Jul | Aug 14 - Grain & Feed Milling Technology by Perendale Publishers

July - August 2014

first published in 1891

•

Dust control

with bulk bag discharger and flexible screw conveyors

In this issue: •

Real-time analysis for early detection of grain quality fluctuations

Storage and silos special

Mycotoxins

How to analyse and reduce the hazard to humans and animals

NIR Multi Online Technology:

•

Feed Focus

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GRAPAS

Pigs Technology from the GRAPAS Asia award

INCORPORATING PORTS, DISTRIBUTION AND FORMULATION

MT GRAIN & FEED MILLING TECHNOLOGY

VOLUME: 125 NUMBER: 4

July - August 2014

Grain & Feed Milling Technology ISSN No: 1466-3872 Perendale Publishers Ltd 7 St George’s Terrace, St James’ Square, Cheltenham, Glos GL50 3PT, United Kingdom Publisher Roger Gilbert Tel: +44 1242 267707 rogerg@perendale.co.uk

Editorial Olivia Holden Tel: +44 1242 267707 oliviah@perendale.co.uk Design manager James Taylor Tel: +44 1242 267707 jamest@perendale.co.uk Circulation & events manager Tuti Tan Tel: +44 1242 267707 tutit@gfmt.co.uk Australia correspondent Roy Palmer Tel: +61 419 528733 royp@perendale.co.uk

MILLING NEWS Giant leap forward in intelligent optical sorting for rice Product range improvement for Jacob Feed Support Products (FSP) - what’s in it for you? Silos Cordoba receives awards Alapala completes new mill for Agthia Grand Mills in Abu Dhabi Perstorp acquires Chemko’s calcium formate and penta businesses FEATURES Reviving the role of education and training in milling A History of Roller Flour Milling Dust control with bulk bag discharger and flexible screw conveyors Animal Feed Milling in India Silos special Mycotoxins - How to analyse and reduce the hazard to humans and animals NIR - Real-time analysis for early detection of grain quality fluctuations FEED FOCUS - Pigs GRAPAS ASIA - technology from the event

Tilly Geoghegan Tel: +44 1242 267707 tillyg@gfmt.co.uk Tom Blacker Tel: +44 1242 267707 tomb@perendale.co.uk Latin America Marketing Team Iván Marquetti Tel: +54 2352 427376 ivanm@perendale.co.uk Pablo Porcel de Peralta Tel: +54 2352 427376 pablop@perendale.co.uk

GUEST EDITOR'S OBSERVATIONS Roger Gilbert, publisher of GFMT

ASSOCIATIONS PORTS

Oman plans dynamic new agro-terminal

Annual Subscription Rates Inside UK: UK£70 Outside: US$140/ Euros110 More Information www.gfmt.co.uk http://gfmt.blogspot.co.uk

2 8 52

COMMODITIES

Raw material outlook, by John Buckley

EVENTS 56 IDMA 2015 Feed & Food in Asia

58 59

The GFMT interview Melinda Farris, executive vice president, IAOM

INDUSTRY FACES 64 Joyce Wilcox joins R-Biopharm Rhône in a food and feed safety analysis role Dr Francisco Saraiva Gomes joins Pontos Aqua Holdings LLC Anitox appoint new Chief Financial Officer

India Marketing Team Assocom-India Pvt Ltd Tel: +91 47 675216 india@perendale.co.uk Nigeria Marketing Team Nathan Nwosu Tel: +234 805 7781077 nathann@perendale.co.uk

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REGULAR ITEMS

Global rice associations

International marketing team Darren Parris Tel: +44 1242 267707 darrenp@gfmt.co.uk

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Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. Copyright 2014 Perendale Publishers Ltd. All rights reserved. No part of this publication may

be reproduced in any form or by any means without prior permission of the copyright owner. More information can be found at www.perendale.com Perendale Publishers Ltd also publish, 'The International Milling Directory' and 'The Global Miller' news service

EDITOR’S OBSERVATIONS

Guest - EDITOR’S OBSERVATIONS

t was a pleasure to assign to our new Australian Correspondent Roy Palmer the task of attending and reporting on the Australian Milling Conference (AMC2014) which attracted some 1400 people to Brisbane in May and covered all milling activities (his brief report is on page 59).

Roy tells me that the International Feed Industry Federation chairman Mario Cutait, was the main plenary speaker on the first afternoon session and set the scene for the future of the feed sector.

Be forthright with our customers During the presentation Mario, who is based in Brazil, mentioned that the industry must be forthright with consumers. The industry is aware of consumers concerns regarding hormones, antibiotics and genetics and tends to go quiet whilst minority groups lobby against these issues. Mario’s point was that the industry should be armed with scientific evidence on such subjects and

Working towards greater rice fortification

series of workshops running over three-and-a-half days will take place in the Hilton Millennium Bangkok, Thailand from September 16-19, 2014 to address the practical and technical issues arising from rice fortification.

The workshops are being organised by The Food Fortification Initiative, PATH, World Food Programme, Micronutrient Initiative, Unicef and the Global alliance for Improved Nutrition. From a regulatory, public health and nutrition point of view, rice fortification is similar to wheat and maize flour fortification, both of which are implemented globally on a large scale. Therefore, fortification levels established for wheat and maize are providing a starting point to establish micronutrient levels for rice fortification. In addition, the experience and knowledge gained through the scale up of flour fortification provides important lessons learned to inform the scale up of rice fortification. From an implementation and technical perspective, rice differs from wheat and maize fortification. During the past decade, technologies to fortify rice, such as coating and extrusion have evolved significantly. As a result, the technological challenges related to changes in taste and color, but also resulting from longer cooking times and washing processes, once barriers to successful implementation of rice fortification programmes, have been overcome. The evolution of cost-efficient technologies combined with research on effective nutrient fortification

should be making its case by getting on the front foot and educating the public on such issues. He added that the industry had no time to waste in working collaboratively and made these important points: • Industry has to proceed in making decisions which are science based • Industry must not only Roger Gilbert, Director and Publisher continue to defend Perendale Publishers Limited itself but to become more pro-active • Industry must embrace and use new technologies and innovations • Industry must continue to work towards Fair Trade • All efforts though whole chain should be to produce more with less and keeping things affordable for end users • We all need to be thinking and acting globally Industry needs to look, think and speak “outside the box.” levels makes rice fortification a feasible solution to reduce micronutrient deficiencies across large segments of the population. The number of countries introducing rice fortification is growing, with Asia and Latin American countries spearheading the efforts. The strategic timing of this workshop is not a coincidence. The organising organisations have come together to plan this event to build on the current momentum to scale up rice fortification. The workshop brings together technical experts, government technical decision makers and private sector and donor representatives to review the current status and way forward for rice fortification. Objectives of the ‘Scaling Up Rice Fortification in Asia’ workshop are as follows: To share up-to-date global and regional evidence and operational experience; To facilitate cross country exchange between countries at differing implementation stages of rice fortification, and to Create a network for continued learning and knowledge exchange in support of national efforts to scale up rice fortification. More specifically the workshop will include discussions on the national, regional and global evidence base and current status of rice fortification in Asia and globally, fortification technology and methods, components of the rice value chain, delivery options, standard setting, aspects of policy and legal environment, and lessons learned from salt and wheat flour fortification. Strategies to overcome bottlenecks and leverage enabling factors will be identified and discussed. Finally, participants will identify practical next steps in the process to expand and scale up rice fortification programmes. GFMT supports this initiative and will report on its outcomes in due course.

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&FEED MILLING TECHNOLOGY

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Giant leap forward in intelligent optical sorting for rice Bühler’s flagship rice sorter features individual defect detection technology, enabling processors to adjust the sensitivity of each defect, individually and in parallel

he Bühler Group, a global leader in rice processing and optical sorting solutions, has further extended its leadership in intelligent optical sorting for rice with the introduction of its most sophisticated, highest-capacity optical sorter yet. Addressing changing and challenging market and consumer requirements, the all-new SORTEX S UltraVision™ significantly increases rice processors’ profitability, by allowing them to define the exact quality

high capacity feed system and improved detection of defects, it is the culmination of over 65 years of sorting experience. The Buhler SORTEX design team have created a completely new optical sorter, from the ground up and, packed with new, advanced, proprietary technologies, the SORTEX S UltraVision™ means processors need no longer compromise yield in order to meet their customer requirements. In-built intelligence enables the sorter to make intuitive decisions about which grain is good and which grain should be rejected,

These modes hold the detailed characteristics of individual rice varieties and defects, allowing operators to tailor sort quality precisely and improve yield. The new user interface gives easy control, allowing swift changes from one rice product to another, or one quality standard to another, significantly reducing costly downtime. “Processors can consistently achieve export quality by just selecting the rice variety, setting each defect’s sensitivity and pressing start,” says Mr Deefholts. Consistency of sor ting per formance is fur ther enhanced with Intelligent Automation – Bühler is currently the only company delivering a fully-automated sorter. By constantly scanning passing rice, selflearning as product changes and adjusting it self automatically, the SORTE X S UltraVision™ removes the need for manual intervention and consistently operates at the optimum level until the end of every batch. Increasing yields still further, even when a ‘perfect’ accept product is required, is new Textured LED Lighting™ technology, together with proprietary-designed, multichromatic ‘Ultra’ cameras, which now detect defects almost imperceptible to the human eye. Plus, Bühler’s intelligent new Crosshair Targeting™ technolog y improves the accuracy of ejection, even at very high capacity, by firing just the right amount of air, removing fewer of the good grains with the reject.

Open construction level for their rice, even when faced with highly contaminated incoming material – and in just three easy steps. Yield is not compromised, which enables processors to deliver increased value for money to their customers. As much Bühler’s customers’ vision as its own, the SORTEX S UltraVision™ tackles critical industry issues. Contamination levels in rice are rising and defects are becoming more subtle and therefore more difficult to detect. Processors also face increased competition and consolidation of rice mills, plus greater pressure to meet demand for many different levels of rice quality, including export standard. To meet this pressure, processors must define which grains are acceptable and which they wish to reject. “Existing optical sorting solutions restrict adjustment for defects without specific controls, so rice processors have been forced to compromise between meeting customer specifications or minimising reject – until now. The SORTEX S UltraVision™ revolutionises this,” says Neil Dyer, Global Product Manager for Buhler SORTEX. Designed and built in the UK, the SORTEX S UltraVision™ is Bühler’s highest ever capacity sorter for rice. With up to six modules, a patented

while its specific defect detection capability allows processors to adjust their sensitivity for each of multiple defects, individually. This groundbreaking functionality gives processors unprecedented control. They can now define the exact ‘accept’ levels necessar y to meet their customers’ requirements - thus eliminating waste and boosting profit. “Many customers stress their need to remove yellow grains reliably, but agree that slightly grey or under-milled grains are acceptable up to a certain threshold,” said Ben Deefholts, Buhler SORTEX Rice Specialist who, with other Bühler specialists, constantly strives to understand changing customer requirements, regularly visiting their processing plants and quality control labs. “ Until now, operators could not distinguish between different shades and have had to increase overall sensitivity in order to remove all subtle yellows, thereby also removing all subtle greys and ultimately reducing yield,” according to Mr Deehfolts, who explained that revolutionising this is Bühler’s SORTE X ProSort™ software, featuring intelligent modes.

Based on Bühler’s philosophy of open construction, the completely new mechanical design of the SORTEX S UltraVision™ makes daily operation even easier. For instance, a simple release opens a cover, allowing unprecedented access to key optical areas, without the need to remove chutes or receptacles. An operator can routinely clean dust in seconds, preventing any build up of meal on the viewing glass that could otherwise compromise sorting performance. The same leading-edge design is behind SORTEX AnywarePro™, which allows customers 24/7 visibility of online data for maximum product yield and sorting optimisation, fault alert, and system usage statistics. Customers can fur ther benef it from

&FEED MILLING TECHNOLOGY

GRAIN

July - August 2014 | 5

EC 1935/2004 plus FDA

QUICK CONNECT ®

installation friendly perfect fitting shock explosion proof tight solid easy to clean easy expandable

Bühler’s global support, providing fault and predicitive wear diagnostics and system performance analysis. “The all-new SORTEX S UltraVision™ forms part of Bühler’s wider range of next-generation high capacity, energy ef f icient , ‘ Ultr aLine’ rice processing equipment delivering outst anding productivity, coupled with lower running costs, to help rice processors improve the sustainability of their operations and maximise their revenue,” said Buhler SORTE X M anaging Direc tor, H amid Kefayati. The SORTEX S UltraVision™ therefore further consolidates Bühler's position as the leading optical sorting technology partner

for rice processors and defines the future of intelligent optical sorting. Buhler SORTEX is a worldwide technology solutions brand, recognised for intelligent premium technology and engineering quality, in optical sorting and rice processing, with a sorter install base of over 25,000 machines worldwide and a global presence in over 140 countries, underpinned by The Bühler Group with over 150 years in process technology. Podcasts: Listen to members of the Buhler SORTEX team talking about their involvement in the development of the SORTEX S UltraVision™ Optical Sorter in a series of podcasts at www.buhlergroup. com/optical-sorting.

QUICK CONNECT ® pull-ring more time-efficient during assembly. INSTALLATION FRIENDLY and easy to dismantle. PERFECT FITTING in long durability with top quality – that is our pipework and distribution system. SHOCK EXPLOSION PROOF safely JACOB pipework system. TIGHT connection for our pipework systems. SOLID and precise in case of retrofitting. EASY TO CLEAN and easy replaceable. EASY EXPANDABLE by variability of our modular system.

Product range improvement for Jacob

he new Jacob Pipework Systems product catalogue, which includes custom parts, is now out. And customers will also f ind numerous additions to the company’s product range. One of the improvements that Jacob offers is a doubling of existing serially produced diameters. The spectrum of diameters included in the catalogue now extends from 60mm to 1600mm, instead of 800mm in the past. A new section with a wide range of custom parts and serially produced variations further complements the range. Availability is ensured

by the manufacturer by expanding the customised production capacities to include an additional 1000 square metres, complete with new machinery.

Exclusive foodgrade range

The new food-grade range makes Jacob the first and only manufacturer of modular pipe systems to offer dual conformity to the EC1935/2004 directive and FDA regulations. More than 1000 product components were tested down to the smallest detail for this range and exchanged or re-constructed where necessary. As part of the fo od - g r ad e r a n ge , t h e catalogue also contains new heat-sealed u-shaped seals and ring seals (silicone/EPDM) which are more resistant to chemicals, temperature and tearing than traditional adhesive-bonded rings.

No time to order during the day? No problem thanks to Jacob’s online shop. Even pipework systems for the capital goods industry can be conveniently ordered 24/7 in Jacob’s online shop. The new shop makes it easier than ever for customers to take project planning into their own hands. It offers the flexibility needed to generate a parts lists, which are used to request quotations online and then place orders right away at any hour of the day. And it is much easier to place repeat orders. This applies also for the mobile online shop for smartphones and tablets, which is easy to access from anywhere. More

information:

Catalogue orders at www.jacob-rohre.de

Heat-sealed u-shaped seals www.foodgrade.eu

Online shop http://shop.jacob-rohre.de

Visit us at POWTECH 2014 September, 30th - October 2nd Nuremberg, Germany, hall 5, booth 5-348, www.powtech.de EUROPE’S NO. 1 IN PIPEWORK SYSTEMS The QUICK CONNECT ® pull-ring makes the acclaimed Jacob modular pipe system even more economical for installation. In new plants for animal feed, pharmaceuticals, chemicals, food, glass, semiconductors or environmental technology as well as for upgrading existing layouts user-friendly system installation becomes precise and easy due to the great versatility of mass-produced pipe components. ORIGINAL QUALITY TO A MODULAR DESIGN  Straight welded, lipped-end pipes and components.  ø 60 mm to ø 1600 mm in a standard range.  With pull-ring or flange connetction.  Up to ø 400 mm normally dispatched immediately from stock.  Powder coated steel or hot-dipped galvanised steel as well as stainless steel.  1-3 mm wall thicknesses.  Larger diameters / special requirements upon request.  Shock-explosion certified pipes and components available. Fr. Jacob Söhne GmbH & Co. KG, Germany Tel. + 49 (0)571 95580 · jacob-pipesystems.eu

&FEED MILLING TECHNOLOGY

6 | July - August 2014

GMP+ Feed Support Products (FSP) -what’s in it for you? by Johan den Hartog, managing director of GMP+ International, Rijswijk, The Netherlands

Safe feed and food starts with secure risk management. For this, GMP+ International offers her knowledge and information through the Feed Support Products (FSP). The Feed Support Products are intended to support all (future) GMP+ certified companies when setting up their company-specific HACCP system.

he responsibility for use and implementation remains with the GMP+ certified companies, the Feed Support Products can offer support in this process. The FSP is also intended as a reference for the auditors within the framework of GMP+ certification.

Products of FSP

The following products are a part of FSP: Fact Sheets - The fact sheets show background details regarding the hazards and the (explanation of the) severity of the risk to animals and humans. The content of the fact sheets is as follows: Nature, history and prevalence; Transmission to the environment, plants, animals and humans; Diagnose of poisoning; Potential hazards and adverse effects; Severity of the hazard; Standards; Analysis methods and Control measures. The information can be used by making the company specific

GRAIN

risk analyses. Fact sheets are available for the undesirable substances (hazards) in the Risk Assessments and for processing aids. Generic Risk Assessments - This section of FSP contains about 200 risk assessments of feed materials for Food-producing animals (including goats, poultry, cattle, sheep and pigs, but also horses and rabbits). Farmed fish will be included. The risk assessments in the FSP database are of a generic nature and represent a worst-case scenario. The risk assessment gives information about a production process and the resulting possible hazards. Product list - This list gives a short summary of all products available. The products (about 500) on the list may be used as a feed material in the GMP+ Feed Certification scheme. Product standards Standards with maximum permitted levels have been issued by legislation and by GMP+ International for many hazards in order to be able to determine if a feed material is safe. All the standards are a part of the GMP+ FC scheme, GMP+ BA1 Product Standards GMP+ Monitoring database - A service from GMP+ International is the GMP+ Monitoring database. Companies can put their analyses into the database and can share these results with a group of companies or with the GMP+ community. Sharing is an option, not a requirement. Monitoring results can be used to assess the likely occurrence of a hazard. The GMP+ Monitoring database is an easy tool for storing and sharing analysis results. You can easily check if the products meet the standards.

Benefits

FSP provides ease of use, an uniform source of relevant data, linking of relevant files and efficient searching. The benefits of use are: • up-to-date knowledge of risks of feed materials • up-to-date knowledge of undesirable substances • assessed by independent experts • uniform source of

knowledge • automatically linking of all relevant files

Core values

The Feed Support Products operates from 4 core values: Practical information - The information in FSP about processing, possible hazards, risk assessments and monitoring data is received from GMP+ companies Science based - The (generic) risk assessments of feed materials fully comply with the requirements referred to in the HACCP manual for the animal feed sector (2008). To substantiate potential adverse effects of a hazard, the information is published in fact sheets for both Undesirable substances and Technical processing aids. The severity of hazards indicated in fact sheets and risk assessments has been evaluated by scientists of RIKILT. Independency - The policy and technical aspects of FSP are reviewed by independent committees, being the International Expert Committee Animal Feed (IEC Animal Feed) and the Technical Committee FSP (TC FSP). TC FSP acts as a HACCP team for the FSP. The TC FSP has members who are representatives of different subsectors and knowledge areas (chemical and microbiological) The meeting of TC FSP will at least take place 2 times a year. Besides the regular members of the TC FSP ‘advisors’ can be invited to TC meetings. These advisors are either laboratory representatives, representatives of the Food and Consumer Product Safety Authority, or scientists (eg. Rikilt). Also independent advisors from certification bodies or consultancy agencies can be invited to (parts of) the TC. Transparency - GMP+ uses a transparent communication to all stakeholders as well as transparent working methods. Procedures for changes are described. Every change is communicated to the GMP+ community via the FSP newsletters. What do we do to have the FSP up to date? The content of the different products continuously changes due to new feed legislation, regulations, emerging risks and

new scientific information. Changes include new feed materials/products, hazards, new “product-hazard combinations” and new standards (legislation). These changes are periodically processed by GMP+ International within FSP by a maintenance procedure. Changes in hazards (severity, effect) are processed in factsheets and/or risk assessments. If needed changes in risk assessments, factsheets, GMP+ standards or monitoring program, are discussed within the TC FSP. Reasons for changes can be (among others): In general: • New feed legislation; • Early Warning System (EWS) from GMP+ • Rapid Alert System for Food and Feed (RASFF); • Feed Crises; • New scientific information/ new hazards (eg. from TNO, Rikilt, EFSA); • Practical experiences from companies Information must be evaluated on the necessity for taking immediate action. In some cases, immediate action is needed, for instance in case of a newly emerging risks. Other type of information, for instance scientific information, can be processed in a later stage and will be filed for planned maintenance of FSP information (annually). If new non-conformities related to food and feed safety occur there must be a short term evaluation about the consequence for feed (if it is a non-conformity from food) and the consequences for FSP. New hazards can be communicated in a short term to the feed sector. GMP+ certified companies are being informed of changes in risk assessments and/ or factsheets by means of newsletters. All newsletters can be found on the GMP+ portal www.gmpplus.org (under “in the Spotlights”).

Information

Do you want to be informed about the changes? Take a free subscription to the GMP+ newsletters: http://www2. gmpplus.org/en/newsletter.php The complete document with the FSP working principles can be found on the GMP+ portal: http://bit.ly/1sGWiIt

&FEED MILLING TECHNOLOGY

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July - August 2014 | 7

Silos Cordoba receives “Cordobeses of the Year Awards 2013”

he gardens of the Fortress of the Christian Monarchs, one of Cordoba’s major landmarks, were the scene of Thursday’s gala Cordobeses of the Year awards, with which Cordoba Journal recognizes the work of individuals and organizations that have excelled in 2013 by their social and business values. One of the winners of the 29th edition of the awards in the business category is Silos Córdoba, which has been a European leader in the manufacture of silos and aims to become a reference as an integrated solutions provider for grain handling, drying and storage.

Hard work and an optimistic view

The CEO of Silos Córdoba, Juan López Regalón, received the Cordobeses of the Year award from the manager of Córdoba Journal, Julio Hidalgo, and stressed the need for the company to continue working “for the future.” Internationalization – work that began two decades ago – research and development are the key pillars of their strategy, that will lead them to become leaders in providing global solutions for grain storage, handling and drying. In 2013 the company reached 46 million euros in turnover and currently

operates in about 35 countries worldwide. However, its CEO said that to achieve this development two pillars have been necessary. On the one hand, the work of his father, who was the founder of the company in 1975, and on the other hand, the “values” transmitted by his Mother. Juan Lopez also recognized the role of the company workers and explained that the recognition by Córdoba newspaper “should serve to motivate us.” This is the second award this year, since they also won the “Wings Award” handed to them by the Andalusian Board earlier this year to recognize their export efforts. At present, the firm specializes in the design and installation of agro-industrial facilities, manufacturing of steel silos, production of handling equipment and metal structures and coatings. Recently, they have also begun work to relocate the headquarters at Scientific Technological Park Rabanales 21.

A blog dedicated to professionals - including nutritionists - in the transportation, storage and milling of grains, feedstuffs, rice and cereals, globally. Hello Millers VIV China and VICS team up in China Livestock Industry Week 2014 An outstanding business opportunity for every professional person and enterprise engaged in China’s animal protein production is being arranged in Beijing, from 20 – 25 September 2014. http://bit.ly/1mIh0DU 18 Health benefits of whole grains Some popular diet books say you should ditch wheat or gluten to shed pounds. But the USDA recommends eating grains daily, and at least half of those should be whole grains. http://bit.ly/1sXvyEq

by Tom Blacker, directory coordinator

here has been a very exciting and fast pace of work for the International Milling Directory (IMD) this month. We have welcomed back many of our companies and increased our coverage in new Equipment Guides, the Events Guide, Products and Services and more. We are proud to be growing the directory into new fields and striving to be with the industry, ahead of the technological curve compared to a year ago. Lots can change over a year in this industry, even when it is not publicly known to the end consumer or even visible within the milling industry itself. This means that technical knowledge of the flour and feed industry becomes increasingly an expectation for more professionals to be accessing useful information about technology and the latest trends. This is one area that the new directory will satisfy, not least in the industry in a ‘smaller’ world where our shared commodities, increasingly sophisticated processes can result in the sharing of the challenges and the benefits. More engagement with the industry has led to a process building upon our success. Research work both with Rob Shorland-Ball and The Mills Archive has brought the International Milling Directory to the fore of being with the right partners. There have been more visits to the industrial sites recently too for our staff, which really has really enabled us to put our motto of 'connecting the milling industries worldwide' into practice. Otherwise, some great events are coming up now that the high-summer season has completed. Firstly, VIV China will be a very important event for us and CropTech-FeedTech will see Roger hosting another event in how digital technology in grain and feed milling is advancing all aspects of the efficient throughput of raw materials to application, product and to market. I hope you can find the International Milling Directory there at stand number: W1.G078. Please do contact me for registering, updating and changing your company or organization in the International Milling Directory. Please contact me before Friday 15th September for inclusion in the new print edition! Email: tomb@perendale.co.uk or telephone: +44 1242 267700.

international milling .com

The premier resource for the global milling industry ONLINE | PRINT | MOBILE

&FEED MILLING TECHNOLOGY

8 | July - August 2014

Alapala completes new mill for Agthia Grand Mills in Abu Dhabi

lapala announced that it h ad succe ssfully completed the erection, commissioning and handover of a new 400-tonne per 24-hour flour milling line for Grand Mills in Mina Port Zayed in Abu Dhabi Grand Mills, which is a part of the Agthia Group PJSC’s

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agri-business division, put its confidence in Alapala by awarding it the contract for the new flour milling line. The company manufacturers both flour and feed. The contract involved the dismantling of the old flour milling line and the supply, erection and commissioning of a new state-of-the-ar t automated milling line in the existing building with the minimum of civil works and damage to accommodate the new milling line. The new milling line was handed over running well within the stipulated time given by Grand Mills. This was carried out by

Perstorp acquires Chemko’s calcium formate and penta businesses

erstorp, a world leader in specialty chemicals, announces the acquisition of the penta and calcium formate businesses from Chemko AS Strážske, a Slovakian chemicals producer. The transaction is part of Perstorp’s ambitious investment plan to increase polyol and calcium formate capacity. Perstorp has signed an agreement with Chemko for the acquisition of its penta and calcium formate businesses, related technology and certain assets. It does not include the manufacturing plant in Strážske, Slovakia, any real estate or employees. The transaction is fully in line with both companies’ strategies going forward. For Perstorp, this is part of an ambitious investment plan to increase its polyol production and

NEWS IN BRIEF CPM Europe BV has relocated its offices from Amsterdam in The Netherlands to Zaandam in The Netherlands. The move took place on August 1, 2014 and the company says it is looking forward to servicing customers from its new building and facilities. www.cpmeurope.nl

a team of highly experienced super visors and erectors from Alapala. Grand Mills has benefitted by reduction of the power consumption and less operating staff. The new milling line has enabled Grand Mills to become a major milling company in the region well in line with its demand for high quality product standards. Agthia Group PJSC is listed in the Abu Dhabi Securities E xchange (ADX ) with its symbol “Agthia”, which in Arabic means nourishment. The majority shareholding is held by Senaat General Holding Corporation, an Abu Dhabi Government entity and the

presence on the calcium formate market. “Perstorp plans to satisfy all customer needs out of the plants we are running at present and we will have sufficient capacity to supply both our current and new customers. Going forward, we plan to further increase capacity to support our customers’ long-term growth”, says Ulrika Andersson, VP Business Unit Penta. Calcium formate is a source of highly digestible calcium for farm animals and it has antimicrobial properties in feed. A lowered pH-value in the feed supports the acidification of the stomach contents. Perstorp markets its feed grade calcium formate as P ro P h orce™ AC 2 0 0 . A n o t h e r application for calcium formate is as an additive that improves the qu alit ie s and proper t ie s of t ile adhesives. Meanwhile, polyalcohol Penta is used in applications such as alkyd resins, PVC stabilizers, synthetic lubricants, varnishes and other products. Perstorp is now producing Penta in three different production plants in Germany, the US and Sweden.

Fire crews fight a fire in a Highland grain drier for more than three hours. A fire service spokesman said the fire at Glackmore, North Kessock, was reported soon after 12 noon. Two appliances from Inverness (Scotland) were at the scene and crews were using a hose reel jet and two smaller jets to fight the fire. It is understood that the grain drier belongs to Highland Grain Ltd, which supplies malting barley to the whisky industry.

rest being held by institutional and individual investors. The group which has four divisions involved in the production of food, beverages and dairy products making it the largest in its sector in the UAE and one of the leading in the region. It also has assets in Egypt and Turkey and employs 2000 people overall. The performance of Alapala in carrying out this project to the total satisfaction of Grand Mills has demonstrated its advanced technology and engineering capabilities acquired over the past 60 years.

NUMBER CRUNCHING

Silos

1873 The year the f irst tower silo in America was erected on Hatch farm, one half mile east of Spring Grove, Illinois, by Fred L Hatch and his father Lewis Hatch in October of that year

30 x 48 The measurements of what is thought to be Americas largest concrete silo located in Berks County, PA, USA. With more than 90,000 cubic feet capacity it can store 3300–4500 tonnes depending upon moisture content! (Sourced from www. sollenbergsilos.com)

80.8 million the number of tonnes of wheat harvested in Canada in 2013 – so much that Canada farmers were struggling to store the harvest 2-3 tonnes: The traditional bins used by the African farmers are small with capacity of up to 2-3 tonnes and include gourds, clay pots, mud-plastered baskets raised off the ground and mud walled silos (‘rumbus’) (http://www. fao.org/docrep/s1250e/S1250E0w.htm) 14,000 In May 2005, Rome - Around 14,000 grain storage silos were distributed to farmers in nine provinces of Afghanistan, due to a FAO project funded by the Government of Germany US$2.4 million The US$2.4 million project will also rehabilitate or construct ten community storage warehouses in major grain-producing areas of Afghanistan to encourage the re-establishment of local grain markets (http://www.fao.org/NEWSROOM/ en/news/2005/102419/index.html) 100-300kg The household ‘metal silo’ can hold from 100 to 300kg for families (http://www.fao.org/fileadmin/user_upload/ ags/publications/silos_E_light.pdf)

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TRAINING

&FEED MILLING TECHNOLOGY

10 | July - August 2014

GRAIN

Reviving the role of education and training in milling by Olivia Holden, GFMT writer

rain and Feed Milling Technology is pleased to be working with nabim to revive our regular ‘training’ features (which forms the basis of today’s nabim correspondence courses) which first appeared in the magazine over 50 years ago and proved extremely popular throughout the 1960s in the UK milling industry. After receiving feedback from our subscribers, and looking at the development in flour, rice and cereals milling around the world, the consensus was that the timely revival of a regular, introductory training feature each issue would provide both a platform for the exchange of knowledge and would be of real practical use in the milling environment. In turn, the overarching aim at Grain and Feed Milling Technology magazine is to highlight to students the presence of nabim, a world leading organisation in the training and certification of mill operatives. As an organisation, nabim has three principle functions; to promote the flour milling industry’s views to the government, parliamentarians, regulators, the media and other interested bodies within the UK industry; to improve the understanding of the operational requirements of the flour mill-

ing sector and to provide information and advice to its members on a wide range of subjects affecting flour milling. Founded in 1878, nabim remains committed to the development of people within the flour and milling industry, both within the UK and around the world. The organisation remains dedicated to providing the most up-to-date education and training packages. The flour milling industry is a highly skilled and challenging industry, with training and education playing a vital role for employee development. Nigel Bennett, secretary of nabim holds the provision of training as being pertinent to nabim’s ‘aims and objectives’ describing their distance-learning programme as “the bedrock of milling training.” nabim have been at the forefront of such training for a century or more. Vital to their success is a programme that is ‘developed by millers, delivered by millers, for millers’. GFMT supports and promotes these objectives. nabim’s training programme is comprised of

seven modules covering fundamental topics from safety, health and hygiene through to mill processes and performance. The added benefit GFMT plans to bring to millers, is a introductory step to greater awareness of the importance of continuing education and training within the milling industry globally. We have very much enjoyed going back through our archives in order to take a look at the correspondence courses. Grain and Feed Milling Technology looks forward to bringing together a feature from the past for the present day reader as part of its coverage of this important topic.

Flour Milling Training Seven steps to success Safety, Health and Hygiene

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Wheat and the Screenroom Mill Processes and Performance Product Handling, Storage and Distribution Flour Power and Automation Flour Milling Management

Enrol students and you will benefit from more knowledgeable and competent millers and colleagues, with consequent improvements in performance.

To enrol or find out more, contact: nabim 21 Arlington Street London SW1A 1RN UK Tel: +44 (0)20 7493 2521 Fax: +44 (0)20 7493 6785 email: info@nabim.org.uk www.nabimtraining.com

&FEED MILLING TECHNOLOGY

GRAIN

July - August 2014 | 11

A History of Roller Flour Milling

Progress with past and present research by Rob Shorland-Ball Pesther Walzmuhle in 1851 in Budapest

by Mildred Cookson Mills Archive Trust, Reading, UK

An early view of the Millennium Mills in Dock Side, London

n March-April G&FMT (Researching and Reporting: The Roller Flour Milling Revolution- pp 14-15) I explained the research project on which, with Bryan McGee and The Mills Archive Trust [MAT], Reading, I have been working for several years. With MAT we have created an IT database of 196 roller flourmills in England including mills still working [i], mills converted to other uses like offices or apartments [ii] and sites of a former roller flour mill [iii]. Of course the story of the ‘Roller Flour Mill Revolution’ is not confined to the UK so we are extending our project a little to Hungary,and to Minneapolis in the USA, to give more context to our UK work. In October I am spending five days in Budapest exploring and photographing, the surviving roller mill sites and buildings in a city which was once the centre of European roller flour milling. Research continues in the UK too and a recent visit to Caudwell’s Mill, Rowsley, Derbyshire, reminded me what a good example survives here of an early roller flourmill owned and managed by an entrepreneurial and forward-looking millers John and Edward Caudwell. John Caudwell built the present mill on an existing corn mill site in 1874 as a water-wheel-powered stone mill. In 1885 Edward replaced the stones with roller plant and in 1887 and 1898 replaced the waterwheels with turbines. Further modernisation by Briddon and Fowler followed in 1905 and yet more by Amme, Giesecke & Konegen in 1914. In 1978 the Caudwell family concluded that the mill, still working some original machinery, was no longer a commercial proposition so, in 1980, Caudwell’s Mill Trust Ltd was formed to preserve the mill and display it to the public for education and leisure. The mill is still open today to visitors and educational groups, no longer milling flour but with the machinery still working to demonstrate the roller milling processes and a very well-stocked shop selling many varieties of flour, including some from Nelstrop’s Albion Mill, Stockport. So the roller flour milling story continues on this site. The most advanced mill opened the year GFMT magazine was launched as Milling newspaper 1891 saw Joseph Rank open in Hull the most advanced roller mill in Britain and other large port mills also switched to roller-milling. Rank, a wind miller who became a leading roller flour milling entrepreneur, developing the Rank Hovis McDougall combine. Today, the Rank name remains as Rank Hovis, the UK's leading flour miller and one of the most recognised names in the milling and baking world. Today there are just 30 or so milling companies in the UK – including several independents like Marriages of Chelmsford, E.B. Bradshaw & Sons of Driffield and Carrs Milling Industries of Carlisle and Silloth – altogether operating around 50 flourmills. Each year, the UK flour milling industry produces around five million tonnes of flour from over seven million tonnes of wheat. In the early 1970s, around 30 percent of the wheat used by UK millers was grown in the UK. Nowadays, that figure is closer to 85 percent (though 2012 was an exception because of the worst UK harvest on record).

Hovis Mill – 1898-1904 in Macclesfield, UK and now apartments

Our Roller Flour Milling Archive

Caudwell’s Mill at Rowsley, Derbyshire, UK

ou will be hearing more over the coming months about the Mills Archive Roller Flour Mill project. The project will consist of three elements.

We have already announced that we wish to build up our archive on roller flour milling and we will be looking for material to add to the collection as well as financial support to build the only dedicated national archive on this important area of our milling heritage. To support and publicise our initiative we are planning an educational programme on the full story of flour milling entitled From Quern to Computer as well as a travelling exhibition on the same theme. We have been identifying sources of material with the help of our project team which includes Rob Shorland-Ball and Bryan McGee, both experts on roller mills (the latter having worked in the area for all his life). We are also examining what The Mills Archive already has and this led me to go through my own collection. Expanding our archive to include roller milling has interested me for some time as I have a significant number of relevant books, photographs and old postcards as well as some superb old illustrated catalogues showing the machinery of Simon, Robinson, Turner, Armfield, Whitmore & Binyon etc. The illustrations show two examples of the material that will go to make up this interesting project. It has been an area neglected by traditional mill people, partly because of the complex flow charts involved and also because the mills are not as romantic to look at as a windmill or a country watermill. Many of these old roller mills have a fascinating history of their own, however. The lives of the owners, developments to the mills’ machinery, the motive power and the Victorian architecture of the buildings themselves with their characteristic tall chimneys are all areas deserving further study. Victoria Mills, Grimsby was listed Grade II in 1986. Situated in North East Lincolnshire, the current mill was designed by the Hull architect Sir W A Gelder in 1889, after the original steam driven mill was destroyed by a fire a year earlier. It was built and owned by the Marshall family who were wealthy Grimsby farmers and landowners with a milling business founded by Mr William Marshall, initially using a windmill in Chantry Lane to produce their flour. Under the management of William's sons Andrew and Charles, the Rector of Doddington, the company was one of the first mills in Britain to adapt the new system of milling using fluted chilled cast iron rollers to crush the grain. The family previously owned a site further up on the Haven, known as Haven Mill, but the opening of Alexandra Dock meant that even larger ships could now be loaded with sacks of flour direct from the mill. The relocation to the dominant site opposite Freeport Wharf with its good road access, to build a much larger, more modern mill incorporating all the latest milling technology was an astute, well-timed move leading to commercial success. The foundation stone of the present mill was laid in April 1889 by Mr John H Marshall. According to the Grimsby News of June 25, 1897, "The new machinery was first put in motion on December 26, 1889.” This was just one year after the original mill was destroyed. To be continued in the next edition …

&FEED MILLING TECHNOLOGY

12 | July - August 2014

GRAIN

by South Pacific Seeds Seed processor contains dust with bulk bag discharger and flexible screw conveyors South Pacific Seeds (SPS), ranks as one of the world’s largest vegetable seed companies. In the 2011–12 crop year the company produced 2930 tonnes of seeds from its facilities in Australia, New Zealand, Chile and the US. The seeds include lettuce, cauliflower, cabbage, kale, carrots, parsley, onions, cucumbers, beets and other vegetables. What you might ask has a seed company based in New South Wales in Australia have in common with milling? The connection is dust! Processing seeds generates atmospheric dust at the company’s Griffith treatment plant. The company has solved the problem by installing a bulk bag discharger and flexible screw conveyors manufactured by Flexicon Corp (Australia) Pty Ltd.

reviously, dust was generated at the beginning of the process where gypsum powder is combined with a glue binder to pelletise seeds for packaging and sale. The powder is extremely free-flowing, with a bulk density of 400gm/l. Bulk bags of gypsum were cut open and emptied into a V-shaped bin feeding an auger that transported the material to a rotary treater. Here, the gypsum is mixed with the seeds and pellets are formed by the rotating action. The machine also adds colour coatings, pesticides and fungicides to the seeds. SPS solved the dust problem by installing a Flexicon bulk bag discharger. Gypsum flows from the bulk bag into a floor hopper, from which the material is transported to the rotary machine by two flexible screw conveyors. The enclosed process has essentially eradicated the dust problem, says Peter Pearson, operations manager. The Griffith plant receives gypsum powder in bulk bags of approximately 350kg. Each bag is loaded by a forklift into the bulk bag discharger frame, where it is suspended by four loops, and unloaded into a 140l, V-shaped floor hopper. The bag is opened, the inner liner is cut, and the powder is discharged through an iris valve.

Bag discharge is aided by Flexicon’s Flow-Flexer™ bag agitation device — two pneumatically driven plates that raise and lower opposing edges of the bag to direct material to the outlet. As the bag empties, the stroke of the plates increases, forming the bag into a V shape and promoting total evacuation. The iris valve essentially eliminates dust, says Pearson. Nevertheless, the company also uses Flexicon’s Bag-Vac™ dust containment system, which is attached to the discharger frame and removes any residual dust. “The powder is particularly dusty and for operational health and safety considerations we automatically added this (dust collection) option,” he says. “As a result we have a clean and tidy working environment that is safe for the operator.”

Flexible screw conveyor ‘fits in’

Material is removed from the bottom of the hopper by a flexible screw conveyor. An agitator and vibrator in the bottom of the hopper help to move and direct the powder to the conveyor inlet. The flexible screw conveyor contains a rotating, stainless steel centreless screw, housed in a durable polymer tube. It measures approximately 6 m long by 80mm OD and is powered by a 2.2kW, 3-phase motor that is located just beyond the discharge

point, eliminating material contact with bearings or seals. From the hopper, the conveyor moves the material at a 45° incline to one side of the rotary treater. At that point the powder is discharged through a small transition hopper into a second, identical flexible screw conveyor that carries it horizontally to an inlet cone on the side of the rotary treater. The combination of the bulk bag discharger with the flexible screw conveyors assures that the delivery of powder to the rotary treater is consistent and uniform, says Pearson. Also, the screw conveyors solved “a big constraint, which was the amount of floor space we had to work in. The rotary machine is positioned in a tight corner and so to have a delivery system that would fit in was fantastic.” He adds that the arrangement of the conveyors provides free access for the forklift.

How seeds are processed

Seeds are received in plastic or cardboard bins of approximately 750l capacity, or in 25kg plastic bags. In the case of bins, the lids are removed and they are emptied by means of a special bin tipper. Bags are cut open. The containers are emptied into steel, wheeled V-bins that move the seeds through a series of process steps for the removal of plant material, soil, insects, stones and light, undesirable seeds. The main processes are: • Cleanup by size, using an air screen cleaner that has a series of screens for

&FEED MILLING TECHNOLOGY

GRAIN

July - August 2014 | 13

Hydronix Moisture Sensors

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Hydronix digital, microwave moisture sensors are designed and manufactured in the UK and provide accurate and cost effective moisture measurement and control in feed meals and pellets, grain, cereal and pulses.

Hydro-Probe XT

scalping and sieving • Sorting by length, using an indented cylinder that can pick up either the seed or contaminant, depending on the crop type • Separation by weight, using a gravity table. The seeds pass over an inclined, oscillating mesh deck with a fan that blows air up through the seed Other cleanup processes include colour sorting, spiral separation and washing. Following cleanup, the seeds are dried to less than seven percent moisture content in drying bins, and then delivered to the pelletiser by a V-bin.

Seeds are weighed and then discharged into the rotary treater, while gypsum powder is delivered by the flexible screw conveyors at a rate of 3.5kg/min. Following the rotary treatment, seeds are dried and graded, then packaged for sale in woven polypropylene bags, plastic pails, cans and foil packages. Seeds are sold by seed count per kilogram in packages that range from about 15kg for the bags, down to a few grams in the foil packages. The company has installed a similar Flexicon system in its New Zealand sales warehouse in Pukekohe.

The Hydro-Probe XT has been speciﬁcally designed to measure moisture in organic materials, typically being installed in or underneath silos or in the material on a conveyor. The Hydro-Mix VII is a ﬂush mounted sensor that is ideally suited to installation in mixers, augers or the inlet / outlet of grain dryers. Both sensors offer a choice of digital measurement modes enabling the producer to select the best option for the material being measured.

Hydro-Mix VII

Rotary treater produces pellets

The pelletiser mixes seeds with gypsum-based powder and a glue binder (as noted earlier), forming pellets, which are easier to plant than single seeds. The machine can also coat the seed with a film containing colourant, fertiliser, fungicide or a pesticide, says Pearson. More

information:

Flexicon Europe Ltd 182 John Wilson Business Park Harvey Drive Whitstable, Kent CT5 3RB Tel: +44 1227 374710 Email: sales@flexicon.co.uk Website: www.flexicon.co.uk Website: www.southpacificseeds.com.au

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13/01/2014 10:00:18

FEATURE FROM

Animal Feed Milling in India

Pondering on Strategic Check Points by Dr P.E. Vijay Anand, Director – India Feed/ Meal Program, US Soybean Export Council, New Delhi, India

he animal feed milling industry in India is highly diverse and ranges from simple feed mixing to hi-tech feed milling.

While the country has progressed quite a bit in terms of improving milling practices, it has a long way to go. Despite progress, wide variations on degrees of modernisation continue to exist. The industry is becoming highly aware that animal performances come in due to two main reasons – genetics and nutrition. Feed milling is thus a major factor that is directly responsible for how animals are produced and how the maximum genetic potential is extracted. Genetic improvements are therefore placing constant pressure on feed manufacturers to produce quality feeds that match increased requirements of breeds without creating additional stress or physiological disturbances. Significant progress is seen in the feed formulation technology but feed milling technology is still yet to see some focused improvements.

Five milled feeds

Feed is mainly milled for broilers, layers, shrimp, fish and dairy. Feeds for broilers and shrimp are considered to be rather mature segments in the feed milling industry as they are technologically advanced in terms of milling and formulations. Fish feeds are relatively of recent origin (since 2006). However a majority of Indian fish farming is yet to take on to using formulated feed as against traditional mash type of feed. Very little cattle feed in India is pelleted and most of it is in mash form called TMR (Total Mixed Ration). Four broad value chain pathways comprise of animal husbandry. They are raw material input system for feeds, feed milling technology, animal production by itself and marketing the produce. Of these the most developed segment in India is the animal production sector which closely matches with International standards especially in the broiler, layer and shrimp segments. Feed milling technology in relative terms need to be improved more. Feed raw material and feed milling are two steps that are found at the bottom most level in the value chain for food. The amount of care taken at these two levels will determine the quality of animal produce that ultimately is used as human food. India has produced an estimated 30.99 MMT of feed from organized feed milling processes in 2013. Commercial broilers accounted for 10 MMT, commercial layer for 11 MMT, poultry breeders used 1.74 MMT, aquaculture comprising both fish and shrimp milled 1.25 MMT. Compounded dairy feeds accounted for 7MMT (various Industry sources, CLFMA, USSEC). It is likely that India will produce 40 MMT by 2020 based on historical growth patterns examined for the past five years. As a sample assessment carried out by USSEC in the last 6 months, it was recorded that 24 feed mills came into operation carrying along an installed capacity of 1.27 MMT. Of these, 15 mills were for producing aqua feeds and rest for poultry. Interestingly an analysis carried out by USSEC in the last five years accounted for 173 new feed mills contributing to a capacity build up of 7.88 MMT. Thus the feed industry has been growing rapidly on capacity terms but it is felt that the industry needs to focus of milling efficiencies too, in order to be able to derive the most from investments. Feed milling is a vast subject as we all know. However a few

selected aspects have been picked up for the purpose of this article. These seem to be very critical points that the Indian feed milling industry should take note of. Broadly the critical points can be classified into internal and external processes effecting efficiencies of Indian mills. Foremost on the internal factor is ‘People on controls’. The mills need to have trained and knowledgeable heads/leaders on five major feed milling sectors, namely, on the formulation front, engineering, QC and inventory control, raw material procurement and the actual production. All these processes are interlinked and call for strong internal management coordination to be able to make the best of the mill. For example the head of production will be responsible on a daily basis for production output and quality of feed coming out from a plant. For this he has to depend on the engineering division that will ensure efficient functioning of each moving part and the processes that are laid down for preventive as well as corrective maintenance. Likewise housekeeping and training of manpower on the shop floor is also interlinked. He has to work in tandem with the QC/lab and the procurement and material logistics divisions to ensure a smooth flow of inputs at the prescribed quality standards. If people’s crossfunctional abilities are well in place, a major aspect in the feed milling sector is addressed. Most feed mills do not have direct control on raw material. They come from different geographies and differ in quality and quantity because, not always is a feed mill located at vantage points where raw material is produced. Agriculture by-products come from varied processes and handling techniques. Procurement of raw material is therefore a challenge and is very critical given these vagaries. Indian feed millers have to gradually move away from purchasing material based on moral guarantee. Verbal agreements and phone agreements are widely used and contracts in most cases are not honoured. A rapid change in raw material procurement style using the guagrentee methods and depending on analytical methods is urgently required. Majority of the feed mills do not have labs while the progressive ones rely on rapid analysis equipment and processes which help take quick decisions and saves money. It is very critical for every feed mill to have an analytical lab that will provide feedback on many qualitative aspects and will help carry out economic assessments. Seven internal processes are critical to Indian feed milling and these usually falter. Improving these aspects will enhance throughput of the mill and reduce wastage or save costs. The key areas are grinding, mixing, control of fines, moisture, pest control, storage techniques and the actual pelleting process. Grinding is a big cost in feed mills. Selection of equipment, a strong maintenance program and optimizing particle sizes saves costs on this section. Particle size is linked to animal performance and many reports indicate that it is correlated to digestion especially in the upper tracts of younger animals. Mixing is the next important aspect that has a bearing on the nutrient uniformity. Mixer testing procedures are often not available and not practiced. Developing a correlation between mix time and diet uniformity would be helpful. Equipment functions as we see are directly or indirectly connected to animal performance and in this case diet uniformity is critical, especially in younger animals. Most feed millers in India are convinced that pelleting is the way forward in feed manufacture and a majority have taken to this method.

&FEED MILLING TECHNOLOGY

GRAIN

It is a known fact that pelleting improves digestibility, improves palatability, thermally modifies starch and protein structures, destroys pathogens, reduces ingredient segregation and minimizes selective feeding. Quality checks become easy when feed is pelleted because 60% of the pellet quality can be determined before it reaches the pellet mill. Pellet quality depends largely on formulation (40%) and grinding (20%). It is common thinking that formulation is an aspect that is often linked with nutritional requirements of the animal and performance but least do mill managers think that it could also contribute to pellet quality. By thinking creatively beyond the present functions of a formulation, least cost or best cost formulations can be made to predict pellet quality. Charts are available on the pelleting ability of commonly available raw material and this could possibly be integrated into a formulation process. It is considered that about 20% of pellet quality depends on conditioning, 15% on die selection and 5% on cooling or drying processes. Production of fines is an economic loss for a feed mill and depends mainly on pellet quality and equipment functioning. Fines hinder pellet cooling, lead to particle segregation, pose fat coating hindrances and lead to selective feeding if given to animals. Higher the amount of fines, more the recycling efforts and cost involved. The throughput of the mill is reduced to the extent fines are recycled – say on a year’s time scale. Finally moisture control is one aspect Indian feed mills need to pay attention to. Moisture check points are present in the system beginning from raw material purchase, all the way to drying, cooling and storage of finished feed. If raw material with high moisture is procured it will result in an economic loss due to its shrinkage in the plant. If the finished product has higher moisture content especially in a tropical country like India, this could result in economic losses owing to marketing problems that may arise. Within the plant appropriate storage methods are of prime importance for Indian feed mills. Improper staking on floor or against walls prompts moisture to migrate to one region in a feed bag. Moisture thus concentrates and increases the overall levels of moisture beyond recommend limits at the particular location inside the bag and encourage mold growth.

July - August 2014 | 15

is an aspect that is largely built into the system by practice and the mills have to evolve an efficient way to manage cash flows.

The future

India’s feed industry will continue to grow because there is an increasing demand for consuming animal products. This is caused due to rising incomes and changing life styles. At the same time cost of production of animal products or feed keep increasing year after year. Feed milling technology and efficiencies have to deeply reflect into their practices, save costs and aggressively look at means to off-set rising costs from external uncontrollable factors. A lot of savings can be obtained by utilising mills better, preventing wastage and optimising each production parameter within the feed mills.

About the author:

Dr P. Emmanuel Vijay Anand is the Director for the Indian Animal Feed, Aquaculture and Soy Meal Program of the US Soybean Export Council. The focus is mainly on soybean product promotion in animal and aquaculture feeds. He also helps improve feed technologies for poultry, dairy and aquaculture, manages industry network and relationships, guides and develops new businesses, provides training for the industry. Dr Vijay has worked in farm management, feedmills, animal health care programs and feed commodity processes and marketing. Dr Vijay has been associated with the animal feed industry since 1993 and is known for his innovation, visionary abilities and working in challenging situations and cultures, both nationally and internationally. He completed is under-graduation and post-graduation in fisheries and aquaculture from the College of Fisheries, Mangalore (University of Agricultural Sciences, Hebbal, Bangalore) and his doctoral research degree (PhD) from the Cochin University of Science and Technology.

Four factors outside industry’s control

Four factors have been identified as external entities on which the feedmills may not have direct control. In order to combat increasing external costs, the mills have to be even more efficient on what they can easily control and/ or increase feed manufacturing efficiencies. Fuel is used for transport and for in-plant operations. Fuel prices have been continuously on the rise in India. There is a double impact on the feed mill through trucks which carry in bulk of the raw material into the plant and finished products out of the plant. Most large plants work on a backup power generation for which diesel is used. Between 2009-13 diesel cost has increased by 85 percent (from INR 35 to INR 64). The other external cost is electricity and this is directly linked with plant machinery operations. For industrial purposes, the power tariff increased from INR 4.16/KWh to INR 4.97/KWh between 2007-08 and 2011-12 which is about 20 percent increase. The third cost affecting feed milling operations will be raw material prices. About 80 percent of operational finances in feed milling operations go for raw material. In volume terms this forms a majority. So when cost and volume together influence this input system, it is of utmost importance to mange this aspect efficiently. Any increasing cost on raw material calls for a focused attentions and planning. Maize in 2010 increased from INR 7683/MT to INR 13,554/ MT while soymeal in 2010 increased from INR 17503/MT to INR 30,891 in 2013 (76 percent increase on both feed commodities). The fourth factor that most feedmills encounter is cash flow. Unfortunately, they are caught between operational investments on incoming raw material and cash flow blockage on slow revenue returns on finished feed on the market front. This

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&FEED MILLING TECHNOLOGY

16 | July - August 2014

GRAIN

STORAGE

catastrophe storage bins by Daniel Wambeke, VP of sales and engineering SCAFCO Grain Systems, Spokane WA, US

CAFCO Grain Systems’ Vice President Mr Dan Wambeke attended the 118th IAOM annual conference and Expo in May where he gave a talk about ways to avoid catastrophe with storage bins and silo maintenance and repair.

uild it right don’t take any short cuts. Good house keeping is important. Avoid steel modification. Silos have a limited life, once they reach the end of their life consider replacing them. Train people who operate bins and silos in their use. One of the big pitfalls with steel bins is that they can be damaged if they are not unloaded correctly. Mr Wambeke then continued addressing the issue of safety. “Be safe on the plant. I have seen a 60ft diameter by 100ft silo unloaded incorrectly and it caused a huge impact on company. It happened about 12 years ago on Snake River.” Grain storage systems are a lot safer than they used to be and grain storage bins can be built to resist earthquakes. Four years ago a lot of bins in Chile were not designed to resist earthquakes and the result was most collapsed. In Columbia they now have bins that have been standing there for two or three years some for around 15 years. The causes of typical grain storage failure are the age of the bin and silo. One of the leading insurers in the grain storage industry says steel silos built before 1995 had a life expectancy of 25 years. After 1995 the design got better with a life expectancy of about 30 years. Bins in Washington State are still operating and they were constructed in the late 1960’s and early 1970’s. However, they are primarily used for country elevators and are only filled and emptied once or twice a year. This is unlike your typical situation advises Mr Wambeke. In order to look after your silo, you should avoid eccentric unloading at all costs. If there are openings in the side of the bin or silo make sure they are designed properly. Negative effects from rapid draw down or by operating negative aeration systems on steel bands causes corrosion around the base. Also, air temperature affects deterioration of concrete silos. People often think that the solution is to wrap cable around them however, Mr Wambeke advised this does no good. Equipment also has an effect on bins. A lot of bins were built back when typical filling and discharge rates were five or six thousand bushels an hour. Now 40,000 bushels an hour are discharged and some old bins are not really prepared for that. Foundation settlements are a real culprit, particularly for concrete silos. Mr Wambeke pointed out that people tend to think that concrete silos are indestructible but concrete silos built before 1977 typically only have one row of circufriental re bar designed to resist tension in walls. When you eccentrically discharge a silo you create bending moments in the wall. This makes the silo go egg shaped and these concrete silos are not prepared for that. Mr Wambeke moved on to discuss the US law code AC313 97. This specifies that if there is any reason for eccentric discharge the silo should have two layers or rebar in the walls.

“It is a lot more difficult to tie the steel and put it in place. If we want silos to last we need to do that. Every steel bin sold by North American companies will have a standard warning against eccentric discharge on the door of the bin and on the roof. The correct way of discharge is through the centre of the bin. The incorrect way is to open one of the side gates and discharge through the sidewall. This creates draw down forces on the wall that the bin is not designed for, making the bin go egg shaped. The result could be catastrophic.” Mr Wambeke provided an example of such an incident to illustrate this point. “There was one eighty thousand viscule bin in a cluster of four. The bin was eccentrically discharged. The plant called the bin company and asked what to do as the bin looked like it was going to fall down. Despite the fact the bin company recommended that they should stop, they continued to unload it. The bin then landed on the ground and it took out the elevator legs and three bins putting the plant out of business for months. Hence, rules are especially in place for steel bins only to be discharged from the centre. If you discharge in another way you cause moments in the wall and draw down forces on parts of the wall.” Mr Wambeke relayed experiences of several bin failures in Washington State and North Idaho. They were not total collapses but a lot of them he stated had something to do with tampering of the original construction of the bin by adding or subtracting latches. Furthermore, managing grain in the storage pays off if you want to maintain the quality of the grain when you put it in. In the northern part of the US most of the wheat you get comes in good condition. It is cool and does not have a big insect infestation. But if you do no not use it very quickly you want to avoid grain deterioration. Once you put it in the bin its never going to get better than it was, but it could get worse. The talk then addressed avoiding uncontrollable insect activity. Controlling insect activity with chemicals and with a good aeration system are normally the best solutions. Equally, paying close attention to the way in which you operate the aeration system is important. It can reduce shrinkage in the grain that you store and reduce weight quality losses. It can also avoid damage to the grain by filling in discharge equipment. On the topic of silo maintenance and repair, Mr Wambeke addressed the use of equipment and tools that can be used in order to maintain grain quality, for example, the proper use of an aeration system. A grain temperature monitoring system is a management tool available to help you know when to aerate and how long to aerate. It can help to detect any unusual activity in the bin like mould growth or unusual insect activity. There are moisture detection systems that come with temperature cables. With these moisture cables positioned in the centre of your bin, you can have a read out sent to your computer. There are insect detection systems also. By using traps inside the bin, any unusual activity is reported back to the computer. Carbon dioxide monitoring inside the bin is a tool that can be used to detect grain deterioration. Staff must be properly trained when it comes to the use of the aeration system advises Mr Wambeke.

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“One of the things that must be kept in mind is what your plant is doing with regards to average temperature, relative humidity, and grain quality.” Mr Wambeke relayed a story about when he was at a crushing plant in Bangladesh. They had Soy Beans in the bin. The people at the plant asked why their Soy Beans were always 3 degrees centigrade. His advice to them was that you should operate your fans in the evening and early in the morning but not in the middle of the day as they had been doing. In tropical climates there is a window from 5 pm to 8pm and maybe from 5am to 8am where conditions are good for cooling without pumping excess humidity into the bin. Mr Wambeke then moved on to discuss corrosion on steel bins. Corrosion usually occurs around the base of the bin if you do not have a good seal. If it is not sealed effectively to stop water from getting in, water gets under the lip of the bin and it comes in contact with the grain. The grain then spoils, mould grows and live acid is produced. Acid attacks the coating of the bin wall and the coating literally disappears in days. This can even corrode the bottom of the stiffeners enough to make the stiffeners buckle. The final topic addressed was that of concrete silos. “Internal Cracks in the walls often happen with concrete silos but it is not a big deal if the cracks are vertical. If cracks are horizontal they are often small and chipping out around the crack and boxing it in should repair them. If it occurs in the outside of the bin it is going to allow water to get in to corrode the reinforcement bar. The bar will pop out so those should be repaired.” At GEAPS there was a program by a structural engineer. He stated that a lot of problems with silos are that people look around the top of the wall connection and either it was improperly designed or the reinforcing steel wasn’t detailed or was not installed the way it should be. A crack develops and the hopper tries to pull away from the wall. However, this is something that can be checked. The advice given was to: “look for any cracks in the junction of a wall knob or - it could be indicative of a future problem. Don’t be cutting openings in a wall just because it is

convenient. These concrete silos were equipped with side caps so they could load by metric and load trains and they cut some pretty big openings in the side of the silos.” When you side-tap a concrete silo you change the forces of the silo walls. You have more drawdown forces on one side than the other and this could lead to problems like the collapse of the silo that was unloaded improperly. It is potentially acceptable on the smaller, older ones. It will work however, it is not advised by Mr Wambeke unless side draw flumes are inside the steel bin. If you have a square silo - a rectangular silo with lots of bins in it watch for cracks, this is indicative of the rewire not being placed properly round the corner. This can be repaired by drilling in there and putting in bolts which will pull the wall back tight, sealing it so no water gets in. If you see on the inside of the silo cracks in the junctions at the interstices or the corners, this is caused by stress in the wall or caused by settlement of foundation. If you know the significant settlement of the foundation, particularly in these multiple bins, then you need to call in a professional to determine where the settlement is and what you might do about it. You can pump concrete under the structure to bring it back up and stop this cracking from happening. Often this is all from grain leaking from one bin to another. When a bin breaks out people think the easiest thing to do is wrap some cable around it but that will put workmen in danger. Put cables round bin a couple of hours later you come back and the cables are loose. The best thing to do is to just unload your bin slowly. Consult a professional either at a bin manufacturer or a consulting engineer about what you might do. If the bin is full, as soon as you can, get the cone down. You will then relieve a lot of stress from the bin. Then you should not load it full born until you have a bin about half unloaded because dynamic forces could cause this opening to get bigger and grain to come falling out. One consultant said ‘if as little as 15 bushels is taken out of a steel bin in an eccentric manner it could case a structural failure. Luckily the stiffeners held it together’. ■

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20 | July - August 2014

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GRAIN

FEATURE FROM

Treatment of grains through conservation cooling by Pari Mamallan, Dr Claus M Braunbeck and Ralph E Kolb

onservation cooling technology is a process of treating the grain on its optimal natural temperature (usually below +13°C) irrespective of any ambient weather conditions, in order to avoid loss results from respirations, insect activity and mildew growth.

The process:

The fan of the GRANIFRIGOR™ grain cooler draws in the ambient air (Fig. 1). This air is cooled by an air conditioner to the desired temperature and is thereby dehumidified. Moisture is extracted. The downstream HYGROTHERM™ unit heats up the cold, moist air. This lowers the relative humidity. Since the HYGROTHERM™ heating unit uses energy from the refrigeration circuit; it involves no further energy costs. The air cooled and dried is pushed through a hose in the ventilation system of the storage facility and is forced through the grain. This process can be employed in a warehouse or in a silo. The outgoing air is led outside via vents, extracting absorbed heat and moisture from the grain. The process is continued until all grain is cooled to the desired temperature level. The storage period timer in Figure 2 shows the estimated good storage time for grain according to its temperature and moisture content. The safe storage time for any particular condition of grain can be read quite simply by matching the grain’s moisture content against its actual temperature. The section of the line on the vertical axis of the storage period gives the possible storage time of the grain. For example, the possible storage multiplies times five (position a to b) for a grain of 14.5 % moisture content if the grain’s temperature drops from 24 °C to 10 °C. However, the gained storage periods of the timer are only approximate values. Grain is a poor conductor of heat. The high temperature of the harvested grain and the heat generated by cellular respiration are poorly dissipated to the outside. This problem is exacerbated by the fact that the air between the grains provides additional insulation. The cavities in a grain mass make up approximately 40 percent of the volume. In addition, the kernels touch one another only at single spots, providing a small area only for heat conduction (Fig.3). This is why bulk keeps its temperature for such a long time. Grain remains cold if it is cooled once that means re-cooling is only necessary for many months even at tropic conditions.

Energy consumption for cooling conservation

The energy consumption of cooling conservation depends on the ambient temperature, the relative humidity of the ambient air, and the moisture content and temperature of the grain. Furthermore the temperature of the cooled grain determines how long the grain cooler is required to operate and therefore how much power it consumes. (Fig.4).

Figure 1: process principle of the grain cooling conservation

Figure 2: Storage period timer for grain

Influence of the cooling conservation on the storage stability of grain Respiration Grain continues to live after being harvested. Losses in freshly harvested grain are primarily caused by its cellular respiration and its heating. The rate of this process is dependent on the grain’s moisture content and temperature. Respiration becomes more inten-

Figure 3: Porsity and contact between the grains and bulk

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GRAIN

Figure 4: Empirical values for energy consumption for one cooling process of grain in the tropics Cooling (K) 20(eg. From 35°C to 15°C) Region

Asia

Climate Zone Tropics Electricity consumption in (KWh/t) 6-12

sive as the temperature and moisture increase. The consequences of heating are loss of substance and increased risk of insects and mildew. A grain cooler avoids the disadvantages of the post-harvest period of the grain. In cellular respiration, oxygen is absorbed and carbohydrates are then converted into carbon dioxide, water and heat. The result is a loss of substance. The grain respiration molecular formula of the chemical process: Animals in the storage facility According to the Food and Agriculture Organization of the United Nations (FAO), approximately 15 percent of harvest crops spoil worldwide.

July - August 2014 | 21

According to the FAO, the loss is caused by the following:  80% due to insects  10% due to rodents and birds  10 % due to fungi Insects and mites Various types of insects are encountered in a grain storage facility. All have in common that their activity depends on the temperature. Figure 6, shows some species of the most common insects in humid tropical areas and their optimal life and development conditions. If insects find optimal temperature and humidity conditions, losses will occur due to feeding and excrement. Insects and mites multiply explosively under favorable conditions. At locations where the insects attack, the respiration of the grain increases and hot spots develop. In addition, there is the metabolic activity of the pests themselves, which further promotes heat and humidity. This creates more favorable conditions for mold and, at very high levels of humidity, even bacterial growth. Losses through insects can be effectively prevented by cooling the harvested crop to temperatures below 15 °C, at which insects become inactive.

Figure 5: Shows the grain heat generation depends on the grain’s temperature and moisture content. In practice, this can be used to determine the substance loss of the stored grain.

Fungi mycotoxin Microorganisms such as fungi and bacteria adhere to the surface of the grain kernel. The development of fungi depends on the temperature, humidity and the grain’s moisture content (Fig. 7). This development is prevented in the storage facility by drying and GRANIFRIGOR™ grain cooling. Mycotoxins can be formed by fungi. Mycotoxins

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22 | July - August 2014

GRAIN

Figure 6: Development of relevant insect dependent on temperature

Grain cooling

GRANIFRIGOR

™

The most natural way of grain preservation:

• Protection against insects and microbes • Without chemical treatment • Short amortisation period • Low energy costs • Independent of ambient weather conditions

Figure 7: Development of various microorganisms as a function of relative humidity, temperature and the grain’s moisture content have a toxic effect on humans and animals. Most mycotoxins are heat-stable and very resistant. During processing they are typically neither broken down chemically nor rendered harmless. For this reason, the formation of toxins must be prevented by preventing harmful fungi.

Summary

GRANIFRIGOR™ grain cooling of wheat, maize, millet, paddy, oats, rapeseed, oilseed, soybeans, peas, nuts, pallets, cacao, beans are worldwide proven, natural process for quality assurance of grains of all kinds. In warm and humid climates, there is virtually no alternative. Cooling conservation is important worldwide. Good storage maintenance and care, as well as good air distribution in the storage facility are all necessary. The temperature of the grain is checked regularly to monitor the process. GRANIFRIGORTM cooling conservation offers a number of benefits which reduce loss, lower cost and simplifies storage management thereby increasing the revenue and thus the market strength of grain granaries and processors. ■ FrigorTec GmbH • Hummelau 1 • 88279 Amtzell/Germany Phone: +49 7520/91482-0 • Fax: +49 7520/91482-22 • E-Mail: info@frigortec.de w w w. f r i g o r t e c . c o m

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24 | July - August 2014

GRAIN

Mycotoxins How to analyse and reduce the hazard to humans and animals

ycotoxins are a major hazard to humans and animals, often being found in a wide range of food and feed samples and causing cancer as a result of ingestion of contaminated commodities. To reduce the risk, there is the need to control mycotoxins in certain types of susceptible cereals and foods. Mycotoxin analysis through the use of immunoaffinity column clean-up prior to HPLC is the worldwide method of choice. These methods have been validated by inter-laboratory studies, in many cases using immunoaffinity columns supplied by R-Biopharm Rh么ne Ltd. They have been shown to improve analysis, enable laboratories to meet legislation and to ensure a safe and wholesome food supply.

Mycotoxins in general

As human life expectancy contuinues to rise, this results in more disease and the discovery of different types of cancer. In many cases, naturally occuring constituents have been found to be the source of the disease. Mycotoxins have not only been shown to cause cancer, but also nephritis, hepatic diseases, various hemorrhagic syndromes, and immune and neurological disorders. Mycotoxins are toxic secondary metabolites produced by moulds on food and feed products. Currently, at least 200 species have been identified and have been shown to produce more than 100 different mycotoxins.

The most common and toxic mycotoxins are aflatoxins, ochratoxin, zearalenone, deoxynivalenol, fumonisins, citrinin, patulin, T-2 and HT-2, which are produced by Aspergillus, Fusarium and Penicillium strains. Different mycotoxins can be produced by the same fungus. Hence different mycotoxins can appear in one commodity. Aflatoxins are produced by the Aspergillus strain, which is found in tropical regions and affects various nuts, maize, dried fruits and spices. Ochratoxin is found in cold temperatures but affects similiar commodities to aflatoxins and can be produced by Aspergillus and Penicillium strains. Zearalenone, deoxynivalenol, fumonisins, citrinin, T-2 and HT-2 are Fusarium toxins and mostly appear in cereals. Whereas patulin is limited to be found on soft fruits, fruit juices and pur茅es. Moulds can infect agricultural crops during crop growth, harvest, storage or processing. The growth of the mould is not necessarily related to the formation of mycotoxins and the stability of the toxin means that they may be present in food when the fungi are no longer present. Mycotoxins are produced depending on the conditions such as humidity, moisture, temperature and rainfall. Another route can be during harvest or transportation by using the same equipment or trucks to handle or transport different food and feed commodities, such as crops, fruits and spices. Only one of those commodities needs to be infected and the spread of mycotoxins

is in progress. Mycotoxins can easily pass along the foodchain when animals are fed with contaminated feed. Studies show that cows which are infected with aflatoxin (B1, B2, G1 and G2) through their feedstuff produce milk which is contaminated with aflatoxin M1. The presence of mycotoxins in the food chain is a major concern and therefore needs to be controlled. There is a growing awareness of the potential hazards of these substances, which can cause severe toxic effects at relatively low levels in food and feed. They can also cause illness and even death in humans and other mammals.

Legal basis for food control

Many countries around the world have prescribed methods of food analysis, where the legal basis for food control is that all laboratories should use exactly the same method. In China there are published official GB methods and these cross reference the relevant international standards, such as International Standards Organisation (ISO) methods from which they are often based. Official methods have invariably been tested by an inter-laboratory validation study to demonstrate that different laboratories using different equipment can achieve comparable results when analysing the same samples. These inter-laboratory studies are based on the results from a minimum of eight different laboratories and establish the method performance in terms of the recovery,

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GRAIN

precision and limits of detection and quantification. These parameters are known as the method performance characteristics, and indicate the performance that any laboratory can expect to achieve when closely following the method. The most widely known Official Methods are those of AOAC International, ISO, and the European Committee for Standardisation (CEN) standards. Organisations such as AOAC International and CEN have a policy that methods are written without reference to specific consumables or other products, as these organisations do not wish to give the appearance of endorsing specific companies. There are currently some 13 different CEN standards covering aflatoxin B1, aflatoxin M1, ochratoxin A, zearalenone, fumonisins and patulin in a wide variety of foods (http://standards.cen.eu/). Of these official standards, eight methods employ immunoaffinity columns for extraction and clean-up prior to analysis by HPLC. Immunoaffinity column HPLC official methods have been published covering cereals and cereal products, nuts and nut products, dried fruit, wine, beer, baby food and infant formula. The attraction of this approach is that irrespective of the matrix, because of the high degree of specificity of the extraction and clean-up, comparable method performance can be achieved for almost any food or animal feed. The immunoaffinity columns work particularly well for

July - August 2014 | 25

pigmented matrices such as spices or otherwise complex matrices where background co-extractives need to be removed.

Immunoaffinity column

Although the specific brand of immunoaffinity column is not specified in the CEN standard, the minimum performance of the column is given in terms of the column capacity and the recovery when mycotoxin standards are applied in solution to the immunoaffinity column. All of the immunoaffinity columns supplied by R-Biopharm Rhône Ltd such as AFLAPREP®, OCHRAPREP®, EASI-EXTRACT® ZEARALENONE and FUMONIPREP® exceed these minimum requirements, and columns are supplied with certificates indicating their performance. The majority of the inter-laboratory validation studies from which CEN standards were generated used R-Biopharm Rhône Ltd immunoaffinity columns, which were supplied to participants who took part in the studies. The demand for further immunoaffinity clean-up columns grows continuously. Due to the fact that more than one fungus can infect the same commodity and certain fungal strains are able to produce more than one type of mycotoxin, modern immunoaffinity columns must be capable of detecting and quantifying more than one mycotoxin in a single run. The product range of R-Biopharm Rhône Ltd also includes multi-toxin immunoaffin-

ity columns such as AFLAOCHRA PREP®, which allows detection of total aflatoxin as well as ochratoxin A; AOF MS-PREP®, detects aflatoxins, ochratoxin A and fumonisins; AO ZON PREP® detects total aflatoxins, ochratoxin A and zearalenone; DZT MS-PREP® detects zearalenone, deoxynivalenol, T-2 and HT-2. Although there are a number of different manufacturers of immunoaffinity columns for mycotoxins, it must be recognised that these products are biologically-based and each company uses different antibodies from different sources. Thus, antibodies exhibit natural biological variability, and therefore behave differently. This means that immunoaffinity columns from different manufacturers do not perform identically nor are they of equivalent quality. Users should therefore be aware of purchasing columns using price as a primary indicator, as cheaper poorly performing columns can have an adverse effect on method performance and can consequently damage a laboratory’s reputation. R-Biopharm Rhône Ltd immunoaffinity columns are manufactured to ISO 9001 and the company employs an ISO 13485 quality management system. R-Biopharm Rhône Ltd products are widely used by ISO 17025 accredited laboratories in Europe and elsewhere, and are widely recognised as being reliable products of a consistently high quality.

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Analytical Solutions to check Mycotoxins in Food and Feed • RIDASCREEN®

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Reference material and standards for quality control

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26 | July - August 2014

NIR Multi Online Technology: Real-time analysis for early detection of grain quality fluctuations by Thomas Ziolko, Product Manager, Grain Milling, Bühler AG in Uzwil, Switzerland

n the grain processing industry, fluctuations in the quality of the raw materials are a given. The earlier the fluctuations are determined, the better the chances are that adjustments and the associated costs, can be kept low. It also guarantees production of end products with consistent quality. To assure this, real-time measuring at different points along the entire process is needed. Groupe Minoteries SA is counting on the timely process control based on Multi-NIR by Bühler AG. NIR spectrometry has been in use in the grain processing industry to monitor quality for many years. More and more companies are using the advantages of this technology, in the lab as well as online, for controlling their ongoing production.

Continuous measurement

The true strengths of NIR really become evident when used in its online version: The grain processing industry primarily takes advantage of the real-time process optimisations it can make using it. NIR continuously monitors the product quality, allowing to immediately make an adjustment if necessary, which directly contributes to the mill's profitability. To ensure that the quality requirements for the end product are met, for example, safety margins for protein, moisture or ash are calculated in. The NIR Multi Online Analyzer from Bühler also provides the possibility to constantly optimise these safety margins with support from the control functions and thus respond more quickly to fluctuations in production. With the simultaneous reduction of random sampling and laboratory analysis, costs can be additionally lowered.

Dilemma solved

In addition to classic referencing methods, NIR lab equipment is used also for quality control in the laboratory at the Bruggmühle Goldach AG, which belongs to Groupe Minoteries SA. Daniel Götz, production manager at Bruggmühle Goldach AG,

GRAIN

was searching for technical solutions for making process adjustments that would allow him to intervene in the event of a deviation at the moment it occurred – without any delay due to time-consuming lab analyses. "A visual control of the Pekar slab sample has been insufficient for meeting Q-requirements for a long time, but it was the only means to determine deviations at the moment of occurrence and to correct them." Bruggmühle Goldach AG found a way out of their dilemma with the NIR Multi Online Analyser MYRG for online analysis of grain, flour and semolina. The newest generation of Bühler NIR uses a spectrometer that rates up to six different measuring points at the same time. The advantage is obvious: the central spectrometer makes it possible to perform real-time analyses of the raw material and end product at up to six different measuring points, supplying the basis for smart regulation of the ongoing production.

Dream fulfilled

For Daniel Götz, the possibility of directly analyzing the mineral content with high accuracy while in production has become more and more a sort of 'dream fulfilled' in view of the increasingly restrictive specification requirements. After a six-month trial period, his original skepticism towards applying NIR online has completely disappeared. "Over just a short period, we collected enough data and experience to eliminate all doubt that this is an NIR which surpasses all other known devices up to now in terms of accuracy of the measurement data. “Since then, we have been able to undertake adjustments multiple times while grinding – adjustments which have been proven to be correct in the lab two days later. With this NIR it is actually possible to produce flour from the mill that is completely accurate in terms of the specifications for mineral content. “It represents an enormous simplification further on down the line." The NIR Multi Online Analyser at the Bruggmühle Goldach AG works with three measuring points; two sensors on the flour and one on the whole grain. "When we determined the measuring positions, we purposely looked to place them as much at the beginning of the process as possible," explains Daniel Götz. "We don't want to use the NIR to measure the final quality. The earlier in the process we analyse the contents, the more varied possibilities we have to influence our product quality. “In the end, we want to not only increase the quality, but also in conjunction with that, profitability,” he adds.

www.gencdegirmen.com.tr

28 | July - August 2014

FEED FOCUS

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PIGS Added value of early-warning systems (EWS) by Johan den Hartog, Managing Director GMP+ International

ost of the feed and food safety assurance systems are focused on prevention of contamination of feed and food materials with undesirable substances or microbiological agents. A certification scheme has three main components: the normative references, the assurance and corrective action tools, and the rules of certification. The normative references determine what is considered as a safe product for consumption, or what is sustainable or responsible related to environment or society. The rules of certification are about the certification process of companies obtaining for a certificate against the involved certification scheme, which the certification bodies have to apply and comply with. The assurance & corrective action tools are the instruments and procedures, which the company obtaining a certificate have to apply in the daily business operations. The assurance tools are focused on preventive actions and measurements in order to avoid the occurrence of contamination. A starting point for the control of potential risk is the application of prerequisite programs in order to create a basic level of control. The Hazard Analysis Critical Control Points (HACCP) approach is important to identify in advance the remaining risks in the process and operations and to determine appropriate control measures, as well as a monitoring plan. A risk could be the purchased / supplied ingredients. For feed or food safety, a full control of the supply chain can be an option, like followed in the GMP+ Feed Safety Assurance certification. In case of product responsibility other supply chain models (material accounting system) can be applied, like book and claim, mass balance and segregated system. Application of a quality management system makes it possible to ensure control measures and monitoring plan in the daily operations in a consistent way. Besides the preventive measures, also corrective actions need to be applied for the case of the occurrence of contamination. It is about traceability, recall procedures and early warning. The aim is to reduce the distribution of contaminated lot(s) of feed or food material in the market or withdraw it. EWS applied within the GMP+ Feed Safety Assurance (FSA) certification operates as follows. If a certified company determines a level of undesirable substance(s) exceeding the maximum permitted level, it is obliged – besides taking the appropriate control and corrective measurements and informing its customers – to notify the scheme manager GMP+ International as well as the involved certification body.

The primary focus of the certification body is to monitor the application of the appropriate actions and measurements by the involved feed company. The primary focus of GMP+ International is to alert the other GMP+ FSA participants about the occurrence of a concrete contamination event in the market, if the contaminated lots are delivered by supply chain partner(s), or the contaminated lots are or can be delivered to other companies in the market. In that case, GMP+ International informs all other GMP+ FSA participants about the involved product (generic name), the kind of undesirable substance(s), the detected level(s), and the country of origin. When other GMP+ FSA participants are also buying or dealing with the reported product from the mentioned origin, they can take the right measures, like sampling and analysing or asking guarantees of his supplier. In 2013, GMP+ International published 29 EWS messages, in 2014 until end July already totally 25. Sometimes more than one EWS message has been related to the same case. It was about Aflatoxin B1 in maize and copra, lead in deer meal, dioxins in pre-mixture and dried beet pulp, peas, maize and soybean extractions, non-dioxin liked PCB’s in fatty acids, dioxin liked PCB’s in apple pulp, chloramphenicol in pre-mixtures and vitamins, ergot in triticale, wheat and rye, ethyl-esters in fish oil, DON and ZEA in maize and maize gluten feed, ambrosia in maize, hydrogen cyanide in linseed, biogenic amines in fish meal, etc. Only a limited number was related to a more or less serious feed safety emergency. Most of the reported issues were controlled in an early stage. GMP+ International always tries to find out the source and cause of contamination, because that could be relevant for the risk assessments and could contribute to avoid occurrence in the future. The GMP+ FSA certified companies observe these EWS messages as worthwhile, because it increases their alertness regarding specific risks. It add also value in comparison of the Rapid Alerts System Feed & Food (RASFF) of the European Union, due to more details and sometimes quicker publication. Of course, the functioning of EWS depends on the willingness of companies to notify a perceived contamination. The increasing number of EWS notifications is a signal of increasing awareness of the common interest of EWS notification. Recently, GMP+ International tightened the obligation to notify contaminations by classifying nonconformity with this obligation as ‘critical nonconformity’. My final conclusion is that EWS is a worthwhile measurement in addition to all kind of preventive actions. It contributes to reduce the spread out of contaminated material in the market and therefor, it contributes to reduce the size of a feed safety emergency.

&FEED MILLING TECHNOLOGY

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July - August 2014 | 29

Paul Phillips gets back £6 for every £1 spent on Digest-it ®

Digest-it treatment boosts slurry value Increasing the fertiliser value of slurry from the pig-finishing unit on Brian and Paul Phillips’s 670 acre Bridge Farm, Northallerton, is showing good results part-way through a 12 month trial period. They have been treating the slurry in the under-floor storage tanks of their slatted pig-finishing houses with Digest-it®, a live culture of aerobic bacteria. So far, before and after treatment analysis has shown a 6:1 return on the investment in Digest-it in terms of artificial fertiliser replacement value. Bridge Farm is a mixed enterprise growing cereals, fattening beef cattle and lambs, and running a 200 sow unit with progeny taken through to finish in slatted finishing units. Introduction of NVZ regulations in 2002 raised awareness of the fertiliser potential of the pig manure, and careful consideration of crop nutrient requirements has increased the earning potential of the pig enterprise. The aerobic bacteria in Digest-it break down slurry solids, releasing the potash and phosphate and converting ammonia nitrogen into organic, plant-available nitrogen. Because increased aerobic microbial activity in the store reduces the levels of the putrefying toxic anaerobic bugs, slurry is converted from a smelly waste to a valuable source of nutrients that support soil fertility and health, and reduces ammonia and smell emissions. The results of the first 4 months’ treatment are shown below.

EXCELLENCE IN YEAST – EXCELLENT IN FEED

Conclusion

Ge any • Made in

erm

G in

ermany • M a

296

PreTreated

PostTreated

Total Nitrogen %

0.600

0.836

+39%

Total Phosphate %

0.125

0.054

-57%

Total Potash %

0.404

0.688

+70%

Slurry Fertiliser Value £/m3

5.87

8.53

+45%

Net Benefit

in G

244

Sample ID:

Digest-it Input Cost £/m

e ad

acts prebiotic for immunity & resistance optimizes digestion processes

Difference

Sample No.:

in G e r m a n y• M

07/06/12

REAL BREWERS‘ YEAST

ad e •M

03/02/12

M ade i n G e rm y • an an

Biolex® MB40

PIG SLURRY ANALYSIS Analysis date:

Digest-it treated slurry has improved the fertiliser value by £2.30 per m3 at an input cost of £0.36 per m3. This represents a cost effective ratio of 6.4:1. Slurry is removed from the under-slat storage tanks twice a year: in February, when it is injected into silage ground, and again in the summer onto stubble turnip fields. In the past, stirring the slurry has had the potential to cause problems with the pigs housed above it, due to the release of ammonia and other noxious gases. Smell has also been a problem when application to land near housing has been necessary. Digest-it reduces smell significantly, and also helps to keep the slurry in a homogenous liquid state, reducing or eliminating the need for agitation, and making injection easier. Digest-it is supplied as a liquid which Paul dilutes and pours into the slats from a watering-can once a week. “So far the analysis has shown a really worthwhile improvement,” says Paul, “and with fertiliser costs increasing, every little helps.

---

0.36

---

+5.87

+8.17

+2.30 (+48%)

*Slurry Fertiliser Value is based on the following fertiliser unit prices, Nitrogen - £0.96, Phosphate - £0.70, Potash - £0.70. Digest-it is priced at £8.00 per litre, with an application rate of 1 litre per 22m3 of slurry.

11.–14. November Hall 14

Leiber GmbH Hafenstraße 24 49565 Bramsche Germany Tel. +49 (0)5461 9303-0 Fax +49 (0)5461 9303-29 www.leibergmbh.de info@leibergmbh.de

Stand F28

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PIGS

The added value of British pig genetics and feed converstion by Dr Rex Walters, International Genetics Consultant

he British pig industry is small in sow numbers but large in global terms due to the widespread export and influence of UK pig genetics. Furthermore, there are several essential features of the industry: • Specialised and highly professional • Market-focused • Quality driven with the highest standards of welfare and safety • Integrated quality assurance • Whole supply chain starting with advanced genetics. Much of the excellent performance of UK pigs comes from the genetic potential supplied with the advanced genetics. British breeders are proud of their achievements in continuing to maintain high levels of genetic progress with very little evidence of any ‘plateau’ effect. A recent publication reported that the achieved commercial value of this genetic progress in the UK was US$19.5 million per year, while current forecasts suggest that future progress could be worth US$30 million per year. Among the main techniques employed by British geneticists and breeders to achieve these high levels of genetic progress have been: • 40 years of focussed within line selection • Initially emphasis on growth and carcase • Now increasing emphasis on reproductive performance • Maximising hybrid vigour • Different sire and dam line selection objectives • Accurate performance testing • Advanced Best Linear Unbiased Prediction (BLUP) • Sophisticated selection indices • Intensive selection on commercial rations • Rapid uptake of new technologies, including biotechnology

Excellent genetic progress

The results of this strategy have been excellent genetic progress across a range of important economic traits. As a direct result, the British pig is proving itself consistently superior in the international market place in independent comparisons. Recent examples of international success are outlined below:

Added value

One of the main tools used in the successful superior breeding of British pigs has been the use of advanced BLUP, combining trait EBV’s into sophisticated selection indices. These indices utilise genetic parameters, population data and industry economic values. The latter are very important as they allow the optimum ranking and weighting of traits. Brief details on the values are shown in Appendix 1. They are: Value of 0.1 FCR = US$1.73 Value of growth (1 day) = US$0.426 Value of 1 mm P2 Backfat = US$1.84 Value of one extra pig = US$51.59 Figure 1: Sow performance – Litters and weaned performance (international review) Litters/sow

Weaned/ lifetime

Britain

5.4

52.8

Netherlands

4.6

39.3

France

4.2

37.6

4.2

36.8

Growth

(Source: Gill) Figure 2: Grower/finisher performance - Terminal sire trials in Germany. Trials in Saxony compared four terminal sire genotypes (British, German Landrace, German Large White and German Pietrain) on a ‘Field’ performance test Age

Fat▪

Weight Growth

Averaged across all the presented results, the added value of British sows is US$214 per year. With annual production of 22.5 pigs sold per year, the total added value per sow is a staggering US$374! Finally, as well as excellent performance, data from the IRTA (Spain) Central Test programme also show significant advantages to UK pigs in conformation across a range of important structural traits: World leader Results from independent international comparisons are showing superior performance over British global competitors. The added value of these benefits is highly significant at more than US$200 per sow per year and over US$7 per pig produced. These combine to give a margin of some US$375 for a breeder/finisher using British genes compared with other breeding stock.

British

173

120.3

698

8.8

Landrace

182

123.9

681

12.0

Large White

185

127.4

689

11.9

Pietrain

204

123.9

609

8.5

▪ Average of three measurements (mm) (Source: SSZV, Germany) British Others Advantage General conformation

7.85

7.74

+0.11

Head, neck, colour, skin

8.23

7.83

+0.40

Back, loin, thorax

8.14

8.03

+0.09

Ham

8.06

7.91

+0.15

Legs

7.74

7.53

+0.21

Reproductive organs

8.39

8.13

+0.26

Metabolic body weight = LiveWt0.75 70kg pig has M body wt = 700.75 = 24.2 Maintenance need per kg M body wt = 0.48MJ DE/day Maintenance feed requirement = 24.2 x 0.48 = 11.61 MJ/day At diet of 13.5 MJ/DE = 0.86kg/day Feed cost saving = 0.86 x US$0.216 = US$0.186

Fixed Costs

Typical fixed costs to 105kg = US$43 From this it is possible to estimate the ‘saving’ per day A 180 day lifetime gives a fixed cost per day = US$0.24 Add the cost savings from faster growth = US$0.186 Value of growth (1 day) = US$0.426

Acknowledgements

With thanks to the British Pig Association and UPB for access to some of the data presented. Appendix 1: Current UK economic values of key traits Feed Conversion Weight gain: 25 to 105kg = 80kg 0.1 FCR saves 80 x 0.1kg of feed = 8kg Feed cost per tonne = US$216 Feed cost per kg = US$0.216 Feed saving = US$0.216 x 8 = US$1.73 Value of 0.1 FCR = US$1.73

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July - August 2014 | 31

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FEED FOCUS

Highly efficient protease enzymes reduce costs, optimise performance and sustain optimum health in Pigs & Poultry

PIGS

Use of feed protease enzymes offer formulation cost savings by allowing inferior quality protein alternatives to be used in feed. An efficient protease improves the digestibility and availability of proteins so alternative sources can be used when prices of grain and oilseed meal fluctuate. Recently, poultry and swine research shows evidence of added value from optimised animal health and performance upon the use of such proteases in the feed. by Dr Ajay Bhoyar, Senior Manager, Global Poultry Marketing, Novus International Inc, USA

rotease enzymes, an important factor in protein digestion, hydrolyze the proteins found in animal feeds and break them down into more useable peptides which are short chains of amino acids. Endogenous proteases are naturally produced in the intestine. The addition of a highly efficient exogenous protease to the feed improves the digestibility of dietary protein. Consequently, the feed cost is reduced by allowing lower crude protein (CP) and digestible amino acids (AAs) inclusion levels in feed formulation. The levels of CP and digestible AAs in the formulation can be effectively low- Figure 1 ered by up to 10 percent, increasing the use of alternative feedstuffs in substitution to soybean meal; therefore reducing the risk of intestinal disorders caused by protein fermentation is also bringing significant economic benefits.

Recent research

Recent research with poultry and swine has shown that diets supplemented with a protease enzyme support gut health and optimise animal performance as compared to un-supplemented diets. This was explained by the effect the enzyme had on reducing the anti-nutritional effects of indigestible proteins in the hindgut of the animal (see Figure1). The use of alternative protein sources in place of soybean meal (SBM), such

Figure 2

as cottonseed meal (CSM), canola meal, rapeseed meal, meat and bone meal (MBM) and corn distillers dried grains with solubles (DDGS), can reduce the level of quality protein and AA digestibility. Supplementing with protease helps those monogastrics that lack adequate levels of endogenous enzymes to digest the proteins in the diet. Supplemental protease also reduces the flow of undigested protein and other anti-nutritional factors entering the large intestine. Without supplemental protease, indigestible protein serves as a fermentation substrate in the gut for undesirable bacterial strains such as Escherichia coli, Clostridium

perfringens, Salmonella and Campylobacter. These harmful bacteria use the proteins that are not digested by the animal, as nutrients and can increase in population, shifting the balance of intestinal microflora against beneficial strains, a situation typically referred to as ‘Dysbacteriosis.’ If pathogenic bacteria thrive, they can produce toxic components such as bacteriotoxins as well as fermentation metabolites such as biogenic amines, ammonia and volatile sulfur compounds. All of which can be detrimental to performance by favoring oxidative stress, intestinal inflammation and lesions, increasing both mortality and morbidity rates.

Gut morphology – Poultry Research

In the gastrointestinal system, the villi increase surface area for absorption by the intestinal wall. Measuring the intestinal villus height-tocrypt-depth ratio is a standard parameter for identifying gut efficiency. Higher ratios indicate better intestinal function Wang, et al. (Animal Feed Science and Technology, 2008). One study looked at the effect of a serine-protease derived from Bacillus licheniformis PWD-1 fermentation on gut morphology in broilers with two protein sources. Researchers fed one group of broilers SBM as a digestible protein while a second group received half of its protein requirement from CSM which has a higher level of indigestible protein than SBM.

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The CSM-fed group had damaged intestinal morphology, suggesting a higher rate of protein fermentation and more intestinal challenges. Results showed that adding protease to the diet significantly increased the gut’s efficiency, regardless of the protein source. The protease overcame the negative effects of the CSM. Figure 2 shows the same effects when even different types of diets were used, in this case typical corn-SBM diets (Odetallah, unpublished data 2003). The photo on the left, from broilers fed control feed with no protease, shows a damaged intestine with small, misshapen villi and deeper crypts. The image on the right, from broilers fed the protease, highlights gut morphology that is more adequate for nutrient absorption with tall villi exhibiting uniform height and shorter crypts as compared to the control. In a more recent study published in World’s Poultry Science Journal (Yan et al; 2012), researchers tested the effect of a protease supplement in broilers challenged with a triple-dose coccidiosis vaccine and fed high-protein diets. The control group was fed a standard, 22 percent protein diet. The other group was fed excess protein at a 30 percent level to specifically provoke a flow of indigestible protein in the hindgut and measure the impact of adding protease. As previously mentioned, fermented proteins can promote the growth of harmful bacteria in the gut. This study, therefore,

measured C. perfringens levels in digesta. When the protein content of the feed was increased, C. perfringens levels increased significantly (see Figure 3), which is a well-known risk factor for necrotic enteritis. However, levels decreased when protease was added with the additional protein. A reduction effect was experienced in regard to these pathogenic bacteria on the fermented protein, as compared to the control group. Protease enzymes help overcome several of the negative effects of protein fermentation by breaking down proteins in the feedstuffs. In addition to helping reduce pathogenic bacteria, the protease enzyme also reduced the secretion of acute-phase protein. Levels of serum a-1-acid glycoprotein were measured to indicate gut barrier function and inflammation. Study results show that adding protease to the high-protein diet significantly improved the inflammatory status of the animals.

Gut Morphology – Pig Research

With pigs, marked changes in gut structure and function occur after weaning, such as villous atrophy and crypt hyperplasia. These generally are associated with poor

Figure 3: Protease Controls the Effect of Pathogenic Bacteria on Poultry performance as they can cause a temporary decrease in feed intake, as well as in the digestive and absorptive capacity of the small intestine. In comparison, an increase in the villus-to-crypt ratio is associated with better nutrient absorption. Intestinal inflammation cause villus atrophy and, thus, reduce nutrient digestibility. The hypothesis that the immune response to dietary antigens, some of which are derived from soy protein such as glycinin and b-conglycinin, leads to local inflammation is considered one of the most plausible reasons for the nutritional weaning-associated morphological changes in the pig intestine. Pro-inflammatory cytokines produced

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July - August 2014 | 35

Figure 4: Protease effect on piglet growth rate and feed efficiency

Figure 5: Protease Effect on Piglet Ileum Morphology

during the immune response to infection might alter protein and lipid metabolism and, as a result, influence growth and efficiency of gain.

Solving the dilemma of dietary protein level at weaning

Supplementation with protease enzymes, likewise, improved weight gain and feed conversion for weaned pigs but reduced feed intake. While most proteins in SBM are easily digested in mature pigs, newly weaned pigs lack ample endogenous protease activity

so some proteins are especially difficult for them to digest. In addition to that, piglets are very sensitive to excess protein fermentation in the intestines. The challenge is that piglets have high requirements for digestible proteins to promote early growth and muscle deposition. However, as mentioned earlier, high-protein diets pose problems due to pathogenic bacteria causing scours, intestinal disorders and morbidity. While a common practice is to lower the protein level in feed to reduce

health problems, this is done at the expense of growth and performance Moreover, newly weaned pigs are immunosensitive to the allergenic SBM proteins glycinin and b-conglycinin which make up approximately 40 percent and 30 percent respectively of total soybean globulin proteins. These proteins cause intestinal inflammation and lead to villus atrophy, disruption of gut barrier functions and loss of appetite. They can impair immune function in newlyweaned pigs. When combined with the stress of weaning, the weaned pigâ&#x20AC;&#x2122;s nutrient metabolism and immune function can be seriously impaired. In a recent study when a highly efficient protease was used, weaned piglet performance was not affected by crude protein levels, driven by the inclusion rate of soybean meal. This result is consistent with other studies. Adding a protease caused less production of ammonia nitrogen, reduced the E. coli population in the cecum, the total anaerobes in the colon and the fecal score in the same way as reducing crude protein, while sustaining growth performance

Significant results in weaning pigs

Research conducted by Wang et al. (Asian-Aust J Anim Sci 2011) to study the effect of a serine - protease on nutrient utilization, gut health and performance during the 21 days after weaning. A group of nurs-

&FEED MILLING TECHNOLOGY

36 | July - August 2014

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Figure 6: Protease Effect on the Piglet’s Intestinal Environment The world´s leading trade fair for animal production

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including

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ery pigs was fed a control diet with 19 percent protein with and without protease and the other group a high protein diet (22 percent) with and without protease. Study results showed a significant improvement in performance when diets were supplemented with protease as measured by a marked improvement in growth and a 14 percent improvement in feed efficiency regardless of a low- or high-protein diet (see Figure 4). Part of the reason for that might be attributed to the improvement in digestibility. However, researchers also found that protease was able to break down 90 percent of the allergenic components of the SBM in vitro, the glycinin and b-conglycinin, which may be another reason why the protease-supplemented piglets performed better. Using protease also allows for improved intestinal functions by supporting a better morphology as evidenced by improved villusheight-to-crypt-depth ratio in this study. Increased crypt depth in both the jejunum and ileum and a higher villus-to-crypt ratio in the ileum were observed in pigs supplemented with protease enzyme after weaning. The improvement in apparent total tract digestibility of dry matter, gross energy, crude protein, and phosphorus in piglets fed diets supplemented with protease enzymes is likely a consequence of this improvement in intestinal morphology (see Figure 5). Similar to the results in broilers, using protease reduced protein fermentation and limited the growth of pathogenic bacteria in the intestine – in this case, E. coli. Reduction in total E. coli can result in fewer health problems such as diarrhea and

the release of pro-inflammatory cytokines (see Figure 6).

Reduction in harmful bacteria

In addition to lower numbers of E. coli, piglets fed diets supplemented with protease enzymes had higher numbers of lactobacilli in the hindgut. These results corresponded with less ammonia nitrogen, less branch chain volatile fatty acids in the digesta and a numerically lower pH value in the gut. The lower pH might favor the development of beneficial bacteria and inhibit the development of harmful bacteria. An abnormally high intestinal pH would provide a better environment for E. coli to colonize in the villi, thus resulting in diarrhea. The reduction in harmful bacteria and the improved biochemical condition of the intestine could possibly enhance the health of the gut ecology as beneficial bacteria would be more likely to thrive. Diarrhea caused by infectious diseases is a serious problem in weaning animals and usually leads to an increased incidence of mortality. Research results indicated that supplementation with protease enzymes reduced diarrhea of piglets as shown by lower fecal scores. This effect might be due to lower fermentation of protein, as well as the hydrolysis of soybean glycinin and b-conglycinin, which increased the utilization of nutrients for growth and decreased numbers of E. coli. This can be shown in (see Figure 7). When a protease was added to the diet, there was no difference in fecal scores between the low- and high-protein diets, when typically fecal scores would be much higher, that is worse, in a high-protein diet.

&FEED MILLING TECHNOLOGY

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Animal feed trials at HGCA by Tom Blacker, from a visit to Cereals UK The UK’s Home Grown Cereals Authority gave an exclusive presentation to Grain and Feed Milling Technology about its new steps in the world of animal feed. Usually researching and providing essential services in the wheat and cereals areas, animal feed is a new sector it is entering into. GFMT’s Tom Blacker spoke exclusively to Dr Jos Houdijk, Reader in Animal Nutrition and Health at Scotland’s Rural College, about this development.

rocessing grain in a feedmill requires a lot of quantity. Companies such as Cargill would tell us to come back with an amount as large as 500 tonnes to process as a minimum, the man from HGCA told me. He found a small pilot plant in France, working with quantities between 100 to 300kg. “We packed up 12 batches of variety specific whole seed grains on a ship to Paris and Bordeaux and they will be processed and sent back to us,” says Dr Jos Houdijk, Reader in Animal Nutrition and Health at Scotland’s Rural College.

July - August 2014 | 37

“We are now in the process of characterising their chemistry and putting them through [feeding] chickens and pigs for the research work. “In the end, what we are trying to achieve is to say to levy payers that different varieties of rapeseeds may have a different feeding value when it comes to the effect on a pig or chicken. “It is going to be a long process to improve the varieties and improve the nutritional qualities, even from a mix of varieties. Nevertheless, if for arguments sake we suppose that the range of varieties are split by half: a good side and a bad side, and if the bad ones can be phased out, quicker than the good ones, then by definition, it should go up in quality: this is what we are trying to achieve,” he added. HGCA hopes to get the first results out in the open by the end of 2014. It will not be in time for drilling seeds this year but hopefully for next year’s drilling. Growth trials will follow when HGCA understands the effect of grain variety on digestible energy and standardized ileal digestible amino acid levels. Grower pigs may expect 7.5 percent of their feed to be formed by these varieties and older pigs at 10 to 12 percent. In poultry, the level will be at about five percent. This new type of formulation will mean HGCA can go higher in information and

advice on using rapeseed for two reasons: first, the information it does have is 10 to 15 years old, the new information will mean that feed formulations can go higher in the amounts of these varieties used; second, a country like Canada is using much higher levels of rapeseed meals with pigs without any side effects in production. Therefore, the potential must be there for the UK, HGCA extrapolates. “In Canada they use more current data than us, in feed formulations based on standardised ileal digestible amino acids and net energy levels. Here, we use that on values from books that do not tell us information about these varieties, which are the differences.” The effects on the animals should hopefully be better digestibility of proteins from one variety compared to another. If we know the digestibility of protein and other minor assets in the protein it’s better. We can then recommend using that variety in feed formulations. This also means using lower amounts of the other varieties in the feed matrix when comparing varieties with soy, he says. Benefits will include the feed industry being more actively able to accordingly formulate diets to requirements. “We can make better use of the differences between varieties. In the past, it was not possible. “We will have a lot of data at the end of this year that will hopefully be published in papers and on the HGCA website,” he says.

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38 | July - August 2014

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may also optimize health and performance, adding even more value for producers. An important change in the Not all the proteases are intestinal ecology of piglets fed the same. protease enzymes was that To maximise the effect on less ammonia was produced formulation cost, gut health and in the gut compared with pigdietary anti-nutritional factors, it lets fed unsupplemented diets. is important to use a protease Excessive ammonia negawith a broad range of activity, tively affects the growth and which allows diversifying the differentiation of intestinal episource of proteins used in the thelial cells, leads to a higher diet. pH value, and increases the Moreover, a suitable proincidence of diarrhea. tease must have a high speed of In addition, a reduction in Figure 7: Protease Maintains Fecal Score in High Protein hydrolysis of indigestible proteins branched chain volatile fatty Diets for Pigs so the flow of protein entering acid is consistent with prothe hindgut is minimized. tease enzymes supplemenOn a commercial basis, Novus supports tation increasing the apparent total tract ability. With increased paracellular permedigestibility of crude protein, which would ability, toxins, allergenic compounds or health and performance with CIBENZA® result in less protein being fermented in bacteria may enter systemic tissues, resulting DP100 which gathers these characteristics in inflammatory or immunologic responses. the gut. and improves the protein digestibility in Still, however, the relationship between feeds over the typical industry averages epithelial barrier function and villous atrophy Benefits to health by as much as 10 percent. This aggresat weaning and in young animals is not comWhile the main reason for including sive, heat-stable, broad spectrum protease pletely understood. enzymes in poultry and swine diets has been complements the monogastric’s endogenous A compromise in epithelial barrier func- to reduce ration costs, supplementing the enzymes to hydrolyze less digestible protein tion possibly increases paracellular perme- feed with a highly efficient serine-protease in animal feeds.

Less ammonia produced

Controlled Experiments Provide Conclusive Evidence Spray-dried porcine plasma is a safe ingredient - and is not a source of Infective PED Virus Research Report by the North American Spray Dried Blood and Plasma Producers Association (NASDBPP)

orcine Epidemic Diarrhea virus (PEDv) is difficult to control and causes high death loss in suckling pigs less than two weeks old, resulting in significant financial loss to all sectors of the swine industry. PEDv spreads quickly and easily. The primary route of infection is through direct contact with infected pigs or from the manure of infected pigs. Other routes of infection responsible for spreading the virus may be contaminated transport vehicles, farm equipment and farm workers and visitors. Industry leaders are actively discussing and reviewing data concerning the role of feed and feed ingredients in the spread of

PEDv. Speculation that PEDv is spread by feed has led to implementation of costly biosecurity programs, often with little controlled research or data supporting the necessity or effectiveness of the program. The first report of PEDv in Ontario, Canada, and the subsequent investigation resulted in the belief that nursery feed containing porcine plasma may be the source of PEDv infections. The CFIA reported infective virus was detected in samples of porcine plasma but infective virus could not be detected in the feed containing the porcine plasma. Even with this conflicting data, many industry professionals concluded spray-dried porcine plasma is spreading the disease. In addition, and despite the long history of indisputable performance benefits, some veterinarians have recommended removing spray-dried porcine plasma and in some cases all porcine-based ingredients from feed for swine. Epidemiology is a powerful scientific tool that can be used to identify associations of exposure to health outcomes. Epidemiologic observation allows scientists to form a hypothesis and then the hypothesis can be tested in controlled experiments

Testing the hypothesis

Independently, NASDBPP and FDA conducted controlled experiments to test the hypothesis that spray-dried porcine plasma may contain infective PEDv. The results of these experiments support the conclusion that spray-dried porcine plasma is a safe feed ingredient. The manufacturing process under industry standards inactivates PEDv.

However, like any feed ingredient, postprocessing contamination is a constant risk and may be the cause of the infective PEDv found on porcine plasma as reported by the CFIA. Hypothesis: If PCR+ spray-dried porcine plasma contains infective PEDv and is a vector spreading PED: 1: Spray drying inactivated PEDv 2: Retained plasma samples subjected to bioassay studies by FDA and NASDBPP were not infective for PEDv 3: Two independent studies using 21-dayold weaned pigs fed five percent PEDv PCR+ plasma in a meal diet for 21 or 28 days post-weaning did not infect pigs with PEDv 4: PEDv inoculated on spray-dried plasma did not survive by: • 7 days stored at 71°F (22°C) • 14 days stored at 54°F (12°C) • 21 days stored at 39°F (4°C) 5: Millions of pigs in Brazil and western Canada fed PEDv PCR+ porcine plasma imported from the US since last summer have not developed PEDv

Conclusion

Experimental results show that PCR+ spray-dried porcine plasma does not contain infective PEDv. Infective PEDv reported by CFIA on samples of spray-dried porcine plasma collected from the field is likely the result of post-processing contamination. Spray-dried porcine plasma investigated by CFIA did not contain infective PEDv when it left the plant. Post-processing contamination may have resulted in the detection of infective PEDv in the samples collected by CFIA.

&FEED MILLING TECHNOLOGY

40 | July - August 2014

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2014

ASIA CONFERENCE

3rd GRAPAS Asia Conference

- Millers learn of farm, fortification and fish issues

he 3rd GRAPAS Conference, held in Bangkok during the Victam Exhibition in April earlier this year attracted up to 130 delegates, many of whom are flour and rice milers, during the course of the day and over the three sessions. Hosted particularly for non-feed millers, and supported by several key company sponsors, the one-day event presented a broad range of engaging presentations that were both informative and educational. We report on four presentations that

were generic in nature and highlighted some of the issues the milling industry is dealing with. Right from the opening presentation delivered by Nipond Wongtra-ngan of the Thai Rice Millers Association on the need for ‘World Rice Reform’, the conference heard about the difficulties faced by the Thai rice farmer due to the sector’s farm support scheme that had failed to deliver prices promised for higher yields. In fact, farmer-backed demonstrations were ongoing in Bangkok with road blockages around the country, to highlight and

express concern over the failure of the government’s support scheme as the conference was being held. Since May, large volumes of stored rice, too over-priced for the market to take up, have deteriorated to a point where the government is now undertaking a program to process the poorest quality into ethanol. Back at the conference Dr Laddawan Kunoot, the former assistant director of the Rice Department and the director of the Bureau of Rice Products Development for the Ministry of Agriculture, (now working in the private sector), drew attention to the plight of farmers and outlined the need to reform rice production and marketing support mechanisms in order to deliver better returns to farmers for this basic of foodstuff. To highlight ways rice farmers could generate better incomes, the conference heard Dr Laddawan’s views of the potential of

&FEED MILLING TECHNOLOGY

GRAIN

July - August 2014 | 41

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42 | July - August 2014

producing more organic rice for consumers who would be prepared to pay more for a healthier product. Her approach was to offer the benefits of ‘brown rice,’ which carried more nutrition to the consumer than the highly polished white rice, as a possible solution. She and her team had identified marketing and brand short-comings which meant the more nutritious brown rice was not easily identifiable through its packaging for the consumer to make informed choices. Price differences alone often lead consumers choosing the less nutritious product. “Organic farmers can make more income from their rice than traditional rice farmers,” she says. “And there is more income to be made from every part of the rice plant produced.” She talked of zero waste and also how farmers could add additional farming options to their operations by incorporating fish, fruit, vegetable and even poultry production onto their farms. Her organisation’s approach is to encourage improved farm management to reduce the heavy dependency on inputs such as chemicals and fertilisers and to use more organic substances in growing rice. She also talked about the importance of improved food safety and identified the link between the farm and the miller as the most critical in delivering a quality product to the consumer both in Thailand and abroad. The adoption of Good Agricultural Practices and certification of farming and processing practices would help achieve greater food safety and provide greater confidence to consumers who would be prepared to pay more. However, she did point out that organic rice production in Thailand was below one percent of Thailand’s paddy rice of 38.8 million tonnes of production this year – slightly above last years output with an expected nine million tonnes going for export (which would be up by a massive 34 percent over 2013 - source USDA). In recent months following the conference, Thailand’s rice farmers have been offered soft loans and cultivation subsidies to assist them through this year’s harvest period.

Fortification

Another non-commercial presentation came from Judith Smit, the rice fortification manager at the World Food Programme who told our conference that rice fortification is an underutilized intervention that should be used to address micronutrient deficiencies. The objective is to increase levels of essential micronutrients and to restore levels of micronutrients lost during processing by adding minerals and vitamins to the rice post-harvest.

GRAIN

Vitamins and mineral deficiencies are one of the main causes of poor health and disability, particularly in children in developing countries and impact over two billion people worldwide. She told delegates that there is a strong business case to address these micronutrient deficiencies and that fortification of staple foods was a proven, cost-effective and sustainable intervention to increase uptake in the general population. “As the staple food for three billion people, rice has the potential to fill a clear gap in the current fortification landscape,” she said.

Fish and rice

The final speaker of the day was the general manager of the International Association of Seafood Professionals, Roy Palmer, who explained that while fishing and fish eating went back further than rice production and consumption, in terms of a staple food source for humans, today aquaculture was the fastest growing sector that produces protein for human consumption. “Eating fish goes back as far as man can recollect and has been traded over many thousands of years as cured, smoked and preserved. However, today consumers are given incorrect information over many years and do not know whether or not they trust retails or the industry that supplies them.” He told millers that greater efficiencies in feeding fish was needed and that millers had a role to play. He also drew comparisons

between the rice and flour milling sectors and the development of fish farming. He said that a developed infrastructure drives innovation and that both rice milling and fish feeding required better infrastructures in order to bring about innovative developments that would drive production, food safety and value for money.

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44 | July - August 2014

The 2014 Asia Awards for Milling Innovation

&FEED MILLING TECHNOLOGY

GRAIN

FMT magazine once again sponsored the GRAPAS Awards for innovation in the cereal milling industries at the 3rd GRAPAS Conference Asia 2014 in Bangkok, Thailand in May. An interesting selection of products were submitted for judging in this year’s competition for innovative developments in milling technology. “Although each of the products offered for judging provide benefits and advantages to one or more milling processes, most of the entries are the result of evolutionary improvements and are not in themselves truly revolutionary,” said the panel of judges this year. “In judging we have given weight to the criteria identified in the entry categories, in particular the benefits to the user in terms of safety, cost effectiveness and efficiency,” they add.

&FEED MILLING TECHNOLOGY

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July - August 2014 | 45

The 2014 winner

The winner this year was ‘hazarmon.com’ produced by 4B Braime Elevator Components. This is an evolutionary product that uses the internet and digital technology to minimise dust explosions. “A dust explosion remains one of the most hazardous risks in the milling and related grain handling industries. Dust explosions have been the cause of more injuries and fatalities than any other cause and thus their prevention is of paramount importance for safe and efficient operation of a plant handling grain or powdered material,” say the judges. The Hazarmon system takes real time condition monitoring of equipment faults, including those which can be a source of dust explosion ignition, to a new level and promises to lead to higher standards of safety and efficiency. The use of ‘cloud’ technology to store data, provide back-up and ensure off site security of use is a major advance. Naming this product the winner they also granted it ‘highly commended’ status.

In third place was the Super SHG Hydrascrew by Morillon SAS of France and given a ‘commendation’ by the judges. “This product meets the need for a means to discharge bulk materials with poor flow characteristics. These materials are frequently encountered in the milling and particularly animal feed milling, industries. “The large size of this new Hydrascrew model suits the trend towards bin dimensions of ever greater capacity to provide economies of scale,” they add. The hydraulic drive is an unusual and attractive feature since it is intrinsically safe in a dusty environment and can provide a high starting torque which is desirable in this application.

Also highly commended was the Combistoner produced by Buhler AG of Uzwill, Switzerland. The cleaning of grain prior to milling or other food use is a vitally important function in the grain processing industries to meet ever higher standards and certification of food purity. The Combistoner takes well proven concepts to a new level by providing equipment for higher (28tonne/hour) and thus more cost effective, capacities. The recycled air option reduces the need for filtration with consequent further savings in energy as well as providing reduced operating and capital cost.

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GRAIN

CONFERENCE

Global Milling Conference Koln, Germany - June 9, 2015

RAPAS Conference 2015 is joining with The Global Milling Conference to host a significant milling conference for millers in Koln, Germany on June 9, 2015. The one-day event will be co-located with the FIAAP conference and held during the GRAPAS, FIAAP and Victam Exhibitions.

with

The Koln Messe Exhibition halls will be called ‘Global Milling Conference with GRAPAS 2015’. “Combining the two milling conferences at a Europe venue will allow us to offer a program that is more encompassing and will draw on the experiences of an established milling conference from the Asia sub-continent that has been developed by GFMT and

grapas 2015

Assocom India,” says Roger Gilbert, patron and co-organiser of the event. “We plan to attract wheat, rice and cereals millers to this one-day conference by providing a platform of speakers who you might not normally find presenting at conferences; experts in their fields who have a unique insight into developments around flour, rice and cereal milling regionally and globally,” he adds.

&FEED MILLING TECHNOLOGY

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For millers to leave their mills and travel to Koln, Germany, for a one-day conference and a three-day exhibition, places demands on the program, says Mr Gilbert. “The program has to be presented as one that millers cannot afford to miss. Therefore the calibre of speaker and presentation subject are paramount,” he says. To offset the cost of engaging speakers, the conference will introduce for the first time, a registration fee of €75/person for the full day, or €30 per session. Coffee will be included between sessions. Those opting for all three sessions will be offered lunch.

July - August 2014 | 47

one-off conference to 75-100 delegates only. Space will be limited,” says Mr Gilbert. The programme will be made up of three separate sessions which delegates can dip into and out of, or opt to attend all. We will favour those who elect to attend the whole programme in allocating space,” he adds. The full programme can be viewed as it develops and delegates can register to attend via this link: www.gfmt.co.uk/grapas2015.

Outline

Session 2: Nutrition 1 Diet – Gluten free? 2) Foodstuffs – A drinking yoghurt from wheat 3) Fibre – Challenges for human consumption 4) Flour & Rice Fortification – Millers fighting malnutrition

Session 1: Food Safety 1) Regulations – Working toward The one-day conference will take great food safety place from 09:30 on June 9, 2015 in a 2) One international standard for conference room alongside Victam. It will flour & wheat grading be broken into three two-hour themed 3) Heat treatments sessions with a coffee and lunch break 4) Training – The benefits from in-between. The whole event will be held training and qualifications in English. A registration fee of €75/ F/V/G(Island):2015 11/8/14 09:57 Page 1 person will be charged for the full day. However, delegates can attend by session for €30/each. Registration will be online with delegates registering up until the day of the conference. “We are aiming to offer this

Session 3: Markets 1) Harvest reports - Soft and hard wheat supply & demand 2) The Roller Mill Revolution 3) China – Wheat and cereal product development in China 4) Dealing with customer complaints 5) Milling 24/7 – A miller’s experience

THE WORLD’S LARGEST ANIMAL FEED PRODUCTION & GRAIN PROCESSING EVENT 9 – 11 JUNE 2015 • COLOGNE EXHIBITION HALLS, COLOGNE, GERMANY

For more event information, visit our Events Register at: www.gfmt.co.uk /events.php Or find up to date event information on your mobile with our web app. Visit www.perendale.com on your device

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For further information please contact: Victam International BV PO Box 197, 3860 AD Nijkerk, The Netherlands T: ++31 (0)33 246 4404 F: ++31 (0)33 246 4706 E: expo@victam.com Free online visitor registration is available from 1st February 2015 at:

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48 |

&FEED MILLING TECHNOLOGY

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GFMT’s market analyst John Buckley reviews world trading conditions which are impacting the full range of commodities used in food and feed production. His observations will influence your decision-making. World soyabean crush is expected to rise by about 10m tonnes to supply about 8.3m tonnes more soyabean meal. Usage is forecast to rise by about 9.6m tonnes – in China, the EU, US, Brazil, Mexico and a host of smaller/ moderate sized consuming countries in response to the lower price.

GRAIN

Feed raw material costs slump to four-year lows

here’s a simple and obvious equation behind the constant decline in raw material costs across the grain and oilseed sector: plantings are up, the weather has been mostly kind and the planned bumper crops are coming through. Even more importantly, though, production is now growing more than most observers expected - and faster than demand. Where else can prices go but towards ‘clearance’ levels? Where that demand response lies has been an issue for lively debate from commentators over the past couple of months during which wheat prices have dropped another 14%, maize by almost, and soyabeans by over, 20%. Taking the drop from this year’s peak prices for these three commodities, wheat at the time of going to press is down by 25.6%, maize by 27.7% and beans by 23%. If we want to compare the price of soya as projected by futures for later in 2014, the drop is over 28%. Back in May, world wheat output was projected at 697m tonnes – adequate to meet foreseen demand. Now it’s seen closer to 705m – just 7m off last year’s record (which exceeded demand by 7m too) after increases for most of the major producing/exporting countries as shown in the table 1. Thanks to a bumper maize crop (see below), world wheat demand is expected to drop by about 5.5m tonnes this season, mainly in North America, the Middle East, China and other East Asia. That’s despite a forecast 5m tonne rise in European wheat consumption on the assumption that a larger crop will boost feed demand. Is that realistic, though, as the EU remains under competitive supply/price pressures from another year of near record maize imports from eastern Europe – plus its own larger domestic crop? World wheat import demand is also seen falling in the year ahead by almost 9m tonnes due to less going to China, Iran, Brazil and others. Overall, world wheat stocks will expand by over 5m tonnes with increases concentrated within China, Europe, former Soviet countries and the USA. That’s the summary of the bearish news for a wheat market whose bellwether Chicago futures contract for soft wheat still, somewhat surprisingly, portrays a 13% premium on prices going into 2015. The Paris milling wheat futures market also carries a premium albeit a far smaller one of about 3.5% going into the forward new crop months. It might be noted, however, that futures have been demonstrably wrong over the past six months about the direction wheat prices would travel, largely because they didn’t anticipate supplies of this magnitude – or the willingness of speculators to short sell the market.

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Table 1: USDA wheat crop forecasts mn tonnes

2013 Final

China 121.9 EU 143.3

2014 May

2014 July

123

124

144.9

147.9

India

93.5

95.9

USA

53.4

54.2

Russia

52.1

Canada

37.5

28.5

Australia

25.5

Ukraine

22.3

WORLD

714

697

705

In recent weeks, wheat has effectively lost all of the premium it acquired during the most tense period of standoffs and conflicts between Russia and Ukraine during the early spring. That situation has, of course, been warming up again in the last few weeks and could yet cause disruption to exports from a region expected to supply the world with 28.5m tonnes – or about 19% of its wheat exports – in the coming year. At this stage, at least, short of an outright war between the two countries, the markets appear to be banking on business as usual continuing, just as it did after all in first-half 2014. Certainly recent quotations coming out of Russia and Ukraine suggest they will be keen export competitors in the months ahead. Russia has been offered 11.5% protein milling at the low price of $239 per tonne, fob terms with 12.5% protein available for about $10 per tonne more. Ukraine meanwhile has been quoting 11.5% proteins at $235/238 and 12.5% at $250. Despite some concerns about untimely rains lowering harvest quality, these two do seem to be able to offer reasonable grade wheats. Those prices compare with US soft

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- chiefly in Bulgaria, Rumania, parts of France and Germany. It’s already reflected in some big premiums being demanded for milling over feed wheat. It also suggests Europe might have more feed grade wheat than usual. Amid a large EU maize crop and the competition from imported CIS maize, that suggests further downward pressures on European feed grain prices. Canada meanwhile has had a huge problem with excess rain flooding fields, holding up and exaggerating farmers’ already downsized planting plans. Crops are developing late in cold, damp conditions. Perhaps 10-15% of acreage is at risk of abandonment or at best poor performance in terms of yield and/or sub-par quality. Canada is carrying 4m tonnes more stock into this season which can supplement export trade . This factor does have the potential to firm up prices at the quality end of the milling wheat market. However, for the time being, the market has plenty of wheat in total to eat through and questions over the strength of forward demand as competition grows from maize.

Maize surplus grows Key feedgrain maize remains on course for a big top of in supply and lower prices amid market ideas that major producers may also out-perform forecasts for a slightly larger crop in 2014/15. The key factor, as always is the US crop. The USDA estimates will be sown on 91.6m acres – 3.8m or 4% less than last year as farmers respond to the steep fall that has already occurred in producer prices. However, thanks to ideal weather, it is also forecasting a 4% rise in yield to 165.3bu/ acre, so a crop not much below last year’s record 353.9m tonnes. The trade consensus is that this doesn’t fully reflect the crop’s stellar condition ratings – the best for 20 years – and that yield will be at least 170 bushels/ acre. That equates to an extra 10m tonnes, ie a crop of about 364m. US consumption of maize jumped by 32m tonnes or 12% over the past season as all sectors – feed, ethanol, food responded to far cheaper prices. The exception was US exports which dropped by 5m tonnes. yet carryover stocks still rose by 11m tonnes or over 50% from last year’s low levels, to a far more comfortable 31.7m tones. For the season ahead, USDA sees US demand about the same although some analysts think that might under-rate the expansionary effect of cheaper corn prices, especially on livestock profitability and on ethanol use (blending of corn ethanol with petrol is approaching maximum levels but with fuel costs down, total red winter wheat recently offered fob around $225/230. However, the consumption could rise – and US exports of the green fuel are also rising. more expensive freight from the Gulf of Mexico doesn’t give the US The current USDA thinking, that US stocks will finish the new season much leverage in the contested markets where the most active sales at 45.8m tonnes (+14.1m or 45%) is a bearish influence on forward maize opportunities lie, chiefly the Middle-East/North African region. Here it prices, both in the US and overseas. So is USDA’s reckoning that stocks is the ‘Black Sea’ exporters who are beating most of the competition, will increase in China and the EU and stay relatively high in the second including the EU’s own, cut-price seller Rumania, followed closely by Russia largest maize exporting country, Brazil (Table 2). Against the bearish US figures, maize production is expected to decline and Ukraine. French exports also seem to be doing quite well, with a big sale in late July (800,000 tonnes plus) to their loyal customer Algeria. somewhat this year in Ukraine and Brazil. However, while that may trim However, there has been talk that second largest EU exporter Germany Ukraine’s exports back by about 4m tonnes from the past seaosn’s record might struggle to keep up this year if its doesn’t get the big orders it won 20m, USDA expects a lot more to be available to the world’s importers last season from Iran. In summary, this all seems to spell a competitive from other sources. Brazil and Argentina – which both have large stocks market ahead between the major EU exporters and against their CIS already – are expected to ship 9m tonnes (30%) more. Moreover, the USA rivals - even before Canada, Australia and the US come into the frame (which USDA sees exporting 5m tonnes less because of this competition) can for world wheat trade further afield. That must surely easily export far more if the world needs it, without be broadly bearish for international wheat prices and changing its own outlook for huge, if not burdensome Table 2: USDA maize crop forecasts it must be reflected to a large extent on the internal carryover stocks in the following 2015/16 season. 2013 2014 2014 markets of the US, Europe and the CIS. It’s no wonder than that maize prices are falling (mn tonnes) Final May July The previous Ukrainian flare up last spring also fast and, like wheat, are at their lowest levels for four coincided with concerns that the US crop would come years. Both grains have, of course, been far lower in the last 20 years than the current futures markets in much smaller than expected after droughts and USA 353.7 353.9 352.1 a wet harvest. In fact the hard red winter harvest show. Even at their lowest in four years, both wheat China 218.5 220 222 is coming in bigger than expected on better yields and maize are still poised about a third higher than Brazil 78 74 74 the ten-year average prior to the great price boom and some passably good protein levels. Stocks of this, the top class of wheat exported by the USA – the of 2007/8, when Chicago wheat hit $13/bu or nearly EU 64.6 64.7 65.6 world’s largest wheat supplier, have also been revised $480/tonne. Ukraine 30.9 26 27 considerably higher recently after the USDA cut is If there is a factor that will eventually underpin India 24.2 22 22 estimate of feed use for this grain. The US also seems and perhaps justify some price rallies, it is the cost of Argentina 24 26 26 to have planted a lot more spring wheat than markets production. Many producers are already feeling the S Africa 14.5 13.5 13.5 expected which will be welcomed by overseas millers pinch – at or below break even - and there has been who want that high quality to improve their grists. quite a bit of talk about cutbacks in acreage on the way. Canada 14.2 12.5 11.6 Not all the developments over the last quarter Longer term, bodies like the OECD are suggesting that Russia 11.6 12.5 13 have been so positive for wheat supplies. As we go to relative crop values and margins will increasingly favour Serbia 6.3 6.5 6.6 press, there remains a possibility that some EU wheat oilseed rather than cereal expansion, putting more and WORLD 984.5 979.1 981 could be downgraded by wet harvest weather to feed more onus on yields to deliver larger crops. These

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COMMODITIES

GRAIN

PORTS Oman plans dynamic new agro-terminal Sohar Port and Freezone have grand plans for a new agro-terminal which will combine public service with private industry. Plans for the agro-terminal include a ‘Food Cluster’ area, which will consist of a sugar refinery under the private ownership of the Oman Sugar Refinery Company (OSRC), and a governmental strategic food reserve facility, controlled by the Public Authority for Strategic Food Reserves (PASFR). The terminal will thus become an important part of Oman’s food security

strategy, assuring a plenitude of silo storage for grain commodities. However, the commodities held at the terminal will be continually replenished: the public joint stock firm Oman Flour Mills (OFM) has been challenged with a task of replenishment and creative selling for excess and ageing stocks, while simultaneously reducing government expenditure. Edwin Lammers, executive commercial manager of the Sohar Port and Freezone, outlined his vision for the agro-terminal: “The Food Cluster is unique in that it

situations usually right themselves in the end through appropriate price signals but the question at what level cereal prices will bottom out, let alone when they will start to rally, will probably not be answered for a while yet. The UK’s Home-Grown cereal Authority and French analyst ODA have both warned of downward price pressures into the harvest period while an OECD/FAO report views a potential two-year slump. In the meantime, consumers can make the most of lower costs, particularly in the feed sector where some market advisors are suggesting the wisdom of taking on more cover than usual.

Oilseed supplies under-rated

Global oilseed supplies are promised to turn out far larger than expected for the 2014/15 season, suggesting a long period of cheaper prices for the protein oilmeal sector. As always, the key factor is the size of the soyabean crop, usually the source of well over two thirds of the world’s total oilmeal supply. In the USA, farmers have sown far more than expected, and with probable record yields on the way, may produce a massive 103.4m

will feature the country’s first dedicated agro bulk terminal designed not only for the handling of wheat and grain shipments on behalf of the government, but also feedstock for the sugar refinery. The facility will also give new impetus to agro-bulk projects.” Given that the OSRC is aiming to produce one million tonnes per year of refined sugar, the Sohar Port and Freezone agroterminal looks set to become a vibrant hub of public and private industry. For more information on the Sohar Port and Freezone visit soharportandfreezone.com As reported in Port technology International Magazine (PTI)

tonne crop – about 14m more than last year’s, equal to 11m tonnes more meal if all the extra were crushed. At this stage, USDA is expecting only 2.3m of the additional supplies to be used in the coming season, the rest going to build up the biggest US stock for several years. USDA also sees Latin American producers turning out bigger crops for yet another year, raising world production for the new season by 20.9m tonnes and world carryover stocks (by September 2015) to a record 85.3m tonnes. This year they were already large at 67m and only two years ago, they were just 53.5m. World soyabean crush is expected to rise by about 10m tonnes to supply about 8.3m tonnes more soyabean meal. Usage is forecast to rise by about 9.6m tonnes – in China, the EU, US, Brazil, Mexico and a host of smaller/moderate sized consuming countries in response to the lower price. Amid static or slightly lower crops of alternative oisleeds/meals, that means soya accounts for all the growth in world protein meal consumption in the season ahead. Those extra soyabean stocks also mean there will be ample supplies available to crush of the market demands more, keeping prices under control or heading ‘South.’ No wonder, soya has become the weakest commodity in the grain and oilseed complex.

KEY FACTORS AHEAD - WHEAT

Die and roll re-working machines

• Tensions between Russia and Ukraine are flaring again and have the potential to ‘spook’ prices up. The trade is hoping the ‘business as usual’ we saw last spring will continue • World stocks will grow more than expected this season as consumption falls faster than production • World wheat trade is declining more than expected from last season’s record high • Key quality wheat exporter Canada’s crop is exposed to downward revision as weather cuts harvest area, lowers yields and maybe threatens quality • The EU has some wet harvest, possible quality issues to deal with • Wheat feeding levels and wheat value remain under further pressure from rising maize supplies, especially within the EU.

COARSE GRAINS • Maize supplies are looking even bigger than expected back in the spring, led by a potential record US crop and ample supplies from Latin America, CIS & Europe • Brisk export competition should keep prices under downward pressure • But consumption could turn out to be under-rated as livestock feeders exploit improved margins flowing from lower corn costs • The EU will probably see its third season of massive maize imports • China continues to release some of its huge maize stockpile, cutting its import needs.

www.oj-hojtryk.dk Phone: +45 75 14 22 55 Fax: +45 82 28 91 41 mail: info@oj-hojtryk.dk

O&J Højtryk A/S Ørnevej 1, DK-6705 Esbjerg Ø CVR.: 73 66 86 11

OILMEALS/PROTEINS • Big US and LatAm crop surpluses continue signal cheaper global oilmeal supplies • But further forward, will producers maintain crop expansions as the value and income from their production falls?

1974

40 2014 YEARS

Dry bulk handling This is a comprehensive description of what we do. Any questions? www.siwertell.com Siwertell is a Cargotec brand

&FEED MILLING TECHNOLOGY

54 | July - August 2014

INDUSTRY PROFILE

GFMT TALKS TO SOME OF THE INDUSTRIES LEADING COMPANIES

GRAIN

R-Biopharm Rhône Ltd by Tom Blacker, Grain & Feed Milling Technology magazine

arket growth, specialised premises and a unique range of products combined with addressing challenges of the future, were all topics covered when GFMT visited the innovative company R-Biopharm Rhône in Glasgow – the host of this years Commonwealth Games - on Friday May 30, 2014. Five members of staff stopped by in Glasgow on their return from Aquaculture UK in Aviemore. There has been a good partnership between the company and GFMT, with articles and advertising published relating to this company’s work and development.. During the visit, we also gained knowledge about the company and what makes them unique, understood their products and saw their facilities first hand. Simon Bevis, Managing Director and Claire Milligan, Product Manager, talked to us about growth in the market, the specialised premises that they work in, the unique features of their products and the markets they reach along with the challenges they will face as they become further internationalised.

From Strathclyde University

As a background to this company, the story begins in 1986. A spinoff venture from Strathclyde University was founded and achieved great growth. Thirteen years later, in 2009, the company moved into purposebuilt premises on the West of Scotland Science Park. Today there are 55 employees researching, manufacturing, marketing and distributing test kits for mycotoxins to vitamin content from the Glasgow premises. The company is a Scottish subsidiary of a German parent company, which is approximately 10 times larger and manufactures a range of different products. Approximately 70 percent of their custoomer are overseas. Exporting to customers all around the world, in around 150 countries, is a reason why they have doubled their turnover since 2009. Trading in Turkey for more than 20 years and other growing markets, they have a strong foothold in developing markets. Simon Bevis said that former Soviet Russian countries are developing and sales to Eastern and Central Europe are also growing. South America is close to this magazine with our employees and office in Buenos Aires, and it is also a focus for R-Biopharm Rhône. The parent company also runs a subsidiary both in Argentina and Brazil and is able to export to these growing markets. In a global context, India, China, Malaysia and Thailand are growing quicker than the Lati American regions, but they still feel that they are doing well for their Latin American customers. Talk of China led us to ask further about this country. In essence, Mr Bevis is confident that with their product’s level of quality and technical ability, the company will become a leader in China. The immunoaffinity columns produced by R-Biopharm Rhône are not patented but they do not expect to encounter any unknown competitive risks to their product and market share.

When turning to Africa, the challenge for many of the developing countries is addressing eating maize that is high in mycotoxins. Eating maize high in mycotoxins can consistently lead to an early death. “The solutions that R-Biopharm Rhône provide did not exist 20 years ago”, Mr Bevis says. “Now it does exist and it is easier for the instruments to detect a value and enact change”. He went on to say that the technology is a lot more sensitive and what may have read as a zero value 20 years ago, now can read with a value. Testing for contaminants, antibodies, vitamins and mycotoxins is a precise science. Mr Bevis decried the general problem of, “ignorance about the problems of mycotoxins in some developing countries” as mycotoxins can develop in many places and through many means – even in logistics, supply chain and storage facilities. R-Biopharm Rhône is able to serve customers by delivering a wide range of testing kits and more. Our tour included a tour of the R&D labs, quality department and cell culture. The company is a proud “pioneer of vitamin analysis” and keeps its reputation alive with consistently striving, investing and innovating. Currently, when analysing the sectors for R-Biopharm Rhône, Ms Milligan says how animal feed and petfood are equally weighted at the moment, with animal feed being notably larger in Asia. On our tour, we discovered that the company is a member of Campden BRI. This was great to see because GFMT was recently the media partner for the first animal feed conference at Campden BRI. (See more on the conference http://bit.ly/globalmiller). Mr Bevis and Ms Milligan emphasised a simple goal for their products- “to be in the right place at the right time”. Mr Bevis was proud to conclude that they wish to grow more, so will invest a grant from Enterprise Scotland in a project to semiautomate production, a total investment of UK£250,000 (US$420,000 or €300,000) which will allow the company to increase production by at least 50 percent. R-Biopharm Rhône are an Investor in People accredited company, and will try for the gold status this coming October. The company is also ISO 9001 and ISO 13485 certified. Staff’s average stay with the company is a very loyal eightyears. Corporate Social Responsibility plays a very important part and the company sponsors a horse named Bailey at a local charity - Riding for the Disabled Association. As the visit concluded, we left very impressed indeed. In this issue, look out for an article on mycotoxins in animal feed.

information:

R-Biopharm Rhône Ltd Tel: +44 141 945 2924 Website: www.r-biopharm.com

&FEED MILLING TECHNOLOGY

GRAIN

July - August 2014 | 55

Milling Industry’s Largest Gathering in the Middle East & Africa The 25th Annual IAOM MEA District Conference & Expo will be held at the Cape Town International Convention Centre (CTICC), Halls 4A & 4B on 3-6 December 2014. Conference and Expo Highlights • Largest gathering of flour & feed milling industry machine suppliers, grain millers and commodity traders from the Middle East, Africa and all over the world • Captivating and vibrant keynote speakers for Management, Technical and Trading sessions • Extensive networking opportunities

Top Notch Keynote Speakers • World renowned keynote speakers include Dr. Beau Lotto, Neuroscientist & Founder Lottolab (UK) and Daniel Basse, President & founder, AgResource Co. (USA) • Evening Functions in Cape Town’s most elite venues • English and Arabic simultaneous translation available • Full access to conference presentations and expo

Management Keynote Speaker Dr. Beau Lotto

Neuroscientist & Founder, Lottolab (UK)

Trading Moderator & Keynote Speaker Daniel Basse

Mike Krueger

Founder & President, The Money Farm (USA)

President & Founder, AgResource Co. (USA)

Organized by:

Mideast & Africa District

www.iaom-mea.com/IAOM-SOUTHAFRICA2014/ Email: info@iaom-mea.com or call 0096824711755

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56 |

EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS

DECEMBER

NOVEMBER

OCTOBER

SEPTEMBER

2014 CALENDAR OF EVENTS 2-3 8-10 9-12

7th International Wheat Seminar

Chennai, India

http://www.wpps.org

The first round of the V Ukrainian Grain Congress

Paris, France

http://www.apk-inform.com/en/conferences/ugc2014/paris/about

EAST AFRIPACK 2014

Nairobi, Kenya

http://www.eastafripack.com

18-19

7th Protein Summit 2014

Rotterdam, The Netherlands

http://www.bridge2food.com

23-25

http://www.viv.net

VIV China

Beijing, China

5-8

2014 AACC International Annual Meeting

Rhode Island, Usa.

http://bit.ly/130zc1N

7-9

Oilseed & Grain Trade Summit

New Orleans, Usa

www.oilseedgrain.com

7-8 8-10

Pelleting of compound feed

Braunschweig, Germany

www.iff-braunschweig.de

Agrilivestock Cambodia 2014

Phnom Penh, Cambodia

http://www.agrilivestock.net

13-15

IFOAM Organic World Congress

Istanbul, Turkey

http://www.bugday.org/portal/index.php

15-17

Vietstock 2014

Ho Chi Minh City, Vietnam

http://www.vietstock.org

15-16 16

JTIC international

Reims, France

http://www.jtic.eu

Ildex Thailand on the move

Nakhon Ratchasima, Thailand

http://www.ildex.com

21-23

Overview of Particulate Handling Technology

Kent, United Kingdom

http://www.bulksolids.com

21-23

Animal Nutrition 2014

Brussels, Belgium

http://www.agraevents.com/event/Animal-Nutrition

21-22

The second round of the V Ukrainian Grain Congress

Kyiv, Ukraine

http://www.apk-inform.com/en/conferences/ugc2014/kyiv/about

22-24

FIGAP 2014

Guadalajara, México

http://www.figap.com

27-29

GLOBALG.A.P. SUMMIT 2014

Abu Dhabi

http://www.summit2014.org

28-30

AgroExpoSiberia

Novosibirsk, Russia

http://www.ifw-expo.com

28-30

Animal Farming Ukraine 2014

Kiev, Ukraine

http://www.nova-exhibitions.com

29-31

Africa grain, pulses and technologies congress and expo

Addis Ababa, Ethiopia

http://www.grainafrica.org

29-30

The thirteenth international conference Fat-and-Oil Industry

Kyiv, Ukraine

http://www.apk-inform.com/en/conferences/oil2014/about

30-31

Aviana Uganda 2014

Kampala, Uganda

http://www.avianaafrica.com

4-5

Biomass Handling, Feeding and Storage

Kent, United Kingdom

http://www.bulksolids.com

5-7

2nd International Congress on Food Technology

Aydin, Turkey

http://www.intfoodtechno2014.org

11-14

EuroTier 2014

Hannover, Germany

http://www.eurotier.com

11-12

The third round of the V Ukrainian Grain Congress

Washington, Usa

http://www.apk-inform.com/en/conferences/ugc2014/usa/about

12-14

ILDEX Cambodia 2014

Cambodia

http://www.vnuexhibitionsap.com

14-16

11th International RiceGrain Milling Machinery and Technology Expo 2014

Raipur – Chattisgarh. India

http://www.indiariceexpo.com

25-27

http://www.bulksolids.com

Pneumatic Conveying of Bulk Solids

Kent, United Kindgom

2-4

Health Ingredients Europe & Natural Ingredients

Amsterdam, The Netherlands

http://www.foodingredientsglobal.com

3-5

Agrilivestock Myanmar 2014

Yangon, Myanmar

3-6

25th Annual IAOM MEA Conference & Expo

Cape Town, South Africa

http://www.iaom-mea.com

2015 JANUARY

FEBRUARY

29-31

Livestock Myanmar 2015

Yangon, Myanmar

http://www.livestockmyanmar.com

6-8

RICE MILLING EXPO 2015

Haryana, India

http://www.ricemillingexpo.com

Oilseed Congress Europe / MENA 2015

Barcelona, Spain

http://www.oilseedcongress.com

9-10 22-25

3rd ICC Latin American Cereal and Grain Conference and ICC Jubilee Conference - 60 Years of ICC

Florianpolis, Brazil

https://www.icc.or.at

APRIL

23-26

IDMA 2015 FAIR

Istanbul, Turkey

http://www.idma.com.tr

MAY

26-23

119th IAOM International Association of Operative Millers Annual Conference & Expo

Palm Springs, USA

http://www.iaom.info

&FEED MILLING TECHNOLOGY

GRAIN

4th International Rice Congress

he theme of the 4th International Rice Congress (IRC2014), which takes place at the Bangkok International Trade and Exhibition Centre (BITEC) in Thailand, is "Rice for the World", reflecting IRC as the largest regular conference and exhibition of the global rice scientific research community and industry. Held under the patronage of the Royal Government of Thailand, specifically the Ministry of Agriculture and Cooperatives, IRC2014 is organised by the International Rice Research Institute (IRRI) and Kenes MP Asia Pte Ltd and will be held IRC2014 will be held from October 27-November 1, 2014. Temperate rice will figure prominently during the congress in two events -1) the 5th Temperate Rice Conference, (TRC5) and 2) the annual meeting of the Temperate Rice Research Consortium (TRRC). TRC5 and the annual meeting of the TRRC aim to place in sharp relief the most recent advances in rice research from various temperate locations all over the world. Researchers

July - August 2014 | 57

also seek to address challenges in temperate rice growing by aligning research initiatives and improving the flow of information, seeds, and technologies among them. Temperate rice is grown in geographically diverse areas, such as Australia, Chile, northwest China, Egypt, North Korea, Russia, Uruguay, Kazakhstan, Uzbekistan, and some parts of the United States. Temperate rice is grown in higher latitudes, where temperatures are generally lower. In these regions, the days are longer during the summer growing season, improving the chances of better crop growth and yield. Because of more sunlight hours, temperate rice yields about 10 tons of paddy per hectare—almost double the tropical average. Thus, despite a far smaller total temperate rice area compared to its tropical counterpart—and the fact that only one crop a year is possible—temperate rice accounts for about 20 percent of global rice production. Keynote topics and speakers at the IRC2014 Congress itself will include: Title: Banking on Rice by Ms Marie Haga: She joined the Global Crop Diversity Trust as Executive Director in March 2013. She had previously been member

and Deputy Chair of the Global Crop Diversity Trust Executive Board. Ms Haga has a background from Foreign Service as a career diplomat, from politics and private sector. Title: The Quiet Revolution in Asia’s Rice Value Chains by Professor Tom Reardon: He is Professor in the Department of Agricultural, Food, and Resources Economics at Michigan State University (joining in 1992) as well as 1000 Talents Program Scholar at Renmin University of China, Beijing. He is also an honorary Visiting Research Fellow at the International Food Policy Research Institute (IFPRI) in Washington, DC. Title: The Free Market Is Key to Rice Production and Trade by Vichai Sriprasert: He is an Honorary President of Thai Rice Exporters Association, and President CEO of Riceland International Ltd since 1978. He was a former president of the Thai Rice Exporters Association during 2002-2005 and former Board member of the Board of Trade of Thailand, during the same period. He has been a board member of the Thai Shippers Council since 2004. He is an expert on parboiling rice and was the first to introduce parboiling rice processing technology from the United

States to Thai rice mills in 1978. Title: Genomes as Indicators of Environmental Health by Professor John Colbourne: He is Professor of Environmental Genomics in theSchool of Biosciences at the University of Birmingham in the UK. He is also Adjunct Professor at the Mount Desert Island Biological Laboratory, a founding member of the Daphnia Genomics Consortium (DGC) and of the Shanghai Consortium for Environmental Genomics and Toxicology, SectionEditor for BMC Genomics, and founding editor of the journal Ecological and Environmental Genomics. Title: It’s the 21st Century: Where’s My GM Rice? by Mr Mark Lynas: Is an author and environmental campaigner, has written several books on the environment, including High Tide, Six Degrees, andThe God Species. His most recent publication, in July 2013, was the Kindle Single ebook Nuclear 2.0: Why a green future needs nuclear power. He is a frequent speaker around the world on climate change, biotechnology and nuclear power and was climate change advisor to the President of the Maldives between 2009 and 2011.

06 07 08 February 2015 An Exposition business to xpand....your xplore....your market

nsure....your future

New Grain Market, Karnal (Haryana) India

India's Largest Technology Oriented International Exhibition & Conference on Rice Milling Industry

Media Partners ATS ALL TIMES SOLUTION

Axis Publication Pvt. Ltd.

ADAMAS Events Pvt. Ltd. SCO 27, IInd Floor, Mugal Canal, KARNAL-132001, Haryana, India RME.Intl@gmail.com www.ricemillingexpo.com

Organizer

58 |

EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS EVENTS

IDMA 2015

There are just 250 days to go until IDMA 2015. The clock is ticking down to what is quickly becoming one of the most influential exhibitions for the milling of flour, feed, semolina, rice, corn and bulgur globally.

n April 23-25, 2015, Istanbul will once again play host to the largest and most focused milling show in Asia Minor. As a bi-annual event, IDMA is now in its 12th year and 6th exhibition. The success of the exhibition is demonstrated by such superb quotes from the exhibitors in 2013 such as: • Bühler AG - “It was very successful and great fair that exceeded our expectations.” • Alapala Makina - “IDMA Fair has now reached maturity level.” • 4B Braime Elevator Components - “It was a really well organized fair.” • Cimbria Türkiye - “IDMA visitor group almost altered climate." • Frigortec GmbH - “We are

looking forward to take part in the next IDMA Fair.” • Kepler Weber - “The visitor quality was pretty good.” • Mysilo Tahıl Depolama Sistemleri - “IDMA is now an international organization.” • Tapco Inc - “We will definitely meet again in next IDMA Fair.” As the leading International milling publication, Grain & Feed Milling Technology is proud and excited to be the global agent for the IDMA 2015. Our publication is now printed in English, Spanish, Arabic as well as Turkish with a longstanding history dating back to 1891. We are confident we know the industry and that we know when to back a winning horse. IDMA expo is that winning horse. If you are involved in International Milling, and you are looking to increase your international database, you should attend IDMA. If you would like to rent a space or a shell scheme call or email us now for a competitive quote (darrenp@perendale.co.uk) or phone +44 1242 827700 and ask for Darren Parris. The International Flour, Semolina, Rice, Corn, Bulgur, Feed Milling Machinery and Pulse, Pasta, Biscuit Technologies Fair - or IDMA

as it is called - has improved itself significantly in terms of both exhibitors and visitors and has succeeded to become the most important meeting platform of worldwide cereal and pulse processing sectors. With visitors from every sector of the milling industry from flour, rice to feed and semolina this exhibition is sure to cover business areas from your sector. In 2013 the exhibition attracted visitors from over 120 different countries and 50 percent of the nearly 500 exhibitors were from companies outside of Turkey. Here at GFMT we consider IDMA as a gateway to the Middle East, Africa and FSU (Former Soviet Union). Our understanding of the region and language specific publications mean that if you book your space with us, your attendance will be broadcast far and wide before the event even starts. You will also appear in all our promotions leading up to IDMA 2015 on April 23, 2015. As the only milling technology fair in the world in terms of its own expertise area, IDMA presents following opportunities: • The widest range of milling machinery, products and services all under one roof

at the same exhibition. If it is milling machinery you are after, it will be available at IDMA • The latest technologies for improved milling practices covering all relevant expertise areas, all of which can be seen and analysed closely • The opportunity to meet with the biggest and most advanced technology companies participating at the fair within the milling sector and to ask in depth questions with the aim of doing business together and building a good cooperation • The possibility to compare companies developing similar technologies • To meet up with over 12,000 visitors from over 120 different countries, many of which are flour or feed millers looking to buy new equipment and systems. Do not miss out on this opportunity to pick up new customers or meet with existing customers. Join us at IDMA 2015. Secure your stand space now. More

information:

Darren Parris GFMT Tel: +44 1242 827700 Email: darrenp@perendale.co.uk

VIV China 2014 September 23-25, 2014 | Beijing, China

The international Feed-to-Meat platform for mainland China

&FEED MILLING TECHNOLOGY

GRAIN

Feed & Food in the Asian Century -AMC 2014

round 1400 people attended the Australian Milling Conference (AMC2014) which was held at the Gold Coast Convention & Exhibition Centre, Queensland in May 2014 and focused on the theme ‘Feed & Food in the Asian Century’. AMC is the conference organised jointly by the Stock Feed Manufacturers' Council of Australia,

July - August 2014 | 59

Australian Technical Millers' Association and Feed Ingredients and Additives Association of Australia, hence there was a strong technical milling program together with trade displays and social functions. The event combined with the *PIX (Poultry Information Exchange) conference. The aim of the conference was to explore the opportunities and the actions required to prosper in the ‘Asian Century’ presenting the latest technologies, processes and innovations to drive growth in both the domestic and international markets. Asia's rise in the 21st century

will profoundly affect Australia's food and feed systems. Demand for food in Asia is likely to double between 2010 and 2050, with China accounting for 43 percent of increased demand, particularly for beef, dairy products, seafood, sheep meat and sugar. Australia's success in the Asian Century will be based on choice, not chance. Rather than drift into the future, AMC2014 was determined to help the industry actively shape it. AMC2014 featured both plenary and specialist feed and cereal milling sessions with some excellent speakers. Although the Minister for Agriculture, the Hon. Barnaby

Joyce MP was not able to be present, he did provide a video to open proceedings. In this presentation the Minister was strong in his convictions that the industry cannot afford to get into boom and bust cycles and highlighted how Australia’s wealth had come from the rural and regional areas and they needed to continue to be ‘at the top of their game’ to compete in the global environment that now existed. The Minister told the delegates that they needed to be aware of the threat of animal liberationists and be prepared to ensure the industry was meeting its obligations through compliance with regulations.

7th PROTEIN SUMMIT 2014

C R E AT I N G V A L U E C H A I N S

18 & 19 SEPTEMBER 2014 | ROT TERDAM

THE 12TH GLOBALG.A.P. CONFERENCE REGISTER TODAY!

Regi 1 Sept ster by . and sa ve € bridge 2food. com

300,-

www.summit2014.org

PARTNERS

Registration, exhibiting & partnership questions, contact Gerard Klein Essink | gkleinessink@bridge2food.com | ph: +31 30 225 2060

For registration and more information, go to www.summit2014.org/registration

&FEED MILLING TECHNOLOGY

60 | July - August 2014

The

interview

GRAIN

Gerard Klein Essink, Director, Bridge2Food

Gerard Klein Essink is Director at Bridge2Food, which is located in Bilthoven, The Netherlands. The Bridge2Food company was founded in 2002 to provide research & consultancy services in fast-moving consumer categories. In recent years, international recognition has led to us developing platforms on food category trends such Sports & Performance Nutrition, Healthy Ageing, Healthy & Nutritional Bars, Ingredients with a specific protein focus and on Food Technology for food technology professionals.

What is Bridge2Food and how did it come about?â&#x20AC;¨ I have founded Bridge2Food in 2002 as a research and consultancy company. During the last 7 years we have gradually evolved into an insights, personal development and network company. The basis of the company is the large international food value chain network in retail, manufacturing, ingredients and technology. Why did you see an opportunity here and what are your ultimate goals for Bridge2Food? I have always loved to accelerate innovation, and connecting and enabling people. Being able to connect the dots and make this faster is fun and rewarding. Sometimes in life you only realise later what the red thread through your work and life is, and I could connect the dots at Bridge2Food. Opportunities are things one sees earlier and faster than another. It is then key to fully embrace them, focus on quality and then just do it. I favour the quote of Michael Kottler: 'it is more important to do what is strategically right than what is immediately profitable'. The goal of Bridge2Food is to play an important role in the growth of innovation and personal development of companies and professionals in the food industry. We want to be the place where professionals are inspired, can develop personally and grow their networks. What activities is it carrying out and how might they develop in the future? We are organising platform meetings with the industries involved in sports and performance nutrition, bars and grains snacks, and healthy ageing, as well as proteins. The protein industry is heavily involved in the areas of global supply & demand, health & nutritional, and technology and new raw material opportunities at our annual Protein Summits. These are relevant platforms for the food, aquaculture, feed, pet food industries. Food proteins courses and a Top Class on protein nutrition are other development platforms. We foresee opportunities to open up our networks to professionals for further personal development. There are more and more demands on professionals to be more entrepreneurial. Open innovation and working with others across the value chain and industries is important and we can play a role since Bridge2Food has a large network, is known for quality and we have an international position.

What type of companies should support the organisation and what contribution should they make? We work already together with food manufacturers, ingredient and technology companies, universities and research institutes across the globe. We are very open in the space of proteins to further develop and grow collaborations. We can provide organisations a good platform for access to market, for sharing their ideas, new developments and innovations through our meetings and digital networks, such as LinkedIn, with the larger world of professionals. Or help them to get in touch with the decision makers. These organisations can help us to increase the awareness of our activities and networks and grow it with us. Together we can make te world smaller and better. Can you explain some of the exciting developments that your activities have highlighted? We are proud for our role in protein space. At our protein summits new collaborations and innovation projects have started in the pulses and other vegetable protein arena. Large companies like Buhler, Cargill, Nestle working with Pulse Canada and CIGI in Canada on developing new standards. Likewise, we have been instrumental in putting proteins on the international agenda through research and consultancy activities. And each time the personal feedback of professionals on the quality of what we do is most rewarding. Is this a global organsation or European-based only? We are based in The Netherlands, yet we operate in the USA, in Europe and also in Asia with activities related to proteins. We also see growth opportunity in Europe and Asia.

Upcoming Bridge2Food platform meetings - 7th Protein Summit 2014, 18 & 19 September 2014 (Netherlands) - 4th Food Technology Professionals Platform, 9 & 10 October 2014 (Maastricht) - 3rd Healthy Ageing 2014, 23 & 24 October 2014 (Paris, connected to SIAL 2014)

An extended version of this interview is on the Global Miller blog at http://gfmt.blogspot.co.uk

Elevator & Conveyor Components 4B Braime +44 113 246 1800 www.go4b.com

Welcome to the market place, where you will find suppliers of products and services to the industry - in association with our sister publication The International Milling Directory

Enzymes Ab Vista +44 1672 517 650 www.abvista.com

Airlocks

Certification Unormak

+31703074120

www.unormak.com.tr

R-Biopharm +44 141 945 2924 www.r-biopharm.com Romer Labs +43 2272 6153310 www.romerlabs.com

Amino acids

+1 450 799 2000

GMP+ International

+90 332 2391016

Analysis

JEFO

www.gmpplus.org

www.jefo.com

Equipment for sale ExtruTech Inc

Conveyors

+1 785 284 2153

Vigan Enginnering +32 67 89 50 41 www.vigan.com

www.extru-techinc.com

Extruders

Colour sorters

Almex +31 575 572666

B端hler AG

www.almex.nl

+41 71 955 11 11

Evonik

www.buhlergroup.com

Andritz

+49 618 1596785

Satake

+45 72 160300

www.evonik.com

+81 82 420 8560

www.andritz.com

www.satake-group.com

Brabender

Animal Health & Nutrition Cenzone

Computer software

+49 203 7788 0 www.brabender.com

+1 760 736 9901

Adifo NV

www.cenzone.com

+32 50 303 211

Dinnissen BV

www.adifo.com

+31 77 467 3555

M端hlenchemie GmbH & Co KG

Format International Ltd

www.dinnissen.nl

+49 4102 202 001

+44 1483 726081

www.muehlenchemie.de

www.formatinternational.com

Bakery improvers

Insta-Pro International +1 515 254 1260

Colour sorters

Bags Mondi Group

SEA S.r.l.

+43 1 79013 4917

+39 054 2361423

www.mondigroup.com

www.seasort.com

Peter Marsh Group

www.insta-pro.com JS Conwell +64 21 043 1027 www.jscextrusion.com

Coolers & driers

Wenger Manufacturing

+44 151 9221971

Consergra s.l

+1 785-284-2133

www.petermarsh.co.uk

+34 938 772207

www.wenger.com

Bin dischargers

www.consergra.com

Denis

FrigorTec GmbH

+33 2 37 97 66 11

+49 7520 91482-0

www.denis.fr

www.frigortec.com

Bulk storage

Feed processing Ottevanger +31 79 593 22 21 www.ottevanger.com

Geelen Counterflow +31 475 592315

Wynveen

www.geelencounterflow.com

+31 26 47 90 699

www.bentallrowlands.com

Famsun (Muyang)

www.wynveen.com

Chief Industries UK Ltd

+86 514 87848880

+44 1621 868944

www.muyang.com

Bentall Rowlands +44 1724 282828

www.chief.co.uk

Flour Rank Hovis

Wenger Manufacturing

+44 1494 428000

Croston Engineering

+1 785-284-2133

www.rankhovis.com

+44 1829 741119

www.wenger.com

www.croston-engineering.co.uk

Elevator buckets

Grain handling systems

Silo Construction Engineers

Alapala

Cargotec Sweden Bulk Handling AB

+32 51723128

+90 212 465 60 40

+46 42 85802

www.sce.be

www.alapala.com

www.cargotec.com

Silos Cordoba

Tapco Inc

+34 957 325 165

+1 314 739 9191

www.siloscordoba.com

www.tapcoinc.com

TSC Silos

STIF

+31 543 473979

+33 2 41 72 16 80

www.tsc-silos.com

www.stifnet.com

Westeel

VAV

+41 71 955 11 11

+1 204 233 7133

+31 71 4023701

www.buhlergroup.com

www.westeel.com

www.vav.nl

Cimbria A/S +45 96 17 90 00 www.cimbria.com

Hammermills B端hler AG

Genc Degirmen

NIR systems

+90 332 444 0894

NIR-Online

Filip GmbH

Van Aarsen International

+49 6227 732668

www.filip-gmbh.com

+31 475 579 444

www.nir-online.de

www.gencdegirmen.com.tr

www.aarsen.com

+90 532 5265627

+44 7805 092067

www.yemtar.com

www.cbpackaging.com

Kepler Weber Group

Mondi Group

+55 11 4873-0300

+43 1 79013 4917

www.kepler.com.br

www.bastak.com.tr

www.binmaster.com

+34 973 21 60 40

www.bredol.com

+41 55 2562100 www.agromatic.com +45 721 755 55

+44 0800 917 1987 www.rentokil.co.uk

www.jacob-pipesystems.eu

Suffolk Automation

Fr. Jacob Sรถhne GmbH & Co. KG, Germany Tel. + 49 (0) 571 95580 | www. jacob-pipesystems.eu

Visit us! www.pipe-systems.eu+44

1473 829188

www.suffolk-automation.co.uk

Recruitment JCB Consulting

+81 82 420 8560

+44 161 427 2402

www.satake-group.com

www.jcb-consulting.com

Rolls

www.milleral.com

Moisture analyzers

Roll fluting +34 965564075 www.balaguer-rolls.com

Safety equipment

www.rembe.com

www.seedburo.com

Vibratory equipment Mogensen Raw Materials Handling +44 1476 566301

Weighing equipment Parkerfarm Weighing Systems +44 1246 456729

Yeast products Leiber GmbH +49 5461 93030 www.leibergmbh.de

Rembe +49 2961 740 50

+1 312 738 3700

www.rotaval.co.uk

www.parkerfarm.com Fundiciones Balaguer, S.A.

+44 1483 468900

Seedburo

+44 1249 651138

www.vibrafloor.com

Hydronix www.hydronix.com

Rota Val Ltd

+33 3 85 44 06 78

www.oj-hojtryk.dk

www.doescher.com

www.vortexvalves.com

www.breitenbach.de

www.aquar-system.com

+49 4087976770

vortex@vortexvalves.com

Vibrafloor

+45 7514 2255

Doescher & Doescher GmbH

+1 785 825 7177

+49 271 3758 0

OJ Hojtryk

www.chopin.fr

Valves

Leonhard Brietenbach

+375 17 213 13 88

+33 14 1475045

www.nabim.org.uk

www.mogensen.co.uk

Aquar-System

CHOPIN Technologies

nabim +44 2074 932521

Used around all industrial Process control sectors.

Satake

+90 332 2390141

Training

Pipe systems

+90 364 2549630

IMAS - Milleral

www.dol-sensors.com

Rentokil Pest Control

+49 571 9580

www.gazelmakina.com

Dol Sensors

Pest control

www.buhlergroup.com

Gazel Degirmen Makinalari

Agromatic

+47 69 11 80 00

Jacob Sohne

www.game-engineering.com

Temperature monitoring

Borregaard LignoTech

+41 71 955 11 11

+44 1522 868021

www.tornum.com

www.lignotechfeed.com

Mill design & installation

+46 512 29100

+46 303 850 00

www.neuero.de

Tornum AB

Akzo Nobel

Loading equipment

www.symaga.com

Pelleting aids

www.vega.com/uk

GAME Engineering Ltd

+34 91 726 43 04

www.payper.com

+44 1444 870055

Buhler AG

Symaga

www.ehcolo.com PAYPER, S.A.

+49 5422 95030

www.mysilo.com

+45 75 398411

Vega

+90 382 266 2245 Ehcolo A/S

www.fine-tek.com

MYSILO

Palletisers

+1 402 434 9102

Neuero Industrietechnik

www.obial.com.tr

www.ugurmakina.com

BinMaster Level Controls

+886 2226 96789

+90 382 2662120

+90 (364) 235 00 26

Level measurement

FineTek Co., Ltd

Obial

Ugur Makina

Bastak +90 312 395 67 87

Silos

www.mondigroup.com

Laboratory equipment

CMY

www.gencdegirmen.com.tr

CB Packaging

www.zhengchang.com

07:18:17

Genc Degirmen +90 332 444 0894

Packaging

+86 21 64188282

9/11/12

+49 5241 29330

Yemtar Feed Mill Machines

Zheng Chang

Game Engineering logo FINAL.pdf

Sifters

Second hand equipment Sanderson Weatherall +44 161 259 7054 www.sw.co.uk

To include your company in both the Grain & Feed Milling Technology market place, and The International Milling Directory, contact: Tom Blacker +44 1242 267700 โ ข tomb@perendale.co.uk

&FEED MILLING TECHNOLOGY

PEOPLE

64 | July - August 2014

GRAIN

INDUSTRY FACES

Joyce Wilcox joins R-Biopharm Rhône in a food and feed safety analysis role

Joyce Wilcox

oyce Wilcox has joined R-Biopharm Rhone from Glasgow Scientific Services, a local authority official control laboratory, where she was providing a food and feed analytical service for the Public Analyst. Joyce graduated from the University of Strathclyde in 2008 with a Masters Degree in analytical chemistry and has built upon the modern sample preparation techniques and instrumental methods of analysis covered in the degree through contract jobs in the food and feed, pharmaceutical and environmental sectors. She has extensive experience in the analysis of food additives and food contaminants, including for example, in artificial colours, mycotoxins, pesticide residues and drug residues, and has developed and validated new methods of analysis for food and feed safety, as well as gaining UKAS accreditation for key methods.

"I am pleased to have joined R-Biopharm Rhone. It is a forward-thinking company, which, in bringing innovative new products to the marketplace, offers solutions to customers for food and feed analysis. I am looking forward to providing a high standard of technical service to support our customers," she says. R-Biopharm Rhône, which supplies the agri-food industry and sells to major multinational businesses in the food industry, is based in the West of Scotland Science Park in Glasgow. It was founded 25 years ago to make mycotoxin kits, which test for poisons created by moulds. Managing director Simon Bevis says, "Joyce is a very welcome addition to our laboratory testing team. She has extensive experience in analytical testing and I believe her knowledge and experience will be a major asset to our business."

Dr Francisco Saraiva Gomes joins Pontos Aqua Holdings LLC

r Saraiva Gomes is an executive specialising in the aquaculture industry. Throughout his career, he has managed a variety of businesses across aquaculture, both by species and geography. Dr Saraiva Gomes brings Pontos Aqua unique strategic and operational insight into the industry’s drivers and opportunities. Prior to joining Pontos Aqua, Dr Saraiva Gomes led the aquaculture business at Novus International Inc, and he sits on the Board of Directors of the World Aquaculture Society. Based in New York, Pontos Aqua was formed in May 2014 to make and manage investments in the global aquaculture and seafood industry. Certain private investment partnerships advised by Tinicum Incorporated (‘Tinicum’) have Dr Saraiva Gomes made an initial equity commitment to Pontos Aqua totaling US$75 million. Pontos Aqua intends to invest in businesses that provide real and sustainable value within the aquaculture and seafood supply chain, businesses that can be enhanced by its operational, strategic and financial support. Pontos Aqua is seeking investment opportunities in the range of US$5 million to US$75 million. Richard Dosik, a principal at Tinicum, said, “Aquaculture is a rapidly growing industry with exciting global investment opportunities. We are thrilled to partner with such an experienced and well regarded industry executive as Dr Saraiva Gomes.” As to his new role, Dr Saraiva Gomes expressed, “I’m enthusiastic. Pontos Aqua is in a unique position to contribute to the growth promise of the industry. “Our goal is to invest in high quality businesses throughout the global value chain. While benefiting from a flexible investment mandate, we will focus on companies with solid management teams and growing revenue streams that operate in bottleneck sectors of the industry. “Raw materials, equipment and services, animal health, feeds and selected aspects of farming are some of the segments where we believe we can help unlock operational value.” About Tinicum Incorporated Tinicum is an SEC-registered investment adviser based in New York City with over US$2.5 billion in assets under management and more than 25 years of experience investing in public and private companies.

Anitox appoint new Chief Financial Officer

ave Smith has joined pathogen control specialist Anitox as Chief Financial Officer. This latest appointment comes at a pivotal point in the companies expansion plans as it looks to move into new markets, launch new products and consolidate its global leader positioning.

“Anitox’s impressive growth and ambitious attitude towards breaking into new markets is what really excites me,” says Dave. “I was looking for a new challenge that not only allowed me to apply my own experience, knowledge and skillset to my job role, but also for a company that is fast paced and has a hunger for seeking new business opportunities. For me, that company is Anitox.” Dave Smith With the company looking to double in size over the next three years, Anitox Chief Executive Officer Rick Phillips, has emphasized the fundamental role Dave has to play. “Daves appointment has come at a crucial time as we look to explore new business opportunities with our BioFuels program and with the launch of our latest Finio product. We need the right people behind us to maintain our high level of financial operating and planning, Dave fits that bill.” Previously holding the role of CFO at AMRest US, Dave has worked with several large and medium sized multinational companies serving in both senior finance and operational roles.

INDUSTRY FACES

Success comes with the original product. Quality always pays off. BĂźhler is setting standards in the grain processing industry for more than 150 years. Whether you grind wheat, corn, rye, oat, buckwheat, soy, or malt grain â&#x20AC;&#x201C; our processes and equipment are finely tuned to get the most from your grain. And this kind of process quality quickly pays off. The highest flour yields and best product quality ensure fast return on investment. www.buhlergroup.com/milling

Innovations for a better world.