FEED MILL MANUFACTURING TECHNOLOGY. PO (ANS) 425 Sec. 601

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1 Instructors FEED MILL MANUFACTURING TECHNOLOGY (FORMERLY FEED MILL MANAGEMENT AND FEED FORMULATION) PO (ANS) 425 Sec. 601 Dr. Peter R. Ferket, Ph.D Professor of Nutrition Department of Poultry Science Dr. Charles Stark, Ph.D. Assistant Professor, Feed Science and Technology Dr. Peter R. Ferket Office: 234 E Scott Hall Telephone: [email protected] Office hours: By appointment. Dr. Ferket's Brief Biological Background Office: 234 C Scott Hall Telephone: [email protected] Office hours: By appointment Dr. Peter Ferket is a native of Canada where he grew up on the family swine and poultry farm near London, Ontario. He earned a B.S. degree in Animal and Poultry Science at the University of Guelph in He was awarded an M.S. degree in poultry nutrition from the University of Guelph in 1983, and a Ph.D. degree in animal nutrition from Iowa State University in In 1988, Dr. Ferket joined the Department of Poultry Science at North Carolina State University where he is responsible for extension education, research, and teaching in the discipline of nutrition, feed formulation, and feed mill management. He has devoted much of his extension and research efforts on nutritional factors that affect growth and health of poultry, with a special interest in turkeys. His work also addresses animal nutrition and environmental issues, nutrient emissions, by-product processing and utilization, feed formulation, and feed mill management. Dr. Ferket is recognized internationally as a frequent speaker at animal and poultry nutrition conferences. He has authored several publications in poultry nutrition, feed manufacturing, and by-product evaluation. Course Prerequisites Introductory Nutrition NTR (ANS, PO) 415 or ANS 230 at N.C. State University; or a basic course in animal and/or poultry nutrition, or animal production; or industry experience.

2 Course Overview This course is about the the art and science of commercial feed manufacturing. The purpose of this course is to introduce you to the feed manufacturing industry. The feed industry is a very comprehensive industry employing people with a variety of skills, including process engineers, economists, marketing experts, animal and poultry scientists, regulatory experts, quality control technicians, transportation and distribution specialists, personnel management specialists, as well as construction and maintenance trades. The feed industry affects all of society because it the "axel in the wheel" of our food supply, in which human food co-products are converted to added-value feeds for animals that in turn provide high quality food for people throughout the world. Thus the feed industry has an awesome responsibility of providing a safe and secure food supply, and support a most significant economic sector of agriculture. Both the quality and the cost of feed are major concerns for the feed industry. Feed comprises over 60 % of animal production, so efficiency and safety is the primary goal of all feed milling operations. Target Student Audience This course is designed to benefit students with the following career interests: Students enrolled in the Feed Mill Management Minor at North Carolina State University Animal and/or poultry science students interested in a career in the animal, poultry, or aquaculture production industries Companion animal and zoo animal welfare and management Pre-veterinarian or veterinarian students Graduate students in the field of life sciences Agricultural engineering students Agriculture extension agents Feed manufacturing plant trainees Feed industry sales and technical service Course Goals 1. Learn about feed industry and feed mill operation and management. 2. Understand the concepts governing feed mill design and operation. 3. Lean about the types of equipment used in a commercial feed manufacturing plant. 4. Learn to administer quality control programs for feed ingredients and feed. 5. Learn good manufacturing practices in order to meet industry and government requirements. 6. Achieve an understanding of the importance of the feed industry to food and companion animals 7. To prepare you for entry employment in the feed industry. 8. Learn the introductory concepts of feed formulation and how it integrates with feed production.

3 Course Content The material covered in this internet-based course is applicable to feed production in both small and large scale operations. This is a very technical course which will require the student to learn a lot of terminology and concepts and solve typical problems in the feed industry. To cover the variety of aspects associated with feed mill management, this course is divided into 4 distinct learning units each including 6 topic modules as shown below: Unit # 1: Feed Industry and Feed Mill Design 1. The Feed Manufacturing Industry 2. Feed Mill Business Feasibility 3. Feed Mill Design and Construction 4. Feed Process Layout 5. Feed Mill Equipment 6. Utilities and Maintenance Unit # 2: Feed Manufacturing Operations 1. Ingredient Receiving and Storage 2. Particle Size Reduction 3. Feed Batching and Mixing 4. Conditioning/heat processing 5. Pellet and Extrusion Processing 6. Cooling and Post-Pellet Applications 1. Housekeeping 2. Occupational Safety 3. Pest Management Unit # 3: Facility and Quality Management 4. Grain and Animal By-products 5. Feed Quality Assurance 6. Purchasing Feed Ingredients 1. Computer Applications 2. Feed Formulation 3. Micro-ingredients Unit # 4: Feed Formulation and Feed Products 4. Premixes and Concentrates 5. Non-ruminant Feeds 6. Ruminant Feeds Within each learning module and topic area, there will be a variety of learning materials, including lecture notes, lecture slide presentations with audio, external reading assignments, homework assignments, and quizzes. Follow the work plan in sequential order as presented and try to keep pace with the rest of the class, following the suggested schedule below.

4 Suggested Learning Schedule Week Learning Units and Lecture Modules 1 Course introductions; personal background, scavenger hunt. 2 Unit 1: Industry Overview; Feed Mill Business Feasibility; Business Feasibility Assignment Unit 1: 3. Feed Mill Design and Construction; 4. Feed Process Layout; Layout 3 Design Assignment 4 Unit 1: 5. Feed Mill Equipment; Equipment Capacity Assignment 5 Unit 1: Mill Management; Management Assignment; Unit 1 Exam 6 Unit 2: 1. Ingredient Receiving and Storage; 2. Particle Size Reduction; 3. Feed Batching and Mixing. Quality of Mix assignment. Unit 2: 4. Conditioning; 5. Pellet and Extrusion Processing; Pellet quality 7 assignment. 8 Unit 2: 6. Cooling and Post-Pellet Applications. Unit 2 Exam. 9 Unit 3: 1. Housekeeping; 2. Occupational Safety; 3. Pest Management; 10 Unit 3: 3. Housekeeping and safety assignments; 4. Grain and Animal by-products 11 Unit 3: 5. Feed Quality Assurance; 6. Purchasing Feed Ingredients; Purchasing Assignment. Unit 3 Exam 12 Unit 4: 1. Computer Applications; 2. Feed Formulation; Feed Formulation Assignment. 13 Unit 4: 3. Micro-ingredients 4. Premixes and Concentrates; 14 Unit 4: 5. Non-ruminant Feeds; 6. Ruminant Feeds. Unit 4 Exam 15 Review / catch up week 16 Final Exam Course Materials All of the important materials required for this course are provided online or via links to other online sources. The text book for supplemental reading is from "Feed Manufacturing Technology V" Ed. Eileen K Schofield, American Feed Industry Association, Inc., 1501 Wilson Blvd., Suite 1100, Arlington, VA. This book can be ordered from the NCSU bookstore or the American Feed Industry Association. Reading assignments and homework assignments due dates will be posted online. Examination and Testing After you have read or listened to the lecture material, completed the self-tests, quizzes, and assignments, you may take the learning unit exam. Once you submitted your exam, you begin the next learning unit. Use of the online discussion board to communicate with your classmates is encouraged, as this will enhance your learning experience.

5 Grading % of Total Grade Feed Mill Design Feasibility Assignment 2.5% Feed Mill Process Layout Design Assignment 5% Feed Mill Capacity Calculation Assignment 5% Mill Management Style Assessment Assignment 2.5% Mill Maintenance and Safety Training Assignment 2.5% Occupational Safety Quiz 2.5% Ingredient and Mixing Quality Assessment Assignment 2.5% Pellet Quality Assurance assignment 2.5% Purchasing Agreement Assignment 2.5% Least-cost Feed Formulation Assignment 2.5% Unit 1 Exam 15% Unit 2 Exam 15% Unit 3 Exam 15% Unit 4 Exam 15% Final Exam 10% Total Grade 100% Course Policies Grading System A Range: A+ 97 to 100 A 93 to 97 A- 90 to 93 B Range: B+ 87 to 90 B 83 to 87 B- 80 to 83 C Range: C+ 77 to 80 C 73 to 77 C- 70 to 73 D Range: D+ 67 to 70 D 63 to 67 D- 60 to 63 No Credit: <60 Failure to turn in an assignment results in a zero for that assignment. Student Conduct: Students are expected to follow the North Carolina State University CODE OF STUDENT CONDUCT. This includes not cheating on exams and quizzes. Students are expected to do their own work and participate equitably on team projects. Academic dishonesty will not be tolerated, including the giving, taking, or presenting of information or material with the intent of unethically or fraudulently aiding oneself or another person on any work related to your class. Disabled Students: NC State is subject to the Department of Health, Education, and Welfare regulations implementing Section 504 of the Rehabilitation Act of 1973.