When formulating an animal premix, it's easy to focus on the active ingredients. Vitamins, trace minerals, enzymes, probiotics, and specialty additives may be the stars of any premix—but they can only perform as well as the foundation they're built on. That's why one of the most important formulation decisions is also one of the most underestimated: choosing the right carrier.
A carrier is an edible, inert or relatively inactive substance that serves as the principal bulk component of a premix. Its role is to dilute, disperse and convey active ingredients so they can be mixed uniformly, handled efficiently and delivered accurately in the final feed. In many premixes, the carrier represents the largest proportion of the formulation, meaning its impact on product quality should never be underestimated.
The carrier is not simply a filler used to increase volume. It plays a critical role in determining whether a premix remains stable, free-flowing and homogeneous throughout manufacturing, storage and transport.
An effective carrier helps to:
Without the correct carrier, even the highest-quality ingredients may fail to deliver their intended nutritional value.
Selecting the right carrier is always a balance between the properties of the active ingredients, the manufacturing process and the requirements of the final product. While no single carrier is perfect for every application, an ideal carrier should possess several key characteristics.
The carrier should be chemically compatible with vitamins, minerals, enzymes, probiotics and other active components.
Factors to consider include:
For example, vitamin stability can be strongly influenced by premix pH. The ideal target pH for maximum vitamin stability is typically between 4.5 and 5.5, although a range of 4.0 to 6.0 is generally acceptable. As pH increases above 6.5, vitamin degradation and oxidation-related losses may increase.
Typical pH ranges include:
Understanding these characteristics is essential when formulating vitamin-containing premixes. Recent stability studies suggest Vitamin A may be more sensitive to organic carriers while B-vitamins are more sensitive to the presence of calcium carbonate. Choosing the correct carrier or combination of carriers can impact the stability and shelf-life of a premix.
Figure 1: Stability of Vitamin A in VIT premixes with 100% calcium carbonate (OR:100C), 100% rice hulls (100R:OC), 33% rice hulls and 66% calium carbonate (33R:66C), or 66% rice hulls and 33% calcium carbonate (66R:33C) stored at 25°C, -60% RH for twelve months
Particle size is one of the most important physical properties of a carrier. Selecting a carrier with appropriate particle size ensures microingredients are evenly distributed throughout the premix.
When carrier particle size closely matches that of the active ingredients and final feed, it helps:
Similarly, bulk density should be compatible with the other ingredients in the blend. Large differences in density can result in heavier particles settling and lighter particles rising, reducing uniformity throughout the product.
Figure 2: Vitamin ADE blend on calcium carbonate versus wheat middlings carrier
Figure 3: Comparison of particle size distribution of common carriers versus vitamin product forms.
Carriers such as calcium carbonate may be sourced in differing particle sizes. A fine granulation may more closely match the vitamin particles, however, due to the high density, it may prohibit even distribution. A coarse granulation may improve flowability but may decrease the homogeneity. A combination of both may help to find the happy medium between homogeneity and mixability.
Good flow properties are essential for efficient premix manufacturing. Poor flowability can lead to:
A suitable carrier should flow easily through mixers, hoppers and feeding systems, helping to maintain manufacturing efficiency and product consistency.
Figure 4: Types of flow
Many active ingredients are highly sensitive to moisture.
A good carrier should:
This is particularly important for vitamins, enzymes and probiotics, where excess moisture can significantly reduce shelf life and performance.
Many premixes contain liquid ingredients such as vitamin oils, essential oils, flavors or antioxidants.
The carrier must be capable of absorbing these liquids while maintaining a free-flowing powder. Insufficient absorption capacity can result in sticky, lumpy products that are difficult to handle and dose accurately.
Several carriers are commonly used in animal nutrition applications:
Calcium Carbonate (Limestone)
However, its high alkalinity and density may create challenges in some vitamin premixes.
Calcium Carbonate (Limestone)
Wheat Middlings
Variability in composition and moisture levels should be considered.
Wheat Middlings
Rice Hulls
Can be dusty and may increase segregation risk if not properly matched with other ingredients.
Rice Hulls
Choosing a premix carrier is far more than a cost decision. The right carrier contributes to product stability, uniformity, manufacturing efficiency and ultimately animal performance.
The best choice will always depend on the specific formulation and application. Successful carrier selection requires careful consideration of pH, particle size, density, flowability, absorption capacity and compatibility with active ingredients.
In short, a well-chosen carrier forms the foundation of a successful premix, helping ensure that every nutrient reaches the animal exactly as intended.
Do you experience handling issues with your premixes? See how dsm-firmenich’s ANH Premix Formulation Experts can help. Contact your Account Manager for more details.
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