Description:FIELD OF THE INVENTION
[0001] The present disclosure relates to a field of food technology. Particularly, the present disclosure relates to an energy rich feed ingredient formulation for animal feed. The present disclosure also relates to a process of preparation of an energy rich feed ingredient formulation for animal feed.

BACKGROUND OF THE INVENTION
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] The animal feed industry in India uses grains such as Maize, bajra, jowar, wheat as primary energy source in their compound/concentrate feeds. In case of cattle, energy in feed is important in ensuring good milk production, health and reproduction. However, the prices and availability of grains fluctuate throughout the year and put increased pressure on the margins of feed manufacturers and farmers.
[0004] Food processing industry in India generates millions of tons of food waste in the supply chain from harvesting to production. Food is marked as “waste” if does not meet quality specifications set by the manufacturer. However, these quality parameters include self-set standards of flavour and feel, which do not govern safety of food. Other sources of food waste include mis-shaped food, transit damages, near-expiration of packed food etc. – all perfectly good food would be otherwise discarded to landfills or incinerators.
[0005] In India, only a small proportion of this food is upcycled today due to logistical and technological limitations. Food waste is spread across thousands of distributors, warehouses, and factories all over India and needs to be aggregated. Further, the collected food is non-uniform in its nutritional value as it is an aggregation of several SKUs with varying moisture, energy, fat and protein parameters. It also comes with its paper and plastic packaging which needs to be removed before the food can be used - which is a very labor intensive and further makes the cost of upcycling prohibitive. All of these challenges pose a difficulty in upcycling and therefore much of this food waste today ends up in landfills or gets incinerated.
[0006] Narayanan et al. [Indian J. Anim. Res., 2009, 43(3), 215-216] discloses that the feeding of food waste or garbage to swine is a common practice throughout the world and is often concentrated around metropolitan centers. Hence a study was conducted to assess the performance of Large White Yorkshire (LWY) piglets fed with the biscuit waste as unconventional feed. The trial comprised of two groups of randomly grouped LWY piglets fed with swine starter ration and biscuit waste respectively. The final body weights for piglets at the end of 8th week were 14.10+2.27 and 10.97+1.6 Kg for starter and biscuit waste fed groups respectively. The non significant reduction in weight gain could be attributed to the lesser crude fibre and protein content in biscuit waste. Hence, it is concluded that supplementation of additional proteins was necessary to obtain optimum growth in piglets when fed with unconventional feed like biscuit waste. This article focused on using on generically named biscuit waste, and not any balanced formulation and this article is for pigs only.
[0007] Kaltenegger et al. [J. Dairy Science, 2020, 103, 10122-10135] discloses Leftover bakery by-products (BP) from bakeries and supermarkets may serve as energy-rich ingredient in ruminant diets. The aim of the present study was to evaluate the effect of the successive substitution of cereal grains by BP on dry matter (DM) intake, milk production, and metabolic health as well as ruminal pH and eating and chewing behavior of dairy cows. Twenty-four lactating Simmental cows (149 ± 22.3 d in milk, lactation number 2.63 ± 1.38, 756 ± 89.6 kg of initial body weight) were fed a total mixed ration containing a 50:50 ratio of forage to concentrate throughout the experiment (35 d). During the first week, all cows received a control diet (without BP) as a baseline (d -7 to 0). In the next 4 wk (d 1 to 28), cows were allocated to 3 groups differing in the BP concentrations of diets [0% BP (CON), 15% BP, and 30% BP on a DM basis]. The DM intake and reticuloruminal pH were continuously measured. Blood and milk samples were taken every week, but only results from the experimental period (d 21 and 28) were used for statistical analyses, whereas results from the baseline were considered covariates. Diet analyses showed that BP inclusion increased the ether extract and sugar contents, whereby starch and neutral detergent fiber decreased. Experimental data showed that feeding BP in the diet increased DM intake. Furthermore, the cows fed 30% BP produced roughly 4 kg/d more milk and energy-corrected milk than the CON cows. The milk urea nitrogen was lower in cows fed the BP. Feeding BP reduced the blood glucose and insulin concentrations, whereas nonesterified fatty acids, ß-hydroxybutyrate, and cholesterol increased linearly. Cows fed 15% BP had the shortest period of time in which ruminal pH was below 5.8, in contrast to CON cows (+188 min/d). Taken together, the results suggest that the inclusion of up to 30% BP in the diets of mid-lactation dairy cows shifted the nutrient profile from a glucogenic diet to a lipogenic diet, holding the potential to enhance performance and lower the risk of subacute ruminal acidosis in dairy cows. This article focuses on effects of compound feed mixed with BP fed to cows. However doesn't talk about the inclusion of any other BP other than Biscuits and breads, cakes and dough. The limits the scope of the article to generic impact on animal.
[0008] Chakkaravarthi et al. [The Pharma Innovation Journal 2022; SP-11(11): 1082-1085] relates to evaluate the effect of inclusion of malt sprouts as an alternate protein source in the diet of Beetal goat kids on nutrient intake and economics of feeding. Conventional concentrate mixtures for goat kids were prepared. Malt sprouts were included in the concentrate mixture at 0, 10, 20 and 30% level to formulate four iso-nitrogenous concentrates. Twenty beetal goat kids were randomly distributed into four groups of five animals each (designated as C, T1, T2 and T3) and a 60-day trial was conducted on beetal goat kids. The animals of each group were fed diet consisting of green fodder and respective concentrate mixture. Intake of nutrients (DM, OM, CP, EE, NDF) was higher (p<0.05) in T1 group than other groups. Malt sprouts inclusion at 10% level in the diet of T1 group resulted in net saving of Rs. 9.82 per kg body weight gain as compared to control group. It was concluded that malt sprouts is cost effective and could be economically included upto 10% in the concentrate mixture of goat kids without any adverse effect on nutrient intake of animals. This article focused on malt sprouts which are byproducts of beer manufacture but not malt based ingredients used in food industry that contain various other ingredients and thereby have a unique material property. Also focus of the article is only on goats.
[0009] GB471559A discloses forage cake for animals is made from a mixture of cereal, pulse, and wheat offals, baked in oven. The mixture may be used alone or with oil-bearing seeds. The cereal may be maize, oats, barley, wheat, rye, buck-wheat, rice, or malt. Suitable forms of pulse are peas, horse beans, grain, soya beans or lentils. The offal constituent of the mixture may be millers' middlings or bran. When oil-bearing seeds are used, ground nuts, palm kernel nuts, linseed, and cotton seed are suitable. Hops, dried or liquid milk, salt, yeast, and in some cases sugar is added. The ingredients are mixed with water and baked into conical cakes, or in the form of dry broken dog biscuit, or flat cakes. Focused on end feed not ingredients. Also limited in the breadth of bakery inclusion.
[0010] Individually, the ingredients used can pose difficulty in directly feeding to animals. Below are some examples of challenges:
[0011] If Sugar syrup, candies, chocolates, bakery products and various sweets are directly fed to cows ad libitum, they may suffer from acidosis for prolonged period and cause serious health issues as mentioned below:
• Fermentation of large quantities of rapidly digestible carbohydrates results in excess volatile fatty acid production, lowering rumen pH and allowing for the proliferation of lactate producing bacteria (notably Streptococcus bovis).
• As rumen pH decreases, starch and lactate-utilizing organisms are inhibited, which further decreases.
• pH until ultimately, only the most acidophilic organisms (Lactobacilli) survives, generating additional lactic acid.
• Increased ruminal lactate concentration drives ruminal osmotic pressure higher, drawing fluid into the rumen and causing systemic dehydration.
[0012] Systemic absorption and metabolism of fermentation end products leads to development of systemic acidosis. Coupled with dehydration and hemoconcentration, the resulting systemic metabolic acidosis ultimately leads to muscular weakness, renal failure, cardiovascular collapse, shock and death.
[0013] Thus, there is need to develop a formulation that overcome the above problems discussed above and having energy rich ingredients.

OBJECTS OF THE INVENTION
[0014] An object of the present invention is to provide an energy rich feed ingredient formulation for animal feed.
[0015] Another object of the present invention is to provide a process of preparation of an energy rich feed ingredient formulation for animal feed.
[0016] Still another object of the present invention is to provide an economic energy rich feed ingredient formulation for cattle, poultry and pigs.

SUMMARY OF THE INVENTION
[0017] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in Detailed Description section. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0018] The present disclosure relates to a field of food technology. Particularly, the present disclosure relates to an energy rich feed ingredient formulation for animal feed. The present disclosure also relates to a process of preparation of an energy rich feed ingredient formulation for animal feed.
[0019] An aspect of the present disclosure is to provide a energy rich feed ingredient formulation for animal feed comprising: 30 to 40 % of a low fat biscuits; 10 to 20 % of a high fat biscuits and cakes; 5 to 15 % of a cereals; 15 to 25 % of bread, buns and dough; 3 to 8 % bran and flour; 10 to 20 % of malt and malt based ingredients; and 4 to 40 % of moisture.
[0020] Another aspect of the present disclosure is to provide method of preparation of an energy rich feed ingredient formulation for animal feed comprising: a) segregating of raw material into unique nutritional classifications; b) de-packing of the raw materials to separate organic material from packaging such as plastic and paper; c) grinding of the organic material to obtain a grinded material having homogenous particle size for mixing; d) mixing of grinded material of step c) with rest materials as per formulation to prepare a mixture at 20% moisture; and e) drying of the mixture having 20 % moisture of step d) to obtain an energy rich feed ingredient formulation for animal feed having less than 8% moisture..
[0021] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The following drawings form part of the present specification and are included to further illustrate aspects of the present invention. The disclosure may be better understood by reference to the drawings in combination with the detailed description of the specific embodiments presented herein.
[0023] Figure 1 illustrates a flow chart of the process.

DETAILED DESCRIPTION OF THE INVENTION
[0024] The following is a detailed description of embodiments of the disclosure. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0025] Unless the context requires otherwise, throughout the specification which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense that is as “including, but not limited to.”
[0026] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
[0027] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable.
[0028] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it is individually recited herein.
[0029] All processes described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0030] The headings and abstract of the invention provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
[0031] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
[0032] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0033] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description that follows, and the embodiments described herein, is provided by way of illustration of an example, or examples, of particular embodiments of the principles and aspects of the present disclosure. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the disclosure.
[0034] It should also be appreciated that the present invention can be implemented in numerous ways, including as a system, a method or a device. In this specification, these implementations, or any other form that the invention may take, may be referred to as processes. In general, the order of the steps of the disclosed processes may be altered within the scope of the invention.
[0035] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0036] The present disclosure relates to a field of food technology. Particularly, the present disclosure relates to an energy rich feed ingredient formulation for animal feed. The present disclosure also relates to a method of preparation of an energy rich feed ingredient formulation for animal feed.
[0037] An embodiment of the present disclosure provides an energy rich feed ingredient formulation for animal feed comprising: 30 to 40 % of a low fat biscuits; 10 to 20 % of a high fat biscuits and cakes; 5 to 15 % of a cereals; 15 to 25 % of bread, buns and dough; 3 to 8 % bran and flour; 10 to 20 % of malt and malt based ingredients; and 4 to 40% of moisture.
[0038] In an embodiment, the low fat biscuits are present in range of 33- 38 %. Preferably, the low fat biscuits are present in 35 %.
[0039] In an embodiment, the high fat biscuits and cakes are present in the range of 13-18 %. Preferably, the high fat biscuits and cakes are present in 15 %.
[0040] In an embodiment, the cereals are present in the range of 8-12 %. Preferably, the cereals are present in 10 %.
[0041] In an embodiment, the bread, buns and dough are present in the range of 18-22 %. Preferably, the bread, buns and dough are present in 20 %.
[0042] In an embodiment, the bran and flour are present in the range of 4-6 %. Preferably, the bran and flour are present in 5 %.
[0043] In an embodiment, the malt and malt based ingredients are present in the range of 13-18 %. Preferably, the malt and malt based ingredients are present in 15 %.
[0044] In an embodiment, the moisture is present in 4 to 15 %. Preferably, the moisture is present in 4 to 10 %.
[0045] In an embodiment, the energy rich feed ingredient formulation has fat content in the range of 10-15 %, protein content in the range of 7-10%, starch content in the range of 50-65 % and has energy in the range of 4000-4500 cal.
[0046] Another embodiment of the present disclosure is to provide method of preparation of an energy rich feed ingredient formulation for animal feed comprising: a) segregating of raw material into unique nutritional classifications; b) de-packing of the raw materials to separate organic material from packaging such as plastic and paper; c) grinding of the organic material to obtain a grinded material having homogenous particle size for mixing; d) mixing of grinded material of step c) with rest materials as per formulation to prepare a mixture at 20% moisture; and e) drying of the mixture having 20 % moisture of step d) to obtain an energy rich feed ingredient formulation for animal feed having less than 8% moisture.
[0047] In an embodiment, the raw material from diverse food suppliers from across India comprising of over 1,000 different types of packaged food items are segregated into 50 nutritional classification. These classifications organize the raw material into certain standardized nutrition-based bins that then form the basis of recipe formulation. In accordance with an embodiment, the raw materials are the waste products and are commercially procured from the various packaged food manufactures including several consumer brands.
[0048] In an embodiment, the de-packing step comprises: i) loading of the packed raw material through a belt and screw conveyor to a depacking chamber in which a shaft rotates at a high speed ranging from 200 to 1000 rpm to convey, rip, and grind at the same time into an organic powder and the packaging residue is conveyed to the back of the chamber for separate collection; ii) passing the organic powder of step i) through two rolling pins to grind and sieve out find traces of plastic and to obtain a powdered material.
[0049] In an embodiment, the grinding of step c) is carried out at a speed in the range of 50 to 3000 rpm.
[0050] In an embodiment, the mixing of step d) is carried out at a speed in the range of 15 to 200 rpm.
[0051] In an embodiment, the drying of step e) is carried out at a temperature in the range of 150 to 170°C and vacuum of 500 to 540 mm of Hg. Preferably, the temperature is 160 °C and vacuum of 520 mm of Hg.
[0052] The present disclosure has developed a method which can systematically sort the various food waste streams, then de-pack and homogenize them into products based on their nutritional values at-scale. The inventors are already processing over 18,000 tons per annum using this technology. Achieving this requires a deep understanding of animal health and feeding science, and development of innovative technologies that process large volume of food waste.
[0053] The present disclosure provides an energy rich feed ingredient formulated with certain selected residual streams from the food industry. The macro-nutrient profile of energy rich feed ingredient formulation is as follows Energy-4000-4500cal, Fat 10-15%, Protein7-10%, Starch>50-65%, Moisture<10%.
[0054] Defining the above macro-nutrient profile as the right product range is the first crucial step in creating a feed ingredient that can be used in compound cattle and poultry feed at large scale. This is for the following important reasons:
[0055] The above nutrient ranges in the end product are the most optimum because they allow for maximum inclusion of diverse range bakery residual streams. Example of present formulation includes breakfast cereal, biscuits, chips, noodles, pasta, flour, dosa batter, pizza dough, cakes, namkeens, pulses, mayo, peanut butter, almond shells etc.
[0056] The product closely mimics the carbohydrate and protein profile of corn. Corn is one of the primary sources of energy in the preparation of animal feed. Inclusion of corn various from 15-30% in cattle feed, and 30-50% in poultry feed formulations.
[0057] The fat profile of 10-15% is the ideal range as it can compete with traditional fat sources in feed such as rice polish. A typical formulation with weight percentage of each ingredient is given in Table 1.
Table 1: A typical formulation is as follows:
Products Moisture range % addition
Low fat Biscuits <7% 30-40%
High fat biscuits & Cakes 20-30% 10-20%
Cereals <7% 5-15%
Breads, buns, dough 30-40% 15-25%
Bran & flour <7% 3-8%
Malt &malt based ingredients <7% 10-20%
Result 100.00%

General Method of Preparation
(i) RM segregation
[0058] As evident from the formulation above, segregation of food into various groups is crucial for ensuring balancing nutrients in the end product. Raw material from diverse suppliers from across India that comprising of over 1,000 different types of packaged food items are segregated into 50 nutritional classifications. These classifications organize the raw material into certain standardized nutrition-based bins that then form the basis of recipe formulation.
[0059] These classifications have been prepared by analyzing a large number of data sets of various marketed products over years.
(ii) De-packing
[0060] Each of the raw materials arrive in original consumer packaging and are through a novel de-packing system. This system is crucial setup as manual depacking is time consuming and very expensive. The system comprises of 4 parts:
(A) Input - belt and screw conveyor on which material is loaded.
(B) Depacking chamber – comprises of a 4 metre long hollow cyclindrical chamber with a shaft consisting of 28 hammers placed at 90 degree to each other. The shaft rotates at high speed ranging from 200-1000 rpm. The material is input to the chamber from the inlet above and moves through the rotating shaft designed uniquely to convey, rip, and grind at the same time the food into powder. The clean organics fall and are collected, and the packaging residue is conveyed to the back of the chamber for separate collection. In this way both food and packing is separated to a high degree of purity and can be used for further processing.
(C) Refining – the output collected from the depacking system which above is put through a secondary seperation process called refining. In this product is conveyed to be passed through 2 rolling pins made of Magnesium Steel to grind the product and sieve out find traces of plastic. The design of these rollers is done uniquely so that sugar material passing through does not stick to the rollers.
(D) Collection- The final product is collected and sent for further use.
(iii) Mixing & grinding
[0061] The inputs from depackaging lines are conveyed to mixing hopper where the formulation is prepared. At this stage of mixing, other raw material including those of a variety of moisture profiles are mixed in pre-determined ratio to create an output having 20% moisture.
(iv) Drying
[0062] The output with 20% moisture is very rich in sugars and starches. And therefore, while the mix needs to be dehydrated to <10% moisture, it must be done so at a pressure and temperature that does not harm the product or cause the product to stick to the machine.
[0063] For this purpose, a rotary vacuum paddle dryer has been customized. The dryer consists of a jacketed hollow shell with a central shaft and rotating paddles. Thermic oil was chosen as the media as it allows for easy variability of temperature which is not possible in steam based dyers. The temperature of drying was kept between 150-170 °C, and vacuum of 520 mm of Hg. The paddles of the dryer rotate between 3-5 rpm providing the optimum contact time that ensures that the material does not stick to the dryer surface.
[0064] Analysis of energy rich feed ingredient formulation of the present invention is carried out. The result of the analysis showed that sugars and other toxicants and other contaminants are in safe zone.
[0065] The final product was collected and packed.
Challenges with individual use of raw materials used in above composition and need superior performance of present formulation in this regard
[0066] There are some qualitative reason below which indicate that the individually these raw materials cannot be given to animals or used in feed and the reason for present formulation is recommended solution.
1. Large variation exists in terms of composition, texture, physical properties, storage conditions, nutritional composition, etc. between and also within each raw material group. Therefore, animal feed manufacturers find it difficult to handle it for use in animal feed as they have to maintain finished product specifications and uniform texture.
2. Feed manufacturers are not equipped with processing technologies needed to handle such food wastes as used above,
a) A State-of-Art food wastes processing facility developed by the present disclosure to begin with de-packing machine ensures that packing materials from large quantities of packed food are segregated from food materials like Low fat biscuits, Cereals etc. and are ready for preparation of present formulation. Further, the vacuum drying facility keeps the moisture level of present formulation at optimum level.
b) Some of the food materials like various confectionaries and malt-based drink mixes are highly hygroscopic which require several precautions while in storage and when added in animal feed to maintain free flow.
c) Some food materials like fruit juices, sugar syrup, bread etc. have high moisture content, addition of these materials, if not taken proper care, may deteriorate the quality of animal feed.
d) Some sweets like Gulab Jamun, Rasogula etc. have high sugar content, if such products are heated in the process of manufacturing animal feed, may get sticky and caramelised which would be difficult to get mixed in feed smoothly.
e) If certain food wastes like Namkeens, potato chips, fruit juices, Gulabjamub and other sweets given to animals ad libitum by the farmers, may create health issues like acute acidosis, which will reduce productivity of animals.
[0088] In brief, State-of-Art manufacturing facilities for processing of food wastes and the above mentioned precautions for each of the food waste groups are not taken care of, then the food waste materials cannot be mixed in feed efficiently. The given formula makes all the food materials mix properly to manufacture present formulation, which can be used by the feed industry for adding it in animal feed, hassle free.

Other key factors that in formulation creation
[0067] Malt is a great source of protein and very well accepted by both cattle and poultry species. However, malt is also very hydroscopic and upon combination with other sugar-based items can cause lump formulation. It was found that the maximum of malt powders must not exceed 15%.
[0068] Maintaining 5-10% flours such as wheat atta, maida or wheat bran is very critical and they are a rich source of starch and fibre and ensure the “free-flow” texture of end product.
[0069] Product with moisture in the range 30-50% must not exceed 25% in the mixed product. More addition causes degregation of material due to risk of fungal growth.
[0070] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
EXAMPLES
[0071] The present invention is further explained in the form of following examples. However, it is to be understood that the following examples are merely illustrative and are not to be taken as limitations upon the scope of the invention.
Example 1
(a) Formulation:
[0072] An energy rich feed ingredient formulation (ECOMIX) is given in below Table 2. The formulation contains less than 8 % of moisture content.
Table 2:
Products Present formulation
Low fat Biscuits 35%
High fat biscuits & Cakes 15%
Cereals 10%
Breads, buns, dough 20%
Bran & flour 5%
Malt &malt based ingredients 15%
Result 100.00%

(b) Preparation of energy rich feed ingredient formulation:
[0073] Raw material was collected from diverse suppliers from across India that comprising of over 1,000 different types of packaged food items were segregated into 50 nutritional classifications. The raw materials were de-packed to separate organic material from packaging such as plastic and paper. The shaft of the de-packing chamber was rotated at a speed of 200 to 1000 rpm. The obtained organic material was grinded at a speed in the range of 50 to 3000 rpm to obtain a grinded material having homogenous particle size. The grinded material was mixed with other materials at a speed in the range of 15 to 200 rpm to obtain a mixture of 20% moisture which was dried at a temperature in the range of 160°C under vacuum of 520 mm of Hg to energy rich feed ingredient formulation for animal feed having less than 8% moisture.
(c) Production analysis of energy rich feed ingredient formulation:
[0074] Salient points of chemical formulation and In vitro as production analysis of energy rich feed ingredient formulation of present invention is as follows:
[0075] High Energy density as products are grain based, rich in fat and pre-cooked
Total Digestible Nutrient % (TDN %): TDN% is Biscuit Meal – 91.25% (Table 3)
Gross Energy (KCal/kg) content was 4800
Net Energy (MeKCal/kg cattle) was 3850
Starch content was 40 to 65 %
[0076] Sugar and Salt to increase palatability of feed: Sugar content varied in the range of 15 to 20% in present formulation.
[0077] Aflatoxin B1 (ppb) level in all products was in the range between 3.7 to 8.8 which was much lower as pacified by BIS for Cattle Feed.
[0078] Microbiological Parameters like the Coliform bacteria were not detected. Further, low value of total viable count indicated that these products can be fed to animals safely.
[0079] Rancidity is an oxidation of fats and oils which gives off flavor to feed and measured in terms of free fatty acids (FFA) and peroxide value (PV). FFA in all the products of present formulation was in the range between 2 to 4 percent whereas PV value was not detected.
[0080] Heavy metals are potent neuro-toxicants that can affect child brain development therefore their testing in animal feed becomes important because of public health. Heavy metals Arsenic, Cadmium, Mercury and Lead were not detected.
Table 3: Chemical content of energy rich feed ingredient formulation.
Parameters Present formulation
Moisture, % 4.00
Crude protein, % 8.94
Fat or Ether Extract, % 16.50
Crude Fiber, % 2.30
Ash, % 2.13
Starch, % 45.5
Sugar, % 18.30
Aflatoxins, ppb 6.50
Gross energy, kcal/kg 4860
Total Digestible Nutrients, % 91.25
Calcium 85.80
Phosphorus, % 0.23
Magnesium 78.50
Potassium 279.00
Sodium 282
Chloride, % 1.03
Sulphur, % BLD
(MLD 1.0)
Iron 9.09
Manganese 2.16
Zinc 2.62
Mercury BDL (MDL 0.1)
Cadmium BDL (MDL 0.2)
Lead BDL (MDL 0.5)
Arsenic BDL (MDL 0.1)
Free Fatty Acids, % 3.83
Peroxide value, % ND
Total Viable count, cfu/g 5.6x103
Coliform count, cfu/g ND (MDL 10)

[0081] Energy rich feed ingredient product formulation ensures that sugars and other toxicants and other contaminants are in safe zone, when included in animal feed as per recommendations as shown in Table 3 above. One of the advantages of the present disclosure is that the formulation is obtained from the waste product and thus the obtained formulation is economic and is completely safe for animal feed as given below.
(d) Effect of incorporation of present formulation on cattle feed formulation cost and its nutritional composition:
[0082] Sample formulation of cattle feed with and without present formulation as shown in Table 4. One formulation was done without present formulation and later in the same formulation 7% of present formulation was incorporated, it can be observed that incorporation of present formulation not only maintaining but improving nutritional parameters of earlier one as shown in Table 4.

Table 4: Cattle feed formulation with and without present formulation (ECOMIX).

[0083] Table 4 revealed that:
a. By incorporating present formulation in the formulation by 7%, cost of cattle feed formulation has been reduced Rs.422.5 per MT and if a feed factory is producing 1000 MTs per month his profit could be Rs.4.225 Lacs.
b. As far as nutritional parameters are concerned, when compared with without Biscuit Meal formulation, the energy level and fat% of the feed has increased by 3% and 2% respectively, making the feed nutritionally better than without Biscuit Meal.
c. Feed and fodder availability status in India: As per the 34th report of the Parliamentary Standing Committee on Agriculture, there is an estimated shortage of 122 million tonnes dry fodder, 284 million tonnes of green fodder and 35 million tonnes of concentrate by the year 2020. (Source: Report of NITI Aayog’s Working Group pertaining to ‘Demand and Supply Projections towards 2033; Crops, Livestock, Fisheries and Agricultural inputs).
[0084] It can be anticipated that the shortage of concentrates still continues or increased as the milk production of the country has been increased. By converting food waste to animal feed concentrate is not only to make use of it efficiently but also help to reduce the feed concentrate shortage of the country.
, Claims:1. An energy rich feed ingredient formulation for animal feed comprising:
30 to 40 % of a low fat biscuits;
10 to 20 % of a high fat biscuits and cakes;
5 to 15 % of a cereals;
15 to 25 % of bread, buns and dough;
3 to 8 % bran and flour;
10 to 20 % of malt and malt based ingredients; and
4 to 40 % of moisture.

2. The energy rich feed ingredient formulation as claimed in claim 1, wherein the low fat biscuits are present in range of 33- 38 %.

3. The energy rich feed ingredient formulation as claimed in claim 1, wherein the high fat biscuits and cakes are present in the range of 13-18 %.

4. The energy rich feed ingredient formulation as claimed in claim 1, wherein the cereals are present in the range of 8-12 %.

5. The energy rich feed ingredient formulation as claimed in claim 1, wherein the bread, buns and dough are present in the range of 18-22 %.

6. The energy rich feed ingredient formulation as claimed in claim 1, wherein the bran and flour are present in the range of 4-6 %.

7. The energy rich feed ingredient formulation as claimed in claim 1, wherein the malt and malt based ingredients are present in the range of 13-18 %.

8. The energy rich feed ingredient formulation as claimed in claim 1, wherein the moisture is present in 4 to 15 %.
9. The energy rich feed ingredient formulation as claimed in claim 1, wherein the energy rich feed ingredient formulation has fat content in the range of 10-15 %, protein content in the range of 7-10%, starch content in the range of 50-65 % and has energy in the range of 4000-4500 cal.

10. A method of preparation of an energy rich feed ingredient formulation for animal feed comprising:
a) segregating of raw material into unique nutritional classifications;
b) de-packing of the raw materials to separate organic material from packaging such as plastic and paper;
c) grinding of the organic material to obtain a grinded material having homogenous particle size for mixing;
d) mixing of grinded material of step c) with rest materials as per formulation to prepare a mixture at 20% moisture; and
e) drying of the mixture having 20 % moisture of step d) to obtain an energy rich feed ingredient formulation for animal feed having less than 8% moisture.

11. The method as claimed in claim 10, wherein the raw material from diverse food suppliers from across India comprising of over 1,000 different types of packaged food items are segregated into 50 nutritional classifications.

12. The method as claimed in claim 10, wherein the de-packing step comprises:
i) loading of the packed raw material through a belt and screw conveyor to a depacking chamber in which a shaft rotates at a high speed ranging from 200 to 1000 rpm to convey, rip, and grind at the same time into an organic powder and the packaging residue is conveyed to the back of the chamber for separate collection;
ii) passing the organic powder of step i) through two rolling pins to grind and sieve out find traces of plastic and to obtain a powdered material.

13. The method as claimed in claim 10, wherein the grinding of step c) is carried out at a speed in the range of 50 to 3000 rpm.

14. The method as claimed in claim 10, wherein the mixing of step d) is carried out at a speed in the range of 15 to 200 rpm.

15. The method as claimed in claim 10, wherein the drying of step e) is carried out at a temperature in the range of 150 to 170°C and vacuum of 500 to 540 mm of Hg.