Corn flaking machine, corn grinding machines, and corn extrusion

(puffing) have distinct impacts on feed quality and animal growth. This article explores their differences, highlighting the advantages of corn flaking with relevant academic data.
In ruminant feed production, the method of corn processing plays a critical role in determining feed efficiency, nutrient digestibility, and overall production performance. Among the commonly used methods,

1. Nutrient Digestibility: A Key Differentiator

1. Corn Flaking:
   The corn flaking machine processes corn through steaming and rolling, resulting in thin flakes with gelatinized starch. This significantly enhances rumen’s starch digestibility, increasing ruminal and total tract starch digestion by 25% and 10%, respectively (Asian-Australas J Anim Sci, 2017). Additionally, the net energy for maintenance (NEm) and gain (NEg) improves by 13% and 16%, respectively, compared to dry rolled corn (DRC).
2. Corn Grinding:
   Grinding mechanically breaks corn into smaller particles but does not alter the starch structure. As a result, starch digestibility is lower than flaked corn, leading to less efficient nutrient absorption. Studies have shown no significant improvement in energy utilization when compared to whole grain diets.
3. Corn Extrusion (Puffing):
   Extrusion involves high-temperature processing, which gelatinizes starch to a greater extent than flaking. However, the extreme heat can degrade some heat-sensitive nutrients, reducing overall feed quality. Furthermore, extrusion is energy-intensive, increasing operational costs.

2. Feed Conversion Efficiency

Feed conversion efficiency (FCE) is a critical measure of how effectively animals convert feed into body weight or milk production. Table 1 summarizes the differences in FCE among the three methods:

Data Source: Asian-Australas J Anim Sci, 2017

• Corn Flaking: Achieves the highest FCR, reflecting better feed efficiency due to improved starch digestibility and energy utilization.
• Corn Grinding: Lower FCR due to incomplete starch digestion and higher feed waste.
• Corn Extrusion: Offers moderate FCR but is less efficient than flaking due to nutrient degradation during processing.

3. Cost of Processing and Energy Use

1. Corn Flaking:
   While the initial investment in a corn flaking machine is higher, the long-term benefits outweigh the costs. Reduced feed conversion ratios mean less feed is required to achieve the same weight gain. Moreover, flaking improves within-pen consistency, reducing variation in animal performance (Table 2, Asian-Australas J Anim Sci).
2. Corn Grinding:
   Grinding equipment is less expensive to purchase and operate. However, the lack of improvement in digestibility and energy utilization often results in higher feed costs over time.
3. Corn Extrusion:
   Extrusion is the most energy-intensive process, significantly increasing operational costs. While it improves digestibility, its high energy demands and potential nutrient loss make it less cost-effective for large-scale feed production.

4. Animal Performance

The impact of these methods on average daily gain (ADG) and gain-to-feed ratio (G:F) is illustrated in Table 2:

Data Source: Asian-Australas J Anim Sci, 2017

• Corn Flaking: Leads to the highest ADG and G:F, reflecting its superior contribution to growth performance.
• Corn Grinding: Results in lower ADG and G:F due to suboptimal nutrient absorption.
• Corn Extrusion: Provides moderate improvements but is less efficient than flaking.

5. Key Advantages of the Corn Flaking Machine

1. Enhanced Digestibility:
   The corn flaking machine ensures starch gelatinization, improving energy availability and nutrient absorption.
2. Better Feed Efficiency:
   Steam-flaked corn reduces feed waste and improves animal performance, leading to cost savings.
3. Consistent Growth Performance:
   Flaked corn supports uniform growth within pens, minimizing variations in average daily gain (ADG).
4. Versatility:
   The corn flaking machine can process various grains, including corn, wheat, and soybeans, making it a flexible solution for feed producers.
5. Reduced Feed Costs:
   By improving feed conversion efficiency, flaking reduces the overall amount of feed required, optimizing production costs.

Conclusion

Among the three processing methods, corn flaking stands out as the most efficient and cost-effective approach for ruminant feed production. The use of a corn flaking machine not only enhances starch digestibility but also improves feed conversion efficiency, leading to better animal performance and reduced operational costs. While grinding and extrusion have their applications, flaking offers a balanced solution that maximizes nutritional value and economic returns.

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References

1. González-Vizcarra, V. M., et al. “Influence of substituting steam-flaked corn for dry rolled corn on feedlot cattle growth performance.” Asian-Australas J Anim Sci, 2017.
2. Owens, F. N., et al. “Corn grain processing and its effect on starch digestion in cattle.” Journal of Dairy Science, 1997.
3. Zinn, R. A., et al. “Influence of steam-flaking on performance and digestive function in feedlot cattle.” Journal of Animal Science, 1990.