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 | The Great Preserver |
| | Propionic acid protects food and animal feed from mold – rising demand |
The EU hygiene directive in force since January 2006 also applies to animal feed, requiring it to be in perfect condition. Animal feed products have to be free of mold and have a long storage life. Propionic acid is the ideal animal feed preservative. It is also an important element in the production of vitamin E. In response to rising demand for propionic acid, BASF started up a new plant at the corporate site in Nanjing, China in summer 2005. The company is now one of the world's leading manufacturers of this chemical intermediate.
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As everyone knows, you can't count on the weather. Its caprices may hit farmers hard. Too dry is bad, too wet likewise. Farmers don't appreciate rain at harvest time, for example. The weather doesn't always play along, though. Farmers who want to ensure peace of mind have two alternatives: either to use special hot air systems to dry their grain prior to storage, or treat it with preservatives. The main thing is to prevent mold from developing. The toxins contained in mold would destroy a farmer's entire feed reserves. An ecoefficiency analysis conducted by BASF compared the two methods. The results show that using propionic acid is more cost-effective and better for the environment.
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Mixes to match every requirement
Farmers can choose from an array of propionic-based product mixes. The right product for a particular application depends on the moisture content of the grain and the planned storage period. Wetter grain and longer storage times call for more of the active substance. "Depending on the moisture content and storage period, farmers need six to 15 kilograms of propionic acid to preserve one metric ton of grain," says Ulrich Roser, BASF's technical advisor for feed preservatives. The preservative-treated grain is stable for around one year and is used by farmers for their own feed mixes, prepared by adding soy meal, minerals and vitamins. The mixes are mainly used for pig feed.
Propionic acid keeps the feed fresh for a long period of time. This acid, like formic acid and acetic acid, belongs to the family of carbonic acids. All three are potent fungicides and can be counted on to kill mold. However, propionic acid is a much more powerful agent than its shorter-chained siblings. The grain needs to be wetted all over with propionic acid in order to prevent mold from developing. Mold toxins cause fertility disorders, digestive problems and immune deficiency in animals. Propionic also effectively combats other pests such as yeasts, bacteria, and insects like the granary weevil, thereby protecting both animal feed and farm animals.
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Natural product and energy supplier
The acid itself is fully digested by farm animals. In fact, dairy cows produce propionic acid in their own rumen as a major byproduct of natural digestion: bacteria in the bovine stomach release propionic acid and acetic acid from the cellulose in the grass they eat. A single cow produces as much as one and a half liters of the acid per day and benefits from it as a source of energy. One kilogram of propionic acid has the nutritional value of two kilograms of barley.
In the maturation process that goes to produce Swiss cheese, bacteria break up lactic acid products into propionic acid and carbon dioxide. The acid prevents the cheese from going bad during the long maturation period. Because of the acid taste, the amount of acid in the cheese must not exceed a certain limit. The acid concentration may rise to as much as one weight percent – a level sufficient to preserve grain with a moisture content of 26 percent for a whole year.
Its reliability as a preservative also qualifies propionic acid for other agricultural applications, for example as an additive in liquid animal feed, hay and drinking water. Microorganisms and algae are no longer able to grow and water does not get contaminated. Propionic acid is extremely effective in combating molds and pests. It is also a major element in herbicide manufacture.
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Animal feed market growing apace
The EU hygiene directive says that farmers and feed mix manufacturers must supply and use feed in perfect condition. Propionic acid-based preservatives are essential to achieve this aim. "Farm-mixed feed in particular is a vigorously growing market in Germany. Our shares in this segment are growing at a huge rate year on year," says Roland Preuss, Product Manager Propionic Acid.
With an annual production capacity of 110,000 metric tons of propionic acid, BASF is global market leader. More than forty percent of the acid produced is used to preserve animal feed. The main markets for propionic acid are the USA and Europe. The Asian market is significantly smaller but growing at a faster rate. The main Asian markets - China, India and Taiwan – have received their supplies from Nanjing since summer 2005. "It has greatly reduced the times we need to supply our Chinese customer base in particular, which includes explains animal feed manufacturers like Huamei, Kangtei and Youxianbao," says Anthony Jones, Manager Asia Pacific Acids Marketing. And Peter Zhang, Marketing Manager Acids in China, backs this up: "Our delivery service has improved enormously since production started up in Nanjing. Our customers are delighted with the speed and reliability of their deliveries."
The largest European market is Germany, followed by the UK. "We have had a long and very successful distribution agreement with BASF on propionic acid. 2005 was a watershed for both companies with much increased volumes and many satisfied customers. UK customers have been delighted with the outstanding service that this distribution partnership has brought for them in terms of the sales personnel, logistics, product availability and quality," says Jamie Mitchell, Business Development Manager with Omnichem Limited/Nickerson Chemicals Limited in Dewsbury, commenting on the long-standing business relationship between this leading UK chemicals distributor and BASF on propionic acid.
Propionic acid is similarly important in Germany. "Propionic acid is the mainstay of grain preservation throughout Germany, now as in the past. And we expect acid preservation to take on even greater importance in the future," says Dr. Sabine Rahn, Product Manager Preservatives and Feed Specialties with AGRAVIS Raiffeisen AG.
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Vitamin E, a growing market
In addition to its use as a preservative, propionic acid is also gaining importance as an element of synthesis. For instance, it is the first molecular element in the multistage process that goes to manufacture vitamin E. Approximately 45,000 to 50,000 metric tons of this vitamin are produced in the world today, and that figure is rising. Around two-thirds of the active substance, supplied in the form of a pale yellow oil, is used for animal nutrition. The main animal feed markets are the USA and Europe. South America, and, to a greater extent, Asia, are emerging markets. "Production figures have been rising for the past 33 years. Vitamin E is now the world's best selling vitamin after vitamin C," says Rudi Schlegel, Commercial Manager Vitamin E with the BASF Fine Chemicals division.
High natural levels of vitamin E are present in young green fodder and wheatgerm. The vitamin E content declines significantly as the plant grows. Vitamin E levels in mature grain are fairly low as a result, and farmers need to add the vitamin artificially when preparing feed mixes for their animals. Vitamin E is mixed with another 12 vitamins in poultry and pig feed, corresponding to 30 to 150 grams per metric ton of feed mix. "It makes animal breeding more efficient because the animals are healthier. All of which ultimately improves the quality of the meat," says Dieter Feuerstein, Technical Manager Animal Nutrition with BASF. Vitamin E significantly enhances meat quality. This nutrient protects the cells, and vitamin E stored in fat depots stays effective in the slaughtered animal. The meat keeps its healthy color and stays fresh for longer.
Vitamin E also has a key role to play in the human organism. Among other things, it is of vital importance to cell metabolism. It also acts as an antioxidant, i.e., it suppresses the breakdown of unsaturated fatty acids and vitamin A in the body. That is why it also has a positive impact when added to other foods, such as beverages or margarine. It helps to prevent margarine from going rancid, for instance.
Apart from its applications in the food industry, vitamin E is a key ingredient in skin creams, hairsprays and shampoos. One hundred grams of skin cream usually contains three to 10 grams of the vitamin. Addition of vitamin E promotes skin cell regeneration and regulates moisture content. Vitamin E also protects the hair from extremes of heat and cold, keeping it shiny and smooth.
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A key agent in the chemical and pharmaceutical industry
Propionic acid in food does a lot of good in its own right, not just as an element in vitamin E production. In the form of a calcium bond, it helps to keep sliced bread fresh. Approximately one-fifth of the propionic acid sold is used to preserve foods, mainly bread. The USA is the largest world market.
This multitalented acid is also in great demand as a raw material for the chemical and pharmaceutical industry. It is used among other things in the manufacture of pharmaceuticals. Another percentage is used in the production of a special solvent that is an ingredient in special coating systems for the industry, an application for which it is ideal because of its high solubility and low evaporation.
For a number of other applications, the acid requires no conversion. It is used in its unchanged state as a solvent, for example in large-scale technical systems for the manufacture of aromatic aldehydes and acids.
In recognition of its many benefits, propionic acid's range of applications is increasing. Its main function is and remains as a preservative in animal feed and food. The use of propionic is set to increase in agriculture in particular, not least because of a recent ecoefficiency analysis. The results leave no room for doubt: A farmer who thinks ecologically and acts economically will opt for propionic acid.
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May 2006
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