Moisture Optimization and Mold Control:
An Integrated Approach to Improving Feed Quality,
Shelf Life, and Feed Mill Profitability in Tropical Climates

Dr. Maloshrie Bora, Senior Program Manager – Feed Safety, Trouw Nutrition South Asia

Across India and South Asia, feed manufacturers today face a common challenge: producing safe, stable, high-quality feed while navigating increasingly variable climate conditions, fluctuating raw material quality, rising production costs, and greater demands for feed efficiency.

Among the many factors that influence feed quality, moisture management remains one of the most underestimated. Yet moisture directly impacts pellet quality, nutrient preservation, feed hygiene, shelf life, production throughput, and overall profitability. Improper moisture management can result in shrinkage, spoilage, mold proliferation, nutrient losses, increased fines, and reduced mill efficiency. Conversely, optimized moisture control can generate significant economic returns while improving feed quality throughout the supply chain.

The Hidden Economics of Moisture Loss
During feed manufacturing, moisture is lost at several stages, including grinding, conditioning, pelleting, cooling, storage, and transportation. Industry observations indicate that feed mills can lose between 0.5% and 1.5% moisture during production, resulting in direct shrinkage and reduced profitability. A feed mill producing 500 tonnes per day can lose approximately 5 tonnes of saleable product for every 1% moisture reduction. In an industry where margins are constantly under pressure, minimizing process losses represents a substantial opportunity for value creation.

Why Adding Water Alone Does Not Solve the Problem
A common industry practice for compensating moisture losses is the addition of water during feed processing. While this may appear straightforward, water possesses high surface tension and does not distribute uniformly throughout the feed matrix. Instead, free moisture often remains on the surface of feed particles, increasing water activity and creating favourable conditions for microbial growth. The challenge for the modern feed industry is therefore not simply increasing moisture content, but ensuring moisture is effectively distributed and retained throughout the feed while maintaining microbial stability.

Mold Growth: A Feed Quality and Profitability Threat
Molds are among the most significant biological threats to feed quality. Beyond visible spoilage, molds consume valuable nutrients, reduce energy content, affect feed palatability, shorten storage life, and create conditions favourable for mycotoxin production. The economic implications can be significant. Raw materials often constitute up to 80% of total feed production costs. Any reduction in nutritional value, shelf life, or feed volume directly impacts both manufacturers and producers downstream.

Emerging Scientific Approaches to Mold Inhibition
Advances in feed preservation technology have moved beyond conventional organic acid applications. Modern solutions increasingly combine multiple modes of action to optimize efficacy under practical feed manufacturing conditions. These technologies typically integrate:
Organic acids
– Buffered acid systems
– Moisture management agents
– Surfactants and emulsifiers
– Synergistic bioactive compounds
Such approaches improve moisture distribution, enhance contact between active ingredients and microbial cells, and prolong preservation effectiveness throughout storage. This scientific evolution reflects the industry’s transition from simple preservation strategies toward integrated moisture and microbial management systems.

Commercial Validation: Integrating Moisture and Feed Hygiene
Research and commercial evaluations have demonstrated that moisture management and mold control must work together. In one reported study, the addition of plain water alone reduced feed shelf life by approximately 33%. However, when moisture was combined with an integrated mold inhibition program, shelf life improved compared to untreated feed while preserving feed quality and stability. Additional commercial applications have shown benefits including:
– Improved feed mill throughput
– Enhanced pellet durability
– Reduced reprocessed fines
– Better moisture retention
– Improved production efficiency
– Greater feed stability during storage
These findings highlight that effective moisture optimization depends on simultaneously managing microbial risks

A Modern Approach for South Asia
Recognizing the unique challenges faced by feed manufacturers in tropical climates, Trouw Nutrition has developed integrated solutions specifically designed to optimize moisture management and feed hygiene.

Among these solutions is the Fylax® portfolio, which combines organic acid technology, moisture management agents, surfactants, and the proprietary ActiProp® technology platform. The objective is to improve moisture distribution, enhance mold inhibition, preserve nutrient value, and support feed mill efficiency within a single integrated program. ActiProp® technology works by increasing mold cell wall permeability and improving access of active ingredients to microbial targets, resulting in enhanced preservation performance compared with conventional approaches. At the same time, moisture-management components facilitate more uniform distribution of moisture within the feed matrix, helping improve operational efficiency and shelf-life outcomes.

In today’s feed industry, moisture management can no longer be viewed simply as a processing parameter—it is a critical driver of feed quality, feed safety, and profitability. As feed manufacturers across India and South Asia face increasing challenges from humidity, raw material variability, and shelf-life pressures, an integrated approach that combines moisture optimization with effective mold control is becoming essential. By preserving nutrient value, reducing shrinkage, improving pellet quality, and enhancing microbial stability, modern feed hygiene solutions can help mills achieve greater operational efficiency while delivering safer, more consistent feed to livestock producers. Ultimately, successful feed preservation is not just about preventing spoilage—it is about maximizing value throughout the feed-to-food chain.

Sustainable Animal Health with Phytogenic Innovations: Dr. Eckel Leading the Way – Ricky Thaper (www.rickythaper.com)

One of the main challenges in modern animal farming is sustainably improving animal health and welfare. Animal health directly impacts food quality and animal productivity. Healthy birds/animals lead to better product quality, reduced treatment costs, more consistent yields, improved farm management and greater customer satisfaction.
In an era where climate change frequently affects animal productivity, natural resources are limited, and the global trade landscape continues to evolve, Dr. Eckel Animal Nutrition GmbH & Co. KG, based in Niederzissen, Germany, has taken a pioneering step toward supporting sustainable, resilient and successful livestock farming. During my recent visit to Germany, I had the opportunity to explore their state-of-the-art manufacturing facility, witnessing firsthand the innovation and commitment behind their global success.

Founded in 1994 by Dr. Antje Eckel, the company was established with a vision to make animal nutrition healthier, more welfare-oriented and sustainable. Over the past three decades, Dr. Eckel has grown from a family business into a globally recognized provider of alternative feeding solutions.

Dr. Antje Eckel has also served in various international roles promoting animal health. A key contributor to the company’s growth is Dr. Bernhard Eckel, Vice President – Sales, who has been associated with the company since its inception.

Further strengthening the leadership is Dr. Viktor Eckel, Managing Director – Products & Innovation, who combines his passion for life sciences and technology in product development. Also part of the team are Mr. Theo Eckel, Head of Purchasing and Ms. Klara Eckel, who leads business development initiatives serves as an authorised signatory.

The Importance of Gut Health
The animal gut is a complex ecosystem hosting diverse microorganisms that evolve with their hosts. Each section of the gut houses distinct microbial communities that shift throughout the animal’s life. In poultry, microbial colonisation begins at hatching and is influenced by the hen and the environment. Feed composition also plays a significant role in shaping the microbial profile and by extension, long-term health.
Managing gut health isn’t simply a battle between good and bad bacteria. Some microbes typically seen as harmful may play beneficial roles under specific conditions, while even beneficial ones can cause harm if imbalanced. A stable microbial balance is vital for maintaining animal health and performance. Gut health disturbances caused by poor feed quality or disease can severely impact productivity.

The long-standing use of antibiotic growth promoters (AGPs) comes with several risks. AGPs not only eliminate harmful bacteria but also beneficial ones, impairing digestion, increasing inflammation and weakening the immune system. Their prolonged use contributes to antibiotic resistance, prompting regulatory bans in many countries.

Phytogenics: A Natural Alternative
This growing concern has fuelled demand for natural, effective alternatives—among which phytogenics play a leading role. Derived from herbs, spices and plant extracts, phytogenic feed additives offer a selective, plant-based approach to enhancing gut health, boosting immunity and improving digestion.

Unlike AGPs, phytogenics target only harmful microbes while preserving the beneficial ones, ensuring a healthier intestinal environment. They also possess anti-inflammatory, antioxidant and immune-boosting properties, further supporting animal well-being.
With three decades of expertise in phytogenic feed additives, Dr. Eckel has become one of the global leaders in sustainable animal nutrition. The company focuses on identifying powerful plant-based compounds that can fully unleash nature’s potential to improve animal performance. Their additive solutions cover poultry, swine, ruminants, aquaculture and pets, with more than 10% of annual revenue invested in R&D.

Global Reach with Local Commitment
From its German headquarters, Dr. Eckel supplies products to Europe, CIS countries, and the Middle East. Through its Bangkok office, the company serves customers across Southeast and South Asia. With a skilled team of almost 80 professionals from over 20 countries, their solutions are now available in more than 40 countries worldwide.

Dr. Eckel’s products are manufactured to strict German quality standards, with over 75% of raw materials sourced from within the EU, ensuring short supply routes, flexible processes, and reduced environmental impact. This results in better animal welfare, high-quality products, and improved profitability for farmers. The company aligns its operations with FAO and UN Sustainable Development Goals and the EU’s climate targets under its guiding philosophy: Act local, think global.

Flagship Products Driving Innovation
Among Dr. Eckel’s top-performing innovations:
Anta®Phyt: A powerful phytogenic complex that enhances gut health and performance in poultry, swine, and ruminants. In a 42-day study with 1,155 broilers, Anta®Phyt increased beneficial bacteria like Lactobacillus and Bifidobacterium, while significantly reducing Escherichia coli. The result: better digestion, improved nutrient absorption, and enhanced growth—without antibiotics.

Anta®Ox Aqua: Designed for aquaculture, this product helps reduce Vibrio levels in shrimp farming. In a field trial with nine earthen ponds, shrimp treated with Anta®Ox Aqua showed a significant decrease in Vibrio counts, leading to better health, lower disease risk, and higher sustainability.

Anta®Catch: The industry’s first triple-action solution to address endotoxin challenges in livestock. Endotoxins cause substantial losses across dairy, poultry, swine, and aquaculture sectors. Anta®Catch not only binds toxins but also strengthens the intestinal barrier and reduces inflammation, offering a holistic solution to improve gut integrity and animal resilience.

These phytogenic products offer a game-changing approach to sustainable animal nutrition. With participation in leading global poultry and livestock exhibitions, Dr. Eckel is expanding its reach and showcasing its innovative solutions to diverse markets.

Jessica Rheindorf, Head of Marketing discussed about Dr. Eckel’s products availability in different part of world. Elisabeth Holl, Senior Technical Manager, updated on Dr. Eckel products. Muhammad Umar, Technical Sales Manager- Key Accounts gave a nice presentation on “Profitable Production and Sustainable Success- Your Phytogenic Solutions in Poultry”. Keerthana Giriprasad, Technical Sales, discussed about feed additive market. Ina Hickmann, Junior Marketing Manager updated us about their activities.

Growing Focus on India
With India’s poultry industry growing at 7–8% annually, the company sees immense potential for collaboration.
“Our solutions can support the sustainable growth of the Indian poultry sector,” said Bernhard Eckel.

“Together with our partners in India, we want to help farmers improve productivity through gut-health-focused, natural solutions,” added Dr. Antje Eckel.

Dr. Eckel is looking forward to working with strong partners to promote healthier animal farming practices in Indian poultry, dairy and aquaculture.

Those interested can contact the company directly (https://www.dr-eckel.de/en)