ISSUE FOCUS 42 FEED & ADDITIVE MAGAZINE March 2026 However, machine design alone is not enough. Only by embedding machines into a connected Manufacturing Execution System (MES) can producers achieve full traceability of products and processes. As one example, an intelligent recipe sequence within an MES (such as Bühler Mercury MES) helps reduce cross-contamination while improving operational efficiency and daily reliability. HYGIENIZATION WHILE PRESERVING BIOACTIVITY: THE CONDITIONING CHALLENGE Independent studies and validation of Bühler’s conditioning solutions have shown that steam conditioning before expansion or pelleting can be a highly effective hygienization step. For example, in broiler feed, salmonella can be reduced below the detection limit at 80–85°C with a retention time of 90 seconds - where the lower temperature applies only with high moisture and tight temperature control throughout the entire conditioned product volume. Consistently achieving the dual goal - sufficient hygienization and preservation of sensitive bioactive ingredients - requires more than sophisticated mechanical and thermal design of the equipment. It also requires precise, continuous monitoring, and control of both steam quantity and quality, which again highlights the importance of a consistently optimized and stabilized process. At the same time, many producers are facing external pressure to push conditioning temperatures and retention times higher - up to 90°C and 360 seconds - for example driven by legal regulations or brand protection guidelines. These requirements can significantly reduce productivity and negatively impact nutritional value. From a process perspective, one major challenge is that moisture of the product entering the pellet mill depends on fluctuating initial moisture and on the difference between the (also variable) meal temperature and conditioning temperature. Combined with long retention times, high conditioning temperatures can therefore cause poor flow behavior, unstable pellet mill performance, and even die blockages - often forcing mills to reduce throughput. From a nutritional perspective, many bioactive additives lose effectiveness at higher temperatures, higher moisture, and longer residence times. A common response is overdosing, which increases formulation cost and the environmental footprint of the feed produced. MOISTURE: THE OFTEN-OVERLOOKED LEVER FOR FEED SAFETY AND PRODUCTIVITY In this complex situation, one key aspect is often overlooked: hygienization depends not only on temperature and time, but also on product moisture. Moisture is a powerful lever. At a given temperature, higher moisture can allow the same inactivation effect to be achieved in significantly less time. If moisture can be reliably controlled across the entire process, it becomes possible to improve productivity, nutrient quality, and feed safety at the same time. This is where digitalization can deliver real operational value - provided it is stable, robust, and usable under day-to-day mill conditions across different recipes and raw material variations. PRECISION FEED MILLING: TURNING DATA INTO SAFER, MORE STABLE PRODUCTION Digitalization in a feed mill - the availability and use of relevant process and product data in suffiBühler batch mixer Speedmix Photo: Bühler Group
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