[Md]

Maximum 20 KW/Ton

[Md]

Use maximum thermal energy

[Md]

Use PPE

[Md]

Excellent question

[Md]

Extrusion technology

[Md]

First aid, PPE, Preventive maintenance, Proper use of fire extinguishers & Hazard recognition and prevention.

[Md]

Cleaning ,Hygiene & Sanitation.

[Muhammad Ahmad]

• Fertility is defined as a complex trait involving biology, management, egg storage, and hatchery practices. Since genetics companies are only one part of this system, what is the role of other stakeholders (hatcheries, feed companies, growers) in supporting the genetic program’s effort to stabilize fertility?

[Muhammad Ahmad]

• In Ovo vs. Spray: The core concepts of immunization apply to both in ovo and spray vaccines. For a vaccine like coccidiosis or E. coli (often spray-applied), what unique challenges exist in ensuring uniform coverage and dose integrity compared to the automated, direct in ovo injection?

[Muhammad Ahmad]

• How should the industry adjust its biosecurity and management strategies to specifically target the known persistence of S. Typhimurium in environmental reservoirs? Does this shift justify a change in the focus of surveillance or disinfection protocols?

[Muhammad Ahmad]

• Given the success of control measures like vaccination, what prudent antibiotic stewardship strategies should the poultry sector prioritize in 2025 and beyond? Should there be greater public transparency and reporting on the use of antibiotics in laying hen flocks, and how can the industry ensure that managing this health risk doesn’t inadvertently lead to an AMR crisis?

[Muhammad Ahmad]

My approach to inventory management and minimizing raw material waste in feed manufacturing is built on three core pillars: Precision Planning, Optimized Rotation & Storage, and Process Control.

The perishable nature, high volume, and fluctuating quality of feed ingredients (like grains, meals, and co-products) make minimizing waste a critical factor for both profitability and sustainability.

1. Precision Planning and Forecasting

The goal here is to buy and hold the minimum necessary amount of raw material to meet the production schedule without risking a stock-out.

| Strategy | Description | Waste Reduction Impact |

|—|—|—|

| Accurate Demand Forecasting | Use historical production data, sales forecasts, and animal performance models to accurately predict ingredient needs. | Prevents overstocking of ingredients that could spoil before use. |

| Material Requirements Planning (MRP) | Utilize software to translate the final feed production schedule into precise raw material requirements, allowing for automated reorder points and order quantities. | Minimizes the financial and physical waste associated with holding excess buffer stock. |

| Vendor Managed Inventory (VMI) & JIT | Where feasible, collaborate with key, reliable suppliers to implement Just-In-Time (JIT) or VMI practices for high-turnover or high-spoilage ingredients. | Reduces inventory holding time and storage costs, decreasing the risk of quality degradation. |

| Safety Stock Optimization | Calculate safety stock not just on lead time and demand variability, but also on ingredient shelf-life. Higher spoilage risk = lower safety stock levels. | Reduces waste from perishable ingredients reaching their expiry date. |

2. Optimized Rotation and Storage

This pillar focuses on managing the physical flow and environment of the ingredients to maintain quality.

| Strategy | Description | Waste Reduction Impact |

|—|—|—|

| First-In, First-Out (FIFO) & First-Expired, First-Out (FEFO) | Strictly enforce stock rotation. Ingredients with the oldest delivery date (FIFO) or the closest best-before date (FEFO) are used first in the feed batch. | Directly prevents spoilage and obsolescence of older stock. |

| Real-Time Inventory Tracking (Lot/Batch) | Employ an Enterprise Resource Planning (ERP) or dedicated Inventory Management System (IMS) to track all raw material lots, including receipt date, vendor Certificate of Analysis (COA), and expiration/retest dates. | Provides visibility to prioritize usage and isolate lots that fail quality checks before they enter the production stream. |

| Climate and Pest Control | Maintain optimal storage conditions (temperature, humidity, ventilation) in silos and warehouses to inhibit mold growth, insect infestation, and caking/clumping. | Reduces loss from biological contamination and physical degradation (e.g., moldy grain, caked minerals). |

| Proper Receiving/Handling | Conduct thorough quality checks upon receipt (moisture, mycotoxins, protein content) and ensure gentle handling to minimize spillage and dust/fines generation during transfer to storage. | Stops sub-standard material from entering inventory and minimizes physical loss during handling. |

3. Process Control and Material Utilization

This addresses minimizing waste that occurs during the manufacturing process itself.

| Strategy | Description | Waste Reduction Impact |

|—|—|—|

| Precision Batching & Weighing | Utilize highly calibrated, automated weighing and batching systems to ensure ingredients are added at the exact level specified by the formula. | Eliminates waste from human error and over- or under-dosing high-cost ingredients. |

| Clean-Out Procedures | Implement rigorous and documented clean-out processes for bins, mixers, and transfer lines to minimize cross-contamination and reclaim “heel” or residual material. | Reduces lost material that gets stuck in the system and avoids waste batches due to contamination. |

| Reutilization of Co-Products/Rework | Establish a system to safely and legally reincorporate dust, spilled feed, or slightly off-spec finished product (rework) into new batches at acceptable inclusion levels. | Turns unavoidable process waste into a valuable input, achieving a closed-loop system. |

| Waste Audit and Root Cause Analysis | Regularly measure and categorize all forms of raw material waste (spoilage, handling loss, process loss). Use this data to identify the root cause of the biggest losses for continuous improvement. | Provides the data foundation for targeted interventions to drive down waste over time. |My approach to inventory management and minimizing raw material waste in feed manufacturing is built on three core pillars: Precision Planning, Optimized Rotation & Storage, and Process Control.
The perishable nature, high volume, and fluctuating quality of feed ingredients (like grains, meals, and co-products) make minimizing waste a critical factor for both profitability and sustainability.
1. Precision Planning and Forecasting
The goal here is to buy and hold the minimum necessary amount of raw material to meet the production schedule without risking a stock-out.
| Strategy | Description | Waste Reduction Impact |
|—|—|—|
| Accurate Demand Forecasting | Use historical production data, sales forecasts, and animal performance models to accurately predict ingredient needs. | Prevents overstocking of ingredients that could spoil before use. |
| Material Requirements Planning (MRP) | Utilize software to translate the final feed production schedule into precise raw material requirements, allowing for automated reorder points and order quantities. | Minimizes the financial and physical waste associated with holding excess buffer stock. |
| Vendor Managed Inventory (VMI) & JIT | Where feasible, collaborate with key, reliable suppliers to implement Just-In-Time (JIT) or VMI practices for high-turnover or high-spoilage ingredients. | Reduces inventory holding time and storage costs, decreasing the risk of quality degradation. |
| Safety Stock Optimization | Calculate safety stock not just on lead time and demand variability, but also on ingredient shelf-life. Higher spoilage risk = lower safety stock levels. | Reduces waste from perishable ingredients reaching their expiry date. |
2. Optimized Rotation and Storage
This pillar focuses on managing the physical flow and environment of the ingredients to maintain quality.
| Strategy | Description | Waste Reduction Impact |
|—|—|—|
| First-In, First-Out (FIFO) & First-Expired, First-Out (FEFO) | Strictly enforce stock rotation. Ingredients with the oldest delivery date (FIFO) or the closest best-before date (FEFO) are used first in the feed batch. | Directly prevents spoilage and obsolescence of older stock. |
| Real-Time Inventory Tracking (Lot/Batch) | Employ an Enterprise Resource Planning (ERP) or dedicated Inventory Management System (IMS) to track all raw material lots, including receipt date, vendor Certificate of Analysis (COA), and expiration/retest dates. | Provides visibility to prioritize usage and isolate lots that fail quality checks before they enter the production stream. |
| Climate and Pest Control | Maintain optimal storage conditions (temperature, humidity, ventilation) in silos and warehouses to inhibit mold growth, insect infestation, and caking/clumping. | Reduces loss from biological contamination and physical degradation (e.g., moldy grain, caked minerals). |
| Proper Receiving/Handling | Conduct thorough quality checks upon receipt (moisture, mycotoxins, protein content) and ensure gentle handling to minimize spillage and dust/fines generation during transfer to storage. | Stops sub-standard material from entering inventory and minimizes physical loss during handling. |
3. Process Control and Material Utilization
This addresses minimizing waste that occurs during the manufacturing process itself.
| Strategy | Description | Waste Reduction Impact |
|—|—|—|
| Precision Batching & Weighing | Utilize highly calibrated, automated weighing and batching systems to ensure ingredients are added at the exact level specified by the formula. | Eliminates waste from human error and over- or under-dosing high-cost ingredients. |
| Clean-Out Procedures | Implement rigorous and documented clean-out processes for bins, mixers, and transfer lines to minimize cross-contamination and reclaim “heel” or residual material. | Reduces lost material that gets stuck in the system and avoids waste batches due to contamination. |
| Reutilization of Co-Products/Rework | Establish a system to safely and legally reincorporate dust, spilled feed, or slightly off-spec finished product (rework) into new batches at acceptable inclusion levels. | Turns unavoidable process waste into a valuable input, achieving a closed-loop system. |
| Waste Audit and Root Cause Analysis | Regularly measure and categorize all forms of raw material waste (spoilage, handling loss, process loss). Use this data to identify the root cause of the biggest losses for continuous improvement. | Provides the data foundation for targeted interventions to drive down waste over time. |

[Muhammad Ahmad]

That’s a statement outlining the broad strategic goals for sustainable and efficient feed manufacturing, rather than a question.

However, based on the context you’ve provided, I can summarize the four key areas of strategic focus necessary to achieve those goals:

1. Ingredient Selection & Nutritional Strategy

This focuses on the “what” and the “why” of the feed formula:

* Balancing Needs: Selecting ingredients that meet the precise nutritional requirements of the target animal (to ensure health and performance) while simultaneously considering the environmental and social impacts of those ingredients.

* Alternative/Sustainable Sourcing: Exploring and incorporating novel or regional ingredients (e.g., insect protein, single-cell protein, co-products) to reduce reliance on major crops like soy and corn, thereby decreasing land-use pressure and deforestation risk.

* Precision Formulation: Utilizing advanced analysis (like near-infrared reflectance spectroscopy or NIR) and software to formulate diets with minimal nutrient excesses, which reduces feed cost and the excretion of nutrients like nitrogen and phosphorus into the environment.

2. Procurement & Supply Chain Logistics

This focuses on the “where” and the “how” of obtaining ingredients:

* Sustainable Sourcing Policies: Implementing strict standards (e.g., certifications for sustainable soy or palm oil) to ensure all ingredients are sourced responsibly, avoiding commodities linked to deforestation or unethical labor practices.

* Supply Chain Transparency: Tracking the origin of ingredients to assess their true environmental footprint and identify risks.

* Optimizing Transport: Strategically locating production facilities and choosing ingredient suppliers to minimize the distance and mode of transport, thereby reducing greenhouse gas emissions.

3. Manufacturing & Production Processes

This focuses on the “when” and the “how much” of feed production:

* Energy Efficiency: Investing in modern equipment and process improvements to reduce the energy consumption (and associated emissions) per ton of feed produced. This includes optimizing pelleting, grinding, and drying processes.

* Waste Minimization: Implementing procedures to reduce feed loss and spillage during handling, mixing, and storage, ensuring resource utilization is maximized.

* Feed Safety & Quality: Maintaining rigorous quality control to prevent contamination or poor mixing, which would lead to inefficient animal performance and potential waste.

4. Environmental and Social Impact Measurement

This involves the “tracking” and “reporting” required for continuous improvement:

* Life Cycle Assessment (LCA): Quantifying the environmental burden (e.g., carbon footprint, water usage) of various feed formulations and production pathways.

* Social Metrics: Evaluating the social impact of the supply chain, including labor practices, community engagement, and food security contributions.

* Setting Targets: Establishing clear, measurable, and achievable sustainability goals (e.g., reducing carbon intensity by a set percentage) and regularly reporting progress to stakeholders.That’s a statement outlining the broad strategic goals for sustainable and efficient feed manufacturing, rather than a question.
However, based on the context you’ve provided, I can summarize the four key areas of strategic focus necessary to achieve those goals:
1. Ingredient Selection & Nutritional Strategy
This focuses on the “what” and the “why” of the feed formula:
* Balancing Needs: Selecting ingredients that meet the precise nutritional requirements of the target animal (to ensure health and performance) while simultaneously considering the environmental and social impacts of those ingredients.
* Alternative/Sustainable Sourcing: Exploring and incorporating novel or regional ingredients (e.g., insect protein, single-cell protein, co-products) to reduce reliance on major crops like soy and corn, thereby decreasing land-use pressure and deforestation risk.
* Precision Formulation: Utilizing advanced analysis (like near-infrared reflectance spectroscopy or NIR) and software to formulate diets with minimal nutrient excesses, which reduces feed cost and the excretion of nutrients like nitrogen and phosphorus into the environment.
2. Procurement & Supply Chain Logistics
This focuses on the “where” and the “how” of obtaining ingredients:
* Sustainable Sourcing Policies: Implementing strict standards (e.g., certifications for sustainable soy or palm oil) to ensure all ingredients are sourced responsibly, avoiding commodities linked to deforestation or unethical labor practices.
* Supply Chain Transparency: Tracking the origin of ingredients to assess their true environmental footprint and identify risks.
* Optimizing Transport: Strategically locating production facilities and choosing ingredient suppliers to minimize the distance and mode of transport, thereby reducing greenhouse gas emissions.
3. Manufacturing & Production Processes
This focuses on the “when” and the “how much” of feed production:
* Energy Efficiency: Investing in modern equipment and process improvements to reduce the energy consumption (and associated emissions) per ton of feed produced. This includes optimizing pelleting, grinding, and drying processes.
* Waste Minimization: Implementing procedures to reduce feed loss and spillage during handling, mixing, and storage, ensuring resource utilization is maximized.
* Feed Safety & Quality: Maintaining rigorous quality control to prevent contamination or poor mixing, which would lead to inefficient animal performance and potential waste.
4. Environmental and Social Impact Measurement
This involves the “tracking” and “reporting” required for continuous improvement:
* Life Cycle Assessment (LCA): Quantifying the environmental burden (e.g., carbon footprint, water usage) of various feed formulations and production pathways.
* Social Metrics: Evaluating the social impact of the supply chain, including labor practices, community engagement, and food security contributions.
* Setting Targets: Establishing clear, measurable, and achievable sustainability goals (e.g., reducing carbon intensity by a set percentage) and regularly reporting progress to stakeholders.

[Muhammad Ahmad]

Feed analysis of different samples from the same type of feed can produce different results due to a combination of natural variation in the feed itself, issues with sampling technique, and analytical variations in the testing process.

Here is a breakdown of the main reasons for these differences:

1. Non-Uniformity in the Feed (Actual Variation)

Even within a single “type” of feed, its composition can vary significantly due to several factors:

* Ingredient Variability: The raw materials (e.g., grains, hay, protein meals) used in the feed naturally vary in their nutrient content based on growing conditions (soil, weather), harvesting time and methods, and storage/conservation processes. For example, the protein content of grain can differ from one field to the next.

* Manufacturing Inconsistencies: For processed or mixed feeds, variation can occur during production:

* Inadequate Mixing: If the feed is not mixed for the correct time or if the equipment is worn, micro-ingredients (like vitamins and minerals) may not be uniformly distributed, leading to “hot spots” or “cold spots” of nutrients.

* Segregation: Even after proper mixing, ingredients can separate (segregate) during transport or delivery due to differences in particle size, shape, or density. This means the feed at the top of a bin might be different from the feed at the bottom.

* Moisture Content: The percentage of water in the feed can fluctuate based on storage conditions and can dramatically affect the nutrient concentration when results are reported on an “as-fed” basis.

2. Sampling Error

The biggest cause of variation often comes from the way the sample is collected. Any analysis only represents the sample submitted, so if the sample isn’t truly representative of the entire batch, the result will be inaccurate for the whole lot.

* Non-Representative Sample: Taking a sample from only one location (e.g., the top of a bag or bin) will likely miss the overall average, especially if segregation has occurred.

* Insufficient Subsamples: A single composite sample should be made from multiple subsamples collected randomly across the entire “lot” of feed (e.g., 10-20 cores from a hay bale lot, or multiple grabs from a bulk bin). Not collecting enough subsamples increases error.

* Sample Integrity Issues: Improper handling, such as allowing a moist sample to heat up or spoil before analysis, can alter its composition (e.g., loss of digestible nutrients).

3. Laboratory/Analytical Variation

Variations can also be introduced during the testing process, though reputable labs take steps to minimize this.

* Method Differences: Different laboratories or even different methods within the same lab (e.g., wet chemistry vs. Near-Infrared Reflectance Spectroscopy, or NIR) can yield slightly different results. NIR results, for instance, are predictions based on calibrations from wet chemistry and may show more variation.

* Precision and Accuracy: All lab tests have inherent variation.

* Precision refers to the consistency of results from repeated tests.

* Accuracy refers to how close the result is to the true value.

* Sample Preparation: Even a small sample must be properly ground and mixed in the lab to ensure the tiny portion analyzed in a specific test is representative of the submitted composite sample.Feed analysis of different samples from the same type of feed can produce different results due to a combination of natural variation in the feed itself, issues with sampling technique, and analytical variations in the testing process.
Here is a breakdown of the main reasons for these differences:
1. Non-Uniformity in the Feed (Actual Variation)
Even within a single “type” of feed, its composition can vary significantly due to several factors:
* Ingredient Variability: The raw materials (e.g., grains, hay, protein meals) used in the feed naturally vary in their nutrient content based on growing conditions (soil, weather), harvesting time and methods, and storage/conservation processes. For example, the protein content of grain can differ from one field to the next.
* Manufacturing Inconsistencies: For processed or mixed feeds, variation can occur during production:
* Inadequate Mixing: If the feed is not mixed for the correct time or if the equipment is worn, micro-ingredients (like vitamins and minerals) may not be uniformly distributed, leading to “hot spots” or “cold spots” of nutrients.
* Segregation: Even after proper mixing, ingredients can separate (segregate) during transport or delivery due to differences in particle size, shape, or density. This means the feed at the top of a bin might be different from the feed at the bottom.
* Moisture Content: The percentage of water in the feed can fluctuate based on storage conditions and can dramatically affect the nutrient concentration when results are reported on an “as-fed” basis.
2. Sampling Error
The biggest cause of variation often comes from the way the sample is collected. Any analysis only represents the sample submitted, so if the sample isn’t truly representative of the entire batch, the result will be inaccurate for the whole lot.
* Non-Representative Sample: Taking a sample from only one location (e.g., the top of a bag or bin) will likely miss the overall average, especially if segregation has occurred.
* Insufficient Subsamples: A single composite sample should be made from multiple subsamples collected randomly across the entire “lot” of feed (e.g., 10-20 cores from a hay bale lot, or multiple grabs from a bulk bin). Not collecting enough subsamples increases error.
* Sample Integrity Issues: Improper handling, such as allowing a moist sample to heat up or spoil before analysis, can alter its composition (e.g., loss of digestible nutrients).
3. Laboratory/Analytical Variation
Variations can also be introduced during the testing process, though reputable labs take steps to minimize this.
* Method Differences: Different laboratories or even different methods within the same lab (e.g., wet chemistry vs. Near-Infrared Reflectance Spectroscopy, or NIR) can yield slightly different results. NIR results, for instance, are predictions based on calibrations from wet chemistry and may show more variation.
* Precision and Accuracy: All lab tests have inherent variation.
* Precision refers to the consistency of results from repeated tests.
* Accuracy refers to how close the result is to the true value.
* Sample Preparation: Even a small sample must be properly ground and mixed in the lab to ensure the tiny portion analyzed in a specific test is representative of the submitted composite sample.

[Jegede Olajumoke]

Thanks for this