Critical Steps in Mash Conditioning

BY EUGENIO BORTONE, PH.D, PAS, DPL. ACAS

REVIEWED AND EDITED BY ADAM FAHRENHOLZ, CHARLES STARK, AND CASSANDRA JONES

Even today, with new advances in processing Starch damage

technology such as extrusion, the pelleting process Starch can be broken by mechanical forces during
continues to be the most popular and economical grinding and pelleting. The broken or sheared
method of compounding animal feeds. The most starch granules can be read by the starch
critical step in this process is preconditioning. The gelatinization method as cooked starch. In reality,
quality of the preconditioning process will depend this is not true starch gelatinization but starch
on particle size of the mix; the steam quality; initial damage. During pelleting, damage is mainly caused
moisture content of the mix; meal initial by friction as the mash is compressed and extruded
temperature as it enters the preconditioner; and the through the working area of the die, as has been
residence time in the preconditioner. Longer well documented by several authors (Skoch, 1979;
residence time in the conditioner permits more Stevens, 1987).
penetration of the moisture and better distribution of
heat, which results in better binding of the feed If one wants to measure the actual degree of cook
particleshence, increasing the pellet hardness that caused by steam conditioning, one must first
can result in a reduction of fines produced. consider the starch damage caused by grinding and
the damage caused during pelleting. The latter can
be done first by establishing a baseline with the
Starch gelatinization mash meal before it is preconditioned and the same
meal after it is preconditioned. The difference
The term gelatinization has been widely used in between the two will be the degree of cook caused
connection with the pelleting process, and more so by exposing the meal to the steam in the
in relation to the production of high-quality pellets. preconditioner. One advantage of the starch
Starch gelatinization is defined as the loss of bi- damage caused during the grinding process is the
refringence, or as the irreversible rupture of the exposure of greater surface area, which in turn can
native secondary bonds in the crystalline region of increase the water absorption of the mix.
the starch granule. According to Hoseney (1986),
the loss of bi-refringence occurs under continuous
heating and excess moisture, which can lead to
increased viscosity and increased swelling (water Steam conditioning
uptake) of the starch granules. The process of adding steam to the mixed meal is
known as preconditioning, or steam conditioning.
It is clear that moisture and temperature are required During this process, the mixed meal is exposed to
to cause the starch granule to gelatinize. Therefore, saturated steam to increase its moisture and
the preconditioner works as a continuous mixer or temperature, which will eventually result in some
chamber in which the meal is moistened and heated starch gelatinization and the activation of other
via saturated steam. This process is time-dependent, binding agents found in the mix. The conditioning
thus the residence time, or the time the meal spends is achieved in a continuous mixer or chamber
passing through the preconditioner, is a major factor known as the preconditioner, or conditioning
for attaining the target moisture and temperature. chamber (see Figure 7-1).
Feed Pelleting Reference Guide Section 2: Conditioning
Chapter 7: Critical Steps in Mash Conditioning
Feed Pelleting Reference Guide Section 2: Conditioning
Chapter 7: Critical Steps in Mash Conditioning
Figure 7-1. Preconditioner.
Figure 7-3. Shaft speed influences residence
time.

Figure 7-4. Increased shaft speed at same feed

rate.

Preconditioning equipment
The preconditioner (see Figure 7-2) is made up of a
screw feeder that takes the meal from the holding
bin to the conditioner; the paddles, which convey
and expose the meal to the steam being injected; Figure 7-5. Paddle template.
and the exit port, which drops the meal into the
chute or feeding port of the pellet mill.

Figure 7-2. Pelleting overview.

Figure 7-6. Determining configuration of

paddles.

The residence time and the degree of fill in the

preconditioner can be increased by reducing the Figure 7-7. Arranging paddle layout.
speed of the shaft (see Figures 7-3 & 7-4) for the
same feed rate, or changing the pitch angle of the
paddles. To change the angle of the paddles it is
recommended to use a template (see Figure 7-5)
that shows the number of paddles and the location
with respect to the shaft. Once the layout has been
established, the operator then can proceed to change
the paddle configuration (see Figures 7-6 and 7-7).
Feed Pelleting Reference Guide Section 2: Conditioning
Chapter 7: Critical Steps in Mash Conditioning
The paddles can be arranged: in a forward Steam
orientation (0 to 90 degrees), which moves the feed An essential part of the preconditioning process is
towards the discharge; in a neutral orientation (0 the addition of steam to moisten and heat the meal.
degrees); in a reverse orientation (0 to -90 degrees), Steam can be classified as saturated, superheated or
which moves feed away from the discharge and wet steam. Saturated steam is 100% vapor held at
increases the degree of fill and residence time; or the temperature and pressure representing its
may be set perpendicular to the rotation (90 vaporization point. Superheated steam is also 100%
degrees) to maximize the mixing effect (see Figure vapor, but has a temperature greater than that of its
7-8). vaporization temperature at current pressure. Wet
steam contains both vapor and free water. In the
Figure 7-8. Paddle angle maximizes mixing pelleting process, saturated steam is used to increase
effect. the temperature and moisture of the mash via the
process of condensation. The condensation occurs
as a result of the drop in pressure and temperature
as steam enters the conditioning chamber, which is
at atmospheric conditions. As wet steam enters the
conditioning chamber it contacts the colder meal
particles and condenses. During the condensation
process, heat is transferred to the meal, elevating its
temperature.
The best configuration should be one that allows the
mash to fill the center section of the preconditioner.
This can be accomplished by putting some of the Steam quality
paddles in the reverse, some in the neutral and some
in the forward pitch orientation (see Figure 7-9). Steam used in the process of conditioning must be
Immediately after the reverse, and closer to the exit as dry (saturated) as possible. The dryness of steam
port, the paddles should again have a forward pitch describes its quality and is defined as the proportion
to allow the mash to flow out of the conditioner. of water droplets in suspension present in the steam.
Beware that too many paddles in the reverse Reimer and Beggs (1993) reported that when steam
position can cause the preconditioner to overfill and of 80% quality (dryness fraction) was used, mash
overload the drive motor. The configuration of the feed entering the conditioning chamber at 12%
paddles should be one that permits the maximum moisture and 18C, exited the conditioner chamber
degree of fill, maximum residence time, and a high at 16% moisture and 84C. However, at 100%
degree of mixing. This encourages constant contact steam quality, the conditioned mash was 91C.
between the feed particles and the steam being
injected into the chamber. The latter can be explained by looking at steam
tables, which show that wet (unsaturated) steam has
Figure 7-9. Pitch angles. substantially lower energy content than dry,
saturated steam at the same pressure. Therefore, it
is very important to ensure the quality of steam
being delivered to the pelleting system. This can be
accomplished by proper insulation of the steam
lines and having adequate steam traps and
separators.

Steam condensation and molecule binding

When steam condenses, it adds moisture to mash
feed, and at the same time it transfers its energy.
Feed Pelleting Reference Guide Section 2: Conditioning
Chapter 7: Critical Steps in Mash Conditioning
During this time-dependent process, the starch apply the physical laws to estimate the necessary
granules swell up until they gelatinize. Similarly, amount of time (residence time) to heat and
proteins will start changing their molecular humidify the particles homogeneously. In general,
structure, in some cases becoming more fluid. It is the higher the heat and water diffusivity, the faster
during this process that the binding of molecules the heat and moisture will flow into the particles.
starts, which is responsible for producing high
quality pellets. Because it is a time-dependent Most feeds have high amounts of ingredients such
process, steam conditioners should have enough as corn, sorghum, wheat and their byproducts. One
residence time to allow the particles to hydrate and of the major components of these ingredients is
heat. starch. At ambient temperature, starch has a
thermal diffusivity coefficient 100 times greater
In the pelleting process, the maximum moisture that than the water diffusivity. In simple words, heat
can be attained without causing the pellet mill to transfer is faster than moisture uptake by the starch
plug is about 17%. In contrast, during the extrusion granules. In most preconditioning situations it is
process moistures can be 20% or higher. The possible to heat up the mash to the target
extrusion process is more flexible in the amount of temperature, but it is more difficult to hydrate it to
water it can handle, and this makes it easier to raise the target moisture level because it requires more
the meal moisture and degree of cook to the desired time. The latter is one of the reasons why it is
levels. Therefore, preconditioners are designed important to have the adequate residence time in the
differently depending on the process. preconditioner: to allow moisture to penetrate the
particles. Keep in mind that moisture and
temperature are key elements, working together,
Steam conditioning: Residence time, mixing and responsible for attaining good pellet durability.
particle size
Film resistance around the particle can be measured
To understand preconditioning it is important to
using the dimensionless Biot number (Bi). When
understand the heat and mass transfer between the
the resistance is in the film around the particle, as is
components. The medium in the preconditioner is a
the case with preconditioners with poor mixing, the
three-phase system of gas (steam), liquid (water)
Biot number is very small (< 0.1). In conditioners
and solids (meal mixture). Steam transfers energy
with good mixing action, the main resistance is the
to the particles via condensation. The particles of
diffusion of water to the particle, and the Biot
meal are relatively cool and steam condenses onto
number is large (> 10). Based on this number, we
them, forming a thin film of water on the particle
can classify most of the preconditioners available
surface. This water is absorbed into the particle,
today for pelleting and they would fall into an
increasing the moisture content. How fast the heat
intermediate category in mixing efficiency where
transfer and moisture uptake occurs will depend on
the Biot number is approximately 1. The film and
the film resistance on the surface of the particle and
internal resistance have a direct impact on the rate
the speed by which the heat and moisture travel to
of hydration into the particle.
the core of the particles. The more solid-to-fluid
contact, the lower the film resistance.
Particle size also has a direct effect on how well the
mash is preconditioned. This can be explained by
Having good mixing in the preconditioner
understanding the relationship between particle size
encourages more contact between the feed particles
and the rates of hydration and heat transfer. It has
and the steam, thus reducing the film resistance and
been demonstrated (Bouvier, 1996) that larger
speeding up the process. The speed at which heat
particles (> 400 microns) require twice as much
and moisture travel to the interior of the particle is
hydration time than smaller particles (< 200
governed by Fouriers and Ficks second laws. The
microns). This is logical since the moisture added
meal is composed of particles that have different
via the steam in the preconditioner will require
internal resistance for heat and moisture. Therefore,
more time to be internalized in a larger particle than
by knowing the coefficients of diffusivity, one can
a small one. In addition, smaller the particle size
Feed Pelleting Reference Guide Section 2: Conditioning
Chapter 7: Critical Steps in Mash Conditioning
results in greater the surface area. The hydration hydration time can be improved in the
rate can be explained in mathematical terms by preconditioner. In the preconditioner there can be
applying the laws of thermodynamics. two types of mixing. One is axial mixing, which
contributes to increasing the particle-to-steam/fluid
The following formula allows one to calculate the contact in the preconditioning chamber. The second
required time necessary to adequately hydrate is radial mixing, which also affects the contact of
particles based on the particle radius: particles with the steam and liquid, but depends
more on the shaft RPM and paddle
Fo = Dt / [(R/3)2] configuration/geometry. Depending on the design,
preconditioners can exhibit a plug flow (very little
Where Fo is Fourier number, D is the water mixing) and mixed flow (highly axial mixing).
diffusivity, t the diffusion time and R the radius of These flows depend, again, on the paddle geometry,
the particle. shaft speed and degree of fill.

Solving for t shows that as the particle radius A common problem in the pelleting process of
increases a longer time is required to hydrate it. animal feeds is the appearance of uneven-colored
This clearly demonstrates that particle size not only pellets. In most cases, this is caused by inadequate
needs to be small enough to improve feed moisture distribution in the preconditioner. This
digestibility, but also to improve hydration rate that can be more easily explained by understanding the
can lead to better pellet quality. If particles are of RTD. In this particular case, the RTD is broad,
more uniform dimensions, hydration rate will be meaning that some particles spend a short time in
similar for most particles, and there will therefore the preconditioner, thus receiving insufficient
be a more uniform distribution of moisture among moisture, while others spend a longer time and are
particles in the meal. This is a good reason for adequately hydrated. This problem is not only
considering post-batch grinding systems to achieve associated with inadequate paddle configuration,
a more uniform particle size. Keeping the particle shaft speed or degree of fill, but also with uneven
size distribution within a narrow range can improve particle size. Even if the preconditioner is properly
the overall pellet quality both in terms of degree of optimized, but the particle distribution is too broad,
cook and pellet durability. the moisture distribution among particles can be
uneven. The large ones will have less moisture,
while the small ones will have a higher moisture
Residence time distribution content. Therefore, particle size of the meal needs
to be as uniform as possible and the RTD needs to
Residence time distribution (RTD) should not be
be as narrow as possible.
confused with residence time (RT). Using a
marker, one can determine the RT, which is the
Fill ratio represents the volume occupied by the
time it takes the marker to exit the preconditioner.
meal in relation to the total volume of the
This assumes a first-in, first-out flow principle.
preconditioner. The meal volume is measured when
Consider this vs. the RTD, which is the average
the preconditioner is stopped. Many
residence time a single particle may stay in the
preconditioners used in the pelleting industry today
preconditioner, and is more representative of the
can have a relatively low fill ratio (~ 30%). Having
typical material flow. The RTD has a characteristic
a small fill ratio means that the preconditioner has
bell-shaped curve. The shorter the distribution, the
more empty spaces. Knowing that steam is a gas,
more uniform, more efficient the preconditioner is
one can clearly visualize that it will tend to fill the
in hydrating and heating particles uniformly.
voids in the preconditioner. When this happens it
can be expected that less steam will be in contact
There are many kinds of preconditioners with
with the material, and heating and hydration will
different configurations for paddle design, shaft
suffer. Therefore, increasing the fill ratio improves
speed, paddle angle and volumetric capacity.
not only the residence time but also the temperature
Understanding RTD can help understand how
and hydration uniformity of the mix.
Feed Pelleting Reference Guide Section 2: Conditioning
Chapter 7: Critical Steps in Mash Conditioning
As mentioned previously, the degree of fill can be communication) has shown that residence time can
improved by properly adjusting the paddle be as high as six minutes. It is clear that such an
configuration (orientations). Angled paddles can extended residence time can improve the meal
increase axial mixing. In contrast, paddles placed at moisture absorption and degree of cook, since both
0 or 90 degrees can increase the filling ratio. Most are time- and temperature-dependent processes.
preconditioners are fitted with paddles that can be
adjusted by the operator. Again, a good paddle Figure 7-12. Concept of new preconditioner.
configuration will include paddles in the reverse,
some forward and some flat (mixing action). Some
preconditioners (see Figure 7-10) also incorporate
retention plates that have the purpose of providing
an obstacle at the end of the unit and thus increase
the degree of fill and the residence time.

Figure 7-10. Retention plates.

Figure 7-13. Inclined preconditioner.

In recent years, new preconditioners have been

introduced to the market, and old versions have Other preconditioners have been designed to work
been improved. Some of the new preconditioners as pressure vessels, taking advantage of the fact that
have been developed based on the principles of at higher pressures the amount of energy transfer is
axial and radial mixing in combination with greater and requires less time. These conditioners
extended residence times. A good example of this have been on the market for some time, specifically
type of preconditioner is shown in Figure 7-11. the Sprout-Waldron pressurized conditioner, which
has been used in the past in extrusion processing.
Figure 7-11. New type preconditioner. The pressurized conditioner by Pelleting Concepts
International, Inc (see Figure 7-14), has been used
in pellet mills with some degree of success.

Figure 7-14. Pressurized preconditioner.

This incorporates a high-speed mixing zone in a

small chamber and then has a larger section where
the meal is allowed to hydrate and heat (see Figure
7-12). Others, as is the case of Stolz in France,
have developed a preconditioner that is inclined
(see Figure 7-13) to increase the residence time and
degree of fill. Work done by Stolz (personal
Feed Pelleting Reference Guide Section 2: Conditioning
Chapter 7: Critical Steps in Mash Conditioning
It is clear that one advantage of pressurized Skoch, R.E., 1979. Influence of steam pelleting
conditioners, based on steam thermodynamics, is conditions on the pelleting process and the
that at higher pressures steam has more energy to nutritive value of swine diets. PhD
transfer to the mash. dissertation, Kansas State University,
Manhattan, Kansas, USA.
Steam tables (Spirax Sarco) show that at sea level, Stevens, C.A., 1987. Starch gelatinization and the
or 1.01 bar of absolute pressure, the energy content influence of particle size, steam pressure and
of steam is 638.3 kcal/kg. On the other hand, at die speed on the pelleting process. PhD
1.15 bar the energy content is 640.7 kcal/kg. This dissertation, Kansas State University,
difference of 2.4 kcal/kg represents an increase in Manhattan, Kansas, USA.
temperature of approximately 3.6C, which can be
an advantage when trying to achieve a high degree Dr. Eugenio Bortone is a Sr. Principal Scientist for
of cook in order to improve pellet quality. Also, at PepsiCo-Frito Lay. He previously served as the
higher pressures the moisture and heat can penetrate R&D Manager for Ralston Purina and earned his
more rapidly into the core of the starch granule to B.S., M.S., and Ph.D. from Kansas State University.
gelatinize it, which may reduce the residence time
in the conditioner. This content was edited and reviewed by Dr. Adam
Fahrenholz, Assistant Professor of Feed Milling at
Other preconditioners have been designed to North Carolina State University, Dr. Charles Stark,
become feeders by including at the exit port a Jim and Carol Brown Associate Professor of Feed
metering screw that feeds the pellet mill and Technology at Kansas State University, and Dr.
regulates the discharge rate of the preconditioner Cassandra Jones, Assistant Professor of Feed
(see Figure 7-15). Technology at Kansas State University.
Figure 7-15. Metering screw at exit port.

This type of preconditioner can also achieve high

degree of fill and increased residence time.
Preconditioner manufacturers continue to strive for
solutions to improve the residence time that can
lead to better degree of cook and better pellet
quality.

References
Bouvier, JM., 1996. Engineering analysis of
preconditioning in the extrusion cooking
process. Cereal Foods World 41(9):738-740.
Hoseney, R.C., 1986. Principles of cereal science
and technology. American Association of
Cereal Chemists.
Reimer, L. and Beggs, W.A., 1993. Harnessing
steam quality. Feed Management 44(1).