NEAT REACTION PRODUCT OF CALCIUM AND VOLATILE FATTY ACIDS AS NUTRITIONAL SUPPLEMENT FOR LIVESTOCK AND POULTRY

Abstract

A process and composition for animal feed supplements without substantial foul odor problems prepared by reacting neat, a calcium metal source selected from the group consisting of calcium oxide and calcium hydroxide with a low molecular weight volatile fatty acid selected from the group consisting of butyric acid, isobutyric acid, 2 methyl butyric acid, valeric acid and isovaleric acid. Under controlled reaction conditions (neat) and a controlled weight ratio of the two reactants a product that is substantially odor free and useful as an animal feed supplement results.

Claims

1. A process of preparing isoacid feed supplements without foul odor problems, comprising: reacting a calcium metal source selected from the group of calcium oxide and calcium hydroxide in a solid phase with a low molecular weight volatile fatty acid selected from the group consisting of butyric acid, isobutyric acid, 2 methyl butyric acid, valeric acid and isovaleric acid, with the mole ratio of calcium metal source to low molecular weight volatile fatty acid source being with the range of about 1:1 to about 1:2, to provide a substantially odor free calcium salt product, useful as an animal feed ration supplement.

2. The process of claim 1 wherein the ratio of calcium metal source to low molecular weight volatile fatty acid source is within the range of about 1:1.5 to about 1:1.9.

3. The process of claim 1 wherein the process is run in a mechanical mix reactor, without any fat encapsulating additive.

4. The process of claim 3 wherein the process is run neat.

5. The process of claim 3 wherein the process is run in a shear mechanical mixer with a paddle dryer system.

6. The product of the process of claim 1.

7. The reaction product of claim 6 in subdivided form.

8. A feed supplement for ruminants, swine, and poultry with no substantial odor problems comprising a subdivided calcium volatile fatty acid feed source, non-encapsulated, and prepared neat from a calcium metal ion source selected from the group of calcium oxide and calcium hydroxide and a volatile fatty acid selected from the group consisting of butyric acid, isobutyric acid, 2 methyl butyric acid, valeric acid and isovaleric acid, with the mole ratio of calcium oxide or calcium hydroxide to volatile fatty acid being with the range of about 1:1 to about 1:2.

9. The feed supplement of claim 8 wherein the mole ratio of calcium ion source to volatile fatty acid source is about 1:1.5 to 1:1.9.

10. The feed supplement of claim 1 wherein the supplement is prepared in a commercially available mixer.

11. The feed supplement of claim 10 wherein the commercially available mixer is a panel dryer.

Description

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Importantly it has been found that the non-putrid smelling isoacid salts of calcium useful for this invention can be produced directly in a reaction mixture of the isoacid and either calcium hydroxide or calcium oxide in solid form with the reactions conducted neat directly in mixers at the normal exothermic reaction temperatures that result from the acid/base reaction which occurs in situ.

[0010] In fact, the reaction can be conducted in for example a Hobart mixer, a twin screw extruder, a vacuum paddle dryer, a ribbon blender, and even small hand batches can be made in ordinary beakers and the like.

[0011] Multiple experiments were conducted utilizing twin screw extruders. The ZSK 26 and ZSK 34 models from Coperion were used for initial development and scale-up modeling, respectively. Each extruder was set-up in a multi-barrel configuration with corresponding screw elements to enable raw material feed and injection as well as ensure adequate mixing, conveying, and discharge.

[0012] The solid calcium hydroxide was introduced through a side feeder. The respective isoacid was injected in one of the downstream ports. The mixture of the calcium hydroxide and isoacid was conveyed through mixing elements and discharged through an open discharge. Multiple variables were independently adjusted to optimize the process including the temperature of the mixture inside the extruder, the screw speed, the raw material feed ratio, and the overall feed rate. As the material reacted, it transitioned from a free-flowing slurry to a clay-like solid to a brittle solid. As such, residence time in the extruder was a key consideration during the experiments.

[0013] The Solidaire paddle dryer from BEPEX was also used for experimentation. The Solidaire paddle dryer consists of a horizontal agitating rotor inside a cylindrical vessel. The vessel is equipped with a heat transfer jacket utilizing steam as the heat source. The rotor is made up of adjustable-pitch and depth paddles, providing fine control over material residence time and material layer thickness.

[0014] Experiments were conducted at defined overall feed rates, adjusted raw material feed ratios, rotor speeds, and jacket temperatures. Residence time was again a consideration during the experiments. To allow for additional mixing/reaction time, a twin-rotor low-speed paddle mixer was used in conjunction with the paddle dryer.

[0015] Importantly the reaction must be conducted in controlled molar ratios, varying within the range of ratios herein expressed to achieve odor free products. For reasons not particularly known or understood and not wishing to be bound by theory, there appears to be something in the chemistry that when one doesn't have the complete reaction to 1:2 metal to acid the hold of the acid as attached is tighter. The 1:2 with both calcium oxide and calcium hydroxide smells more than the lower ratios.

[0016] The best results are obtained less than 1 to 2 ratios since the closer one gets to 1:2 ratio it will begin smelling more. These best results smell wise are obtained when the metal:acid ratio is within the range of about 1:1 to about 1:2 with the most preferred range being 1:1.5-1:1.9.

[0017] From time to time, it has been mentioned that this reaction is a neat reaction. Neat is used in the context of chemical reactions to refer to a reaction conducted without added solvents, carriers, or catalysts i.e., with just the reactants together. This is illustrated in the below examples, where the products are made and then headspace odor measured.

[0018] In the below examples the term “IBA” refers to isobutyric acid, “BA” to butyric acid, “2MBA” to 2 methyl butyric acid, “3MBA” to 3 methyl butyric acid, and “VA” to valeric acid. In the following examples the importance of using neat reactions and using the proper ratio of calcium oxide or calcium hydroxide to form the low molecular weight salts of volatile fatty acid are illustrated, both with respect to hand mixed samples and use of high shear mixing devices commonly available.

[0019] Smell is measured by using gas chromatograph headspace analysis. Measured headspace ppm less than 15,000 ppm constitutes tolerable odor.

EXAMPLES

[0020] The procedure for the hand mixed samples of Examples 1-5 is as follows:

Example 1

[0021] “X” gr of CaO or Ca(OH)2 as indicated is weighed in a 100 mL beaker. To this solid is added “y” gr of the acid and the mixture is stirred by hand. Heat is given off in the mixing.

[0022] The solid is allowed to cool and then sealed in a container until analyzed by GC/MS head space analysis, for odor or volatile component, measured in parts per million.

TABLE-US-00001 Mole IBA total CaO wt(gr) Moles Ratio wt(gr) wt(gr) 5.12 0.09 1.20 9.65 14.77 5.83 0.10 1.50 13.74 19.57 5.44 0.10 1.75 14.96 20.40 5.27 0.09 2.00 16.56 21.83

Example 1 Table (Headspace Analysis)

[0023]

TABLE-US-00002 Average PPM Ratio (IBA/Ca) 15.7 1 5792.5 1.5 8207.7 1.75 10714.6 2

Example 2

[0024]

TABLE-US-00003 CaO Mole IBA total wt(gr) Moles Ratio wt(gr) wt(gr) 8.7 0.16 1 13.67 22.37 7.9 0.14 1.5 18.62 26.52 9.1 0.16 2 28.59 37.69 7.8 0.14 2.1 25.74 33.54 7.5 0.13 2.2 25.92 33.42 8.4 0.15 2.3 30.35 38.75 8.2 0.15 2.5 32.21 40.41 8.9 0.16 3 41.95 50.85

Example 2 Table (Headspace Analysis)

[0025]

TABLE-US-00004 Ratio Free IBA (IA/Metal) (average ppm) 1.0 14.8 1.5 3724.4 2.0 8996.4 2.1 14960.8 2.2 23406.0 2.3 30578.0 2.5 70008.6 3.0 237036.0

[0026] The result in Example 2, as illustrated in Table 2 demonstrates the dramatic uptick in putrid smell, measured in ppm in headspace as the mole ratio exceeds 1:2.

Example 3

[0027]

TABLE-US-00005 Ca(OH)2 wt Mole nBA Total (gr) Moles Ratio wt(gr) Weight(gr) 6.9 0.09313 1.5 12.31 19.21 7.3 0.098529 1.75 15.19 22.49 7.2 0.097179 2 17.12 24.32

Example 3 Table (Headspace Analysis)

[0028]

TABLE-US-00006 Ratio (nBA/Ca) Average PPM 1.5 11.9 1.75 9.4 2 10.1

Example 4

[0029]

TABLE-US-00007 Ca(OH) Mole 2MBA Total Weight 2wt(gr) Moles Ratio (gr) (gr) 12.1 0.163315 1 16.67935 28.78 12.3 0.166014 1.5 25.43256 37.73 11.9 0.160615 1.75 28.7064 40.61 12.6 0.170063 2 34.73716 47.34 12.4 0.167364 2.1 35.89506 48.30 12.7 0.171413 2.2 38.51413 51.21 12.5 0.168714 2.3 39.63069 52.13 12.6 0.170063 2.5 43.42145 56.02 12.9 0.174113 3 53.34635 66.25

Example 4 Table

[0030]

TABLE-US-00008 Ratio Free 2MB (IA/Metal) (average ppm) 1.0 7106.8 1.5 35.7 2.0 6972.5 2.1 12597.4 2.2 17097.9 2.3 21316.5 2.5 27580.1 3.0 146751.3

[0031] As evidenced in Example 4 with use of Ca(OH).sub.2 and 2 MB, results similar to Example 2 were observed.

Example 5

[0032]

TABLE-US-00009 Ca(OH)2 wt Mole Ratio Mole Ratio 2MBA Total Weight 8.9 0.120124 1 12.26828 21.17 8.7 0.117425 1.5 17.98889 26.69 8.6 0.116075 1.75 20.7458 29.35 8.9 0.120124 2 24.53656 33.44

Example 5 Table (Headspace Analysis)

[0033]

TABLE-US-00010 Ratio Free 2MB (IA/Metal) (average ppm) 1.9 20.7 2 5395.5 2.1 9671.8 2.4 17533.6

Example 6

[0034] In Example 6 samples were made using calcium sources and isovaleric acid with the ratios shown in Table 6, the headspace measurements in ppm are shown for each.

Example 6 (Ca:Isovaleric Acid Salts)

[0035]

TABLE-US-00011 Ca:Acid Headspace Ca Source Ratio analysis ppm CaO 1:2 2354 Ca(OH)2   1:1.9 2312

[0036] The importance of the respective mole ratios of reactants to effectively reduce or eliminate putrid odor is demonstrated by the produced data relating to headspace measurements in parts per million in the table form ppm data.

Example 7

[0037] In this Example 7, the Ca(OH)2 was added to a Hobart mixer and the mixing motor was started. To this was added the liquid acid neat. The acid used was a mixture of IBA and 2MBA (70% IBA/30% 2MBA). The mixer continued mixing for 3 hours and the product was collected and tested for head space analysis. Table 7 reports the collected data.

TABLE-US-00012 TABLE 7 (headspace analysis) Ratio Ca:Acid HS ppm 1:1.8 3887 2MBA, 6460 IBA

Example 8

[0038] Another Hobart mixture was made using Ca(OH)2 and butyric acid as the reactants. Table 8 reports the collected data.

TABLE-US-00013 TABLE 8 (headspace analysis) Ratio Ca:butyric aicd ppm 1:1.9 737

Example 9

[0039] Examples 9 and 10, and 11 are neat runs using a solidare paddle mixer/dryer as previously described and made by BEPEX. The mole ratio of IVA to calcium source, and the headspace ppm measurements are in Table 9. The calcium source was Ca(OH)2.

TABLE-US-00014 TABLE 9 Paddle Dryer Average Ratio PPM (IBA/Ca) 1054.4 1.57 2085.8 1.42 1133.3 1.18

Example 10

[0040]

TABLE-US-00015 TABLE 10 Paddle Dryer, (headspace analysis) Average Ratio PPM (IBA/Ca) 656.7 1.48 10595.8 1.74 1833.3 1.54

[0041] In the paddle dryer neat run is shown in Example 10 the calcium source Ca(OH)2.

Example 11

[0042] Still another paddle dryer example using as the calcium source Ca(OH)2 is set forth in Table 11.

TABLE-US-00016 TABLE 11 (headspace analysis) Average Ratio PPM (IBA/Ca) 1660.9 1.25 1734.4 1.42 4616.4 1.49

Example 12

[0043] Yet another paddle dryer experiment with Ca(OH)2 and 2MBA with these results:

TABLE-US-00017 TABLE 12 (headspace analysis) Acid/Ca ratio Free 2MBA 1.3 121

Example 13

[0044] Another example using a paddle dryer experiment with CaO and IBA with the results:

TABLE-US-00018 TABLE 13 (headspace analysis) Acid/Ca ratio Free IBA (ppm) 1.0 12

Example 14

[0045] Examples 14 and 15 were run continuously in the twin screw extruder, neat as earlier described using the 25k 34 model from Coperion. The calcium source is Ca(OH)2 for each of Examples 14 and 15.

[0046] Extruder

TABLE-US-00019 TABLE 14 Ca(OH)2-IBA-(headspace analysis) Ratio rpm HS 1:1.5 350 4308 1:1.7 400 5454

Example 15

[0047] Extruder

TABLE-US-00020 TABLE 15 Ca(OH)2-2MBA-(headspace analysis) Ratio rpm HS 1:1.5 540 72 ppm

[0048] Example 15 uses 2MBA and Ca(OH)2 at the mole ratio set forth in Table 15.

[0049] For each of Examples 14 and 15 headspace (HS) measurements were below 15,000 ppm indicating tolerable work environment odor.

Comparative Example A (Ammonium Salts of Isoacids)

[0050]

TABLE-US-00021 TABLE A Isoacid Mole Ratio Headspace, ppm nBA   1:1.9 153920 nBA 1:2 184341 IVA   1:1.9 168069 IVA 1:2 177443

[0051] While smell is subjective one can see that the ammonium salts are all over 150,000 ppm. This will give a very strong odor. Generally speaking, one considers anything under 15,000 ppm to be acceptable in odor.

Comparative Example B

[0052] A hand mixed comparative example was prepared in a similar fashion as was done in previously (example 6) but this time it was done in water (50%) and the water evaporated before testing on the head space. The ratio was Ca(OH)2 to isovaleric acid 1:2

TABLE-US-00022 Ratio HS ppm 1:2 36800

[0053] The comparative examples demonstrate the criticality of using the correct salt and the importance of a neat reaction.

[0054] One can see from the written description and the Examples and the data observed that the invention is operable and is effective at odor reduction and can therefore be commercially effective to prepare nutritionally enriched isoacid nutrients.