EUREKA PROJECT > 4187 PRESALOW
SPAIN
Control of swine food chain for decreasing salmonella prevalence
The present project is focused on the development of a new automatic system to incorporate additives (new antibiotic and other additives) to animal feedingstuffs, to control Salmonella.
Status > ANNOUNCED - 11-Jun-2008 Technological Area Market Area Start Date > 31-May-2007 Duration > 31 Months Participating countries > SPAIN, BELGIUM | Main contactCINCAPORC S.L. MR. ANTONIO MONTULL > GENERAL MANAGER Organisation type > SME |
Project Description
Usually, the antimicrobial and antifungal products are incorporated into the feed during the dosage phase, so the additives are homogeneously mixed with other raw materials and after they have to continue the normal granulation processes, carrying an associated heat treatment, air cooling, and so on, that may reduce the efficacy of the added product (antimicrobial), produce evaporation losses and generate the emergence of subsequent contamination in the feed. The project was born of the approach to develop a new automatic system of additives (antibiotic and other additives) incorporation to animal feeding-stuffs at the end of the process of production of feeding-stuffs. Thus, the system will guarantee the quality and security in the feed production process and will permit the control of several micro-organisms incidence in pigs (specially Salmonella), preventing Salmonella passage to human food chain. The control of the incidence of the Salmonella in pig is a subject of an increasing interest, mainly by the preoccupation of the consumers in food security provoked by the recent crises. For that reason, the study of measures to prevent the contamination by Salmonella in pigs is increasing in Europe. This contamination is produced to a great extent by the consumption of animal feeding-stuffs infected by the microorganism. The study of measures of control of the presence and control of Salmonella in animal feeding-stuffs should be made in association with handling procedures in farms to avoid the recontaminations and crossed contamination. Therefore, the project is going to study the addition of an antimicrobial (for the control of Salmonella) at the end of the feed production line. In this way, once the additive is mixed with the feed the final product is obtained without any new treatment except the storage. This fact will require a complete study and several adjustments of the antimicrobial dose which is necessary to exercise the same effect on feed. The project also includes a subsequent monitorisation of the feed to study the effect of the treated feed (feed + antimicrobial) on the incidence of Salmonella in animals (pigs). Therefore, the project will require the implementation of the following tests: - Simulation laboratorial tests to assess the potential effectiveness of antimicrobial losses during processing of the feed mainly due to the thermal treatment associated with granulation process as well as potential interactions (positive and negative) with other antibiotics or additives, which are also included in the same moment. This will provide for the addition of new requirements in the new system and the best presentation (powder or liquid). - Analytical on raw materials and feed without antimicrobial to isolate and identify the strains of Salmonella present (because it determines resistance or sensitivity to treatments). - Analytical on feed made with the new production system, in order to: 1. To verify the dose of antimicrobial in the feed when it arrives to the farm (to consider if one part is lost by evaporation during storage and transportation). 2. To check the hygienic quality of the feed (antimicrobial effectiveness to get a feed Salmonella free). - Analytical on animals to determine the initial levels of Salmonella and assesses the effectiveness of feed with antimicrobial to control Salmonella prevalence. Obviously, to avoid continuous recontaminations these experiments must be carried out on a farm that has a comprehensive management control and that has introduced a series of Biosecurity measures to limit the external and uncontrolled infection risks. The development of the project will suppose a change in the traditional system of feeding-stuffs production, since it is going to be made a control throughout all the processes of production until the storage of the formulas and after the verification of the hygienic and qualitative quality of the end item, is going to be made the automatic addition from additives and antibiotics for the control of the incidence of the salmonellas in the pig species. The system will allow incorporating a series of additives, enzymes, acids, oils and antibiotics at the end of the animal feeding-stuffs production process in conditions of maxima security, hygiene and control. These additives are added in small doses to fit formulations to the requirements and concrete exigencies of the clients according to the scope animal requirements depending on age, productive state, etc. and to the legal exigencies. Between the technological objectives it emphasises the development of a new protocol of animal feeding-stuffs manufacture that includes the addition of an anti-salmonella compound at the end of the production process, when the product is arranged to leave the factory towards the farm. Thus, the dose of additives will be reduced, and it will be allowed making formulations specially adapted to the concrete exigencies of the clients. The main impact of the project in the animal sector is to be able to guarantee the traceability of foods consumed by the animals, guaranteeing that its composition when coming out of the factory contains additives enough to the incidence of the Salmonella in the feeding of the pig, but diminishing to the maximum the doses of these additives, because when taking place the addition on order, the doses can be adapted to the necessities of the clients. The dwell time of the feeding with additives in the factory decreases and the possibility of crossed contaminations is eliminated. On the other hand, the dose of additive-antibiotics is fit because they will be added once the hygienic quality (specially presence of Salmonella) has been verified in each animal feeding-stuffs lot. This project will be of great impact in the pig farms, since it has been demonstrated that when the levels of Salmonella stay below a certain limit its incidence does not have substantial effects on the pig production and the quality of the obtained end item. That is why the project will allow firstly improving the productivity of pig farms (when reducing the productive losses due to sublicical Salmonelosis) and secondly obtaining and end item of better quality (with a reduction of the risk of passage of Salmonella to the carcase). Keywords: anti-salmonelosic, swine, animal feeding.
Technological Development Envisaged
The main technological innovation in the project is focused on developing an automated and controlled system for including additives in finished animal feeding-stuffs, using a complex system that allows for adding under conditions of maximum hygiene and safety, completing the productive chain of animal feeding-stuffs with total traceability. The final product will have a high hygiene quality and its characteristics will allow for controlling the incidence of Salmonella in pigs in different productive states, guaranteeing an end item (meat) of high quality and without Salmonella. Moreover, the project will develop a new anti-salmonella product for contamination control in swine feeding. Therefore, the system will consist of diverse components that will display new features: - A new mechanical system that will allow for incorporating several combinations of additives aimed at controlling Salmonella according to the age and productive state of the animals to be fed. - An automatic system to control the information generated in this part of the productive process being integrated into the general system of controlling information, facilitating the total traceability of the feeding produced. - The new system is integrated into the general production control system, so it will allow for controlling the whole production process and those parameters that are considered fundamental to obtaining a homogenous product, safety and high quality. It will also allow for automatically achieving those performances that favour productive processes and optimise production conditions. All the information generated in this last stage of the productive process will be incorporated into the general system to obtain a safer and more quality process as well as a very complete file that will contain the historical information of the whole productive processes, from the raw material arriving at the factory through to the animal feed leaving the factory and arriving at the farm. Several animal feeding-stuffs formulations will be obtained depending on the combination of antibiotics and additives for Salmonella control, and also depending on the age and productive stage of the animals to be fed. Several new production protocols will be developed. They will include the new incorporated systems such as the analysis of the finished feeding, the addition of additives, the verification of the added concentrations, the homogenisation of the animal feeding-stuffs, etc. Finally, the new system is totally compatible and complementary with all other measures of biosecurity that should be adopted for fighting and controlling Salmonella. Therefore, this system can be integrated perfectly into a global plan for controlling Salmonella.
Main contactCINCAPORC S.L. MR. ANTONIO MONTULL > GENERAL MANAGER Organisation type > SME |
Contribution to project
The organisation as a specialised company in swine feed production and pig breeding will be the coordinator of the project. So it will be responsible of the fulfilment of the Project objectives and planning. All along the project there should be a fluid exchange of technical information between the participants, so as to share the results of the tests and trials are conducted in both companies to optimise performance and ensure the project's success. As the coordinator, CINCAPORC will be responsible of this communication flow. CINCAPORC will contribute its experience in the feed production and in pig production (because it has numerous farms under integration system), to adjust the feed production process so that the antimicrobial addition will be carried out in the end of the production line, and to verify the effectiveness of the product both on feed quality as later on animals prevalence levels. Thus, CINCAPORC will participate in the different project implied tasks like the following ones: - Analysis of technical and user requirements for swine sector: the different system necessities will be studied from different levels as: technical and user. - Design of the new system to guarantee the feeding quality, safety and manufacture according to the swine sector necessities. In this task, as well as the electromechanical and informatical design, different procedures will be designed for a proper system control and management. - Analysis of the systems for additives addition at the end of the production process. - Development, integration and putting into operation of the system developed in its food production facilities. - Cost-benefit analysis with the use of the new additive for Salmonella control in pig food. - Test for traceability verification. - Isolation and identification of different Salmonella serotypes. - Development, integration and running out of the different components involved in the new system. - Design and development of new feeding production protocols. - Tests for the validation and optimisation of the developed system and protocols. - Tests for the validation of the new anti-salmonella effectiveness at different pig productive stages. - Evaluation and conclusions from the field assays. - Planning for the dissemination of the results. At the end of the project the company will participate in the elaboration of a closing report in which the obtained results and conclusions will appear. It will also appear the degree of fulfilment of the initial project objectives and any significant incidence.
Expertise
The organisation is a Spanish company located in Fraga, Spanish city that is situated in Huesca, Aragon. The company has a very long familiar tradition in the pig sector. The activities of CINCAPORC started on 1970 with the creation of a sows farm, a butcher and a delicatessen, although the company was not constituted as CINCAPORC until 1985. The animal feeding-stuffs plant was built in the year 1976 and was restructured in the year 1990. After this restructuration the plant reached a production of 13,000 tons per month. Nowadays, the company has different swine farms which are mainly located in Cataluna and Aragon geography. In these farms the company has more than 20,000 sows and more than 450,000 pigs for slaughter-house are breeding. The company guarantees to its customers some production standards and animal handlings that are more advanced that those than the law demands. These compromises are clearly explained by the following examples: * The environmental control in farms has been implanted since 1994. * All farmers, working in CINCAPORC, are fulfilling the animal well-being legislation what will take effect in 2013. In 2005 CINCAPORC became the first Spanish company that obtained a certificate under EUREPGAP IFA Norms for pig production. The company has one rooted culture in Innovation and Development with the objective to obtain some technologically advanced tools to improve its products and processes. Thus, the company is the first Spanish company that applies in its HACCP (Hazard Analysis Critical Control Point) some on-line controls. At the end of year 2005, the company conformated an R & D team, by means of the presentation of some projects of technological innovation. The R & D team creation and development has had the final objective to position the company in the vanguard of its sector. The main CINCAPORC activity is its ample human resources. A group of people that are specialised in diverse fields related with animal and feeding production such as veterinary, agronomist engineers, nutritionists, computer science technicians and so on. CINCAPOR is a company that has a compromise with the swine sector from the production to the consumer, offering a company culture based on the innovation and the respect, with a human team identified with the values of the company.
Main contactKEMIN EUROPE N.V. Dr. Stefaan Van Dyck > Principal Scientist Organisation type > SME |
Contribution to project
The organisation will contribute its previous experience and know-how in the development of antimicrobials for designing a product specifically for Salmonella (specially effective for the most common Salmonella strains in pigs production), to determine the best formula for the product addition (liquid or powder), to adjust the dose (taking into account the possible effectiveness loss during feed processing that does not occur in the system proposed in this project. That is, KEMIN will be in charge of all tasks that fall to anti-bicrobial. The company will make the study, the investigation and the improvement of several antibiotics and additives combination for Salmonella control, and its repercussion on sanitary quality of pig feeding when the addition occurs at the end of the feeding manufacture process. Thus, KEMIN will design and develop the anti-salmonella compound and the different concentrations to be added for the different animal test. The company will make several laboratorial tests and some in vivo assays at low scale, participating in the evaluation of the results in order to optimise the anti-salmonella product. Moreover, KEMIN may also undertake small-scale experiments to evaluate the possible product passage along the food chain, to establish possible suppression periods, and so on. At the end of the project, KEMIN will also collaborate to the results dissemination activities. KEMIN will carry out their investigations at laboratorial level on an anti-salmonella according to different criteria: - Different Salmonella serotypes frequently isolated in animal feeding-stuffs depending on the raw materials used. - Salmonella serotypes sensitivity and resistance to different antibiotic. - Age and productive stage of the animals that are going to ingest the feeding. - Other special animal requirements on minerals, oligoelements, and other additives. Several studies will be carried out putting special attention in those additives that can interfere with the antibiotic effectiveness.
Expertise
The organisation is a global corporation headquartered in Des Moines, Iowa (U.S.A.). The company is made up of 11 independent companies, supplying 6 markets in nearly 60 countries, making KEMIN capable of providing the best solution to any nutritional problems. As a nutritional ingredient manufacturer, KEMIN INDUSTRIES INC. is a privately held corporation and was founded in 1961. KEMIN AGRIFOODS EUROPE's mission is to develop and implement the most advanced nutritional solutions available nowadays. Since 1973, KEMIN AGRIFOODS EUROPE has created, manufactured and marketed a wide range of special ingredients for the feed and food industries. Established in 2001, KEMIN PHARMA's mission is to discover and develop pharmaceutical drugs, then to produce, market and sell them. The company focuses on anti-infective products, using the latest technologies, including high-throughput screening, a state-of-the-art separation, technologies for structure elucidation, proteomics and clycomics. The Main Research Scientist for Palasurance products acts as a technical expert, exploring and advancing new pet food flavour technology for the Palasurance product line of palatable pet food. He is involved in the identification, design and development of products, ingredients and formulae that enhance the palatable quality and meet customer needs. This person is in charge of guiding the product evaluations and analysing data. Much effort is put into achieving product breakthroughs in the palatable quality of pet food. The person also aims to achieve the business objectives and to contribute to achieving KEMIN's vision. The Main Research Scientist and his scientific team take part in all product development phases, from concept through to market launch.