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Barley fodder prod - Purwokerto
Nov2016

11/19/2016

Time to share experience & knowledge on hydroponic barley
fodder production technology

CONTROLLED ENVIRONMENT TECHNOLOGY
FOR BARLEY FODDER PRODUCTION

• 1996 - 2003 – Operating fodder system at UPM Malaysia.
• 2011 – Due diligent work on H2O Farm in UK.

Teknologi lingkungan terkontrol untuk
produksi foder barli

• 2014 – Due diligent work on Foddertech in USA.
• 2016 – Due diligent work on Agritom system (Turkey, Qatar & Dubai).

ZAINAL JELAN


• Present – Al-Afandi Est. Jeddah, Saudi Arabia.

DVM MSc PhD

jelanzainal@yahoo.com
UNSOED Purwokerto.
19 Nov 2016

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Barley grains

Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Germinations (sprouting) of barley grains


• One of the earliest cultivated cereal (Serealia)

• Germination (Perkecambahan):
Process of “ a seed developing into new plant”

• Uses:
• Most as livestock feed; alcohol & starch
production.

Chain of processes where stored proteins, fats
and starches in grains/seeds are broken down into
simpler forms for use by the growing plan.

• Least use as staple human food.

• Germination depends on:

• Characteristics of barley grains


• Internal factors:

• A hard grain:

‒ Variety
‒ Conditions (post harvest management)

‒ Very likely to stay undigested.
‒ Need processing to improve digestion
(removing hulls, grinding or breaking of
the bran layer).

• External factors:





Barley grain


‒ Traditional way to soak before feeding.
• Two significant nutritional values:
‒ High starch content (energy source).

• Germination of barley (or other grains & seeds)
results in a big increase in sugar content (when
compared before sprouting).

‒ Higher crude protein than other cereals.
• Optimum growth conditions in soil
o
• 20 C environmental temp.
• 20 to 180cm rainfall (tolerant to dryness)
• Soil pH 4.5 to 8.3 (better in alkaline)
Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

Oxygen/air
Temperature
Humidity/water
Light / Darkness


Barley grain
STARCH

(Becomes
shoot)
(Becomes
root)

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod - Purwokerto
Nov2016


11/19/2016

Key terminologies

Nutritional benefits of barley fodder
• During sprouting, starch in grain is converted to sugar (gula ):
‒ Better utilized in the rumen than the dry grain.
‒ Rumen pH is more stable & reduces acidosis.

SPROUT
Consists of a grain/seed that is just

Traditional
practice

• Sprouted grain lacks enzyme inhibitors (compared to its
dormant form):

beginning to grow a small root


‒ Minerals & vitamins can absorbed more efficiently.
• Digestibility improvement:




Sprouting time:
6-8 days

• High content of usable energy (Metabolizable Energy):

BARLEY FODDER



A common name to the stage when
the sprouted grains continue to grow

Barley fodder (8-day)........ 85%
Ground barley …………... 70%

Barley grains ……………. 55%

until they start to produce first leaf,

• Palatable:

when it is harvested
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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

Readily eaten by all farm animals



About 15% of the mass of sprouts is in the leafy portion.
The rest in residual grains/seed and roots.
Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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• Development of the technology:
• Earlier time

2. Clean and safe feed.

Feeding sprouted grain to livestock is an old practice.

3. Accelerated (fast) fodder growth.

‒ >200 years ago, European dairy farmers fed sprouted
grains to cows during winter.

4. High yield of high value feed from a small land area.

‒ Many improvised methods to produce the grain fodder
for livestock production systems.

5. Low cost of production:
Sprouting time:

6-8 days

• Modern days - early advances in Australia:
‒ Concept of high yield production under controlled
environment

‒ Easy & low maintenance
‒ Trouble free operations

‒ Design of the trays for optimum growth and yield of
fodder and irrigation of fodder

6. Simple operating procedures:

‒ Automated / computer-controlled environment of
chamber

‒ Unskilled farmer can handle
‒ Not labor intensive (1 man working 2 - 3 hrs/day for 2
MT production system.


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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder production technology

1. Optimum (quality and quantity) fresh fodder yield
daily and all through the year irrespective of weather.

‒ Low water utilization (uses 3% of the amount of water
required for standard forage production)



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Process benefits of the production system

‒ Low energy consumption

11 to 12 Mega Joule per kg DM

• High content of vitamins A, E, B complex and C. Vitamin of
some seeds can increase by 20 times their original value.

Recent interest

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod - Purwokerto
Nov2016

11/19/2016

Advancement of the fodder production technology

Recent acceptance and benefits of the barley fodder production technology
• Demand to provide better nutrition:

• Current technology involves:

‒ For animals of superior genetic potential that requires high
plane of nutrition e.g. dairy animals

i. Design and concept for better efficiency and mass fodder
production.

‒ As a strategy to sustain nutrition of animals during seasons of
poor fresh forage supplies e.g. winter months, long dry
seasons and floods that destroy pastureland.

‒ Automation for industrial production
‒ Automation for reduced manpower
‒ Transportable production unit

• Present a chance for producers to control some aspects of their
forage needs and ensure a consistent daily supply of highly
digestible forage.

ii. Making optimum conditions & facilities of the chamber:
‒ For high grain germination.

• Opportunity to provide fresh pasture to farm animals in arid lands
e.g. Middle East

‒ For high yield of fodder at harvest.
‒ Economy of production.

• Land limitation for fresh fodder production. Build a more sustainable
farm on limited land base.
• Demand for organic forage - e.g. in the US
• Save costs of high value feed production.

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Conversion of barley grain to fodder

Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Stages of growth of barley fodder (8-day system)

• Dry matter of barley fodder (at harvest):

Day
1

- Approximately 14% (140gm/kg):

Day
5
Average Fodder Height
(Yield ratio 1:7.5)

- Moisture content of 86% (860gm/kg)
- Suitable to mix with dry feed (forages & straws)

Day
Day
2

• Yield of barley fodder:
- Ratio of 1:7 (1kg grain produces 7 kg fodder)

1kg DM

~140 to 150 kg grains = 1,000 kg fodder

Day
6

1kg grains

- Factors influencing yield:
- Germination rate of grain
- Variety of grain

About
1kg DM

- Quality of grain

Day
3

7kg Fodder

Day
7

- Grains preparation
- Growth environment (in the chamber/room)
Day
4

Day
8

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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(cm)
Nil

2

Nil

3

3-4

4

7-8

5

10-12

6

13-16

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16-18

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20-23

ZAMJ – (2014)
Idaho US Dairy Farm

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod - Purwokerto
Nov2016

11/19/2016

Reasons for preference for barley grains as fodder

Growing requirement for barley fodder in chamber

• Most nutritious of the small grains.

• A climate-controlled room

• Barley sprouts are generally suitable
feed for many farm animals.

‒ Temperature at 18-20 C
o

‒ Humidity 70%

• Grows (germinates) the fastest and
easiest.

• Optimum lighting conditions (??)
‒ Fluorescent light

• Most cost-effective of all the grains to
produce fodder.

‒ LED light or Grow lights
• Air quality and movement

• Can be grown with other seeds/grains
in the same tray.

‒ Air filtrations system & fan
‒ UV light - environment sterilization

• Barley grains store well.

• Water quality

• Not in competition as staple food of
most world population – price is more
stable.

‒ Ordinary household water
‒ Water sterilization by ozone gas
• Nutrient supply system (irrigation system)

ZAMJ – (2011) H2O Farm UK

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Nutrient supply (irrigation system) to fodder – Technical Diagram

Nutrient supply (irrigation system) to fodder
• Water:
‒ Few technologies use only water to irrigate
the grains and fodder.
‒ Technically, sprouting grains do not need
nutrients at the early growth (7-10days),
except water.
• Nutrient (fertilizer) solution
‒ Some technologies use specific mineral
fertilizer solution as growth medium.
• Irrigation techniques:
1. Spray (fine jet spray) on the fodder.
2. Thin film nutrient flow in the trays of
fodder.
• Grains (and the growing fodder) is kept just wet
on the trays at all time.
‒ Intermittent spray or flow of nutrient solution
or water.
‒ Fully automated systems (computer
controlled or simple timer).
Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod - Purwokerto
Nov2016

11/19/2016

Rack and trays for sprouting barley

Rack and trays in the grow room/chamber for producing barley fodder

• Racks:

A technology developed by Foddertech US.

‒ To hold the trays
‒ Racks are fixed to the floor or movable/mobile

• Trays
‒ For holding the grains
‒ Specifically designed (usually patented)
‒ Various sizes
‒ Fixed to the rack or movable

ZAMJ – (2016) Sheep farm, Qatar

ZAMJ – (2014) Idaho US Dairy Farm

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Recent acceptance and benefits of the barley fodder production technology

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Issues in production of fodder
• Mold is the number one problem:

• Demand to improve the nutritional status of the animals.
• Particularly for animals of superior genetic potential
that requires supplementary (high plane) nutrition e.g.
dairy animals

‒ Contaminated barley grains.

Soak grains in water
with addition of
hydrogen peroxide

‒ Poor sanitation of the room
• Low yield of fodder

• Strategy to sustain nutritional condition during seasons
of poor fresh forage supplies e.g. winter months, long
draught seasons and floods that destroy pastureland.

‒ Low germination of grains

Use UV lights &
disinfectants

‒ Quality of grains

• Present a chance for producers to control some aspects of
their forage needs and ensure a consistent daily supply of
highly digestible forage.

Buy good grains

• Opportunity to provide fresh pasture to farm animals in arid
lands e.g. Middle East

How much fodder to feed to animals?

• Land limitation for fresh fodder production. Build a more
sustainable farm on limited land base.

• DEPENDS ON YOUR PURPOSE OF FEEDING
‒ As supplements of fresh fodder:

• Demand for organic forage - e.g. in the US

10-20 kg/day – DAIRY COWS

• Save costs of high value feed production.

2-5 kg/day – DAIRY GOATS

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod - Purwokerto
Nov2016

11/19/2016

Preparation of barley grains for germination

Some production operation

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ZAMJ – (2014) - Idaho US Dairy Farm
Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Some production operation

Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Some production operations

ZAMJ – (2016) Dairy cattle Farm, Dubai, UAE.

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ZAMJ – (2014) - Idaho US Dairy Farm
Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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Barley fodder prod - Purwokerto
Nov2016

11/19/2016

Some production operation

Feeding barley fodder to animals
Dairy cows

Dairy goats

Beef cattle

Horses

Chicken

Pigs

Rabbits

Ostriches

Zoo animals

Deer

Alpacas

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 19Nov2016

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Barley fodder prod. – Seminar, UNSOED Purwokerto. 17Nov2016

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