Sep | Oct 11 - Grain & Feed Milling Technology

October

2011

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•

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Producing Flaked Breakfast Cereals

Milling Technology Redefined

Direct Cold Plasma: The innovative answer to odour control in the food and feed industry

In this issue: •

Sample preparation of feeds and forage for NIR analysis

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15-Year Celebration: Fortifying with folic acid prevents 22,000 birth defects annually

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Global Feed Markets: Wheat supply grows and grows as corn crop shrinks

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

GRAIN &

FEED

MILLING

News:

Increased competition brings greater automation and quality control to the grain, milling and feed business Key event brings together 90% of China’s feed industry Game Engineering Ltd - 25 years of experience Precia Molen producing special automatic discontinuous totalising bulk hopper scales 30 years of formic acid production at Kemira Sodrugestvo acquires Lider Armazens Gerais in Brazil Perstorp appoints new manager R&D and innovation Grain milling focuses on food safety and HACCP programs Big squeeze at Flexicon’s bulk handling test laboratory Achieving maximum capacity for your bucket elevator

TECHNOLOGY

October

2011

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Features:

The Virtual Mill at the DMSB: Simulation of a 200-tonne wheat mill under professional conditions Sample preparation of feeds and forage for NIR analysis Producing Flaked Breakfast Cereals Milling Technology Redefined Direct Cold Plasma: The innovative answer to odour control in the food and feed industry 15-Year Celebration: Fortifying with folic acid prevents 22,000 birth defects annually

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 Editorial Manager Nicky Barnes Tel: +44 1242 267707 nickyb@gfmt.co.uk

4 6 7

12 18 22 24 26 28

Commodities: Raw material outlook, by John Buckley

30

Design and Page Layout James Taylor Tel: +44 1242 267707 jamest@gfmt.co.uk

Book Review

Sustainable Agriculture and Food Agriculture and the WTO: Towards a New Theory of International Agricultural Trade Regulation Technology of Functional Cereal Products

Circulation & Subscriptions Manager Tuti Tan Tel: +44 1242 267707 tutit@gfmt.co.uk

40 40 41

International Marketing Team

What is this? This is a QR (Quick Reference) graphic that is unique and scannable using a free application on any smartphone or tablet. QRs - although around for some years - have come of age as portable hand-held devices have become increasingly popular. We are adding QRs to major features and will be supplying QRs to our advertisers to place in their advertisements if they wish. They can be pointed to any url or digital destination - and can be changed at any time in the future meaning related information can be kept up-to-date. Perendale generates and manages QRs for all it customers and authors free-of-charge!

Caroline Wearn Tel: +44 1242 267707 carolinew@gfmt.co.uk Sabby Major Direct: +44 1242 267707 sabbym@gfmt.co.uk Lee Bastin Tel: +44 1242 267707 leeb@gfmt.co.uk Annual Subscription Rates Inside UK: UK£70 Outside: US$140/ Euros110 More information www.gfmt.co.uk

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 2011 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: 122 number 5

issn No: 1466-3872

Guest - EDITOR’S OBSERVATIONS

Guest editor - Roger Gilbert

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or the first time Perendale Publishers Limited will host with GRAPAS a milling conference that is focused on rice, flour, cereals, oilseeds and grain processing for Asia.

The GRAPAS Asia exhibition is co-hosted and co-located by Victam International to run alongside its VICTAM Asia and FIAAP Asia exhibitions. GRAPAS Asia is being held in Bangkok, Thailand from February 15 – 17, 2012 at BITEC – the Bangkok International Trade and Exhibition Centre. GRAPAS Asia will be complemented with a oneday conference for the grain processing sector.

Perendale Publishers Limited – the publishers of the International Milling Directory and the long-standing Grain and Feed Milling Technology magazine – is proud to be chosen as patron of this new conference. Perendale is also sponsoring the GRAPAS 2012 Award.

The GRAPAS Conference for Asia Keeping firmly in mind the need to provide information and new ideas in a timely and efficient way, the 2012 GRAPAS Conference will be held in two parts on one day – the opening day of the exhibition – February 15, 2012; it will comprise independent morning and an afternoon sessions. Delegates can choose to attend either or both parts depending on their timetable and their interests.

“Establishing a new conference in these difficult economic times will not be easy. However, the expansion of Victam into related milling sectors, such as rice and pasta processing, means that a wider audience can benefit from technology presentations. We are keen to focus on topical issues of the day and keep the programme tight to deliver high value and quality information to industry professionals in a timely manner,” says Roger Gilbert who is organizing the event on behalf of GRAPAS. “We will be providing a programme focused on addressing issues facing the rice, flour and grain processing sectors in Asia.

“I’m proud that Perendale has been chosen as patron of the conference. We will be promoting the event widely and aiming to have in excess of 200 delegates in attendance. We are asking delegates to pre-register, for a small registration fee, so that we can accommodate speakers and delegates accordingly, especially with translators, headsets and catering arrangements involved.”

The theme of the conference Guaranteeing food and feed safety through greater use of technology in the control of product quality at each step of the milling process, from raw material collection-through processing-to-product dispatch.

The conference will be in English with simultaneous translation into/from the Thai language.

Registration and further details For an updated programme, please visit the conference website to register http://conta.cc/nneulE There is an early bird discount of 33% for all delegates registering online prior to November 30, 2011.

Are you a Perendale bookworm?

Perendale Publishers Ltd, the publishers of Grain & Feed mIlling Technology, has set up an online Amazon-based ‘Book Shop’ that lets you browse a wide range of recently-published reports and books on Grain & Feed relaed topics. You will soon be able to read an extended review before making your selection and purchasing directly from Amazon.

We will undertake to put forward for your consideration the most recent publications and as a result become a reference point for your reading and research.

Book store Of course you will be charged for any books purchased, but you will be dealing directly with Amazon, which has a world-class ordering/payment gateway, packaging and mailing service.

Consult Perendale Publishers Online Book Store at:

www.perendale.com/books &feed milling technology

Grain 2 | September - October 2011

September - October 2011 flow in a small LIW-unit

NEWS

P

lenty of companies within the grain, milling and feed industries have realised an increasing need for automation in production lines and reduction of production costs.

Furthermore, the business has realised a dramatic increase in raw material prices, with few or no signs of short-term improvement.

With a weighing solution from Jesma in Denmark, companies within the business can both automate their production processes and at the same time supervise the production for improving the quality of the end product and reduce waste percentage.

Process weighing ‘In-line’ weighing is an effective

The picture shows Mr Torben Bodin and the LIW from Jesma

Mr Torben Bodin and the JesFlow from Jesma 4 | September - October 2011

Increased competition brings greater automation and quality control to the grain, milling and feed business

way of avoiding over dosing of expensive additives, and adjusting the production to the actual need.

Jesma is able to supply a wide range of dynamic and continuous scales and gravimetric dosing systems and at the Danish grain processing and flour manufacturer Lantmännen Cerelia in Vejle, such a gravimetric system has been installed.

The system consists of a flow scale type JesFlow in combination with a continuous ‘loss-in-weight’ unit for dosing of an additive.

At Lantmännen Cerelia the production manager Mr Torben Bodin explains, “In the past it has been difficult to find an accurate and reliable solution to measure the actual flow.

“It is our highest priority to know the actual product flow as we dose additives very accurate in relation to the main flow. At the same time the main flow is fluctuating, so the dosing of the additive has to follow the fluctuations very accurately.

“It is important for Lantmännen Cerelia that the product mix is as we expect and identical, we had to think of new ways to achieve the required endquality,” he adds.

“Previously we have been using a combination of volumetric and gr avimetric dosing technologies, however, with the new system from Jesma, we both measure and dose additives gravimetric and we can establish an essential endquality of our products.

“At Lantmännen Cerelia our position is clear – the process must be controlled as accurate as technology enables and the result of the Jesma solution has been an absolute success,” concludes Mr Bodin.

The regulation of the additive dosing through a ‘loss-inweight’ system reacts quickly and effectively due to the ‘Master-Slave’ regulation based on the main flow.

Managing Director of Jesma Mr Palle Serup explains: “At Jesma we have extensive experience within continuous weighing and gravimetric dosing of any bulk material.

“Based on our experience we find it easy to enter a dialogue with our customer at an early stage to find the best suitable and technical optimum solution for the project. “ Jesma not only delivers standard units, but also develops a lot of customer- and projectadapted weighing solutions. It is highly surprising how much the raw material consumption can be reduced only be choosing the correct weighing solution.

emptied, and the loss in weight in relation to the time results in the mass signal, which controls the dosing to the required value.

The Jesma-developed control system continuously updates the ratio between the required amount and the actual dosing.

When the bin is nearly empty and it is re-filled the control syste m use s t he hist oric values as basis for the relation between actual dosing and the weight loss in the bin. When the bin is full the control syste m switche s b ack to normal operation.

This type of control, without ‘freezing’ the operation during filling of the bin, results in a unique dynamic accuracy and a very accurate regulation of the product flow.

‘Loss-in-weight’ unit

Mr P alle Serup expl ains : “Jesma is a ver y dynamic company, which constantly aim at developing new products and concepts which helps our customers achieve their goals.

“We are a very innovative company where quality and flexibility are corner stones in our development.

“We aim our products at a quality that reflects the rest of our company, which means total quality control and tested equipment. For that reason we are confident that our equipment lives up to the high standards of our customers when it leaves our factory.”

A ‘loss-in-weight’ unit can be used any where where continuous dosing of powder or another bulk material needs to be dosed with high accuracy and reliability.

Regulation of the mixture by using weighing systems results in a more accurate mix compared to other available techniques. This results in a more uniform end product, and thus higher end-quality.

Jesma’s ‘loss-in-weight’ units are designed according to the specific requirements of the customer, and are available with capacities from few kg to several tonnes per hour.

All units are designed and constructed according to the actual product and thus secures a high operational safety and optimum user friendliness.

During operation of the ‘lossin-weight’ unit the bin is slowly

Dynamic and development

More

information:

Jesma Vejeteknik A/S Helsingørvej 18 DK-7100 Vejle Denmark Tel +45 75 721100 Website: www.jesma.com

&feed milling technology

Grain

News

CONFERENCE ! e c n e r e f n o c day e n o e h t r o f Register now S SECTORS

S & OILSEED OUR, CEREAL

E RICE, FL

CE FOR TH A CONFEREN

@ VICTAM ASIA, BANGKOK,THAILAND

FEBRUARY 15, 2012

Bangkok International Trade

www.

& Exhibition Centre (BITEC)

.org Conference patron:

September - October 2011

NEWS

Key event brings together 90% of China’s feed industry The Grand Ceremony for the most influential large enterprises of China’s animal husbandry and feed industry will be held in ZhengChang from October 19 – 21, 2011

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enterprises and enterprise internal investment parties’ understanding, friendship and cooperation to strengthen the cohesion of feed industry, comprehensive strength of China feed industry, and to create a good environment and harmonious development of feed industry.

Through the Association’s connection and lateral exchange The large enterprise leaders between enterprises, boosting who yielding 90% of Chinese domestic feed enterprise feed production will be in the playing a positive role in the meeting to communicate on development of domestic feed the future development of industry and animal husbandry economy. The ce re m o ny o f China feed industry association is primarily constituted by member entrepreneurs of China feed industr y association.

Large-scale refers to the Caption: The previous Grand Ceremony of enterprise China’s animal husbandry and feed industry having industry inf luence and China feed industry trends and social responsibility, and one of the following conditions: patterns.

Hosting the China industry a) The annual production of compound feed to be event is required with strong 150,000 tonnes or 40,000 industry influence and social tonnes of concentrated feed, responsibility. or additive premix feed to be Z h e n g c h a n g , a s C h i n a' s more than 10,000 tonnes, largest feed manufacturer and sale rate against production engineering service provider to be more than 90 percent, w i l l e n d e avo u r t o s e e k having specialised technology development for feed industry development institutions, colleagues at home and abroad f u n d i n g fo r t e c h n o l o g y to build good communication development of annual sales platform, integrate resources should not be less than 1.5 effectively, actively promote percent. cooperation so that can create b) The annual production of value for more customers.

20,000 tonnes of feed-grade The ceremony of China feed lysine, methionine or feed industry association seeks to 10,000 tonnes, production streng then communication and sale rate of more than and li aiso n b e t we e n t he 90 percent , with special large-scale feed enterprises, technolog y development enhance feed enterprises and institutions, funding for Government agencies, between he President of China’s feed industry association, the Ministry of agriculture, animal husbandry and Veterinary Council Board, Vice President of China feed industry association, China feed industry's most influential business leaders in the industry and mainstream media will attend a Grand China feed industry in mid-October.

6 | September - October 2011

technology development of annual sales should not be less than two percent. c) The annual production of feed-grade phosphate 50,000 tonnes, produce and sale rate of 90 percent percent, with specialized technology development agencies, f u nd i n g fo r t e c h n o l o g y development of annual sales should not be less than 1.5 percent. d) The annual output is over US $ 10 0 million of feed grade vitamin feed additive production enterprise class and other classes, with specialised technology development agencies, f u nd i n g fo r t e c h n o l o g y development of annual sales should not be less than two percent. e) Annual output is over RMB 200 million of feed production e nt e r pr i se s , s p e c i a li se d technolog y development agencies, funding for technology development of annual sales should not be less than two percent. f) Feed Material Production E nter prise s who h aving annual production of 150,000 tonnes of feed raw materials, sale rate against production to be more than 90 percent, with specialised technology development agencies, f u nd i n g fo r t e c h n o l o g y development of the annual sales should not be less than of one percent, or enterprises for annual trade of more than RMB 200 million of the feed material.

Large enterprise Association's main tasks: a) Reflect the requirements of large enterprises, coordinating l ar ge , m aint e n a nce a nd the legitimate rights and interests of large enterprises of industry b) Organisation of feed industry major policies in particular investigation of major

issues such as supporting the development of large enterprise strategy, policy recommendations c) Promptly inform feeds at home and abroad and relevant industry news and the latest published the laws, regulations and policies d) Organising large enterprises leading to safeguarding the common interests of industry, lead in the supporting and participating in the activities of the organisation of China feed industry association, lead the promotion of industry self-regulation, lead execution regulations of feed industry e) Guiding large enterprises taking the lead in promoting system innovation, management innovation, and technological innovation, taking the lead in establishing a modern enterprise system and enterprise credit system f) Organising communication of technology innovation in enterprise management and advanced experience in such areas g) Organising large international cooperation and exchanges, expanding the inf luence of large enterprises and entrepreneurs at home and abroad h) Organising large enterprises active in the anti-dumping, countervailing and safeguard measures i) Under taking industr y management department, deleg ate of Chin a feed industry association, or other work assigned by Zhengchang fully undertaken well the China event is bound to strengthen communication and cooperation bet ween enterprises, improving communication among enterprises and Government, protecting the interests of feed enterprises, and promoting enterprise development and play an important role.

&feed milling technology

Grain

News

News

September - October 2011

NEWS

Game Engineering Ltd - 25 years of experience

G

ame Engineering Ltd has over the past 25 years, amassed the experience required to carry out the design and installation of materials, processing and handling plants across a wide array of sectors including ; Animal & petfood, biomass & fuel generation, grain & seed, waste recycling and construction & quarrying.

G ame h ave de signed and installed numerous production plants over the years and made alterations for the major producers and built green field sites for the up and coming independent manufacturers.

Raw material storage ; grinding ; mixing ; extruding and vacuum coating projects along with their control can all be undertaken by Game. “ O u r e x p e r i e n ce i n t h i s

industr y is a guarantee of successful solutions to client’s requirements, we work closely with major machine manufacturers to provide streamlined processes tailoring the design to the client’s budget and allowing for the future addition of equipment and processes as companies grow,” says the company.

A n example of a projec t which Game completed for a client consisted of a bulk storage block of six smooth walled bins (with a capacity of 60 cubic metres), screw dischargers rated at 20 tonnes per hour, weigh boat suspended under the bulk storage silos, discharge and transfer handling equipment

rated at 20 tonnes per hour, grinding system with twin one tonne live bins, mixing system and minor ingredients

and conveying systems suitable for handling dried extrusions at four tonnes per hour.

The end result was a facility that manufactured dr y produc t s to meet the ever-increasing product demand, with the clients r ange of dr y pet foods stocked in most major supermarkets nationally.

and sack tipping station for adding sack additions directly into t he mixing chamber, extruder and pneumatic conveying system suit able for transferring product to dryer at five tonnes per hour of wet product , dryer and conveying systems suitable for handling dried extrusions at four tonnes per hour, coater and screening and conveying systems suitable for handling dried extrusions and a cooler

More

information:

Game Engineering Ltd Witham St Hughs Business Park Witham St Hughs Lincoln LN6 9TW United Kingdom Tel: +44 1522 868021 Fax: +44 1522 868027 Email: sales @game-engineering.com Website: www.game-engineering.com

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&feed milling technology

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SIZERS

COMPACTORS

September - October 2011 | 7

September - October 2011

NEWS

Precia Molen producing special automatic discontinuous totalising bulk hopper scales

O

ver the past four decades Precia- Molen has established a worldwide reputation as the leading supplier for weighing equipment for use in bulk transshipment and storage facilities.

The proven concept of one basic design for multi purpose applications in intake, transshipment and out loading operations, makes the standard ABS-xl scale suitable for a wide range of dry free-flowing bulk commodities such as cereals, expellers, tapioca, soya meal and many derivatives. Special versions are available for fertilizers, sugars and liquids.

The standard Automatic Bulk Scales, type XL, are suitable for dry and free flowing bulk products with a bulk density of 0.5 – 1 tonne/m3.

Products with lower bulk densities are also handled by the ABS and specials designs always possible on request. For products with higher bulk densities (for example fertilizers up to 1.2 tonne/m3) small modifications are sufficient.

Precia Molen received last year a special demand from customer for weighing fertilizers and phosphates with higher bulk densities. Now Precia Molen Breda is producing the two special hopper scales for fertilizer and phosphates with bulk

30 years of formic acid production at Kemira

K

emira Oyj has produced formic acid for 30 years now. The production of formic acid has been expanded gradually and the current production volume is over 100,000 tonnes per year.

Kemira actively develops new applications for formic acid, especially for the feed, chemical, and leather industries.

“The main t arget of the development work is either to replace more harmful products

with a formic acid based product, or to improve the customer process," tells Marjo Luoma, director for the Formate product line.

“A good example of our newest products is Tanfor A which improves the efficiency of the soybean oil epoxidation process.

“Lowering the environmental load of the formic acid production is crucial for Kemira. We are developing processes which use renewable biomass based raw materials for formic acid

densities from 1.2 up to 1.4 tonne/ m3 and bigger product sizes.

Capacity up to 1750 tonne/hour, 24 hours per day.

The inside of these hopper scales are completely executed in stainless steel and have special designed feeding and discharge gates. Feeding gates suitable for coarse and dribble feed. Stainless steel cylinders are taking care of the correct and fast movements of the gates.

The feed section and weigh hopper have UHMW-PE liners because of the abrasive products. The surface of the liners takes also care of an improved product flow. The hopper scales will be installed by Precia

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All warehouses are leased to leading agricultural companies, including Sodrugestvo, through exclusive long-term agreements.

Lider also owns and operates two

transshipment terminals in Minas Gerais and Tocantins for Vale SA, a Brazilian diversified mining multinational corporation and one of the largest logistics operators in Brazil.

“The acquisition of Lider allows us to increase our static storage capacity from the existing 600,000 tonnes to almost 900,000 tonnes in the states of Sao Paulo, Minas Gerais and Goias. This capacity

K

A chemist and microbiologist by trade, Schwarzer has been active in research and development of 8 | September - October 2011

innovative feed additive concepts for over 30 years. Previous functions include R&D management positions at other major feed additive companies.

Schwarzer will be based at Perstorp’s Waspik location in The Netherlands.

His responsibilities will include managing the R&D department

information:

Website: www.preciamolen.com

says Mr Luoma.

The prospect of formic acid applications and customers is still developing. The bulk of the product is exported from Finland either unprocessed or as a further processed solution for the leather and textile, chemical, pharmaceutical, and feed industries in about 60 countries.

The salts of formic acid, formates, are used in several applications, for example, as de-icers at airports and as oil drilling fluids.

increase will allow us to provide an even better service to Brazilian agricultural operators in these key regions.

“We will also continue to invest heavily, in coordination with Vale, to make sure that our new transshipment facilities offer the best possible value to all market participants, while the ever increasing crops create more and more challenges to bring grains to ports,” says the company.

M ac h ad o M eye r ad v ise d

Sodrugestvo for the transaction.

The acquisition was entirely financed by Sodrugestvo’s own fund, without recourse to debt.

The Lider operation will be integrated into Carol-Sodru SA, the joint venture between Sodrugestvo and Carol, which already operates 14 silos in the states of Sao Paulo, Goias and Minas Gerais.

Perstorp appoints new manager R&D and innovation oen Schwarzer has been appointed as manager R&D and innovation for feed additives producer at Perstorp Performance Additives.

More

production,” says Luoma.

“Formic acid is a simple organic acid which is chemically the same naturally degradable acid that red ants have produced in the nature for already millions of years.”

When Kemira started the formic acid production in cooperation with Valio in Oulu in fall 1981, most of the production was sold to Finnish farms as a silage additive.

“Still today the preservation of silage is an important application for formic acid, even though the acid today is sold for numerous applications all over the world,”

Sodrugestvo acquires Lider Armazens Gerais in Brazil

ider, the largest Brazilian private company engaged in the storage and transshipment of grains, owns 15 warehouses located in Brazil’s fastest growing agricultural regions.

Molen on site. Precia Molen also takes care of the engineering for the steel tower construction for the two hopper scales and the complete installation works on site.

The I400 ABS controller in combination with the RIO-box (remote in- and out-puts in stainless steel cabinet with integrated pneumatic valves and controlled by the CAN- OPEN field bus) completes the Precia Molen weighing system (MID, OIML approved). Hopper scale accuracy according OIML R107, class 0.2 (+ and – 0.1 %).

and developing products and innovative concepts. Schwarzer will lead the search for particular molecules, their activity and the way of application and he will provide technical support for various feed additive product groups.

“Perstorp is a basic producer of several important raw materials that are used in feed additives. Managing the R&D department of a driven,

More Information: Website: www.kemira.com

More

information:

Website: www. feintuchcommunications.com

innovative and focused business unit to support a continuously changing market with new concepts is very appealing,” he says.

Koen Schwarzer will be replacing Marc Kinjet who recently changed positions to business development manager Asia.

More information: Website: www.perstorp.com

&feed milling technology

Grain

News

News

September - October 2011

NEWS

Grain milling focuses on food safety and HACCP programs

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he International Grains Program collaborates with industry organization to offer HACCP certification and training on food safety in grain milling.

Grain milling professionals interested in answering the question of how to apply food safety practices and implement hazard analysis critical control points programs (HACCP) that specifically relate to grain milling can do so at the Grain Milling: Food Safety and HACCP workshop planned for October 11-13 at the Kansas State University International Grains Program (IGP) Conference Center.

“This workshop is the result of a partnership between K-State, AIB International and the International Association of Operative Millers

(IAOM),” says Mark Fowler, IGP associate director and workshop coordinator. “We are excited to continue this unique workshop that both addresses the development of a HACCP program and fits the food safety needs of our participants from the grain processing industry.”

During the workshop, participants will learn fundamentals of good manufacturing practices, sanitation schedules and HACCCP programs specifically related to the flour milling industry, and then apply this knowledge in designing a HACCP program for the onsite Hal Ross Flour Mill. According to Fowler, its curriculum caters to both a USA and international participants and emphasizes the importance of safe practices within the industry as a whole.

Collaborating on this workshop for a third year has strengthened the relationship between the three organizations and has allowed them to grow their audience, while still

presenting the curriculum in a hands- on, interactive environment.

“AIB International has a strong presence in food safety and the grain science department has endless resources in grain proce ssing and exce lle nt facilities,” says Bill Pursley, vice president of food education for AIB International and workshop presenter. “Combining those two factors with the access

Big squeeze at Flexicon’s bulk handling test laboratory

F

or many years Flexicon Europe has maintained a dedicated test laboratory to demonstrate the versatility and practicality of its bulk handling systems and show how it contributes to improved distribution of free-flowing and not-so-free-flowing materials to downstream processes or into intermediate storage hoppers.

Last month Flexicon Europe added a hydraulic Bulk Bag Conditioner to the recently expanded Test Facility at its production plant in Kent.

The new equipment overcomes the problematical occurrence

&feed milling technology

Grain

facing many organisations when bagged bulk materials such as hygroscopic chemicals, certain types of spice blends, heat-sensitive products and many more have compacted and solidified during storage and shipment.

They reach a point at which pneumatically actuated flow promotion accessories integral to bulk bag dischargers are inefficient or completely ineffective.

The Bulk Bag Conditioner incorporates two hydraulic rams with specially contoured end plates, which gently press opposing sides of bulk bags reinstating a more free-flowing material state.

Where more stubborn materials

are a regular occurrence Flexicon can equip the Bulk Bag Conditioner with a hydraulically-actuated, variableheight turntable enabling in-frame bag rotation and conditioning at varying heights; the height of the turntable and the number of 90-degree rotations being useradjustable.

Having been treated in the Bulk Bag Conditioner loosened bulk solid material is then ready for induction into bulk bag unloaders with discharge through bag spouts.

Measuring 2210mm high by 3378mm wide and 1981mm deep, the conditioner is designed to accommodate the most popular sized bulk bags. It is fully enclosed

we have to IAOM’s extensive network, it allows us to offer a course that is really unique to the industry.”

To enroll, go to www.aibonline. org. The course is listed under the seminars and courses header.

Those interested in registering can also call AIB International at +1 800 242 2534.

This class is just one example of the partnership courses offered through IGP. In addition to flour milling, IGP regularly offers short courses in feed manufacturing and grain management, grain marketing and risk management, and flour milling and grain processing.

For more information about IGP programs, go to the IGP website at: www.grains.k-state.edu/igp.

on all four sides for operator safety and includes full-height doors that are interlocked preventing actuation when the doors are open.

Visitors to the Flexicon Test Laboratory are now able to see the Bulk Bag Conditioner working alongside other Flexicon bulk handling systems such as the Company’s flexible screw and pneumatic conveyors, bulk discharger units and bag fillers.

The functionality of the expanded test facility enables Flexicon to fully trial the handling of specific materials to maximise performance.

More

information:

Website: www.flexicon.co.uk

September - October 2011 | 9

September - October 2011

NEWS

News

Achieving maximum capacity for your bucket elevator

T

here is a demand for increasing the capacity of new and old bucket elevators par ticularly for handling grain.

Factors that influence the capacity of an elevator are:

along the cover to the outlet, minimising the amount of dust created and material damage.

A flat top cover design as well as any break in the head cover, such as explosion vents or gaps, will make the material rebound onto the pulley and will result

there are other factors to consider that can also affect your bucket elevator’s capacity.

Other Considerations Bucket Fill – Material enters an elevator bucket through the front and the sides. Buckets

Initial Discharge

Speed

Typical Material Handled

Bucket Style

Centrifugal

@ 10 O’clock

Medium To High

Feed & Grain

CC-S, Starco, J Type Steel, GB Spidex Bottomless Buckets

Centri-gravity

@ 12 O’clock

Low to Medium

Cement, Wood Chips, Steel Shot

Starco Jumbo, Super Starco Steel Buckets

Gravity

@ 2 O’clock

Low

Pellets, Fragile Materials

AA, MF-Continuous Buckets

Discharge Type

* Visit www.go4b.com for details on each bucket style

b u c ke t t y p e , s h a p e a n d disch arge ch ar ac teristics , optimum speed in relation to pulley size, shape of head and boot, material characteristics such as size, shape and density, angle of repose, coefficient of friction and terminal velocity.

The most common cause for loss of capacity in an elevator is the bucket discharge, which can be caused by the incorrect belt speed in relation to the pulley diameter, the wrong elevator bucket for the material and the wrong head shape. Below is a table showing the three types of discharge and their common characteristics.

Centrifugal discharge is normally used for grain and other materials, which are handled at medium to high belt speeds.

The material will star t discharging from the bucket at about 10 o’clock from the horizont al and continue s discharging around the pulley in arcs towards the head cover and outlet until empty.

Head Cover - It is necessary to design the head cover so that the material will slide smoothly 10 | September - October 2011

in material back legging and/or down legging.

Belt Speed - There is a minimum and maximum centrifugal belt speed for each different bucket size and pulley diameter. The recommended elevator bucket types for centrifugal discharge are CC-S, J-Steel, Starco, Super Starco and bottomless buckets.

Consult your manufacturer for speed recommendation.

Centri-gravity discharge is normally used for discharging powders, pellets, cement and fragile materials at slow speeds.

The elevator buckets start to discharge at top dead centre (12 o’clock) and continue until approximately 50° afterwards.

Recommended bucket types for centri-gravity discharge are Super Starco Steel and Starco Jumbo (SJ) buckets.

Gravity discharge is typically used for discharging sluggish, ae r at ed m at e r i al s , w hic h basically fall out of the buckets at around the 2 o’clock position.

S low r unning cont inuou s elevator buckets can be used for gentle handling of fragile materials.

Along with bucket discharge,

with straight sides do not fill as well as buckets with tapered sides. As shown below, 4B’s CC-S, Starco and Super Starco buckets have tapered sides which allow them to fully fill and discharge material better than any other CC type bucket.

Elevator Head – To facilitate the discharge of material from the elevator head, the outlet should be large enough for the required capacity and should be at minimum 45° from the head shaft for grain and low friction particles. For other products such as meals, cement, sticky materials, and wood chips, the outlet should be at 50° to 55°.

Elevator Belt – Maintain proper belt tension to help avoid belt slippage on the drive pulley.

A lagged head pulley will help reduce slip and wear on the belt.

Monitoring – Always install belt slip, belt misalignment and be aring te mper ature monitoring systems to help with safety and maintenance requirements.

Elevator Boot – To ensure an efficient intake and reduce material damage and dust,

place the intake at a minimum angle of 45° from horizontal when handling grain, 50° for meals or pellets and 55° for industrial materials, to a point at least 4 inches above the line of the boot shaft so that material is directly fed into the buckets. The area of the intake should be large enough for the required volume of material.

When handling grain, fitting a liner in the boot 1 to 2 inches from the lower bucket tip will increase the bucket fill, reduce grain damage and the amount of power required.

Boot Pulley – Most boot pulleys for grain are smooth surfaced, but for sticky meals which build up on the inside of the belt and cause belt stretch as well as other belt issues; a wing type pulley is best as it allows the surplus material to fall through the wings instead of building up between the pulley and the belt.

A wing type pulley also reduces damage to pellets.

4B offer a Free Bucket Elevator Engineering Service to help their customers trace the faults in underachieving elevators.

On completion of an online bucket elevator questionnaire (http://www.go4b.co.uk/uk/ elevator-design-service.asp) 4B engineers provide their customers with engineering information on how to improve the performance of their bucket elevators.

4B can help you trace the faults in underachieving elevators.

Complete its online elevator questionnaire (http: //www. go4b.co.uk/uk/elevator-designservice.asp).

More

information:

4B Braime Elevator Components Ltd Hunslet Road Leeds, LS10 1JZ United Kingdom Tel: +44 113 2461800 Fax: +44 113 2435021 Email: 4b-uk@go4b.com Website: www.go4b.com

&feed milling technology

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September - October 2011

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30/09/2011 16:42

The Virtual Mill at the DMSB: Simulation of a 200-tonne wheat mill under professional conditions

by Uwe Schulz and Hasso Klabunde, Deutsche Müllerschule Braunschweig, Germany

T

he educational and training programme offered at the Deutsche Müllerschule Braunschweig (DMSB) is unique in Germany, Austria and Switzerland. Graduates of the DMSB work in leading positions in grain and feed mills and in mill construction firms.

To make teaching more practically orientated, the building of a school mill was discussed, like the one that is in use at the ENSMIC, our partner school in France.

In 2008, an exam paper dealt with the requirements in space, buildings and machinery on the premises of our school on the Salzdahlumer Strasse in Braunschweig.

Besides the costs, which could not have been covered by the Supporters’ Society of the DMSB and supporting companies, another argument for not building the mill was the problem of disposing the products of the grinding process.

So, emphasis was put on the modernisation of the existing laboratory equipment and the installation of new equipment for testing and training, instead.

This included the new centre for convey12 | September - October 2011

ing equipment (see picture 1), the installation and modernisation of several training stands, for example, machines for pneumatic conveying, a roller mill with plansifter and the updating of hardware and software in the automation laboratory.

The co-operation of the teachers at our school with partners in the industry resulted in the idea to visualise the grinding process in a flour mill on a personal computer. This would give the DMSB students an opportunity ‘to run a mill’ under conditions similar to those in a real mill. We call this system a ‘Virtual Mill’.

The company Keller-HCW/ Laggenbeck has years of experience in process visualisation and the programming of mill controls and was available as a partner. Mr Hartmann, Mr Sparenberg and Mr Stallmeyer were engaged in transforming the project into reality. Mr Klabunde, who has been a senior expert for our school for many years and has always been ready to give his professional advice, took part in the

development of the principal structure of the simulated mill.

He also set up a PC programme that is able to communicate with the process control and process visualisation. This allows us to show how the mill reacts to changes of the grinding parameters (like the grinding gap or the mesh size of the sieves in the various passages) very similar to the reactions that occur in a real mill.

Siemens AG offer with their programme Principal structure of the Virtual Mill

&feed milling technology

Grain

Working in the centre for conveying equipment

FEATURE

FEATURE „Siemens Automation Cooperates with Education (SCE)“ educational institutions the opportunity to acquire professional software for process visualisation and process control at low cost. This enabled us to configure the Virtual Mill using hardware and software with industry standard and to combine them with real measuring, protecting and controlling devices. Mr Schulz, teacher for automation at our school, set up a PLC programme, which allows to simulate faults and their consequences close to reality.

Hardware and software cost about €60,000.

The sum was paid by the Supporters’ Society of the DMSB between 2008 and 2010.

The actual state While developing the Virtual Mill, various earlier projects on the basis of PLC and operator panels were realised. These are now available for student experiments and training during their automation lessons.

The experience that was gained during this work and a lot of further ideas and suggestions made by DMSB teachers and specialists, led to the realisation of the Virtual Mill, which today consists of the following hardware and software components (see picture 2):

Dell PC with Windows XP-Profession operating system

Flow chart of the Virtual Mill

Production Management System ‘CellaTrace’ by Keller-HCW Process Visualisation Software ‘CellaControl’ for grain mills by Keller-HCW, based on Simatic-WinCC

by Siemens PLC system (in form of a software PLC), Simatic-WinAC/LC in

the programming environment Simatic Step7 Network intercommunication via Ethernet and PROFIBUS DP with connection to two systems Simatic S7 CPU 315 2 DP/ PN via DP/DP couplers Hardware components, such as level indicators by VEGA or elevator monitoring by Agromatic.

Calculation software based on ‘VisualBasic’ Fault simulation programmed in Step7-S7 Graph The mill’s flow chart (see picture 3) depicts a real 200-tonne wheat mill. It forms the basis for calculations of machinery and the determination of grinding parameters for the teaching in subjects related to grain milling.

Short description of the simulated milling process The job management in the Virtual Mill is done by the production management system CellaTrace.

Here, raw materials, finished products, bin data and laboratory data are generated.

Jobs are automatically transferred to the process control system CellaControl and fulfilled by the simulated mill. The user will also receive circulation reports (see picture 5).

The mill that is realised and simulated

CellaTrace

CellaTrace circulation report

&feed milling technology

Grain

September - October 2011 | 13

FEATURE

Software-based PLC WinLC RTX

within the software-based PLC system (see picture 6) is visualised on the basis of Simatic Win-CC using CellaControl, which has already been adopted in numerous real mills.

The Virtual Mill includes the following main plant components: • Grain silo with truck reception, precleaning and storage • Cleaning section with screen room and dampening (see picture 7) • Milling section with first-break scales, roller mills and sifters (see pictures 8 and 9) • Flour silo with bins, blending and loading-out (see picture 9) The components of the plant can be run automatically as well as hand-operated. It is possible to address all indicators and protection devices to find out how the plant reacts.

By setting the roll gap in the roller mills and by changing the sieve mesh in the plansifters it is possible to influence the actual grinding process. After the calculation has been started, the resulting parameters, for example, the feed on the individual passages or the current and power input of the drive motors, can be visualised in the respective process displays. This will be explained in more detail in following part of this article.

How the running of the mill is ‘visualised’ There is pre-set basic adjustment of the mill with a certain capacity, certain roll gap settings, plansifter sections with respective meshes and certain percentages of product tailings.

14 | September - October 2011

On this basis, the feed on the following passages and the yield of final products is calculated. The basic adjustment also pre-sets the power input of the drive motors in the roller mills, the moisture content at which the wheat is ground and the relative air humidity.

The following settings can be changed: Mill capacity, roll settings, sieve meshes in the plansifter, conveying of final products, grinding moisture and relative air humidity. The resulting changes in the planVisualisation of the process, screen room sifter tailings are calculated and the feeds on the following passages and the yield are determined. The power input of the drive motors is also calculated, In the last column the individual percents and it is tested if the maximal power input is are converted into the feed from the first already reached. break. The graph below gives the numbers in form of a sieve analysis. The three-column table on the right shows the actual feeds Roller mill setting, sieve analysis from the first break, as well as, on the right, and feeds on passages The setting of the roller mills in the first the feeds before changing the roll settings.

In the small table below the yields of flour passages is of great importance.

These product streams are the largest in one and two, and of germ and bran which a mill, and even a slight maladjustment will can also be seen before and after changing result in significant changes in the feeds. An the mill settings.

Changes of the grinding moisture and the example screenshot is shown in picture 11.

The rollers of the break passages I and II relative air humidity can be entered in the have been set two percent higher than the spaces in the bottom left corner. If for example, original setting. This results in smaller feeds the moisture is set higher, the tailings from the of the front passages and larger feeds on the plansifters is not sifted so well, the quantities back passages. The flour yield of quality one change, more bran and less flour is produced.

The changes are small, but noticeable. is reduced by two percent.

The same will happen when the mill This is partly compensated by 1.1 percent due to larger feeds in the following passages, capacity is increased or the relative air but the overall flour yield will be reduced humidity is set higher. This influences all passages and, consequently, the flour yield. from 80.1% to 79.2 percent.

The calculation is simply a mathematical comThe column on the left of picture 11 shows a list of the passages. Break passage II putation of the feeds on the basis of the sifter is highlighted. The roll setting can be changed fractions in percents. Details like the moisture loss using the sliding button on the right of and the losses of flour in filters are neglected. the column. The result is shown in the next column in form of a table.

In the picture, all passages are set to normal (= 0), only break passage I is set seven points higher, break passage II four points higher.

The table in the top centre shows the quantities of the individual fractions of the break sifter II, which has been selected here.

On the left are the sieve meshes and the yields in individual and total percents.

The column ‘to’ (‘nach’) gives the passage were the oller mills with specification and possible roll gap tailings are sent to. setting

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&feed milling technology

Grain

September - October 2011 | 15

FEATURE

Roller mills with overview of specifications

Consequently, the figures differ slightly from reality, but nevertheless they show the ranges and the correlations, because the differences are minimal and do not affect the training purpose.

The percental feeds to the passages and the yields are transferred to the PLC, where they are compared with limit values. If the limit values are exceeded, the system is alarmed and the interlocking reacts.

Roll settings and power input at the roll drives The operator in a real mill has an ammeter on each roller mill, which has a red marking indicating the maximal value.

This shows him the scope within which he may set the rolls. In our Virtual Mill we also have an ‘ammeter’ which is represented by the column ‘actual A’ (‘A ist’) in picture 11 next to the roll setting.

When the roll setting is changed with the sliding button on the left, the ampere value in the column pactual Ap also changes. The calculation also takes into account the feed and a milling factor based on the sieve analysis

Picture 10: Flour silo with loading-out section

before and after the rolls. When the maximal value is exceeded, an ‘!’ is added in the column ‘maximal A’, the transgression is signalled to the PLC, the motor stops work and the interlocking is triggered.

If the roll settings remain within the permitted limits, a new calculation can be carried out using the command ‘New calculation’ (‘Neu rechnen’). The new feeds, yields, power inputs and milling factors, caused by the changes, is transferred to all following passages. At the same time, the outputs of all roller mill drive motors are summarised and indicated in the lower right corner as kW and kW/t.

What can DMSB students learn when using the Virtual Mill?

The Virtual Mill can simulate all processes that occur in a real mill: Starting with grain reception and storage in silo bins, then conveying and blending in the silo, cleaning and preparing the grain in the grinding bins, the actual grinding, the conveying to finished product bins and finally the loading into bulk trucks.

Just as in a real mill, the PLC equipment is given a ‘job’ for every procedure, and the fulfilment of this job is monitored in detail. In case of faults, for example, the complete filling of a bin an alarm is set off and the interlocking system is actuated. Then, the job has to be started again from the beginning.

In the grinding equipment itself, the interdependencies between roll setting and plansifter meshes or between feed to passages and flour yield can be analysed, as well as the results in the following passages when these Display of the programme that sets the mill parameters are changed.

It is also possible to study

16 | September - October 2011

the correlation of roll setting and power consumption of the roller mills.

Finally, it is possible to examine how mill capacity, grinding moisture and relative air humidity are correlated and how countermeasures can be taken by changing the adjustment of the mill.

In a real training mill, many of these facts could not be imparted, because the necessary amount of data would not be readily available.

So, the miller will learn how to run a mill in a surrounding that is close to his practical work, and the future millwright will become acquainted with circuit, interlocking and monitoring devices of the plant.

Summary and outlook The Virtual Mill provides teachers and students at the Deutsche Müllerschule and other interested persons with a complex system for training and study.

It visualises machinery and automation in modern mills and it simulates the results of changes in milling parameters in a realistic environment.

In the worst case production will be stopped because due to an overload in the roller mills the motor protection devices respond and the respective passage comes to a standstill.

But this will have no actual consequences, as it would have in a real mill.

In future, the Virtual Mill will become part of lectures and practice in the subjects Process Engineering, Milling Machines and Business Economics. It can also be used in other subjects, for example, data from laboratory training can be entered into the production control system to ‘produce’ appropriate mixtures of milling products.

The subject Process Construction will use the given machinery equipment as a basis for planning other mills, in the subject Mill Construction these plans will be checked for statics and conformance with building regulations. More teaching concepts making use of the Virtual Mill will follow.

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Sample preparation of feeds and forage for NIR analysis

by Dr Andreas Theisen, Sales & Application, Retsch GmbH, Haan, Germany

T

he feed quality has a decisive influence on the productivity of livestock farming. However, high-quality forage considerably adds to the costs of stock breeding.

Consequently, economic considerations focus on the quality and quantity of the components used in the production process.

This includes reliable analyses of feedstuff and ingredients from receipt of goods to final inspection as the best way to ensure a balanced feeding of the animals while keeping cost and profit orientation in focus.

Near Infrared Spectroscopy (NIR) is the most important analytical method for the

Table 1: The measurement results of various parameters in ground and unground rabbit food pellets only show slight differences

Parameter

Ash

Moisture

Fiber content

Fat

Protein

Ground rabbit food pellets Average

8.58

10.20

11.68

Standard deviation

0.07

0.23

0.34

3.11

13.70

0.03

0.18

Unground rabbit food pellets Average

8.67

10.81

11.46

3.16

13.19

Standard deviation

0.10

0.15

0.59

0.03

0.13

determination of protein content, moisture, fat and ash in feeds and forage.

The advantage over classical methods

such as Kjeldahl is the simultaneous determination of several parameters. Moreover, NIR spectroscopy is a quick method, which requires neither consumables nor reagents.

Therefore it is used whenever high sample throughput and great flexibility are required. The identification and qualification of raw materials as well as the quantitative analysis of convenience products can be carried out within seconds to guarantee highest product quality and safety.

A much discussed issue related to NIR analysis is the necessity of sample preparation. Users often face the problem of having to decide whether sample preparation is required or not.

What does sample preparation for NIR analysis involve?

Figure 1: Fiber content of the ground (blue) and unground (green) wheat sample resulting from 10 measurements. The analysis of the unground sample clearly shows a systematic as well as a considerable statistic error.

18 | September - October 2011

Sample preparation for NIR does not require digestion or extraction; it is mainly about size reduction of the sample material.

This involves two aspects: 1. Homogenising the sample 2. Achieving the required grind size

&feed milling technology

Grain

Whereas an inhomogeneous sample leads to systematic errors in the subsequent analysis, a sample, which is too coarse causes statistical errors. This will be explained in the following.

The penetration depth of NIR radiation in grain or forage is up to 1mm, measured in diffuse reflection.

Thus, the composition of the sample’s deeper layers is not detected. That is not a problem if the sample/pellet is homogeneous in itself. When examining pellets coated with fat or grains and seeds, however, the ingredients of the analyzed layers are over represented in relation to the complete sample.

If the material is homogeneous but does not have the required analytical fineness, the surface actually analysed is reduced. This is due to the fact that the light inside the sample is scattered and not returned back to the detector.

The same happens with light, fibrous samples with a low bulk density. As this effect is influenced by the filling level of the sample container and the surface actually analyzed, the statistic error is rather big in such cases.

Test series with different samples The different properties of ground and unground samples when analysed with NIR are demonstrated exemplarily with three different materials: rabbit food pellets, wheat grains and hay. The samples were analyzed

10 times, the spectrometer was refilled for every measurement.

The samples were pulverized in Retsch’s cyclone mill Twister. This mill was specially designed for sample preparation of food and feed for subsequent NIR analysis. In the Twister size reduction is effected by impact and friction between the rotor and the friction surface of the fixed grinding ring.

The feed material pass-

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September - October 2011 | 19

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FEATURE

“NIR spectroscopy is a simple and suitable method to determine a series of relevant parameters in forage and grain.

The general opinion is that it doesn’t require any sample preparation” ground and unground samples hardly show any difference.

Table 2: The analysis of wheat grains shows a considerable difference in the ash and fiber content of the ground and unground sample

Parameter

Ash

Moisture

Fiber content

Fat

Protein

Ground wheat Average

2.80

9.68

1.10

1.17

9.02

Standard deviation

0.03

0.09

0.05

0.03

0.07

Unground wheat Average

0.10

9.80

6.90

1.38

8.46

Standard deviation

0.10

0.25

0.62

0.16

0.45

Table 3: The analysis of hay shows a strong difference in the protein content and standard deviation between ground and unground sample

Parameter

Ash

Moisture

Fiber content

Fat

Protein

The results for wheat are different The table shows a considerable discrepancy between ground and unground sample, particularly with regards to ash and fiber content.

This is due to the fact that only the surface of the unground wheat grains is analysed resulting in an over representation of the kernel shell.

The third analyzed sample is hay This sample shows a substantial difference for the average and the standard deviation of the protein content. This is because of the varying bulk density of the unground sample.

Conclusion Ground hay Average

9.53

5.70

28.56

1.36

6.17

Standard deviation

0.07

0.12

0.29

0.04

0.12

Average

9.31

6.25

26.26

2.44

9.94

Standard deviation

0.07

0.09

0.68

0.18

0.43

Unground hay

es through the hopper (with splash-back protection) onto the rotor, which is rotating with high speed, and is thus submitted to preliminary size reduction. The sample is then thrown outwards by centrifugal acceleration and is pulverized between rotor and grinding ring. The two-step grinding ensures particularly gentle but fast processing so that the feed material only remains in the grinding chamber for a very short time.

The integrated cyclone provides cooling of

20 | September - October 2011

the sample and the grinding tools which helps to preserve the moisture content. The sample properties to be determined are not altered in any way. The ground material is separated in the cyclone and collected in a sample bottle.

The cyclone mill Twister is also suitable for processing large numbers of different materials as no cleaning between samples is required.

The quantitative measurements were carried out with the NIR spectrometer TANGO from Bruker Optik GmbH. The first sample to be analysed was rabbit food pellets. The measurement results of the

NIR spectroscopy is a simple and suitable method to determine a series of relevant parameters in forage and grain. The general opinion is that it doesn’t require any sample preparation.

The results presented in this article show, however, that it does make a difference if the samples are ground in a suitable laboratory mill before being analysed, particularly if they are inhomogeneous.

Only then is it possible to guarantee meaningful and reliable analysis results.

More

information:

Dr Andreas Theisen, Sales & Application, Retsch GmbH, Haan, Germany Tel: +49 2129 /55610 Email: mk@retsch.com, website: www.retsch.com

&feed milling technology

Grain

FEATURE

PRODUCING FLAKED BREAKFAST CEREALS P

roducing flaked breakfast cereals from pellets or grits by passing them between contra-rotating rollers is a prime example of a process that is much more complex than it appears. Achieving the consistent high quality demanded by consumers at the high outputs needed by producers requires a great deal more process expertise and precision engineering than might be assumed.

Baker Perkins flaking rolls are used by leading multinational and regional breakfast cereal makers, to convert cooked grains and extruded

22 | September - October 2011

pellets into a wide range of corn, bran, multigrain and other flakes ready for toasting.

Grits and pellets up to 10mm thick are reduced to flakes as thin as 0.3mm.

With 30 years experience in providing flaking rolls to customers throughout the world, Baker Perkins cite the control of three key process variables as essential to achieving the highest flake quality.

The first is achieving an even, regulated product feed across the full width of the rolls. Uneven feeding causes differential heat build up in the rolls and leads to inconsistency in flake thickness. Colour, moisture, size and texture of the finished product are all adversely affected. To avoid compromising quality with excessive ‘doubles’ it is important that the feed be regulated to ensure that pellets and grits are processed individually To achieve these objectives for different product types Baker Perkins engineers productspecific feed systems.

Extruded pellets and multigrains are fed by a vibratory conveyor and spreader. For cooked corn grits, a grooved roll feeder is used, with the flexibility to adjust gap height and roll speed. A

distribution box is typically used for whole grain wheat.

The second challenge is to maintain a precise and constant gap between the 2-ton contra-rotating flaking rolls: this is crucial to achieving consistent product quality. Any minor variation changes flake thickness and bulk density, resulting in under- or over-toasting and rejected product. Adjustability is also important to maximise flexibility.

A recently upgraded automated hydraulic system positions each roll via a linear transducer: the roll gap is continuously measured and adjusted against a set point. Effective sealing against dust ensures reliability and a low cost of ownership. The system is compact and accommodated within the envelope of the machine to minimise footprint, but is readily accessible for maintenance.

The third process variable that must be accurately controlled is roll surface temperature. Consistent roll surface temperature is essential for optimum flake consistency and is achieved via an effective water cooling system.

The latest generation of machine incorporates an advanced roll cooling and water circulation procedure.

Effectiveness has been refined through a contraflow water circulation system, with water channels close to the surface to maximise heat removal efficiency. High flow rates of up to 10,000 litres per hour control water temperature within a 0.2ºC tolerance band – water temperature can be varied by the operator.

The solid flaking rolls themselves offer the unique feature of a welded outer

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FEATURE

layer of hardened tool steel over a tough carbon steel interior. As well as long life – typically 10,000 hours before regrinding – there are additional cost benefits. The outer layer permits a number of re-grinds, and at the end of natural life another outer layer can be welded to the roll: conventional rolls need replacing at this point. The outer layer can also be repaired in the event of damage by stones or other foreign objects.

The scraper blades that clean each roll are made of hardened but flexible alloy to ensure uniform contact across the roll width.

Two features extend blade life: they are held in position by a variable pneumatic pressure system; the blades are also reversible and may be reground several times. An optional oscillating knife increases the effectiveness of scraper action.

A major improvement introduced on the latest generation of machines is the substitution of a precision timing belt drive for the previous torque arm gearbox. With independent drive to each roll, speed can be varied to change the nature of the flake if required. Maintenance is reduced because AC motors and timing belts require no routine work.

In an environment in which workplace noise is rapidly growing as an issue, the new flaking roll drive features acoustic covers over the roll drives as standard; there is also an option for hinged acoustic covers at each end of the unit.

These flaking rolls are designed for ease of use. There is full PLC control with a touch-screen HMI providing clear process visualisation and intuitive operation. The set-up facility is recipe driven, and there are comprehensive alarm functions plus a recent alarm history.

Simple, open design maximises accessibility to the flaking rolls themselves for cleaning and maintenance whilst conforming to worldwide safety standards; the simple frame construction allows for easy roll removal.

The latest machine also has a smaller footprint.

On leaving the flaking roll, the product is transferred to a toaster where a mois-

ture content of 18 to 20 percent must be rings, alphabet shapes, and cocoa balls reduced to 3 percent. Discharge options can be extended, through additional units to suit customer preference include a bi- (including the flaking roll), to make a directional belt conveyor, a vibratory con- range of flakes, multigrain flakes and filled veyor, and a vacuum take-off system with pillows.

Baker Perkins provides the process and sampling tray.

The choice of standard 780 or 1220mm engineering expertise to reconfigure the roll widths allows a range of outputs to a lines, and works with customers to develop new product ideas, often in the Baker Perkins maximum of 1,500kg/hour.

Flaking rolls are an essential module in Innovation Centre at Peterborough, where the Baker Perkins Cereal Master TX and a comprehensive range of equipment is EX expandable lines. These allow manu- available for trials. Each installation is individufacturers to install a basic line for a limited ally specified to match the customer’s exact range of cereals, and then add more units product needs. to increase the range and value of products as market and business conditions change.

The Cereal Master TX includes a flaking roll in Our technology based its standard configuration on the 2-Parameterfor making Resonance-Technology, wheat and this makes it possible bran flakes to control density using the traditional steam and moisture in your cooking procproducts ess.

Other units can be added later  fast to extend  accurate the prod cost effective uct range to include corn, multigrain and frosted flakes.

A standard Cereal Master EX line producing extruded cereals such as corn balls, multigrain

Inline

moisture + density

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&feed milling technology

September - October 2011 | 23

Grain

AD_DoescherDoescher_90x132.indd 1

30/09/2011 11:08

FEATURE

MILLING TECHNO

by Suzan Sert, Area Sales Specialist, Alapala Machine Industry Trade Inc, Turkey

S

imilago is founded on operation speed practicality, safety, hygiene and precision, its details have been dissolved in a perfect manner and furthermore it is a status symbol.

The disassembling of a roll set and assembling of another roll set is performed within 20 minutes; the roll set is applied to a simple vehicle by being lifted via a mechanism used

“Apart from conventional feeding systems, for which no practical or maximum cleaning could not be ensured in the most rapid way until today”

on every machine without utilising any other external lifting mechanism; furthermore, in the assembling stage, all these details are realised with practical solutions without the use of any special tool.

Hygienic conditions have been ensured to all internal surfaces at an utmost degree.

Apart from conventional feeding systems, 24 | September - October 2011

for which no practical or maximum cleaning could not be ensured in the most rapid way until today, this device provides the opportunity to perform rapid cleaning in a maximum way. It uses either a vacuum cleaner or by wiping out up to the dismountable inlet compartment via its window. Note: this compartment can be opened forwards and upwards automatically and is easily cleaned by opening the cover on the top without performing any other process, thus the compartment is dismounted easily from underneath from the feeding roll and from the main rolls.

User will not look into the machine from behind a glass cover anymore and must not open a glass cover for cleaning the external surface.

This is a standard structure that can be applied to standard chassis on single-deck and double-deck models. Moreover, on the same body, a montage of 250mm and 300mm rolls can be implemented.

Especially setting and positioning precision of roll spaces and the position repeat precision have achieved values that could not be accomplished before and this provides an opportunity of top setting automation on the same structure.

However, although a feeding automation product level control is performed with several different methods, this has been dissolved with a user-friendly system requiring

no re-calibration for any other product.

Practical use is enhanced through special software solutions, graphics and a touchscreen, which asked the question: what else would a wheat kernel, a miller, the company’s boss or the end consumer wish for?

Its power, durability, simplicity for being easily comprehended by anyone adds to its aesthetic, additional performances and additional efficiencies which are proven additional advantages.

Similago: Functional parts The carrier frame is a desk type. The bearings and rollers are directly mounted onto the frame. It is machined with CNC as a whole with precision parallelism and is made of high strength special quality carbon steel in a welded structure.

It has a sturdy construction and provides high efficiency, high performance, effective and efficient operation that is reliable and long servicing, precision and strong in structure, complete sealing and requires little maintenance.

In the hygienic milling chamber, the rollers differentially driven by special profiled belt and pulley group - with tensioning pulley­ carry out the milling operation.

The overheating of the rollers is controlled by means of the air circulation delivered by the aerodynamic structure and the chamber is free of dust-catching corners and details.

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LOGY

REDEFINED

For control purposes, an isolated door with double walls (Alapala design) is provided. This door operates with a weight system without a latch and it can be quickly mounted/dismounted without any bolted connection.

For maximum hygiene, all surfaces are smooth to prevent dust catching and even the remotest parts are designed to allow easy access and quick cleaning.

Especially the inaccessible chamber in

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feeding roller section can be accessed by opening the front door and the automatic sliding of the feeding rollers to the front and above and allows for easy cleaning.

Product intake and product feeding system A transparent polycarbonate glass is provided, which can be easily dismantled from outside, for cleaning without the need to dismantle the intake pipe or any other part.

A dispensing hoe is provided at the back for evenly distributing the product on the roller surface and a feeding system, equipped with specially profiled spreader cylinder and manually adjusted trap-door for setting the spreading thickness of the product, is provided at the front. In single- and double-deck models of Similago the same frame is used for 250mm and 300mm diameter rollers.

September - October 2011 | 25

FEATURE

Direct Cold Plasma: The innovative answer to odour control in the food and feed industry

by Havard Vetrhus, Director Sales & Marketing, Applied Plasma Physics AS, Norway Tel: + 47 5160 2220, Email: havard.vetrhus@app.no

I

ncreasingly, feed manufacturers are being required to address the issue of release of odour and harmful contaminants into the surrounding community.

Local communities, special interest groups and government legislation all bring pressure to bear on factories to minimise real or perceived risks of contamination.

There are no universally applied standards for odour or Volatile Organic Compounds (VOC) emissions, and to provide solutions that fit specific factory needs can be complex. There is no single solution but understanding the feed manufacturers problems certainly helps a great deal.

In recent years, there have been numerous changes regarding where production facilities are situated. Factory closures and relocation of manufacturing units has become commonplace.

At the same time urban sprawl has resulted in residential areas being built closer to previously remote industrial areas.

Another pressure companies face is meeting local environmental needs.

So what does the industry need from its odour abatement equipment? This is a complex question and the answer needs to include: • A compact design minimising space requirements

26 | September - October 2011

• End of pipe solution • Low running cost • Minimal maintenance • Ability to operate at normal feed manufacturing temperatures, to avoid cooling costs • High odour removal efficiency • No chemical additions and need to maintain chemistry • No liquid effluent waste • Instant on/off – no warm up time • Modular construction, ease of relocation if change of production location and ease the ability to add on modules according to required capacity • Competitive capital cost This is a tall order but there is a technology can answer most of these needs: Cold Plasma.

A high tech, high voltage solution In 2003 a global petfood manufacturer tested a new technology for odour removal, referred to as Direct Cold Plasma, on drier and extruder flash-off exhausts.

The technology had obvious advantages over more conventional solutions. As a result the petfood manufacturer looked for a suitable technology partner for collaboration on the application of cold plasma on petfood applications.

In 2003 they formed such an agreement

with APP (Applied Plasma Physics AS).

APP is both an R&D and equipment supply company, specialising in the application of high voltage technology and non-thermal plasma systems for industrial processes. APP has now delivered more than 200 systems, most running on difficult applications.

APP has experience on ultra high odour applications – where odour levels can be over 200,000 odour units per m³ - and the company achieved odour removal efficiencies of up to 97 percent. Another advantage that is unique for this specific technology is that both odour and dust are removed from the production emissions.

Cold plasma technology – Nature in a box Odour bearing gases enter the cold plasma module, where care is taken to distribute gases evenly as it enters the reaction chamber. The reaction chamber comprises a cluster of hexagonal cells. Running centrally through each cell is a corona wire, which is isolated from the rest of the chamber.

The high voltage generator distributes a modulating high voltage supply to each corona wire, and this process results in a discharge between the corona wire and the cell wall.

The discharge promotes the emission with high-speed electrons, which collide with background gas molecules creating chemically active species known as radicals

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FEATURE

and charge carriers. This is actually identical to what happens with pollution in the atmosphere. Reactions occur with the odour bearing compounds in the gas to be treated.

Ambient air may be injected just prior to the reaction chamber to optimise humidity and temperature as well as adding ions to the gas stream.

In essence the cold plasma process encourages ‘oxidation’ of the odour bearing compounds at low temperature by creating discharge (cold plasma).

A closed-loop cooling unit ensures that operating conditions within the high voltage generator are maintained within controlled limits. A proprietary control system monitors the high voltage passed to each of the corona wires in the reaction chamber, and controls the voltage modulation that generates the cold plasma.

The system also detects arcs between the corona wire and the cell wall, automatically shutting down electrical supply for a fraction of a second before power is reinstated.

The reaction chamber may be operated with the gas flow passing upwards or downwards depending on site layout. The unit is capable of operating on emissions with relative humidity close to 100%, although the closer to 100% RH the unit operates, the higher the possibility of arcs and consequently risks of reduced efficiency.

The unit can be operated with emission temperatures up to 70°C.

symaga_quarter page_IAFD2011

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10:09

In most cases in the feed industry, the emission temperature from dryers will be less than this temperature limitation.

Maintenance is minimal, if the unit is used as a dust collector as well as odour abatement system, then the unit would have a ‘wash-down’ maybe once per week and an internal inspection once a month would be recommended. Operating costs are very low and mostly associated with the cost of electricity; 10-20kW for a standard 20,000m³/h cold plasma unit.

A costing exercise produced by one of APP’s customers, is shown below. This is based on a 10-year period, including both investment and operating cost for a volume of 20,000m³/h. The operating costs for the scrubber alone or scrubber biofilter do not include cost of water.

Testing in the petfood and fish feed industries Since 2003, extensive testing with a pilot system both on extrusion flash-off, driers and coolers has been carried out. All possible variables have been reviewed to determine the optimum operating conditions for the cold plasma system.

Variables tested: • Residence time (determines volume to be handled by a standard module) • Effects of water scrubber at inlet or outlet of cold plasma • Cold plasma unit operating alone • Adding water to humidify inlet or outlet gas • Air infiltration volume (ion enrichment) • Intensity of cold plasma generation • Geometry and arrangement of reaction cells The pilot plant (test unit) is designed to

Page 1

handle 1600m³/h and tests were repeated to check validity. Independent Olfactometry testing was used as a means of determining odour reduction efficiency.

Test results indicate that odour removal efficiencies of up to 90 percent are achievable within the food and feed industry and that the standard colds plasma module will handle around 20.000Am³/h.

Higher efficiencies may be achieved by using a final polishing module. During testing, both high and low odour concentrations were experienced; nonetheless cold plasma achieved real odour reductions even on very low inlet concentrations, something that is not always the case on alternative technologies.

Overall the tests indicated that the cold plasma unit operated most effectively without a scrubber either at the inlet or outlet.

Dust removal was very effective (99% reduction).

As a result of these tests, several petfood sites have now installed cold plasma technology for their processes. As per today, 50 units are in operation in the petfood industry, a figure that will increase substantially in the years to come.

The experience of the environmental needs of the feed industry, and APP’s approach to innovative design is combined to offer a competitive alternative solution to a problem that is of increasing significance to the food and feed industry.

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September - October 2011 | 27

FEATURE

15-Year Celebration: Fortifying with folic acid prevents 22,000 birth defects annually

I

n just 15 years, adding folic acid to flour has become a life-altering business practice resulting in the prevention of more than 22,000 serious birth defects every year. That’s 60 babies a day born worldwide without these birth defects because flour is fortified.

The Flour Fortification Initiative (FFI) is celebrating the progress made in helping children get a healthy start in life and encouraging fortification to become standard milling practice globally.

now mandatory milling practice in 54 countries and voluntary practice in approximately 20 other countries. In addition to preventing birth defects, countries report significant cost savings by averting the healthcare expenditures required to treat children with spina bifida.

Spina bifida is one of three birth defects known as neural tube defects. In spina bifida, the baby’s spine does not form correctly, leading to loss of movement in mild cases or paralysis in severe cases. Spina bifida can be

acid through bread, noodles, pizza crust, crackers and every other food made with the fortified wheat or maize flour.

In 1996, the same year that Oman began fortifying, the United States changed its regulation for enriched cereal grains to include the addition of folic acid, and flour millers had until January 1998 to comply with the new law. Implementation moved faster in Oman because the country has only one mill.

“The mill was well-equipped to introduce the fortification with no major investments,

“The Flour Fortification Initiative (FFI) is a network of public, private, and civic sector partners working together to make flour fortification standard milling practice so that people worldwide are smarter, stronger, and healthier” “The success is obviously in the numbers of healthy children born as a result of flour fortification, but it is also the success of multiple partners working together,” said Scott Montgomery, FFI director. “This achievement required flour millers to implement fortification, and it required the collaboration of international scientists, non-governmental organizations, individual country officials and premix suppliers. In highlighting this 15-year milestone, we are celebrating the contributions of many.”

In 1996, Oman Flour Mills began fortifying flour on a trial basis with enough folic acid to prevent birth defects like spina bifida. This is

28 | September - October 2011

treated but cannot be cured. Anencephaly is another neural tube defect in which the brain does not form properly. It is always fatal. The least common neural tube defect is encephalocele that leads to a sac-like protrusion of the brain. Its severity depends on where the sac is located.

Research published in 1991 unequivocally showed that folic acid prevents neural tube defects. Now it is estimated that 50 to 70 percent of these birth defects can be prevented if a woman gets 400 micrograms of folic acid daily at least a month before a baby is conceived and very early in her pregnancy.

Fortification provides an extra supply of folic

and the Minister of Health, Dr Ali Moussa, was also the chairman of the board of the Oman Flour Mills,” recalled Dr Deena Alasfoor who is now the director of Nutrition for the Ministry of Health in Oman.

Iron and other B vitamins have been added to flour in some countries since the 1940s, and several countries in the Middle East were considering this in 1996 as part of a broader focus on improving nutrition.

Oman Flour Mills began fortification as a trial to see if it was feasible before a multi-sector regional workshop was held in Oman in October of 1996. By the time of the workshop, fortification was deemed successful,

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FEATURE and the Oman mill continued to fortify with no interruption.

Before 1996, some countries added folic acid to flour because everyone needs this vitamin to produce and maintain new cells and decrease the risk of anemia caused by folic acid deficiency. However, the addition levels were too low to significantly reduce the rates of neural tube defects. With encouragement from international consultants, Oman added folic acid to flour at the rate of 1.5 parts per million. This proved to be an adequate amount to reduce the number of children born with spina bifida in Oman from an average of 3.17 per 1,000 births before fortification to an average of 0.96 per 1,000 births after fortification.

The World Health Organization now offers recommendations for fortifying flour with folic acid based on a country’s level of flour consumption. The recommendations range from 1 to 5 parts per million.

As the practice of fortifying flour with folic acid has spread, countries from Canada to Argentina and South Africa to Iran report 30 to 70 percent declines in neural tube defects. The declines vary based on how much folic acid is added to flour and the rate of these birth defects before fortification. In the United States, fortification of flour and breakfast cereals is credited with preventing 1,000 neural tube defects a year.

The U.S. Centers for Disease Control and

Prevention has called it one of the “Ten Great Public Health Achievements” in the last decade.

Children born with spina bifida require multidisciplinary medical treatment, including surgeries, physical therapy and continence care. Wellington Hospital in New Zealand found that a newborn with spina bifida had undergone surgeries costing US$ 569,000 before his second birthday. The hospital’s study also found the direct surgery and hospital costs for six teenagers with spina bifida, from their birth, was US$ 790,000 per individual.

The cost to fortify flour with iron, zinc, folic acid and other B vitamins is between US$1 and US$3 per metric ton of flour.

When countries compare the cost of fortifying flour with the healthcare savings averted by having fewer children born with spina bifida, prevention always proves more economical. Chile’s cost for fortification compared with the savings in surgical treatment and rehabilitative services for children with spina bifida represented a cost:benefit ratio of 1:12. South Africa saved 30 rand for every one rand spent on fortification when it calculated the cost of treating a child with spina bifida during the first three years of life.

“Children born with spina bifida need the best medical care available; and the money spent to help them be more

comfortable and productive is certainly worth every penny,” Montgomery noted.

“Preventing these birth defects, however, saves millions of healthcare dollars and keeps thousands of children from struggling with a life-long disability.”

Millers who fortify flour may see buying premix and conducting quality control tests as standard business practice. Families whose children who may have been born with a neural tube defect without flour fortification, however, surely see it as a life-altering business practice.

The Flour Fortification Initiative (FFI) is a network of public, private, and civic sector partners working together to make flour fortification standard milling practice so that people worldwide are smarter, stronger, and healthier. Wheat and maize flours are most commonly fortified with iron, folic acid and other B vitamins such as riboflavin, niacin, and thiamine. Other nutrients often added to flour at each country’s discretion include zinc, vitamin A, vitamin B12, and vitamin D. For

more information:

Sarah Zimmerman FFI Communications Coordinator USA Tel: + 1 404 7275477 Email: szimme2@emory.edu Website: www.FFInetwork.org

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24/02/2011 14:24:49

September - October 2011 | 29

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.

“With the Latin American planting season approaching,

Wheat supply grows and grows as corn crop shrinks

weather there will be keenly watched for its potential to push up prices. There is also some debate about whether farmers there will sow more maize instead of soya and whether the ‘La Nina’ weather

C

ROSSWINDS continued to buffet world grain and feed markets during the later summer months, making for choppy conditions and a lack of consistent price direction.

Wheat had all the bearish news on the supply side. Crops across the ‘Black Sea’ region (mainly Russia, Ukraine and Kazakhstan) are doing even better than traders hoped in July, more than doubling their export potential compared with last year and promising a return to the region’s price-cutting, custom-grabbing tactics of late 2009 (though with some possible caveats on the amount of quality grain available). Europe’s wheat crops are also yielding far better than expected after a droughts and early summer heat-waves threatened devastation. However, Germany’s ability to offer as much high quality bread-wheat as usual seems to have been compromised by a wet harvest for the

second year running. Canada and the Northern US have struggled somewhat with wet weather and in the US case, potential quality problems, for their top grade spring breadwheat harvests.

Fortunately for consumers, Canada’s crop is turning out bigger than expected while the US spring wheat harvest is showing higher protein levels that will mitigate smaller crop size. There is also plenty of good quality, higher-than-normal protein, US hard red winter wheat for now, albeit under the cloud of a drought threats to autumn planting of next year’s crop for this important breadwheat class. Australia another key breadwheat exporter, meanwhile appears to off to a good start with weather and could get above normal yields as well as a far better quality crop than last year’s although the other major southern hemisphere breadwheat supplier, Argentina has some dry weather problems.

Overall, with Canadian, European, CIS and

phenomenon might cause troublesome dry conditions. Both should become clearer in the next few months”

30 | September - October 2011

&feed milling technology

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COMMODITIES

Indian crops all much bigger than expected a month or two ago, there is clearly no lack of wheat on the world market for self-supplying or importing users. Indeed, world production es timates are s till r ising constantly as we go to press with the International Grains Council and the US Department of Agriculture currently predicting 677/678m tonnes – 26/30m more than last year and the third biggest crop ever.

Some analysts see that expanding even more when all the harvests are in. Even with global consumption rising by an above-trend 20/22m

tonnes (due to more substitution of tight, expensive maize in the feed sector), world ending stocks of wheat in July 2012 now seem likely to exceed the past season’s relatively high 193m tonnes – hardly justification for still rather high wheat prices.

Wheat, of course, cannot be viewed in

isolation from the coarse /feed grains which, thanks to maize, are presenting a far more bullish story than we expected in our last issue. This is mainly due to troublesome crop weather in the largest supplying country, the USA. As mentioned earlier, this crop was sown late after a wet spring. Now it seems that the planted area was smaller and the rate of abandonment larger than expected.

Heatwaves have interfered with pollination during July, resulting in some unusually poor predictions for national average yields and a what looks like a disappointing crop in a

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September - October 2011 | 31

year when markets needed a big rebound in production to replenish thin stocks. Where the US crop will end up will only be answered when the combines have rolled, starting in September, and may not be fully clear until late in the calendar year. At this stage, the official figure of 317m tonnes is little more than 1m above last year’s and about 26m tonnes less than analysts hoped for earlier in the year and could yet shrink further if the USDA decides, as markets expect, that its has over-estimated planted acreage.

The good news is that, so far, the world maize output for ec a s t r e mains about 31m tonnes higher than last season’s and would still be a new record 850/860m amid bigger and/or better than expected crops in Brazil, Argentina, the EU, and Ukraine – all the big alternative sources to the USA. However, amid a smaller US sorghum crop and an inadequate recovery in global barley production this year, a disappointing US maize crop still leaves a balance of fairly tight coarse grain supplies, putting increased onus on wheat to meet growth in global feed demand.

(Wheat is expected to supply 15m tonnes of this growth in 2011/12 co pared with 10m for coarse grains in total.

As said, the US maize crop story is not played out yet. It could yet turn out better than the pessimists fear if the US ‘yield-hit’ from poor pollination has been over-rated.

There are also some mitigating factors on the demand side of the market that may held keep cereal feed costs under some sort of control. US exports, feed and ethanol consumption of maize all appear to be slowing down quote sharply in response to tight supplies, high prices and the general economic malaise affecting the US, European and global feed and fuel markets.

This has already resulted in the US going into the new next season with slightly higher than expected carryover stocks.

Demand for maize is expected to remain flat or falling across these sectors in 2011/12. Even so, by the close of the new season, US and world ending stocks of maize will decline to rather risky low levels. That alone suggests continuing interest from the speculative community, which could make maize costs reluctant to backtrack from their

32 | September - October 2011

recent record high levels. Continuing strength in maize will inevitably underpin the value of wheat and other cereals as alternative feeds.

A similar situation for the US soyabean crop has kept a firm undertone beneath the market for oilseed meal. Under the same planting/

growing weather stresses as maize, the soya crop estimate has already shrunk over the last two months by about 5m tonnes to 84m, about 6m less than last year’s crop and equal to about 4.8m tonnes less soyabean meal. This is important in the context of world oilmeal supplies – to which soya normally contributes about 70%. However, the situation is not quite as bad as this might suggest. World stocks of soyabeans are large, thanks to last spring’s big Latin American crops, and can be drawn down to supplement crush. There is also considerable leeway in the surplus implied between estimated soyabean output and crush, (the bulk of which is usually assumed to go to food/direct feed uses or stocks).

Last season it was 40m tonnes; this season it could shrink to about 25m, helping crush continue to expand to meet an estimated

growth of 4% (about 8m tonnes) in world soya meal demand. Against that, however, supplies of some alternative oilmeals – especially rapeseed, the EU’s principal home-grown oilseed, will be relatively tight after a smaller than expected harvest.

As mentioned above, the speculators have

not given up yet on grain and oilseed prices reaching even higher levels. For coarse grains and soyabeans there is certainly a case to be made for an ongoing bull market, provided demand holds up in these economicallystraitened times. Wheat is plentiful but its value will be influenced by how the feed commodities perform and but the amount of quality grain available. Maize does need to rebuild stocks but may not now be able to star t that process until the next US crop is harvested in last quarter 2012.

Soyabeans and other oilmeals will look to Latin America to keep supplies up and prices under control – so any weather problems in the latter region will certainly find markets sensitive.

Main commodity highlights since our last review Wheat – plenty of wheat but less quality milling?

LATEST estimates from the International Grains Council confirm much larger than expected wheat crops in Russia, Ukraine, Kazakhstan, the EU and Canada, putting the world total 26m over last year’s. If the highest trade and semi-official national estimates for some of these countries are correct, we can expect that total to rise further in the coming months, possibly put ting the crop ahead of 2009’s (estimated at 679/684m by the IGC and USDA respectively).

World wheat consumption is expected to soar by 20/22m tonnes, much of which will be down to increased feeding in place to tight and expensive maize. This is quite a shift from the position of the past few years (see chart), when feed use of wheat stagnated, even fell year-on year. Globally, feed demand for wheat is currently seen by the USDA rising by 15m to a 21-year high of 130.1m tonnes.

Europe itself is predicted to use 56.5m tonnes of wheat this season, 4m more than in 2010/11.

Demand from this sector is also seen rising in the former Soviet countries (+3.2m tonnes), the USA (3m) and China (4m tonnes). It would not be surprising to see the final world

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Grain

COMMODITIES wheat feeding total go even higher than this as many Asian and other maize consumers will be interested in this season’s large supplies of sub-par quality wheat from the Black Sea region and other suppliers who have suffering quality downgrades of their milling wheat crops from wet harvests.

Despite the constant increments being made to world crops, wheat prices embarked on a renewed rally in August partly linked to concerns about North American and German quality supplies but probably influenced far more by fresh support from ‘outside’ investors – chiefly speculative funds covering heavily sold ‘short’ positions on the futures markets.

than markets expected including a spring wheat component (about 17.4m tonnes) similar to last year’s. Canadian quality is expected to be much better than from last year’s crop with harvest weather recently looking promising – so more high grade wheat should be available for export to European and other customers.

The other area of concern, is next year’s US hard red winter wheat crop – the biggest component in wheat expor ts from the world’s biggest wheat exporter. Over the past season, unusually large exports of these grades,

Table 1: IGC crop estimates (main suppliers)

2008

2009

2010

2011F

EU

150.7

138.3

136.8

137.5

CIS

117.3

113.6

82.3

107.6

Inc Russia

63.8

61.7

41.5

57

Ukraine

25.9

20.9

16.8

21

Kazakhstan

13

16.5

10

15

USA

68

60.4

60.1

56.5

Canada

28.6

26.8

23.2

24

Australia

21.8

22.2

26.6

24.8

Argentina

8.4

8.8

14.7

13

India

78.6

80.7

80.8

85.9

In September so far, the trend has reversed as the global wheat supply position has improved and the US and Euro-zone economic crises spooked speculative investors out of the futures markets. As we write, the Chicago market is about 10% off its mid-August highs.

European milling wheat futures are down by only 4% from their late-August peaks due to the weakness of the Euro.

There is a genuine concern about US spring wheat supplies. The crop was planted late amid wet weather and harvest acreage estimates keep declining. Current estimates (which could shrink further in coming weeks are for a crop of 12.9m tonnes (v last year’s 15.5m) and with lower starting stocks, a 17% drop in total supplies to 18.7m tonnes. However, the US is only expected to use about 7.5m of its own spring wheat with a similar amount going to export. Demand is down from last year because US millers are using more hard red winter wheat (from a particularly high quality crop this year) while foreign buyers are taking a lot less US wheat overall, switching to other cheaper origins, especially the Black Sea suppliers.

Strength in US hard wheat prices has also been undermined somewhat by Canadian officials issuing a surprisingly high crop estimate of 25m tonnes about 2.5m more

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Grain

in effect, helped save the day for many foreign consumers when Black Sea wheat supplies ran short. However, traders are worried that a prolonged drought in the southern Plains will prevent many farmers from sowing this crop in the early autumn. The past year’s HRW output had already declined by about 22% as farmers switched to other, more promising crops. Even if the US cuts HRW exports in 2011/12 by about 29% as the USDA currently predicts, pipeline stocks of this grade could shrink by almost 30% by next June. An even smaller crop then would imply much tighter supplies of HRW than the market has grown used to.

Does this matter so much in a year when the Russians and others will hike their export potential by far more? At this stage the forward futures markets are quite bullish still, the Chicago soft red winter wheat contract quoting prices more than 10 % higher into mid-2012 (though it would not be the first time by any means, if futures ‘price-revelation’ proved wide of the mark). For the near term, though Russia continues to make all the running in pricing of wheat on the world export

September - October 2011 | 33

markets, undercutting the US and Europe by about $10/20 per tonne (and at one point as much as $30/40) to win the lion’s share of non-routine export tenders. So far, neighbouring Ukraine and Kazakhstan, also with far larger crops this year, have taken a lower profile in export markets, concentrating on bringing their crops in and, in Ukraine’s case, still hampered by the tangle of red tape that was imposed to control outflows of grain during the Russian and other regional crop failures. However, we can expect both of

Russia’s neighbours to be keen competitors for exports in the months ahead, helping to restrain wheat prices on world and European markets - although with some caveats. Much of the Ukrainian crop is thought to have been severely downgraded by wet weather and fit only for feed rather than milling (though presumably a lot of the crop can be blended up with some of the more expensive North American quality wheat). There has also been talk in the trade of Russia having a more finite supply of good quality wheat than markets have been assuming after its early-season onslaught on the export market, in a bid to recapture its tarnished reputation as a reliable, cheap supplier. Time will tell but, on past experience with the CIS countries, the old adage ‘big crops get bigger’ has often been true and of the supplies are there, we might

34 | September - October 2011

expect all three of the main regional supplies to try to cement their return in the wheat export markets. All had ambitious export expansion plans before last year’s weather problems and all have invested heavily in infrastructure to facilitate these – often in joint ventures with multi-national grain and agribusiness companies who will want to see some return. For these reasons, it would not be surprising to see combined regional exports easily reaching or even exceeding the 32.5m tonnes forecast by USDA. Last season, these countries supplied just 13.6m compared with 2009/10’s 35.8m and 2008/09’s record 37m.

Not to be overlooked is India’s retur n for the f ir s t time in several years as a major world wheat expor ter, initially allowing about 2m tonnes. Adding all these increases in supply to the world total cer tainly mitigates the impact of expected lower supplies from the US and the European Union. Even here the news has been improving in the past two months as the EU-27 crop total has jumped back to about 136/137.5m tonnes – slightly ahead of last year’s. This is an incredible turnaround after some jeremiahs were forecasting possible 20/25% yield losses at the height of the early summer droughts and heatwaves. Although the two biggest producers, France and Germany, have seen smaller crops, output is up in Eastern Europe, Spain and the UK. Total EU wheat supplies will still be lower than last season’s because starting stocks of 11.7m tonnes were drawn down by about 4.5m to maximise exports during Russia’s temporar y absence from the market.

However, exports are expected to drop back by about 6.6m in 2011/12 and impor ts to rise by 3m tonnes, leaving a slightly higher stock at season’s end next July 1. Indeed, so far this season, impor ts are actually exceeding expor ts, putting fur ther restraint on domestic EU cereal prices.

KEY FACTORS & QUESTIONS FOR THE MONTHS AHEAD Final quality outcome and volumes for North American, German and, late in the year, Australian/Argentine breadwheats Northern hemisphere planting/weather this autumn – will the US get rain in time for hard red winter sowing?

Russian and other CIS export strategy. Will they continue to market aggressively – or will they (Russia especially) put more into stocks after last year’s crop scares? How much milling as opposed to feed wheat can the Ukraine export?

US domestic & world import demand for feed wheat – will it continue to increase if maize supplies tighten?

Coarse grains – smaller than expected US maize supply The USDA’s September estimates had been keenly awaited by grain markets on both sides of the Atlantic as one of the main arbiters of feed supply and pricing in the months ahead. In the event, the all-important US crop estimate turned out just below average trade guesses at 317.4m tonnes – 11.4m lower than last month and only 1m more than last year. However this was heavily offset by cuts of 7.6m tonnes in US consumption and 3m tonnes in exports.

USDA thinks that corn prices of $7/bushel (about $276/tonne) will cut use across the board within the US itself – not only in animal feed but even in the ethanol fuel sector, for the first time in several years.

At the same time, non-US maize output was raised by 4.8m tonnes, leaving world total production only 6m tonnes smaller than forecast in August and still almost 31m tonnes bigger than last year’s. Against that, world demand, is seen rising by just 18m tonnes, (7.3m less than in August). So while global ending stocks at the end of 2011/12 (next September) will still be historically tight – things won’t be quite as squeezed as expected last month.

Maize futures initially rose in response to the US crop forecast, implying many traders think it will shrink further as the USDA adjusts acreage, if not yields, in later estimates. The Department is still counting fields that were planned for corn and prevented by wet weather, although some analysts think it has made allowance enough for these in its current estimates. Good yields from early harvested fields in September meanwhile suggest that the losses from poor pollination during a hot July might have been exaggerated although the earliest planted fields were always expected to do better with a longer growing period.

In the same vein, not all the US trade believes demand will be as low as the

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USDA thinks in 2011/12 – especially if prices star t to drift back and crank it up again. Time will tell.

In Europe itself, the maize crop is one of the biggest ever after good summer rains boosted yields. The USDA boosted its forecast by 1m tonnes in its September estimates to 61m but French analyst Strategie Grains thinks another 700,000 can be added to that figure, putting it 5.8m tonnes over last year’s and roughly in line with expected consumption.

Maize crops may also be better than expected in other supplying countries.

Argentine estimates are running as high as 30m tonnes compared with the USDA’s latest forecast of 27.5m and last year’s 22m tonnes. The Argentine government has already announced a big jump in its expor t allocations to about 20m tonnes compared with last year’s 15m. Third largest exporter Ukraine also upped its maize crop forecast to 20m and expor ts to 12m versus the USDA’s forecast of 10m and last year’s 5.5m tonnes.

Among the other coarse grains, world barley output is up by about 8.5m tonnes this season but for the second year running, demand will out-run supply (by 4.5m versus last season’s 11.2m tonne shor tfall), so world stocks will continue to decline. European output is similar to last year’s when it ran about 3m tonnes shor t of demand. However, EU consumption is expected to drop back in 2011/12 as some feed demand switches over to the more abundant wheat crop.

Sorghum output on the other hand is down by 5m tonnes this season and will barely match expected demand. Adding in the other coarse grains puts the world total for this cereal group about 11m tonnes behind demand. The resultant drawdown in world stocks will leave them at around 13% of consumption – about seven weeks’ supply.

Overall, the outlook for coarse grains suggests the markets may just about scrape

36 | September - October 2011

by in 2011/12 by slowing demand growth.

That means keeping prices high enough to ration demand although pundits will doubtless continue to argue in the months ahead where the ‘equilibrium’ price lies. One thing is clear, however. These relatively low stocks make it imperative for the US and other coarse grain producers to come up with a better crop next year and any weather scares will find markets very sensitive.

KEY FACTORS IN THE MONTHS AHEAD - The final size of the US maize crop – smaller or bigger than the USDA September number?

- China’s maize ‘deficit’ and its attempts to fill that with imports – markets get jittery when China moves - Global economic problems – not good for consumer confidence, so negative for meat and feed demand and a potential restraint on grain & oilseed prices - Speculators’ interest in commodities – is the party over? Probably not quite yet.

- Ethanol competition for maize supplies – amber signals for endless government subsidies and demand growth does seem to be slowing. But shortages of sugar-based ethanol from Brazil are tightening the world market for green fuels, supporting their value. That could turn out more bullish for maize going forward

Oilmeals – soya less tight than thought Oilseed meal prices were star ting to look fr isk y in the summer months as concer n built that the mar ket leading US soyabean crop would turn out much smaller than expec ted af ter weather problems. Cer tainly this crop will be well down in 2011 – by about 6.6m tonnes or 7% . However, the situation there does now seem to be stabilising, even allowing

for some upward adjustments. World soya supply is boosted by larger than usual carr yover stocks from last season in Latin America – about 9.5m tonnes more than a year ago. This relatively good overall supply is expected to allow world soyabean crush to still rise by about 10m tonnes in the coming season, equal to about 8m tonnes more soyabean meal.

The supply outlook for other oilmeals is mixed – more cottonseed and sunf lower meal and, by supplementing this year’s smaller output with car r yover s tock s from las t year, fair ly s table r apeseed meal supplies. Europe will be far more dependent on rapeseed impor ts after a disappointing harvest here. This does have the potential to push up prices although the brunt of the impact will be on canola oil consumers as rapeseed meal tends to follow the soya meal market. Overall, the supply increase for oilmeals should be able to approximately match the anticipated rise in world demand without the need for much fur ther price-rationing.

Soyabean prices had been f ir m all summer on the factors mentioned above but are dipping a bit as we go to press as the latest round of economic jitters sparks fresh doubts about the strength of world commodity demand, especially related to fuel and meat consumption. Estimates for top soya consumer China’s soya demand have already been scaled back a bit although the rate at which its planners expect pork and poultry production to expand suggests it will remain a potential bullish force in this market.

Wi th the L atin A mer ican planting season approaching, weather there will be keenly watched for its potential to push up prices. There is also some debate about whether farmers there will sow more maize instead of soya and whether the ‘La Nina’ weather phenomenon might cause troublesome dr y conditions. Both should become clearer in the nex t few months.

KEY FACTORS IN THE MONTHS AHEAD - Final US soya planting estimates and weather in the next two months - Is China, the engine of world crush growth, slowing down?

- How much soya will the Latin Americans sow this autumn?

- Did Canada meet its rapeseed planting targets & is the crop there under or overrated?

- EU winter rapeseed plantings - up or down for 2012?

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adv-ildex-india-2012-90x132-V2.indd 1

September - October 2011 | 37

06-07-11 13:03

THE GLOBAL MILLER Hi I am the Global Miller Welcome to The Global Miller page in GFMT. This page highlights what is happening in the world of milling, covering stories that appear daily on our blog.

I will be blogging the latest news from around the world that relates to the movement, storage, milling and use of all types of grains and cereals for the food and feed industries. To receive my reports regularly why not sign up to this blog directly or follow us on Twitter and Facebook?! - The Global Miller by Martin Little, Blog Editor Cargill open new grain silo in South-Western Romania In South-Western Romania Cargill official Martin Schuldt, head of Cargill’s business in Romania, opened a new grain silo in Drobeta Turnu Severin the opening ceremony was attended by Marius Balu, president of Mehedinti county council, local authorities, Cargill employees and customers. This new grain silo will take collected grain from Mehedinti and surrounding counties such as Dolj, Caras - Severin and Timis.

Read more at: http://gfmt.blogspot.com/2011/09/cargill-open-new-grain-silo-in-south.htmll Finnish feed company admitted using cow parts in their feed Saarioinen’s a Finnish feed company has been using cow parts in its animal feed production, and they have admitted that they been doing that for years.

Cow intestines has been banned by officials as there are fears of it carrying mad cow disease or bovine spongiform encephalopathy. The problem was first brought to light by a Finnish Food Safety Authority (Evira) inspector in January. A an internal probe has been launched into how potentially dangerous cow parts came to be mixed into feed.

Read more at: http://gfmt.blogspot.com/2011/09/finnish-feed-company-admitted-using-cow.html Butterball closes plant due to high feed and fuel costs Butterball LLC the largest turkey company in the US, has been forced to close one of its plant in Colorado at the end of this year. The reason for its closure has been attributed to high feed cost and fuel costs, the company has said that it will focus on its other plant more efficiently. The company also pointed out that over the last five years its feed costs have increased on average US$65 million (€48.036 million) per year.

Read more at: http://gfmt.blogspot.com/2011/09/butterball-closes-plant-due-ti-high.html

http://gfmt.blogspot.com

38 | September - October 2011

Grain

&feed milling technology

Book review Sustainable Agriculture and Food

I

n 2008 Sustainable Agriculture and Food was published by Earthscan. It was edited by Professor Jules Pretty OBE, Professor of Environment and Society and Head of the Department of Biological Sciences at the University of Essex, UK, and chief editor of the International Journal of Agricultural Sustainability.

This publication comes in four volumes, and is a comprehensive and carefully selected collection of writings available about sustainable agriculture. Professor Jules Pretty has complied this collection that starts from ancient times and bring us up to the most modern information available on a subject he is an expert in.

The four volumes of this publication cover an extensive range of topics from the historical to the modern day issues we are facing. Such as climate change, greenhouse gases, agricultural contamination. Eco-agriculture and agro-ecology as well as landscape restoration, the modern industrialised global food system and corporate control. Volume four looks at how we think about land and our relationship to it. It also looks at agricultural subsidies and policies that shape food poverty and sustain agriculture into the future.

Volume I: History of Agriculture and Food Part I: Before Agriculture

Part II: Part IV: Volume II: Part I: Part II: Part III: Part IV: Volume III: Part I: Part II: Part III: Part IV: Volume IV: Part I: Part II: Part III: Part IV:

Early Agriculture Modern Agricultural Reforms Agriculture and the Environment Agricultural Harm to the Environment Agroecology and Sustainability Communities and Social Capital Ecological Restoration and Design Agriculture and Food Systems The Global Food System Poverty and Hunger Diet and Health Localized Food Systems Policies, Processes and Institutions Ethics and Systems Thinking Participatory Processes Governance and Education Enabling Policies and Institutions for Sustainable Agricultural and Food Systems

To say this is a comprehensive book is an understatement; the sheer volume of material contained within its covers makes this publication a major resource of great value that will guide the future thinking in agriculture and sustainability. I believe this book is a must for any agricultural department, students and teachers, decision makers and anyone interested in the sustainability in the food system.

ISBN 978-1-84407-408-2

Agriculture and the WTO: Towards a New Theory of International Agricultural Trade Regulation

U

nderstanding international agricultural trade is a complex issue, and a constant battle, as every country has its own interpretation of the laws passed from the World Trade Organisation (WTO). There also is confusion about how non-trade concerns become part of the trade concerns and sorting out these issues is paramount to having an effective international trade.

Agriculture and the WTO, published in 2009, was written by Fiona Smith Lecturer in Laws, University College London.

In writing this book Fiona Smith challenged the standard attitude towards international agricultural trade. She firmly believes that in understanding the problem that seems to prevent international agricultural trade is the key to moving forward. She argues that the problem is not a series of interconnected problems but rather a single multifaceted problem with several interlocking strands.

Contents: Chapter one: International agricultural trade regulation: charting the landscape Chapter two: Current perceptions of the problem Chapter three: Two models of disagreement Chapter four: Polycentrism and the issue of market access Chapter five: Cultural divergence, polycentricity and subsidies Chapter six: Towards the future This book has been written for a broader audience, making it easier to understand and comprehend, though the subject matter is complicated. Fiona Smith has created a well-written book that allows laypersons to understand the complicated debates that surround international agricultural trade.

This is a good starting point for political students interested in international regulations on agriculture and trade. Also economic student would find this book of interest along with economist and politicians. Well worth a read.

ISBN 978 1 84542 490 9

40 | September - October 2011

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September - October 2011 | 43

Events 2011

18th - 20th October 11

october 2nd - 5th October 11 22nd Annual IAOM Mideast & Africa District Conference & Expo, Dead Sea, Jordan Contact: Eva Mulyana, PO Box 566, P.C. 112, Ruwi, Muscat, Sultanate of Oman Tel: +968 2471 2338 Fax: +968 2471 1340 Email: info@iaom-mea.com Web: www.iaom-mea.com

4th - 6th October 11

*

20th - 22nd October 11

*

6th Livestock Asia 2011 Expo & Forum Asia’s International Feed, Livestock & Meat Industry Show, Kuala Lumpur Convention Centre, Kuala Lumpur, Malaysia Contact: Ms. Ery Tan/ Ms. Michelle Ha, Suite 1701, 17th Floor, Plaza Permata, 6 Jalan Kampar, Off Jalan Tun Razak, 50400 Kuala Lumpur, Malaysia, Tel: +603 40454993 Fax: +603 40454989 Email: support@ambexpo.com Web: www.livestockasia.com.

4th - 6th October 11 Animal Farming Ukraine 2011, International Exhibition Center (IEC), Brovarskiy Prospect 15, Kiev, Ukraine Contact: Mr. Kuno Jacobs (Project Manager, BTO Exhibitions BV, Europaweg 187, 7336 AL Apeldoorn, The Netherlands Tel: +31 55 534 11 40 Fax: +31 55 534 01 68 Email: info@bto-exhibitions.nl Web: www.bto-exhibitions.nl

6th - 6th October 11 HGCA Grain Market Outlook Conference, The Queen Elizabeth II Conference Centre, Broad Sanctuary, London, SW1P 3EE, UK Contact: Events Team, AHDB, Stoneleigh Park, Kenilworth, CV8 2TL, UK Tel: +44 247 647 8720 Email: events@hgca.ahdb.org.uk Web: www.hgca.com

13th - 14th October 11

*

62nd JTIC International Milling & Cereal Industries Meeting, Reims, France Contact: AEMIC, 268 rue du Faubourg St Antoine, 75012 Paris - France Tel: +33 1 47 07 20 69 Fax: +33 1 44 24 56 25 Email: aemic@wanadoo.fr Web: www.jtic2011.eu

18th - 18th October 11

*

GLOBALG.A.P TOUR 2011 – Atlanta, The Westin Peachtree Plaza, Atlanta, USA Contact: Nina Kretschmer, c/o GLOBALGAP Foodplus GmbH, Spichernstr.55, D-50672 Cologne, Germany Tel: +49 221 57993 693 Fax: +49 221 57993 89 Email: kretschmer@globalgap.org Web: www.tour2011.org

44 | September - October 2011

*

VIth International Grain Trading Conference Global and Middle East grain outlook 2011, Sharm El Sheikh, Egypt Contact: Ms. Anna Gerasimova, Russian Grain Union, Orlikov lane 1/11, Zip code 107139, Moscow, Russia Tel: +7 495 607 82 85 ext. 124 Fax: +7 495 607 83 79 Email: gaa@grun.ru Web: www.grun.ru/en/events/detail. php?SECTION_ID=196&ID=1325

*

Aviana Africa 2011, Accra, Ghana Contact: Dr. Inderjit Singh, 13/29 Subhash Nagar, Delhi - 27, India Tel: +91 9582709491 Email: info@aviana.co.ke Web: www.aviana.co.ke

30th October 11 - 1st November 11 2nd Annual Southeast Asia District Conference, Grand Hyatt Bali, Bali, Indonesia Contact: Shannon Henson, 10100 W. 87th Street, Suite 306, Overland Park, KS 66212 USA Tel: +1 9133383377 Fax: +1 9133383553 Email: dme@iaom.info Web: www.iaom.info/conferences/asia/ asia_conf.htm

*

Overview of Particulate Handling Technology, Kent, UK Contact: Caroline Chapman, The Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich, Central Avenue, Chatham Maritime, Kent, ME4 4TB, UK Tel: +44 20 8331 8646 Fax: +44 20 8331 8647 Email: Wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com

1st - 3rd November 11 Grain Tech Expo 2011, Exhibition center “KyivExpoPlaza” Salyutna 2b, Kyiv, Ukraine Contact: Mr Vladimir Malishev, Vorovskogo street 4, of.410, 01001, Kyiv Ukraine Tel: +380504468855 Fax: +380444906469 Email: walter@kmkya.kiev.ua Web: www.grainexpo.com.ua

7th - 11th November 11

december

Vietstock 2011 Expo & Forum – Vietnam’s No. 1 International Feed, Livestock & Meat Industry Show, Saigon Exhibition & Convention Centre, Ho Chi Minh, Vietnam Contact: Ms. Michelle Ha, Suite 1701, 17th Floor, Plaza Permata, 6 Jalan Kampar, Off Jalan Tun Razak, 50400 Kuala Lumpur, Malaysia Tel: +603 40454993 Fax: +603 40454989 Email: support@ambexpo.com Web: www.vietstock.org

1st - 3rd December 11

2nd - 3rd December 11 3rd National Conference - Sensible Grains Sector Policies for 12th Five Year Plan (2012-2017), New Delhi, India Contact: Raj Kapoor, Assocom-India Pvt. Ltd, Flat No. 601, DDA Building, District Center, Plot No.4, Laxmi Nagar, Delhi - 110 092, India Tel: +91 1147675218 Fax: +91 1147675201 Email: rajkapoor@assocom-india.com Web: www.assocom-india.com

21st - 22nd November 11 GLOBALG.A.P. Public Workshop CFM (Compound Feed Manufacturing), Cologne/ Germany Contact: Daniela Fabiszisky, GLOBALG.A.P, Spichernstr.55, 50672 Cologne, Germany Tel: +4922157993 33 Fax: +4922157993 89 Email: fabiszisky@globalgap.org Web: www.globalgap.org

8th - 10th December 11

*

23rd - 23rd November 11

*

Buhler-KSU Executive Milling Course, Kansas State University, Manhattan, KS, USA Contact: IAOM Course Administrator, 10100 W 87th Street, Suite 306, Overland Park, KS 66212, USA Tel: +1 913 338 3377 Fax: +1 913 338 3553 Email: info@iaom.info Web: www.iaom.info/courses & workshops/ residentcourses.htm

*

IAI Expo, NDRI, Karnal, India Contact: Ms. Shweta Baweja, 923, Sector-9, Urban estate, Karnal, India Tel: +91 9991705009 Fax: +91 1842231050 Email: iai@pixie.co.in Web: www.iaiexpo.co.in

*

Livestock Philippines 2011 Expo & Forum – 1st International Feed, Livestock & Meat Industry Show, SMX Convention Centre, Manila, Philippines Contact: Ms. Michelle Ha/ Ms.Miza, Suite 1701, 17th Floor, Plaza Permata, 6 Jalan Kampar, Off Jalan Tun Razak, 50400 Kuala Lumpur, Malaysia Tel: +603 40454993 Fax: +603 40454989 Email: support@ambexpo.com Web: www.livestockphilippines.com

GlobalG.A.P TOUR 2011 – Bangkok Contact: Nina Kretschmer, c/o GlobalGAP Foodplus GmbH, Spichernstr.55, D-50672 Cologne, Germany Tel: +49 221 57993 693 Fax: +49 221 57993 89 Email: kretschmer@globalgap.org Web: www.tour2011.org

23rd - 25th November 11

november 1st - 2nd November 11

*

9th - 11th November 11

Anniversary 10th International Conference “Fat-and-Oil Industry - 2011”, President Hotel, Kiev, Ukraine Contact: Ramazanova Olga, Christina Kriva, Chicherina str. 21, Dnepropetrovsk, Ukraine Tel: +380562320795 Fax: +380562320795 Email: ramazanova@apk-inform.com, ved2@ apk-inform.com Web: www.agrimarket.info/conferences/ oil2011/

2012 january 24th - 26th January 12

*

2012 International Poultry Expo and International Feed Expo, Atlanta, GA, USA Contact: Pennie Stathes, 1530 Cooledge Road, Tucker, GA 30084, USA Tel: +1 678 5141977 Email: pstathes@poultryegg.org Web: www.ipeweek12.org

28th November 11 - 1st December 11 World Agricultural Forum Congress 2011: Rethinking Agriculture to Sustain a Growing Global Population, Renaissance Hotel, Brussels, Belgium Contact: Lucy Kinnear, 174 Hammersmith Road, W6 7JP, London, UK Tel: +44 2082 674587 Fax: +44 2082 674486 Email: lucykinnear@worldagriculturalforum2011.com Web: www.worldagriculturalforum2011.com

february 2nd - 4th February 12

*

ISRMAX India 2012, Chandigarh, India Contact: Geetika Malhotra Asudani, Pixie Consulting Solutions Ltd, #923/9, Urban Estate, Karnal, Haryana, India Tel: +91 9991705003 Fax: +91 1842231050 Email: Isrmex@pixie.co.in Web: www.isrmexindia.com

7th - 9th February 12

*

EuroKarma 2012, MTPolska Center Ul. Marsa 56, 04-242 Warszawa, Poland Contact: Agnieszka Niemczewska, PO Box, 73, 32-332 Bukowno, Poland Tel: +48 514 544 048 Email: info@eurokarma.eu Web: www.eurokarma.eu

* See our magazine at this show • More information available

&feed milling technology

Grain

AQUAFEED INGREDIENTS, ADDITIVES, FORMULATION

AQUAFEED PROCESSING TECHNOLOGY

1 5 – 1 7 F e b r u a r y 2 0 1 2 . B a n g k o k I n t e r n a t i o n a l Tr a d e a n d E x h i b i t i o n C e n t r e , B a n g k o k , T h a i l a n d

For everything you need for producing and packaging safe and cost-effective aquafeed No new hw in ome B

ITEC

The conferences Aquafeed Horizons Asia 2012, The FIAAP Conference 2012, Petfood Forum Asia 2012, The Thai Feed Conference 2012

Supported by Thailand Convention & Exhibition Bureau

Co-located with GRAPAS Asia 2012 The show for rice & flour milling, grain & noodle processing, breakfast cereal & extruded snack production

Further information For additional information and free visitor registration visit: www.fiaap.com or www.victam.com

‘

’

a partnership with synergy...your key to success

Events *

7th - 10th February 12

22nd - 24th February 12

Cereals-Mixed Feed-Veterinary--2012, AllRussian Exhibition Centre, Moscow, Russia Contact: Tatiana Sokolova, P.O.Box 34, Moscow, 129223, Russia Tel: +7 495 7555035 Fax: +7 495 7556769 Email: ts@expokhleb.com Web: www.breadbusiness.ru

VIV/ILDEX India 2012, BIEC centre, Bangalore, India Contact: Guus van Ham, P.O. Box 8800, 3503 RV Utrecht, The Netherland Tel: +31 30 295 2302 Fax: +31 30 295 2809 Email: viv.india@vnuexhibitions.com Web: www.viv.net

8th - 9th February 12

28th February 12 - 3rd March 12

Ildex Bangkok, BITEC, Bangkok International Trade & Exhibition Centre, Bangkok, Thailand Contact: Mr. Jobe Smithtun, N.C.C. Exhibition Organizer Co., Ltd. (NEO), 60 New Rachadapisek Rd, Klongtoey, Bangkok 10110 – Thailand Tel: +662 229 3000 Fax: +662 229 3001 Email: info@qsncc.com Web: www.ildex.com

IPACK-IMA 2012, Fieramilano, Milan, Italy Contact: Cristina Bassan, Corso Sempione 4, 20154 Milan, Italy Tel: +39 02 3191091 Fax: +39 02 33619826 Email: ipackima@ipackima.it Web: www.ipack-ima.com

15th - 17th February 12

*•

FIAAP, Victam & GRAPAS Asia 2012, BITEC, Bangkok, Thailand Contact: Andy West, Victam International, Po Box 411, Redhill, Rh1 6We, Uk Tel: + 44 1737 763501 Email: Andrew.west733@ntlworld.com Web: www.victam.com

March 3rd - 6th March 12 GEAPS Exchange 2012, Minneapolis, Minnesota, USA Contact: 4248 Park Glen Rd, St. Louis Park, MN USA Tel: +1 952-928-4640 Fax: +1 952-929-1318 Email: info@geaps.com Web: www.geaps.com

22nd - 24th March 12

AUGUST

Ildex Vietnam, The New Saigon Exhibition and Convention Center (SECC), Ho Chi Minh City, Vietnam Contact: Mr. Jobe Smithtun, N.C.C. Exhibition Organizer Co., Ltd. (NEO), 60 New Rachadapisek Rd, Klongtoey, Bangkok 10110 – Thailand Tel: +66 (0) 2 203 4241 Fax: +66 (0) 2 203 4250 Email: info@qsncc.com Web: www.ildex.com

29th - 31st August 12

November

May

13th - 16th November 12

20th - 22nd May 12

EuroTier 2012, Hannover / Germany Contact: Dr. Karl Schlösser, DLG, Eschborner Landstrasse 122, 60489 Frankfurt/Main, Germany Tel: +49 69 24788259 Fax: +49 69 24788113 Email: eurotier@dlg.org Web: www.eurotier.com –

Poultry Information Exchange 2012, Gold Coast Convention and Exhibition Centre, TE Peters Drive, Broadbeach, Queensland , Australia Contact: Danielle Bolton, PO Box 96, Wamuran Q 4512, Australia Tel: +61 7 5429 8480 Fax: +61 7 5429 8486 Email: admin@pix.org.au Web: www.pix.org.au

* See our magazine at this show • More information available

2011/12 OUT NOW 46 | September - October 2011

*

ISRMAX Asia 2012, Bangkok, Thailand Contact: Geetika Malhotra Asudani, Pixie Consulting Solutions Ltd., #923/9, Urban Estate, Karnal, Haryana, India Tel: +91-9991705003 Fax: +91-184-2231050 Email: isrmex@pixie.co.in Web: www.isrmaxasia.com

&feed milling technology

Grain

*

Events

IPACK-IMA 2012.

Experiencing amazing growth, coupled with a consistent increase in international visitors. A truly global event. The only processing, packaging and logistics exhibition to receive United Nations food agencies’ official recognition.

A business community that encourages interaction between technology providers and end-users, using both the web and traditional channels.

Innovation and sustainability are the event’s top priorities. This is why IPACK-IMA 2012 is the perfect place to become a market leader.

CALEIDOS-NEXXUS.IT

No better place to trade

Fieramilano, Milan - Italy 28 February - 3 March 2012 ipack-ima.com Organized by: Ipack-Ima spa - corso Sempione 4 - 20154 Milano - Italy tel. +39 023191091 - fax +39 0233619826 e-mail: ipackima@ipackima.it - www.ipack-ima.com

AMB Exhibitions HH 2&3 2011_Layout 1 6/3/2011 3:37 PM Page 1

michelle.ha@ubm.com

&feed milling technology

Grain

September - October 2011 | 47

WEBLINKS

2011 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

Alapala Machine Industry and Trade Inc. = www.alapala.com Almex b.v. = www.almex.nl Applied Plasma Physics AS = www.app.no Baker Perkins Ltd = www.bakerperkinsgroup.com Bastak Gida Makine Medikal paz. Lth. Lhr. San. Tic. Ltd Sti = http://www.bastak.com.tr Braime Elevator Components Ltd = www.go4b.com Bruker Optik GmbH = www.brukeroptics.com Buhler AG = www.buhlergroup.com

Obial = www.obial.com.tr

Chopin Technologies = www.chopin.fr

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

Consergra s.l = www.consergra.com

Perstorp Performance Additives = www.perstorpfeed.com

Doescher & Doescher GmbH = http://doescher.com/

Precia-Molen = www.preciamolen.com

Extru-Tech = www.extru-techinc.com

Rembe GmbH Safety & Control = www.rembe.com

Feintuch Communications = www.feintuchcommunications.com

Retsch GmbH = www.retsch.com

Flexicon (Europe) Ltd = www.flexicon.co.uk

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

Flour Fortification Initiative = www.sph.emory.edu/ wheatflour/index.php

Satake Europe Ltd = www.satake-europe.com

GAME Engineering Ltd = www.game-engineering.com GAME Engineering Ltd = www.game-engineering.com

Shanghai ZhengChang International Machinery and Engineering Co., Ltd = www.zhengchang.com

Handling Techniques Ltd = www.handlingtechniques.co.uk

Silos Cordoba = www.siloscordoba.com

Hydronix Ltd = www.hydronix.com

Suffolk Automation Ltd = www.suffolk-automation.co.uk

Imas = www.imas.com.tr

Symaga SA = www.symaga.com

Jacob Sohne GmbH & Co = www.jacob-pipesystems.eu

Tapco Inc = www.tapcoinc.com

JCB Consulting Ltd = www.jcb-consulting.com

TSC B.V. = www.tsc-silos.com

Jesma Vejeteknik A/S = www.jesma.dk

UWT (UK) Ltd = www.uwtuk.com

Jiangsu Zhengchang Cereal Oil and Feed Machinery Co.,LTD = www.zhengchang.com

VEGA Controls Ltd = www.vegacontrols.co.uk

John Staniar & Co. = www.johnstaniar.co.uk

Zhengchang Group (ZCME) = www.zhengchang.com

JSConwell Ltd = www.buhlermillbank.co.nz Kemira Oyj = www.kemira.com Leonhard Breitenbach GmbH = www.breitenbach.de Mogensen Raw Materials Handling = www.mogensen.co.uk Mondi Industrial Bags GmbH = http://www.mondigroup.com Muyang Group = www.muyang.com MYSILO DIS TICARET LTD. STI = www.mysilo.com NABIM = www.nabim.org.uk

SCE nv, Silo Construction & Engineering = www.sce.be

Wynveen International B.V. = www.wynveen.com

Built by feed millers for feed millers. Equipped with the industry‘s most efficient drive system, the new Bühler pellet mill Kubex™ T saves up to 20% of energy – while boosting line capacity to up to 80 tons per hour. With the Kubex™ T you save costs, reduce your carbon footprint and make your operation even more productive. Gaining competitive advantages has never been easier.

For more information please visit www.buhlergroup.com/kubex-t

Bühler AG, Feed & Biomass, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 28 96 fu.buz@buhlergroup.com, www.buhlergroup.com

Kubex™ T pellet mill.

Developed in close cooperation with leading feed millers.

Direct drive concept. Saves up to 20% of energy compared to conventional drive systems.

Variable die speed. Formulationspecific optimization of production process and pellet quality.

Up to 585 kW motor power. Boosts line capacity to up to 80 t/h.

Belt- and gearless drive system.

For minimum maintenance and ultimate machine availability.

ABS control for press rolls.

Prevents roll slippage and protects machine against blockages.

360° accessibility. Wide-opening sliding doors on both sides.

The world’s most compact design.

Fits anywhere and everywhere.

Almost double capacity with same footprint as conventional pellet mills.

Innovations for a better world.