High-Fat and High-Protein Animal Feed Supplement and Process of Manufacture

Abstract

A system according to various embodiments can include a source for supplying a material to be treated, an extruder, at least two screws, and a drive coupled to the screws for axially rotating the screws. The extruder includes an inlet for receiving the material, which is fed therein in a controlled manner. The screws are provided within the housing of the extruder. The screws have a plurality of compression and release stages that create mechanical heat which is directly applied to the material to change the mechanical properties of the material thereby facilitating a conversion of a physical state of the material from a non-compactable state to a compactable state as the screws rotate and move the material longitudinally along the screws to produce a final product, for example, a feed tub for use as an animal feed.

What is claimed is: 
     
         1 . A system, comprising:
 a source for supply of a material to be treated, the treated material having an initial composition of a first high nutritional value, the initial composition on a dry basis comprising (a) a first protein content within a range of approximately 25% to 35%, and (b) a first fat (oil) content within a range of approximately 8% to 16%;   an extruder comprising an elongated housing having an inlet end and a discharge end, and the inlet end configured to receive the treated material;   at least two rotatable screws provided within the housing and extending between the inlet end and the discharge end, the screws have a plurality of compression and release stages that create mechanical heat which is directly applied to the material to change mechanical properties of the treated material thereby converting a physical state of the material from a non-compactable state to a compactable state as the screws rotate and move the treated material longitudinally along the screws to produce a compactable material;   at least one drive coupled to the screws for axially rotating said screws;   a container for collecting the compactable material dispensed from the extruder, the container comprising a housing, the housing having a top portion, a bottom portion and side walls defining an initial shape having a centerline in a circumferential direction of the container;   at least one expandable panel disposed within at least one side wall of the container;   a top hat member having a generally top hat configuration, the top hat member includes an annular flange, a cylindrical portion and a lip member that extends from the annular flange and fits within the top portion of the container to form a seal therein, wherein the annular flange extends outward from a base of the cylindrical portion and sits substantially flush upon the top portion of the container for providing an extra volume to the container as the container is filled with an overflow of the compactable material dispensed from the extruder before compression;   a compression press system for compressing the compactable material into the container to produce a final product formed as a solid within the container, and the compression press system includes a hydraulic ram and an outer collar for surrounding and retaining the container during compression;   the hydraulic ram configured to move from an initial position toward the compactable material in the container thereby compressing a volume of the compactable material for a predetermined time to produce the final product having a substantially uniform density throughout;   wherein compressing the volume of the compactable material expands the at least one expandable panel and side walls such that the housing container changes from the initial shape so that the centerline expands approximately within a range of 20%-80% to define a parabolic shape;   a vacuum chamber having a first plate and second plate and the vacuum chamber pneumatically connected to a vacuum line to a vacuum port to create a vacuum between the first plate and the second plate of the vacuum chamber, and wherein compressing the volume of the compactable material with the hydraulic ram causes a predetermined amount of excessive compactable material to overflow the first plate, and wherein the vacuum is created to remove the excessive compactable material from the first plate; and   the final product having a final composition of a second high nutritional value, which is produced without additives, and the second high nutritional value is substantially the same as the first high nutritional value.   
     
     
         2 . The system of  claim 1 , wherein the substantially uniform density product comprises a feed supplement having a high-fat and high-protein content for use as animal feed, wherein the high-fat and high-protein content is produced without additives. 
     
     
         3 . The system of  claim 1 , wherein the substantially uniform density product comprises a feed tub. 
     
     
         4 . The system of  claim 3 , wherein the feed tub comprises a feed supplement having a high-fat and high-protein content for use as animal feed, wherein the high-fat and high-protein content is produced without additives. 
     
     
         5 . The system of  claim 3 , wherein the feed tub comprises a uniform density of protein to enhance flavor and regulate feed intake. 
     
     
         6 . The system of  claim 1 , wherein the substantially uniform density product comprises a feed block. 
     
     
         7 . The system of  claim 6 , wherein the feed block comprises a feed supplement having a high-fat and high-protein content for use as animal feed, wherein the high-fat and high-protein content is produced without additives. 
     
     
         8 . The system of  claim 6 , wherein the feed block comprises a uniform density of protein to enhance flavor and increase feed intake. 
     
     
         9 . The system of  claim 1 , wherein a final fat content of the treated material after being dispensed from the extruder into the container remains substantially the same or increases on a nutritional analysis basis as that of an initial fat content of the treated material before extrusion. 
     
     
         10 . The system of  claim 9 , wherein the initial fat content of the material before the extrusion increases by a range of ½% to 2% to produce a final fat content of the material after the extrusion. 
     
     
         11 . The system of  claim 1 , wherein the treated material comprises distiller grain. 
     
     
         12 . The system of  claim 1 , further wherein compressing the compactable material with the hydraulic ram compresses the compactable material into ribs provided in the side walls of the container such that the material solidifies rigidly within the ribs of the container.