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From formula to product: a real challenge.

Designing a balanced nutritional formula is only the first step. The real challenge begins when that formulation must be converted into a physical product, processed in an ABA plant under very specific technical, operational and economic conditions.

In the world of animal nutrition, a formulation can be flawless on paper and completely different in practice. This difference is most evident in feed production plants, where industrial processes, equipment limitations and the physical nature of ingredients can transform or even ruin what appeared to be an ideal nutritional formula.

From formulation to production: a critical transition

Nutritionists invest time and knowledge in designing formulas that meet the specific nutritional requirements of each species, growth stage and production objective. However, that design only makes sense if it remains intact until the final product is consumed by the animal. The transition between formulation and production is not a minor step; it is a critical phase that can directly affect the quality and efficiency of the feed.

The formulas that appear functional in formulation software can present multiple challenges during production. This is due to factors such as: the physical handling of the ingredients, the technology available in the plant, and the way the components interact under thermal, pressure and mixing conditions.

Physical and operational incompatibilities: ingredients under pressure

One of the main challenges faced by ABA plants is the physical incompatibility of certain ingredients with industrial processes. For example:

Ingredients with high fat content, such as fishmeal or vegetable oils, can reduce the friction needed in the pelletizer, resulting in brittle pellets or pellets with low durability.
Ultra-fine powders, such as calcium carbonate or some vitamin premixes, tend to segregate during mixing or cause dusting problems in the environment, affecting both product safety and homogeneity.
Fibrous ingredients or ingredients with irregular granulometry can generate blockages in hoppers or flow difficulties, interrupting the plant's operating efficiency.

This type of incompatibility requires close collaboration between the nutrition team and the production area to adjust both the formulation and the process, either through the selection of more suitable particle sizes, the use of binders or emulsifiers, or by premixing complicated ingredients.

Equipment limitations: between the ideal and the possible

Not all production plants are state-of-the-art. Many operate with machinery that, although functional, has significant restrictions in terms of mixing capacity, residence times, temperature control or dosing accuracy.

Even in modern plants, it is necessary to consider that:

Some mixers have time or speed limits that prevent proper incorporation of sensitive micro-ingredients.
Pelletizers can reach temperatures that degrade thermolabile nutrients such as vitamins A, D, E or digestive enzymes, unless post-pelletizing techniques are applied.
The lack of automated dosing systems can lead to errors in the inclusion of costly additives or in the homogeneity of the final mix.

Added to this are economic considerations. It is not always feasible to implement process changes just to adapt a nutritional formula, especially if this implies reduced efficiency or increased costs. In these cases, it is key to prioritize sustainable adjustments and solutions that strike a balance between what is nutritionally desirable and operationally viable.

Nutrient losses: the invisible enemy

Another aspect that is often underestimated is nutritional losses during processing. Exposure to heat, pressure or moisture can profoundly affect the integrity of certain key nutrients:

Vitamins such as C, B1 (thiamine) and B2 (riboflavin) are particularly sensitive to heat.
Enzymes used to improve digestibility, such as phytases or xylanase, lose their effectiveness if they are not thermally protected.
Functional additives, such as probiotics or organic acids, require specific encapsulation or post-processing liquid application technologies to maintain their viability.

Here, the choice of the appropriate form of nutrient (thermal protection, coating, etc.) and the addition strategy (before or after pelleting) are essential to ensure that the feed performs its function in the field.

Bridging the gap: communicating and working together

The key to overcoming these challenges lies in the continuous collaboration between nutritionists, plant operators, quality control technicians and the maintenance team. Visiting the plant, understanding its capabilities, monitoring processes and adapting formulas with a holistic view of the system allows closing the gap between the ideal formulation and the production reality.

Animal nutrition does not end at the computer. It starts there, but it takes shape at every stage of production, from mixing to final packaging. Understanding limits, adapting to processes and anticipating losses is what makes the difference between an average feed and a truly efficient one.

Metalteco, the best technology to bring your formulation to reality

Metalteco's technology makes the difference. Our equipment is precision engineered to preserve the nutritional integrity of formulas from the first to the last step of the production process. We know that transforming a technical formulation into a functional feed requires more than quality ingredients: it requires reliable, efficient machinery adapted to the real challenges of the industry.

The engineering applied at Metalteco offers solutions that minimize thermal losses, ensure homogeneous mixing and enable accurate dosing of even the most sensitive ingredients. With high-performance pelletizing systems, temperature control, high-efficiency mixers and post-pelletizing options, our technologies bridge the gap between the ideal formulation and the finished product.

Investing in Metalteco equipment is investing in productivity, nutritional quality and sustainability. Because in modern animal nutrition, having state-of-the-art technology is not a luxury: it is a necessity.