Jul | Aug 10 - Grain & Feed Milling Technology

August

2010

• Mycotoxin

testing: ready for this year’s harvest?

• Added value

by Flour Heat Treatment

• Making Feed

Pellets

In this issue: • Technical design and equipment

- Key to improving feed quality and nutrition

• Factors affecting pelleting and energy consumption •

Fusarium mycotoxins

– What’s all the fuss about?

A subscription magazine for the global flour & feed milling industries - first published in 1891

GRAIN &

FEED

MILLING TECHNOLOGY

August

EDITORS OBSERVATIONS -

News:

EMCEglutenPlus elevates the effect of wheat gluten 4B Braime Elevator Components Ltd ‘Watchdog Elite’ system brings 21st Century protection to a veteran ship-unloader Efficient to the last grain Instrumentation crucial for automation of grain milling process New products in the range: Hot galvanised pipework system for bulk goods Tapco adds exclusive non-sparking belt splice

2010

Features

Technical design and equipment - Key to improving feed quality and nutrition Factors affecting pelleting and energy consumption Making Feed Pellets Added value by Flour Heat Treatment Mycotoxin testing - ready for this year’s harvest?

Fusarium mycotoxins - What’s all the fuss about?

Food Security - A proposal for South Africa

Publisher Perendale Publishers Ltd 7 St George’s Terrace, St James’ Square Cheltenham, Glos, GL50 3PT United Kingdom Tel: +44 1242 267700 Fax: +44 1242 267701 info@perendale.co.uk Production Editor Nicky Barnes Tel: +44 1242 267707 nickyb@gfmt.co.uk Design and Page Layout James Taylor Tel: +44 1242 267707 jamest@gfmt.co.uk Circulation & Subscriptions Manager Tuti Tan Tel: +44 1242 267707 tutit@gfmt.co.uk International Marketing Team Caroline Wearn Tel: +44 1242 267707 carolinew@gfmt.co.uk Sabby Major Direct: +44 1242 267707 sabbym@gfmt.co.uk

2

Commodities:

Raw material outlook, by John Buckley

Book Review

OECD Publications

3 4 4 6 6 8 8 10 14 18 22 26 30 32 28

42

Classified section

44

Ev en ts

46

WEBLINKS

48

Annual Subscription Rates Inside UK: UK£70 Outside: US$140/ Euros110

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 2010 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.

volume: 121 number 4

issn No: 1466-3872

Guest - EDITOR’S OBSERVATIONS

Guest editor - Roger Gilbert, IFIF

C

odex Alimentarius agreed at its 33rd Commission Meeting in Geneva in early July 2010, to establish a second Ad Hoc Intergovernmental Task Force on Animal Feeding.

It should be obvious now that we have the full attention of Codex focused on our industry, that without sound feed manufacturing practices that protect the integrity of our production systems, we can’t ensure safe food

This is good news for our industry!

In this issue there are seven key features that I’m sure you will find interesting. GFMT looks at the food security situation as it faces South Africa and how the food-price crisis has taken a back seat on the international stage now that we in the developed world are dealing with the financial crisis! Jannie de Villers of the SA Agricultural Processors Association has some insightful observations to make and ones which I can support in addressing food shortages.

Talking of feed and food safety, mycotoxins are also back in the headlines and Professor Simon Edwards of Harper Adams University College in the UK asks “What all the fuss is about?” – again he provides another interesting view on a serious issue that will cause us to ponder.

In a related article Richard Fielder of Romer Labs looks into mycotoxin testing to give readers some practical and useful information.

Finally, on a technical level there are two features that address pelleting and a superb feature on the heat treatment of flour.

A new Feed Task Force will bring feed and feed safety issues firmly into focus within the world body that governs food safety and trade. The issues on the table need attention at this level to bring about a more level playing field for industry and to the benefit of consumers everywhere.

What is the new Feed Task Force likely to cover?

Although the terms of reference have not been fully defined, they look to include the following two aspects: • Develop guidelines - intended for government use - on how to apply existing Codex risk assessment to the various types of hazards related to contaminants/residues in feed ingredients, including feed additives used in feedingstuffs. These guidelines may also cover rates of transfer from feed to edible animal products and will be drawn up in such a way as to enable countries to prioritize and assess risks based upon local conditions, use and exposure all seen from a human health perspective.

• Develop a list of hazards in feed ingredients and feed additives of international relevance that are reasonable likely to occur, and are thus likely to warrant attention.

A final aspect may well be to establish criteria for the global identification and notification of emergency situations affecting the feed sector was put forward and could be based on an existing rapid alert system run by FAO/WHO called Infoscan.

The new Feed Task Force will run for a limited time period – possibly up to three years in duration - and be hosted by Switzerland in conjunction with a co-host country yet to be named. The IFIF has supported Codex in its work on feed safety and fair trade and will use it 4th International Feed Regulators Meeting in Atlanta, USA in January 2010, to determine what additional contribution the industry might be able to make.

It is interesting to note that Codex has been working through Electronic Working Groups (EWG) on Feed in recent years to address some of the less controversial matters such as the incorporation of feed into Codex documentation. It is clear that feed has been recognised at the highest level within governments and others in the food sector as a critical and central component in ensuring food safety.

In this issue

Grain Report As GFMT goes to press I notice the International Grains Council has issued its latest report indicating there are heightened market concerns over the outcome of this year’s harvests in some key northern hemisphere exporting countries.

By contrast, rice markets continue to weaken.

Milling wheat export quotations in the EU and the Black Sea region climbed by around US$70 per tonne in response to reports of significant drought-induced yield losses in some areas, with markets also speculating about possible export restrictions in Russia and Ukraine.

However, substantial new wheat sales were still being recorded from those countries.

John Buckley takes up the story in his regular column and I’m sure provides a useful and timely round-up of background information to the markets.

Please don’t forget to look at the IFIF website where we carry links to key ingredient price reference sites which you might find useful, as a quick link - on a day-to-day basis.

Feed is the foundation for a sustainable protein food supply that allows us to express our human potential both in growth and mental capacity.

Let’s work to keep feed and food safe!

Roger Gilbert Secretary General International Feed Industry Federation

Apology and correction On page 9 of the last edition of Grain & Feed Milling Technology we stated that I’Ansons Bros Ltd was based in Iceland. The company is in-fact based in the United Kingdom. We would like to take this opportunity to apologise for any confusion caused.

2 | July - August 2010

&feed milling technology

Grain

News

July - August 2010

EMCEglutenPlus elevates the effect of wheat gluten

M

ühlenchemie develops a new complex of enzymes and protein fractions – improved baking performance for less added gluten.

Many years of research have been crowned for Mühlenchemie GmbH & Co KG by the successful development of a unique complex of protein fractions and enzymes.

New EMCEglutenPlus augments the effect of the wheat gluten in the mixture.

The result is that excellent baking results can be obtained with no or reduced amounts of added gluten.

A high protein and wet gluten content in wheat guarantees consistently good baking results.

&feed milling technology

Grain

For the production of wheat flour, therefore, millers and bakers often add vital wheat gluten or mix in superior and thus more expensive grades.

This approach has only limited success, and the same is true of attempts to compensate for the deficits of gluten-poor flours by adding various baking improvers.

As the natural composition of the proteins in wheat gluten is not geared to the purpose of baking bread and rolls, Mühlenchemie decided to look for ways in which the flour’s own gluten network could be tweaked to react as well as possible to the baking process.

The solution is E MCEglutenPlus, a newly developed combination of

suitable proteins with crosslinking enzymes. This promotes an interaction between the gluten’s polar and non-polar proteins. As a result, additional proteins are taken up and crosslinked.

Irrespective of whether the gluten is already contained in the flour or added in the form of vital wheat gluten, the covalent cross-linking promoted by the enzymes noticeably improves the rheological properties of the flour.

Farinograph tests show that the use of this product will, for example, result in greater water absorption, producing a dough that is stable for longer and develops in optimum fashion.

In many cases there is then no need to add costly vital wheat gluten.

If larger volumes of gluten are still required, it is possible to reduce the quantity added by up to 50 percent without impairing the baking results in any way.

More

information:

Nicole Schulze Mühlenchemie GmbH & Co KG Kurt-Fischer-Straße 55 22926 Ahrensburg Germany Email: info@muehlenchemie.de

July - August 2010 | 3

July - August 2010

4B Braime Elevator Components Ltd

‘Watchdog Elite’ system brings 21st Century protection to a veteran ship-unloader

T

he worldwide manufacturer of Material Handling and Electronic Components, 4B Braime Elevator Components Limited, based in Leeds, UK, has supplied its stateof-the-art condition monitoring equipment to one of two veteran ship-unloading system located at the Port of Tilbury on the River Thames.

The Port is London's major gateway, handling significant levels of diverse cargo including the importation of paper as the UK's leading port, containers, grain, and various bulk handling facilities, all of which are handled at a number of berths both in dock and on river facilities.

The Port's Grain Terminal facility handles around 1.5 million tonnes per year, making it one of the biggest in the UK. The ship-unloaders, in the form of Marine Legs are the main component of two rail-mounted, mobile Marine Towers installed on the quayside in the 1960s.

Based on the then well-known North American ‘Great Lakes’ design, the Marine Towers are

4 | July - August 2010

quite unique within the UK. Although the equipment is over 40 years old and has, since installation, handled many millions of tonnes of grain, it is still in excellent working condition and is a key element of the grain operations at the port.

Major update Following a major overhaul of one of the Marine Legs in 2003/2004 it was decided to bring the condition monitoring right up to date and the 4B Braime Watchdog Elite system was chosen to be installed on the Marine Tower.

The Marine Leg is an extremely heavy duty, purpose built, bucket elevator; designed to be deployed into a ships hold in order to dig into and unload grain cargos to shore. Raising and lowering of the leg, together with luffing, is achieved through a winch and rope system controlled by an operator in a cabin mounted high in the Marine Tower.

The 35-metre long Marine Leg elevator operates at a capacity of 860 tonnes per hour, is fitted with 4B Braime HDPE CCS elevator buckets bolted to a continuous 1120mm wide belt and runs at a speed of 3.5 metres per second.

Although 4B Braime Watchdog Elite

elevator monitoring systems have been around since 1984 and over 2000 systems have been installed, this is the first to be fitted to such a mobile device.

The Watchdog Elite system Fundamentally, all Bucket Elevators are at risk during normal operation, regardless of the product being conveyed, because of a number of issues.

These include possible bearing and drive faults, misaligned head and tail pulleys, belt slipping and rubbing and bucket damage and rubbing.

Together with the potential for inlet and outlet chute blockages common with any conveyor and the prospect of poor maintenance and housekeeping due to inaccessibility or lack of personnel, it is clear why comprehensive monitoring solutions are necessary.

If, in addition to this, the product being conveyed is combustible or even explosive then monitoring is absolutely essential! The installation cost of the system is insignificant when compared to the consequences if workers, plant and equipment are not adequately protected and a failure occurs.

The Watchdog Elite effectively mitig ates t hese risk s by constantly monitoring a number of conditions. These include belt speed, belt alignment, bearing temperature, pulley alignment,

blocked chute detection and acceleration.

Up to four digital and six analogue parameters can be monitored and all data is collated at the Watchdog Elite Control Unit and monitor (shown above).

The Control Unit is usually mounted adjacent to the conveyor or is sometimes positioned in the operators control room. Capable of running on voltages ranging from 12VDC to 240VAC, the IP66 rated unit has a LCD screen that displays machine status messages (available in four languages), and a super-bright LED display that shows belt speed. Calibration and set-up parameters are accessed via a password and front panel touch buttons. An optional PLC interface is available.

At Tilbury the following conditions are constantly watched: B e l t unde r s pe ed and misalignment are monitored by WDA High Power sensors which detect moving ferrous material, in this case bucket bolts - since nonferrous elevator buckets are being used. This is a non-contacting extended range sensor, designed to detect targets which are up to 100mm away. Sensors mounted either side of the Marine Leg casing monitor belt alignment.

Alarms for under speed are set at > 10 percent for 180 plus seconds and immediate shutdown at >20 percent.

All four main conveyor shaft bearings are monitored for

&feed milling technology

Grain

News

News

July - August 2010

temperature with trips set at 80˚C and alarms for 180 seconds and real-time readouts are given from 50˚ C - 120˚C. Blocked chute detection is provided in the infeed chute by the installation of a Binswitch capacitance style sensor that can detect plugs. All Watchdog Elite systems are approved for use in hazardous environments including ATEX Zones 21 and 22 in Europe, CSA in the USA and Canada and IECEx on a worldwide basis and the WDA sensor is approved for use in ATEX Zone 20. All the sensors employed have been developed by 4B Braime over the last 25 years and are renowned for their ruggedness and reliability.

The system at Tilbury has been installed since 2004 and has, to date, been constantly reliable – even though most components are constantly exposed to an unforgiving marine environment.

No components have been replaced during this period.

Over the six years a number of potential incidents have been avoided due to the early detection and quick response capability of Watchdog Elite. These occur maybe three or four times per year and are mainly due to belt misalignment.

This has given the operator the opportunity to re-align the elevator belt without incurring further damage. Whilst the Watchdog Elite is a ‘Guardian’ system, constantly monitoring for a change condition indicating a potential performance failure, the Port of Tilbury actually use the information in a quite sophisticated way.

Andy Lamb, Engineering Manager at the Tilbury Grain Terminal, explains, “When the Watchdog gives us a first

&feed milling technology

Grain

indication of belt slip and raises an initial alarm, we use this as a ‘trigger point’ to deploy our planned maintenance scheme.

“There is a strong correlation between that very early, slight ‘out of order’ condition and the timing of a service. By doing this our maintenance regime is tied to hours of machine usage not absolute time and therefore we only service when necessary. “ T h i s s ave s v a l u a b l e manpower resources and obviously money.”

Such has been the success of this installation; the customer is now looking to replicate it on the second Marine Leg and in addition has now decided to extend the Watchdog Elite system philosophy into the main silo block itself.

The technology will be the ‘big brother’ of Watchdog – the T500 Elite. This system is capable of monitoring up to 256 inputs every four seconds and has full integration capability with the on-site PLC set up. *Marine Leg overhauled by Stock Redler Ltd

T Bearing 2

T Bearing 1

T Motor

Speed sensor Alignment top

Save conveyors Alignment bottom Speed sensor

T Bearing 3

T Bearing 4

ALT605

bearing temperature

More

information:

Simone Biock Marketing Manager 4B Braime Elevator Components Hunslet Road, Leeds, LS10 1JZ, United Kingdom Website: www.go4b.com Email: 4b-uk@go4b.com

ALS197/906 speed/-alignment control

For safety concerns in your mill call Agromatic

Agromatic AG

Switzerland (head office) Agromatic AG CH-8637 Laupen Tel. (+41) 55 256 21 00 Fax (+41) 55 256 21 11

Gemany Agromatic GmbH D - 01454 Radeberg Tel. (+49) 3528 4521 45 Fax (+49) 3528 4875 32

ATEX Austria Agromatic Ges.m.b.H A-2201 Gerasdorf Tel. (+43) 2246 2925 Fax (+43) 2246 27655

July - August 2010 | 5

July - August 2010

Efficient to the last grain Instrumentation crucial for automation of grain milling process

M

eneba develops, produces and markets raw materials and cereal-derived ingredients for bakery products, foodstuffs, animal feed and industrial applications. The production pl ant in Rot t e rd a m , t he Netherlands has over 300 silos with an average storage capacity of 300 tonnes. Meneba processes about 750,000 tonnes of grain annually destined for the Dutch domestic and foreign markets.

Milling grains into a variety of end products is a complex logistical challenge that requires manual intervention at many stages in the process, including opening and closing of hatches.

The silos with grain are interconnected at the top and the bottom with chain conveyors (redlers) and elevators. The need for more flexible and efficient use of products, and the legal requirements for traceability, encouraged Meneba decide to automate the routing system.

The mill had 60,000 possible routings between the silos

before automating the routing system. That was the challenge.

Solution Meneba hired EKB Groep to design the automation system.

EKB Groep brought the number of routes essential for the processes back to 6000 during the definition of the required 6 | July - August 2010

design solution and advised a Siemens solution using PCS7 and Simatic IT with a redundant Profibus DP backbone.

The Simatic IT links with the Manufacturing Execution System (MES) which takes care of the tracking and tracing of all ingredients. The complete logistical process is now automated: from incoming grains to feeding into production.

A range of process instrumentation connected through either Profibus DP or Profibus PA completes the solution: Pointek CLS200 capacitance level switches and four Sitrans LU10 ultrasonic level controllers on the silos, a Sitrans LR400 radar transmitter for the level on powder and dust hoppers and a Siwarex FTA weighing controller for batching.

EKB Groep designed an ISA-88 structure with Simatic Batch, PCS7 and Route Control.

It automatically selects the most efficient route available for flow of material at any time, concurrent with processes running at the same time. A pneumatic system coupled with Siwarex batching systems now transports the correct volumes of material from silo to production and vice versa.

An AS-Interface bus system was used for digital I / O, which integrates seamlessly into Profibus DP. Meneba has more than a decade of experience with Siemens level switches and controllers. At present 280 capacitance Pointek CLS200 level switches help control the high levels of all silos.

The switches are equipped with sensors on cables of 2.5 meters in length that signal when the content of the silo reaches the top to prevent overfilling and spillage.

The four S itr ans LU10

ultrasonic level controllers we only need the process measure the volume in 40 silos. operators and maintenance Each controller operates with staff. Manual intervention in the 10 long-range ultrasonic sensors milling process is a thing of the T h e S i t r a n s L R 4 0 0 past,” says Mr De Jonge. radar level transmit ter continuously monitors the More information: material levels of the powder Siemans a n d d u s t h o p p e r. T h i s 1954 Technology Drive powerful FMCW (Frequency Post Office Box 4225 Peterborough Modulated Continuous Ontario, K9J 7B1, Canada Wave) radar device performs Tel: +705 7452431 particularly well in bins and Website: www.automation.siemens.com silos with extreme dust. Most instruments are integrated via Prof ibus into Simatic Sitrans LU PDM ( Process Device Sitrans LU is a long-range nonManager), which allows contacting ultrasonic controller the operators to p r ov i d i n g c o n t i n u o u s l eve l progr am t he devices measurement of materials including and run diagnostics liquids and solids in tanks up to 60 from the control room. meters (200ft) in up to 10 vessels. It operates with Echomax XPS30/40 transducers for long ranges.

Benefits With the automated system, Meneba can trace Sitrans LR400/460 all batches of products Sitrans LR460 has replaced Sitrans and materials. The LR400 for level measurement on solids. company has complete It is a continuous radar level transmitter co nt rol of t he r aw featuring 24GHz frequency-modulated materials and ingredients continuous wave technology and with the benefit of greater Process Intelligence echo processing. flexibility in the processes Sitrans LR460 is designed for difficult and optimizing material solids applications, including those with stocks. extreme dust, high temperatures and “The attractive long ranges up to 100 meters (328 feet). side effect of this modernisation is that we Siwarex FTA can expect a significant Siwarex weighing systems are ideal decline in energy costs. for high accuracy verification weighing.

Now the new system is The system, consisting of a processor activated when needed, and one or more load cells, can be and af ter the task is applied throughout the manufacturing completed the system process. Siwarex weighing modules are shuts off, whereas in designed for direct integration into a the past the system was Simatic automation system in either running continuously,” central or distributed configurations. s ays J ohn de J onge , Chose Siwarex FTA for weighing, project manager at dosing and batching systems, as Meneba. well as for filling, bagging, loading / In addition, Meneba unloading scales (totalising), and as saved considerably in dynamic checkweigher with maximum manpower. precision and speed. Siwarex FTA can “We were working be directly integrated in Simatic S7-300 24/7 with five shifts. Now, or ET200M. with the new system

&feed milling technology

Grain

News

Eco Dry – The new Generation of Cereal Dryers

Your benefits: ● Energy saving potential of up to 20 % (drying maize using our continuous cooling column)

● gentle drying process ● uniform drying temperatures reducing hotspots ● minimized discharge of fines (canola, flax) Contact us. We would like to discuss our dryer innovations and new developments with you.

Schmidt-Seeger GmbH Eichstaetter Strasse 49, 92339 Beilngries – Germany Telephone: +49 8461 701-0, Fax: +49 8461 701-133 info@schmidt-seeger.com, www.schmidt-seeger.com

September 6 - 8, 2010

0 1 0 2 a in h C V I V it Come and vis www.viv.net

Beijing

VIVChina 2010

The international platform for the Chinese Feed to Meat industry

New CIEC, Beijing &

adv Grain viv china 190x132 grainfeed.indd 1 feed milling technology

23-07-10 July - August 2010 | 7 10:08

July - August 2010 New products in the range:

Hot galvanised pipework system for bulk goods

J

acob can now of fer customer s a new hotgalvanised pipework system, 3mm wall-thickness ex-warehouse, which is specially designed for conveying bulk goods in outdoor areas.

This system has been developed in response to the particular requirements in the grain processing industr y, wherever a wall thickness of 3mm is required a n d t h e p ro d u c t s t o b e conveyed exhibit abr asive characteristics.

The comopany’s standard hot galvanised range includes 500, 1000 and 2000mm lengths of straight pipes, segments, cone pieces, 45° forks, spouts from square to round and inspection pieces. Also included in the range is the hot galvanised two-way valve with manual operation or alternatively with drive.

The various components are series manufactured as an easy-to-install modular s y s t e m , w h e r e by t i g h t l y sealed connections can be made quickly and easily using galvanised pull-rings with sealant. The hot galvanised

pipes and fittings are available in the common diameters DN 200, 250, and 300mm.

With a wall thickness of 3mm, the pipe system is suitable for conveying abrasive bulk materials such pellets, grain, and other coarse -gr ained products, for example, but still remains easy to install.

Expertise in bulk material, dust extraction and ventilation systems The Jacob modular pipework system ( DN 60 - 8 0 0 mm standard diameters) is used worldwide in almost all areas of industry for the construction of bulk material conveyance

systems and dust extraction or ventilation pipelines.

Many examples are to be found in the food and luxury goods industry (coffee, cocoa, sugar, grain, tobacco, etc.) in concentrated feed production plants among others.

J acob’s innovative developments, short delivery times and easy-to-install pipe systems with wall thicknesses of 1mm to 3mm using pullring connections or loose flanges ensure the company's prominent position in all industries whose production processes require pipework systems made of stainless steel or powder-coated or galvanized metal.

Jacob’s 3-D service provides its customers with a DVD containing drawings of the pipes and fittings, as a practical and time-saving aid for creating engineering drawings.

More

New in series production: As part of its standard range, ex warehouse, Jacob Rohrsysteme now offers a range of hot galvanised products, including two-way valves with a wall thickness of 3mm.

information:

Jocob Söhne GmbH & Co Niedernfeldweg 14 D-32457 Ponta Westfalica Germany Tel: +49 571 9558-0 Email: post@jacob-rohre.de Website: www.jacob-rohre.de

Tapco adds exclusive non-sparking belt splice

T

apco Inc, of St Louis, Missouri in the USA, and an industry-leading manuf ac turer of elev ator buckets and bolts, recently added a bronze non-sparking belt splice to their product line.

The new Tapco-Splice NS is manufactured to accompany their existing zinc-plated DuraSplice.

This style of clamp splice holds belts in a vice-like grip, putting an end to the double 8 | July - August 2010

belt thickness common to other splicing systems.

Unique teeth at the top of the clamp provide extra gripping power.

The nonsparking Tapco-Splice NS - made in the USA exclusively for Tapco - fits all pulley diameters and is recommended for belts rated up to 800PIW.

Tapco-Splice NS is supplied with a 4-1/2” Grade five hex he ad bolt , accompanied by a Gr ade eight hex compression nut , along with a self-adhesive template for creating the bolt holes in the belt.

Tapco stocks over 900,000 elevator buckets and 14 million

elevator bolts in their North American facility.

“We are constantly adding innovative items, like the TapcoSplice NS, to our inventory in order to keep our customers up and running”, says Carl Swisher, Tapco Sales Manager.

More

information:

Tapco, Inc 225 Rock Industrial Park Drive St Louis, MO 63044, USA Tel: +1 314 7399191 Website: www.tapcoinc.com

&feed milling technology

Grain

News

Quality and nutrition

Feature

Technical design and equipment

by Shao Jianxin, Engineer, ZCME, China

W

hy do some feed factories earn profits while others don’t? Why do feed of some factories sell well? The reason behind is technical design and equipment selection.

Choosing skilled feed engineering constructors and comprehensive solutions providers are also vital for the success of a company.

The factors affecting feed quality can be summed up in three aspects, namely: • The quality of raw material • The feed formula • The process technology With the same level of raw material and formula, the quality of feed only depends on

process technology and equipment performance.

As the digest system of chicken, pig, fish, shrimp and pet varies, feed of different size and degree of ripeness are demanded. It is one of the important methods for the modern feed companies to improve product quality by upgrading process technology.

Impact of grain size on feed nutrition

Generally, grain size should take consideration of many factors like feeding method, process costs, capacity and growing characteristics of animals.

Its empirical value should be no more than 1/3 of the diameter of pellet.

Appropriate grain size can improve digestion rate of the nutritious element. Research has shown that Table 1: International best grinding particle size if the even size of corn feed for Animal Raise stage Best size recommended (μm) sow is reduced from 1200um to 400um, its digestion rate could be Ablactation 0~14d 300 raised by 14 percent, dry materials in manure could be reduced Pork Ablactation 14~35d 400 by 21 percent and the nitrogen Grice ≤500（Corn） would be lowered by 31 percent.

Fattening pig 500~600（Corn） Over grind could lead to Sow 500~600（Corn） more consumption of energy, less Growing pig 15~30kg 323(batch) capacity and destroy of nutrition Dorking 700~900（Corn） of feed. The research data proves that VA of pellet after repeated 900 grind would decrease 40 percent.

Beef cattle 1~1.5cm（straw、corn stalk） The key point of grain size 2~7cm（corn stock、hay） control technology is to grind Fish ≤0.5mm（batch） each raw material to the best Shrimp 150~175 size suitable for digestion so as 10 | July - August 2010

to ensure the batch feed can acquire best raising efficiency and economic profit. It is mandatory to study the best digestion size of each raw material for different animals as shown in Table 1.

Pulverization and micro-pulverization must be applied for aquatics feed.

Research has shown that carp feed ratio could raise 5-10 percent if the screen of grinder has been reduced from 1.5mm, 1.2mm to 1.0mm, 0.8mm, 0.6mm. As a result, grain size has a markable influence on variation of nutrition.

Grain with excessive small or big diameter could break into layers which would affect the digestion rate of feed nutrition. It is only by selecting proper technical design, professional company and equipment can good quality feed be made.

Impact of batch on feed nutrition Formula is a major impact factor for feed nutrition and pellet quality. Formula with high content of grain like corn and soybean cannot produce high quality pellet feed due to the lack of natural bond.

Addition of highly cohesive wheat can improve pellet quality.

It is necessary to combine each element in the formula and keep fat to lowest limit. In case of large proportion of adding materials, the condition process should be adjusted or the materials should be added after pelleting.

As the core process of feed production, batching accuracy has a direct impact on feed composition and nutrition absorption of the

&feed milling technology

Grain

Feature

Quality and nutrition

animals. As a result, the feed nutrition can be balanced only with appropriate batching system.

The batching process has a important effect on batching accuracy and composition.

The major technical improvements lie in following aspects: 1: The batching scale must be checked regularly so as to ensure measurement accuracy of batching equipment 2: The formula should be right and the raw materials can be replaced 3: The materials should be fed at proper speed 4: The control system should be correct 5: The batching equipment must be operated in correct way 6: The batching equipment should be clean so as to avoid cross contamination 7: The batching process especially the use of medicine should be carefully recorded No-error computer control technology is adopted to manipulate batching accuracy.

Micro additives can be premixed and

batched and high accurate batching system can be adopted.

Impact of mixing conformity on nutrition Conformity is vital for feed quality as it will determine whether the animal can get full nutrition from the feed. The air balance between mixing bin and mixer also has an impact on nutrition.

Too big finish product bins and pellet bins and too long transportation lines will destroy conformity of feed and reduce the conversion rate of the animal.

It is critical to choose the right mixer, mixing period and feeding method in order to ensure conformity and nutrition. The control of mixing conformity covers mixing feed, concentrated feed, additives, premix feed and liquid feed.

The technical improvements in batching process have the following aspects: 1: Proper mixer must be selected to ensure conformity 2: The materials should be added in

correct order with big materials added at first and small ones added later. All materials should be added in proper amount and order especially for production of premix feed 3: In case of change of formula, the mixer should be thoroughly cleaned to avoid cross contamination 4: Premix should be separated from major mixing process in order to prevent cross contamination 5: The transportation distance and height of materials after batching should be as short as possible and no conveying equipment like pneumatic device should be adopted as it would cause separation of materials

Impact of pelleting on feed nutrition 1. Pellet quality control: pellet quality is the precondition of feed nutrition which must be strictly manipulated. The conditioning quality is the primary control point of pellet quality which includes tem-

The Hydro-Probe II Moisture Sensor Measures Moisture & Reduces Cost

The Hydro-Probe II digital microwave moisture sensor provides accurate and cost effective moisture control in feed meals and pellets, grain, cereal and pulses:

• • • • •

Monitor and adjust moisture levels in real time Reduce energy costs during the drying process Reduce waste and improve quality Suitable for bins, silos, conveyors and chutes Not affected by dust or colour

enquiries@hydronix.com

www.hydronix.com

&feed milling technology

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GFMT quarter page vertical 105 x 147 plus 3mm bleed.indd 1

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Quality and nutrition

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steam supply and control systems, conditioning, pelleting, cooling and screening equipment with all control parameters scientifically adjusted.

The steam fed into conditioning units must be unsaturated steam, free from condensed water so as to ensure enough ‘pasting’ of starch and prevent machine blockage due to too much moisture. The steam must go through a water trap and a pressure reducing valve before entering the conditioner.

steam with proper characteristics is a precondition of pellet quality.

Technical improvements of steam pressure and flow rate covers following aspects to ensure high quality of feed: 1: Control the conditioning of meals, including the adding of steam and oil, and check the quality of steam and keep a good record of it 2: Control the product from the pellet mill and keep record of it 3: Control the cooling time, moisture and temperature of feed in accordance with the room temperature and moisture 4: Control the fat coated on the surface of feed 5: Check the hardness of pelleted feed and keep good records Conditioning process is vital for pellet quality.

The mixed materials with high content of grain usually stay for at least 40-60 seconds in the conditioner.

Meanwhile, the temperature inside the conditioner should be kept between 85-98℃ to improve ‘pasting’ of starch.

Materials with high fibers must stay for shorter time in the conditioner. In case of addition of liquids like molasses, the materials should stay longer in conditioner perature, time, water and ‘pasting degree’ (maximum 30 minutes) so that it would of starch. A secondary control point absorb molasses fully. covers powder rate, cooling temperature, High temperature conditioner with short moisture, blade-even degree and water time (60-160 seconds) can kill bacteria.

Many conditioners of this type have been developed in several countries. The durability of feed Table 2: Anti-nutritional factors of common raw materials of feed at high temperature should also Anti-nutritional be considered during conditionfactors Distribution Inhibit function ing.

Materials with bad durability Protease Pea seed, beet under high temperature and poor inhibitor broomcorn Restrain activity of trypsin and pepsin, facilitate secrete of pancreas ‘strength’ should avoid conditioning Rapeseed, cabbage, at high temperature. Instead, they Glucoside Kale, etc Prohibit growth, increase cardiolipin and reduce appetite should be coated later so as to Lectin Pea seed Impair intestinal wall, lose more endogenous protein, inhibit growth ensure pellet quality.

Tannin Pea seed and cake, etc Weaken absorption of protein, carbohydrates 2. The impact on vitamins: it is injures gastric mucous membrane, destroy metabolization of protein vulnerable to increase conditioning Gossypol Cottonseed and cake and iron time and raise temperature as the Interfere biological effectiveness of mineral elements, form protein vitamins with poor thermal stabilPhytic acid Pea seed complex ity would be easily lost during the Saponine Soybean Destroy absorption of nutrition, reduce appetite pelleting process. Vitamins like A, E, C, thiamine hydrochloride, etc will Lignin Pasture Destroy absorption of nutrition, reduce appetite be killed rapidly as the temperature Alkaloid Pasture Reduce appetite, inhibit growth and conditioning time is raised.

NSP Grain feed Facilitate pasting of materials inside enteron, weaken absorption of nutrition The critical condition for conditioning of feed with vitamins is durability of the feed. To meet the above Meanwhile, the flow rate of steam must as following: temperature ≥90°C, moisrequirements manufacturers need proper be matched to the feeding rate. As a result, ture≥15%, time ≥60 seconds.

12 | July - August 2010

&feed milling technology

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Quality and nutrition

As a result, it is necessary to choose formulation with sound thermal stability. A good pellet conditioner, correct air admission and mixing methods are also the vital factors for pelleting process.

3. Feed enzymes: pellet process also affects feed enzyme and other microbials.

Enzyme and microbial are biological products, the activity of which are usually damaged under the comprehensive function of high temperature, humidity and pressure. It is reported that the activity of phytase drops by 87.5 percent at temperatures of over 80℃.

So the utilisation rate of N.P. will be affected. The microbe additives in the feed is especially reactive to high temperature so that its activity will be lost completely if the pellet temperature exceeds 85℃. It is better to coat enzyme after pelleting or to use enzymes with better thermal stability.

4. Impact on anti-nutrition factors: part of anti-nutrition factors and harmful substances will be killed during the conditioning of pellet. Anoxia sterilisation before pelleting can kill various bacteria effectively and improve feed quality. It has been a key research subject for professional technicians.

Animals have different reactions to the same anti-nutrition factors as its species and age vary. The anti-nutrition factors can be divided into positive inhibitors for carbohydrate, minerals and prolease, etc. The pelleting process adopts conditioning, high temperature extrusion methods to weaken the antinutrition factors as listed in Table 2 to maximum limit.

5. Impact of pellet on starch and protein: the starch would become ‘pasted’ and protein would be denaturated after conditioning so that the animal can digest and aborb the starch and protein better.

However, it is the technical issue of a professional company to determine the raw material of specific size for specific animals. Protein denaturation has little influence on amino acid but improves its absorption rate greatly so that protein can be highly utilised.

6. The impact of post-cooking: after conditioning, the ‘paste’ degree and water durability of pellet should be improved, however, some thermal alert vitamins are destroyed.

As a result, it is better to use formulations with sound thermal stability or apply the improved coating technology so as to preserve nutrition values of the feed as much as possible; which is mostly used in the production of aquatics feed or special aquatics feed for shrimp for example.

7. Impact of storage and transportation: cross contamination usually takes place during storage and transportation. Residue in transportation vehicles, bins, buffer hoppers and process equipment could cause cross contamination. Harmful microbe and pests are also source of cross contamination.

To meet increasingly high demand of security, sanitation and nutrition of feed, it is necessary to equip residue-free conveyor and bins, apply scientific technology of cleaning and sequencing. Heat treatment technology should be applied which includes cooking at high temperature, extrusion, high-pressure treatment and ultraviolet irradiation, etc. With the comprehensive application of the above technology, the fin-

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13.07.2010

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ish pellet feed can obtain satisfactory quality and nutrition.

Impact of technical process The anti-nutrition factors in feed can cause disease of pigs and pets and retard the growth process. As they are closely related with process technology, nutritionists have developed many methods to eliminate anti-nutrition factors.

However, the nutrition elements in feed would lose at the same time.

Extrusion and expansion at high temperature can improve feed quality and limit lost of nutrition; anoxia sterilisation could kill bacteria effectively and keep vitamins; fermentation could eliminate toxic effect of anti-nutrition factory and keep vitamins; enzymes preparation cannot only erase toxic effect of feed but also provide a health function.

Getting rid of anti-nutrition factors in raw materials has become vital in selection of process technology and equipment. Feed quality and nutrition can be only be guaranteed using professional technology and equipment.

With the development of nutrition, technicians of professional company can work out better methods to eliminate anti-nutrition factors and make more contribution in improving feed quality and nutrition.

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July - August 2010 | 13

Energy consumption

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Factors affecting pelleting and energy consumption

by Rainer LĂśwe, Research Institute of Feed Technology of IFF, Braunschweig-Thune, Germany

T

he prosperity of industrial feed compounding is based on the refining effect of mixed and processed raw materials, especially since the introduction of the pelleting process in the 1920s.

ments at same time, especially regarding the fact that almost 80 percent of the total costs are related to raw material input and a mere of 20 percent is on hand with respect to technical exercise of influence.

The production of firm and stable pellets requires high pressure implying high energy consumption and/or reduced throughput.

Compound feed complies with different Fewer throughputs stand for extended retenquality attributes like hygienic and nutritional tion time under pressure and thus produce physiological aspects, technical characteristics, better compaction. and environmental compatibility. Despite raisThe specific energy demand rises anyway. ing additional costs for equipment as well as But of course, pelleting is not just a matter for electrical and thermal energy consumption, of pressure and energy input. currently up to 70 percent of the compound The pelleting process can be divided in feed produced in Europe and in the USA, are three main procedures: pelleted.

- conditioning the pre-processed comThe requirements with respect to pellet plete feed meal (complete except quality, especially durability, differ according for sensitive micro components to to the animals to be fed, to the kind of livebe added on top or end of line) stock breeding and in some cases to the - compacting and consolidatdemand of the farmers too. ing the mash into pellets Pellets should be hard and resistant - cooling the moist and hot pellets to all demands placed on them from the to a storable and conveyable product various stages in the production process Besides technological items material to the feeding trough, be as dust-free properties are of important impact. Next as possible and be of good appearance to density, the particle size distribution is in colour, texture and surface without of special interest because it affects the fractured areas which may cause abrasion. pelleting process significantly: from both theoretical and practical experience it is Advantages of pelleting well known that fine structured material Pelleting compound feed offers sevFigure 1 illustrates a typical but simplified flow almost allows trouble-free production eral advantages compared to just ground, diagram of a feed production plant of firm pellets, but causes high energy mixed mealy feedstuff. consumption for milling.

The hectolitre weight (tap density) of the Coarsely grounding feed, at the recent Digestibility is increased, thus the nutrient bulk material is raised to some extent, so lower utilisation is enhanced and there is less feed request of nutritionists, tends to produce less transportation and storage volume is required. stable pellets, because bigger particles preGenerally, pellets are free-flowing; arching in wastage.

The efficiency of the pelleting process is determine breaking points within the pellets, bins and silos is reduced.

Emptying and dosing is quite easy with no measured by a large production throughput creating more cross sectional areas within the at low power requirement and an output of pellet and thus more abrasion. segregation arising within the product.

Depending on material’s properties (hardContamination risk from bins and hoppers pellets with low abrasion index, fulfilling high or even conveying equipment is of minor inter- quality aspects and resulting in almost low ness, brittleness or even flexibility) those particles are crushed between rollers and die est because of the very small amount of resi- specific energy consumption (kWh/t).

These are conflicting objectives of high consuming more energy and causing probably dues that arise when transporting stable pellets.

Heat treatment during the pelleting process demands and it is difficult to meet the require- more wear.

14 | July - August 2010

reduces microorganisms, the overall hygiene state is improved and storage periods may be extended - up to storage conditions, decay is deferred.

Benefits are not only given with respect to transport and handling but also to livestock management. Feed composition is guaranteed even in small units, all components of the mixture are incorporated homogeneously in the pellet, ensuring an even supply of ingredients and nutrients, selective feeding is impossible.

Due to market conditions, the composition or components may be changed without the risk of the feed being refused by the animals.

Palatability is also improved. The integrated thermal process modifies starch and creates a certain taste and smell which, by the way, may be covered by special additives in order make the feedstuff distinctive.

&feed milling technology

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Energy consumption Table 1: Effects due to different feed processing measures

The original (primary) particle size is changed.

This additional operating expense has to be set in relation to less energy input during milling. Commonly, the breakdown of energy consumption of compound feed production is 60 percent for pelleting and about 16 percent for milling (see Figure 3).

Although these figures are not statistically affirmed and based on feed producer survey in Germany, frequently asked coarser mixtures may cause a different ranking.

Factors affecting pellet stability Feed ingredients influence pellet stability in different ways.

While – depending on moisture content and temperature – starch and protein may cause more stable pellets, fat as a lubricant reduces friction in the die holes and leads to weaker pellets.

Increasing the fat contents leads to partial coating of the feed particles, which prevents the penetration of the steam and thus the development of binding agents – moisture bridges as well as the gelatinisation of starch [Reference 1].

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Short-term While formulaLong-term Effect conditioning Expanding Extruding tion and preparation conditioning and pelleting are beyond the press operator’s control, he Structure changes low no high very high is left with a number Hygienisation low very high very high very high of other parameters Matrix changes low low high very high to exercise influence on the pellet mill is reached when using small bore-hole diamoperation and hence on the product quality.

It is evident from the large number of influ- eters.

Normally, the energy consumption will rise encing factors that there can be no standard for linearly, while the pellet stability tends towards the plant setting.

The pelleting system has to be adapted to a final value the longer the die holes are.

A considerable influence on pellet stability actual requirements by means of adjustment takes the press throughput. and it has to cover a very wide spectrum.

For fixed die dimensions and a given Manipulation is possible through die and roller selection, rotary speed, gap width and number of die holes, the load of each hole consequently pressure conditions, but also by increases with higher throughput: the power throughput and steam regulation, always tak- intake rises while the pellet-stability decreases. ing due account of the motor load or current This can be explained by the minor compaction of the thicker layer pressed into the holes intake.

Longer die channels increase the prob- at a time [Reference 2]. ability that binding will take place between the feed particles so that – supported by Double-stage pelleting enhanced frictional forces – the pellet durabilAnother important factor is the precomity is adequately improved. The same effect paction of the feedstuff before entering the die

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July - August 2010 | 15

Energy consumption

hole – caused by double-stage pelleting, the gap width between roller and die (automatic gap control) or the roller speed. The higher the speed (or the number of rollers), the smaller the material plug being pushed through the bore, the better the compaction inside the plug.

Figure 2: compiles compacting affecting factors

Figure 3: Breakdown of energy consumption

The addition of pelleting aids can bind, for example fatty contents, by increasing the surface area; this may reduce pellet abrasion.

But the effect of auxiliary agents depends to a high extend on feed mixture recipes. Friction reducing tensides or surface active agents may improve pelleting behaviour, too.

By facilitating the easier transfer of heat (vapour) through the meal, which is conditioned more intensively, surfactants may reduce pellet press energy consumption.

Another effect is the possible reduction of undesired moisture loss (shrink) which under certain conditions may give support to raise the production rate [Reference 3].

Finer grinding of the compound-feed components leads to larger specific surfaces and thus to more favourable conditions for the absorption of liquids and the effectiveness of the saturated steam and results in more firm pellets.

Application of the saturated steam creates more favourable conditions for 16 | July - August 2010

establishing bonds between feed particles improving pellet stability. However increasing the amount of steam is limited because of crossing admissible moisture levels reducing the friction in front of and within the die channels.

Factors affecting energy consumption Considering potential energy savings, specific conditions of industrial compound feed production need to be taken into account. Increasing customer focused production of small batches as well as intensified use of hydrothermalmechanical treatment (in consequence of highly demanded hygiene safety) ran up costs for energy consumption (Reference 4).

To assess the energy efficiency of a process, its specific electrical energy requirement (kWh/t) should be related to effect-specific energy consumption, for example with respect to the refinement process, refinement targets and capacity utilisation.

This would allow general conclusions regarding specific processability.

When comparing different sites within one company, the balance sheets should be checked as to whether initial conditions are in fact comparable. An assessment always needs to consider not only energy consumption, but also investments and amortisation, maintenance, wear and tear and the cost of spare parts [Reference 4].

Influences on energy consumption are manifold: plant diagram, processing capacity and its utilisation are essential to realise aspired processing aims.

Handling hundreds of formulations and producing batch sizes between 1.5 tonne and 50 tonne is economically challenging.

Besides structure of components and mixture formulations technical condition of machinery and equipment as well as maintenance affect energy consumption.

Last but not least technological discipline and education of the staff take effect (Reference 4).

Besides material, machine and process parameters, the processing aims determine the energy input: hygienisation efforts, reduction of antinutritive substances, decomposition of certain ingredients, pellet stability.

It is essential to understand that the higher the targeted processing level, the higher the energy input. Qualitative effects of refinement processes are shown in Table 1.

In refinement processes, part of the electrical energy inputs can be provided by cost-efficient thermal energy in the form of saturated

Feature

steam. Adding as much steam as possible during pre-conditioning is thus desirable.

Depending on absorbability and other fluids within the mixture, and taking into account that 0.6 percent of saturated steam will increase process temperature by approximately ΔT = 10 K (Figure 4), minimum content should be approximately three percent (pelleting) to five percent (expanding).

However, steam input is limited due to pressureless operation of the pre-conditioner by the maximum possible feed temperature and moisture with respect to pelleting (lubricating effect) and storage stability (moulding).

To ensure thermal energy is used efficiently, loss minimisation and the maximum levels of steam that can be added need to be considered. Measures for saving thermal energy are, for example, sufficient boiler pressure to allow a drying phase by pressure reduction directly in front of the conditioner, accompanied by an adequate number of steam traps, insulation of all steam pipes, conditioners etc and of course stringent avoidance of leakages.

The grinding process With respect to grinding processes, the specific energy requirement is determined by material properties, the required particle size reduction, the comminution equipment and the process and plant layout.

Generally, particles should be only as fine as

Figure 4: Increase of temperature when conditioning compound feed by means of saturated steam necessary and as coarse as possible, since the energy requirement rises exponentially with increasing fineness [Reference 5].

Measures to discharge the mill-motor load, such as the preliminary separating of fines, closed-circuit processes or multi-level size reduction, can achieve energy savings of between five and 25 percent.

Frequency controlled drives allow selective circumferential speed to realise roughly aspired structures and particle size distributions.

&feed milling technology

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Feature

Energy consumption

Development trends include larger designs for hammer mills, and the increased use of hammer mills with vertical rotors and roller mills with two or more assembly levels (roller pairs with different gaps), either instead or combined.

Both machines are preferable in terms of energy use, but with roller mills material-specific processing restrictions need to be taken into account.

Figure 5: Influence of saturated steam addition on energy requirement, pellet durability and process temperatures

Heat recovery

References

Additionally possibilities for heat recovery from production processes for heating circuit water for social rooms or offices should be reviewed.

Because of low enthalpy and possibly hygienic contamination direct use of thermal energy from cooling or drying air for raw or feeder water is not recommended. A benefit from this energy recovery would rather be a reduction of odour emissions. Checking the possibilities of combined heat and power cycle may be useful.

The total energy requirement of a feedmill is decisively determined by plant layout, formulation texture, type and technical state of the equipment, plant capacity, load factor and technological discipline among the staff.

In addition to the measures mentioned, the prevention of energy losses (next to steam accommodation pressure-air supply) and the use of low-cost electricity rates basically re-present further optimisation potentials; in view of energy costs developments, these should certainly be taken into account.

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[1] Heidenreich, E. - Löwe, R. Pelleting technology: looking to the future - International Milling Directory 2000, pp. 55-60 [2] Löwe, R. - Judging pellet stability as part of pellet quality - Feed Tech 9 (2005), pp. 15-19 [3] Birchmore, J. - Surfactant’s benefits to feed manufacturers - Feed Magazine/ Kraftfutter 3-4 (2010),pp. 17-21 [4] Feil, A - Is it possible to cut energy costs for the production process?

- IFF colloquium Braunschweig May 2005 International Research Institute of Feed Technology [5] Löwe, R. - Vermahlungstechniken für Futtermittel - Tierernährung für Tierärzte, TiHo Hannover April 2007, Proceedings pp. 33-34; Editor J. Kamphues and P. Wolf

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Feed Pellets

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Making

Feed Pellets A

feed mill needs to produce pellets in a hygienic way with the least costs and the highest efficiency. This cannot be realised without the close relationship between the operators in the field and the engineers at the drawing table.

Through this cooperation equipment manufacturer CPM Europe, in Amsterdam, The Netherlands, has been able to launch many ‘firsts’ which have later been adopted and copied to become industry standards.

Plant operators working in the feed industry often consider the handling of their pelleting equip­ment to be an art.

Manufacturers of these ma­chines consider their businesses to be closely related to science. But this science can learn from the pelleting ‘artists’ by developing and implementing demands and views from practice.

The engineers at CPM Europe are the last ones to deny that practice is closely intertwined with their work on the computer controlled drawing programs.

"Our close relationship between practice and our ability to translate practical improvements into factual equip­ment, has delivered us almost always a competitive advantage which is especially valuable in 18 | July - August 2010

our indus­try - which is not specifically known for its innovative power," says the company.

Conditioning with hygieniser

reduces electrical power use and reduces wear of dies and rollers. Furthermore, with condition­ing more difficult (cheaper and/or) ingredients can be used.

Conditioning is a combination of moisture addition (steam and/or water), mechanical

CPM is active in the grinding and pelleting section of the Table 1: Comparison of expander and CPM hygieniser as a feed manufacconditioner before pelleting turing process.

Expander CPM hygieniser Before pelleting the feed mash needs Maximum formulation flexibility Formulation fat level 8% max to be treated 250 kW drive installed 2.2 kW drive installed before it enters 12 kWh/tone average (expander + 8 kWh per tone average (hygieniser + the pellet mill. pellet mill) pellet mill) This condi$0.75 per tone wearing items No wearing items tioning of the Increased parts wear with limestone mash has sevor oyster shell eral advan­tages.

No sensitivity for abrasive elements in Proper condiin formulation formulation tioning ensures High skill required to operate Very simple to operate a better pellet qual­ity (hardDown time risk due to blocking No down time risk ness, durability) High starch formulation increases No sensitivity for high starch resulting in betblocking risk formulations ter conversion Moisture content in pellets difficult to Moisture content in pellets simple to rates with the maintain maintain animals.

High temperatures effect sensitive Simple and accurate temperature Conditioning elements like vitamins control improves pellet Controlled product retention time for mill capacity, Product retention time is not controlled optimum salmonella destruction

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Feature

Feed Pellets

treatment (kneading and shearing) and thermal treatment (time/tempera­ture).

Especially the last feature has become essential in feed manufacturing.

Through higher temperatures the feed is hygienised and bacteria are already killed in the conditioner. CPM was at the forefront of this development with the introduction of the hygieniser or super conditioner. This piece of equipment has shown to be an extremely efficient con-

Since 1883

have to be by-passed or discarded before pelleting.

CPM has overcome this problem “CPM was at the by developing the ‘Hot Start Mixer’, forefront of this which functions as a buffer in the development start-up of the condition­ing process. with the The paddles and screw in the first section of the hygieniser at startintroduction of up turn in reversed direction until the hygieniser the mash has reached the required or super temperature and then the direction conditioner” is changed and the mash can flow through the hygieniser.

There is no longer any need for a by-pass and the full batch of feed can ditioner before pelleting and it is much be used without chance of recontamination. cheaper than an expander, which is also often used.

Specialist in pelleting Table 1 shows die differences between an Around 50 percent of all pellet mills expander and die hygieniser. used in the world are made by CPM. So the company, indeed, can call itself a specialist in pelleting.

Hot start mixer Pelleting is not just the use of a machine One small thing was still a problem: when starting the conditioning process the first that turns ground and mixed ingredients into approximate 100 kg of a new run did not pellets, it is a process and begins after the reach the required temperature and would grind­ing process with conditioning, followed

Roll Speed

Since 1883

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CONTACT CPM/Europe BV Distelweg 89, 1031 HD Amsterdam, The Netherlands, Phone +31 20 494 61 11, Fax +31 20 636 42 94, info@cpmeurope.nl

CONTACT CPM/Europe BV Distelweg 89, 1031 HD Amsterdam, The Netherlands, Phone +31 20 494 61 11, Fax +31 20 636 42 94, info@cpmeurope.nl

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July - August 2010 | 19

Feed Pellets

by die actual pelleting and then cooling of the hot pellets and where applicable the addition of fats.

Pelleting is also about energy consumption.

The way the die and the die rolls are positioned largely deter­m ine how much energy can be added to the product. There is a close relationship between energy consump­t ion and pellet quality.

The more energy is put into the pellet the better its quality will be.

At the pellet mill this is limited to maximum 20kWh/ tonne.

The consumption of energy is also dependent on the roller distance to the die.

An increase in roller distance will result in higher energy consumption. To be able to manage this process CPM developed the lineator, which enables die operator to adjust the roller distanc­ es while pelleting and thus give himself the opportunity to influence pellet qual20 | July - August 2010

ity without stopping the production.

Energy efficiency is also depending on the method of power transmission in die pellet mill.

For this reason CPM pellet mills operate with a gear box instead of double V-belt drive.

Gearbox trans­ mission has a high efficient power transmission. For a 250kW with an operating time of 6000 hours per year and an energy price of eight eurocents per kWh this would mean an energy cost of €120,000.

At 11 percent higher efficiency this would mean a saving of 13,200 in the advantage of a gear box drive.

Quick die change Every pellet plant operator knows the burden of chang­ing a die. Not only is it a heavy and time consuming job, it also adds considerably to the down-time of the plant.

The CPM engineering group in Amsterdam has developed a quick die change system for its 32" and 36" pellet mills.

The objective was to have the pellet mill up and running with a new die only 30 minutes after the end of the previous run. This means that for the actual (hot) die change only 20 minutes are being reserved.

To meet this objective CPM installed a pneumatic die hoist, automatic knives positioning, automatic roller adjust type lineator, 18 segments die clamp type bear claw and pre-assembled die with stiffening ring and rotary cone.

Feature

With this system two people can remove a die in less than four minutes and the same people can fit a new die in less than five minutes. The quick die change clamp can also be mounted on existing machines that have been supplied

by CPM in the past 10 years.

Roll speed measurement The latest innovation is the roll speed measurement, which has been in operation for testing over one year and is now mature to sell on the CPM Pellet mills.

The new integrated roll speed measure­m ent device works with very little maintenance and high accuracy.

It was observed that with clean die and rollers, the roll speed measurement allowed an automatic 'zero-positioning' of the Lineator. Until now this 'zero-positioning' proved to be a rather subjective interpre­tation by various operators.

Different operators can 'pre-load' the rollers differently against the die to set the zero-position. With the roll speed measurement the zero-position is set at the moment both rollers are rotating at nominal speed.

In practice, influencing the pellet quality is reached by using a thicker die or BOA-compactor or expander.

Now CPM introduced another option with roll speed measurement system together with a Lineator. The operator can safely move the rollers from the die and creating a “variable die” and so influence the pellet quality, all this can be done due to the roll speed measurement.

The roll speed measurement continuously measures the roll speed so that it stays above a certain speed, so that the die doesn’t choke.

Due to this “variable die” specifications less die changes are needed and the different batch are made with the optimal “variable die.”

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information:

CPM Europe B V Distelweg 89 Amsterdam, NL-1031 HD The Netherlands Tel: +31 20 4946111 Fax: +31 20 6364294 Email: info@cpmeurope.nl Website: www.cpmeurope.nl

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Heat Treatment

Feature

Added value by

Flour Heat Treatment

by Urs Schwendener, Process Engineer, BĂźhler AG, Uzwil, Switzerland

The Flour Heat Treatment (FHT) process provides modified grain-based milling products with specific characteristics for a wide range of applications in the food industry. Heattreated flours are opening up new market segments for the grain milling industry

T

he physical and chemical properties of flour depends on the original grain quality. However, the grinding process allows the baking characteristics to be controlled to a certain extent.

Thermal and hydrothermal treatment modifies flours in such a manner that they can be applied not only for baking, but also in numerous other areas of food processing.

Thermally-treated flours are a response to the issues of recipe optimisation, enhancement of convenience and product safety, which are omnipresent in today’s food processing industry.

22 | July - August 2010

In addition, such flours do not have to be declared.

Flour Heat Treatment (FHT) allows the physical, rheological, microbiological, enzymatic and chemical flour properties to be selectively modified.

During thermal treatment, the flours are exposed to the action of heat in order to strengthen the gluten and to reduce the water content. The purpose of hydrothermal treatment is to partially gelatinise the starch and to inactivate enzymes and microorganisms.

A very wide range of applications exist for such thermally and hydrothermally modified flours. Generally speaking, they can be divided into the following groups:

bakery products, binders, coatings, and carriers:

Bakery products Thermally-treated flours with a strengthened gluten structure are used for making high-ratio cakes, where high proportions of sugar and fat are applied.

To obtain a long shelf life of fresh doughs, raw materials are required which have a low level of microbiological contamination. The heat treatment hygienizes the flour by inactivating a large portion of the microorganisms.

The high temperature denatures part of the enzymes, making them incapable of reaction.

This also has a positive effect on the shelf life.

Certain proportions of FHT flour may

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Grain

Feature

Heat Treatment

increase the water absorption capacity of the bread dough.

Binders The hot viscosity of flour can be selectively increased by the FHT process. Such flours are used as thickeners in soups and sauces.

The action of the heat dries the flour.

Flours used in instant soups must have a low water content to prevent them from releasing moisture to the other ingredients.

Microorganisms and enzymes are inactivated by the process heat. This increases the shelf life of the products.

Hydrothermally modified flours with an increased cold viscosity and water absorption capacity can be applied for making sausages or instant desserts.

Coatings Hydrothermally-treated flour is excellently suited as a batter (liquid dough) for coating fish, meat, and vegetables with breading.

The optimised cold viscosity allows wet panadas to be uniformly applied to the product virtually without dripping. Such bat-

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Grain

ters serve as binders between the meat or fish and the dry panada. Their purpose is to ensure that the bread crumbs will adhere permanently to the meat. It is not allowed to rupture or blister, even when deep-frozen or deep-fried.

The higher the cold viscosity, the thicker the wet panada coating that can be applied.

Carriers Untreated flours are hardly ever used as carriers for flavorings, spices, or enzymes because the flour component substances might affect the actual product.

FHT flours, on the other hand, can be applied as carriers. The reactivity of their component substances is minimised, for the gluten has been denatured and the enzymatic activity and the microorganism count have been reduced. The water content of such carriers must be low to ensure that no water will diffuse from the carrier into the actual product.

Other applications In the FHT process, it is possible to stabi-

lise bran and germ (for example of wheat).

This extends the shelf life to a significant extent. The thermal action largely inactivates the enzymes, which appreciably slows down the rancidity process.

In addition, microbially induced spoilage is reduced because a large part of the microorganisms has been inactivated by the heat.

Stabilized bran and germ are characterised by their nut-like taste. They can be used in bread, breakfast cereals, cereal bars, etc.

July - August 2010 | 23

Heat Treatment

A new field of application is the stabilization of rice polishings as a preliminary stage to subsequent oil extraction from rice hulls.

Flour heat treatment process Thermally and hydrothermally treated flours can be produced on the same system when the Buhler FHT process is used. A loss in weight dosing scale supplies the system with a constant, defined

stream of product flowing at a rate up to 2500kg/h.

In a conditioner, steam and – depending on the type of treatment – water are injected into the flour. Then the flour is transferred to the retention screws, where the actual “cooking process” takes place.

Thermopneumatic conveying systems dry the moist product to the required water content. Agglomerated product is removed by sifting, reduced to a defined particle size, and returned to the flour. After the end product has passed through the metal detector, it is conveyed to the finished-product bins, from where it is bagged or loaded out in bulk into trucks.

The most important process parameters are the throughput rate, the steam and water quantity, the temperature, the retention (dwell) time, and the drying temperatures. These parameters are permanently controlled and monitored by a PLC control system. They are visualised and recorded online, enabling the entire process to be carefully logged.

FHT process versus extrusion Frequently, the question arises as to the difference between the FHT process and extrusion. The two processes do not compete with each other.

Unlike extrusion, where the flours are exposed to the very powerful action of heat, moisture and mechanical forces, the flour in the FHT process is treated only hydrothermally or thermally.

Hydrothermal treatment allows a low to medium starch gelatinisation degree to be 24 | July - August 2010

Feature

obtained. With in a medium degree of gelatinisation, the FHT and extrusion processes overlap to some extent. The extrusion process allows a starch gelatinization degree up to 100 percent to be achieved.

Flours that are subjected solely to thermal treatment will to some degree retain their baking properties and therefore differ fundamentally from extruded flours.

FHT is the optimal process for modifying flours on a customer-specific basis. Such flours open up a wide range of applications in the most diverse fields of the food production industry.

Buhler is a global leader in the supply of process engineering solutions, especially technologies for grain processing plants and nutrition solutions. Buhler is present in over 140 countries and has some 6600 employees worldwide.

More

information:

Urs Schwendener Process Engineer Bühler AG Uzwil Switzerland Tel: +41 71 9552259 Email: urs.schwendener@buhlergroup.com Website: www.buhlergroup.com

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Mycotoxin testing

Feature

Mycotoxin testing: ready for this year's harvest?

by Richard Fielder, Romer Labs, UK

M

anaging the risks posed by mycotoxins in the food supply chain is both complex and difficult to predict.

How will this year compare to last year for the grain and feed producers and millers?

Constant revisions are needed to our assessments. For example, the European trade organisation COCERAL have recently made reductions to their harvest forecasts for the main grain and oilseed crops in the EU. Meanwhile the UK Met office has scrapped seasonal weather forecasts, replacing them with fortnightly and monthly ones. The task is no different for the agronomist and food technologist who need to continually assess the risks of not just single but multiple fungal toxins that need to be controlled at every stage of the supply chain.

A mycotoxin-based HACCP system The object of this article is to present suitable options for monitoring critical control points in a mycotoxin-based HACCP system. Before doing so, it is necessary to clarify certain concepts, especially regarding the characterisation of hazardous mycotoxins.

Although mycotoxins are chemical compounds that appear as residues in commodities, ingredients, feeds and food, they are considered biological hazards rather than chemical hazards because their presence is a direct consequence of fungal contamination at some point in the system.1,2 Cereals and nuts are the most sensitive foods to mycotoxin contamination.

26 | July - August 2010

Nonetheless, these contaminants can also be detected in products of animal origin such as milk, meat, eggs, and plant derived products such as coffee, wine, dried fruit, etc. The variety of commodities, feeds and foods that can be contaminated by mycotoxins is as vast as the type of contaminating mycotoxins (more than 300 are known).

Therefore, establishing a model for a mycotoxin control system in the food supply chain is no simple task.

Monitoring methods: fungal or mycotoxin analysis?

As already mentioned, despite being chemical substances mycotoxins are considered biological hazards. This could lead us to believe that the correct methods for monitoring critical control points (CCP) are those that detect, quantify, identify and classify fungi.

However, we must consider that in many cases the different processes that eliminate fungi from commodities / ingredients will result in mycotoxins remaining throughout the food processing chain because of their chemical stability.

In other situations, potential mycotoxigenic fungi might be detected but are not producing toxins due to them being a nonproducing

Key Analytical Questions : Test on-site or outsource ?

Sampling: how & how many ?

Which: toxins, test, samples ?

What target levels for action ?

How much will it cost ?

How reliable ?

strain, the nutrient source being inadequate, or because the environmental conditions are not favourable for generating the mycotoxin in question.

In addition to a possible lack of correlation between the presence of potentially toxigenic fungi and mycotoxins in a particular food product, the disadvantage of these methods is the time required.

Obtaining the end results for a single isolated strain can take between two to three weeks.

However, when monitoring a CCP in the supply chain real time measurements are required. These methods are therefore more applicable to performing a hazard analysis, than to monitoring a HACCP system once it is implemented.

Method choice and sampling The analytical method selected depends on a number of factors such as the type of sample, the levels of mycotoxins to be detected, the control point to be monitored and the availability of technological, economical and human resources to perform the determination.3 For all such methods the first step of sample collection and preparation is the most critical to determining what is detected and what is not.

In fact, nearly 90 percent of the error associated with mycotoxin assays can be attributed to how the original sample was collected. This is because only a few percent of kernels in a contaminated lot may contain mycotoxins, and these contaminated kernels are usually not evenly distributed within the lot of grains. 4,5,6,7

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Grain

Feature

Mycotoxin testing

Challenges of Mycotoxins : Predicting harvest conditions Assessing the risks from single and multiple toxins Limiting their financial impact Meeting new legal safety limits Maximising international trade

Testing for mycotoxins generally consists of three steps: 1: several small samples are taken at random from the lot and pooled into one larger ‘lot sample’ 2: the entire lot sample is ground to a fine particle size and a representative subsample, the ‘analytical sample’, is removed for analysis and 3: the mycotoxins are extracted from the analytical sample and finally determined From the risk perspective, if the producer wishes to avoid the chance of rejecting an acceptable lot (Producer Risk), sampling may need optimising.

If the producer wishes to avoid the chance of

wrongful acceptance (Consumer Risk), sampling may need increasing. The choice of method can therefore be influenced by the number of samples to be tested. When there is a set amount of money available, the decision is whether to choose a low-cost, on-site test capable of analysing many samples versus testing fewer samples by more expensive outsourced analysis.

Mycotoxin methods for HACCP monitoring Some of the fastest and most affordable methods used are generally those based on ELISA technology.

ELISAs utilise antibody reactions in wells to provide quantitative results and are suitable for many sample types. In common with all methods, it is important to ensure that the individual ELISA kit is validated for the mycotoxin and commodity in question, so it is ‘fit for purpose’.

Romer Labs® has over 80 validations for its AgraQuant® ELISA kits with different sample matrices. After sample preparation the ELISAs take between 15 and 25 minutes to perform and are frequently used by industries for

monitoring their CCPs, with results comparable to more specialist testing by HPLC.8,9 There are broadly two other types of commercially available methods for detecting mycotoxins that provide even faster determination, which are very useful especially at the point of reception for raw materials.

Firstly, there are those based on detecting the natural fluorescence of the toxins, such as the FluoroQuant® Afla test kit. This test has just been adopted for the next five years by USDA’s grain inspection (FGIS) to test corn.

FluoroQuant® is simple and quick to perform, taking just five minutes after sample extraction using sample clean-up columns and a reader.

Secondly, there are other immunologicalbased methods (like ELISA), that are performed using a strip type format which indicates the presence or absence of a particular mycotoxin with reference to a cut-off point.

Romer Labs® has the AgraStrip® series of lateral flow devices (LFDs) for determining aflatoxins and deoxynivalenol (DON) in different products such as corn, raisins, soy, nuts, wheat, etc.

Three cut-off levels are available for afla-

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Romer Labs ® UK Ltd - Ireland & UK Tel: +44 845 519 5010, Fax: +44 1745 827150 e-Mail: enquiry@romerlabs.com

July - August 2010 | 27

Feature

Mycotoxin testing

EU Mycotoxin Legislation : No. 1881/2006 – food No. 105/2010 – food (New) No. 1126/2007 – food No. 2003/100/EC – feed No. 401/2006 - food Recommendations: 2006/576/EC – feed 2006/583/EC – cereals 2003/598/EC – food

toxins in-line with legislative limits: 4ppb, 10ppb and 20ppb. This allows one to choose the most appropriate LFD according to the commodity and its end use.

For example, the AgraStrip® Afla 4ppb is used for analysing almonds exported to the European Community. Some LFDs are quantitative rather than qualitative when used with an optical reader. Romer has recently improved its AgraStrip® XReader when testing for DON, it provides instant (semi-) quantitative results with greater accuracy, for a wider range of commodities, using updated software.

As in the ELISA tests, it is necessary to verify that the analysed matrix is included among the validated commodities.10,11

Reliability of results All quality management systems must verify the correct functioning of methods used for monitoring and strive for improvements.

There are two ways of ensuring this, which rather than being mutually exclusive, complement each other and so both options should be used to verify that the analysis provide precise and accurate data for decision making.

The first option is using matrix reference materials (MRMs) or internal control samples.

These are product samples used to audit the analytical procedure as they contain a known level of contamination with the mycotoxin of interest and their certificates include the value of uncertainty of determining the mycotoxin in the product.

This reference or control sample is tested in the analytical system used, at a frequency established according to the number of analyses performed at that point.

Romer Labs® Biopure range offers a wide range of MRMs for several toxins at different levels of toxin contamination. These samples include a certificate of analysis which complies with ISO guides 31 & 35.12 The other option is to send samples from the different monitoring points to (reference) 28 | July - August 2010

laboratories with analytical systems that can certify the value of the samples.

This is also performed when wanting to confirm results that are very close to the acceptance or rejection level for the critical limits established. These laboratories use chromatographic techniques, HPLC, TLC, LC-MS/MS, GC-ECD, which are highly sensitive and precise. If possible, the laboratory should be accredited (for example ISO17025) or have a good Quality Assurance system to ensure that their results are accurate and that trained analysts are competent to perform the method employed.

Romer Labs® operates laboratories on three continents, in Singapore, the USA and Austria, all of which are certified (or are in process of certification) under the international norm ISO17025 and have the most advanced technology, including LC-MS/MS.

Preparation for 2010 harvest Monitoring mycotoxins throughout the production chain is one safety measure.

Other tools to prevent contamination include the monitoring of environmental conditions that might favour the production of mycotoxigenic fungi for example, measuring water activity and temperatures.

The coming months are critical for the quality of this year’s harvest, which is why the UK’s Home Grown Cereal Authority have just launched their fusarium mycotoxin risk assessment to calculate the risk of contamination, even though the levels of mycotoxins are generally very low in UK grain.

A good HACCP system has to be capable of coping with all factors that put the production chain at risk. Mycotoxins do not occur in isolation as discussed here, and need to be considered in the context of all the other food safety risks.

References: 1. FAO /IAEA Training and Reference Centre for Food and Pesticide Control (2001 Reprinted 2003) Manual on the Application of the HACCP System in Mycotoxin Prevention and Control. Rome.

2. D. Aldred, N.Magan, M. Olsen, Chp. 7: The use of HACCP in the control of mycotoxins: the case of cereals. In: Mycotoxin in Food – Detection and Control. Woodhead Publishing Limited, England.

2004.

3. P.S. Knass, Micotoxinas en la Industria Alimentaria: Mantener la Situación Bajo Control. Énfasis Alimentación 6: 52-61 FLC Editores.

4. Coker RD, Nagler MJ, Blunden G, Sharkey AJ, Defize PR, Derksen GB, and Whitaker TB (1995).

Design of sampling plans for mycotoxins in food and feeds. Natural Toxins, 3, 257-262.

5. Richard J (2000). Sampling and Sample Preparation for Mycotoxin Analysis. RomerTM Labs’ Guide to Mycotoxins, 2.

6. Whitaker TB, Dowell FE, Hagler WM, Giesbrecht FG, and Wu J (1994). Variability associated with sampling, sample preparation and chemical testing of farmers’ stock peanuts. J Assoc Off Anal Chem Intl, 77, 107-116.

7 Whitaker TB (2003). Standardisation of mycotoxin sampling procedures: an urgent necessity. Food Control, 14, 233-237.

8. Zheng Z., Humphrey C., King R.S., Richard J.L. Validation of an ELISA test kit for the detection of total aflatoxins in grain and grain products by comparison with HPLC. Mycopathologia (2005) 159: 255-263.

9. Zheng Z., Hanneken J., Houchins D., King R.S., Lee P., Richard J.L. Validation of an ELISA test kit for the detection of Ochratoxin A in several foods commodities by comparison with HPLC. Mycopathologia (2005) 159: 265-272.

10. Zheng Z., Richard J.L., Binder H. A review of rapid methods for the analysis of mycotoxin.

Mycopathologia (2006) 161: 261-273.

11. Zheng, Z.M. Validation Report of AgraStripTM Total Aflatoxin Test, Romer Labs study number SIN-2005- 01, 2005.

12. G. Häubl . F. Berthiller . R. Krska . R. Schuhmacher.

Suitability of a fully 13C isotope labeled internal standard for the determination of the mycotoxin deoxynivalenol by LC-MS/MS without clean up.

Anal Bioanal Chem (2006) 384: 692–696

For

more information:

Richard Fielder (Director) Email: richard.fielder@romerlabs.com Tel: +44 845 5195010

Author’s note: Romer Labs is the leading global provider of niche diagnostic tests for the agricultural, food and feed industry.

More

information:

Romer Labs Diagnostic GmbH Technopark 1 3430 Tulln Austria Tel: +43 2272 615331 Fax: +43 2272 615331-11 Email: office-europe@romerlabs.com Website: www.romerlabs.com

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Fusarium mycotoxins

Feature

Fusarium mycotoxins – What’s all the fuss about?

If the grower does not know the intended end use (of grain), he should not assume it is for animal feed; “feed wheat” in the grain trade is used as a quality specification rather than a defined end-use

by Prof Simon Edwards, Harper Adams University College, UK

F

usarium mycotoxins are toxic chemicals produced by a group of fungi called Fusarium. These fungi produce mycotoxins when they infect cereals, resulting in a disease called fusarium head blight (see photo).

Fusarium infects the crop during flowering in early June and symptoms develop about a month later in early July.

Ten years ago farmers and processors were largely unaware of what fusarium mycotoxins were, let alone aware of the potential issues.

But things have changed drastically since then and mycotoxins are now one of the top issues for wheat quality. In 2006, the European Commission set legislative maximum limits for fusarium mycotoxins, deoxynivalenol (DON) and zearalenone (ZON) in unprocessed cereals and finished products.

The Home Grown Cereals Authority (HGCA) and Food Standards Agency (FSA) awarded two research grants to Harper Adams University College to identify the extent of fusarium mycotoxins in UK cereals and the impact of agronomy in 2001.

These five-year projects identified the varying extent to which UK cereals suffer from mycotoxin contamination and the “Good Agricultural Practice” that can be adopted to minimise the risk from fusarium mycotoxins.

Unfortunately, the project identified that the fusarium mycotoxins concentration is highly dependent on weather with rainfall at key growth stages of the crop being critical. The Good Agricultural Practice to reduce fusarium mycotoxins - Use Fusarium resistant varieties - Avoid maize as previous crop - Plough to bury crop debris; if using min-till, chop/mix as much as possible - Use a high rate of a recommended head blight fungicide at correct timing (early flowering) - Avoid lodging and harvest delays

30 | July - August 2010

extent of the fusarium mycotoxin issue there- concentrations exist in small and damaged grains fore fluctuates each season depending on rainfall and in chaff and dust, so cleaning can give some in early and late summer. reduction, but this is highly dependent on the qualThe HGCA has developed a fusarium risk ity of the grain consignment before cleaning. assessment to allow growers to assess the risk Higher concentrations also exist in the bran of exceeding the legal limits for fusarium myco- compared to the flour fractions, so milling results toxins in harvested wheat. in an increase in mycotoxins in the bran fraction The assessment is based on the known and a decrease in the flour fractions compared risks and includes both agronomic factors (loca- to the original grain. tion, rotation, cultivation, varietal resistance and Experimental results have shown that the disfungicide use) and rainfall at key stages of crop tribution of DON and ZON is different within development (flowering in early June) and pre- the grains. DON is highly water soluble and can harvest (August). therefore move within the grains if repeatedly The risk assessment is a Crop Assurance rehydrated (eg during a wet harvest), whereas Scheme requirement and the score is Table 1: Maximum mycotoxin limits included on the grain passport. If the score is for wheat and wheat products high then a DON test should be performed Mycotoxin (ppb) to check the level present.

At the moment, National Association Product DON ZON of British and Irish Millers (Nabim) request a DON test is completed for each consignUnprocessed wheat 1250 100 ment of wheat delivered to mills irrespecGrain and mill fractions for tive of the risk assessment score. This will 750 75 human consumption be reviewed after the start of the 2010 Wheat-based products 500 50 intake and maybe relaxed based on early Wheat-based products for infants 200 20 season results.

One of the trade issues raised by the Note: Limits for barley and oats are as above except DON limit for unprocessed oats is 1750ppb mycotoxin legislation is that grain is sold based on a quality specification of milling or feed wheat and yet, feed wheat may be sold on ZON has low water solubility and appears to for human consumption. largely remain where it was produced, which is Growers consider that if grain is sold as feed mainly in the bran fraction. wheat then it is destined for animal feed and Results from the 2008 harvest agreed with does not require a fusarium risk assessment or previous findings that DON is produced in early mycotoxin test. summer during Fusarium head blight infection In reality, if the grower does not know the and ZON is produced in late summer as the intended end use, he should not assume it is crop ripens. for animal feed; “feed wheat” in the grain trade This results in a change in the mycotoxin is used as a quality specification rather than a profile depending on when in the summer we defined end-use. have rainfall.

A wet delayed harvest results in a greater increase in ZON than DON. In this scenario, Robust molecules Fusarium mycotoxins, DON and ZON are as experienced in 2004 and 2008, we have robust molecules and there is very little reduc- more wheat exceeding the ZON limit than the tion during processing, even with high tempera- DON limit. The 2008 was the worst wet harvest experienced for many years and we had close tures for example, baking.

The main reduction achieved during processing to 30 percent of the harvested UK wheat crop is partitioning during cleaning and milling. Higher exceeded the legal limit of 100ppb ZON. This

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PUB85x254-T5X

28/01/10

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Fusarium mycotoxins

Percentage of UK wheat harvest samples exceeding legal limits for DON and ZON

was a major issue for the industry, but particularly for bran production as the majority of UK wheat would have produced Year DON ZON bran greater than 100ppb.

As a result of these 2001 0.4 0.7 high levels and the dif2002 1.7 0.6 ficulty in supply of bran 2003 2.4 1.2 that would allow production of high-fibre finished 2004 5.5 11.3 products within limits the 2005 1.5 1.2 European Commission 2006 0.0 0.3 set a one-year derogation 2007 4.0 2.7 for high-fibre breakfast 2008 13.1 28.6 cereals and wheat bran as 2009 2.0 5.3 an intermediary product of 100ppb and 125ppb ZON respectively which ended in October 2009.

There is much less of an issue for fusarium mycotoxins in feed.

There are guideline limits of 8000ppb DON and 2000ppb ZON for wheat intended for animal feed.

These levels are very rare in UK cereals. There are lower limits for finished feeds and these vary for different livestock due to differences in sensitivity, with lowest limits set for pig feed.

Ruminants and poultry appear more tolerant to fusarium mycotoxins although there were reports of poor hatchability in poultry after the 2008 harvest.

An evolving disease It is important to note that fusarium head blight is an evolving disease and continues to change. Fusarium graminearum, the main producer of DON and ZON, is increasing in Northern Europe and is currently spreading up the eastern side of the UK. From 2001-2005, levels of fusarium mycotoxins were consistently low in Scotland, but in 2009, the first wheat samples above legal limits for DON were identified

in the south east of the country.

The situation for barley and oats is different.

For barley, fusarium mycotoxin levels have been consistently low with only a few samples exceeding the ZON limit as a result of delayed harvests. For oats, DON and ZON levels have been consistently low but oats have relatively high levels of two other closely related toxins, HT2 and T2.

There is currently no legislation for these mycotoxins but legislation is under discussion and could be an issue of oat processors depending on limits set.

HGCA continue to fund research at Harper Adams, Fera and TAG to improve the fusarium risk assessment.

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Food security

Feature

FOOD SECURITY

A proposal for South Africa

by Jannie de Villiers, Executive Director, SA Agricultural Processors Association, South Africa

A

t the same speed at which the credit crunch and recession in the Developed World reached the inhabitants across the world, the food-price crisis disappeared from the radars of leaders in the Northern Hemisphere. Researchers and policy makers, however, are hard at work and their results are to be seen in quite a number of protectionistic measures to improve food security.

The fundamentals that have driven the food prices in 2007/08 are still there and are just temporarily covered by the recession.

As soon as the world awakens from the recession we will see the oil prices surging; followed by maize prices driven by the biofuel sector.

Global freight rates will increase from their current levels of US$40/tonne-$90/ tonne again. China, India and Brazil will increase their demand for proteins, for example in poultry meat production, etc and this will support grain prices.

We could have shortages in electricity producing pap and bread in SA. High food prices are a drop in the ocean compared to food unavailability!

We currently have a window of opportunity to do something about food security whist the recession last.

Definitions Food security is defined by the availability of food which is the responsibility of the free market. This will ensure enough safe food to be physically accessible to all.

32 | July - August 2010

The second leg of food security is affordability which is the responsibility of Government providing a policy environment whereby competition will drive down prices, economic growth and job creation will provide the means to buy the food and a social safety network to assist those in distress.

Lastly, affordability also necessitates infrastructure provision by Government to ensure a proper support system for the market.

Food self-sufficiency, however, has to do with surplus production, no imports and exports of surplus food. In South Africa the self-sufficiency index (production as percentage of consumption) for white maize over the past 10 years has been 131 percent. For yellow maize the selfsufficiency index for the same period was 116 percent but for wheat the self-sufficiency index is only 77 percent.

South Africa: A Proposal In an effort to maintain food security in South Africa, we would like to propose the following as the building blocks for healthy food security in our country: Maintain the free market - We need to maintain the free market mechanism as a system to ensure the availability of food to all. Although tempting to increase the self-sufficiency

indices of the various staple foods in the country, the free market system remains the most credible system to ensure enough food to the people of South Africa.

Invest in infrastructure - The agricultural sector has been left with very poor infrastructure and disinvestment by the South African Government over the past 10 years.

If we want to avoid a similar experience than that which happened with Eskom, we need serious investment in especially our rail infrastructure.

In the 1980s 85 percent of all grains was transported by rail and the processing sector has been developed for rail intake. The current percentage transported by rail is in the vicinity of 30 percent and is ¹ 20–30 percent less expensive than road transportation.

This inefficiency in our rail system is adding substantial cost to the price of basic food products in South Africa. The goal should be to transport 85 percent of grain in South Africa on rail by 2012.

This will not just save consumers substantial costs in basic foodstuffs, but also a tremendous saving in the maintenance account of our road system as well as a decrease in the congestion especially around our cities. It has been reported that the road infrastructure in South Africa is built to past 20 years.

Recently some data was released that showed 78 percent of the roads in South Africa are already older than 20 years.

The fixing of all the main grain corridors is essential for farmers to maintain their access to the markets. Quite a number of grain silos in this country have been delisted on the JSE

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July - August 2010 | 33

Food security

because of either stolen railway lines or poorly maintained rail lines.

International information indicated that the bulk carrier ships that is been built in the world is getting bigger by the day. This necessitates a deeper draft in the ports of South Africa to ensure our participation on imports and exports of soft and hard commodities.

Spending on research: Government spending on research in agriculture has decreased in the past 10 years with the major impact of climate change we need to increase the spending in research to maintain the current levels of production. Early surveys have indicated a three to five percent drop in yields for every 0.56˚C increase in our average temperatures.

South Africa also has to invest more in our water usage and research.

If the quantity of water becomes a problem and we replace all irrigated maize and wheat production with dry land yields, we will see a minimum of 12 percent drop in production.

This will most certainly put South Africa at a deficit grain situation.

We have also noted that the quality of water has deteriorated substantially because of pollution affecting food safety severely.

Infrastructure spending on capacities at the local Government level to process sewerage and the enforcement of pollution legislation especially in the mining sector becomes of critical importance affecting food security.

The capacity to process the registration of new products that enhances the productivity of our crop production as well as animal health needs to be improved substantially. A backlog of up to two years is preventing the agricultural sector of benefiting from new technologies that is already been successfully used in the Developed World.

Genetically modified foods: The global perception of genetically modified organisms is also threatening the availability of food in the world. The acceptance of GMOs in maize and the non-acceptance of GMOs in wheat are putting wheat at a huge disadvantage.

Farmers are planting more and more acceptable bio crops (maize and soya) as it becomes more profitable and wheat is loosing substantial acreage planted. This will eventually lead to a situation where either the wheat price needs to increase substantially to maintain its profitability to farmers, or consumers will have to accept the genetically modified properties that could be used in wheat.

No proven information has been published that shows any safety concerns with regard to the uses of GMOs. The continuous supply of electricity to our 34 | July - August 2010

processing plants remains an essential part of food security. The basic rule applies: ‘no electricity = no food’.

We need to ensure a proper supply of the skills needed to produce and process food for South Africa.

Feature

sector role players in agriculture need to be supported. Jointly they are providing the critical support services to new black farmers that become part of the main stream economy.

Other opportunities

In analysing the white maize crop estimates in South Africa over the past 14 seasons, it became eminent that 13 of the past 14 season the Department of Agriculture’s National Crop Estimates Committee has under estimated the maize crop.

This leads to higher maize prices to consumers.

It also influences our ability to export profitable as we are not sure about the crop size.

Government needs to increase the amounts available to improve the crop estimates to the extent that it will be within the ±5 percent margin as was agreed upon between all role players.

We therefore recommend that the producer independent crop estimate system be maintained and that only scientific inputs be used to estimate the crops in South Africa.

This history has proven that biased information supplied by farmers is without exception under estimating the crops in more than 90 percent of the instances.

We would also like to list a few other legs to the proposal of a food secured South Africa: • No food should be used for the manufacturing of biofuels • The speculation on the JSE Securities Exchange (Safex) should be limited where it affects food • South Africa should strive to become a preferred food aid supplier to the World Food Programme especially in our African region • Higher prices will be best cured by higher prices and let the market react to that • It is also of huge importance that the World Trade Organisation finalise its DOHA Round to improve a free and fair trade environment in agriculture internationally Lastly, we would like Government to continue with their fight against collusion and to increase competition to drive prices down. This is an essential part of a healthy free market. The Competition Commission in South Africa has done us a great favour in their recent offensive action against collusion practices in South Africa.

Agricultural tariff system

Conclusions

The Department of Agriculture has approved a new trade and tariff policy regime but it is not being implemented due to the fact that the major implementation body reports to the Department of Trade and Industry.

The trade and tariff policy are very powerful policy tools to enhance food security.

Actions taken by the Argentinean government to ban wheat and maize exports are red lights indicating that South Africa should reconsider relying so much on basic food imports in times of global short supplies. The net result that selective import duties on chicken meat (as an example) will have on jobs and food security could outweigh the initial increase in food prices.

In conclusion, the proposal for healthy food security in South Africa is not to panic with ad hoc policy decisions that would have a long term detrimental impact on South Africa.

The Government has done very well thus far and did the sensible thing in its reaction towards the food price crisis. We do however, need a much bigger commitment in terms of investment in agriculture to ensure the smooth supply of food at affordable prices to the people of South Africa in future.

Lastly, consumers in the country as well as policy makers need to be educated that food prices eventually must carry the cost to be food secured as well as to protect the environment in which the food is produced.

Market information: Crop estimates

Sustainable transformation In evaluating the food security in our region it is sad to note that although most of the SADC members are better endowed with climate and agronomic conditions, yet they remain food insecure. It is just proving that it has more to do with the policy environment than with the climatic environment.

Successful initiatives undertaken by private

More

information

Jannie de Villiers Executive Director SA Agricultural Processors Association South Africa Email: jannie@grainmilling.org.za

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GLOBAL GRAIN & FEED MARKETS Every issue 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.

Two key factors caused a shift of emphasis in the maize market during the last month. One was an official update of US planted area which came in well below trade expectations. The other was a lower than expected US quarterly stock estimate at June 1, the result of feeders and ethanol consumers having to use more of last year’s lower quality crop to get the same end result.

36 | July - August 2010

Cheap cereal offers dry up amid FSU/EU crop concerns

W

orld prices of cereals, as measured on the benchmark Chicago futures market – were getting incredibly cheap during June – maize edging towards three and wheat to four-year lows under pressure from excessive stocks, uncertain forward demand for feed and expected large world crops. But the picture has changed radically in the last few weeks as those optimistic world wheat crop estimates have started to slide on unexpected weather problems – first in Canada, then Europe itself and latterly in the former Soviet Union, where coarse grain output could take an even bigger hit from droughts and heat-waves.

At the same time the US has not only found itself with less old crop maize stocks than it expected (a legacy forewarned in earlier GFMT’s amid last year’s poor quality/lower energy value crop) but a much smaller than expected increase in planted area – though the latter could be offset by ideal weather promising bumper yields.

Stocks of wheat, as our regular readers will be well aware, are still huge by any traditional

reckoning. And even if this year’s world wheat crop (details below) does fall, say, 10m or 15m tonnes below the previously assumed level, the carryover into 2011/12 season will still be ample, though probably no longer larger than this year’s.

Maize, as the main constituent of global coarse/ feed grain supply, is hardly in a squeeze either.

Although US ethanol demand for this grain is still expanding, the growth rate has definitely slowed.

Demand for maize from the animal feed sector, while apparently higher than expected in the US itself, is also subject to some caveats going forward amid still slack conditions in livestock markets there. Export demand for US maize, especially from some of the key Asian importers is also looking less than stellar as the global economic recession threatens a ‘double-dip’ and many buyers show increasing interest in an abundance of discounted feed grade wheat.

That said, the radical turn downwards in wheat crop estimates is a caution to the bears, at the least, a warning that markets may have become complacent about excessive supply bringing ever cheaper prices. There is also the possibility that the top quality wheats may be in less abundant supply than expected earlier after Canada’s spring wheat sowings were held up and eventually downsized by incessant wet weather. The US, which sowed far less winter wheat this year, has also had some problems with rain slowing harvest and resulting in some lower than expected proteins and vomitoxin scares for soft wheats – though that situation seems to be improving as we go to press. In Europe, French traders have been concerned about heatwaves and a prolonged drought resulting in quality loss from shriveling

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COMMODITIES

or, at best, lower specific weights.

Some eastern European and former Soviet countries which (despite their emphasis on the middling milling and feed grade wheats), often have some good quality too, may also take a hit from dry weather/heat in terms of volume if not quality.

However, these crops are not yet in and it is quite possible that some of the countries getting a bit too much of the sunny dry weather will also see some bonuses in terms of higher proteins – so it is maybe it bit early to worry about constant big hikes in price premiums demanded for top grade milling wheats.

For oilseed crops, the picture remains much brighter. Record Latin American soya crops have been confirmed and, while a bit slower than expected coming to market, these will eventually fill the coffers to overflowing, resulting in stock buildups to record high levels during 2010/11. The US has meanwhile expanded its soyabean plantings to a record level too. The massive influx of

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meal-rich soya will more than make up for disappointing Canadian and EU rapeseed crop prospects and a probable flattening out in production of some other oilseeds including sunflowers. Provided the crush incentive is there, there is ample if not excessive oilseed raw material to keep meal buyers well supplied.

Meanwhile, for European grain and feed customers, much of the benefit of cheaper international prices has been denied by the chronic weakness of the euro. Thanks to the almost daily drip of worrying news about Euro-

info@aviana.co.ke July - August 2010 | 37

zone indebtedness, the common currency recently sank to its lowest level in almost four years versus the US dollar – in which most commodities are traded internationally. Since the start of this year, whatever has gone on in

the international cereal, oilseed and product markets, this has added almost 15% onto Euroquoted prices - although the effect has been ameliorated in recent weeks by a partial rally in the common currency and a downturn for the dollar amid a massive EU debt rescue package and renewed US economic gloom..

If there is a plus side to these economic worries it is the quelling of speculators’ enthusiasm to invest in perceived riskier assets – a group in which commodities like grains figure prominently. This is likely to remain the case while Euro-zone anxiety persists, especially with the US economy still showing signs of faltering and the Chinese, seen as the engine of global economic recovery, trying to rein in their own growth.

None of this news is bullish for industrial or food demand for raw materials.

The price of crude oil is often a pretty good indicator of the way the economic wind is blowing as well as directly affecting commodity prices. Not only is it, along with gold and some other leading commodities, a favourite of

investors, crude is also directly linked to the value of cereals and oilseeds. Crude’s price, after all, influences profitability and demand for bioethanol which takes up a third of the US maize crop. Since April, crude has come back from its highs in the mid-$80s to just over $70 per barrel before rallying recently to the mid-70’s.

38 | July - August 2010

While cereal markets had probably become oversold – and farmers certainly needed some respite from the endless decline in crop values – current supply/demand balances offer no justification for a return to the bull markets for cereals, let alone oilseed products. Lower than expected wheat and coarse grain crops will probably mean firmer prices in the season ahead than would have been expected a month or two ago. But, barring a late weather upset in the USA, supplies remain large enough to keep this rally in check.

Commodity highlights World wheat crop still over-rated?

Recent weather problems in Canada, Europe and the FSU have resulted in the US Department of Agriculture lopping 7.5m tonnes off its world wheat crop estimate and recent reports from the countries concerned suggest there may be more ‘downside’ before all the crop numbers are counted. However, with world wheat stocks still riding at 8-year highs – and likely to stay loose well beyond the end of the new season, there is nothing in the overall wheat balance to explain the still huge premium or ‘contango’ quoted on the forward futures markets. Chicago May 2011, for example was recently asking 65c/bushel or about 11% more than the spot month after reaching a high of 80c ($29/tonne or 16%) at one point. On the one hand, the US soft red winter wheat crop (the basis of the Chicago market) is well down this year on unusually small planted area. However, carryover stocks of this grade from last year are large and the total supply will still comfortably exceed both US domestic and export demand. That hasn’t stopped the US cash market rising too with the export price for SRW rising from $182 in early Jun to $234/tonne (fob) in July. This seems slightly bizarre amid the USA’s poor export performance for this grade which, even before the firm dollar is taken into account, is outpriced by all the other main origins. Prior to the recent run-up in euro-terms, the French soft wheat price was undercutting the US (in dollars) by about $20/tonne. However, the European wheat market is influenced by what goes on in Chicago and has added

the latter’s strength to the list of reasons (weak euro, better export demand, lower than expected domestic crop) why EU prices should have a pre-harvest rally. The firm EU export price, of course, spills over into the value of domestic grain too.

At the lower end of the scale, the ‘Black Sea’ exporters had been offering much cheaper wheat with milling (grade 4) recently down to just $160, about $15 cheaper than the EU, and feed grades as cheap as $138.

However, in recent weeks that has all changed amid worrying reports coming out of the former Soviet Union about heat and drought affecting production on this year’s smaller sown areas. The Russian crop is now seen about 49/51m tonnes compared with 57/60m earlier and last year’s 61.7m while Ukraine’s could be down from 20m to 18.5m tonnes. Kazakhstan, often a useful source of harder/quality breadwheats is meanwhile expected to produce only 11m tonnes this year against earlier hopes it would repeat last year’s 17m tonne crop. All of these figures are well down on USDA forecasts, suggesting that at least 8.5m tonnes more has to come off the world wheat crop forecast.

Fortunately for consumers, the Black Sea Region is going into 2010/11 with fairly large stocks for the second year running (about 19m tonnes) which should be be used to supplement exports. Readers may recollect it was only a few months ago that Russia and its neighbours were publicising ambitious plans to massively expand their exports into ‘non-traditional’ wheat markets in Asia and other regions. The ‘Black Sea’ exporters are aware that a ‘reliable supplier’ image is not to be discarded lightly so, despite some probable caution in for the early weeks of the new season, many analysts expect them to service all the export business they can once crop sizes are known (unless, of course, damage from heatwaves, drought etc turns out even greater than expected). That said, these usually highly competitive suppliers will probably not be undercutting the market to anything like the same extent we have seen in the last couple of years.

Concern is also focusing on the extent to which Canada will be able to perform its usual function of leading quality hard wheat supplier. Weeks of incessant rain have cut the planted area drastically, almost certainly by far more than the 200,000 ha (to 9.2m) recently estimated by Canadian officials who took their survey too early in the month to count all the

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COMMODITIES abandoned acres. With some trade estimates ranging down to as little as 7.3m ha (versus last year’s 9.9m), there is talk of a total wheat crop as low as 18.5m compared with recent hopes of 24.5m and last year’s 26.5m tonnes.

As always with Canada, the proportion of top grade bread wheats in the total harvest will depend on weather in the run up to crop maturity and harvest. However, on current pointers, supply from this source does look likely to fall and this has already driven export prices of CWRS sharply higher.

Offsetting that slightly, the USDA did keep its US spring wheat sowing forecast at a surprisingly high 5.63m ha against trade ideas it would lop this figure. This crop is in the best condition seen for many years and, if the weather continues to co-operate, it should yield well in terms of both quantity and quality. However, the US hard breadwheat export benchmark (DNS) is still rising to reflect the threat to Canada’s crop, reaching a 19-week high of $296/tonne in mid-July.

US hard red winter bread wheat – the largest component of US wheat exports – had a shaky start to harvest under damp

conditions that were producing some worryingly low proteins. These seem to have improved somewhat since the harvest moved north under clearer skies. The US soft red winter harvest was also challenged by showers causing quality problems including greater incidence of vomitoxin in some states.

Among other key milling wheat producers, Australia still seems to be on course for its third large crop in a row with a developing La Nina climate phase expected to bring adequate rains. Argentina sowed a lot more wheat for its next crop and could expand output to about 12/14m tonnes from last year’s unsually poor 9.6m. If the growing season goes well, this important breadwheat supplier could have twice as much for export as last year’s measly 4.5m.

Turning briefly to demand, world wheat consumption is expected by the International Grains Council to rise from 649m to 658m tonnes, largely in the feed sector and especially in Asia. That should be easily accommodated if the crop reached the IGC’s projected 664m tonnes. Even if we knock off, say, 10m to 15m tonnes to account for

possible Canadian, Black Sea or European losses not yet factored in, this would not make much of a dent in the huge 2010/11 surplus stock which the IGC estimated over 200m tonnes in late June. Overall, then, wheat

supplies should be more than adequate to meet demand – though some questions about quality remain to be answered by harvests in some key producing countries.

Less maize supply than thought Two key factors caused a shift of emphasis in the maize market during the last month. One was an official update of US planted area which

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COMMODITIES came in well below trade expectations. The other was a lower than expected US quarterly stock estimate at June 1, the result of feeders and ethanol consumers having to use more of last year’s lower quality crop to get the same end result. With yield prospects still bright, the US corn crop is now seen just 3.3m tonnes lower than in June at 336.4m tonnes. With the above reduction in starting stocks (still bigger than last year’s), total availability will be about

6.4m tonnes under earlier forecasts but only about 1.5m below the 2009/10 supply. This in itself is not statistically significant enough to move prices. Neither is the anticipated rise of 5m tonnes in next season’s US ethanol usage of maize which will be neatly offset by lower feed/residual demand. US exports are also seen unchanged in 2010/11, so stocks carried into 2011/12 will be less than 3m tonnes below those brought into this season.

A third factor pushing up maize value recently has been the steep rise in wheat prices which maize has been obliged to follow as a competing feed ingredient. However, whereas Chicago wheat has risen by as much as $1.73/ bu ($63/tonne) or 40%, maize has only gained 57c ($22/tonne) or about 17%. This seems to underline the US trade’s fairly sanguine appraisal of the domestic balance – that supplies will be adequate to meet demand.

Maize prices have also been anchored by a sense of anti-climax after all the hoohah two months ago about China emerging as a mega-buyer of US corn. In the event, China’s own crop appears to be doing much better than thought earlier, when cold and dryness threatened a potentially poor result.

Although USDA’s forecast looks a bit high at 166m (and last year’s Chinese crop may well have been 10m below the official 155m figure), this second largest world consumer of maize is showing no sign of concern about the adequacy of supply. So far it has bought about 2m tonnes from the US, probably as insurance when the crop was looking vulnerable. Ideas that it might take another 5m or 6m over the next six months are being played down, leaving

40 | July - August 2010

forecasts for world total import demand for this grain only about 3.5m tonnes higher for 2010/11 than in the past season.

Overall, world corn production in 2010/11 is expected to grow from last season;s 809m to about 832m tonnes, slightly ahead of consumption needs of 831m. About 10m tonnes of that is expected in China so if anything major does go wrong with that crop, analysts will have to make some big changes to this world balance. At this stage that looks unlikely, especially after recent good rains. A snapshot of other major maize suppliers shows some mixed trends.

Europe’s own crop is now seen at just under 57m tonnes versus last year’s 55.8m but it has recently been exposed to some potentially damaging heatwaves and dryness so a downward revision would not be surprising. USDA was recently forecasting the FSU countries would hoist output from 17.9m to 21.4m tonnes but that too looks less likely now after the extreme heat in Russia in the past month. Ukraine managed to export over 5m tonnes in each of the past two seasons and has become an important subsidiary supplier. In the southern hemisphere, Argentina and Brazil both expect slightly smaller crops but current thinking is that both will keep exports up at last year’s good levels, Brazil maybe even exporting more as it draws down large carryover stocks too.

Among the other coarse grains, world barley production prospects have been marked down sharply in recent weeks to account for potential crop losses in Europe and the former Soviet Union. Total output is seen around 135m tonnes compared with 142.5m earlier, last year’s 149m and 2008/9’s 155m tonnes. World barley producers are carrying about 5m tonnes more stock into 2010/11 than they managed the previous year but with world consumption expected to exceed output by about 9m tonnes, the stock figure will shrink by almost 6m tonnes in 2010/11 to a three-year low of about 27m.

Apart from these tighter supply balances, barley prices will also be forced to rise with the trend in EU and world wheat prices.

Oilmeals/proteins WORLD OILSEED supplies will show no growth in the new season ending August 2011 as smaller South American soyabean crops and disappointing Canadian and EU rapeseed production more than offset higher output

of cottonseed, peanuts, palm kernels and sunflowerseed, new USDA forecasts indicate.

While the US is heading for another big, possib ly record soyabean crop this year, Argentina is expected to reduce sowings this autumn (for harvest spring 2011) while both the major Latin American producers are expected to see their yields retreat somewhat from this year’s high levels. The result could be a world soya crop of around 251m tonnes – about 8.5m less than the current season’s record level. As far as soya users are concerned this need not present any problems as this season’s supply was in record surplus. USDA estimates about 65.4m tonnes will be carried into the new season compared with just 43.7m last year – so the total soya supply will actually be even larger. That means that, as long as the crush incentives are there, adequate raw materials will be available for all the meal production the market needs. At this stage, USDA estimates world meal demand will grow from 159m to 168m tonnes. Even then, stocks of the raw soyabeans at the close of the new season could still be record large.

Where soya supply and prices go, the rest of the oilseed/meal complex must follow. Most of the other oilseeds are forecast in larger supply in 2010/11, the main exception being rapeseed.

Canada’s crop, earlier thought capable of reaching 12m tonnes has been planted late on smaller than expected area after incessant rains and could be lucky now to scrape 10m. The EU harvest, planted on a larger area is also seeing stress from droughts and heatwaves and too much rain in some eastern member states with the current forecast of 20.6m (v last year’s 21.5m) seen open to further reduction.

However, by drawing on stocks and importing more whole rapeseed, the EU is expected to keep crush and meal production close to the past season;s high levels.

This year’s record South American soyabean production has helped to keep prices down in Europe in recent months. Since May, meal in Hamburg has declined from about $292/ tonne for nearby deliveries to $282 and as low as $273 at one point. Euro-quotes have been also fallen but at a slower pace during the period of extreme euro weakness. Cheaper meal in Europe has contrasted with a stronger US market, where tight old season soyabean supplies and strong Chinese demand have forced crushing well below year-ago levels. Under current conditions of good supply, meal prices are expected to stay fairly stable until the autumn when Latin American producers reveal their sowing plans.

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Book review OECD Publications

T

he OECD is a unique forum where governments work together to address the economic, social and environmental challenges of globalisation. The OECD is also at the forefront of efforts to understand and to help governments respond to new developments and concerns, such as corporate governance, the information economy and the challenges of an ageing population. The organisation provides a setting where governments can compare policy experiences, seek answers to common problems, identify good practice and work to co-ordinate domestic and international policies.

The OECD member countries are: Australia, Austria, Belgium, Canada, Chile, the Czech Republic,Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Japan, Korea,Luxembourg, Mexico, The Netherlands, New Zealand, Norway, Poland, Portugal, the Slovak, Republic,Spain, Sweden, Switzerland, Turkey, the United Kingdom and the United States.

The Commission of the European Communities takes part in the work of the OECD. OECD Publishing disseminates widely the results of the organisation’s statistics gathering and research on economic, social and environmental issues, as well as the conventions, guidelines and standards agreed by its members.

Agricultural Policies in OECD countries - At a glance 2010. An OECD

Publication, published 2010, pages 130, ISBN 978-92-64-08380-6 PDF. These books can be download from the OECD website at: www.oecd. org/publishing/corrigenda Published in alternate years the 2010 OECD Guide to the Global Agricultural Industry is permeated by significant doses of both pessimism and optimism.

This publication examines agricultural policies in OECD countries in response to the request by OECD ministers to monitor and evaluate the implementation of the principles for agricultural policy reform. The secretariat uses a comprehensive system for measuring and classifying support to agriculture in order to provide insight into the increasingly complex nature of agricultural policy.

Ongoing changes in agricultural policies require that the methods used to calculate and present the Producer and Consumer Support Estimate.

This year’s report emphasises the recent developments in agricultural markets and discusses future challenges for agricultural policy reform in the context of rapid fluctuation of world agricultural prices.

Chapter 1 provides an overview of developments in agricultural support in OECD countries, evaluates the estimated support to agriculture and draws some conclusions about the progress in agricultural reform being made in OECD countries. Chapter 2 summarises trends in developments of support and its structure for each OECD country and Chapter 3 contains detailed background tables.

Agricultural Outlook, 2009-2018

T

his is a somewhat alarming look at the current world state of agriculture and perhaps more alarmingly, the outlook for where the animal feed industries and major millers will be looking to promote their businesses.

This report covers biofuels, cereals, oilseeds, sugar, meats, and dairy products over the 2009-18 period.

The market assessments are based on a set of underlying assumptions regarding macroeconomic factors, agricultural and trade policies and production technologies.

They also assume normal average weather conditions and longer term productivity trends.

The Agricultural Outlook presents a consistent view on the evolution of global agricultural markets over the next decade and provides a

baseline for further analysis of alternative economic or policy assumptions.

In 2009, agricultural markets are characterised by a reduction in commodity prices following their rapid rise over the 2006-08 period. This report examines the general and commodity-specific factors behind the price declines. There is also a discussion on the evolution of retail food prices which have come down but not as quickly as international commodity prices and with considerable regional variation.

Looking forward, real commodity prices over the 200918 period are projected to remain at, or above, the 19972006 average. An expected economic recovery, renewed food demand growth from developing countries and the emerging biofuel markets are the key drivers underpinning agricultural commodity prices and markets over the medium term.

OECD FAO - Published 2009, Pages 279 42 | July - August 2010

&feed milling technology

Grain

Classified section Analysis

Bulk Storage

• Automation Products, Inc. • Brabender® GmbH & Co KG • CHOPIN Technologies • Diversified Laboratories, Inc. • Evergreen Analytical Services, Inc. • Farmertronic Industries A/S • Foss Analytical AS • FOSS UK • Lancaster Laboratories • NDC Infrared Engineering Ltd • Neogen Corporation • Pfeuffer GmbH

AquafeedClassified40_2x40mFINALrevsd 2/23/10 12:35 AM Elevator Buckets Feed processing

• Agora Services Ltd

Silo Construction & Engineering

®

STYLE CC-XD (XTREME DUTY)

Polyethylene Elevator Bucket

SCE Maximum bulk storage

CRAFTMANSHIP IN THE ANIMAL FEED AND FOOD PROCESSING INDUSTRY

ELEVATOR BUCKETS & BOLTS

St. Louis, Missouri USA

T:+1 314 739 9191• F:+1 314 739 5880 www.tapcoinc.com

WWW.OTTEVANGER.COM

Extruders

www.sce.be +32(0)51 723128

WWW.EXTRUDER.NL / WWW.EXPANDER.NL

• Schmidt-Seeger GmbH • Silos Cordoba S.L

Block 10 Todd Campus West of Scotland Science Park Acre Road, Glasgow Scotland G20 0XA

Almex b.v., Verlengde Ooyerhoekseweg 29 7207 BJ Zutphen, Netherlands, tel.: +31 (0)575 572666 e-mail: info@almex.nl, internet: www.almex.nl

Tel: +44 141 945 2924 info@r-biopharmrhone.com www.r-biopharm.com R-Biopharm Rhône Ltd, Unit 3.06 Kelvin Campus, West of Scotland Science Park, Maryhill Road, Glasgow, G20 0SP Scotland Tel: +44 (0) 141 9452924 Fax: +44 (0) 141 9452925 info@r-biopharmrhone.com, www.r-biopharmrhone.com

Competence in Food and Feed Analysis

Commercial Grain Silos Bulk Feed Silos

Caleruega 12, 1OC 28033 Madrid, Spain Contact Antonio Benitez BiopharmRhoneClass.indd 1 31/03/2010 15:36 Phone +34 91 767 00 74 Fax: +34 91 767 02 38 Animal Health & Nutrition E-mail: inpsa@symaga.com inpsa@manchanet.es

• Seedburo Equipment Company • Systech Instruments Ltd

• • • •

Anderson International Corp Amandus Kahl Anderson International Andritz Feed & Biofuel

Flour improver

• Alicorp SA

CENZONE TECH INC.

• Teta Engineering Inc.

2110 Low Chaparral Drive San Marcos CA92069 USA Tel: 760 736 9901 Fax: 760 736 9958 Web: www.cenzone.com

• Alicorp SA • Doves Farm Foods • Dr Eckel GmbH

Buhler AG CH – 9240 Uzwil, Switzerland T: +41 71 955 11 11 F: +41 71 955 66 11 E: milling@buhlergroup.com

www.muehlenchemie.de

www.buhlergroup.com

E-mail: cenzone.tech@worldnet.att.net

• Danisco Animal Nutrition • Frank Wright Trouw Nutrition International • Noack - Group of Companies • Papillon Agricultural Products, Inc

• Brabender • Clextral Buhler Class ad_GFMT10.indd 1 11/12/2009 • Dinnissen BV • EEC-Eder • Extru-Tech Inc • Jiangsu Muyang Group Co Ltd.

09:07

• • • •

Flour improvers Enzymes Baking premixes Advice on applications

Kurt-Fischer-Strasse 55, D-22926 Ahrensburg Tel.: + 49 (0) 4102 / 202 001, Fax: -010 info@muehlenchemie.de A member of the Stern-Wywiol Gruppe

Ein Unternehmen der Stern-Wywiol Gruppe

• Prima Ltd • Smiths Flour Mills

To advertise in our low-cost classified section, please contact Caroline Wearn Email: carolinew@gfmt.co.uk

For more company information, visit: www.gfmt.co.uk/market

44 | July - August 2010

&feed milling technology

Grain

Pa

Classified section Mill Design & Installation • Bratney Companies • Croston Engineering Ltd

Painting

Rolls

• Agora Services Ltd • Euroquip Fabrication Ltd • Silocare Ltd, Silocheck Ltd Stewart Inglis

INDUSTRIAL PAINTING LTD British Gas ERS Approved Painting Inspector

Andritz Feed & Biofuel BV Andritz Feed & Biofuel Condex (UK) Ltd Jiangsu Muyang Group Co., Ltd. Kay Jay Chill Rolls Pvt Ltd La Meccanica srl di Reffo

Thirty years experience in painting and anti-corrosion coatings , quality control etc. From Europe to the Middle East and in the oil industries from the North Sea to West Africa. please call for more information: Tel: +44 1289 386525

AT LAST .... low-cost classified advertising that really works!

From 2010, whether your business is a blue chip multi-national or a sole trader ... GFMT has changed the rules of classified advertising.

enquiries@stewart-inglis.co.uk

www.stewartinglis.co.uk Process control

• TekPro Ltd

Millson Engineering Limited Muench-Edelstahl GmbH

Mill design construction Supply Chain • Wallace & Associates Inc. • Columbian TecTank

Analysis & Control Intake and Inline measurement of moisture, protein, temperature, structure, ash, fat, fibre, starch and colour. Recipe management and traceability records.

Croston Engineering Ltd Tarvin Mill Barrow Lane, Tarvin Chester CH3 8JF Tel: 01829 741119 Fax: 01829 741169 E-mail: admin@croston-engineering.co.uk Website: http://www.croston-engineering.co.uk BULK STORAGE, HANDLING, AND PROCESS ENGINEERS FOR THE ANIMAL FEED, GRAIN, FLOUR, BAKERY, HUMAN AND PET FOODS INDUSTRIES

Products we produce and Export: ®

For maximum control and efficiency call:

01473 829188 www.suffolk-automation.co.uk

• Converteam UK Ltd • KSE Protech BV

• • • • • • •

Banana Meal Banana Powder Crude Tuna Fish Oil Crude Sardine Fish Oil Tuna Fish Meal Sardine Fish Meal Tapioca Chips & Tapioca Powder

Email: palmview@pldtdsl.net Website: www.palmviewtrade.com

Equipment for sale

• Interstates • Lurgi PSI Inc • Younglove Construction LLC

Packaging

PALM VIEW TRADE “Your Reliable Supply Chain Manager”

Recruitment AGRI-Associates Agribusiness Recruiters

A Foeth BV Condex (UK) Ltd

• Arodo BVBA

CB Packaging is a market leader of multi-walled paper sacks. With over 50 years of experience, we offer solutions for a wide range of industries, including animal feeds, pet food, seeds, milk powder, flour and root crops.

For more information, please call Tim Stallard: +44 (0) 7805 092067 www.cbpackaging.com

&feed milling technology

Grain

Both these high traffic channels specialise in the targeted positioning of industry, government and academic documents and information.

Each document is accompanied by independent, unsolicited reader statistics, recording the number of visitors to each document. All future GFMT Classified Advertisements will now appear in these sites with their own traffic records.

In addition, all Classified Advertisements will now be accompanied by a 250 word (maximum) profile of your company or service ... at no extra cost! You will also be able to update your profiles twice a year to help you showcase new products and services. All profile content will be ‘keyword compliant’ to guarantee maximum exposure to the major search engines.

Milling Industry Recruitment Specialist

Classified Advertising rates for 2010 will remain the same as those for 2009 ... but with all the extra exposure.

www.jcb-consulting.com +44(0)161 427 2402

CHECK OUT THE RATES AND AVAILABILITY NOW!

A Clondalkin Company

FLEXIBLE PACKAGING

From early 2010 all GFMT Classified Advertisements will now appear on the websites our TWO online distribution channels: DocStoc and Scribd.

Filter Screen Supply Ltd Wirtech AG, Process Engineering For more company information, visit: www.gfmt.co.uk/market

Other The International Milling Directory

July - August 2010 | 45

Events 2010

29th September 10 - 1st October Animal Farming Ukraine 2010, IEC, Kiev, Ukraine Contact: Kuno Jacobs, CIS Exhibitions BV, Eemnesserweg 27a, 3743 AD Baarn, The Netherlands

AUGUST

The world´s top event for animal production

5th - 11th August 10 6th Food Science International Symposium, Beijing, China Contact: Anita Habershuber, ICC, Marxergasse 2, 1030 Vienna, Austria

Tel: +31 35 5426515 Fax: +31 35 5426517 Email: Kuno.Jacobs@cis-exhibitions.nl Web: www.animalfarmingexpo.com

Tel: +43 1707 72027551 Fax: +43 1707 7204 Email: anita.habershuber@icc.or.at Web: www.icc.or.at/events.php

OCTOBER

*

7th - 8th October GLOBALGAP Summit 2010, HILTON London Metropole Hotel, London, United Kingdom Contact: Nina Kretschmer, c/o GLOBALGAP Foodplus GmbH, Spichernstr 55, D-50672 Cologne, Germany

*

10th - 12th August Agritech South Africa 2010, Pietermaritzburg, South Africa Contact: Winnie Gagan (Ms), Exhibition Manager

PO Box 11183, Dubai, United Arab Emirates Tel: +971 4 3406888 ext. 262 Fax: +971 4 3403608 Email: Winnie@alfajer.net Web: www.agritechsouthafrica.com

Tel: +49 2215 7993693 Fax: +49 2215 799389 Email: kretschmer@globalgap.org Web: www.summit2010.org

*

Your Business Driven by Innovations

20th - 22nd August 10 Grain Tech India 2010, Bangalore, India Contact: Lalitha V. Rajan, T-30 First Flr, Khirki Ex., Maviya Nagar, New Delhi 110017, India

12th - 13th October Overview of Particulate Handling Technology, Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich at Medway, Kent, United Kingdom Contact: Caroline Chapman

Tel: +91 11 64521572 Fax: +91 11 26681671 Email: mediatoday@vsnl.com Web: www.graintechindia.com

Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich at Medway, Central Avenue, Chatham Maritime, Kent ME4 4TB, UK Tel: +44 2083 318646 Fax: +44 2083 318647 Email: wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com

SEPTEMBER

More than 1,800 international manufacturers on 170,000 m2 exhibition floor space

3rd - 6th September 10 International Rice & Flourtec-2010, India-Bangalore Contact: Vashdev S G, No 25,3 Rd Floor. 8 Th Main Road. Vasanthnagar Bangalore-560 052 India

Over 130,000 visitors from 96 countries All the innovations for breeding and keeping cattle, pigs, poultry, fish Leading technologies for the use of renewable energies

*

12th - 13th October 10 Agribiotech & Seed Markets, Jakarta, Indonesia Contact: Angelia Lim, CMT

Tel: +91 099 64441922 Fax: +91 080 22352772 Email: vashdev@tepl.net Web: www.triuneexhibitors.com

6th - 8th September 10 VIV China 2010, Beijing, China Contact: Anneke van Rooijen, P.O. Box 8800, 3503 RV Utrecht, The Netherlands,

28th - 30th September 4th Food Proteins Course, Utrecht, The Netherlands Contact: Marjolijn Cohen, Jan van Eijcklaan 2, 3723 BC Bilthoven, The Netherlands

*

13th - 15th October 10 61es JTIC & 5e IAOM Eurasia meeting, Reims Congress Center, France Contact: AEMIC, 268 rue du Faubourg Saint Antoine, 75012 Paris, France Tel: +33 47 072069 Fax: +33 14 4245625 Email: aemic@wanadoo.fr Web: www.jtic2010.eu

*

Tel: +31 30 2252060 Fax: +31 84 8327225 Email: mcohen@bridge2food.com Web: www.bridge2food.com

www.eurotier.de

If you have an event that you would like to see in our pages, send you event information to: tutit@gfmt.co.uk

Decentral

For more event information visit: www.gfmt.co.uk/events.php

including

* • More information available

See our magazine at this show

RZ_105x297_Anzeigen_ET_Opt_EN Kopie.indd 1

46 | July - August 2010

20.04.2010 14:30:58 Uhr

*

Tel: +65 6345 5701 Fax: +65 6345 5928 Email: angelia@cmtsp.com.sg Web: www.cmtevents.com

Tel: +31 30 2952772 Fax: +31 30 2952809 Email: viv.china@vnuexhibitions.com Web: www.viv.net

Exhibition Grounds Hanover / Germany 16 – 19 November 2010

*

&feed milling technology

Grain

WEBLINKS

2010 related links

In every issue of GFMT, we will be providing a list of companies and web links related to key stories and topics within each specific issue.

If you would like information on how your company can get involved, please contact our Marketing Manager, Caroline Wearn.

Email: carolinew@gfmt.co.uk | Tel: +44 1242 267707

Agromatic AG = www.agromatic.com Alapala = www.alapala.com

National Chamber of Milling = www.grainmilling.org.za

Almex b.v. = www.almex.nl

nv SCE = www.sce.be

Braime Elevator Components Ltd = www.go4b.com

Obial = www.obial.com.tr

Buhler AG = www.buhlergroup.com

Ottevanger Milling Engineers B.V. = www.ottevanger.com

Calibre Control = www.calibrecontrol.com

Palm View Trade = www.palmviewtrade.com

CB Packaging Ltd = www.cbpackaging.com

Perstorp Performance Additives = www.perstorpfeed.com

Cenzone Tech Inc = www.cenzone.com

R-Biopharm Rhone Ltd = www.r-biopharmrhone.com

Chief Industries UK Ltd = www.chief.co.uk

Romer Labs UK Limited = www.romerlabs.com

Cimbria A/S = www.cimbria.com

Satake Corporation = www.satake-japan.co.jp

Consergra s.l = www.consergra.com

Satake Europe Ltd = www.satake-europe.co.uk

CPM Europe B V = www.cpmeurope.nl

Schmidt-Seeger GmbH = www.schmidt-seeger.com

Croston Engineering Ltd = www.croston-engineering.co.uk

Shandong Yingchun Steel & Silo Manufacturing Co Ltd = www.silo86.com

Extru-Tech Inc = www.extru-techinc.com Hydronix Ltd = www.hydronix.com In Vivo NSA = www.neovia-additives.com Institute of Feed Technology of IFF = www.iff-braunschweig.de Jacob Sohne GmbH & Co = www.jacob-pipesystems.eu JCB Consulting Ltd = www.jcb-consulting.com JEFO Nutrition Inc. = www.jefo.com Jiangsu Muyang Group Co Ltd = www.muyang.com John Staniar & Co. = www.johnstaniar.co.uk JSConwell Ltd = james@buhlermillbank.co.nz Leonhard Breitenbach GmbH = www.breitenbach.de Muhlenchemie = www.stern-wywiol-gruppe.de NABIM = www.nabim.org.uk

Shanghai ZhengChang International Machinery and Engineering Co., Ltd = www.zhengchang.com Silos Cordoba = www.siloscordoba.com Stewart Inglis Limited = www.stewartinglis.co.uk Suffolk Automation Ltd. = www.suffolk-automation.co.uk Symaga SA = www.symaga.com Tapco Inc = www.tapcoinc.com TSC B.V. = www.tsc-silos.com UNORMAK = www.unormak.com.tr Victam International = www.victam.com Vigan Engineering S.A. = www.vigan.com Wynveen International B.V. = www.wynveen.com

Alapala, brings wheat to life A journey’s seeds are planted in the soil in a season when the nature sleeps and keeps company with wind. Rain feeds clouds and sun grows these golden infants of the earth up. However it will not be that easy to raise them like all children. It needs time, patience, care proficiency and pains.

Then it is time for skilled hands to reap crops and another journeys starts from the soil towards tables with tastes. And then technology, workmanship, strength and hard work take over the task.

Now it is time for wheat to turn into flour.

We, Alapala, join this journey with our machinery we design and manufacture by devoting the same care we show while sowing seeds. To add zest to life‌..

Back in 1900, a Swiss man invented muesli. Our passion for the finest flakes and grains has just as long a tradition. Buhler has mastered the entire process from the kernel to the flake, and from oats, millet, barley, and spelt to corn and soy. Talk to us – we’ve developed equipment and methods that are highly effective at every stage of the process, with high yields, unparalleled cleanliness and outstanding product quality. We owe all this to the inventor of the breakfast cereal. And to muesli lovers all over the planet.

Bühler AG, Grain Milling, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 66 11 milling@buhlergroup.com, www.buhlergroup.com

The solution behind the solution.