Case Study: Enhancing Animal Nutrition with Advanced Biotechnology Process Technology

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 and are commonly used to improve silage. 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. Lactic acid bacteria therefore have an indirect but important influence on nutrition for both humans and livestock. 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 final product.

The starting point is a fermentation process in which lactic acid bacteria, in particular Lactobacillus is used. This fermentation takes place in special bioreactors under controlled conditions such as temperature, pH value and nutrient content. The specific introduction of microorganisms capable of growth, known as inoculation, begins with a suitable quantity of lactic acid bacteria cultures. For this purpose, the strains are isolated from natural resources, screened for their properties and evaluated in experiments. Potential strains are produced on a small scale and stored in small portions at -80°C. Before the main fermentation, the bacteria can be pre-propagated to increase the number of viable cells.

The duration of fermentation differs depending of the produced microorganism, it can range from a few hours to several days. During this process, the lactic acid bacteria multiply until the desired cell density is achieved.

Pioneers in agricultural lactobacilli

Following this approach, the Austrian company Lactosan 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 six hundred products, which is distributed in over fifty 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 livestock 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 lactic acid bacteria offers the opportunity to use advanced technologies in animal nutrition and feed production.

This is where the collaboration with Hecht Technologies 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 production. 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 Paffenhofen 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 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 effortless 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 and sack 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 by Hecht

The expansion of production capacities not only enables greater efficiency in existing products, but also opens new business areas. At this point, the leading role of reliable process technology must be mentioned. The functions of the system can be represented in five systems.

Initially, one of the starting materials, in this case sugar, is fed via one of two weighed big bag discharging stations and conveyed by means of a PCC 300 with two inlet nozzles and discharged into a downstream on-site container with agitator. A vapor barrier is installed between the PCC 300 and the on-site tank to prevent vapors from rising from the tank.

In addition to the fermentation and separation of the lactic acid bacteria, additional material is fed into the mentioned on-site container by an operator at three possible sack discharging stations in the backfill. These three stations are identical in structure and function. Further vapor barriers prevent vapors from rising from the on-site container into the drop line.

In the crushing line, a batch of lactic acid bacteria in frozen state is discharged in two blenders. The ground material is conveyed by a PCC 200 to the harvest tank line and can then be filled either into Big Bags by a Big Bag filling station or with the help of a suction shoe in smaller quantities into drums or sacks.

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 Conveyeor (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.

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 approximately 250 kg in 6 h.

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 Hecht Technologie and the biotech company Lactosan highlights the importance of reliable process technology in biotechnology. 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 and feed additives production that meets ever-increasing quality standards.