ºC -120ºC reduces the bacterial and fungal count significantly and effectively sterilises cereals without significantly breaking down amino acids and vitamins.
Post-toasting treatment of raw meterials
Conditioning /flaking
After processing raw meterials with the Toaster -such as soya beans, cereals and pulses- the resulting product becomes soft and malleable. Therefore, processed raw meterials can be flaked without significant dust production and without loss of natural colour and appearance.
|
Typical analysis for processed wheat: | Bacteriology: | ||
|---|---|---|---|
|
Protein |
12,5% |
Total count |
< 10,000 / g |
|
Carbohydrates |
72,5% |
Yeast |
< 1,000 / g |
|
Ash |
1,5% |
Mould |
< 1,000 / g |
|
Moisture |
8,5% |
Hemolytic bacteria |
< 1,000 / g |
|
Fibre |
3,0% |
B. cereus |
< 100 / g |
|
Fat |
2,0% |
Salmonella |
no trace in 50 g |
|
Total |
100% |
||
|
Calorific value FEs/100 Kg feed |
123 |
||
|
Тypical analysis for toasted soya beans: |
Bacteriology: | ||
|---|---|---|---|
|
Protein |
38,0% |
Total count |
< 10,000 / g |
|
Carbohydrates |
25,0% |
Yeast |
< 1,000 / g |
|
Ash |
5,0% |
Mould |
< 1,000 / g |
|
Moisture |
7,5% |
Hemolytic bacteria |
< 1,000 / g |
|
Fibre |
5,5% |
B. cereus |
< 100 / g |
|
Fat |
19,0% |
Salmonella |
no trace in 50 g |
|
Total |
100% |
Urea |
0,02 -0,2 mg N / g /min. |
|
Calorific value FEs/100 Kg feed |
146 |
Trypsin inhibitors |
5,000 - 10,000 TIU / g |
Technical data
|
Detail |
Data |
|---|---|
|
Oven temperature |
200ºC - 960ºC |
|
Product temperature |
45ºC - 120ºC |
|
Energy consumption |
800 - 950 kcal/Kg water removed |
Measures
|
Type |
A |
B |
C |
D |
E |
F |
G |
|---|---|---|---|---|---|---|---|
|
AT 800 |
1350 |
6600 |
6980 |
Ø900 |
Ø1270 |
2430 |
800 |
|
AT 1500 |
2470 |
7800 |
8250 |
Ø1200 |
Ø1620 |
2690 |
800 |
|
AT 2500 |
2300 |
8900 |
9600 |
Ø1360 |
Ø1860 |
2910 |
800 |
|
AT 2500 S |
3000 |
10900 |
11150 |
Ø1608 |
Ø2130 |
3210 |
800 |
Product models
|
Type |
AT 800 |
AT 1500 |
AT 2500 |
AT 2500S |
|---|---|---|---|---|
|
Power burner unit (kW) |
800 |
1 500 |
2 500 |
2700 |
|
Water evaporation capacity (kg/h) |
800 |
1 500 |
2 500 |
2700 |
|
Air outlet at 110 C (m3/h) |
7 000 |
11 000 |
16 000 |
22000 at 85-95 ºС |
|
Capacity |
Ranges from 1-12 t/h |
|||