Hydrothermal processing protects protein for high

Hydrothermal processing protects protein for high

Hydrothermal processing protects protein for high-performing dairy cows
Dr. Heinrich Kleine Klausing, Deutsche Tiernahrung Cremer GmbH & Co. KG
High yielding cows need quality feeds of which the proteins become available
in the intestines without being degraded by the microbes in the rumen. The
German feed milling company Deutsche Tiernahrung Cremer (main brand
name in the market: deuka) has developed and patented a new hydrothermic
process to protect feed protein.
Market situation – basic parameters
Dairy cattle management is going through a historic phase of radical change as regards yield and performance. The milk yields that have improved on many farms and
are continuing to rise steadily now make far higher demands on the management
and detailed structuring of total feed rations. The quality of the basic diet, optimising
of the dry matter intake, and consideration of the most recent findings on carbohydrate and protein metabolism are particularly important here. These aspects make
high requirements of basic ration supplements in line with the performance. During
recent years research has paid special attention to protein supplies for high-yielding
dairy cows.
If feeding of high-yielding cows is considered first of all under business management
aspects, then especially the milk protein content achieved represents a particularly
important criterion under milk quota conditions. If a farm can increase the milk protein
content at a constant milk fat content by just 0.1 % on average, for example by optimised feeding measures, this means extra earnings of € 45 a year for a dairy cow
with an annual yield of 9000 kg (at € 0.005 per kg milk for +0.1 % protein). Moreover
no additional quota costs are incurred for this.
If one considers the protein supply of dairy cows against this background, it should
first be noted that the most important source of protein – even at peak lactation – is
and remains microbial protein. Optimal fermentation in the rumen means a correspondingly strong microbial population. Highly digestible protein mass with an amino
acid pattern that is almost optimal for the cow is conveyed towards the rennet or
fourth stomach and small intestine via the constant flow of rumen fluid and feed particles with adherent rumen microbes. The amount of microbial matter and hence highly
digestible protein which is formed depends on various parameters. These are headed
by the supply of rumen-available energy and corresponding nitrogen to the dairy cow.
The most important basis for optimal energy and nitrogen supply is the highest possible intake of dry feed matter. This is influenced to a large extent by the quality of the
basic feed and the balanced design of the total ration. The largest quantity of rumen
microbes per time unit is formed when fast-fermentable carbohydrates such as sugar
and quickly degradable starch are fed. The share of these carbohydrates in the ration
is, however, distinctly limited by the requirements made of a feed structure suitable
for ruminants. Thus even optimal rations can only cover approx. 60 to 70 % of the
protein requirement at the small intestine during early lactation of high-yielding cows.
There is consequently a "supply gap" which has to be balanced via the total ration.
A further important aspect must be taken into account as regards milk protein contents at the start of lactation in high-yielding cows. At the start of lactation many cows
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with a peak performance rate go through a negative energy balance for several
weeks, and in some cases for several months – the energy output with the milk is
well above the energy intake with the feed. These cows mobilise their body reserves
built up during the preceding late lactation in order to balance the deficit. Since these
mainly consist of body fat that is released, the energy shortfall can only be balanced
in this way too. And this balance is "effective", since energy for about 6 to 7 kg milk
can be released from one kg body fat. The consequence of this for milk production is
that although sufficient energy can be made available at short notice, the protein
supply does not "keep pace". Although a corresponding quantity of milk with an adequate milk fat content is achieved, the milk protein content is often below 3 %. In
herds with sub-optimal energy and protein supplies that are not in line with performance, we therefore often find typical progress patterns for the protein content in
the milk (graphic 1). In practice attempts have been and still are being made today to
counter this circumstance by a distinct "advance supply" of protein in the ration.
However this is "normal" feed protein, and a correspondingly high share is released
in the rumen. Due to the limited energy quantities in the rumen this protein practically
cannot be converted into microbial protein. The evident consequences of this energy
undersupply and nitrogen oversupply in the rumen are, for example, distinctly elevated urea contents in the milk. Fertility problems are often already programmed in
this lack of harmony in the nutrient supplies for dairy cows.
Graphic 1: Course of the protein content in the milk at sub-optimal and optimal
supply with energy and protein.
Milk protein content in %
3,9
3,7
3,5
3,3
3,1
2,9
2,7
2,5
1
2
3
4
5
6
7
8
9
10
11
12
Lactation month
suboptimal
optimal
The logical conclusion to be drawn from the above circumstances is that more protein
should be allowed to "flow" through the rumen directly into the small intestine, in
other words the share of "flow-through protein" in the ration should be increased. The
"UDP share" in the protein (i.e. the share of the undegraded dietary protein in the
rumen by comparison with the total protein) varies substantially in the customary feed
components available today. In order to be able to supply the fresh-lactating, highyielding cow with sufficient useful protein (nXP) in the small intestine to meet needs,
the content of rumen-resistant protein ("UDP share") must be about 35 % of overall
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protein in the total ration. This cannot be achieved with the customary ration components available today, i.e. untreated matter. Since even the best qualities of basic
feed have relatively slight UDP shares, customary mixed or total rations only contain
about 25 % UDP for balancing/supplementing conventional protein feeds. Thus soya
bean meal that was held to be the protein component for dairy cows for many years
in practice is now considered to have a UDP component of only 30 % - just as much
as rape-seed meal. This value was also taken over in the latest version of the DLG
feed value tables. In order to be able to achieve the necessary 35 % UDP in the total
ration for high-yielding cows, silage-rich rations must therefore be upgraded with protein components whose UDP share is well above 40 %, and of course which then still
remain highly digestible in the small intestine.
So far various processes are known for reducing the degradation of plant protein by
rumen microbes. These include chemical processes such as treating with formaldehyde or xylose, and physical processes. In the physical processes the protein
components are treated by " hydrothermal pressure" and this causes a structural
change in the protein. The disadvantage of the hydrothermal pressure methods
known so far ("extrusion technologies"), which also result in a detectable degree of
substance change, is the need for energy-intensive and hence costly drying of the
product after treatment. Furthermore, with all methods the question of how to retain
high digestibility of the undegraded ("protected") feed proteins in the small intestine
must be considered - regrettably this has not yet been answered comprehensively.
Against the background of the changes described in the market and its environment,
considering the constantly broadening knowledge about the requirements of highyielding cows as regards protein supply in the small intestine, and in view of the hitherto not very satisfactory methods of producing "rumen-protected protein", deuka has
in recent years looked intensively in its own research and development at new technologies for refining single and compound feed by natural means, if possible without
using additives. The outstanding result of these research efforts is the opticon®
technology, patented for deuka, and the rumen-protected protein-rich special feed for
high-yielding cows deukalac UDP 39, produced using this process. The background
of the technology, the verified quality-determining product criteria, and the high performance capability of this unique new development that has been tested comprehensively in practice are introduced below.
Description of the opticon® technology
opticon® is a hydrothermal pressure process technology developed and patented by
Deutsche Tiernahrung Cremer, aimed largely at refining single and compound feeds
for productive livestock in agriculture (Patent DE 199 13 514 C 1). The process is
characterised on the technology side by invention-specific configuration of the auger
geometry in the thermal pressure treatment duct and the appropriately developed
process parameters (temperature, moisture content, pressure, shear forces, dwelling
time, energy dissipation, expansion and product structure). These form the crucial
basis for the uniqueness and high degree of improvement achieved in the rumenprotected protein provider deukalac UDP 39. A specific high level of substance conversion (distinctly elevated UDP share in the total protein) is achieved in the treated
product by purely physical means without using additives. deukalac UDP 39 displays
unchanged high protein digestibility and high Biological Value, as tested on young,
growing monogastric animals. The background here is the large-scale avoidance of
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Maillard reactions (irreversible bondings between lysine and reducing sugars) in the
product, which are encountered in conventional extrusion technologies and particularly in processes using free sugar.
The opticon® technology (figure 1) can be described as a trail-blazing further development of known extrusion technologies for producing animal feed. By comparison
with known methods, a distinctly lower energy input is used in the process to achieve
a certain substance conversion.
Figure 1: opticon® production facility at the deuka plant in Höltinghausen
The very energy-intensive drying of treated product necessary in conventional extrusion is not needed thanks to selected moisture extraction in a detensioning phase
("flash phase"). This contributes substantially to conserving resources and lends the
process a correspondingly high environmental soundness and high economic viability. Vorher (2001) therefore described the opticon® technology as "an up-to-date development".
Product description deukalac UDP 39
deukalac UDP 39 is made up of 50 % HP soya bean meal and 50 % 00 rape-seed
meal. The components are ground and mixed in the usual fashion. After this the mixture is treated in the opticon® production plant and the content of rumen-stable
protein ("UDP share") for supply covering the needs of high-yielding cows is increased to 50 % (basic passage rate 5 %/h from the rumen). The content of sulphurous amino acids in the product is secured via the share of rapeseed meal.
This protein protection is achieved by purely physical means without the addition of
chemical substances. The product also contains per kg: 7.0 MJ NEL, 390 g crude
protein, 300 g nXP and 14 g RNB.
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By means of this treatment deukalac UDP 39 acquires a unique crumbly structure.
Treatment also lends the product a pleasant, baking-type odour and taste. That is
why high-yielding cows absorb deukalac UDP 39 very well.
deukalac UDP 39 is used directly on the farm for targeted upgrading of the basic
feed ration, as a protein supplement in mixed rations (MR) and total mixed rations
(TMR), and as an additional protein supply for high-yielding cows in the "top dressing". In compound feed plants deukalac UDP 39 is used in special compound feed
varieties for high-yielding cows. The exact quantities and processes are addressed to
the individual on-farm feeding situation.
Results of substance conversion achieved in treated feeds, especially deukalac
UDP 39
All known treatment methods for producing rumen-protected protein (thermal pressure, addition of chemical products) essentially have the same target mechanism to
start with – a "blockade effect" for the proteases produced by the rumen microbes.
This is common to all methods – but the details of technical/physical realisation are
crucial. In the production process the physical parameters of temperature, pressure,
moisture content, dwelling time and shear forces applied must be very precisely coordinated. The goal is to achieve a change of the tertiary and quaternary structure of
the proteins (texturing") in the treated product – in other words a certain "protein denaturation". A change in the protein structure can be shown with the aid of photos
taken with the scanning electron microscope. For this untreated rape-seed meal and
the material treated accordingly via the opticon®-production plant were examined.
Figures 1 and 2 document that the opticon® treatment results in a change in the protein structure ("texturing") that is visually evident with 1000-fold magnification.
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Figure 1: Scanning electron microscope photo of untreated rape-seed meal
(magnification 1000-fold)
On treatment, however, care must be taken to ensure that the digestibility of the protein - or rather of the amino acids in the protein - in the small intestine is not reduced
sustainably. For this the structural changes in the protein (folding up and refolding in
the tertiary and quaternary structure – "texturing") should only go so far that although
the degradation per time unit in the rumen is reduced (in other words the proteases
formed by the rumen microbes are less able to attack each other in the time unit), the
protein molecules are "unfolded" again at a low pH value (between pH 2 and 3) in the
stomach (i.e. the process is reversible) and the bonding places for the body's own
proteases in the stomach and further down in the small intestine are fully accessible
again.
Figure 2: Scanning electron microscope photo of opticon®-treated rape-seed
meal (magnification 1000-fold)
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When looking more closely at process technologies to protect proteins prior to degradation in the rumen, and the resulting UDP content in the treated products, the question naturally arises as to how the forecast data can be verified. Up to the end of the
90s the UDP content in a product could only be estimated via expensive in situ / in
sacco experiments with rumen-fistulated ruminants (primarily oxen or cows). In the
second half of the 90s a work group under Dr. Karl-Heinz Südekum at the Institute for
Animal Nutrition and Metabolic Physiology of the Christian Albrecht University in Kiel,
then addressed the task of developing an in-vitro method and validating this with the
aid of in-situ examinations. The result is a process for estimating crude protein degradation in the rumen and hence the UDP share in the overall protein of a feed with
the aid of chemical fractioning of the feed protein in accordance with the "Cornell net
carbohydrate and protein system (CNCPS)" (Shannak et al. (1999), Shannak
(2000)).
This new estimation process has the advantage of achieving well validated data on
the UDP content of a feed relatively quickly and at reasonable expense. These data
are stated as a function of a ruminal passage rate of 2.5 or 8 %/h. This method was
first used during the development of the opticon® process technology to assess the
degree of substance change achieved and hence the UDP content in the single feed
treated. The special product deukalac UDP 39 was repeatedly examined during development and within the framework of quality assurance to assess the UDP content
achieved using this method too. The data show clearly that deukalac UDP 39 has a
mean UDP 5 value of over 50 % and a mean UDP 8 value of more than 60 % for all
samples examined. In the calculation of rations for high-performing dairy cows with
deukalac UDP 39, a UDP share in total protein of 60 % is taken on the basis of this
results (basis: passage rate 8 %/h from the rumen).
A further question which arises is whether a rumen-protected protein carrier component lying well above 60 % UDP share in total protein would be better. It is known
from literature that a very high degree of rumen protection (UDP share in total protein
of 70 % and more – basis: passage rate of 8 %/h from the rumen) can be achieved
by very intensive treatment of protein carriers, especially with chemical additives like
formaldehyde or lignosulphonate or a combination of such products with physical
treatment). However, this can then very quickly result in a distinct reduction of the
small intestine digestibility and hence in lower protein value for the animal. This is
also pointed out in a wide variety of papers in relevant international literature. Such
intensive treatment is known as "overcooking". The main feature responsible for reduced protein digestibility in the small intestine in such "overcooked" products is a
very far-reaching reaction between reducing sugars and the amino acid lysine – the
Maillard reaction. This chemical process is only reversible to a very limited extent
even under the pH conditions prevailing in the stomach. It leads to the reduction in
small intestine digestibility already described. Consequently it is not the absolute
level of achievable degradation protection in the rumen that is of prime importance,
but instead the quantity of digestible protein that reaches the small intestine with one
kilogram of protected protein component. To put it more clearly, a "high level of rumen protection" does not necessarily help a lot if the treatment reduces digestibility in
the small intestine.
However, data on the assessment of small intestine digestibility of the treated protein
can only be obtained from in vivo investigations. Digestibility determinations in young,
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growing rats represent a further possible way of examining the influence of treatment
on the digestibility of the protein in the intestine. Within the framework of the process
and product development, appropriate comprehensive examinations were conducted
to assess the protein quality in protein feeds treated via opticon® and the product
deukalac UDP 39 at the Research Division Nutritional Physiology "Oskar Kellner"
(Research Institute for the Biology of Productive Livestock) in Dummerstorf. The criteria "true protein digestibility" and "Biological Value" were used above all to determine the protein quality (graphic 1 and 2).
Graphic 1: Influence of the technical treatment on the true protein digestibility
in growing rats (5 rats per group)
6
83
deukalac UDP
39
deukalac UDP
39
81
,8
82
8 2 ,8
,6
,2 8
4,
84
,
80
76
,8
79
7 8 ,2
,3
digestibility, %
85
9
88
,
2
90
72
,6
75
70
SBM
RSM
untreated
opticon-treated
SBM treated
with sugar
pro duct
Rapeseed
expeller treated
with sugar
pro duct
RSM treated
with chemical
pro duct
treated with additives
Special attention should be paid to the "Biological Value", in other words the share of
absorbed nitrogen used in the body for the N-maintenance metabolism and for the
new synthesis of body components containing N (growth). KOLB und GÜRTLER
(1971) attribute "a high degree of safety in Biological Value determination of proteins"
to this criterion. Results of over 100 % in the Biological Value can be explained by the
regressive derivation of the intestinal loss of nitrogen (ILN) and the nitrogen maintenance need (NMN). The investigation results show that in a comparison with untreated initial products, and especially standard commercial products treated using a
special sugar or a chemical additive, the single feeds rape-seed meal and soya bean
meal treated via the opticon® process as well as the special product deukalac UDP
39 have the highest protein quality.
The balance test with rats was taken deliberately to study the protein quality of the
treated products, on the one hand because this methodology has been standardised
and verified for decades. On the other hand, it was important for a critical assessment of the protein quality, especially in the treated products, that in the rat as a
monogastric animal the protein that is demonstrably protected to a certain percent-8-
age in the time unit prior to degradation is not subject to the influence of rumen microbes prior to digestion via the body's own enzymes. Possible damage to the protein
and possible resulting reduced digestibility and consequent deterioration of the "Biological Value" is shown most clearly in young, growing, monogastric animals. The
criteria "Biological Value" permits a comparative relative classification of different
feed proteins to each other.
Graphic 2: Influence of the technical treatment on the Biological Value in growing rats (5 rats per group)
10
120,2
2,
7
10
102
2,
0,
,3
10
99
100
99
1 0 ,8
0,
1
6
5
105
95
%
,3
88
,2
88
,8
90
80
85
85
SBM
RSM
untreated
deukalac UDP
39
deukalac UDP
39
opticon-treated
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SB M treated
with sugar
pro duct
Rapeseed
expeller treated
with sugar
pro duct
treated with additives
RSM treated
with chemical
pro duct
Results achieved in practice with deukalac UDP 39
The high performance capability of deukalac UDP 39 was tested comprehensively in
scientific trials as well as day for day in practice. For example one trial was carried
out on the trial farm Lycee Agricole La Touche in Britanny (France). Following the
trial conditions and the results.
With replacement of 1 kg soybeanmeal/rapeseed meal by 1 kg deukalac UDP 39 the
cows in the trial group received 58 g more by-pass protein per day and that leads to
an significant increase in daily milk yield by 1 kg. Interesting to see is the decrease in
number of cells in the milk. This is a sign for a balanced metabolism and with that for
a better health of the cows and this is reported several times from practice too.
Summary
deukalac UDP 39 is a unique, selectively refined special product developed by
deuka for high-yielding cows with a UDP share of 60 % in total protein. The UDP share is achieved by selective treatment of the initial mixture (50 % HP soya bean meal
and 50 % 00 rape-seed meal) via the patented, hydrothermal pressure process technology opticon® developed by deuka. The specific high rate of metabolism takes
place purely physically without the use of additives. deukalac UDP 39 possesses
high protein digestibility documented by scientific experiments and high Biological
Value. Comprehensive results from practice on farms with high-yielding herds of between 9,000 and over 11,000 kg milk yield per cow and year on herd average document the high performance capability and effectiveness of deukalac UDP 39. The
opticon® process technology conserves resources thanks to its low energy outlay by
comparison with the hydrothermal treatment methods known to date (no product dry- 10 -
ing is necessary). The process and the refined product deukalac UDP 39 are thus
characterised by high environmental soundness and cost-effectiveness.
With the new development deukalac UDP 39, the high-yield dairy cattle farms have
at their disposal a unique, new, rumen-protected protein source which fully satisfies
the requirements of "high UDP share with high digestibility", "secured quality constancy", "safe feed intake", "high milk forming capacity", "high cost-effectiveness",
"refinement by natural means without additives", and "environmental soundness".
Thus balanced feeding of high yield cows oriented to performance and health is substantially improved.
Literature
KOLB, E.; GÜRTLER, H. (1971): Ernährungsphysiologie der landwirtschaftlichen
Nutztiere; Gustav Fischer Verlag; p. 131
SHANNAK, S. (2000): Abbauverhalten der organischen Masse und Rohproteine von
Futtermitteln während ruminaler in situ Fermentation
Dissertation agr., Christian-Albrechts-Universität Kiel
SHANNAK, S.; SÜDEKUM, K.-H.; SUSENBETH, A. (1999): Schätzungen des ruminalen Rohprotein-Abbaus aus dem in sacco-Abbau und der chemischen Analyse
Proc. Soc. Nutr. Physiol. 8, 71 (Abstract)
SCHRÖDER, A. (2002): 1 Jahr Erfahrung mit dem pansengeschützten Proteinträger
deukalac UDP 39 in der praktischen Fütterung
Tagungsbericht 2002 "6. Symposium zu Fragen der Fütterung von Kühen mit hohen
Leistungen", p. 109-116
VORHER, K.F. (2001): Der variable Expander – eine zeitgemäße Entwicklung;
Mühle+Mischfutter 138, p. 524-526
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