Dr. Badineedi Hanumanth Rao – Technical Executive – Livestock Nutrition
Dr. Sushant Mhatre – AGM – Techno Commercial
Dr. Jayanta Bhattacharyya – Director – Techno Commercial
Poultry farming is a rapidly growing sector within animal agriculture, driven by rising global demand for meat and eggs. Feed quality is a determining factor in the success of poultry operations. In the competitive and cost-sensitive world of poultry production, feed quality is the cornerstone of flock health, performance, and profitability. While precise formulations are essential, it’s the actual nutrient value of the raw materials and the consistency of finished feed that ultimately determine bird outcomes. Contaminated, adulterated, or nutritionally imbalanced feed can lead to compromised bird health, reduced growth rates, poor feed conversion ratios (FCR), and economic losses. Therefore, pre-assessment of feed ingredients and finished feed is not merely a best practice—it is a necessity.
Importance of Raw Material Pre-Assessment
The feed manufacturing process begins with the selection and procurement of raw materials and the quality and safety of these ingredients directly influence the nutritional integrity and safety of the final feed. Pre-assessment of raw materials is a critical control point that ensures only high-quality inputs enter the production line. This process helps to reduce nutritional variability, enhance feed consistency, and minimize the risk of contamination.
- Nutritional Quality Evaluation
To ensure optimal nutrient supply, raw materials must be evaluated for their basic nutritional composition:
- Proximate Analysis: This includes measurement of moisture, crude protein, crude fat, crude fiber, and total ash content. These values help in determining the nutritive value of the ingredient and aid in balancing feed formulations.
- Amino Acid Profiling: Critical for high-performance poultry diets, this analysis ensures that essential amino acids like lysine, methionine, and threonine are present in sufficient quantities.
- Energy Estimation: Calculating Metabolizable Energy (ME) is essential for formulating energy-balanced rations, ensuring optimum growth and feed efficiency.
B) Contaminant Screening
Screening for potential contaminants is vital to prevent feed-related health issues and production losses:
- Mycotoxins: Particularly aflatoxins and ochratoxins, which are harmful even at low concentrations. Mycotoxin contamination can impair immune function and reduce productivity.
- Heavy Metals: Elements such as lead, mercury, and cadmium can accumulate in poultry tissues and pose serious health risks to both birds and consumers.
- Pesticide Residues: Traces of agricultural chemicals used in crop production must be assessed to ensure they remain within permissible limits.
- Microbial Load: Presence of pathogenic microorganisms like Salmonella, Escherichia coli, and molds must be evaluated to prevent disease outbreaks and spoilage.
Table: 1. Ingredient assay table
*Moisture, Impurities, Unsaponifiables **W = Weekly, E = Every Load Source: Table from feedtech V, AFIA.
Pre-Assessment of Finished Feed
Once the feed is manufactured, it must undergo post-production testing to verify its nutritional accuracy, physical quality, and microbiological safety. This step ensures that the final product is both effective and safe for animal consumption.
- Physical and Nutritional Quality Parameters
Key quality parameters assessed in finished feed include:
- Pellet Durability and Texture: Proper pellet hardness and minimal fines ensure better intake and reduce feed wastage.
- Homogeneity: Uniform mixing of micronutrients, vitamins, minerals, and medications is essential to deliver a balanced diet and prevent deficiencies or overdosing.
- Moisture Content: Maintaining appropriate moisture levels prevents microbial growth, especially mold, during storage.
- Mycotoxins: Regular monitoring and preventive measures are essential to ensure feed safety and performance.
- Pathogen Testing: Finished feed is routinely tested for the presence of pathogens, particularly Salmonella spp., which is a major concern in poultry production.
Modern operations must go beyond paper formulations and implement a robust pre-assessment and quality control system. Even a 2–3% variation in key nutrients such as calcium, phosphorus, crude protein, or metabolizable energy (ME) can result in immunosuppression, skeletal deformities, higher feed conversion ratios, or economic losses (Singh et al., 2020; Pesti et al., 2009).
Let’s explore three real-world case studies that demonstrate why testing raw materials and finished feed should never be optional.
Case Study 1: Mortality and Lameness Due to Mineral Imbalance
A broiler farm in the southern region of India reported continuous mortality and lameness among growing birds. Laboratory evaluation of feed samples and tissue diagnostics revealed:
- A clear imbalance in calcium and phosphorus
- Positive test results for Infectious Bursal Disease (IBD)
Interestingly, a neighboring flock fed with the same formula plus NSP enzymes (NSPases) showed no mortality—highlighting the role of enzymes in enhancing nutrient release and gut integrity (Cowieson et al., 2010; Chandel et al., 2022). Further investigation found that the Dicalcium Phosphate (DCP) in use had lower-than-declared phosphorus content (14.5% instead of the standard 18%). The farmer attempted to correct this by supplementing sodium hydrogen phosphate via water. However, by then, birds were already showing signs of rubbery legs, stunted growth, and poor performance.
Key Learning: Even slight raw material deviations can compromise skeletal health and immunity. Pre-assessment of minerals like DCP is critical before inclusion.
Case Study 2: Mycotoxin Risk Missed Due to Visual Assumptions
A feed mill in central India sourced visually clean maize, assuming it to be toxin-free. However, a third-party analysis revealed aflatoxin B1 levels exceeding 50 ppb, well above the BIS safety limit of 20 ppb for poultry (FAO, 2011; Ghosh et al., 2018).
Birds fed this contaminated maize developed:
- Enlarged livers (hepatomegaly)
- Immunosuppression and poor vaccine response
- Secondary infections and increased mortality
- The economic consequences included poor FCR, lower livability, and treatment costs.
Key Learning: Visual appearance is NOT a reliable indicator of quality. Even clean-looking maize can carry invisible aflatoxins. Routine testing is essential.
Case Study 3: Protein Deviation Due to Undeclared Adulteration
In southern India, a layer farmer observed a drop in egg production and pale yolks. Investigation revealed that the soybean meal used, though labeled as 46% crude protein, was adulterated with urea, a common but illegal nitrogen booster (Vijayasarathi et al., 2018).
Analysis showed:
- Low lysine and methionine digestibility
- Reduced feed intake and consistency in laying
- Pale yolk pigmentation
The farmer shifted to verified suppliers and began routine amino acid digestibility checks, which resolved the issue within two weeks (Sindhu et al., 2021).
Key Learning: Don’t rely on crude protein values alone. Always validate digestible amino acid levels—especially lysine and methionine—for optimal performance.
Field Data Snapshot: Real Deviations in Indian Poultry Feed
(Source: CARI-ICAR reports & FeedTech India lab data, 2021–2024)
Key Takeaways
- Raw material variability is real—especially in DCP, maize, and soybean meal
- Routine lab testing of Ca, P, CP, fiber, and toxins is non-negotiable
- Feed enzymes and toxin binders provide support but are not a substitute for QA
- Finished feed must be tested to confirm actual delivery matches formulation
- Testing costs far less than losses from mortality, poor FCR, or egg drop (Patra et al., 2020)
Final Thoughts
A feed may look perfect on paper, but what matters is what reaches the bird’s gut.The pre-assessment of raw materials and finished feed is fundamental to achieving sustainable, safe, and profitable poultry production. Implementing robust quality testing and control measures at every stage of feed manufacturing ensures optimal bird health, enhances performance, and reduces production losses. Moreover, consistent feed quality strengthens consumer trust in poultry products, especially in an era of rising concerns over food safety, antibiotic resistance, and regulatory compliance. As the poultry industry continues to evolve, prioritizing feed quality assurance remains more important than ever. In a competitive, low-margin industry, Quality Assurance isn’t optional—it’s survival.
References
Chandel, B.S., et al. (2022). Use of NSPases in mineral-deficient diets. Poultry Science Journal.
Cowieson, A.J., et al. (2010). Mechanisms and benefits of feed enzymes. World’s Poultry Science Journal.
FAO (2011). Feed quality assurance manual. FAO, Rome.
FeedTech India Pvt Ltd (2023). Internal QA Data presented at Poultry India Expo.
Ghosh, R.C., et al. (2018). Aflatoxins and seasonal risk. Indian Journal of Veterinary Research.
ICAR-CARI (2022). National Feed Quality Audit Report.
Patra, A.K., et al. (2020). Cost of QA in feed systems. Indian J. Economics and Development.
Pesti, G.M., et al. (2009). Formulation based on tested nutrients. Animal Feed Science and Technology.
Ravindran, V. (2013). Feed cost and productivity. World’s Poultry Science Journal.
Sindhu, N., et al. (2021). Digestibility variation in soybean meal. Indian J. Animal Nutrition.
Singh, A.K., et al. (2020). Nutrient variability and bird performance. Indian J. Animal Nutrition.
Sunder, G.S., et al. (2021). Phytase and Ca–P balance in broilers. Animal Nutrition and Feed Tech.
Vijayasarathi, S.K., et al. (2018). Detection of adulterants in soybean meal. Animal Feed Science and Technology.