High-yielding cows and beef cattle require a particularly high amount of high-quality protein. Therefore, components with a high proportion of rumen-protected proteins are crucial for ensuring a balanced diet. For a long time, formaldehyde was used to achieve this protection, but it has now been banned throughout the EU. Our pressure-hydrothermal expander process is a modern alternative that reliably and sustainably protects proteins without any chemical additives.
Cows cover a large part of their protein requirements through the microbes in their rumen. However, as the animal's performance increases, this supply becomes insufficient. Therefore, high-quality feed components that are not pre-digested in the rumen, but rather resorbed directly in the small intestine, are essential. Our process specifically increases the proportion of rumen-protected proteins (UDP), which is exactly what is needed in this situation.
The UDP value (UDP = UnDegradable Protein) describes the proportion of rumen-stable protein in total crude protein (CP) and indicates the percentage of proteins directly available for digestion in the small intestine. The rumen stability of feed must be calculated by taking into account a specific retention time in the rumen. For high-yielding cows, about eight percent of rumen contents are estimated to enter the intestine per hour. The UDP content of feed is typically calculated based on an eight percent passage rate and expressed as UDP8.
The efficiency of technical feed processing, or rumen stability, is assessed using various testing and estimation methods. These results are then used to evaluate the relative effectiveness of different processes or treatments compared to the initial product. Since the results vary, it is necessary to continuously sample the raw material and finished product to generate a stable and reliable database.
Pressure hydrothermal treatment instead of chemical additives
Our pressure hydrothermal expander process uses physical effects instead of chemical additives. The combination of steam, pressure, and temperature alters the protein structure, increasing the UDP value and making the proteins more readily available in the small intestine.
This is how the process works: First, the process material undergoes preliminary grinding with a crushing roller mill and steam preconditioning in a continuous mixer. Then, it is briefly heated to high temperatures under high pressure using the KAHL crown expander (High Temperature Short Time, or HTST). Afterwards, the hot, expanded product is fed into the KAHL long-term conditioner (also known as a hydrothermal reactor), where it is held at a temperature close to the boiling point for approximately 20 minutes. This process significantly increases the UDP value while improving digestibility in the small intestine.
Finally, the expanded product (expandate) is cooled with ambient air in the KAHL belt cooler. The result is a nutrient-rich, storage-stable expandate that can be optimally integrated into total mixed rations (TMRs) and shows little tendency to segregate. If necessary, it can be pelleted with minimal extra energy.
Production line for rumen-stable feed proteins
Main machines of a UDP expander line from increasing the rumen stability of feed protein
More efficiency – less energy
Our process increases the rumen stability of proteins and improves the sustainability of feed production. The targeted control of heat, pressure, and moisture minimizes electrical energy consumption. Unlike totally hydrothermal processes, which require energy-intensive hot air drying, the final product only needs to be cooled by ambient air in the belt cooler - not dried. This saves energy and significantly reduces the CO₂ footprint. Additionally, targeted protein modification improves the digestibility of nutrients in the intestine, especially in rapeseed meal and other monocomponents. This increases feed efficiency, and thanks to better protein utilization, feed intake can be reduced without any loss in milk production or fattening performance.
Our pressure hydrothermal expander technology shows that modern feed production can dispense with chemical additives while meeting the highest performance, efficiency, and sustainability standards. Many feed producers around the world are already using this process successfully.
