Animal feed block composition

Compositions and method for forming a weather resistant, non-flowable and stackable animal feed block from flowable premixes. A first premix comprises particular cane molasses, dissolved calcium chloride, fat, water, and urea having a pH between about 4.4 and about 5.5. A second premix comprises water soluble salts of orthophosphoric acid which when mixed with the first premix provides a block having a hardness of 4.0 in 6 hours or less and minimum loss in field weather conditions. A dry blend of animal feed supplements may be included in the block.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates generally to a weather resistant, non-flowable, and 
stackable animal feed block and, more particularly, it relates to such a 
block which provides an animal feed supplement for controlled intake. 
2. Brief Description of the Prior Art 
The prior art discloses the preparation of animal feed supplements 
including molasses, with the addition of phosphoric acid to serve as a 
preservative and as a source of dietary phosphorus, and urea has been 
added to supply non-protein nitrogen. Fats have been included in these 
feed supplements. However, most of these supplements, in earlier days, 
have been in liquid form and were utilized by mixing into animal feed 
rather than permitting free-choice feeding by animals. 
In addition, the prior art discloses blocks to provide controlled intake 
and supply dietary requirements to animals, such as salt blocks, mineral 
blocks, protein blocks and molasses blocks. 
Also, U.S. Pat. No. 3,420,672 discloses the formation of a stable emulsion 
of animal fats in molasses containing feed supplements, but requires a 
starch emulsifying agent. The starch is present in relatively large 
quantities and such quantities are desirably avoided. 
U.S. Pat. No. 4,027,043 discloses an animal feed supplement which contains 
a major portion of molasses and various solidifying components like 
phosphate or phosphoric acid and a metal oxide or salt in sufficient 
quantities and proportions to solidify the product. This patent also 
discloses the presence of an edible fat or oil along with a fat 
emulsifying agent to prevent separation of the fat or oil from the solid 
composition. 
U.S. Pat. No. 4,798,727 discloses an acidic feed supplement block which is 
formed from the reaction of an acidic liquid mixture comprising (a) a 
sugar-containing source, such as molasses, (b) an orthophosphate source or 
precursor, (c) magnesium, and (d) sufficient calcium to provide total 
calcium to magnesium weight ratio of between about 1.5 and 3. The method 
results in the formation of a liquid molasses mixture having an acidic pH 
prepared by mixing two solutions, at least one of which contains molasses, 
and an orthophosphate compound with a second solution comprising 
sufficient calcium to react with the phosphate in the presence of 
magnesium so as to form a solid block. However, this block requires 
substantial hardening times. 
U.S. Pat. No. 4,800,092 discloses two methods for providing the composition 
of the U.S. Pat. No. 4,798,727. 
The prior art, however, has not provided animal feed supplement blocks with 
the best weatherability, nor the provision of two distinct fluid phases 
which are stable over substantial periods of time, but which, when mixed 
together, provide a high degree of hardness in a short period of time. 
More particularly, the prior art has provided blocks which erode under 
weather conditions found in the field resulting in loss of valuable 
supplements and has not provided for the formation of stackable hard 
blocks in short periods of time, such as about 6 hours or less. In 
addition, the prior art blocks did not provide stackability but tended to 
slump when stacked thereby interfering with storage and shipment of the 
block. 
OBJECTS OF THE INVENTION 
It is a principal object of this invention to provide an improved 
composition and method for forming an animal feed block which has high 
weatherability and which is capable of rapid development of hardness by 
mixing of two liquid phases or premixes. 
It is a further object of the invention to provide a two-phase block 
formation system, each of the phases being flowable and maintaining 
flowability over a substantial period of time for shipment and 
distribution. 
A still further object of the invention is the provision of a composition 
and method which will provide a block having a hardness within 6 hours or 
less to permit stacking and which can incorporate additional supplemental 
material for animal nutrition. 
Still further objects and advantages of the invention will become apparent 
by reference to the following description and examples. 
BRIEF STATEMENT OF THE INVENTION 
This invention is directed to the provision of a weatherable and stackable 
animal feed block which is formed to a hardness in excess of 4.0 within 6 
hours and which comprises two phases or premixes which remain flowable 
over extended periods of time. One phase comprises a particular cane 
molasses in an amount from about 65 percent to about 80 percent. Not all 
cane molasses provide the desired results of the invention and it has been 
found that the cane molasses utilized should not increase in viscosity 
more than 31/2 times over a 24 hours period upon the addition of dissolved 
calcium chloride, the calcium chloride being added at a level of 3.84 
percent (dry basis) to the molasses. Beet molasses and certain cane 
molasses do not provide the results of the invention because the viscosity 
excessively increases upon the addition of the dissolved calcium chloride 
thereby impairing flowability. 
The composition further includes in the first phase calcium chloride at a 
level on a dry basis of between about 3.0 percent and about 4.5 percent in 
dissolved form. Other divalent cations such as magnesium should not be 
used in the first phase. 
Sufficient water should be present in the first phase to dissolve the 
calcium chloride. In this connection the calcium chloride may be initially 
dissolved in water or the water can be added to the molasses before 
addition of calcium chloride. The water in phase one should be at a level 
of between about 5.75 percent and about 8 percent. 
The first phase further requires from about 3.3 percent to about 7.0 
percent of a fat to provide weatherability to the block. It is not desired 
to provide any emulsifying agent with the fat and the fat can be a soft 
oil or hard fat, as desired. Lower levels of fat do not provide the 
weatherability desired and high levels of fat will produce unacceptable 
high viscosities. 
In order to maintain flowability of the first phase, between about 4.9 
percent and about 8.5 percent of urea prills is added which serves to 
maintain the fluidity of the first phase over extended periods. While urea 
provides a source of non-protein nitrogen for the animal feed block, it is 
primarily added to the first phase to maintain fluidity and avoid crystal 
formation and undue viscosity increase. Absent the presence of the urea, 
the first phase will set up and become unsatisfactory for purposes of the 
invention. 
The first phase should have a pH in the range of from about 4.4 to about 
5.5. 
The invention further contemplates a second flowable phase or premix which 
includes from about 47.75 percent to about 52.25 percent of 
orthophosphoric acid at a concentration in excess of 75 percent, and from 
about 47.75 percent to about 52.25 percent of sodium hydroxide at a 
concentration in excess of about 40 percent to form a sodium phosphate 
solution. The ratio of sodium (Na) to phosphorous (P) should be in the 
range between 0.90:1 and 1.25:1. It is important that the sodium hydroxide 
be added to the orthophosphoric acid in such dilution and rate so as to 
avoid the formation of trisodium phosphate which is insoluble. It has been 
found that for purposes of the invention the polyphosphates such as sodium 
hexameta-phosphate, sodium tripolyphosphate, ammonium polyphosphate and 
others will not work to provide the desired results. As indicated, the 
presence of insoluble trisodium phosphate also avoids the enjoyment of the 
results of this invention. 
This second phase should have a pH from about 5.0 to about 6.2. 
The two liquid phases or pre-mixes are mixed together, when desired, as by 
a manufacturer, or by a producer at a feedlot. The convenience of 
transport and shipment of the two phases avoids the need for preformation 
of blocks and certain difficulties in their handling. The mixture of the 
two phases should include between about 46 percent and about 75 percent of 
phase one and between about 11 percent and about 25 percent of phase two. 
Upon mixing, the resulting composition should have a pH of between about 
4.0 and about 6.0, and preferably has a pH of about 5.0. The ratio of 
dissolved calcium (Ca) to phosphorous (P) should be in the range of from 
about 0.26:1 to about 0.32:1. 
The combination of phases should provide a block hardness of at least 4.0 
in 6 hours or less. The resulting hard block provides for controlled 
feeding and stacking of many blocks on one another. The blocks of the 
invention have high weatherability and low weather erosion. The hardness 
of the blocks provides good storage and shipment features. 
In order to provide a desired nutrition for animals, a dry mix can be 
educted into the mixture of phase one and phase two before hardening, and 
additional supplements can be added such as vitamins, urea, limestone, 
selenium, protein rich meals and mineral mixtures. The limestone should be 
substantially insoluble in the mix so as to avoid addition of calcium (Ca) 
in ionic form to the block-forming ingredients. Likewise, magnesium oxide 
or other form of magnesium (Mg) may be added for nutritional purposes, but 
it should be substantially insoluble in the two phases of the animal feed 
and should not contribute magnesium in ionic form to the block. 
If soybean meal or other protein rich meals containing phosphate are 
provided in the dry mix, lesser amounts of orthophosphoric acid may be 
utilized in the second phase. 
Some of the supplements, such as vitamins and selenium may be added to 
phase one, i.e. other than in the dry blend. 
Basically, the two phases when reacted provide a carrier for the dry 
ingredients, if used, although soluble phosphates in the meals may provide 
a source of phosphate ion in addition to that provided by phase two. 
The invention is most enjoyed by obtaining a hardness of 4.0 within six 
hours. The hardness is determined in accordance with the following method 
and use of the indicated equipment: 
Ametek Force gauge (Model T-10P) is forced one inch into the gel. The 
hardness is measured as the force necessary to insert probe one inch. 
Weatherability of the hard block is determined by forming a block in 
accordance with this invention, weighing the block, and then spraying the 
block with water over a period of 10 minutes (150 ml/minute flow rate). 
The loss of weight during the spraying period is a measure of the 
weatherability of the block. 
In general, in accordance with the method of the invention, phase one is 
prepared by dissolving calcium chloride in water and/or sufficiently 
diluted cane molasses. However, total solids content of the calcium 
chloride, urea and molasses solids should not exceed 68 percent to avoid 
substantial increases in viscosity or crystallization of the cane 
molasses. 
Urea is added into the mixture of molasses and dissolved calcium chloride 
and, as indicated, the presence of the urea in solubilized form serves to 
maintain the flowability of phase one for extended periods of time. The 
fat is then added to the mixture and the fat may be a soft oil such as 
soybean oil or may be a hard fat such as tallow. The fat is necessary to 
provide the weatherability of the block and, while it serves as an energy 
source for the food supplement, it is primarily present to provide 
protection against the elements in the field. After mixing in of the fat, 
the remaining cane molasses is added to complete the basic formulation of 
phase one. Various nutrients may be mixed into phase one ingredients 
provided they do not significantly effect an increase in viscosity or 
crystallization. After the ingredients are mixed, they may be placed in a 
suitable container for shipment. It has been found that the phase one 
ingredients can be held as long as 3 months without losing flowability or 
substantially increasing in viscosity. Thus, it remains readily mixable 
with phase two. 
Phase two is formed by placing the concentrated orthophosphoric acid into a 
container or kettle and is slowly neutralized by the addition of diluted 
sodium hydroxide, the rate being adjusted so as to avoid the formation of 
trisodium phosphate, an insoluble compound. The sodium hydroxide is 
desirably ,diluted to about 47-55 percent, and is preferably a 50 percent 
solution. This results in the formation of a flowable sodium phosphate 
solution, which can be placed into a container and held for shipment over 
extended periods of time and it has been found that the second phase can 
be held for shipment for as long as 3 months. 
Various ingredients can be blended together to provide a dry blend for 
addition into the feed block to provide additional supplemental materials 
for animals. A particularly desired supplement is soybean meal but other 
protein rich meals can be included. Meals can be derived from various 
sources. The dry blend can include cracked corn and other cracked seed. 
Various additional minerals, selenium and vitamins may be included, and 
further non-protein nitrogen can be added by further addition of urea 
prills. 
It is possible to dilute the cane molasses with other nutritive liquids 
with lower solids relative to cane molasses, such as corn distiller 
solubles, other molasses, potale, brewer's condensed solubles, and stick 
water, but these nutritive liquids should not comprise more than about 15 
percent of the amount of nutritive liquids used, or a level such that 
block solids fall below 70 percent. The stick water can serve to provide 
both fat and protein. 
To form the block when the dry ingredients are added, the first phase and 
second phase are mixed together, and the blended dry ingredients are 
educted into the mixture. The final blend is discharged into a form of 
desired shape to provide the blocks of the invention. 
If magnesium is desired in the blocks for nutritional purposes, it should 
be introduced in insoluble form and generally will be introduced as 
prilled magnesium oxide. The magnesium, if in ionic form tends to 
interfere with gelation of the blocks of the invention and, therefore, 
should not be dissolved in the block. In other words, the magnesium does 
not contribute to the gelation or hardening of the block in accord with 
what we have found. 
The invention will be more particularly understood by reference to the 
following Examples:

EXAMPLE 1 
In order to form a first flowable premix, the following ingredients were 
blended together: 
______________________________________ 
Based on Based on 
Ingredient Final Block 
First Premix 
______________________________________ 
84 Brix cane molasses 
36.43% 79.21% 
Calcium chloride 1.84% 4.00% 
Water 2.66% 5.79% 
Prilled urea 2.25% 4.90% 
Animal fat 2.81% 6.10% 
______________________________________ 
The calcium (Ca) is present at 1.12 percent based on the first premix. 
Minerals and vitamins were included in the first premix and were as 
follows: 
______________________________________ 
Based on 
Final Block 
______________________________________ 
Selenium .110% 
Mineral mix .100% 
Vitamins, A, D, E 
.022% 
______________________________________ 
However, these additives may be included with the dry mix, if desired. 
The pH of the first premix was 4.96. 
A second flowable premix was prepared comprising the following: 
______________________________________ 
Based on 
Based on 
Final Block 
Second Premix 
______________________________________ 
Phosphoric acid (85%) 
6.68% 47.76% 
Sodium hydroxide (50%) 
7.32% 52.24% 
______________________________________ 
The percent phosphorous (P) in the second premix is 12.6 percent based on 
the second premix. 
The pH of the second premix was 6.15. 
The ratio of calcium to phosphorous was about 0.29:1 when the premixes were 
combined. The pH of the combined premixes was 5.1. 
A dry blend was prepared by blending together the following ingredients in 
the indicated percentages: 
______________________________________ 
Based on 
Based on 
Final Block 
Dry Blend 
______________________________________ 
Ground corn 8.37% 20.92% 
Limestone (CaCO.sub.3) 
8.50% 21.25% 
Corn gluten meal 18.0% 45.00% 
Prilled magnesium oxide 
3.2% 8.00% 
Prilled urea 1.93% 4.83% 
______________________________________ 
To form the first flowable premix, 15% of the molasses to be used was 
diluted with the 5.79% water and the 4.0% calcium chloride was mixed in 
until dissolved. After dissolving of the calcium chloride, the 4.9% of 
urea prills were added and mixed until dissolved, whereupon tallow in the 
amount of 6.10% was added and mixed into the flowable mixture. The 
remainder of the cane molasses was added. 
The cane molasses was obtained from Florida and had a viscosity of 5740 
cps. After addition of dissolved calcium chloride at a level of 3.84 
percent based on molasses, and mixing with the cane molasses, the 
viscosity increased over 24 hours to 19860 cps or an increase 3.46 times 
the initial viscosity. This was quite acceptable for use in the first 
premix and maintaining its flowability for a three month period. 
To form the second flowable premix, the orthophosphoric acid (85%) was 
placed in a kettle and the sodium hydroxide (50%) was slowly added to 
avoid formation of trisodium phosphate. After formation of the sodium 
phosphate solution, it was poured into a container for shipment and later 
use. The ratio of sodium to phosphorous in the second premix was 1:25:1. 
The ratio of calcium (Ca) in the first premix to phosphorous (P) in the 
second premix was 0.29:1. 
Each of the premixes when stored under ambient conditions remained flowable 
after three months and were readily mixable. 
To prepare blocks, a mixture of 46.00% of premix one, 14.0% of premix two 
and 40.00% of the dry blend were combined by mixing premix one and premix 
two together and educting the dry blend into the premises In six hours, 
the blocks had a hardness of 4.0 and were stackable for extended periods 
of time without slumping. 
The blocks when tested for weight loss by the method previously described 
lost 1.95 percent of initial 
EXAMPLE 2 
In order to form a first flowable premix, the following ingredients were 
blended together: 
______________________________________ 
Based on Based on 
Ingredient Final Block 
First Premix 
______________________________________ 
84 Brix cane molasses 
42.57% 74.70% 
Calcium chloride 2.45% 4.30% 
Water 4.42% 7.75% 
Prilled urea 4.70% 8.25% 
Animal fat 2.85% 5.00% 
______________________________________ 
The calcium (Ca) is present at 1.20 percent based on the first premix. 
Minerals and vitamins were included in the first premix and were as 
follows: 
______________________________________ 
Based on 
Final Block 
______________________________________ 
Selenium .110% 
Mineral mix .100% 
Vitamins, A, D, E 
.022% 
______________________________________ 
However, these additives may be included with the dry mix, if desired. The 
pH of the first premix was 5.10. 
A second flowable premix was prepared comprising the following: 
______________________________________ 
Based on 
Based on 
Final Block 
Second Premix 
______________________________________ 
Phosphoric acid (75%) 
9.16% 50.89% 
Sodium hydroxide (50%) 
8.84% 49.11% 
______________________________________ 
The percent phosphorous (P) in the second premix is 12.06 percent based on 
the second premix. 
The pH of the second premix was 5.95. 
The ratio of calcium to phosphorous was about 0.316:1 when the premixes 
were combined. The pH of the combined premixes was 5.00. 
A dry blend was prepared by blending together the following ingredients in 
the indicated percentages. 
______________________________________ 
Based on 
Based on 
Final Block 
Dry Blend 
______________________________________ 
Soybean meal 21.5% 86.00% 
Limestone (CaCO.sub.3) 
3.5% 14.00% 
______________________________________ 
To form the first flowable premix, 5.75% water and 4.30% calcium chloride 
were combined. After dissolving of the calcium chloride, 8.15% of urea 
prills were added and mixed until dissolved, whereupon tallow in the 
amount of 5.0% was added and mixed into the flowable mixture. The 
remainder of the high Brix cane molasses was added. 
The cane molasses was obtained from Australia/Mexico and had a viscosity of 
10,150 cps. After addition of calcium chloride and mixing with the cane 
molasses, the viscosity increased over 24 hours to 31,800 cps or an 
increase 3.13 times the initial viscosity. This source is quite acceptable 
for use in the first premix. 
To form the second flowable premix, the orthophosphoric acid (75%) was 
placed in a kettle and the sodium hydroxide (50%) was slowly added to 
avoic formation of trisodium phosphate. After formation of the sodium 
phosphate solution, it was poured into a container for shipment and later 
use. The ratio of sodium to phosphate in the second premix was 0.51:1. 
The ratio of calcium (Ca) in the first premix to phosphorus (P) in the 
second premix Was 0.316:1. 
Each of the premixes when stored under ambient conditions remained flowable 
after three months and were readily mixable. 
To prepare blocks, a mixture of 57.00% of premix one, 18.0% of premix two 
and 25.00% of the dry blend were combined by mixing premix one and premix 
two together and educting the dry blend into the premixes. In six hours, 
the blocks had a hardness of 4.0 and were stackable for extended periods 
of time without slumping. 
The blocks when tested for weight loss by the method previously described 
lost 2.69% of initial weight. 
EXAMPLE 3 
To determine the effect of different molasses in the formation of blocks of 
the invention, the following molasses were tested to determine viscosity 
increases in 24 hours by addition of calcium chloride at a level of 3.8% 
(dry basis) based on weight of molasses. 
______________________________________ 
24 Hr. 
Brix Viscosity (cps) 
Viscosity Increase 
______________________________________ 
Cane Molasses 
Florida 84.0 5,740 19,820 3.46 
Hawaii 84.0 11,250 36,860 3.30 
Mexico 84.0 10,800 32,400 3.00 
Australia/ 
84.0 10,150 31,800 3.13 
Mexico 
Thailand 84.0 3,520 19,000 5.40 
Beet Molasses 
84.0 11,650 94,200 8.09 
______________________________________ 
The use of Thailand cane sugar molasses and beet molasses were unacceptable 
for the first premix and desired block formation. Accordingly, the 
experience shows that the viscosity should not have an increase in excess 
of about 3.5 times. 
EXAMPLE 4 
To demonstrate the effect of using phosphates other than soluble 
orthophosphates, various polyphosphates were substituted at comparable 
phosphorous levels to show gel rates, i.e. hardness after 6 hours. 
______________________________________ 
Phosphate Source 6 Hour Hardness 
______________________________________ 
Example 2 Block 4.4 
Sodium Hexametaphosphate 
0.3 
Sodium Tripolyphosphate 
0.0 
Ammonium Polyphosphate 
1.2 
______________________________________ 
EXAMPLE 5 
For purposes of comparing the effect of polyvalent cations other than 
calcium in the block, magnesium and aluminum ions were substituted f-r 
calcium ions in the formulation at equal molar levels and block hardness 
after twenty four hours was determined with the following results: 
______________________________________ 
Cation 24 Hour Hardness 
______________________________________ 
Magnesium 0.0 
Aluminum 0.5 
Calcium 5.6 
______________________________________ 
EXAMPLE 6 
The effect of pH on block hardness is indicated below by measuring pH at 
the time of mixing the first premix and second premix and determining 
hardness after 24 hours. 
______________________________________ 
pH 6 Hour Hardness 
24 Hour Hardness 
______________________________________ 
3.0 
0- 0.3 
3.5 1.4 2.4 
4.0 4.3 5.2 
4.5 4.2 5.8 
5.0 4.4 7.2 
5.5 4.0 6.8 
6.0 4.0 5.7 
6.5 1.8 3.0 
7.0 0.5 1.4 
______________________________________ 
The pH was adjusted with phosphoric acid or sodium hydroxide to achieve the 
desired pH level. 
The 24 hour hardness of 5.4 is equivalent to a 6 hour hardness of 4.0. 
However, a hardness of less than about 5.4 after 24 hours does not provide 
the necessary hardness for stacking and shipping purposes. 
It has been found that an improved animal feed block having high 
weatherability and stackability can be provided in a short period of time 
by careful selection of certain parameters which have not been previously 
set forth. The block is derived from two phases which remain flowable over 
extended time periods and can be separately provided to permit formation 
of blocks when needed. 
The various features of the invention on which are believed to be new are 
set forth in the following Claims: