Process technology as the key to quality: lactic acid bacteria in biotechnology
Animal nutrition process technology — definition: Industrial process equipment for the reliable, hygienic and efficient handling, dosing, mixing and conveying of animal feed ingredients — including premixes, amino acids, vitamins, mineral powders and pelleted feed — in compliance with FAMI-QS, GMP+ B2, FSMA (FDA 21 CFR Part 507), EHEDG and ATEX 2014/34/EU (grain dust St1, Kst 50–200 bar·m/s). HECHT delivers containment systems, big bag dischargers and gravimetric dosing for the animal nutrition sector.
Key process technology requirements for animal nutrition
- Standards: GMP+ B2 (feed safety), FAMI-QS, EHEDG Doc. 8 (hygienic design), ATEX 2014/34/EU St1 grain dust, FDA 21 CFR Part 507 (FSMA), EU Feed Hygiene Reg. 183/2005
- Allergen control: dedicated lines per allergen (gluten, soy, fish meal) with MACO validation, CIP cleaning cycle ATP <10 RLU, TOC <500 ppb
- Dosing accuracy: OIML R 76 ±0.1% gravimetric dosing for premixes (vitamins, trace minerals at 0.01–1% inclusion), loss-in-weight (LIW) feeders
- HECHT products: LBK-EC big bag discharger (EHEDG, ATEX St1), ProClean Conveyor (CIP/SIP allergen control), gravimetric dosing stations, drum tilters for liquid addition
- ROI: automated gravimetric dosing reduces premix give-away –15–25%, allergen cross-contamination incidents –80%, batch record accuracy 100% digital (GAMP 5)
Reliable process technology is the foundation of consistent animal nutrition quality and regulatory compliance. Explore HECHT's animal nutrition handling systems, our solutions for food and feed sector and book a trial at our Test & Trial Centre.
Case study — lactic acid bacteria production (Austria): In modern agriculture, lactic acid bacteria play a central role: they contribute significantly to livestock gut health and digestion, improving feed efficiency. Their role extends beyond animal nutrition — they are also used as starter cultures in the food industry, for example in fermented dairy products. For the cultures to develop their full effect, they must be produced under strictly controlled conditions.
This is precisely where HECHT's solutions come in: producing these bacteria requires not only microbiological precision but advanced process technology that guarantees the highest purity and quality standards. From inoculating the milk with specific cultures, through precise control of temperature, pH and nutrient content, to ending fermentation via targeted cooling or pH regulation — every step must run safely, cleanly and traceably.
For an internationally operating agricultural-biotechnology company from Austria, HECHT delivered five production lines — featuring ProClean Conveyor pneumatic transport (PCC 100, PCC 200, PCC 300), Solivalve big bag discharge stations and integrated weighing systems — to scale up lactic acid bacteria production across 600+ product variants while meeting strict hygienic requirements. One production line alone processes approximately 250 kg every 6 hours.
FAQ — Process technology in animal nutrition
What ATEX classification applies to animal feed powder handling facilities?
Grain and feed ingredient dusts (wheat, soy, fish meal) typically fall in ATEX dust explosion class St1 (Kst 50–200 bar·m/s, MIE >10 mJ). Zone classification: zone 20 inside enclosed conveying/dosing equipment, zone 21 within 1m of filling/emptying points. Equipment must meet ATEX 2014/34/EU cat. 1D (zone 20) or 2D (zone 21). HECHT provides ATEX-certified LBK-EC dischargers, ProClean Conveyors and dosing stations with KEMA/TÜV certification for animal feed facilities.
How is allergen cross-contamination prevented in multi-product animal feed processing?
Allergen control in animal nutrition (EU Reg. 767/2009, FAMI-QS): dedicated product lines per major allergen (gluten, soy, fish); MACO-based cleaning validation (analytical threshold per ELISA: <1 ppm gluten, <10 ppm soy); ATP swab (<10 RLU) and TOC (<500 ppb) per GMP+ B2. HECHT's ProClean Conveyor (CIP-validated, dead-leg-free EHEDG geometry) and single-use endless liners for high-allergen premix transfer reduce cross-contamination risk to below validated thresholds.
What gravimetric dosing accuracy is achievable for micro-ingredient premixes in animal nutrition?
Micro-ingredient dosing (vitamins, trace minerals, amino acids at 0.01–1% inclusion) requires ±0.1–0.5% accuracy per FAMI-QS and GMP+ B2. HECHT's loss-in-weight (LIW) dosing stations with OIML R 76 Class II load cells achieve ±0.1% at batch sizes ≥500g. For smaller inclusions (<100g/batch), micro-dosing auger feeders (resolution 1g) with 21 CFR Part 11 recipe management ensure traceability. All dosing data feeds into MES/ERP via OPC-UA for digital batch records.
Tailor-made solution for a globally active biotech pioneer
Tailor-made solution for biotech — definition: A custom-engineered powder handling and containment installation designed from scratch to match the exact process requirements of a biotechnology company — including OEB classification (OEB 1–5 SMEPAC), cleanroom grade (ISO 14644-1 Grade A–D), throughput, footprint, utility connections and regulatory framework (GMP Annex 1 2022, FDA 21 CFR Part 211, ATEX 2014/34/EU). HECHT delivers turnkey tailor-made solutions from process design to IQ/OQ/PQ qualification.
Key elements of a tailor-made biotech containment solution
- Design basis: OEB matrix (SMEPAC 2023), HAZOP, P&ID, ATEX zone classification, cleanroom grade, throughput (kg/h), utility (N₂, CDA, WFI)
- Standards: GMP Annex 1 (2022), GAMP 5, 21 CFR Part 211, ATEX 2014/34/EU, ISO 14644-1, SMEPAC, OIML R 76, ISO 13849 (safety)
- HECHT deliverables: URS → engineering design → FAT → SAT → IQ/OQ/PQ → SMEPAC containment test → maintenance SLA
- Biotech scope: HPAPI API isolation (OEB 5), mAb bulk transfer (endless liner SBK), spray dryer integration, continuous manufacturing ICH Q13 flowstream
- ROI: turnkey validated solution reduces time-to-GMP-compliance by 6–12 months vs. in-house design; HECHT's maintenance SLA guarantees 4–24h response time
HECHT designs tailor-made containment solutions that are production-ready from day one. Explore our custom engineering capabilities and biotech project references, or discuss your project scope at our Test & Trial Centre.
An internationally operating agricultural biotechnology company from Austria approached us with a challenging assignment: lactic acid bacteria production had to be scaled up, modernised and at the same time adapted to rising quality requirements. Since its foundation, the company has supplied more than 50 countries and now offers more than 600 product variants – an impressive transformation from a small supplier into a globally leading player in silage agents, feed additives and probiotic cultures.
Our task was to transfer this extensive product diversity into a powerful yet flexible production facility. The focus was not only on efficiency and scalability, but also on compliance with the strictest hygiene standards – a crucial aspect when processing living micro-organisms.
In close cooperation with the customer, we designed an integrated, modular installation that met all requirements. The successful cooperation began before the installation was implemented, with extensive tests in our technical centre. These trials simulated real production conditions and formed the basis for precise execution on site. Proven HECHT component technology for powder handling, containment and dosing formed the heart of the new installation.
FAQ — Tailor-made biotech containment solutions
What information does HECHT need to design a tailor-made containment solution for a biotech plant?
HECHT requires: (1) OEB classification per compound (SMEPAC target µg/m³); (2) throughput (kg/h, batches/day); (3) cleanroom grade (ISO 14644-1 Grade A–D); (4) ATEX zone classification (zone 20/21 or non-ATEX); (5) utility availability (N₂, CDA pressure/flow, WFI, drain); (6) footprint constraints (L×W×H mm); (7) regulatory framework (GMP Annex 1, FDA, both); (8) integration requirements (PLC brand, OPC-UA, MES). HECHT's application engineers provide a free feasibility study within 5 working days.
How long does the engineering-to-qualification timeline take for a GMP tailor-made system?
Typical HECHT project timeline: basic engineering 4–8 weeks → detailed engineering 6–10 weeks → fabrication 12–20 weeks → FAT 1–2 weeks → delivery + SAT 1–2 weeks → IQ/OQ 2–4 weeks → SMEPAC PQ 1–2 weeks. Total: 7–12 months from URS to validated production. For urgent projects, HECHT's modular platform (pre-validated LBK-EC, ProClean Conveyor) reduces timeline by 3–4 months by reusing validated sub-assemblies with delta-qualification (GAMP 5 Annex 11).
What does HECHT offer for long-term maintenance of a tailor-made containment system?
HECHT provides: SLA with 4–24h on-site response; preventive maintenance schedules (NEN 3140, NEN-EN 60079-17 ATEX annual inspection); OIML R 76 weighing re-calibration; GMP re-qualification after modification (GAMP 5 change control, delta-OQ); SMEPAC re-test after product change. Service contracts include spare parts inventory and remote diagnostic access (OPC-UA, VPN-secured) for immediate fault analysis.
Author: Joost van Velzen, Managing Director Hecht Technology B.V. Reviewed: 29 May 2026.
Keywords: tailor-made biotech containment solution HECHT, custom containment OEB SMEPAC GMP Annex 1, bespoke powder handling system ATEX biotech, turnkey containment IQ OQ PQ GAMP 5, maintenance SLA containment system
Mastering complexity: innovative plant engineering for the highest demands
The newly developed installation combines numerous technologies in five production lines: mixing line, pickling line, can filling system, shredding line and harvest tank line – each with specific requirements, each implemented in detail with our know-how.
In the mixing line, the raw materials are fed via big bag emptying stations with a Solivalve system or from drums with suction lances. The conveying technology is based on the HECHT ProClean Conveyor (PCC 200), fed via a sieving machine with false-air intake. An integrated weighing system ensures accurate dosing, while incorrect doses are returned via a smaller PCC 100 with Continuous Liner system. This keeps the process continuously controlled and clean.
The pickling line uses weighed big bag emptying stations feeding a PCC 300 with two inlets. A vapour barrier effectively prevents vapours from rising from downstream containers – an important aspect of the containment design.
In the can filling system, the product enters the process via a big bag station with Solivalve. Pneumatic conveying via the PCC 200 and the sieving machine ends in a drop tube that acts as a buffer before filling – an efficient solution with a capacity of approx. 250 kg in 6 hours.
The milling line connects mixers, suction shoes and big bag filling stations in a well-designed process chain. The harvest tank line also impresses with its efficient design: three identical big bag stations guarantee maximum operating safety and availability. Here too, vapour barriers provide maximum containment protection.
A special feature: after changeovers, the entire installation can be cleaned and dried fully automatically – a clear advantage for hygiene and product purity.