F e e d i n g r e d i e n t s n e w s f r o m T e s s e n d e r l o G r o u p May 2006

Dicalcium phosphate:
The production makes the difference
This article describes two different methods that exist for the
production of dicalcium phosphate. The dicalcium phosphates that
result from these two processes differ significantly in terms of New dioxin legislation
composition, purity and, most importantly, phosphorus digestibility. p2

The most commonly used production method is known as P digestibility for pigs p3
the “wet acid” route in which rock phosphate is reacted with
sulphuric acid to produce phosphoric acid. After
High technological p5
concentration and purification to reduce the level of
undesirable elements, this phosphoric acid is reacted with a additives
calcium source such as quick lime or limestone to produce
dicalcium phosphate.
The insoluble fraction, consisting mainly of calcium fluoride,
is removed and the liquor is purified (see picture page 4).
Process chemistry Phosphoric acid route Because monocalcium phosphate is readily soluble in water
Phosphoric acid production it cannot be precipitated.
Ca10(PO4)6F2 + 10 H2SO4 Æ 6H3PO4 + 10CaSO4 + 2HF

Production of anhydrous dicalcium phosphate Process chemistry Hydrochloric acid route

H3PO4 + CaCO3 Æ CaHPO4 +CO2 +H2O Dissolution in hydrochloric acid
or Ca10(PO4)6F2 + 12 HCl Æ 3Ca(H2PO4)2 + 6CaCl2 + CaF2
H3PO4 + CaO Æ CaHPO4 + H2O
Saturation of monocalcium phosphate solution to produce
This phosphoric acid production process generates large dihydrated crystalline dicalcium phosphate
quantities of gypsum, which contains significant levels of Ca(H2PO4)2 + Ca(OH)2 Æ 2CaHPO4.2H2O
undesirable elements. As a consequence, apart from a few
exceptions, production in Western Europe is no longer
carried out and phosphoric acid has to be imported from
other regions.
The quality of the phosphoric acid, in terms of levels of
impurities or undesirable elements, can have a major effect
on the purity, composition and digestible phosphorus content
of the resulting dicalcium phosphate. Therefore, Tessenderlo
Group liaise closely with suppliers of feed grade phosphoric
acid to ensure that the quality of their products is strictly
controlled.

Processing for purity

Another method, which was first used by Tessenderlo
Group, is the dissolution of rock phosphate in hydrochloric
acid to deliver a very pure and crystalline dicalcium
phosphate. The process starts with the dissolution of finely
ground rock phosphate in diluted hydrochloric acid, resulting
in the formation of a monocalcium phosphate solution.
Microscopic view of crystalline dicalcium phosphate
(Aliphos Dical)

Aliphos Italphos Windmill

Therefore, additional calcium is added to saturate the liquor
and to change the molecular structure from monocalcium
phosphate into dicalcium phosphate. Dicalcium phosphate
crystals are precipitated and after filtration and drying the
resulting product is a very pure crystalline dihydrate
dicalcium phosphate that is sold as Aliphos® Dical.
Advantages of Tessenderlo’s process
Dissolution is a gradual process, offering a number of
advantages for animal feeding applications:
• The low temperature of the process prevents the
formation of biologically unavailable meta- and/or pyro-
phosphates
• As a crystallization process it ensures a very
predictable composition and a highly pure dicalcium
phosphate, virtually free of undesirable elements
• The hydrate structure is recognized to be nutritionally
beneficial as has been proven in several trials with a
wide range of animal species (see also the results of a
recent pig trial presented on page 3)
In a later stage this crystalline dicalcium phosphate
dihydrate is used for the production of either monocalcium or
monodicalcium phosphate. The use of high quality dicalcium
phosphate in these types of feed phosphates results in
chemically stable and pure products with a low content of
undesirable elements. Also the nutritional value of these
products (Aliphos® Monocal & Modical) is proven to be the
highest on the market.
Legislation on undesirable substances:
dioxins and dioxin like PCBs
On the 3rd of February a new Commission Directive
2006/13/EC on undesirable substances in animal feed with
regards to dioxins and dioxin-like PCBs was published. This
latest edition includes permitted maximum contents for a
group of 12 PCBs that exhibit similar toxicological properties
to dioxins and are therefore often termed ‘dioxin-like PCBs’.
According to this legislation, maximum contents for feed
materials of mineral origin, such as inorganic feed
phosphates, are 1.0 ng WHO-PCDD/F-TEQ/kg for dioxins
and 1.5 ng WHO-PCDD/F-TEQ/kg for the sum of dioxins and
dioxin like PCBs.
The results of the dioxin analyses performed during
February 2006 on the inorganic feed phosphates of
Tessenderlo Group are published in the table below.
Analyses are performed at Carso France, an official
accredited laboratory. In line with our results of previous
years, the dioxin levels in all inorganic feed phosphates of
Tessenderlo Group are well below the legal maximum
content and the same is true for the sum of dioxins and
dioxin like PCBs.

Dioxins Dioxins +
Dioxin-like PCBs
(ng/kg) (ng/kg)
ALIPHOS DICAL 0.10 0.10
ALIPHOS MONOCAL 0.08 0.08
ALIPHOS MONOMAG 0.03 0.03

WINDMILL DICALPHOS 0.14 0.15

ALIPHOS MODICAL 0.03 0.04
WINDMILL MAGNUMPHOS 0.02 0.03
WINDMILL MONAMPHOS 0.05 0.07

ITALPHOS DICAL 0.06 0.08

ITALPHOS MONOCAL 0.03 0.06
ITALPHOS MODICAL 0.02 0.03

Dissolution tanks of finely ground rock phosphate with

diluted hydrochloric acid

Aliphos Italphos Windmill

New results on digestible phosphorus (P) content
of three types of feed phosphates for pigs
In 2005 Tessenderlo Group carried out a trial at the Agricultural Research Centre (FAL;
Braunschweig, Germany) to evaluate the P-digestibility of Italphos Dical, Aliphos Dical and Aliphos
Monomag using pigs. It is known from literature (CVB, 1990) that there are differences in digestible
P-content of DCP dihydrate (Aliphos Dical; DCP2H2O) compared to DCP anhydrate (Italphos Dical;
DCP0H2O). However, often no differentiation is made between the two chemically different products
and only one value for P-digestibility of around 70% has been assigned to all forms of DCP used in
pig feeding (DLG Information 1/1999). Aliphos Monomag, a calcium-magnesium phosphate (CaMgP)
was tested because no accurate P-digestibility figure exists for such a product.

Materials and methods Differences in dP-content caused by

The basal diet was a so-called semi-synthetic diet (GR) with a low P-content (less differences in feed phosphate
than 1.0 g calculated digestible P per kg DM). Phosphates were added to the base production
diet at a rate such that the total calculated digestible P did not exceed 2.0 g per kg Feed phosphates including dicalcium
DM (Table 1). phosphates (DCP), can be
manufactured by various methods. This
Table 1: Composition of the mixed feeds (g/kg) can result in products with different
GR DCP0H2O DCP2H2O Ca-Mg-P chemical compositions (see pages
Italphos Dical Aliphos Dical Aliphos Monomag 1&2). The purity of the raw materials
Corn starch 635.0 635.0 635.0 635.0 used in the processes but certainly the
Sugar beet pulp 150.0 146.0 145.5 144.5 different process conditions do have
Potato protein 85.0 85.0 85.0 85.0 major consequences for the digestibility
Albumen protein 65.0 65.0 65.0 65.0 of such products.
Cellulose 30.0 30.0 30.0 30.0 Aliphos Monomag is produced by
Soy oil 15.0 15.0 15.0 15.0 means of reacting a calcium source and
Vitamins / trace 5.0 5.0 5.0 5.0 a highly reactive magnesium oxide
elements (MgO) with feed grade phosphoric acid.
CaCO3 9.5 4.5 5.0 8.0 The resulting product is a homogeneous
NaCl 3.0 3.0 3.0 3.0 chemical complex of monocalcium and
Lysine-HCl 2.0 2.0 2.0 2.0 monomagnesium phosphate.
L-Tryptophane 0.5 0.5 0.5 0.5 The three phosphates investigated in
MgO -- 1.5 1.5 -- this trial were analysed according to a
Phosphate -- 7.5 7.5 7.0 method known as XRD-analysis. With
this method the composition of the
Both calcium and magnesium were added to the trial feeds to arrive at more or less product can be estimated. Aliphos Dical
the same levels in the trial diets to exclude any affect on P-digestibility. Twelve contained mainly dihydrate dicalcium
castrated males (hybrids “BHZP”) were used in the trial. Three balance trials were phosphate (CaHPO4.2H2O) as well as
carried out with these animals in the live weight range from 36.6±0.9 kg up to traces of dicalcium phosphate
61.6±1.2 kg in an incomplete Latin square arrangement (Table 2). anhydrate (CaHPO4). In contrast to this,
Italphos Dical contained mainly
Table 2: Design of the trial dicalcium phosphate anhydrate
Days Period GR Italphos Aliphos Aliphos (CaHPO4) together with CaCO3,
Dical Dical Monomag Ca(OH)2 and traces of CaO. Aliphos
Monomag is composed of monocalcium
1-7 Pre period Anim. 1-3 Anim. 4-6 Anim. 7-9 Anim. 10-12
phosphate Ca(H2PO4)2.xH20 and
8 14 Collection Anim. 1-3 Anim. 4-6 Anim. 7-9 Anim. 10-12
monomagnesium phoshate Mg(H2PO4)2
15-21 Pre period Anim. 4-6 Anim. 7-9 Anim. 10-12 Anim. 1-3
together with MgO and CaCO3.
22-28 Collection Anim. 4-6 Anim. 7-9 Anim. 10-12 Anim. 1-3
29-35 Pre period Anim. 7-12 Anim. 1-3 Anim. 4-6
36-42 Collection Anim. 7-12 Anim. 1-3 Anim. 4-6

Feedstuffs were analysed for crude nutrients and mineral elements. N, P, Ca and Continued on next page
Mg were analysed in faeces and urine. The P digestibility (dP) of the different feed
phosphates was calculated according the following formula:

DPtest feed (%)-DPGR (%) x (1-a)

DPfeed phosphate (%) = a

a = analysed P content of the feed phosphate (g/kg DM) x ratio of the test
component in test feed (kg/kg) / analysed P content of the test feed (g/kg DM)

Aliphos Italphos Windmill

Results
The analyses of the trial feeds are shown in Table 3.
The average feed intake of all animals in the whole trial Table 5: P-digestibility of the experimental diets and feed
period was 1503 ± 83 g/day. The average LW was 48.5 ± phosphates (%)
8.1 kg with an average live weight gain (LWG) of 590 ± 116 n dP diet dP
g/day. The results of the P-balance trial are shown in Table phosphate
4. GR 12 17 ± 13
Italphos Dical, DCP0H2O 8 55 ± 7 72.1
Table 3: Results of analyses of the trial feeds Aliphos Dical, DCP2H2O 5 60 ± 6 79.9
GR Italphos Aliphos Aliphos Aliphos Monomag, 9 65 ± 4 83.9
Dical Dical Monomag CaMgP
Ash (% DM) 3.4 3.2 3.8 3.6
Cr. Prot. (% DM) 15.8 15.7 15.3 15.6
Ca (g/kg DM) 5.59 5.52 6.15 5.61 Conclusion
P (g/kg DM) 0.76 1.99 2.01 1.91 Differences were found in P-digestibility between Italphos
Mg (g/kg DM) 0.53 1.10 1.23 1.12 Dical (DCP0H2O) and Aliphos Dical (DCP2H2O). The P-
ME (MJ/kg DM) 16.00 16.13 16.21 16.31 digestibility from Italphos Dical was 72%, however, DCP
dihydrate Aliphos Dical scored a much higher value of 80%.
Table 4: P intake and excretion per day These differences clearly reflect differences in chemical
n P intake P faeces P urine composition; anhydrous vs. dihydrate dicalcium phosphate.
mg mg mg This is also in line with previous studies for poultry where
GR 12 1036±59 854±116 20±3 similar differences between DCP2H2O (80%) and
Italphos Dical 8 2700±167 1213±171 17±2 DCP0H2O (70-75%) were found (Van der Klis and
Aliphos Dical 5 2628±99 1050±184 18±1 Versteegh, 1993; Potter et al, 1995; De Groote and
Aliphos 9 2550±147 884±132 16±2 Huyghebaert, 1997; etc).
Monomag“ The dP content of Aliphos Monomag was 84%, which is to
be expected for a product in which the greater part of the P
is found in the form of MCP (Aliphos Monocal), which has a
Table 5 shows the P-digestibilities of the experimental diets. 90% digestibility for pigs.
After subtracting the effect of the basal diet, the P-
digestibility of the different feed phosphates can be This article will be published in Kraftfutter Feed
calculated. Magazine, a European Feed Business Magazine.

Sedimentation of insoluble material out of the monocalcium phosphate liquor.

Aliphos Italphos Windmill

Tessenderlo Group enlarges the
range of high technological additives
Tessenderlo Group has cooperated closely with SODA Feed
Ingredients for about ten years in the commercialization of
coated acids and other products. The Micropearls of SODA
Feed Ingredients are already well known in Europe and the
range has been enlarged with the recent introduction of new
microencapsulated products. SODA Feed Ingredients’
research team has used its considerable knowledge and
expertise to develop Microcapsules or Micropearls which are a
combination of simple feed preservatives and essential oils.
This produces an excellent tool for the natural control of the ACIXOL
health and performance of animals through the feed.
In FORMAXOL, the REPAXOL is combined with formiate and
Production in EURHEMA citric acid through a fluid bed process. This combination has
SODA Feed Ingredients has many years’ experience in the the advantage of providing strong formic acid activity enhanced
manufacture of these products in its EURHEMA plant located by the effect of the essential oils.
in Cavriago Italy. This high technology plant has developed in
response to the demands of today’s feed industry. The ISO Extensive research
9001:2000 quality system was implemented several years ago Scientific publications have shown the benefits of the use of
and the plant introduced a full HACCP plan in early 2005. This ACIXOL and REPAXOL in broiler feeds (M. Lippens et al.,
was followed in March 2006 by FAMI-QS certification for the Arch. Geflügelk., 69(6).S. 261-266, 2005). In the figure below a
production of feed ingredient mixes which is equivalent to all calculation is made of the financial result in this trial. It shows
existing GMP systems for the feed industry today. Fully that the coated products give a 1.5% advantage over the
equipped to meet the high standards of the EU Feed Hygiene control group.
regulation, Soda FI developed a new range of products based Several field trials have demonstrated that the combination of
on their knowledge of the technology of encapsulation and these protected feed ingredients is also very effective in
their extensive experience gained through consultation with the piglets, pigs, sows and layers/breeders. Reports are available
pig and poultry industry on this subject. on request. Tessenderlo staff and the SODA FI technical
department are happy to advise you on how to achieve the
New Products most cost-effective solution.
The new range of products: REPAXOL, ACIXOL, and
FORMAXOL combine acids and essential oils in a high Your requests will be forwarded to the responsible people in
technological premix which allows their gradual release within your area or contact animalnutrition@tessenderlo.com
the digestive tract. The intelligent use of this combination of
101
ingredients gives pig and poultry growers the possibility of
addressing the challenges of today’s animal husbandry such
as suboptimal condition of the breeding animals (pigs, poultry 100
and rabbits) as well as maintaining performance in an era 100 100
where more ‘natural’ methods of animal production are often
99
demanded by the final consumer. These products also give the 99.20
feed compounder the possibility to work with products that are %
quite difficult to handle when used individually. 98 98.55
REPAXOL is a combination of essential oils and can be
efficiently used at low dosages (50 to 300 ppm) in all types of 97
animal feed. The essential oils are protected in a way that they
are heat stable. REPAXOL is used as an ingredient in two
other products of this range. In ACIXOL organic and inorganic 96
acids are combined by spray freezing with REPAXOL. The
synergy between the acids and the essential oils makes it an 95
ideal product for continuous use in pigs, poultry and turkey Negative control Avilamycin 10 AciXol 500 RepaXol 100
feeds.
Relative production cost of broilers (CLO-Melle Belgium, 2005)

Tessenderlo Group Feed Ingredients

Leading the world in feed phosphates

Tessenderlo Group
Troonstraat 130, B-1050 Brussels, Belgium
Tel: +32 2 639 1811 Fax: +32 2 639 1940
www.tessenderlogroup.com
animalnutrition@tessenderlo.com