Digital Re-print - September | October 2009

Feature title: NIR-Online GmbH provides additional benefit for feed industry

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NIR-Online GmbH
provides additional benefit for feed industry
E
very animal feed producer
knows, the closer moisture
content comes to the permitted
threshold the more profitable
production becomes. Maximum
exploitation of this potential can
be achieved by using the on-line
analyser. Real time permanent
process control assures that each
batch precisely reaches the required
moisture and protein value.
12 | September-october 2009
RKW in Kehl, Germany generates
substantial additional annual turnover
by using NIR-Online analytical technol-
ogy. RKW produces 75,000 tonnes of
mixed feed annually and has installed a
NIR-Online process analyser at the end
of the mixer unit. If a batch shows data
below the permitted moisture value an
appropriate level of water can be added
promptly therefore increasing produc-
tion revenues.
NIR online Feature
Starting signal for production
At noon within the RKW Kehl production
facility, new daily orders are started.
First of all the mixing unit recalls valid recipe
codes for the mixtures and checks whether all
the necessary raw materials are in stock. Each
feed variety is composed of the main cereal
components soy and maize. Minerals, vitamins
and amino acids are also added. The main
components need a certain ratio so that each
recipe offers the required content of moisture,
Grain &feed millinG technoloGy
Feature NIR online
Another NIR-Online device is installed in the laboratory for moisture control of dog and cat feed. This mobile system consists of a
turning sample dish with a large capacity of approximately one litre of feed. The NIR-Online measuring device is installed above
the dish. Other basic, quick, moisture analysers can only test very small quantities, NIR-Online however, delivers by contrast more
reliable representative data as a result of the larger sample size. Each sample rotates for 40 seconds on the tray.
fat, protein, crude fibre and starch. Due to the “More and more customers feed their Heimtiernahrung GmbH, like RKW, is
fact that the quality of raw materials is vari- cattle, pigs, horses, poultry, small animals an affiliate of ZG Raiffeisen Karlsruhe and
able, the ideal mixing ratio has to be carefully and pets with customised special mixtures,” produces10.000 tonnes of dry feed for cats
calculated. explains Hans-Peter Luhr, general manager and dogs annually.
Currently RKW Kehl has approximately of RKW Kehl, whose customers are farmers Both affiliates jointly use the technical and
400 feed recipes in its database with an in Baden, part of the German state Baden- human resources in Kehl. Like other mash com-
increasingly upward trend. Württemberg in the southwest of Germany. panies, RKW Kehl and Heimtiernahrung GmbH
Measure
and Optimise
in Real-Time
NIR-Online intelligent
laboratory and inline control
system will measure moisture,
protein, temperature, fat/oils, ash,
crude fibre, starch, ethanol, sugar,
amino acids, PH values, colour,
structure and particle size all in
real-time during the production process.
Suffolk Automation
UK Distributor for NIR-Online
Unit 4, Hadleigh Enterprise Park
Crockatt Road, Hadleigh
Suffolk IP7 6RJ
Tel: + 44 (0)1473 829188 ®
mail@suffolk-automation.co.uk
www.suffolk-automation.co.uk
Grain &feed millinG technoloGy PREVIOUS PAGE NEXT PAGE September-october 2009 | 13

check all incoming raw materials by drawing
samples for analysis in the laboratory with a
NIR-Online spectrometer.
Mixtures under scrutiny
When the mixer starts to produce the
ordered batches via the process
control system, the selected raw
materials are scaled and mixed.
Within one hour RKW Kehl
can produce approximately 10
batches of three tonnes each in
its mixing facility.
Time has an important role as
Hans-Peter Luhr emphasizes.
“Our biggest requirement is
for customised mixtures which
are produced on request. This
means the span of time between
production and delivery needs
to be extremely short.”
14 | September-october 2009
The important questions crucial for qual-
ity control are:
• Does a feed mixture fall below a
required protein and fat content
• Is there scope for addi-
tional moisture?
NIR online Feature Feature NIR online
Previously these questions
could only be answered follow-
ing the long waiting times of a
traditional laboratory analysis.
The process
The process analysers of
NIR-Online solve this prob-
lem in the wink of an eye.
The 200x220x135mm NIR
device with a vision panel is
installed at the end of the
mixing unit.
The feed mixtures are
irradiated with near infrared
(NIR) light through the vision
panel. Reflected light passes
back through the vision panel
and is read by a diode array
spectrometer. The reflections
vary depending on the con-
centration of measured param-
eters in raw materials and feed the financial advantages of the NIR-Online ensuring moisture addition is precisely “The investment in NIR-Online technol-
mixtures. solution. controlled for each batch. ogy will be paid for in a few months”
Every 30 millisecond a This benefit is further increased with the “If we are able to approach only 0.5
measurement is made in the possibility of adding moisture in real time. percent to the moisture set point of a batch Representative samples
20 minute production cycle The NIR-Online process software cal- we can sell more than 375 tonnes of addi- Another NIR-Online device is installed in
– therefore RKW Kehl gets culates the difference between actual value tional mixed feed per year – a substantial the laboratory for moisture control of dog
hundreds of thousands real and set point without stopping production additional asset,” calculates Mr Luhr. and cat feed. This mobile system consists of
time readings. Data is proc-
essed online by the NIR proc-
ess software ‘SX-Center’ and
shown as a continuous graph
on a monitor in the switch On-Line NIR analyser
room.
If preset parameters are over
or under run, corrective adjust-
with camera
ments can be made immedi-
ately. The Diode Array On-Line Analyser is an advanced
Adjustments and modern NIR analyser for use in Grain, Flour,
in real time Food and Feed processing.
If too low a protein value is
measured the further process-
ing or delivery of the feed mixture is • Real-time analysis of moisture, protein, fat,
stopped as well as the production of prior color and more
batches.
“By using NIR-Online expensive rejects
• Integration with plant control systems
and complaints can now be minimised,” • Accurate and robust diode array technology
said general manager Luhr as he described
• Many systems installed worldwide
To discover more about the DA
7300 On-Line NIR Analyser
and for local contact information
visit us at www.perten.com
SPECIALISTS IN QUALITY CONTROL OF GRAIN, FLOUR, FOOD AND FEED
www.perten.com
Grain &feed millinG technoloGy Grain &feed millinG technoloGy September-october 2009 | 15

“RKW produces 75,000 tonnes of mixed feed
annually and has installed a NIR-Online process
analyser at the end of the mixer unit.
If a batch shows data below the permitted moisture
value an appropriate level of water can be added
promptly, increasing production revenues”
a turning sample dish with a large capacity
of approximately one litre of feed. The NIR-
Online measuring device is installed above
the dish.
Other basic, quick, moisture analysers can
only test very small quantities, NIR-Online
however, delivers by contrast more reliable
representative data as a result of the larger
sample size.
Each sample rotates for 40 seconds on
the tray.
“We can reach the exact set point for
moisture in cat and dog feed with NIR-
Online analysis,” Mr Luhr emphasises.
16 | September-october 2009
“The balancing act between the shelf life
of the product and the acceptance of a quality
product by the livestock is consistently achieved.”
Complete documentation
The Production Managers overview:
“With NIR-Online devices we are able
to detect and compensate very subtle and
short-run variations in production, the mix-
tures, the raw material quality and moisture
content is made in real time.”
If the spectrometer is completely inte-
grated into the existing process control sys-
tem, highly detailed documentation is made
PREVIOUS PAGE NEXT PAGE
NIR online Feature
TOUR2009
Good
Agricultural
Raiffeisen Kraftfutterwerke Practice
Kehl GmbH & Co. KG /
Heimtiernahrung GmbH GLOBALG.A.P. I Nairobi I Montevideo I Kuala Lumpur I Washington, DC I Athens
RKW Kehl (www.rkw-kehl.
de) commenced trading in 1964,
Heimtiernahrung GmbH in 1987.
Both companies are affiliates of central
cooperative ZG Raiffeisen Karlsruhe,
whose area of operation is Baden,
part of Germany’s south-western state
Baden-Württemberg. RKW Kehl pro-
duces 75.000 tonnes of mixed feed for
farming annually.
Moreover, around 130,000 tonnes of
cereals are transhipped resulting in a busi-
ness volume of 35 million Euros in 2008.
Heimtiernahrung GmbH produces
10,000 tonnes of dog and cat food
annually which are sold by Raiffeisen
cooperatives in Germany, Switzerland
and Austria as well as other retail sales
companies. Turnover in 2008 was 10
million Euro.
available. RKW Kehl can therefore meet the
highest expectations of production quality
as well as the legal demands for traceability
within production processes.
NIR-Online process analysers
NIR-Online process analysers are world-
wide sold pre-calibrated, optical systems
for online analysis, monitoring and control
of organic and non-organic substances in
production and processing.
Due to the special configuration, NIR-
Online systems can be integrated in nearly
every production environment. The expen-
sive costs of traditional NIR laboratory analy-
sis are no longer necessary, instead of this
random examination a continuous real time In Collaboration with our
insight in the process is provided. Quality local partners FPEAK (Nairobi),
INAC (Montevideo), qa plus
variations in the production can be analysed (Kuala Lumpur) and Agron
and adjusted in seconds making long delays (Athens)
for laboratory results history.
For non-organic products like metals
TOUR 2009 will be where You are!
or minerals a NIR-Online system with an
additional high-resolution camera is recom-
mended. The camera is able to measure
external features of non-organic products.
Even minimal differences in colour, structure
Your opportunity to learn about latest develop- Nairobi, Kenya – 15th September 2009
and size allow analysis of chemical ingredients
with results represented graphically.
ments of GLOBALGAP and have an input into the Montevideo, Uruguay – 24th/25th September 2009
Standard! Kuala Lumpur, Malaysia – 14th/15th October 2009
1. Join in and have your say on the revised content for Washington, DC, USA – 29th October 2009
More inforMation: the next version of the GLOBALGAP Standard! Athens, Greece – 11th/12th November 2009
NIR-Online GmbH 2. Deepen your knowledge by visiting on site exhibitors!
3. Discover the latest news on GLOBALGAP! More Information on Programme, Fees
SAP Partner Port, Altrottstrasse 31 4. Explore, discuss and debate Good Agricultural and Details for Registration are available on
69190 Walldorf / Baden, Germany
Practices - risks and challenges! www.tour2009.org
Tel: +49 6227 732660 5. Network with many experts from around the world!
Fax: +49 6227 732670 6. Visit one of our interesting destinations close to your
Website: www.nir-online.de
home country!
Grain &feed millinG technoloGy
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