Análise do produto acabado em uma indústria de ração

Abstract

Cattle feed is provided as a dietary supplement to ruminants and is of fundamental importance for the good zootechnical performance of animals, as it directly impacts their well-being. For this reason, it is essential to ensure a minimum level of quality throughout the production process. The nutritional quality of feed is directly related to the adequate levels of nutrients for each stage of animal development. One of the major challenges faced by the feed industry is to balance cost reduction and minimization of losses throughout the production process, while maintaining a high quality standard. This study was developed in a feed industry, where it was found that the protein levels of the "Engorda Standard 14%" feed were, on average, 4% above the expected value. Considering that protein is the most expensive component in feed formulation, this deviation represents a significant potential financial waste for a company. In order to identify the causes of this inconsistency, several checks were carried out, such as analysis of the formula used, assessment of the quality of the raw materials, verification of the automatic weighing system, calibration of the protein content reading equipment, review of the sample collection procedure and, finally, complete monitoring of the production process, from formulation to completion. During this last stage, it was identified that, during the bagging process, significant losses of feed of various types occurred. These remains were reprocessed and, later, fully incorporated into the feed under study, which considerably increased its protein content. This resulted in financial losses, since “Engorda Standard 14%” is one of the lowest value products marketed by the factory. With the reprocessing, the costs of raw material, labor, electricity and steam were doubled, without the corresponding financial return, in addition to the delivery of a product with a nutritional value above that specified. To mitigate these losses, it was proposed to incorporate small amounts of reprocessing into the feed formulation in a controlled manner, so as not to compromise the final protein content. In addition, it is recommended that a laboratory analysis of the feed be performed for each batch produced, by the company's internal laboratory, to verify whether the protein content is within the expected range. In the event of discrepancies, the market value of the feed should be adjusted according to the results obtained. In addition to these measures, a training program was proposed for employees, changing their skills regarding the new reprocessing, analysis and traceability procedures. It was also suggested that the production process be completely reassessed, with a focus on standardization, loss reduction and increased operational efficiency.