Christian Rabe, Head of Applied Feed Technology, Evonik, Germany
Christian
Rabe started his education at the Technical University (TU) in Munich with a
Bachelor of Bio-Process Technology, followed by a Master of Process Technology
at the TU Braunschweig. In 2010, he started working on process development for
the production of different feed additives at Evonik.
Mr Rabe
possesses more than 10 years of practical experience with process technology
and application of feed additives in different functions within Evonik. During his
career he has also been involved with quality assurance and new product development
for feed additives.
He has also worked on starting up new production sites for feed additives and implementing equipment at customer sites to handle these feed additives all over the world. To achieve this, he tries to get as many as possible different insights into the feed industry and then look at it from different angles.
Looking back at your life, which events in particular lead you into a career in the feed sector?
At
university I learned a lot about producing chemical or biotechnological
substances in an optimum way to reduce the required resources. However, the
application of these products often leads to an increased demand for resources.
Starting
my career at Evonik, I was involved in the production of feed additives. Very
early on, I got insights into the application of these products. I was
fascinated by the beneficial effect you can achieve with feed additives on
animal welfare and the ecological footprint. These effects are based on
scientific research.
Because
of the product value of these feed additives, I wanted to go deeper into their
application. After getting further insights into the feed industry, including
quality assurance and new product development, I really focused on feed mill
production and still try to optimise this process as much as I can.
Where do you still see as being the highest optimisation potential in a modern feed mill, what would you say are the relevant core process steps?
For this
question you need to distinguish between two important aspects. First, are you
finding the same amount of all components in the final feed as you added? So,
do you have a sufficient recovery rate? This is highly influenced by the dosing
accuracy.
And
second, is the added component always the same in each small feed portion? So,
do you have a sufficient homogeneity? This is highly influenced by the mixing
homogeneity.
To
answer these two questions, you need to look deeper into the dosing and mixing
process. Of course, all process steps during feed production will influence the
final feed quality but mixing and dosing still have a high optimisation
potential if you compare theoretical and practical data.
For both
process steps, the performance is much higher in theory than in practice. We
have measured this using the Evonik long term test in commercial feed mills all
over the world. And these process steps can be improved easily by changing some
parameters.
While
the equipment parameters are fixed by the available equipment, the physical
product and process parameters can be influenced by, for example, using dry or
liquid ingredients. So, at this point you can directly improve mixing
homogeneity and dosing accuracy by using more dry ingredients.
What would you say is the influence of feed quality for the ensuing value chain?
A
certain amount of essential feed additives is needed for every animal to
achieve uniform performance. Different available scientific publications
demonstrate what will happen if essential feed additives are not well
distributed in the final feed; you will not achieve a uniform body weight or
animal performance in the animals.
Therefore,
the production of the final feed with the right quality is one essential piece
of the puzzle to achieve sustainable meat production. Without having optimised
feed production, you will use too many resources and, therefore, will lose
money during meat production.
Do you see any emerging trends for feed production in modern feed mills?
In
future feed mill operations will be more and more automised and more and more
data will be created during production. This will help to improve the overall
feed production process. Connecting the different process steps and adapting
each one because of slight changes to others will help you to run the feed
production in an optimum way all the time.
A very
interesting example is online analytics. If you are able to react to
fluctuations in raw material quality on a single batch level, you can reduce
all the safety margins you have added to get a constant feed quality.
Connecting
online analytics with your dosing equipment will allow you to get this benefit,
and this technique is already available. But one further step is to get data
from animal performance directly and also use these data for feed production.
So, you will connect your animal performance with your feed mill production and
get your dedicated final feed.
How do we check feed quality and if required, how can it be improved?
One
important point of feed quality mentioned above, is that all added ingredients
need to be homogeneously mixed and added in the right amount. Of course, lots
of other process steps next to dosing and mixing are important for achieving a
sufficient feed quality.
But
there is an easy way to check your mixing and dosing performance by just
measuring a so-called mixing profile. There are several service providers
available to do this, Evonik can check your dosing and mixing performance by
measuring the content of different amino acids in the final feed, for example.
You just
take ten samples from one mixing batch during a running operation. That is all.
Afterwards you know if you need to improve your mixing and dosing process or
not.
There
are lots of factors influencing the mixing homogeneity and dosing accuracy you
can check. These include the physical product properties, the maintenance
status of the equipment, the set of process parameters, the amount of added
liquids, the type of raw materials, the way of proportioning the products and
the type of equipment.
For this
list I do not want to claim completeness, but optimisation of all of these
parameters can increase mixing homogeneity and dosing accuracy, therefore
improving feed quality.
The Global Miller
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