FEED MILL MANAGEMENT AND FEED FORMULATION



FEED MILL MANAGEMENT AND FEED FORMULATION

PO (ANS) 425 or NTR 525 Syllabus

Instructors

Dr. Peter R. Ferket, Ph.D

Professor of Nutrition

Department of Poultry Science

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Dr. Peter R. Ferket

Office:             234 E Scott Hall

Telephone:       919-515-5409

Email:              Peter_Ferket@ncsu.edu

Office hours:   By appointment.

Dr. Charles Stark, Ph.D.

Assistant Professor, Feed Science and Technology

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Office:             234 C Scott Hall

Telephone:       919-515-5399

Email:              Charles_Stark@ncsu.edu

Office hours:    By appointment

 

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.

Course Overview

This course is about 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 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

• Know the origin and structure of the feed milling industry

• Know the fundamentals of feed milling business operations and mill design

• Develop programs related to inventory control, process scheduling, and mill safety

• Understand and evaluate feed manufacturing processes

• Know feed formulation constraints of feed ingredients and how to purchase them

• Know the fundamentals of feed quality assurance

• Know good feed manufacturing practices and feed manufacturing regulations

• Understand the appropriate uses of feed additives and feed product enhancers

• Know how to formulate animal feed premixes, concentrates, and complete feed products

• Understand the fundamentals of least-cost feed formulation and parametric analysis

• Know the different feed products required for each animal species and how to design feed programs

The material covered in this course will be taught in class during the spring semester or each semester as an online WebCT-based. This course, applicable to feed production in both small and large scale operations, is a technical course that require students to learn terminology and concepts related to the management and operation of commercial feed mills, and solve typical problems in the feed industry. Students enrolled in PO(ANS) 425 and NTR 525 class-room section will participate in the same lecture and laboratory sessions, but the NTR525 students will receive more advanced assignments, provide group leadership, and require to read more advanced literature.

To cover the variety of aspects associated with feed mill management; this course is divided into 6 distinct learning units each including 4 or more topic modules as follows:

 

|Unit # 1: Introduction to Feed Mill Management |

|1. Feed Industry Overview |3. Feed Mill Design |

|2. Feed Mill Business Feasibility |5. Feed Mill Equipment |

|Unit # 2: Feed Mill Management & Operations |

|1. Personnel Management |4. Scheduling |

|2. Feed Mill Maintenance |5. Feed Mill Safety |

|3. Inventory Control |  |

|Unit # 3: Feed Manufacturing Process & Control |

|1. Receiving |6. Pelleting |

|2. Particle Size Reduction |7. Extrusion |

|3. Batching |8. Cooling and Drying |

|4. Mixing |9. Post-Pelleting Applications |

|5. Conditioning |10. Packaging and Load-out |

|Unit # 4: Quality Assurance |

|1. Feedstuffs and feed ingredients |4. Feed Processing Quality Assurance |

|2. Ingredient purchasing |5. Finished Feed Quality Assurance |

|3. Ingredient Quality Assurance |  |

|Unit # 5: Feed Regulations |

|1. cGMPs and HACCP |4. Prohibited Mammalian Products |

|2. Feed Recalls |5. Medicated Feed Labels |

|3. Feed Mill Inspections |6. Bioterrorism |

|Unit # 6: Feed Formulation |

|1. Feed Additives and feed product enhancers |3. Feed formulation principles |

|2. Premix and concentrate formulation |4. Feed products and feeding program |

 

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.

Learning Schedule

The schedule below approximates the suggested learning schedule for the online course. The class-room section offered in the spring will cover similar topics during two 90 minute lectures and one 120 minute laboratory experience at the NCSU Educational Feed Mill Unit on Lake Wheeler Road.

 

|Week |Learning Units and Lecture Modules |

|1 |Course introductions; personal background, scavenger hunt, benchmark quiz |

|2 |Unit 1: Industry Overview; Feed Mill Business Feasibility; Business Feasibility Assignment |

|3 |Unit 1: Feed Mill Layout Design; Feed Mill Equipment; Feed mill Layout Assignment; Unit 1 Exam |

|4 |Unit 2: Personnel Management; Feed Mill Maintenance; Inventory Control |

|5 |Unit 2: Scheduling; Feed Mill Safety; Scheduling and Safety Assignments; Unit 2 Exam |

|6 |Unit3: Receiving; Particle Size Reduction; Batching; Mixing |

|7 |Unit 3: Feed Conditioning; Pellet Processing; Extrusion; Cooling |

|8 |Unit 3: Post-Pellet Applications; Packaging and Load-out;  Unit 3 Exam. |

|9 |Unit 4: Feedstuffs and Feed Ingredients; ingredient purchasing; Ingredient quality assurance |

|10 |Unit 4: Feed Processing Quality Assurance; Finished Feed Quality Assurance.  Unit 4 Exam |

|11 |Unit 5: Good Manufacturing Practices and HACCP; Feed Recalls; Feed Mill Inspections |

|12 |Unit 5: Prohibited Mammalian Products; Feed Medications and Labels; Bioterrorism.  Unit 5 Exam |

|13 |Unit 6: Feed Additives and Feed product enhancers; Premix and concentrate formulation |

|14 |Unit 6: Feed formulation principles; Feed products and feeding programs. Unit 6 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. 

Differences between PO(ANS)425 and NTR 525

Although similar content will be delivered in class lecture, supplemental reading materials and assignments will be more advanced for the graduate students. The graduate level version will be given midterm examinations that have a higher degree of difficulty than the undergraduate version, and questions will challenge knowledge of application and problem-solving. The assignments for the graduate version will demand a higher degree of understanding and effort than the undergraduate. Those enrolled in NTR525 will be required to lead group efforts associated with field trip reports, laboratory exercises, and group discussions, and also act as group spokes persons for all group presentations unless otherwise instructed. In contrast to those enrolled in PO(ANS)425, the NTR525 students will be required to each to work on a major class project of their choice as related to feed mill management and feed formulation and present it as seminar (lecture) to the class at the end of the semester. As with the midterm exams, the final exam for the NTR525 will be a higher degree of difficulty than for those enrolled in PO(ANS)425.

Examination and Testing

After the student has participated in the lecture and completed the self-tests, quizzes, and assignments for each learning unit, they must take the learning unit exams.  Assignments will be submitted to the online drop box or handed to the instructor in person. The use of the online discussion board to communicate with classmates is encouraged, as this will enhance your learning experience.

 

Grading                                                                      % of Total Grade

Feed Mill Design Assignments                                                   15%

Occupational Safety Quiz                                                          2.5%

Ingredient and Feed Quality Control Assignment                        2.5%

Purchasing Agreement Assignment                                             2.5%

Feed Label Assignment                                                             2.5%

Premix Formulation Assignment                                                 2.5%

Least-cost Feed Formulation Assignment                                   2.5%

Unit 1 Exam                                                                             10%

Unit 2 Exam                                                                             10%

Unit 3 Exam                                                                             10%

Unit 4 Exam                                                                             10%

Unit 5 Exam                                                                             10%

Unit 6 Exam                                                                             10%

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:       ................
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