Mar | Apr 13 - Grain & Feed Milling Technology

March - April 2013

first published in 1891

In this issue: •

Additives for flour standardisation

•

Measures for increasing the energy efficiency of UFA feed mills in Switzerland

•

Importance of trace minerals for nutrient stability in feed

•

Managing mill maintenance - Maintenance

Part I: Enzymes

•

Fine grinding and BS3 Xylanase improve productivity in weaners

•

Super chilled grains

options and challenges

INCORPORATING PORTS, DISTRIBUTION AND FORMULATION

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

GRAIN &

FEED

News:

Replacing soybean meal in pig diets A diverse range of series-manufactured and special pipework products Aflatoxins pose new risk to European maize production - Romer Labs Bühler officially unveils its new customer service centre in London Extru-Tech completes first of its kind petfood extrusion validation study FAMI-QS and GMP+ International move ahead with a memorandum of understanding Animal performance can be put at risk with poorly derived phytase matrices 4B Components launches ultra heavy duty elevator bucket line Global warming affects crop yields – but it’s the water not the heat New website site launched for NIR technology

MILLING TECHNOLOGY

March - April 2013 Published by

Features:

Steaming ahead Measures for increasing the energy efficiency of UFA feed mills in Switzerland Additives for flour standardisation - Part I: Enzymes Fine grinding and BS3 Xylanase improve productivity in weaners Improving pig health management with a versatile enzyme The missing link Managing mill maintenance - Maintenance options and challenges Super chilled grains Importance of trace minerals for nutrient stability in feed and optimized trace element supply of animals

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 Publisher Roger Gilbert Tel: +44 1242 267707 rogerg@perendale.co.uk

4 5 5 6 7 7 8 8 9 9

10 14 18 24 30 32 34 36 40

Associate Editor Alice Neal Tel: +44 1242 267707 alicen@perendale.co.uk

Commodities: Raw material outlook, by John Buckley

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Design and Page Layout James Taylor Tel: +44 1242 267707 jamest@gfmt.co.uk Circulation & Subscriptions Manager Tuti Tan Tel: +44 1242 267707 tutit@gfmt.co.uk

In the footsteps of Broomhall

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industry events

54 55 56 57

VIV Russia Indo Livestock 2013 - Expo & Forum NGFA 117th annual convention

International Marketing Team Darren Parris Tel: +44 1242 267707 darrenp@gfmt.co.uk Lee Bastin Tel: +44 1242 267707 leeb@gfmt.co.uk Tom Blacker Tel: +44 1242 267707 tomb@gfmt.co.uk

the gfmt interview Hao Yun - ZhengChang Chairman

industry faces

64

Schenck Process appoints domestic sales manager for air filtration products Alltech searches for next extraordinary minds in science Change is sales structure at Vortex John Brown Scholars take part in Novus programme

Latin America Marketing Team Ivan Marquetti Tel: +54 2352 427376 ivanm@perendale.co.uk Pablo Porcel de Peralta Tel: +54 2352 427376 pablop@perendale.co.uk

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Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom.

All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers

India Marketing Team

accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published.

Assocom-India Pvt Ltd Tel: +91 47 675216 india@perendale.co.uk

©

Copyright 2013 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.

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

Global Miller THE

volume: 124 number 2

issn No: 1466-3872

Guest - EDITOR’S OBSERVATIONS

Guest editor - Yiannis Christodoulou, Agentis Innovations

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here are many good events to attend these days and they are all getting better. Now there's good reason for feed millers to add VIV Asia to their lists, and somewhere near the top! Why? Because of the focus show organiser VNU is now placing on milling.

The introduction of CropTech-FeedTech and its special theme of debating a topic rather than just sticking to the format of presentations, means that feed millers visiting VIV shows can participate in meaningful discussions about feed technology. They can also pass on their experiences and feedback on to equipment suppliers and gain a fuller understanding of why companies develop products and services the way they do.

The great debate at VIV Asia 2013 in Bangkok in March was around the topic 'Digital Engineering in the Feed Manufacturing Industry'. It generated lots of interaction and proved a valuable experience for the 80-100 people who attended. In fact, VNU was so impressed with the outcome that it will now offer a CropTech-FeedTech debate at each of its future VIV exhibitions. The next show is VIV Russia, May

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any companies that consider automation limit investment to the batching and pelleting processes in the belief these will yield the greatest returns on investment. At Agentis Innovations we focus on a much wider potential return which we call the ‘holistic approach to automation’. The aim is to capitalise on the large-scale economic benefits of automating the complete process from order processing to farm delivery.

The holistic approach to feed mill automation In the past five years the cost of ingredients and many feed additives has risen significantly but too many feed companies still do not have tight control on stock inventory, scale tolerances and the volume of recycled fines and rework arising from inefficient production procedures and equipment, which is common throughout the Asia Pacific region. It is our belief that such a lack of control is unsustainable and automation is essential if feed companies wish to remain competitive.

Automation provides a number of key benefits including: • Replacing the need for manual control resulting in more consistent and accurate production • Eliminating human errors • Automatic control of cross contamination • Improved physical and nutritional quality • Reduced down time and increasing capacity utilization throughout the plant • Optimisation of each process step and machine output • Reduction in energy costs of more than 30 percent • Transparency in operation and real time traceability • Accurate control of stock inventory- both raw materials and finished product.

The combination of these benefits results in return on investment typically less than six months. Security access to the system and format of reports can be tailored to the needs of each client providing CEOs and financial officers with remote updates in real time of productivity, inventory and costs of production.

2 | March - April 2013

21-23, 2013 in Moscow.

Perendale Publishers Limited was pleased to be asked to co-sponsor the debates and I have been specifically asked to chair them from now on, based on the outcome achieved in Bangkok. This is a personal honour for me and one I will take seriously. To ensure the debate continues and does not just occur at VIV events, I intend to establish a LinkedIn group to record and continue the debate online between events. I will also ensure CropTech-FeedTech is reported on an ongoing basis in GFMT. It’s apt that our guest editor this issue works in digital engineering. Yiannis Christodoulou is president of Agentis Innovations, Thailand, a company which creates automation software for mills. Yiannis played an important role in the debate at VIV Asia and I look forward to discussing the future of milling with him face-to-face soon.

I invite you to join the great debate! CropTech-FeedTech and 'Digital Engineering in the Feed Manufacturing Industry' no matter where you are or what shows you can attend.

Roger Gilbert - Publisher

Once a decision has been made to automate the process, it is important to realise that all automation software control systems are not the same.

Agentis Innovations is the strategic partner for TAT Energy and Engineering Co Ltd and their technology has been developed in Thailand and is now the standard for the majority of the Thai feed and aqua feed industry.

Today our products can be found in more than 60 feed mill companies representing more than 10 countries in the Asia Pacific Region including Thailand, India, Malaysia, Philippines, Vietnam, Yiannis Christodoulou, Pakistan, Bangladesh, Indonesia and many President, Agentis others. The reason for our success is a Innovations combination of a unique understanding of the Asian feed mill market and a policy to work only with the highest standard hardware (PLC and sensors) using digital communication and own company software.

Agentis Innovations and TAT Energy and Engineering Co Ltd developed their own programming capability because of the limitations of using SCADA software. The main benefit is this allows us to produce any combination of reports that may be required by the client and in a format that can be integrated with a clients own Enterprise Resource Planning system, such as SAP. This point is extremely important when considering just using the SCADA controls supplied by an equipment manufacturer. In general these are very inflexible because they are specific to the machine, for example pellet mill, and not for the individual clients feed mill system.

It also means we are able to accommodate any future expansions that maybe required and also communicate with all equipment, scales and sensors in the process to provide one stop traceability and stock inventory. This is usually not the case with SCADA supplied by an equipment company.

We have also developed award winning automation controls for handling of bags, both incoming and outgoing which are generally not available elsewhere in the industry.

In summary our product range is specifically developed to achieve the core goal of providing optimisation and cost saving solutions that enhance the competitiveness and profitability of our customers

&feed milling technology

Grain

Have You Experienced This In Your Elevator?

For over 35 years, and in more than 50 countries, Tapco has been solving the problem of bent & torn steel buckets.

®

STYLE CC-HD (HEAVY DUTY) Polyethylene Elevator Bucket Urethane • Nylon

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apco nonmetallic buckets have the ability to absorb impact in the elevator leg and “give” or “yield” to bypass an obstruction. They then return to their original shape and keep on working for you.

Tapco buckets weigh less than their pressed steel counterparts, lack sharp edges and therefore are far safer and easier to handle when fitting an elevator.

With 900,000 buckets in 93 sizes stocked throughout the world, Tapco has what you want, when you need it!

Tapco also maintains over 15 million elevator bolts in imperial and metric threads in six styles. Tapco fanged elevator bolts have been specifically FANGED HEAD designed to work with nonmetallic buckets.

Elevator Bolt Contact Tapco or visit www.tapcoinc.com today.

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Tel.: +1 314 739 9191 • Fax: +1 314 739 5880 • Email: info@tapcoinc.com • www.tapcoinc.com The color blue, when used in connection with elevator buckets, is a U.S. registered trademark owned by Tapco Inc. © 2011 Tapco Inc.® All rights reserved.

March - April 2013

NEWS

THE GLOBAL MILLER A blog dedicated to professionals - including nutritionists - in the transportation, storage and milling of grains, feedstuffs, rice and cereals, globally.

Hello Millers At the Global Miller we are firm believers in the theory that all work and no play makes for a very dull time. This ethos is reflected on the blog. Of course we post news and event updates but we also like to have a bit of fun from time to time.

Here are some of our favourite unusual stories and videos: We start the column with a blast from the past. 1889 in fact. These photos from Victoria in British Columbia, Canada show a rice mill in action. Fascinating stuff. http://bit.ly/YXHNkt We've all heard the phrase 'taking work home with you' but what if your home was the same as your workplace?

Hardcore grain and feed fanatics don't just work in mills, they live in them too.

This article takes a look at weird and wonderful mill conversions in the USA. Some of the novel uses include apartments, a museum and even a climbing wall.

Which would you choose? http://bit.ly/ZlMLpX Four mills in Germany have been fined a total of 65 million euros for fixing the price and quantity of flour over a seven-year period. The Bundeskartellamt, Germany's competition regulator, has concluded its cartel proceedings and imposed fines of approximately 41 million euros on 22 companies, the association of German mills (Verband Deutscher Mühlen e.V.) and their representatives. A first fine of approximately 24 million euros had already been imposed in the same proceeding in October 2011. http://bit.ly/15NQhzN Silos Cordoba has been busy in Kazakhstan. Check out this footage of the company's recent modernisation of grain storage facilities 'Tonkeris' in Kazakhstan. http://bit.ly/WBSVTO A new study released by the US soybean industry emphasises maintenance of the US grain transportation system. This is a shift from the recent years when the industry focused on new construction and is a reaction to the government's repeated funding delays. http://bit.ly/13Fdwwk True to our name, we have also been busy circumnavigating the globe attending many milling conferences and trade shows. This year we have already been to…

Chennai for the First Global Milling Conference, Atlanta for IPPE, Louisville for the GEAPS Expo, Bangkok for VIV Asia and Istanbul for IDMA. You can find full reports and photos from these events on the blog and our Facebook page.

http://gfmt.blogspot.com

This monthwe have added our pictures from VIV China to our Facebook page - take a look at: http://www.facebook.com/GrainFeedMillingTechnology

Replacing soybean meal in pig diets

I

n light of talks examining the economic significance of replacing soybean meal in pig diets, researchers at the University of Illinois have examined the amino acid concentrations and digestibility of nutrients in canola, cottonseed and sunflower products.

Using soybean meals as a comparison, Hans Stein, professor of animal sciences, and his team examined the amino acid digestibility in intact canola seeds and canola meal along with cottonseed meal, intact sunflower seeds, dehulled sunflower meal and sunflower meal with hulls.

“Soybean is by far the biggest oilseed crop in the world but canola, cottonseed and sunflowers are grown in areas where soybeans can’t grow.

When the oil is taken out of the seed, meal is left over, as with soybean meal,” says Stein.

The results revealed that due to higher fibre contents, the digestibility of amino acids in all three products was lower than that of soybean meal.

“Soybeans do not contain as much oil as canola and sunflower. When you take more oil out, the seed hull becomes a bigger proportion of what you have left over – and that’s where you have all the fibre,” says Stein.

Sunflower meal had the greatest crude protein digestibility and amino acid value among the replacement meals, with the values for most amino acids in cottonseed meal either equalling or outweighing those in canola seeds and canola meal.

After soybean meal, canola and cottonseed contain the greatest concentrations of crude protein and indispensable amino acids.

Though according to Stein, cot tonseed is not used as much as it could be in pig production because it contains gossypol – an anti-nutritional factor that prevents the utilisation of lysine.

“But low gossypol varieties are now available and it’s been shown that if you add enough iron to the diet, it can bind the gossypol, which will then not bind the lysine,” he explains. “You can use cottonseed in the diets and they’ll do fine. Cottonseed meal has a relatively good digestibility compared with canola and sunflower meal, so more it could be used than is used today.”

I n o rd e r t o b e considered an economical alternative to soybean meal, the cost of sunflower and canola meal needs to be significantly reduced to compensate for reduced amino acid digestibility and a lower concentration of amino acids and energy.

&feed milling technology

Grain

News

News

March - April 2013

NEWS

A diverse range of series-manufactured and special pipework products

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he new Jacob Hygiene Distributor f inds its customers wherever the requirement for frequent cleaning of the inner surfaces necessitates quick and easy disassembly and reassembly of t he p ar t s . Th ank s t o t he innov at ive de sig n of the distributor, this can be achieved even in its installed state. The entire shaft and flap components can be removed and refitted easily without using any tools at all.

Jacob manufacturers pipe systems based on the modular concept and sell them worldwide. Pipe systems for bulk material handling as well as dust extraction and exhaust air units for environmental engineering (cooling air/exhaust air) are the largest application areas for Jacob pipe systems (diameters 60 - 800 mm or larger for customised production, 1-3 mm pipe wall thickness, steel pipes are primed, galvanised or stainless steel).

Aflatoxins pose new risk to European maize production - Romer Labs

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he European Commissions’ R apid Alert System for Food and Feed (RASFF) has reported 10 notifications on aflatoxin B1 in maize of European origin since the last maize harvest in autumn 2012. In the 10 years prior to the last harvest (between 2001 and 2011) a total of nine cases of aflatoxins were reported in maize. Aflatoxins have been mainly an ‘import problem’ up to now. However, global warming is increasingly affecting the mycotoxin map in Europe, producing ‘tropical toxins’ within Europe’s borders.

This is most likely not the last case of aflatoxins in maize for European farmers. “Conditions are very favourable for the grow t h of A spergillus in southern areas of the European mainland due to climate change.

NEWS IN BRIEF Irrigated grain production in Southeast Asia is predicted to decline due to climate change.

According to the International Food Policy Research Institute, irrigated rice production in Asia could fall by 20 percent and irrigated wheat as much as 25 percent by 2050.

Grain

This means that Europe will have more homemade aflatoxin cases in its crops in the future,” says Prof Rudolf Krska, an international mycotoxin expert from the University of Natural Resources and Life Sciences (BOKU) in Vienna, Austria.

“The food and feed industry has to adapt its risk management to cope with this new threat and minimize aflatoxin exposure in Europe.”

The origins of the contaminated maize reported in the RASFF were mainly southeastern Europe, including Bulgaria, Greece, Romania, Serbia and in Italy. The average level of aflatoxin B1 was 59.28 ppb (parts per billion or µg/kg) and the maximum 204 ppb in Serbian maize – 10 times above the maximum level for feed. The EU regulatory limit for aflatoxin B1 in feedstuff is

Integrated rice-fish farming is the need of the hour says, the Financial Express, Bangladesh.

Although rice production is wellestablished in the country, fish farming lags behind. However, around 10.14 million hectares of rice fields, there is scope to integrate fish production and rice farming. In addition to increasing fish production, combined ricefish production can also improve productivity and profitability of rice farming.

&feed milling technology

20ppb, whereas in food it is 5ppb.

Aflatoxin B1 is one of the most carcinogenic substances on the planet, 100 times more toxic than pesticides, for instance.

The producing moulds, which are different species of Aspergillus, have been mainly a problem in tropical regions and can either occur on the field, but also in inappropriate storing conditions. M ajor maize exporting nations such as Argentina, Brazil and the USA have developed riskmanagement systems over recent decades to handle the aflatoxin risk. Europe can take t he se e x am ple s t o adapt their systems to this new reality where aflatoxins are now on the agenda.

Testing for aflatoxins requires sophisticated sampling methods which need to be done at the very beginning of

Three scientists at Purdue University, USA have been awarded a $1 million grant from the Bill and Melinda Gates Foundation to develop genomic tools to improve sorghum. The aim of the research is to identify sorghum gene functions, especially those that play a role in crop yield, protein and starch digestion, and disease resistance.

the supply chain to deal with the heterogenic distribution of this contaminant. Testing methods have to be ver y sensitive as limits are between 5 and 20 parts per billion (ppb).

At the reception point, this testing can be done with lateral flow devices or Fluorometric methods. The reference method of choice in laboratories is nowadays LC-MS/MS, which is a technolog y that can simult aneously detec t all major mycotoxins, including aflatoxins.

India's growing grain mountain could be set to topple. The country has enough space to store 47 mt of wheat and rice but stockpiles are forecast to reach 100 mt in June 2013. A sixth consecutive bumper wheat harvest is due to get underway in March pushing the reserves up.

However, the country runs the risk of wasting the crops due to its inefficient food distribution and storage systems.

March - April 2013 | 5

March - April 2013

NEWS

Nick Reynolds, application specialist, testing for toxins in the laboratory

Bühler officially unveils its new customer service centre in London

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xcellent customer service has always underpinned Bühler’s global success, but the opening of a truly world-class customer service centre at its optical sorting centre in East London will help take things to a new level.

“This is just the latest in a series of customer service centres we operate in locations around the world,” says Colin Chaffers, director of customer service and technology, Bühler Sortex. “It’s been designed to enhance our customers’ experience and provide them with the facilities they need in

a welcoming and comfortable environment, whether they are with us for training or to see our technology in action while testing their products.”

State of the art technology In a significant investment that will benefit customers old and new, Bühler has replaced its previous facilities with a specially designed 500m² centre, featuring an applications laboratory, housing a comprehensive range of state-of-the-art optical sorting technology. Chaffers continues, “At our new facilities visitors can see sorting demonstrations

of fresh, chilled, frozen, dry and dehydrated foods, as well as non-food commodities such as plastics.”

T h e ce n t re a l s o h a s a n applications library, containing the results of all optical sorting samples trialled and tested in London, a laboratory, fully equipped to analyse customer samples and carry out research projects into areas such as toxins, a meeting room, a customer training centre; and a customer relaxation area, complete with TV, Wi-Fi and refreshments.

Chaf fers adds, “ We want visitors to feel as comfortable as

possible. We want them to see the centre as their London base while visiting us. And it’s not just about the wonderful facilities – it’s also about the knowledge and expertise of our staff, which will also enable them to get the very most from their time with us. The centre is filled with highly trained and experienced engineers, technicians and trainers who are here to help customers find the right solution for their optical sorting needs.”

More

information:

www.buhlergroup.com

Below: New optical sorting customer centre officially opened on February 25, 2013, Buhler, London, UK

6 | March - April 2013

&feed milling technology

Grain

News

News

March - April 2013

NEWS

Extru-Tech completes first of its kind petfood extrusion validation study

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traditional lab studies based on testing equipment ranging from beakers and pressure pots to table-top model extruders.

Moreover, most testing has been completed at very low production rates of 30 grams to a few kilograms per hour. In contrast, Extru-Tech configured a BSL-2 pilot plant outfitted with an E525 productionscale extrusion system, capable of producing nearly 8,000 pounds of product per hour, and the equipment was configured for the production of an industry-generic, lowmoisture, dry-expanded pet food. The selected formula was then charged with a threeserotype cocktail of Salmonella, an inoculant that represents typical contamination events in the manufacturing process.

As part of the study, Extru-Tech also considered the fact that a dry inoculant introduced into the ingredient stream better represents how the pathogens are usually present within contaminated raw ingredients. If Salmonella is in a liquid, which is of ten the case in research studies, heat

aintaining their industry leadership role in food and product safety, Extru-Tech recently completed an industr y-f irst scientif ic validation study that used a production-scale extruder to prove extrusion's effectiveness in controlling Salmonella in dry pet food. In effect, Extru-Tech’s scientific validation, which was conducted at the company’s Level 2 Bio-Safety Extrusion Lab in Manhattan, Kansas, USA, proved the kill/lethality step of the extrusion system as an effective control against the persistent pathogen.

Since 2010, the Food and Drug Administration has had a zero tolerance policy for Salmonella, which is why the pet food industry has experienced a dramatic increase in recalls over the past few ye ars.

However, even though every m a nu f ac t ure r s t r i ve s for products that are 100 percent pathogen free, applicable and validated scientific studies to support properly designed pet food safety systems weren’t possible until now.

To t h i s p o i n t , p e t f o o d manufacturers have relied on

FAMI-QS and GMP+ International move ahead with a memorandum of understanding

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n March 1, 2013, FAM I - QS and GMP+ International established a memorandum of understanding (MoU) following the rise in third party certification as a feature in the global feed chain.

The memorandum, based on the trust between FAMI-QS and GMP+, will aim to facilitate the world trade feed by eliminating technical barriers to trade without jeopardising feed safety.

The agreement comprises of the production and trade of feed products. By working together, those certified are covered by

both FAMI-QS and GMP+ International schemes.

Both companies have also agreed to work together on topics like accreditation, harmonisation of schemes and promotion of feed safety assurance all around the world.

As part of the memorandum, the organisations will also launch a global benchmark exercise.

It is expected that the agreement, based on ISO/IEC guide 68 ‘arrangements for the recognition and acceptance of conformity assessment results’ will increase confidence, trust, recognition and global acceptance.

&feed milling technology

Grain

will transfer quickly and kill it quickly. However, this is not a representation of what happens in a petfood plant, and creates a false set of operational parameters that do not control Salmonella.

“Extru-tech is using actual equipment that you would find in most pet food plants in a biohazard laboratory or a pilot plant,” said Jim Marsden, PhD, Kansas State University. “Raw materials can be inoculated with Salmonella or other pathogens and the effect of the extrusion process can be exactly quantified. This process is a breakthrough for the pet food industry.”

All three replications of the challenge study resulted in a log reduction of Salmonella t h at e xce eded t he 5 - log reduction requirement of a CCP allocation. Extru-Tech also discovered that many readily available and scientific methods of inoculation rendered a result that was not truly representative of a

contamination event because of the method by which the raw material was inoculated.

“ExtruTech is documenting the parameters that are required to deactivate Salmonella in the extrusion process,” said Dr M ar sde n. “ There are other production steps that follow where Salmonella could re-contaminate the product.

Consequently, ExtruTech is looking at those additional steps to identify interventions that could be applied downstream to prevent recontamination.”

Extru-Tech, Inc., headquartered in Sabetha, Kansas, currently produces and markets one of the industry's most complete lines of extrusion processing systems, along with a full line of ancillary equipment and customized equipment so l u t i o n s fo r s p e c i a l i ze d processes. Since 1985, ExtruTech has installed extrusion systems worldwide, designed for the production of human food, petfood, aquatic feed and animal feed products.

Swiss

Milling Conference

7th and 8th June 2013, Rust, Germany The Swiss Milling Conference is a leading conference which is formed by the Student's Association of the Swiss School of Milling and the Swiss head millers. The aim of the Milling Conference is to concentrate on subjects that intensively move the worldwide milling industry.

Including presentations in the fields: · · ·

Food safety Energy saving Value Adding (in general)

You still have the possibility to send your suggestions, inputs, ideas on the different topic/presentation to Urs Dübendorfer Email: urs.duebendorfer@buhlergroup.com

March - April 2013 | 7

March - April 2013

NEWS

News

Animal performance can be put at risk with poorly derived phytase matrices

I

norganic phosphorus is of ten the second most expensive nutrient in a diet, and consequently there is pressure to minimise dietary phosphorus safety margins.

Most producers use a phytase e nz y me a nd re l y o n t he manufacturer’s recommended matrix value to determine how much added phosphorous can be removed from the diet.

AB Vista stresses the need for feed producers to be aware of the safety margins placed on phytase matrices to ensure animal performance and prof itability is not compromised and to make true efficacy comparisons between the different phytase products.

With many phytase matrices derived from amalgamations of growth performance and/ or digestibility trials, there is growing concern among nutritionists that the matrix values applied to a given phytase do not accurately represent the results seen in the field.

Given that the inorganic P is the second most expensive nutrient in the diet, even small adjustments to the P matrix can result in significant cost savings when using a phytase.

Field results with Quantum Blue consistently show that the matrix is achieved in the vast majority of cases where it is employed. As market economics continue to put

consequently P release. At AB Vista we strongly recommend feed producers consider how the matrices are derived, taking into account the safety margins applied, in order to evaluate product efficacy.”

Not all phy t ases matrices are derived in the same way and some use a 50 percent confidence limit. Quantum B lue m at r i x for av ail a b le p h o s p h o r u s i s c a l c u l at e d based on a 90 percent conf idence value, assuring customers that in 90 percent of the time Quantum Blue is included in the feed, it will release a P level equivalent to or higher than the recommended value.

pressure on P levels in diets, the robustness of claimed phytase matrices will be tested more than ever before, and as a result such conservative approaches to matrix derivation become more and more warranted.

M i ke B e d f o r d , r e s e a r c h director, AB Vista says, “With rising costs, decisions made on the P matrix of the phytase and the P requirements of the animal are now under intense scrutiny. As a result, safety margins in dietary P are under pressure, challenging the matrices of all phytases to a greater extent. Factors such as mineral levels in the diet and intrinsic animal metabolism will affect enzyme activity and

4B Components launches ultra heavy duty elevator bucket line

4

B Components Ltd, a worldwide manufacturer of material handling and electronic components, has designed a new large sized ultra-heavy duty elevator bucket line intended for the most severe agro-industrial uses, such as port and river terminals, ethanol and fertilizer plants, or frac sand and aggregate operations.

NEWS IN BRIEF The struggling rice milling industry in Sindh, Pakistan is to receive financial aid from the State Bank of Pakistan (SBP) and the Sindh Enterprise Development Fund (SEDF). The State Bank of Pakistan has agreed to extend the credit finance to commercial banks for onward lending to rice millers at 6.25 percent in a bid to prop up the ailing industry.

SEDF will deposit 30 percent of the principal amount with the SBP as credit guarantee and will earn a profit, as well. Of this, SEDF will pick up 6.25 percent due to rice millers and payable to the SBP to support rice millers.

8 | March - April 2013

The new super strong JUMBO CC-S® offers greater carrying capacity, along with ultradurability and wear resistance. It has the thickest front lip, front corners and walls available for longer life. The JUMBO CC-S® is a High-Efficiency™ elevator bucket, and comes in six sizes ranging from 14x8 to 24x8 with additional sizes pending.

As an extension of the proven

savings and storage efficiencies.

“The JUMBO CC-S® offers a substantial upgrade opportunity for anyone requiring thicker walled elevator buckets”, said Carl Swisher, Sales Manager for Material Handling at 4B Components.

and successful heav y duty CC - S ® e l ev at o r b u c ke t , t he J U M B O CC - S ® a l so incorporates the long lasting Iceberg ® Edge front wear lip and the unique tapered bottom. Designed for the closest possible vertical spacing (projection +1/2”), the tapered bottom ensures efficient bucket fill and discharge, especially in low-prof ile conf igurations.

This design allows the buckets to nest inside one another, delivering tr anspor t cost

The recall of several speciality flour lines by Dakota Specialty Milling has had a knock on effect on major producers in the USA. Frito-Lay and Mondelez have both been forced to recall some of their snacks, cereal and biscuit products as a precautionary measure.

The Philippines is close to becoming self-sufficient in rice production, according to the Philippine Information Agency.

The country needs to produce an additional 2 million metric tons of rice to reach the target of 20 million tons.

Dakota Specialty Milling company voluntarily recalled some of its speciality flours on February 14, 2013 due to the possible presence of fragments of thin metal wire from a defective screen on one of its manufacturing lines at a milling facility. The recall was initiated as a precaution to ensure consumer product safety.

Wheat growers in Washington have come out in opposition to labeling of GM crops. Genetically modified wheat is not yet commercially available in the state but the Washington Association of Wheat Growers has come out against plans that would make labeling of GM products mandatory.

The first recipients of the International Milling Education Foundation (IMEF) Scholarship Program for Professionals have been named as Dan Ramseyer, Benjamin Ruch and Julie Wavinak.

The scholarships will provide tuition for all three professionals to take the IAOM Correspondence Course in Flour Milling over the course of the next two years.

IMEF is the philanthropic partner of IAOM. The IMEF Scholarship program was established in 2008 to support the education of undergraduates in the sciences of grain milling. In 2012, the program was expanded to include training opportunities for professionals already working in the industry.

Grain

&feed milling technology

News

March - April 2013

NEWS

Global warming affects crop yields – but it’s the water not the heat

G

raeme Hammer, professor in crop science at the University of Queensland’s Alliance for Agriculture and Food Innovation (QAAFI), Australia and his colleagues have been developing increasingly sophisticated computer models to predict the growth and yield of agricultural crops.

Previously it has been widely accepted that the yield loss experienced by American mid-west maize growers during hot seasons is attributable to temperature increases caused by global warming. Hammer’s modelling study however, demonstrates that the direct effect of the decline is not

NUMBER CRUNCHING

Cereals

2.7% predicted fall in global cereal production since 2012 5.5% reduction in wheat

due to an increase in temperature but rather an evaporative demand for water, which causes an increase in plant water use.

“Increasing temperatures mean increasing demand for water and so greater plant water use and ultimately more water stress during the crop life cycle.” Hammer says.

“A good human analogy would be to imagine someone standing in a desert.

You would start to sweat more as the temperature increased and more rapidly use up your reserves of water.”

The ability to accurately predict and explain the physiological basis behind maize harvest declines is a reassuring validation of Hammer’s models.

New website site launched for NIR technology

A

new website has been l au n c h e d a i m e d at professionals in the feed industry, specifically those who work with near infrared (NIR) spectroscopy technology.

2.5% percent decline in coarse grains 0.7% increase in global rice crop from last season 1.4% decline in wheat utilization between 2012 and 2013 1% forecast drop in total utilization of coarse grains (due to reduced industrial maize use for ethanol production in US) 1.5% potential increase in world rice utilization 497 million tonnes predicted world cereal stock at close of crop season 2013

25 million tonnes - less than opening level in 2013

22.6% in 2012 vs. 20.6% in 2013 decline in world cereal stock-to-use ratio

12% increase in FAO cereal price index since October 2012 6.9% contraction in cereal trade in 2012/2013 due to reduced export supplies and more expensive grains

http://nirperformance.com As an online resource centre, the website offers objective advice and know-how. With contributions and resources provided by industry experts, NIRperformance’s online community aims to share knowledge and foster innovation so that everyone can benefit from an active, focused feed industry network.

Powered by FOSS, NIRper formance.com is different to other feed industry website. There are no fees or obligations when participating.

The only thing required is a passion for accurate feed analysis and a desire to share knowledge and learn from one another.

H

ello to all millers and Grain & Feed Milling Technology readers! Since the inaugural column in 2013's f irst issue, muc h a s c h anged Tom Blacker and we're more than ready and prepared for publishing the International Milling Directory (IMD) this July.

In February, we took the IMD on the road to Louisville, Kentucky in the USA. The IMD proved very popular with GEAPS members as we found out to our delight at the show.

We are always keen to hear from IMD members and meeting some face-to-face at GEAPS in Louisville. My review of the event is published in this magazine; look out for my review on page 58 including photographs of stands and people.

The next events are always close by these days.

Recently we attended VIV Asia in Bangkok, Thailand and IDMA in Istanbul, Turkey and we'll soon be at Cereals 2013 in the UK. Back in the office, it's been a hive of activity with renewals and registrations here at Perendale Publishers Ltd. We must give a special mention to the new member of our team, Richard Sillett. Richard is an Oxford graduate who will be getting fully into the job of delivering the 22nd edition of the IMD which will be for the coming year, 2013/14. He’s already added lots of good ideas and practical help.

Also, recently, the IMD has welcomed Aciklar Flour Company, Kay International, Milluno, TOTE Tank, WAM Engineering and Yeni Un San ve Tic A.S. as newly registered companies. We look forward to this truly international cast of companies joining the directory.

We are still taking new registrations and by visiting and registering at www. internationalmilling.com it couldn't be easier to ensure representation in the Products & Services section, International Organisations or the excellent and unrivalled Equipment Guides.

In addition to the annual printed directory, you can also find us uploading, creating and sharing via: Our blog: www.millinginternational.com Facebook: www.facebook.com/internationalmillingdirectory Twitter: www.twitter.com/IntMD Pinterest www.pinterest.com/tomperendale I hope that's enough to satisfy all - especially our tech-savvy and online readers!

Source: FAO Food Outlook, November 2012 March - April 2013 | 9

FEATURE

STEAMING AHEAD

by Thomas Stuecken, chairman, Osprey Deepclean, UK

H

ygiene and food safety of raw materials and end products are vital in the grain and feed milling industry. Millers take great care to ensure processes meet all legislative and food safety requirements. At the same time, consumers expect food to be safe and are increasingly taking an interest in how their food is produced.

Cutting corners in the area of food safety can have a serious impact on business. Grain and feed products in mills are at risk of being contaminated by foreign material, insects, microbes and vertebrate pests. In addition to high hygiene standards, effective sanitisa-

10 | March - April 2013

tion reduces the risk of fine organic dusts accumulating on ledges and crevices, which could result in damage from a fire or dust explosion.

Food and site safety concerns, coupled with high costs for energy, water and wastewater treatment are motivating the requirement for hygiene systems that do not employ chemicals and that can save on large amounts of water.

Just as steam power became the fuel that drove the Industrial Revolution – dry steam technology is the latest development playing an increasingly important role in driving trends in 21st century industrial cleaning.

Innovative cleaning using minimal water Compliance and stringent auditing requirements, combined with pressure of time constraints and cost concerns, means millers are looking for a hygiene system that can save money and work quickly, while being extremely effective.

OspreyDeepclean and its sister manufacturer, OSPREYFRANK have developed an innovative dry steam technology system which uses less water than traditional cleaning-in-place (CIP) methods. The new technology meets the challenges of cleaning in environments such as dry food areas, where water systems can’t be used or where there

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FEATURE is sensitive machinery, motors or anything electric and adversely affected by water.

The technology, which is the first of its kind in the UK, uses a continuous flow heating coil system to heat water to such a high degree that it becomes extremely hot vapour. The emitted dry steam contains minimal moisture and efficient cleaning capability is produced from the steam pressure made on the surface area.

Is all steam cleaning the same?

So steam is simply steam? Well actually, no. Steam can be produced in a range of different grades, each matching different industry applications. Picking the cleaning method best suited to your operation depends upon a number of options including the nature of the surface to be cleaned and the type of material or residue found on crushing or milling apparatus, conveyors and elevator pits and silos.

To date, conventional CIP systems have tended to rely on traditional boiler systems which are only required to heat the water to a maximum of 75 degrees and rely on high water flow and minimal pressure, using a lot of water in the process.

Most food related sites use hot water that comes off the boiler through hoses, using foamers, liquid chemicals and other sanitation agents. They can use between 200-1,000 litres of water per hour to blast a surface clean. They can also have the negative side effect of sending dangerous bacteria airborne, spreading them through the plant without killing them. This ‘wet steam’ system does not use a vapour process.

Benefits of dry steam cleaning Efficient cleaning capacity is produced from the steam pressure made on the surface to be cleaned and the solvent power of micro drops at a high temperature, with minimal moisture present.

The continuous steam system provides constant steam quality which can be adjusted by volume and dryness. Water flow and heating power can be controlled and adapted by an electronic control system.

The amount of water saved depends upon the flow rate of the water system and the pressure employed, but it can save up to 90 percent of water used. OspreyDeepclean’s dry steam technology will typically use between 10-30 litres of water per hour, whereas a conventional system will use between 2001,000 litres per hour.

Conventional cleaning leaves the risk of potentially dangerous residues contaminating food and raw materials. Then you also have the issue of getting into difficult spaces, such as tight crevices in storage areas or complex shaped equipment.

Dry steam sanitises surfaces, penetrating cracks, crevices and other hard-to-reach areas where manual and traditional cleaning methods, which mainly rely on potentially hazardous chemicals, fail to achieve the required standards.

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As well as being applicable to a wide range of work settings, steam can be used to undertake innumerable cleaning tasks.

The system can be used on feeding, mixing and blending vessels, machinery, conveyor belts, rollers, pipelines and also general floor areas, storage spaces and much more. As it is applied to the surface, dry steam leaves very little residue and can almost touch dry, especially when compared

includes the fully auditable dry steam belt sanitation unit (BSU) which cleans conveyor belts to allergen level, saving up to 3 million litres of water per annum.

The organisation has also developed a central steam system for food production and packaging areas. This is much like a central vacuum, which facilitates cleaning by simply plugging the steam hoses into central steam pipes without the need for handling cleaning machines. The sophisticated equipment can be used for the cleaning of heavy parts and for plastic parts cleaning. The machines start from a 3kW single phase unit and reach up to 144kW units available in electric, oil or gas heated coils.

to any other cleaning method.

No additional ingredients are required in the steam to improve cleaning power, as efficient cleaning capacity is produced from the steam pressure made on the surface to be cleaned and the solvent power of micro drops at a high temperature, with minimal moisture present.

However, where specific tasks or locations demand it, ingredients can be added to improve the solidification of specific substances, for instance within liquid fat application devices which could congeal without the use of additional ingredients.

Dry steam machines for different applications The technology Osprey Deepclean has developed is available in a range of dry steam machines for different applications, based on many years’ experience of creating bespoke steam solutions. This March - April 2013 | 11

FEATURE

Electrical cabinet

This fully integrated system permits the whole cleaning process to become auditable using sophisticated PC software.

Training Modern milling machinery is more efficient and faster than ever and is one of

12 | March - April 2013

Steam generators

the key investments a company makes.

Given the significant sums of money for new machinery and the damage defective products can do, it pays to ensure staff are trained and confident to operating necessary equipment.

Any new sanitation process will require

training with regards to correct usage.

The new dry steam technology can be adjusted by volume and dryness to provide a constant steam quality, which can be easily managed and adapted by an electronic control system.

Osprey Deepclean’s technology is available in a range of dry steam machines for different applications. Training is required, so the various accessories can be used effectively to safely remove micro-organisms and bacteria.

Due to the ease of use, industrial steam cleaners translate to labour savings as well.

Running costs are reduced because the steam can reach the most inaccessible spots, avoiding repeated dismantling during maintenance and upkeep operations, which can halve time taken.

This new boiler free technology is at the forefront of water saving science.

Energy, water, and waste costs are kept to a minimum, reducing operating costs and overheads and therefore increasing turnover and profit. Thanks to its sanitising properties, environmental edge and extreme versatility for all settings and cleaning tasks, dry steam cleaning is most definitely here to stay.

More Information: Tel: +44 1242 513123 Email: info@ospreydc.com Website: www.ospreydc.com

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FEATURE The Kubex T9 pellet mill allows energy savings as high as 30 percent to be achieved thanks to its new drive technology.

Measures for increasing the energy efficiency of UFA feed mills in Switzerland

by Peter Hofer, production manager, UFA, Switzerland and Viktor Borner, segment sales manager feed, Bühler AG, Switzerland

U

FA is Switzerland’s largest animal feed producer, with sites in Herzogenbuchsee (300,000 t/a), St. Margrethen (90,000 t/a), Sursee (85,000 t/a), and Puidoux (70,000 t/a). The finished product is marketed in the form of either expanded or pelleted feed. The average electrical energy requirement was cut within 10 years by about 4 percent, while thermal energy consumption was reduced by 10 kWh/t. And this was accomplished while increasing the upgrading degree from 60 percent to currently 100 percent. All feed produced in the UFA facilities is thermally hygienized.

On the basis of measures already implemented or still in the planning stage, the authors here explain the potential for increasing energy efficiency.

Biblis plant in Herzogenbuchsee (constructed in 2001/2002) The plant was highly energy-efficient right from the start. Thus, a multistage grinding system using two-pass crushing mills and 14 | March - April 2013

vertical-rotor hammer mills reduces the energy requirement by about 30 percent in comparison to a direct grinding system.

Since it went into service, the following measures for enhancing energy efficiency have been implemented: • The exhaust air of the compressed-air generators and blowers is used for the flake dryers and for blowing hot air into the thermal systems for drying. These and additional measures result in savings of 120 MWh of natural gas per year.

• Smart control of the compressedair generators and a pressure band reduction have enabled savings to be achieved on the order of 0.5 GWh of electrical energy per year.

The following measures will be taken shortly: • Installation of a fifth thermal line, equipped with a Kubex T9 pellet mill.

These new-generation pellet mills have direct drives. Their motors have an energy efficiency exceeding 95 percent and are water-cooled, and losses due to gearings or V-belt drives have

been entirely eliminated. This allows electrical energy savings on the order of magnitude of 20-30 percent compared to conventional pellet mills.

• Application of differential-pressure controllers on the large dust collection filters. They enable the purge-air requirement for cleaning the filter bags (sleeves) to be slashed. The payback time of this investment is a mere few months.

St. Margrethen plant (rebuilt in 2006/2007) The post-grinding system in this plant is equipped with a pre-screening stage ahead of the vertical-rotor hammer mills. This combination in St. Margrethen cuts the energy requirement by about 20 percent in comparison to conventional horizontal hammer mills. Frequency converters allow the grinding texture of the feed to be adjusted during ongoing production and markedly reduce the starting current.

Since it went into operation, the follow-

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FEATURE ing measures have been taken to increase energy efficiency: • The exhaust heat of the compressed-air generators and the flash steam of the condensate separation system of the steam boilers are used for preheating the feed water. This cuts annual natural gas consumption by 210 MWh. The following measures will be taken shortly: • Application of differential-pressure controllers on the large dust collection filters, which slashes the purge-air requirement. The payback time of this investment is just a few months.

Puidoux plant (constructed in 1993, expanded in 2010) The factory in Puidoux was acquired by UFA in 2005. In 2010, a third thermal line including a HYSYS pelleting system was added.

With the expansion, the following measures for cutting energy consumption were taken: • Installation of a Capstone C65 microgas-turbine for generating electrical energy, with a maximum (net) output of 60 kW. The 300°C hot exhaust gases are first used for heating the feed water for the steam boiler and then the water of the building heating. The entire residual heat contained in the hot

exhaust gases is mixed with the turbine cooling air and the ambient air and blown as hot air into the thermal systems for drying. This system configuration allows (almost) 100 percent utilization of the fuel.

• Installation of lowpressure-purged dust collection filters with differential-pressure controllers for the pellet coolers. The purge-air blower is equipped with a frequency converter and supplies only that amount of compressed air which is currently needed by the one to three filters, which can be activated and deactivated as required.

• Cooler fans have been provided with frequency converters.

This markedly reduces the starting current and allows energy-optimized operation as a function of the ambient temperature.

UFA Biblis in Herzogenbuchsee: The largest UFA plant with an annual output of about 300,000 metric tons.

www.symaga.com symaga@symaga.com

Offices and Factory: Ctra. de Arenas km. 2,300 13210 Villarta de San Juan • Ciudad Real- Spain T: +34 926 640 475 • F: +34 926 640 294

grain silos

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hoppered silos

Madrid Office: C/ Azcona, 37 • 28028 Madrid - Spain T: +34 91 726 43 04 • F: +34 91 361 15 94

March - April 2013 | 15

FEATURE

Multistage grinding system using a DFZL crushing mill. It allows the grinding texture of the feed to be adjusted to animals‘ specific needs and up to 30 percent energy to be saved compared to a directgrinding system

The following measures will be taken shortly: • Installation of a multistage grinding system using two-pass crushing mills and vertical-rotor hammer mills, which reduce the energy requirement by as much as 30 percent in comparison to a direct-grinding system.

The grinding texture can be automatically controlled by the process control system to meet the specific animals’ needs.

ated by UFA. In 2007, it underwent a total overhaul and was equipped with a stateof-the-art process control system allowing unmanned operation.

The Bühler standard control system served as the basis of the new control system. But one challenge was still to programme the control system for unattended nighttime operation. UFA’s specifications were the following: the mixing line and the pellet mill and expander line were to produce feed fully automatically during the night shift. This means that the control system of the plant must move to a secure mode in the event of faults. The system must automatically acknowledge and correct any faults detected. In addition, it must ensure plant and personnel safety at all times.

Last, but not least, the new control system was also to alert the standby staff via SMS in case of unplanned incidences, and remote maintenance was also to be possible.

In unmanned operation, the control system must make the decisions that are otherwise made by the experienced operator. In order to enable it to do this, it must receive large volumes of information from the sensors and respond according to defined instructions. For example, sensors monitor the temperatures and vibrations in the hammer mill, in the mixer, and in the expander as well as in the machine bearings. This cutting-edge control system also allows optimal, energyefficient operation of the entire plant.

With the expansion, the following additional energy-saving measures were implemented: • Installation of a multistage grinding system using two-pass crushing mills with pre-screening and intermediate screening ahead of the hammer mill.

This cuts the energy requirement by about 30 percent compared to a directgrinding system. The grinding texture

Urs Steiner, production manager with UFA Sursee, in the control centre: smart control and sensor systems enable unattended night time production

Sursee plant (constructed in 1965, expanded in 2007) The factory in Sursee is the oldest of the four feed mills oper16 | March - April 2013

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FEATURE can be automatically controlled by the process control system to meet the specific animals’ needs.

Energy-saving measures taken by UFA In order to further reduce energy consumption and to spare the environment, UFA continuously adapts its feed mills to the latest technological knowledge. For example, over the past 10 years about 5 percent electrical energy and 17 percent thermal energy per metric ton of animal feed produced have been conserved - and this while at the same time increasing the upgrading degree from formerly 60 percent to currently 100 percent.

Efficient energy utilization by combined heat and power generation Utilization by combustion of the energy that is chemically stored in the energy carrier for generating electrical power as the highest-value form of energy improves the calorific value of the heating oil by a factor of about three compared to pure steam generation. This so-called ‘combined heat and power generation’ process substantially increases exergetic efficiency. This means that the chemical potential contained in the fuel (heating oil, natural gas) is exploited almost to the physically possible limit, since electric power is generated beside heat.

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Utilization of the exhaust heat of compressors Instead of blowing the heat exhausted by the air compressors into in atmosphere as exhaust heat, it is systematically utilized for - say - preheating the boiler feed water or operating hot-air heat exchangers instead of using steam. Together with other heat recovery measures, this systematic utilization of exhaust heat alone enabled UFA to save a total of about 880 MWh of thermal energy in 2011.

An additional roughly 1 GWh of electric power was saved by efficiency-improving measures.

Micro-gas-turbine in Puidoux

Application of energy-efficient motors Basically, UFA today only procures electric motors of the energy efficiency class IE3 according to IEC 60034-30 or higher.

Distinguished with CO2 label thanks to systematic energysaving strategy UFA has a comprehensive energy management system in place, which ranges from saving power by using a staircase lighting control system (5 MWh/a) to refurbishing entire plants. This has allowed the UFA factories to discharge 500 metric tons less CO2 into the atmosphere in absolute terms than in 2008 while increasing their volume

by 10 percent. In all, some 3,100 t less CO2 were emitted into the environment in 2011 than would have been the case if development had continued unchecked. Thanks to the targeted reduction of carbon emissions, UFA is exempted from paying CO2 duties on fuels and is allowed to carry the Swiss CO2 Label.

March - April 2013 | 17

FEATURE

Additives for flour standardisation -

Part I: Enzymes

by Lutz Popper, Mühlenchemie GmbH & Co. KG, Germany

I

n biological systems, all the conversion processes can take place quickly at relatively low temperatures and mild chemical conditions, because enzymes help to run the reactions with lower energy input.

Because of the ability to perform very complex reactions under these mild conditions, enzymes are produced in industrial scale, mostly by micro-organisms. The development of new enzymes in short succession all around the world is fueled by increasing competition. High quality and low cost products manufactured with the help of these enzymes have the chance to compete better in the market.

Enzymes are used in many areas of the food industry. In contrast to most other food application, enzymes used in the flour industry do not show their effects at the moment they are added, that is, right in the mill. In order to see the effect of enzymes in flour, the baker must add water. This problem of time and place is the general challenge in the flour improvement business, but it gets even more complex when it comes to enzymes.

But enzymes also have definite advantages as they are specialised on distinct effects, used in very small dosages, natural and completely deactivated under baking conditions.

As with all the concentrated natural substances, enzymes pose the risk to cause aller-

18 | March - April 2013

gic reactions. Therefore, it is advised that the employees in contact with enzymes should wear gloves, mask and goggles. Although with a lower probability because of the dilution in flour or bread improvers, the same risk is present for bakers. Therefore, enzyme producers are trying to manufacture preparations that emit less dust.

For a long time, α- and ß-amylase were thought to be the only enzymes that could be used in the milling industry. This view has changed dramatically since the introduction of hemicellulases two decades ago, and has now received another blow through the success of lipolytic enzymes. There are many more enzymes (Table 1) that still play niche roles for certain applications, but which may turn out one day to be as versatile as the aforementioned types.

most enzymes, amylases also act on substances that are well in contact with water.

Alpha-amylase breaks down unbranched moieties of starch molecules, releasing dextrins. These dextrins act as substrate for beta-amylase and glucoamylase, which in turn produce sugars like maltose and glucose that can be directly used by yeast. By the action of amylases, the dough viscosity is decreased (water released from the starch), the fermentation power and the volume are increased, taste and colour are improved, the crumb softness is retained and the shelf life is extended.

Amylases The most used types of amylases in flour industry are alpha-amylase, beta-amylase and amyloglucosidase (glucoamylase). Like

Figure 1: Enzyme production scheme

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FEATURE gram of a 50,000 SKB/g amylase per 100 kg of flour). There is much less native enzyme in flour with Falling Numbers above 400 seconds, therefore 3 grams or more of the same amylase may be used. On the other hand, in flours with very low FN values, using trace amounts of amylase (like 0.1-0.2 grams of 50,000 SKB/g amylase) will not affect the FN but may have a beneficial effect on the dough properties and volume yield.

Glucoamylase

Figure 2: Hemicellulolytic enzymes Kopie

Enzyme active malt flour Seeds need enzymes to start with their vital activities, therefore high amount of enzymes are produced during the germination step.

Grains to be used for enzymatic purposes will be germinated before processing. Enzymeactive malt flour is produced from germinated barley, wheat or rye. The functions of these products are generally similar.

Besides alpha- and beta-amylases, there are other enzymes in malt flour, like proteases and glucanases. While some of these have positive effects on baking, some do the opposite. Like the enzymes natively found in flour, enzymes from malt flour also have a considerable effect on the Falling Number (FN). If the enzymatic activity of flour is very low, malt flour up to 150 grams per 100 kg can be used in order to decrease FN values to 250-300 seconds. In the case of FN below 300 s, enzyme active malt flour may result in sticky doughs even when used at below 50 g per 100 kg. The activity of malt flour is mostly stated as the diastatic power (DP) and is usually at around 400 DP. This activity may be interpreted as 80-120 SKB/g.

Fungal amylase Usually fungi belonging to Aspergillus genus are used to produce fungal amylase.

The species are well defined and do not produce toxic or carcinogenic substances.

The fungi are grown in large fermentation tanks end left producing and excreting the desired enzymes to the fermentation fluid.

The fermentation broth containing the raw enzyme is processed by centrifugation, filtration, precipitation, ultrafiltration and the like to result in a purified concentrated enzyme solution. This concentrate is converted to powder by spray drying, mixed with bulk material to standardise the activity and free flowing agents to provide ease of usage in mills. As a dry powder most enzymes are very stable and can be kept for years without losing much activity. Figure 1 provides a scheme for the production of enzymes from plants, animals and microbes.

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Amylase from fungal sources is mostly alpha-amylase. Most detrimental side activities are prevented by selection of suitable subspecies and processing conditions. At normal dosage, fungal amylase does not interfere with FN values because it is not stable at the temperature (approx. 95 째C) of the standard assay. There is another, modified FN test to determine the effect of fungal amylase, which employs lower maximum temperatures at around 82 째C. The dosage of alphaamylase preparations depends on their activity. In order to express the activity of alphaamylase, the unit for the test method developed

by Sandstedt, Kneen and Blish (1939), the SKB, is used. Even though different suppliers use different test methods, the results are often converted into SKB. For wheat with Falling Numbers between 300 and 350 s, the typical dosage is adjusted as 500 SKB per kg of flour (that is, 1

Also called amyloglucosidase or previously gamma amylase, this enzyme breaks starch to its smallest building blocks, glucose.

It also can work on the branching points of amylopectin, as opposed to alpha-amylase.

With this property, glucoamylase helps improving the browning of baked products and stabilises the fermentation in prolonged fermentation processes. There is no viscosity lowering effect of this enzyme because it leaves the large starch molecules basically unaffected, at least within the relatively short time of baking processes.

Hemicellulase The term hemicellulase designates a family of enzymes. All the members shown in Figure 2 are able to break down the pentosans (therefore they are also called pentosanases), but their

March - April 2013 | 19

FEATURE

Figure 3: Action of protease on gluten Table 1: Enzymes suggested for bread and flour improvement (not exclusive)

impacts on dough and baking properties vary widely.

It is assumed that pentosans form a network with gluten; the more pentosans are involved, the firmer the network.

Because they bind large amounts of water (approximately 10 times their dry weight), they reduce the availability of water for the gluten reducing its expandability.

Additionally, pentosans can be cross-linked to each other by the so-called oxidative gelation, increasing their ability to bind water further.

That is a main reason why darker wheat flours and mixtures containing rye flour have a lower volume yield than white flours. The volume yield of all flours can be increased considerably by adding hemicellulases.

Many of these enzymes are derived from Aspergillus strains selected for or specialising in the production of hemicellulases.

Hemicellulases are often sold in compounds with amylase and other enzymes.

The most common hemicellulase for baking applications is an endo-1, 4-ß-xylanase.

It is not possible to give a general dosage recommendation as there is no standard method of determining hemicellulase activity. The available methods are usually based on determining the release of reducing sugars, the reduction of viscosity or the breakdown of synthetic or coloured molecules and are very difficult to relate to each other. Moreover, even the use of a standard method for different hemicellulases does not necessarily permit conclusions in respect of baking properties, presumably because the points at which hemicellulases of different origin attack the pentosan molecules are too various.

Enzyme

Claimed Effect

Alpha-amylase, bacterial

Oven-rise, anti-staling, liquefaction

Alpha-amylase, cereal

Oven-rise, anti-staling

Alpha-amylase, fungal

Energy supply for yeast, dough & bread structure

Alpha-amylase, maltogenic, intermediate heat stable

Anti-staling

Ascorbic acid oxidase

Protein strengthening

Beta-amylase

Energy supply for yeast, browning, taste

Branching enzyme (glucotransferase)

Water binding

Cellulase

Water binding

Furanosidase, arabinofuranosidase

Dough structure, water binding

Protease

Ferulic and cumaric acid esterase

Dough structure, water binding

Glucoamylase, (amyloglucosidase)

Energy supply, colour, flavour

Glutathion oxidase

Protein strengthening

ß-glucanase

Structure, liquefaction

Glucose oxidase, galactose oxidase, hexose oxidase

Protein strengthening

Hemicellulase, xylanase, pentosanase

Dough structure, water binding, volume yield

Laccase, polyphenol oxidase

Dough strengthening

Carboxyl esterase (lipase, phospholipase, galacto­lipase etc.)

Flavour, in-situ emulsification, dough stability and volume yield, dough brightening

Lipoxygenase, lipoxidase

Dough structure, decolourization

Exo-Peptidase

Colour, flavour

Peroxidase

Protein strengthening

Protease, proteinase, endo-peptidase

Protein relaxation, liquefaction

Pullulanase

Structure, water binding

Sulfhydryl oxidase

Protein strengthening

Sulfhydryl transferase

Protein strengthening

Transglutaminase

Protein cross-linking, gluten stabilization

Proteases (also known as proteinases or peptidases) split the protein strands of the gluten molecule (Figure 3) and thus lead first to a softening and then to a complete collapse of the structure. A purified single and very specific protease would only be able to break down a few of the peptide bonds, resulting in only limited softening.

With short gluten structures a slight softening may well be desirable; in this case it has a similar significance to the use of L-cysteine. The proteolytic action is more time-dependant than the function of cysteine. As a result, it increases with the fermentation time of the dough. That is why there is a considerable demand for enzyme preparations that do not contain even traces of protease.

The use of protease is less crucial with flours that are rich in gluten. It is even very common in the production of pan (toast) bread, where a soft dough that precisely fills the tin is required. Proteases are also very useful in the production of cracker,

20 | March - April 2013

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FEATURE

Figure 4: Reaction of glucose oxidase and some probable effects on dough components

such as the tyrosine groups in protein or the feruloyl residues in pentosans.

The oxidative cross-linking of the pentosans is called oxidative gelation, a reaction resulting in increased dough firmness and dryer dough surfaces. The limiting factor in this process is the availability of oxygen because of other chemical and biochemical reaction consuming oxygen.

Therefore, the conditions for oxidases are only good on the surface of the dough where plenty of oxygen is always available.

This limitation can be solved by technical measures during dough preparation, for example overpressure or the supply of extra oxygen through the mixing tool.

Carboxyl esterases

Figure 5: Classification and distribution of the main lipids in wheat flour (averages; % d.s.; modif. from Pomeranz and Chung, 1978, using data from Chung and Ohm, 2009)

biscuit or wafer flours where elasticity of the gluten is not desirable.

Glyco oxidases There are several oxidoreductases in nature that convert sugar molecules into the corresponding acids, or, as in the case of sorbitol oxidase, that convert a sugar alcohol into the corresponding sugar. The most common oxidase (from a commercial perspective) is glucose oxidase. Other examples are maltose or galactose oxidase. More generic terms used for all these enzymes are hexose oxidase or pyranose oxidase.

The enzyme glucose oxidase (GOX) is usually derived from the mould Aspergillus, sometimes from Penicillium species. Honey

is also a rich source of GOX. The enzyme stems from the pharyngeal glands of the bees. However, its suitability is rather restricted by the taste of its carrier.

One effect of GOX in the dough is to oxidize glucose to form gluconic acid with the aid of atmospheric oxygen, but the slight souring that occurs in the process is negligible; its other effect is to transform water into hydrogen peroxide (Figure 4). This oxidizing agent acts on the thiol groups of the gluten, either directly or via several pathways, inducing formation of disulphide bonds and thus tightening of the protein. Since hydrogen peroxide is a rather non-specific oxidizing agent, it may also react with other reducible substrates, for instance phenolic component

The term carboxyl esterase comprises all lipolytic enzymes, for example (triacyl) lipase, phospholipase and galactolipase. They all catalyse the hydrolysis of acyl residues (fatty acids) from lipids. Wheat contains about 2.5-3.3 percent lipids, a typical bread flour about 2.5-2.7 percent (Chung & Ohm, 2009), but only about 1 percent are free lipids that are easily accessible by lipolytic enzymes. A schematic representation of the lipids composition of wheat flour is given in Figure 5. Lipase converts non-polar lipids into the more polar structures diglycerides and monoglycerides, i.e. emulsifiers (Figure 6). Lipids of wheat flour are already polar to some extent, namely phospholipids and glycolipids are converted into more polar and hydrophilic lyso-forms by phospholipases and glycolipases.

The in situ formation of mono- and diglycerides from wheat lipids results in dough strengthening and larger volume yield, but according to the author’s findings doesn’t have a significant effect on starch retrogradation and hence bread staling. This is in contrast to the effect of mono- and diglycerides which are added to a bread formula: due to interaction with starch they are able to reducing the staling rate. On the other hand, their effect on volume yield is very limited.

Most probably, the action of enzymatically formed emulsifiers on volume yield is pronounced because they are already located at the right sites of the dough for improving the

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&feed milling technology

Grain

March - April 2013 | 21

FEATURE omitted; the dough pieces will keep the shape given by the cutting; shrinkage and bending in the oven as well as the formation of hairline cracks (checking) are avoided. With suitable amylases, expensive recipe components such as milk solids otherwise necessary for sufficient browning can be omitted. Furthermore, the whole process will be less dependent on flour quality.

Other flour applications

Figure 6: Effect of carboxylesterases on wheat lipids

Figure 7: Cross linking of protein by transglutaminase

protein properties; but for anti-staling effects, not enough emulsifier is formed to interfere with starch retrogradation.

Nevertheless, they have a distinct effect on the shelf life of bread because they create a better ‘starting point’ at the beginning of the storage due to improved volume and crumb structure. With the staling rate unchanged, this results also in a better structure (crumb softness) at the end of the storage period.

Interestingly, it is being disputed whether the doughs have to contain additional fat, and if so, what kind of fat, for the lipase to work satisfactorily.

According to our findings, fat reduces the efficacy of lipase, probably by ‘distracting’ the lipase from the ‘right target’, i.e. the flour lipids.

Initially, there was also the problem of a possible impairment of taste due to the release of flavour-active fatty acids, particularly if butter is involved. The most recent carboxyl esterase are more specific in this concern and hence do not affect the flavour in most applications.

Transglutaminase This enzyme causes bond formation between protein folds or different protein strands (Figure 7). It needs lysine 22 | March - April 2013

and glutamine groups to work. Although lysine is a limited amino acid in flour, the levels are enough for transglutaminase to work. The result is a strengthening effect on the dough, like ascorbic acid.

Because it is rather expensive compared to ascorbic acid, its use is limited.

A special usage area can be in very long or retarded fermentation processes where very low amounts of the enzyme will work sufficiently long.

Enzymes for biscuits, crackers and wafers Whereas a high protein content and strong gluten are desired properties in many bread processes, flours with little and weak gluten are preferable for durable baked goods. The tendency of dough to spring back after rolling and the undesired formation of gluten lumps in wafer batter are the reasons for this requirement. Whether a flour with low and weak protein is available or not, the use of elasticity-reducing agents will have benefits in all stages of the process: The lamination will be more uniform; reduction of the thickness of the dough sheet can be performed faster and more reproducibly; relaxing periods for the dough sheet can be shortened or even

Enzymes have also been introduced into flour applications others than baking, for example noodles or steamed bread. For steamed bread the desired properties are similar to those in bread baking, but the technology is quite different and requires different types of enzyme compounds. In many types of steamed bread, specific lipases are very useful, providing stability, volume and a bright crumb colour.

Except for certain types of Asian noodles, for example Japanese udon noodles, a firm bite and a high cooking tolerance are advantageous. For instant noodles, the requirements are quite different, because the reduction of oil uptake during frying and a fast water uptake upon cooking are of utmost importance. Furthermore, avoiding the cracking of dried noodles is a typical aim, although this problem is caused in many cases by inadequate drying conditions. Finally, the colour of the fresh or dry noodle is important. A bright colour without speckles is a desirable property of many but not all types of noodles. All of these challenges can be approached by enzymes, namely by carboxyl esterases and lipoxygenases.

References Chung, OK, Ohm, JB, 2009. Wheat Lipids. In: Wheat - Chemistry & Technology, Khan, K, Shewry, PR (ed.), AACC Press, 363-399.

Pomeranz, Y and Chung, OK, 1978. Interaction of lipids with proteins and carbohydrates in breadmaking. J. Am. Oil Chem. Soc., 285-289 .

Sandstedt RM, Kneen E and Blish MJ, 1939.

A standardized Wohlgemuth procedure for alpha-amylase activity. Cereal Chem. 16, 712-723.

Read the second part of this article in the next issue of Grain and Feed Milling Technology. Lutz Popper will discuss additives other than flour and standardisation services.

More Information: Website: www.muehlenchemie.de

&feed milling technology

Grain

FEATURE

Fine grinding and BS3 Xylanase improve productivity in weaners

by Dorthe K Rasmussen, Marie Lybye Andersson, Lisbeth Jørgensen, Pig Research Centre, Denmark

I

n the Danish pig production industry, carbohydrate-splitting enzymes, primarily xylanase, are often added to pig feed to improve gain and feed conversion ratio (FCR). Several trial activities have investigated various enzyme products for pigs – nationally as well as internationally - all with highly varying outcome. Danish trials with finishers revealed effects on FCR ranging from 0 – 3 percent when xylanase is added to the feed. Lately, most trial activities have focused on the effect of xylanase on finisher production, whereas in Denmark in recent years no investigations have focused on the effect of xylanase on weaners.

certain types of bindings. Xylanase splits coherent xylose units in large complex molecules such as arabinoxylans. Arabinoxylans constitute a significant part of the fibre fraction in grain and by-products of grain with the highest concentration found in wheat.

There is an on-going development of new xylanases that may have a significantly greater potential than the xylanases currently available. BS3 Xylanase from DuPont Nutrition Bioscience ApS (previously Danisco) is one such product. BS3 Xylanase has not previously been tested on pigs in Denmark or in other countries.

Finisher trials have demonstrated a poorer FCR when pigs are fed coarsely ground meal feed compared with finely ground meal feed. The outcome of a small-scale trial with different grinding of feed for weaners indicated that coarse grinding reduces the digestibility of feed.

A finisher trial comparing finely ground, pelleted feed with coarsely ground meal feed

Enzymes are proteins found in plant and animal tissue where they form part of the structure and decomposition of chemical compounds. They act as catalysts accelerating processes that would otherwise not occur or would occur very slowly. Enzymes are specific, i.e. they can only break down

Table 1: The trial comprised weaners in the growth period 8 - 30 kg. The trial set-up comprised six groups all fed not-heat-treated meal feed Group Grinding Sieve profile in grain, % under:above 1 mm Xylanase

Material and method

1

2

3

4

5

6

Fine

Coarse

Fine

Coarse

Fine

Coarse

65:35

40:60

65:35

40:60

65:35

40:60

None

875 units/ kg BS3 Xylanase

875 units/ kg BS3 Xylanase

4,000 units/kg Porzyme 9302

4,000 units/kg Porzyme 9302

None

FUNDING The project was financially supported by the Pig Levy Fund and the GUDP programme under the Danish Ministry of Food, Agriculture & Fisheries. Project ID: VSP09/10/51; journal no.: 3405-10-0098.

24 | March - April 2013

revealed that the effect xylanase was not affected by grinding, i.e. the effect of adding xylanase was identical for the two types of feed. Despite a negative effect on feed conversion, coarse grinding is an interesting option as it improves gastric health and the gastrointestinal tract. In terms of health, it is therefore be relevant to clarify whether the addition of xylanase may neutralize a drop in FCR. The aim of this trial was to establish the effect on weaner productivity of adding one of two different xylanase products to coarse or fine meal feed, respectively. The effect was recorded on daily gain and FCR analysed jointly in a production value.

The trial is part of a co-operation between DuPont Nutrition Bioscience ApS, Aarhus University, Department of Animal Science, and Pig Research Centre. The overall purpose of the project is to establish the potential for improving FCR, reducing feed costs and minimising the environmental impact of using xylanases.

The trial was conducted at Pig Research Centre’s experimental station with weaners purchased at weaning. Two different housing units were used for the trial: one with 12 pens/section each holding 16 pigs, and the other had 18 pens/sections each holding 11 pigs.

The effect of feeding the pigs either a fine or coarse wheat-based diet combined with the addition of xylanase was investigated from approximately 8 kg (approximately one week after transfer to the weaner section) until approximately 30 kg. The trial design is shown in Table 1.

The trial comprised 61 replicates per group corresponding to 781 pigs/group and

&feed milling technology

Grain

FEATURE Table 2: Scale for scoring of gastric ulcers/lesions

a total of 4,686 pigs. Fine grinding was defined as approximately 65 percent particles below 1 mm and 35 percent above 1 mm, while coarse grinding was defined as approximately 40 percent particles below 1 mm and 60 percent above 1 mm. Fine grinding was obtained with a 2.5 mm sieve versus 5.5 mm for coarse grinding. Table 1 shows the expected activity of the two xylanases.

ended at approximately 30 kg in order to examine their stomachs.

The white part of the stomach was evaluated at the Laboratory for Pig Diseases in Kjellerup (DK) according to the scale normally used for scoring stomachs (Table 2).

Feed and feeding

Samples from the diets in each group were collected at each feed Table 3: Average particle distribution in ground wheat production and split according to (Retsch sieve) the TOS principles (Theory of Fine Coarse Sampling).

Grinding (2.5 mm sieve) (5.5 mm sieve) The diets were analysed for energy content (Enzyme Digestible Organic Matter at 0.3

13.5 Above 2 mm, % ileum = EDOMi) and for lysine 27.1

37.4 1-2 mm, % methionine, cystine, threonine, calcium, phosphorus and phytase 72.6

49.1 Below 1 mm, % at Eurofins Steins Laboratorium Average of 9 samples of each type of grinding A/S. Enzyme activity was analysed

by DuPont Nutrition Bioscience were also used for calculating the producApS. In nine samples of ground wheat (one tion value: • Average price of a 7 kg pig: DKK 913 from each production round), particle disper pig, ± DKK 9.47 per kg tribution was analysed using the Retsch • Average price of a 30 kg pig: DKK 331 sieve. per pig, ÷ DKK 5.72 per kg (25-30) / DKK + 5.41 per kg (30-40) Production value and statistics • Weaner feed: DKK 1.77 per FUgp – The production value was obtained by using the following variables: • Value of gain calculated on the basis of the pigs’ gain in kg × value of 1 kg gain • Feed costs calculated as (end weight ÷start weight) × FUgp per kg gain × DKK per FUgp • Productive days, which is the number of days the average pig was in the trial.

Based on prices of the last five years (September 1, 2006 – September 1, 2011), the following values

The diets complied with the Danish nutrient standards for weaners in the weight interval 9-30 kg, and phytase was added to the diets (100% inclusion). All diets included a safety margin on the calculated amino acid content of 5 percent above the current standard and of 10 percent for phosphorus and calcium. A safety margin is included to neutralize any effect of nutrient deficiencies per feed units as the addition of xylanase increases the energy content of a diet. The addition of xylanase increases the energy level of a diet by approximately one feed unit per 100 kg feed, and the formulation of the diets in this trial did not take this into consideration. Thereby, the outcome of the trial will be the pigs’ biological response to xylanase without having included the effect in the energy value of the grain.

To ensure optimum conditions for xylanase, the feed consisted of 67 percent wheat, which contains large quantities of arabinoxylan, which is the carbohydrate most often split by these xylanases.

At the trial start, the pigs were fed a meal-based starter diet. For the first 14 days post-weaning, the pigs in all groups were given 2,500 zinc (prescribed by the herd vet) mixed manually into the feed regardless of whether the pigs were fed starter diet or weaner diet. The pigs switched from starter feed to trial feed (weaner feed) 1-2 weeks post-weaning. All pigs switched diets at an average weight of 8 kg (trial start). The pigs were fed not-heat-treated meal feed ad lib from dry feeders. Feeding was managed by a computerised dry feeding system.

Recordings All recordings were made at pen level.

Weight and number of pigs were recorded upon transfer to the weaner section and at departure from the weaner unit at approximately 30 kg. The trial period began when the pigs switched from the starter diet to the weaner diet. Date, weight and cause were recorded for all pigs that were moved to a hospital pen, died and were destroyed.

Number of pigs and date of treatment were recorded for all disease treatments. Sick/ weak pigs were moved to a hospital pen and treatment procedures followed the regular routines of the farm. Feed consumption was calculated from trial start to departure from the weaner unit.

Forty-six pigs (23 pigs fed finely ground feed and 23 pigs fed coarsely ground feed) were destroyed immediately when the trial

&feed milling technology

Grain

Analyses of feed

Score

Evaluation 0

Normal stomach without changes

1-3 Keratinisation 4-5 Erosion 6-8 Ulcers or scars from ulcers 9-10 Contracted oesophagus

March - April 2013 | 25

FEATURE

"The effect of adding xylanase to pig feed did not vary regardless of whether the feed was finely ground or coarsely ground. This trial thereby did not confirm the hypothesis that the addition of xylanase may affect the reduced FCR seen when feeding coarsely ground meal feed"

identical feed prices in all groups.

One kg gain was valued at DKK 5.97, which was the value of the average gain in the entire period.

Production value (PV) per place unit/day was calculated as follows: PV per place unit/day: (value of gain ÷ feed costs) / productive days.

An average price of pigs and feed based on 5 weeks (weeks 23-27, both weeks included) and the price of the product as stated by the producer were used for calculation of the actual PV. This did not include identical feed prices in the six groups.

• Price of 7 kg pigs: DKK 236, ± DKK 11.64 per kg • Price of 30 kg pigs: DKK 397, ÷ DKK 6.39 per kg (25-30) / + DKK 6.55 per kg (30-35 kg) • Weaner feed: a) Groups 1-2: DKK 216 per 100 FUgp b) Groups 3-6: DKK 216.46 per 100 FUgp Data was subject to analy26 | March - April 2013

Table 4: Average analysed enzyme activity for BS3 Xylanase and Porzyme 9302, ± standard variation of enzyme activities Group

3

Xylanase

4

5

BS3 Xylanase (TXU)

6

Porzyme 9302 (DXU) 4,000 DXU/kg

Declared enzyme activity, U/kg Analysed enzyme activity, U/kg

875 TXU/kg 1,053±246

935±324

-

-

4,151±965

3,176±625

Table 5: Production value (PV) and actual PV for weaners for grinding and inclusion of xylanase.

Factor

Grinding

Xylanase

Level

Fine

Coarse

None

BS3 Xylanase

Porzyme 9302

PV per place unit/day, DKK1

1.59

1.50

1.52

1.58

1.55

PV index1)

100

94

100

104

102

Actual PV per place unit/day DKK2)

1.78

1.67

1.69

1.76

1.72

Actual PV index2)

100

94

100

104

102

Effect of grinding

Effect of BS3 Xylanase

Effect of Porzyme 9302

***3)

*4)

NS5)

No statistical calculations of actual PV

1) 5-year prices (September 2006 - September 2011). When comparing production value, there must be a minimum difference for grinding of 2 index points and minimum 3 index points for xylanase for a difference to be significant (p<0.05).

2) 5-week prices (wks 23-27, 2012) and price of xylanase as informed by the producers (see Appendix 1).

3) Significant (p<0.0001).

4) Significant (p<0.05).

5) Not significant.

&feed milling technology

Grain

FEATURE Table 6: Production results for the entire trial period for grinding and inclusion of xylanase.

Factor

Grinding

Xylanase

Effect of grinding

Effect of BS3 Xylanase

Effect of Porzyme 9302

Level

Fine

Coarse

None

BS3 Xylanase

Porzyme 9302

-

-

-

Daily grain g/day

561

543

544

560

553

*1)

*1)

NS2)

FCR, FUgp/day

0.99

0.98

0.97

0.99

0.98

NS2)

NS2)

NS2)

FCR, FUgp/kg gain

1.76

1.81

1.80

1.77

1.78

*1)

*1)

NS2)

1) Significant (p<0.05).

2) Not significant.

sis in the MIXED procedure in SAS as a factor trial with the two factors grinding (to levels: fine versus coarse) and xylanase (three levels: none/product 1/ product 2). Production results, daily gain and FCR was summed up in a production value (PV) that was subject to statistical analysis as primary parameter with weight at transfer as co-variable.

If significant differences in PV were observed, each individual production parameter was subject to analysis in the same model as PV. The model for calculation of PV included the variables housing unit, batch (replicate) and group. Production value was calculated using identical feed prices

and with the average number of analysed feed units for the two groups without xylanase (112.7 FUgp per 100 kg) as the analysed energy content in the groups with xylanase was approximately 1 FUgp per 100 kg higher than in the feed without xylanase. This procedure was employed to ensure that the pigs’ biological response to xylanase inclusion was obtained. Disease and mortality rates were recorded as secondary parameters, and the trial was not designed to detect any differences in these two parameters.

Disease recordings and mortality rates were subject to analysis in the same model as PV. Ten pens were excluded from data

processing either due to the fact that the pen in question was a significant outlier or due to inadequate data quality.

Results and discussion Nutrient content For most nutrients, the declared and analysed contents corresponded in all six diets. The analysed content of calcium and phosphorus was lower than declared, but due to the safety margin and since this deficiency was identical in all groups; it did not affect the outcome of the trial. The analysed phytase content was approximately three times higher than declared, which is attributed to the fact that the analysis method detects the added

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Ann A5 victam 0212.indd 1 Grain feed milling technology

21/02/12 March - April 2013 | 15:37:04 27

FEATURE Table 7: Health in relation to grinding and inclusion of xylanase Factor

Grinding

Xylanase

Effect of grinding

Effect of BS3 Xylanase

Effect of Porzyme 9302

Level

Fine

Coarse

None

BS3 Xylanase

Porzyme 9302

-

-

-

Treatment for diarrhoea, days per pig

1.82

1.35

1.63

1.52

1.60

*1)

NS2)

NS2)

Mortality

0.7

1.0

1.2

0.8

0.6

NS2)

NS2)

NS2)

Dead and moved to hosp.pen, %

3.9

6.0

5.4

4.6

4.7

*

NS

NS2)

1)

2)

1) Significant (p<0.05).

2) Not significant.

as well as the natural content of phytase in the feed.

Porzyme 9302 increased the EDOMi value by approximately one percentage point as seen in other trials. BS3 Xylanase did not have the same impact in EDOMi (0-0.45 percentage points).

Particle distribution and enzyme activity Fine grinding was intended to be 35 percent above and 65 percent below 1 mm, while coarse grinding was intended to be 60 percent above and 40 percent below 1 mm. The average particle distribution found with a Retsch sieve in ground wheat is shown in Table 3. Coarse as well as the fine grinding was slightly finer than intended, but the difference between the two was as planned.

Table 4 shows the average of nine enzyme activities for each of the four groups in which xylanase was added to the feed.

For both xylanases, enzyme activities varied over the course of the trial in all four diets. Variations in enzyme activity were also observed in previous trials.

The average enzyme activities found during analyses corresponded fairly well with the declared value except for group 6 where activity where found to be lower than declared (Table 4). Previous trials with finishers also found lower activities than declared.

Production results Table 5 shows the production value in relation to grinding and inclusion of xylanase, respectively, along with a comparison of the two or three levels for each factor. Production value was significantly lower (p<0.0001) for pigs fed coarsely ground feed compared with pigs fed finely ground feed. This is attributed to a significantly lower gain (p<0.0001) and a poorer FCR (p<0.0001). Grinding thereby affects FCR in weaners in the same way as in finishers.

No interaction was observed between the factors, which means that the effect of adding xylanase was identical regardless of grinding. Consequently, the effect of adding xylanase was not greater in coarsely ground 28 | March - April 2013

feed than in finely ground feed, and this corresponds with findings in another finisher trial.

The addition of BS3 Xylanase resulted in a significantly higher production value (p<0.05) compared with feed without xylanase. This difference was caused by a positive impact on gain (p<0.01) and on FCR (p<0.05) among the pigs given BS3 Xylanase. Despite a numerically higher gain and a better FCR, Porzyme 9302 did not significantly affect the production value.

The vale ‘actual PV per place unit/day’ shows the production economy in feeding weaners meal feed with xylanase with today’s prices. The additional cost (DKK 5.2 per tonne finished feed) of adding BS3 Xylanase was fully covered by the improvement in gain and FCR, which is illustrated with an index above 100.

Health Table 7 shows health conditions of the pigs in the trial in relation to the two factors (grinding and xylanase).

Treatments for diarrhoea averaged 1.6 days per pig. Pigs fed finely ground meal feed had significantly more treatment days for diarrhoea than pigs fed coarsely ground feed.

The outcome of a weaner trial comparing meal with pelleted feed also revealed fewer treatments among pigs fed meal feed with a coarser particle distribution than pelleted feed. In another trial, the impact of feed on the gastrointestinal tract was analysed by comparing coarsely ground meal feed with finely ground pelleted feed for weaners.

Results revealed that coarsely ground meal feed makes it more difficult for pathogen bacteria to pass the stomach and colonise in other parts of the intestinal tract.

Dead and removed pigs averaged 4.9 percent for all six groups. Mortality averaged 0.9 percent with no differences between the groups. However, the number of dead pigs and pigs moved to hospital pens differed significantly (p<0.01) between the group with coarsely ground feed and finely ground feed. The majority of those moved were pigs fed coarsely ground feed. This does not correspond with the fact that this was also the group with the fewest treatments for diarrhoea. This may, however, be explained by the fact that pigs moved were small

wherefore the herd manager decided to move them to a hospital pen.

Gastric changes Examinations generally revealed very few changes in the white part of the stomach among the examined pigs. Forty of 46 stomachs were scored index 0, which equals a normal stomach with no changes.

Six were scored between index one and six. An index below six is not considered to be of significant importance to the pig as research has demonstrated that daily gain is not affected until the index reaches six or more. It is known from finisher trials that meal feed protects against gastric changes, and this is probably the reason why very few changes were found in this trial. Results did not indicate any significant differences in gastric health regardless of whether pigs were fed finely ground or coarsely ground meal feed. However, 46 stomachs are not enough to make any conclusions on small differences in gastric health.

Conclusion The effect of adding xylanase to pig feed did not vary regardless of whether the feed was finely ground or coarsely ground. This trial thereby did not confirm the hypothesis that the addition of xylanase may affect the reduced FCR seen when feeding coarsely ground meal feed.

Production value was significantly higher among weaners fed finely ground feed compared with coarsely ground feed, which is attributed to a higher daily gain (approximately 3%) and a better FCR. BS3 Xylanase also positively affected the pigs’ daily gain and FCR by 2-3 percent compared with the pigs fed feed without xylanase, which was reflected in a significantly higher production value for the pigs fed BS3 Xylanase. The additional cost of adding BS3 Xylanase to pig feed was fully covered by the improved gain and FCR. Results revealed no significant effect of adding Porzyme 9302.

More Information: Website: www.pigresearchcentre.dk

&feed milling technology

Grain

FEATURE

Improving pig health management with a versatile enzyme

Table 1: Better homogeneity on barley-based diet from 42 to 70 days of age (Customer, France 2011)

Initial weight at 42 days (kg)

by Caroline Joos, technical support, Adisseo, France

R

ecent trials confirm that the introduction of a versatile NSP (Non-Starch Polysaccharides) enzyme in pig diets, improves performance and homogeneity of animals from weaning to slaughter.

This has a positive impact on health management by a reduction of re-allotting and increased clean downtime.

The homogeneity within batches is not always measured and/or reported in trial reports although it is worth looking at. Pig producers know that in respect of a minimal clean downtime between batches and a limited mixing across batches, it is necessary to ensure proper animal health management.

Low performance and/or high heterogeneity between animals make it difficult.

In practice, it means that more homogeneous animals spend less time in the facilities because the time between the first and the last individual to reach target weight is reduced. More homogeneous animals also means less mixing both after weaning and when animals are brought to fattening rooms, which reduces stress and the spread of pathogens. Enzymes can contribute to increase piglets and pig homogeneity; as proven by recent research achieved in collaboration with Adisseo testing Rovabio® Excel, added on top of the usual formulation.

Besides the general effect of an efficient NSP enzyme to increase digestibility, a versatile enzyme containing a wide range of enzymatic activities, may have more assets than a mono-activity enzyme to impact each individual metabolism and counteract animal diversity.

From -16 to -26% on piglet final weight variability In the experimental station of a customer in France, a trial was conducted on piglets fed a barley-based diet from 42 to 70 days of age. Daily weight gain was improved by 3.9%, and feed conversion rate was reduced by 4.3% with Rovabio® Excel (Table 1). Moreover, the coefficient of variation decreased by 16 percent, proving the effect 30 | March - April 2013

of the enzyme on homogeneity of the batch. The first wickers graph (Graph 1) clearly shows that final weight of the lightest piglets is significantly increased with Rovabio® (27.2 kg vs 23.7 kg).

This trial confirms the results observed in two other trials carried out in Germany.

The University Of Applied Sciences of Nürtingen, showed that the addition of Rovabio® Excel on a wheat-based diet improved piglet growth performances (Table 2) with a final weight increase of +1 kg (+ 3.4%). The coefficient of variation on final body weight was reduced by 20 percent and the gap between the lightest and the heaviest piglets was significantly reduced - from 20 kg to 13 kg with Rovabio® (Graph 2).

At the University of München, the piglets fed a corn-soybean diet showed that Rovabio® Excel significantly improved piglet performances (see Table 3). As a result, piglets receiving Rovabio® were

Control

Rovabio®

Enzyme effect

14.1

14.2

-

Daily weight gain (g/day)

666

692

+3.9%

Feed conversion ratio

1.63a

1.56b

-4.3%

Feed intake (g/day)

1077

1083

+0.6%

Final weight at 70 days (kg)

31.8

32.5

+2.2%

Final weight variability (CV in %)

9.8%

8.3%

-16%

Table 2: Better homogeneity on wheat-based diet from 30 to 70 days of age (Nürtingen University, Germany 2002)

Control

Rovabio®

Enzyme effect

Initial weight (kg)

10.1

9.9

-

Daily weight gain (g/day)

458a

486b

+6.1%

Feed conversion ratio

1.75

1.73

-1.5%

Feed intake (g/day)

803

839

+4.5%

29.3

30.3

+3.4%

11.8%

9.4%

-20%

Final weight at 70 days (kg) Final weight variability (CV in %)

Table 3: Better homogeneity on corn-based diet from 28 to 69 days of age (München University, Germany 2003)

Control

Rovabio®

Enzyme effect

Initial weight (kg)

7.4

7.4

-

Daily weight gain (g/day)

516

542

5.0%

Feed conversion ratio

1.72

1.7

-1.2%

Feed intake (g/day)

890

923

3.7%

Final weight at 70 days (kg)

28.5

29.6

3.7%

16.0%

11.9%

-26%

Final weight variability (CV in %)

Table 4: Three times less variability on corn-based diet from 28 to 154 days of age (Kasetsart University, Thailand 2012)

Control

Rovabio®

Enzyme effect

6.7

6.7

-

Initial weight (kg) Daily weight gain (g/day)

747

761

1.9%

Feed conversion ratio

2.66a

2.54b

-4.5%

Feed intake (g/day)

1980

1930

-2.5%

98.8

100.8

2.1%

Final weight variability (CV in %)

Final weight at 154 days (kg)

4.57%

1.26%

-72%

Days to slaughter weight for the last pig

144

126

18 days

Days to slaughter weight for 75% of pigs

134

124

10 days

&feed milling technology

Grain

FEATURE

Graph 1: Piglet size

Graph 3: Gain up to four days for 75 percent of piglets to reach target weight

heavier (+ 3.7 % at 70 days of age). Final weight variability was significantly reduced by 26 percent.

From the piglet weight distribution at the end of the three experimentations, the number of days needed to reach target weight could be determined. The first indicator to be considered is the number of days needed to bring the last piglet to target weight. However, to be closer to management practice on field, a second indicator was calculated: the number of days needed to bring 75 percent of the piglet batch to target weight, when usually the batch can leave the weaning facilities.

A positive impact kept until slaughter A trial was carried out in 2012 from weaning to slaughter and confirmed that the reduction of variability with Rovabio® Excel is also demonstrated during the fattening period, and that the time needed to reach slaughter weight is more homogeneous with Rovabio® across individuals.

This trial conducted on corn-based diets at the Kasetsart University in Thailand, shows that Rovabio ® Excel decreases feed conversion ratio by 4.5% and significantly reduces the variability within batch (-72%). The faster growth brings a potential reduction of the fattening period by three days, and the reduc-

&feed milling technology

Grain

ADVERTISE

Graph 2: Smaller gap between lightest and heaviest piglets with Rovabio®

tion of heterogeneity allows reducing the on diverse diet types and unique metabolic fattening period by seven extra days for specificities.

75 percent of the batch to reach 100 kg bodyweight. Altogether, with the addiMore Information: tion of a versatile enzyme from weaning to slaughter, the fattening period can be Trial reports are available upon request Email: caroline.joos@adisseo.com reduced by ten days and the number of overweight or downgraded pigs can potentially be reduced.

In these four trials with different diets and metabolic phases, in all cases, growth performances and animal PRINT homogeneity were Do you want to reach a global audience significantly to promote your products. GFMT not improved only distributed to our mailing list of with Rovabio® key industry decision makers, we also distribute the magazine at the top Excel until industry events throughout the year. slaughter.

This has ONLINE been possible thanks to Your advert will continue to work for you the versatility long after the print edition is in the hands of Rovabio®. of our readers. We have a comprehensive The fact that online distribution system, ensuring Rovabio® your adverts is reaching customers for a contains 19 minimum of five years. enzymatic activities To find out more please visit: allows a positive response over animal http://www.gfmt.co.uk/advertising.php homogeneity March - April 2013 | 31

FEATURE

THE

MISSING LINK

by John Eiting, sales engineer, Modern Process Equipment Corporation, United States

I

n many processing facilities, the grinding or milling of products is a key element in the process. However, transportation and conveying are often an afterthought to the design and implementation of the production process. Many times, conveying is added or altered due to increased production capacity, or changes in the production process.

Whatever the reason, often the planning of conveyor selection and design doesnâ&#x20AC;&#x2122;t receive the consideration it deserves, thereby making it a ripe target for many of the problems that a processing facility with a focus on milling can face.

Figure 2

In January 2013, society saw a focus on controlling the risk of explosions within hammer mills, with much of the risk associated with these dangerous dust explosions being placed directly on the shoulders of the process that creates the dust in the first place: bucket elevators and pneumatic conveying systems.

A balancing game These systems produce dust as a result of their daily operation, thus, when using bucket elevators or pneumatic systems, decreasing the risk of dust explosions now requires additional technology and sensors, as well as safety personnel and dedicated cleanup

staff. These advances in technology and the increase in regulations, codes and standards have increased the safety in plants and have reduced the occurrence of dust explosions; but one big problem still exists: they do not address the underlying issue of dust. These means of conveying inherently generate dust, and without first addressing this issue, preventing the risk of dust explosions will always be played as a game of â&#x20AC;&#x2DC;catchupâ&#x20AC;&#x2122;.

Dust control plays a critical part in the conveying puzzle. If a transport system is not specifically designed to prevent the proliferation of explosive dust, the processing facility must play a dangerous balancing game between funding additional technology and adding labor force.

Cutting corners on

Figure 1

32 | March - April 2013

either, and you will risk dangerous explosions that can damage machinery and, most importantly, your workforce.

System explosions pose

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FEATURE a huge problem to the milling industry. Over the years, solutions have been sought in varying conveying systems such as bucket, screw, and drag, dilute and dense-phase pneumatic. While each system has its strengths and weaknesses, none control nor reduce the generation of dust.

The superior solution To address the problem of dust generation, Modern Process Equipment (MPE) of Chicago, IL, USA has developed the Chain-Vey, a tubular drag chain system that utilizes molded-on, food-grade discs pulled by a 316 stainless steel chain through a stainless steel tube. The result? A fully enclosed conveying design that contains dust and reduces product degradation through gentle and energy-efficient conveying. As a point of reference, the Chain-Vey acts similarly to a bucket elevator, gently carrying segments of product from one location to another. More specifically, the Chain-Vey offers a multitude of additional advantages including: - Completely enclosed design - Flexible design configurations - Long conveying distance capability - Multiple inlets and discharge points - Few moving parts and low maintenance - Energy efficiency

Typical Chain-Vey configurations Case 1 (Figure 1) Typical configurations can range from single inlet or single outlet, to a system with 10 inlets and 10 outlets with multiple twists and turns along the way. No matter the length or complexity of the design, gentle product handling is maintained throughout the conveying process.

Case 2 (Figure 2) In both cases above, (Figures 1 and 2), the product moves through the Chain-Vey via stainless steel chain and molded-on discs.

This chain is extremely durable and will not stretch, fray nor deteriorate.

Turns or corners in the system are accommodated through the use of ‘sweep elbows’ that can range from 10-90 degrees and are designed to minimise friction. When necessary, the design utilizes ‘live corners’ with rotating wheels that eliminate resistance, thereby enabling long runs and multiple turn situations.

Typical power requirements for the Chain-Vey range from 1-5 HP and, when compared to alternative conveying systems, such as dilute or dense-phase pneumatic systems, the energy savings can be as much as 90 percent. Assume that the requirement exists for a 100-foot conveyor length at a run rate of 12 hours a day and 250 days

a year. A Chain-Vey will achieve electrical energy savings between $5,000 USD and $10,000 USD per year.

In summary, MPE's development of the Chain-Vey conveyor technology meets the increasingly challenging demands of bulk product transport and is a flexible and efficient alternative to traditional conveying methods.

About MPE Modern Process Equipment Corporation (MPE) is a leading manufacturer of particle reduction equipment. MPE Granulizers achieve a very uniform particle grind distribution with minimal ‘fines’ for various products ranging from dry foods to chemicals and even abrasive minerals. MPE specialises in dry grinding applications where particle uniformity and grind consistency are desired.

MPE also manufactures the Chain-Vey, a tubular drag conveyor that is specifically designed for food, chemical and other bulk powder products. The MPE Chain-Vey can transport products up to 200 feet with minimal product degradation. Sanitary and CIP Chain-Vey designs are also offered.

More Information: Tel: +1 773 254 3929 Email: solution@mpechicago.com Website: www.mpechicago.com

The right storage solution starts with the right advice.

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Storage decisions can affect your operation for decades. That’s why so many companies around the world trust Westeel with their storage needs. Not only do we supply some of the most advanced storage products available, we support our products with the expert project leadership and sound engineering advice necessary to ensure that the decisions you make today continue to serve your company well for years to come.

2013-03-25 3:02 PM March - April 2013 | 33

FEATURE

Managing mill maintenance

Maintenance options and challenges

by Alice Neal, associate editor, Grain and Feed Milling Technology, United Kingdom

L

et’s be honest: maintenance is not the most glamorous topic in milling. It is rarely something that gets people excited or attracts a great deal of new inventions and technologies. However, I hear time and time again that well looked after equipment is just as important as raw materials in producing a top quality end product.

president, Feed Services, National Grain and Feed Association, United States.

One of the biggest difficulties in maintenance is cost. “The grain and feed industry is a highly competitive, low-margin business. Making the maintenance programme perform in the most cost-effective manner possible is an on-going challenge that every facility faces,” says Fairfield.

There are various types of maintenance and the type used will depend on the needs and resources of each individual mill. Regardless of the maintenance options used, a comprehensive maintenance programme is integral to the smooth running of a mill.

“The success of all aspects of grain and feed facility operations, such as quality, safety, housekeeping and customer service, is affected by the effectiveness of a facility’s preventive maintenance programme – making an appropriate programme a priority in today’s highly competitive market,” says David Fairfield, vice

Maintenance benefits

Approaches to maintenance David Fairfield, vice president, Feed Services, National Grain and Feed Association, United States explains the key maintenance options.

Reactive maintenance This approach follows the ‘if it ain’t broke, don’t fix it’ or ‘run-to-failure’ principle. Reactive maintenance is a form of maintenance in which equipment and facilities are repaired only in response to a breakdown or a fault.

This type of system has a minimal programme cost structure, but that can be offset by very significant costs associated with equipment repair and lost production.

Preventive maintenance A preventive maintenance programme includes procedures for inspecting, testing, and reconditioning equipment and other systems at regular intervals according to specific instructions. The goals in performing such procedures are to prevent failures in service and to prolong the life of the equipment or system.

This type of system typically provides the advantage of a defined framework in which maintenance activities can take place on a 34 | March - April 2013

Broadly speaking the benefits of an effective maintenance programme can be broken down into three categories: avoiding breakdowns; efficient equipment; a safe working environment. Preventing breakdowns helps avoid costly downtime and big repair bills. Equipment that is not looked after will, over time, stop working efficiently and will produce an inferior product. And as an employer, you have a duty to ensure that the mill is a safe place to work.

Changing maintenance Increased regulatory requirements have put

scheduled basis. A possible disadvantage of this type of system is that the ‘right’ maintenance mix is not achieved. When this occurs, a facility may in some instances experience equipment failures due to inadequate inspection and servicing. In other instances, it may be wasting maintenance dollars by spending too much time servicing and inspecting properly functioning equipment.

Predictive maintenance Predictive maintenance - often referred to as condition monitoring - may be defined as the use of maintenance techniques to help determine the condition of in-service equipment and systems in order to predict when maintenance should be performed. The ultimate goal of predictive maintenance is to perform maintenance at a scheduled point in time when the activity may be accomplished in the most cost-effective manner and before the equipment or system loses optimum performance.

Predictive maintenance techniques can be especially valuable for sophisticated equipment that is critical to a facility’s operation.

However, predictive maintenance may require specialised equipment and training, which may

greater emphasis on the importance of performing and documenting maintenance activities.

However, it’s not necessarily all about putting pen to paper and logging maintenance manually.

There is a variety of computer software on the market which has been specifically designed to track and monitor the maintenance process.

These programs can be part of automation systems designed for the whole mill or purchased as stand alone packages specifically to monitor maintenance.

A package will typically include systems for equipment data and repair history, parts inventory, maintenance schedules, maintenance work scheduling and report generation. “Frequently, each area within the program is interactive by design; for example when parts are used, the spare parts inventory levels are reduced and equipment repair history updated.

“This reduces the time required to manually update separate records and helps improve record keeping accuracy,” says Fairfield.

be too expensive when evaluated against the frequency, cost, and consequences of equipment failure.

Reliability centred maintenance A reliability centred maintenance programme establishes a program framework that helps ensure that the proper maintenance activity is performed at the right time, and that the equipment is operated in a way that maximizes its opportunity to achieve a reliability level that is consistent with the safety, environmental, operational, and profit goals of the facility. This is achieved by addressing the basic causes of equipment and system failures and ensuring that there are facility plans in place to prevent or lessen the business impact of such failures when they occur.

Establishing a reliability centred maintenance program typically involves a considerable investment in time to identify the appropriate maintenance regime for the facility. This type of programme may be best suited for large, complex operations, but once implemented can be cost-effective because targeted and appropriate activities are applied across the entire facility.

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FEATURE

Maintenance case study Name: Tom Smolen Job title: Plant Manager Company: Kent Nutrition Group Country: USA

Can you give a short overview of what you do?

I manage the overall operations of a livestock feed mill. We produce all types of animal feeds in meal and pelleted forms.

We are a one-shift operation, producing product five days a week.

How do you manage different types of maintenance?

Maintenance is a wide variety of forms, preventative, inspection, emergency, and training. When managing an operation you need to be sure all aspects are covered. As new pieces of equipment are introduced, you need to ensure your maintenance staff are upto-date on looking after it. Downtime needs to be scheduled and planned for within the parameters of production.

Everything revolves around customer service and quality. A mill needs the equipment functioning properly to deliver a quality product when the customer needs it.

What specific areas do you consider when thing about maintenance?

What are the consequences of not planning maintenance work?

All are critical to an operation. How can we do better, whether by new equipment or by changing how we utilize the existing equipment to perform better? Can we change something to improve our operation? Sanitation is critical since our end user is the consumer and they are buying the animals we manufacture for, so we need to consider the overall nature of our product and follow GMP’s and HACCP fundamentals.

A dirty operation and one that cannot stay operational.

Most companies are concerned about keeping costs down. How can good maintenance play a part in this?

How do you balance schedule planned repairs and up-grades with emergencies?

Emergencies take priority but we plan our maintenance to avoid having the emergencies. Doing the inspections and lubrications keep us ahead of emergencies.

What are the biggest problems you have related to maintenance? How do you deal with them?

It is always easier and cheaper to plan downtime on a piece of equipment, than have the equipment go down and now you need to spend excess time to either get it running and come back later to fix it, or overtime to fix it right. A well maintained plant runs smoother and stays cleaner.

Budgets. We plan our maintenance so we can follow our budget. As we follow our schedule we adjust our priorities and may have to put off some items until we can better afford to do it. That does not mean we disregard maintenance on items, we just delay some upgrades.

How important is it to have a maintenance schedule?

How much of an issue is downtime due to maintenance?

It is critical. When costs are tight, maintenance always seems to be the first thing to cut back on. But if one has a schedule to follow, then you can also plan your costs and control your budget better.

Almost non-existent.

What advice would you give to millers to ensure effective maintenance?

Just do it.

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March - April 2013 | 35

FEATURE

Super chilled grains P

by Joan Rius, managing director Conserfrio, Spain roducts such as grains, seeds, oilseeds, nuts, and similar are still alive when stored after harvest. Their vital activity consumes their own mass and oxygen, generating carbon dioxide, water and heat. This can create a multitude of well-known troubles such as stored product weight loss and quality decrease.

Graph 1: Adequate conditions for grain storage

Graph 2: Silo chilling sketch

Insect infestation is a particular problem in poorly stored grains. Insects eat and infect the stored product, which is also reheated due to their vital activity. Insects start their presence from 13ºC, although the real insect infestation occurs from 18ºC with a peak between 30ºC and 40 ºC for most insect species.

Mould presence and subsequently dangerous toxins, some of them carcinogenic, may enter into the food chain. Unfortunately, not all micro-flora presence is avoided by chilling the grain, since some species can survive below zero degrees centigrade. However, for the most part, micro-flora growth stays under control since most micro-flora species develop at temperatures between 20ºC and 40ºC. In addition, water condensation inside silos and warehouses, can make grains stick to the silo/warehouse wall and rot.

In the case of grains with a high oil or fat content, their quality decreases quickly due to the fat oxidation. Heat speeds up this unwanted process.

Some products change colour under inadequate storage conditions. For example rice changes colour from white to yellowish, and later to orange. The colour change is a clear indication of product damage during storing, and its price drops a lot.

The evidence Graph 3: Sketch of grain chilling in a warehouse 36 | March - April 2013

Graph 1 shows different effects of storing a product (in this case the graph is suitable for wheat and corn) under different condi-

Table 1: Weight loss of grain during its storage Case: Product: corn Amount: 1.000 MT Moisture: 15% Storage time: 3 months

Grain temp ºC

Weight loss, MT

Chilled grain

10 ºC

0.5

Temperate grain

20 ºC

6

Non-chilled grain

30 ºC

9

Non-chilled grain

40 ºC

30

tions of temperature and water content.

From the graph it is evident that a high product temperature or moisture, or both, will damage the grain irreversibly.

Table 1 shows the weight loss that occur during any grain storage depending on different grain conditions. In just three months, the weight loss may be the 3 percent of all storage. Quality loss occurs also although is not accounted in the table.

Solving storage issues Traditional methods to try and solve these issues include natural aeration. Under cold weather, ambient aeration is an excellent practice. It must however be expertly used since the different ambient air conditions between day and nights may create uncontrolled dryings or re-wettings of the stored product.

Under hot or hot and humid weather conditions, aeration is not applicable since the air does not have the right conditions to be blown into the stored product. If air is blown into the product under such conditions, there is a high risk of product reheating and product rewetting that will damage it soon.

&feed milling technology

Grain

FEATURE Grain chilling in a flatbottom metal silo

To reduce insect infestation, a common practice is the use of fumigation. The chemical products used have to expertly and carefully managed, for safety reasons. And do not decrease grain temperature.

The Conserfrio system ®

The Conserfrio ® system can be used

Warehouse grain chilling

All of these benefits give a very quick payback of the capital investment in the chillers, typically achieved in one or two years.

Our system is suitable to be used in silos (made of metal or concrete, flat bottom or conical bottom) and warehouses, not needing additional civil works. The cooling units need only electrical energy.

The chiller replaces the fan. The chilled, dry air is introduced into the silo through existing ducts.

In warehouses, the chilled air may be introduced through ducts placed under or over floor. In both cases a ducting system must be previously installed.

Conclusion

A low temperature is key point for a good storage

independently of ambient weather conditions. Even under rain or fog there’s no risk of rewetting the grain. Our system is based on the making of constant conditions under which the grain storage is easy, natural, safe and profit earning.

Practices like turning the grain to cool it have weak success and waste lots of energy, also breaking some percentage of grains.

There are many direct savings and benefits related to a correct chilled conservation.

The most important are: • Avoiding fumigation means cost savings • Less weight loss, in other words higher product output at the end of storage time • Higher product quality means a higher selling price • Higher head grains after the milling process. This point is especially important in the rice industry • Energy savings in the drying process. It is possible and safe to store product with a higher moisture content if grain temperature is low. A drying-cooling combination achieves relevant energy savings.

&feed milling technology

Grain

Refrigeration of a hopper silo

Grain chilling in a concrete silo

and grain storage facilities can all benefit of our technology.

Consergra is pioneer in the application of chilled aeration in many products.

Throughout the years, we have gained lots of experience in the bulk preservation of products such as paddy rice in all its varieties and lengths, cargo rice, milled rice, maize, wheat, barley, sunflower seeds, cotton seeds, beans, soybeans and green coffee beans to name but a few.

In benefit of the human and animal health and of the environment as well, grains and seeds must be responsibly treated as food.

More Information: Website: www.consergra.com

The system has demonstrated to be the most natural and cost-effective to preserve grains, seeds and perishable granulates during storage. A low storing temperature not only reduces the product vital metabolic activity but also most of the troubles of a storing without control.

Typical users of chilled aeration are from small farms with as little as 100 ton storage up to large plants with storing capacities of around 100,000, 500,000 or even 1,000,000 mt.

Rice mills, flour mills, feed mills, malting plants, oilseed crushing plants March - April 2013 | 37

PORTS

PORT REPORT New contracts for Schenck Process in the United Kingdom and Jordan Schenck Process has secured two major contracts for Redler mechanical conveying equipment for use in ports in United Kingdom and Jordan.

The contract in Liverpool, United Kingdom is for Peel Ports and is an extension to the animal feed storage facility valued at several million pounds. Schenck Process is acting as the M&E contractor for the bulk materials handling equipment and this will be interfacing with the existing system and supplying new high capacity 800t/ph chain conveyors, a long high level belt conveyor plus a MaxiStore and reversing shuttle conveyor complete with the site wiring, controls, installation and commissioning.

The project in Jordan is for the new grain terminal at the Port of Aqaba in Jordan. The contract valued at £4 million is a significant award with this being the third grain silo project secured in the past 12 months within the Middle East region.

The order is for five packages including the chain conveyors, belt conveyors, belt and bucket elevators, magnetic separators and bulk weigh scales with other business opportunities available within the project for Schenck Process.

Noise reduction project finally given green light in Vancouver Having received the necessary project 38 | March - April 2013

permits from the Vancouver Fraser Port Authority (VFPA), Canada, Cargill can now move forward with its noise mitigation project, first announced in April 2012.

The multi-phase project supports efforts to reduce noise impact levels caused by Cargill’s grain terminal located on Vancouver’s North Shore and will consist of the installation of two fan exhaust silencers, eight dust collector silencers as well as sound absorbing barriers along the north side of the facility.

The project also includes the re-distribution of ventilation fans to reduce noise levels for the nearest residences.

“We are looking forward to moving on to the next phase of this project”, said Gerry Dickie, general manager at Cargill’s North Vancouver grain terminal. “We understand the positive impact that these improvements to our facility will have on reducing the noise levels experienced by the surrounding community, and we are thankful to the VFPA for approving our plans.”

“We are very pleased to be supporting Cargill as it invests in its operations and the community through the noise mitigation project,” said Duncan Wilson, vice president of corporate social responsibility at Port Metro Vancouver. “Together with our tenants, terminals and partners in industry we continually coordinate investments to preserve the quality of life that communities have grown to expect in the busy and growing region of the Lower Mainland.”

Record grain exports at Melbourne Port Terminal February 2013 was a bumper month for grain exports at Emerald Grain’s Melbourne Port Terminal, Australia.

The grain handling facility has reported its strongest month of exports since it opened in 2000. During February, more than 185,000 tonnes of grain passed through the facility and on to eight destinations across Asia and Africa including China, Japan and Mozambique.

Glen Collision, general manager storage and handling, Emerald Grain said the record month was thanks to improved efficiencies across Emerald’s supply chain.

“Emerald has a long-term lease of two locomotives which transport grain quickly from Emerald’s storage sites in New South Wales and Victoria and through to the port.”

Melbourne Port Terminal’s previous highest month of exports was 145,000 tonnes in July 2012.

The terminal requires grain exporters to deliver a minimum 50 percent of grain via rail to help increase throughput.

“Emerald has also introduced an efficient truck-scheduling system enabling 4,000 tonnes road deliveries per day,” said Collison.

“The system assists with the flow of traffic through Appleton Dock and means logistics companies enjoy a much

&feed milling technology

Grain

GrainCorp able to transfer bulk grain capacity Australia’s competition watchdog, the Australian Competition and Consumer Commission (ACCC) has agreed GrainCorp’s plans to allow customers to transfer grain capacity to other users in its port network.

“This change will result in a more efficient use of port terminal capacity by reducing the chance that capacity will go unused at peak times,” said Joe Dimasi, ACCC commissioner.

A similar system is already implemented by other operators including CBH and Viterra.

At present GrainCorp handles the majority of grain shipping from eastern states on a first come first serve basis. It’s hoped that the new system, which comes into effect on April 23, 2013, will help reallocate capacity to its most economically efficient use. The revised protocols are available on GrainCorp’s website.

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WELCOME TO THE TWENTY FIRST EDITION OF THE INTERNATIONAL MILLING DIRECTORY

ila

First birthday for CBH and Watco rail partnership On March 30, 2013 the CBH Group and Watco reached their first year anniversary working together to move the state’s grain harvest on rail.

Colin Tutt, general manager operations, CBH Group, said that since CBH and Watco ran their first rail service from Kwinana twelve months ago, nearly 5 million tonnes have been moved on rail.

“Together, we have moved 3.5 million tonnes into Kwinana port and Metro Grain Centre, and 1.5 million tonnes into both the Geraldton and Albany ports,” he said.

“We have been through a transition period during these first 12 months while the new locomotives and wagons were slowly brought online.

We are extremely pleased with the volume of grain that has been moved on rail, especially in the wake of the record 15 million tonne crop of the 2011-12 season.

“This performance will improve over time to provide Western Australian growers even more efficiency and lower freight rates.”

Watco WA Rail provide rail logistics services to the CBH Group including train crewing, planning, scheduling and tracking, rolling stock maintenance and inventory control.

Watco WA Rail chief operating officer Jim Griffiths said that while there have been some teething issues and challenges in operating on the WA tracks, overall the efficiency of the fleet is performing very well.

“In some instances the new locomotives and wagons can in pull up to 25 percent more grain to port with each journey, so while we are limited by track infrastructure, the increased load capacity helps us to better achieve tonnes to port,” he said.

http://www.perendale.com

faster turnaround. “Everyone along the grain supply chain benefits from port efficiencies. “Growers see better returns on their grain, exporters can meet their shipping slot requirements and international customers have access to high quality grain from south eastern Australia.”

Most grain leaving the port over February was exported in bulk (loaded directly into the ship’s hull) while around 20,000 tonnes was packed in containers.

“Some African destinations don’t yet have the capacity to receive grain in bulk.

Melbourne Port Terminal’s container packing facility means Emerald still has the ability to reach this important export market,” said Collison.

Emerald took control of Melbourne Port Terminal’s operations when it acquired storage and handling group Australian Bulk Alliance in March 2012.

The facility has 48,000 tonnes of onsite storage and the capacity to export more than 1.2 million tonnes of grain per year.

March - April 2013 | 39

FEATURE

Importance of trace minerals for nutrient stability in feed and optimized trace element supply of animals

by Dr Detlef Kampf, Orffa Additives, The Netherlands

T

race element supplementation element availability is dependent on health legal limits inevitably raises the question of to maintain optimal health and and also on the presence of stress. The trace trace elements with high bioavailability, and performance in livestock is often element bioavailability, however, depends to understand even at lower concentrations underestimated. This is partly due to the further on a number of factors such as in the feed the supply to the animals and fact that trace elements perform very performance stage, trace element status, also the possible additional effects at least complex functions in the metabolism and form of the chemical bonds, trace element partially.

Important for absorption of, for example, deficiencies can lead to general disorders in dosage and antagonists which inhibit absorpanimals and due to the important physiolog- tion (Flachowsky 2000). The lowering of the zinc, manganese and copper are the mutual interactions as well as the dieical functions it is therefore tary amounts of iron, calcium, necessary to provide them to Table 1: Legal limits for trace elements in animal compound feed phosphorus, potassium and the animal through the feed.

Max. content in sulphur and further antagoOn the other hand, higher Trace compound feed Species nists. Unbalanced or high levels allowances for example of element (mg/kg of some of these elements zinc and copper have also compound feed) lead to shortages of the other specific effects on intestinal elements. For example, a zinc health. To address the difficult Piglets until 12 weeks of age 170 surplus will cause copper transdiscussion about physiology, port across the enterocytes intestinal health and finally Bovine before the start of rumination 15 (intestinal epithelial cells) to be environmental pollution too, Other bovines 35 blocked due to the formation the supply of trace elements Copper Ovines 15 of intestinal metallothionein. in the EU is regulated by law This is also recognised as a (EU Regulation 1334/2003).

Crustaceans 50 secondary copper deficiency.

Several years ago, the Other animals 25 Other factors affecting the maximum concentrations Cobalt All species 2 availability of trace elements in the feed were significantare, for example, mycotoxins, ly lowered again to reduce Equines 4 crude fibre, tannins and phytic the heavy metal output in Dairy cows / Laying hens 5 acid (Schenkel and Flachowsky the environment (Table 1).

Iodine Fish 20 2002).

Impact on bioavailability It is known that the bioavailability of trace elements is difficult to compare due to the anatomy of the digestive tract between the different species. In addition, the trace element uptake capacity of the intestine decreases with increasing age of the animals in general. Furthermore, recent studies show that the trace 40 | March - April 2013

Iron

Manganese Selenium Zinc

Other animals

10

Piglets until 1 wee before weaning

250

Ovines

500

Pet

1250

Other animals

750

Fish

100

Other animals

150

All species

0,5

Pet

250

Fish / Milk replacer

200

Other animals

150

Characterisation and differentiation The various feed additives approved as trace element sources can be distinguished in terms of their availability for the animal. The best-known and largely used inorganic trace mineral sources of sulphates and oxides vary mainly due to their solubility. The main task of these trace mineral sources is to dissolve in the aqueous

&feed milling technology

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FEATURE medium of the digestive tract and sulphates are attributed to a higher value than oxides.

A product with very low solubility, for example, copper oxide, therefore should not be used (any longer) in feeding livestock.

(degradation and damage of sensitive ingredients such as vitamins or fat as well as forming harmful free radicals and peroxides and reducing palatability of feed) (Miles et al. 1998; Lu et al. 2010; Pang and Applegate

Graph 2: Impact of increasing dosages of various copper sources on the phytate phosphorus hydrolysis by phytase (Pang and Applegate 2006)

Graph 1: Impact of various copper sources on the concentration of vitamin E in feed (Lu et al. 2010)

The good solubility of sulphates, however, provides us with the disadvantage that for example dissociated copper ions are very reactive (strong pro-oxidant that initiate and speed up oxidation) and therefore promote adverse reactions with feed components

2006; Shurson et al. 2011).

In contrast to inorganic, organically bound trace elements (trace element chelates) are stable in the diet and absorption by the animal is improved due to their chemical structure. Their advantage is thus superior

2012

March - April

January - February

2012

2012

November - December

2011

October

compete for the same absorption capabilities. The positive effects of organically bound to inorganic trace elements were confirmed in numerous scientific studies (Kincaid et al.

1997, Nockels et al. 1993, Wedekind et al.

1992). Nevertheless, an adequate assess-

CONFERENCE

See our previous editions online for free May - June

in isolation from the solubility of inorganic trace elements, but also in reducing the absorption-inhibitory responses in the digestive tract. These are mostly antagonistic interactions with feed components that

2011

In this issue: •

LC-MS/MS:

•

Mould control

The New Reference Method for Mycotoxin Analysis

•

Assessing cereal quality parameters

•

Grinding by a proven concept makes your choice simple

•

Bulk storage & handling

•

Efficiency

•

Animal feed milling is one of the most buoyant activities in the agri related field

In this issue:

•

in grain and feed preservation

Fast, reliable and flexible: the world of modern bulk weighing

In this issue: •

NIR in practice

•

Rice and contract terms

•

•

New weighing software for UK co-operative

A subscription magazine for the global flour & feed milling industries - first published in 1891 GFMT12.03.indd 1

Controlling Insects with heat

•

Improving supply from farm to fork

•

Victam Asia Product Showcase

•

Global grain & feed markets

GFMT12.02.indd 1

•

Preservatives Preservatives are a recurring topic in public discussions

Increasing storage capacity

•

•

Digital microwave moisture measurement

•

Global grain & feed markets

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

A subscription magazine for the global flour & feed milling industries - first published in 1891 22/06/2012 08:48

Energy saving in flour milling

In this issue:

•

17/04/2012 13:05

GFMT12.01.indd 1

African advances

•

•

Mycotoxins an overview

•

Database for animal diet formulation techniques: A glance to last decade

Get in line Process analysis solutions open new opportunities for improved profit and quality

Optical sorting Optical sorting has come of age and should be considered as a serious option for inclusion in any modern wheat cleaning plant

•

Food safety in the grain milling industry

•

Recent advances in rapid grain testing

GFMT11.06.indd 1

Producing Flaked breakfast Cereals

•

Milling Technology Redefined

•

A subscription magazine for the global flour & feed milling industries - first published in 1891 02/02/2012 10:12

•

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

•

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

•

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 30/11/2011 17:28

GFMT11.05.indd 1

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March - April 2013 | 41

FEATURE

Graph 3: Impact of increasing dosages of various copper sources on the oxidative stability of soybean oil (Kampf 2012)

Graph 4: Relative bioavailability of copper from hydroxy copper compared to copper sulphate in cattle (Spears et al. 2004)

Graph 5: Relative bioavailability of zinc from hydroxy zinc compared or zinc sulphate in cattle (Schaeffer 2006)

Graph 6: Solubility of zinc from hydroxy zinc and zinc sulphate and impact on production of volatile fatty acids in the rumen (Schaeffer 2006)

ment of the quality of organically bound trace elements must be taken. It should be noted at this point that the products on the market significantly differ in quality that can be checked by simple analytical methods (Helle and Kampf 2008).

Traditionally, minerals have been categorised as either organic or inorganic. In 2012 a new category of trace minerals, known as hydroxy trace minerals, obtained EU approval as a feed additive for all animal species. These new products (Di copper chloride tri hydroxide – Cu2(OH)3Cl – and Zinc chloride hydroxide monohydrate - Zn5Cl2(OH)8(H2O) – brand name: IntelliBond®) belong in the group of inorganic trace mineral sources, but have similar chemically stable structures such as organically bound trace elements. Covalent bonds and a unique crystalline matrix structure provide a reliable stability, which differentiates hydroxy trace minerals from other organic or inorganic minerals.

In addition, there are major advantages from a nutritional point of view. In comparison to copper sulphate, these products are virtually insoluble at neutral pH, which provides increased trace mineral stability in the intestine. Less reactive trace element ions occur in the upper digestive tract, which 42 | March - April 2013

is associated with fewer interactions with other feed components. There are already numerous studies that demonstrate in comparison to sulphates the better protection of feed components (Lu et al. 2010; Miles et al. 1998; Pang and Applegate 2006). Due to the crystalline structure the trace elements are slowly released over the full length of the small intestine resulting in more efficient trace element absorption and a very good effect on intestinal health. Trial results in all animal species confirm the superior effects compared to sulphate (Allee et al. 2011; Luo et al. 2005; Miles et al. 1998; Spears et al.

2004, Shao et al. 2010).

Effects of various trace element sources in feed Improved stability of sensitive feed ingredients by using stable trace element sources e.g. chelates or hydroxy trace minerals in comparison to sulphates was already demonstrated in many trials (Miles et al. 1998; Lu et al. 2010; Luo et al. 2005; Banks et al. 2004; Liu et al.

2005; Pang and Applegate 2006; Shurson et al. 2011; Kampf 2012). All these results are based on the non-hygroscopic and nonreactive (non-pro oxidative) characteristics of these trace element sources. In one example copper from copper sulphate at a high dosage

level showed a negative impact on vitamin E stability in feed and in contrast, hydroxy copper was not negatively affecting the stability of vitamin E and showed comparable results as by using lower levels of copper sulphate (Lu et al. 2010; graph 1).

In another trial increasing dosage levels of copper sulphate were tested in comparison to other trace mineral sources on the phytate phosphorus hydrolysis by phytase In vitro. In this study copper sulphate has shown due to the high solubility and hence a high reactivity (formation of insoluble complexes with phytate) a strong negative impact on phytate phosphorus hydrolysis. In contrast, as well as the copper lysine complex and the hydroxy copper did not influence the phosphorus hydrolysis (Pang and Applegate 2006; Graph 2).

A recent trial was conducted to test the direct negative impact of copper from various copper sources and different dosages on the oxidative stability of soybean oil under Rancimat test conditions. In this study a strong negative effect of the copper dosage was observed. Beside this copper sulphate reduced the oxidative stability relatively by 9 and 46 percent, in contrast hydroxy copper only by 5 and 36 percent respectively (Kampf 2012; Graph 3).

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FEATURE

Effects in animals Much trial work has been carried out in monogastrics and in ruminants where stable trace element sources for example chelates or hydroxy trace minerals confirmed better effects when compared to sulphates with regards to an improved bioavailability, intestinal efficacy and gut health (Allee et al. 2011; Kidd et al. 1996; Luo et al. 2005; Miles et al. 1998; Nollet et al. 2008; Spears et al. 2004; Wedekind et al. 1992). This is based on the fact that stable trace element sources are, in contrast to sulphates, insoluble at neutral pH and will due to the covalent bond structure only partially dissolve in the acidic environment of the stomach. As a consequence more intact molecules will be available and effective in the lower parts of the digestive tract, which results also in improved gut health.

In one example in broilers a 13 to 16 percent higher bioavailability (expressed as tendon copper, 10 d deficient model, 0 - 6 ppm Cu) of hydroxy copper was measured in contrast to copper sulphate. In a second trial (same trial conditions) a 25 percent higher bioavailability for hydroxy copper and 35 percent for copper chelate was measured (Klasing and Naziripour 2010). Other research groups figured out a better relative biological value of organic zinc chelate by 1.64 (measured as tibia zinc content) compared with zinc sulphate as a reference zinc source (1.00) in broiler (Star et al. 2012).

Not statistically proven but nevertheless numerically higher broiler tibia zinc concentrations especially in combination with a phytase supplementation was examined by Schlegel et al. (2010). In a recent meta-analysis the same authors reported that broiler bone Zn responded slightly better (not at significant value) to organic zinc than inorganic zinc with increasing zinc levels (Schlegel et al. 2013). Noteworthy is the fact that in all these experiments in advance of the measurements no zinc deficiency situation has been created, whereby the positive effect of a more readily available source of zinc would have manifested better.

In another example Allee et al. (2011) showed that increasing dosage levels of hydroxy copper from 15 to 200 ppm in piglets resulted in significant linear increases in average daily gain (ADG) and average daily feed intake (ADFI) at 7, 21, and 42 days on test. Feed conversion ratio (FCR) was improved linearly by addition of hydroxy copper over the 42-day trial. In this trial the dose/response relationship of hydroxy copper on daily gain and feed conversion in piglets (0-42 days) resulted in a breakpoint of the maximum copper effect already at a dosage of 130-140 ppm (in comparison maximum copper effect of copper sulphate is at around 200-250 ppm) which indicates that hydroxy copper has a higher intestinal efficacy and is more valuable on gut health as copper sulphate (Allee et al. 2011).

In ruminants the positive effects of organically bound to inorganic trace elements were confirmed in numerous scientific studies and the major advantage was a better bioavailability compared to sulphates under the presence

&feed milling technology

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of stress or antagonists (Kincaid et al.

1997, Nockels et al. 1993, Wedekind et al. 1992). In diets containing copper antagonists like molybdenum and sulphur a higher relative bioavailability of copper (based on plasma copper, plasma ceruloplasmin and liver copper) from hydroxy copper compared to copper sulphate was measured, too (Spears et al. 2004; graph 4). In another trial of the same research group the relative bioavailability of zinc from hydroxy zinc compared to zinc sulphate based on plasma zinc, and retained zinc, respectively, was also determined as better (Schaeffer 2006; Graph 5).

In an additional trial the amount of soluble zinc was measured and compared with the production of volatile fatty acids in the rumen (Schaeffer 2006; Graph 6). Zinc sulphate delivered higher concentrations of rumen soluble zinc and showed a negative impact on the microbial fermentation (expressed as production of volatile fatty acids). In contrast zinc from hydroxy zinc was less soluble in the rumen and therefore not influencing the rumen microflora (Schaeffer 2006; Graph 6). This fact could be the explanation for a direct effect of trace elements on milk yield improvement in dairy cows.

The supplementation of trace elements plays an essential role in maintaining optimal health and performance of livestock. When considering the supply of trace elements not primarily the absolutely fed, but the usable amount of trace elements for the animal is crucial. This requires accurate knowledge of the composition of the feed and if possible, the diminishing availability of trace elements and interactions with other feed ingredients. The trace element supply can be improved by the use of high-quality trace mineral sources such as organic chelates, however, the assessment of the used quality is essential.

Another new form of high-quality trace elements are hydroxy trace elements, which recently received EU approval and which are characterised by excellent stability and processing properties together with a high physiological significance. The positive effects of chelates and hydroxy trace elements in feed (better stability of sensitive feed components and ingredients) as well as in animals (higher bioavailability) have been already confirmed in numerous publications.

Literature is available upon request from the author.

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March - April 2013 | 43

513459_GrainFeed_47x270_gb_4c_RZ.indd

126.03.13

11:19

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.

Some analysts have forecast a 5% decline in combined Russian/Ukrainian sunflowerseed sowings with Ukraine alone down 7-10%, after less land was freed up for spring crops by ‘winterkill’ of autumn-sown grain crops. Ukraine farmers might also have been deterred by a 17% drop in last year’s yields due to lack of timely rains.

44 | March - April 2013

Crop hopes should keep raw material costs in check

H

OPES of a major rebound from last season’s disappointing crop performance put wheat prices under further downward pressure for much of the period since our last review and helped restrain frisky corn/soya prices too. On the leading Chicago futures market, the bellwether soft red winter wheat contract fell at one stage to as little as $247 per tonne for near delivery compared with last July’s peak of about $347.50.

European soft milling wheat followed suit despite a weak euro and rapidly disappearing supplies from last year’s smaller than expected crop, at one stage reaching eight month lows of €232/tonne on old-crop months. Traded prices on world export markets also declined, soft milling wheats settling about $20 either side of the $300/tonne level on fob terms. For US soft red winter wheat that was about $60/80 cheaper than last summer’s peaks.

Two factors have driven wheat market weakness.

One is the widespread idea that this year’s global crop might actually come close to the 2011 record 697m tonnes as output recovers in the former Soviet Union and Europe and increases in Canada and Australia. That total may be a bit optimistic, given the poor start to the US hard red winter wheat crop and a number of weather issues in western Europe and Russia. Still, a healthy addition to next season’s wheat supplies is nonetheless backed by bodies including the International Grains Council, the UN Food & Agriculture Organisation and the US Department of Agriculture (whose unofficial forecasts have been among the highest).

That said, the view seems to be gaining hold that next season’s world surplus stock of wheat will not increase much as demand increases too.

But then, global stocks are hardly small to start with, having run close to the record 200m tonne level for the past three seasons and – even in his supposedly tighter year - still expected to finish at a comfortable 178m. This relatively small decline has been due to total wheat consumption falling this season by almost 25m tonnes. Although the US

raised its wheat use by 4m tonnes (to meet feed shortages after its small maize crop) consumption elsewhere fell far more steeply, mainly in the EU, Russia and Ukraine. Their combined decline, mainly in feed use, resulted in world total consumption in this sector dropping by almost 13m tonnes.

The other factor weighing on wheat prices has been export competition, which has been sustained for far longer than many had expected at the start of this season when it was becoming clear that ‘Black Sea’ harvests were going to disappoint again. In the event, Russian exportable supplies are thought to have collapsed by 11m tonnes while two other key exporters, Argentina and Australia are also expected to each ship 4m tonnes less than in the previous season. But on the other hand, Indian exports are seen increasing by 7m on-year to a new record 10m tonnes versus zero normally.

Canada’s sales are also seen rising by 1m, Europe’s by 3m. At the same time, this season’s world import demand has dropped away by 12m tonnes, (after declines in Egypt, EU, Africa, Middle East), leaving exporters competing for shares of a smaller cake.

Interestingly, this has occurred despite constant reports that wheat’s unusual discount to maize is pushing the coarse grain out of Asian feed markets.

Some analysts had expected wheat prices to firm up when Russian and Ukrainian supplies started to dry up at the turn of the year. However, India, burgeoning with record stocks and with another huge crop around the corner, then stepped up as the cheapest export offer - but quickly found itself still in a pricing (and quality) contest with US and European soft wheats too. Along with the continued presence of Canada and Australia and – even yet - small volumes of wheat still trickling out of Russia and Kazakhstan, there has been no apparent shortage for importers wanting to take advantage of the drop in wheat prices (up to 22%) from last summer’s highs.

While there has been no real justification to push prices up, US wheat futures markets have gone firmer again in the past month. This is partly

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COMMODITIES

due to US exports finally picking up and even starting to approach the needed pace for the (recently reduced) official forecast for the season. At the same time, maize has extended its unusual price premium to wheat on both the US futures and physical markets, leading to a steady surge in wheat orders from domestic feeders and even from the US ethanol industry (despite wheat’s lower value in terms of starch/fuel production canceling out much of the advantage of its price discount v maize). However, possibly some of those substituting wheat in this and other sectors may be using it as a bargaining tool to keep their maize costs under control.

Along with the higher exports this picture of improving US wheat demand (although not yet proven in the official seasonal forecasts for US wheat usage) has begun to unsettle the speculative community. For some time, funds and other ‘outside’ investors had built up record large short (sold) positions on the futures markets, effectively betting on wheat prices falling further rather than rising. As these operators have been forced to cover their exposure, that has injected a self-fuelling element into the rally on the Chicago markets.

In recent weeks, along with strong EU exports and a weak euro, the US trend has also spilled some strength into the European wheat market and into international wheat export prices to a lesser extent (Paris milling wheat futures recently at six-week highs).

However, this latest mini-rally would not have been possible without some help from a relatively firm maize market, the latter underpinned by an ever tightening supply after last year’s short US crop. As the IGC reminded markets this past month, it is not only US stocks of maize that will finish 2012/13 at unusually low levels. World stocks are also expected to fall to a 16-year low. However, if all goes well with the coming US and other world crops of maize, that inventory could be back to an eight-year high by September 2014.

All this, of course, has implications for wheat demand and value. If maize prices do shift, as futures promise, from their current modest premium over wheat to a steep 24% discount

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by the end of the calendar year, wheat demand and pricing will clearly be affected.

Like wheat, maize is also s e e ing lowe r world demand – a 6.7% fall in this season’s exports on the back of a 10% drop in consumption. A big US maize crop this summer will – provided world supplies keep at least steady too - result in a lot more maize and less wheat being fed there.

Cheaper prices should also boos t overall feedgrain use (The IGC sees barley output up 6% too).

At this stage – a US maize crop rebound is expected of at least 30 % from this year’s unusually low 274m tonnes to around 360/370m tonnes. Thatv will not only boost demand but replenish US s tock s, helping to keep forward maize prices down through the coming season.

However, we

must also remember, the US crop has only just begun sowing and, as recent wet conditions have reminded traders, there remain a world

March - April 2013 | 45

of weather possibilities to get through yet.

Wheat – export competition may keep prices down The biggest single factor affecting medium/long-term wheat costs in the months ahead will by the success or otherwise of ‘Black Sea’ (CIS) attempts to recover production from last year’s disappointing , dr oughthit levels. Russia has had one or two problems with winterkill and dryness in its key southern (export supply catchment) area and officials are currently talking a wide crop range of 40/50m tonnes (probably near the median 45m) compared with last year’s 37.7m and 2011’s bumper 56.2m tones. A few years earlier, Russia was producing over 60m so this year’s crop would hardly be a banner one. Russian stocks will also be very low by the end of this season and officials have talked about giving priority to rebuilding these before embarking on any aggressive export campaign.

Even so, some Russian exporters have already started selling some of the new crop forward as cheaply as $265/275/tonne fob terms – a massive discount to domestic old crop costs.

This strategy may also risk exporters have to compete with the government when they come to source the sold grain as officials want to prioritise rebuilding depleted intervention stocks and are reportedly also planning to offer prices equivalent to $250/290/tonne. That said, the Russians have historically gone for the early season import trade and they have a ‘reliable supplier’ reputation to rebuild for their future trade expansion plans (see GFMT’s passim) so their early, active presence can’t be ruled out. Last year’s Russian exports more than halved to 10.5m tonnes but the coming season could see a rebound to maybe 14-15m tonnes. There have been a few 20m forecasts which, given perfect summer weather, can’t be ruled out.

Ukraine has had an exceptionally kind winter with little frost damage and most of its wheat crop is in good condition. There has even been talk of the total (winter abnd spring) crop reaching a record 21m tonnes versus last year’s 15.5m and the 2011 record 18.8m.

Ukraine has also got off to a flying start with its spring plantings and looks likely to have another huge maize crop which will reduce wheat feeding and leave more for export. At this stage, traders are talking 8m to 9m tonnes of exports versus this year’s 6.,5/7m but that

46 | March - April 2013

figure could go up too. Kazakhstan should also see some comeback in wheat output after drought cut last year’s crop from 22.7m to 9.8m tonnes and exports from 11m to 6.5m.

If the Black Sea crops do come back as planned, they will be up against more competition for world import trade – from India (maybe another 10m tonnes of unusual expor ts) and from expected bigger EU, Canadian and Australian crops, with the usual caveat of normal weather permitting across the board. The main exception is the world’s largest wheat exporter, the USA, where drought has diminished prospects for its hard red winter crop – its biggest (and therefore the world’s) single country export component.

However, even that crop is improving with recent rain and snow. With old crop HRW exports running lower on lack of demand and comfortable stocks of this class and wheat in total likely to be carried into 2012/13, the US should still be able to export freely.

Will world wheat trade recover from this season’s 12m tonne drop? There are no obvious contenders yet to boost the figure in the import side and the top buyer Egypt has run out of trade finance and is cutting back sharply on purchases. Will as much wheat be fed to livestock in the US, Asia feed markets etc? Probably not, if corn production rebounds as much as forecast, returning to its usual discount versus wheat. However, countries which normally use a lot of wheat in feeds – but had to cut use during the past tight/ expensive season (especially Europe and the CIS) may use more as supplies rebound and prices come down.

Overall, the outlook is for adequate wheat supplies. Barring several severe weather upsets (realistically there are always one or two), the forward new crop prices quoted on the

US wheat market currently look too high – especially against maize which is now heavily discounted for last quarter 2013 against the spot market and at a huge discount to forward wheat prices too. European wheat markets in contrast, are heavily discounted on new crop, Paris milling wheat futures 10% to 12% below current crop prices, mainly on the assumption that domestic wheat crops will increase this summer.

In conclusion, amid higher global output, increased export competition, limited import recovery prospects and less pressure to feed wheat instead of maize, the European market’s prospect of cheaper wheat costs ahead starts to look more realistic than the picture painted by US futures.

KEY FACTORS IN THE MONTHS AHEAD – WHEAT • The extent of European and Black Sea crop rebounds from last year’s disappointing levels • Spring, summer and harvest weather in the northern hemisphere • The extent to which wheat use in feeds is reduced if maize crops recover as planned

Maize –season of plenty ahead?

Crosscurrents have continued to tug at maize prices, restraining the price advance to about 6.5% compared with the near 10% added to wheat’s February lows. The main factor on the upside has been that spectre of low end-season stocks, especially after USDA recently added 2.5m tonnes to its US feed use forecast. There have also been reports of recovering demand from the US corn ethanol sector (40% of US maize disappearance). This has all made farmers cautious about parting with their remaining old crop stocks, expecting to get higher prices for as these as supplies dwindle in last quarter 2012/13 (Jun/Aug). This strategy is not without risk, though, as the US futures markets say maize will be cheaper by well over $1/bushel (about $47/tonne or 16.6%) from July to September, dropping by another 5% by December.

At the same time, competition for maize import business on international markets is heating up to an almost unprecedented degree.

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COMMODITIES

Thanks to a vast improvement in weather over first quarter 2013, Latin American maize crops are now expected to reach record levels.

Argentina’s is up from 21m to 25/26m, Brazil’s from 73m to perhaps 76m. Between them they could export 45/47m tonnes compared with 15/25m normally. Ukraine, which for the second year running, produced twice as much

corn as usual in 2012, is now expected export in 2012/13 close to last season’s record 15m tonnes exports. The competition has been undercutting US maize by as much as $20/30 per tonne, resulting in constant downgrades to USDA’s seasonal export forecast for this grain. At 22.5m tonnes this will be the lowest on modern record – less than a quarter of world maize trade against well over half normally.

With the full brunt of LatAm harvests yet to be marketed, their dominance is likely to remain – at least until the next US crop proves its forecast recovery and can then be offered at those much cheaper prices indicated by the futures markets.

Even then, the US could be facing yet another year of increased competition from the Ukraine which expects to harvest about 21m tonnes again this year. The EU’s own maize crop – which fell 11.5m tonnes last year – could also rise sharply with more normal

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Assessing prospects, addressing challenges World grain and oilseed prices have retreated from their highs, but supplies remain tight following last year’s poor harvests in key exporting countries. While South American crops look set to break new records this season, drought conditions in the US remain a concern, and a recovery in demand will keep supplies under pressure.

With renewed price volatility, biofuel mandates have come under intense scrutiny, and the potential for policy-driven restrictions to trade, particularly should harvests disappoint again, are an enduring market concern.

The IGC Grains Conference brings together key decision makers, industry representatives and other stakeholders to discuss the latest developments in the grain and oilseed markets together with the policy challenges they present.

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weather. The Commissions crop forecasting unit MARS recently forecast yields rebounding by almost 17% which would add at least 9m tonnes to this year’s production.

KEY FACTORS IN THE MONTHS AHEAD – MAIZE • US maize planted area and growing weather will decide if US/world stocks return to ‘normal’ levels, prices fall as futures forecast • Rising global export competition for the USA from Latin America, CIS countries and India may contribute to cheaper maize costs ahead • Will Europe’s own maize crop rebound, easing supplies here?

• US corn consumption for ethanol seems to be picking up again and could be a mildly bullish factor for prices • China’s growing feed demand and its maize deficit – will it stabilize or expand in 2013/14, demanding more from the world market?

• Speculators’ enthusiasm to buy into any crop weather problems Proteins/oilmeals - demand to mop up extra soya?

The oilmeal sector also remains promising for cheaper costs ahead. Improved weather is

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www.iaom.info/education March - April 2013 | 47

helping record Latin American crop forecast materialize and, if the US sows as much as most analysts expect – and gets more normal weather/yields this year – supplies will be more than adequate in 2013/14.

Some question marks remain over 2013 crops of other key oilseeds like sunflowers and rapeseed. However, the sheer size of the increase in soya supplies should be enough to push up world total oilseed production by some 26m tonnes or about 6% . All these alternative oilmeals, of course, cannot divorce their pricing from the market leader soya meal – accounting for 55% of total meal output and with its higher protein content, the most valuable meal too. Currently the futures markets are predicting US soya meal prices will be over 15% cheaper by last quarter 2013 although, if all the US production comes through, that may considerably understate the potential decline in costs in this sector.

Sunflower/rapeseed prospects Some analysts have forecast a 5% decline in combined Russian/Ukrainian sunflowerseed sowings with Ukraine alone down 7-10% , after less land was freed up for spring crops by ‘winterkill’ of autumn-sown grain crops.

Ukraine farmers might also have been

deterred by a 17% drop in last year’s yields due to lack of timely rains. EU sunflower output is meanwhile forecast by French analyst Strategie Grains to rise by over 11% to 7.8m tonnes but stocks of sunflowerseed in EU and global terms will be unusually low at the start of next season, so domestic supplies may still need a bigger top up than this from imports.

European rapeseed crop prospects are mixed as northwest France and the UK had far too much rain, waterlogging, intermittent mild weather and freezing blasts. Some reports suggest 20% or more UK winter sowings could fail. However, Germany, Denmark and some eastern states are looking better than last year with less frost damage, so the total EU figure could yet increase within a range of 18.5/20.5m tonnes. Like sunflowerseed, rapeseed has drawn stocks to very low levels in EU and global terms so supplies are unlikely to be loose next season. On the bright side, Ukrainian crop prospects are much better than last year’s so more could be exported from this frequent EU supplier. The largest exporter, Canada expects to sow less canola as farmers shift to wheat but, providing this year’s slow snow melt doesn’t hold up sowing, a return from last year’s weather-hit yields (they fell 20%!) to normal levels could yet

yield a record crop on the planned area.

Down under, Australian rapeseed output was recently forecast to increase from last year’s 3.64m to about 3.5/3.7m tonnes, some estimates even approaching 4m which would be welcomed by impor ters. With world stocks at a nine-year low, bigger rapeseed crops are needed this year to avoid short supplies towards the close of next season although rapeseed meal, as noted above, will have to continue pricing at a discount to what it is hoped will be relatively abyndant soya meal.

KEY FACTORS IN THE MONTHS AHEAD – OILMEALS/PROTEINS • US spring soyabean planting and growing weather • South America’s delayed marketing of a record crop – more competition ahead for the USA’s peak, post-harvest marketing period and further downward pressure on soya costs?

• Chinese demand for soya meal – is it starting to peak or just pausing for breath?

• EU/CIS rapeseed & sunflowerseed and Canadian canola plantings - and their crop weather

WANT NEWS?

Grain & Feed Milling Technology magazine has two new options for you - online and up to the minute!

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The Global Miller blog is an online offshoot of Grain & Feed Milling Technology magazine.

While the bi-monthly magazine covers milling issues in-depth, the Global Miller takes a lighter approach. The columnists dig out the best daily industry stories, show and event news and highlights from the print magazine and bring them to you ever day ...

The Global Milling News service is a new development from the Perendale Publishers Limited family of grain, feed and flour milling publications. The site scours the web to find relevant stories from around the globe. The information is then ranked and orgnaised by topic, making it easy to find information. If you’re searching for a specific topic, you’ll find it at Global Milling News.

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48 | March - April 2013

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FROM OUR ARCHIVES

In the footsteps of Broomhall

In the footsteps of Broomhall In this issue we take a look back at the new products on the market 60 years ago.

50 | March - April 2013

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FROM OUR ARCHIVES

&feed milling technology

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In the footsteps of Broomhall

March - April 2013 | 51

2013

PRODUCT

SHOWCASE

XTREME DUTY (CC-XD) ELEVATOR BUCKET Tapco Inc.’s 508mm x 254mm (20" x 10") Xtreme Duty (CC-XD) elevator bucket — with 26,837.64mm (1,056.6 cubic inches (rated at industry standard of 110% of water level) of actual capacity — runs at speeds up to 940 fpm. The 508mm x 254mm (20" x 10") CC-XD features a 15.875mm (5/8") thick rounded front.

The buckets are made with 35%-50% more resin throughout, and are available in nylon, urethane and polyethylene. U.S. Food and Drug Administration (FDA)-compliant resins are standard in polyethylene and urethane.

FDA-compliant nylon resin is available by special request. For more information, contact Yassine Abbad at 1 314 739 9191 or 1 800 288 2726 or visit www.tapcoinc.com.

www.tapcoinc.com BINMASTER’S SMARTBOB BinMaster’s SmartBob inventory management system is for level measurement and inventory tracking of grain in bins, tanks, or silos containing granules, solids, or powders. The SmartBob bin level sensor takes highly accurate measurements automatically at predetermined time intervals or on demand. Data is sent to a Windows-based eBob software program or remote push-button control console. SmartBob2 has the ability to manage from one up to 128 bins of heights up to 180 feet (55 meters).

www.binmaster.com

BRABENDER GLUTOPEAK The innovative GlutoPeak method patent-registered by Brabender offers a technically professional solution for rapid and definite quality determination of gluten. The aggregation behaviour of the gluten unit is measured in one sample for characterization of the functionality of flours, wholemeals, baking mixes or vital gluten. One measurement takes between 60 and 600 seconds and thus justifies its designation as “rapid method” in all respects. Hence, with typical flours or baking mixes of averaged 10 tests per hour are feasible with mini samples of 3-10 grams and quite easy handling. Thus the GlutoPeak facilitates – in proven Brabender quality – optimization of production and efficient use of existing resources.

www.brabender.com CENTURION COMMERCIAL STORAGE BINS - Flat bottom bin capacities from 50 to 18,292 tonnes and hopper bins from 118 to 1,536 tonnes.

VEGA HIGH PERFORMANCE GRAIN CLASSIFIER Efficient cleaning, high throughput rate, and low energy consumption.

- New structured commercial roof now available.

With its new solution for cleaning and classifying of wheat, rye, oat, rice, maize, and barley Bühler combines several advantages in a single machine: a high throughput rate, a compact and robust design as well as an easy exchange of

- All Centurion Commercial Storage Bins feature G115 galvanized coating with the majority of sheets being rolled from 50-ksi steel.

- The unique patented design features purlin-free assembly, saving time and money.

sieves. Furthermore, the machine has a considerably lower energy consumption than comparable solutions on the market.

www.buhlergroup.com 52 | March - April 2013

& www.westeel.com Grain

feed milling technology

GRANOLINO II Agromatic introduces the new granolino II the new whole kernel moisture meter granolino II can be supplied ex stock What’s new? Compact design, larger display, extensive product storage for up to 99 different free flowing products.

The unit is equipped with printer interface or with complete printer.

Different product compounds are possible depending on the country.

All moisture testers have the following basic languages: English/German/French/Spanish - depending on the region further six languages are possible.

JUMBO CC-S - ULTRA-HEAVY DUTY BUCKETS 4B Braime Elevator Components has designed a new large-sized ultra-heavy duty elevator bucket line intended for the most severe agro-industrial uses, such as port and river terminals, ethanol and fertilizer plants, or frac sand and aggregate operations. The new super strong JUMBO CC-S offers greater carrying capacity, along with ultra-durability and wear resistance. The JUMBO CC-S is a high-efficiency elevator bucket, and comes in six sizes ranging from 14x8 to 24x8 with additional sizes pending.

The electronic unit has been manufactured in SMD technique and the actuator has industry quality.

The ecuracy of measurement and repetition could be increased due to the high product volume.

The display shows: productname, date, time, water content abolute, hectoliterweight, product temperature.

www.agromatic.com ECONASE XT AND MIXER LIQUID APPLICATION Raise your standards of performance with Econase XT and Mixer Liquid Application Looking for improved profitability in uncertain times?

Econase XT Mixer Liquid Application technology optimises production and feed efficiency, offering you significant cost savings.

The only liquid NSP enzyme stable enough to add prior to pelleting.

• Improved FCR • Consistent in-feed homogeneity • Can reduce power consumption when pelleting To find out more visit our website www.abvista.com or email us at econasext@abvista.com

www.abvista.com QUANTUM BLUE Performance Quantum Blue – a revolution in feed performance Phytate anti-nutrient effects could be costing you up to $6 per tonne in lost performance.

Quantum Blue is an enhanced E.Coli – derived phytase developed for use in animal feeds. Optimised for maximum phytate destruction, Quantum Blue unlocks more value for your business than any other phytase.

• Greater phosphorus release • Unrivalled intrinsic thermostability • Proven additional feed efficiency

www.go4b.com CONSERFRÍO® GRAIN CHILLER Consergra, S.L. is a specialist in grain conservation, and manufactures the CONSERFRÍO® grain chiller. It’s a modern, highly energy-efficiency cooler which helps to conserve a wide variety of grains, seeds, oily and granulated perishable items stored in silos and warehouses. Its use, independently of climatic conditions, prevents shrinkages of weight, rotting, insects damage and toxin build up. The conservation with the CONSERFRÍO® is natural and highly cost-effective, the pay-back on the investment is extremely fast. Our units, installed all over the world preserve millions of tons of grain every season.

Our product range covers from 40 up to 500 ton per day, per machine. Consergra, S.L. puts their 50 years experience at your service!

www.consergra.com RIDA®QUICK MYCOTOXIN TESTS - Immunochromatographic tests - 20 separately packed test sticks - Sample preparation for 10 samples approx. 10 min - Easy and fast sample preparation as well as test implementation - Test can be performed immediately RIDA®QUICK Aflatoxin RQS (Art.No. R5205) RIDA®QUICK DON (Art.No. R5904) RIDA®QUICK Fumonisin RQS (Art.No. R5606) RIDA®QUICK Zearalenon RQS (Art.No. R5504)

To find out more visit our website www.abvista.com or email us at quantumblue@abvista.com

& www.abvista.com

Grain

feed milling technology

www.r-biopharm.com March - April 2013 | 53

Events 15th - 17th April 13

*

3rd Africa Sugar Outlook 2013 InterContinental Nairobi, CITY HALL WAY, PO BOX 30353, NAIROBI, 00200, KENYA Contact: Ms. Siew Tee TEOH, 111 TripleOne Somerset #10-06, Singapore 238164 Tel: +65 65 082458 Fax: +65 65 082408 Email: siewtee.teoh@ibcasia.com.sg Web: www.africasugar.com

16th April 13

*

Evaluation of Electrostatics in Powder Handling, The Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich, Central Avenue, Chatham Maritime, Kent, ME4 4TB, 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 2083 318646 Email: wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com

17th April 13

*

Dust Explosions – How to demonstrate DSEAR/ATEX Compliance, The Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich, Central Avenue, Chatham Maritime, Kent, ME4 4TB, 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 2083 318646 Email: wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com

26th - 28th April 13

*

Rice Tech Expo – Lucknow, India, IISR (Indian Institute of Sugarcane Research), Near Base Hospital, Cantonment, Raibareli Road, Lucknow, Uttarpradesh, India Contact: Sharif. Sk, 546, 5th floor, Al-Karim Trade Centre, opp: Ranigunj bus stop, Secunderabad-500 003, India Tel: +919848 043036 Fax: +91 8662 490201 Email: ricetechexpo@gmail.com Web: www.ricetechexpo.com

29th April 13 - 3rd May 13

*

117th Annual IAOM, International Association of Operative Millers, Hilton Fallsview Hotel and Niagra Falls Convention Center. Niagra Falls, Ontario, Canada Contact: Shannon Henson, Director of Meetings and Exhibits. IAOM, International Association of Operative Millers, 10100 West 87th Street, Suite 306 Overland Park, Ks 66212 USA. Tel: +1 9133 383377 Fax: +1 9133 383553 Email: shannon.henson@iaom.info Web: www.iaom.info

54 | March - April 2013

*

1st - 2nd May 13

4th International Grains Conference, Hotel Le Meridien, Janpath, New Delhi, India Contact: Raj Kapoor, 601, DDA Building, District Centre, Laxmi Nagar, Delhi – 110092, India Tel: +91 1147 675218 Fax: +91 1122 457230 Email: grain@assocom-india.com Web: www.grain.assocom-india.com

*

21st - 23rd May 13

Practical Powder Characterisation and Sampling for Industry, The Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich, Central Avenue, Chatham Maritime, Kent, ME4 4TB, 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 2083 318646 Email: wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com

22nd - 24th May 13

•*

VIV Russia 2013, International Crocus Exhibition Center, Moscow, Russia Contact: Guus van Ham, P.O. Box 8800, 3503 RV Utrecht, The Netherlands Tel: +31 302 952302 Fax: +31 302 952809 Email: viv.russia@vnuexhibitions.com Web: www.viv.net

4th - 4th June 13

*

•*

Indo Livestock 2013 Expo & Forum, Bali Nusa Dua Convention Center, Bali Indonesia Contact: Didit Siswodwiatmoko / Devi Ardiatne, Jl. Kelapa Sawit XIV Blok M1 No. 10, Kompleks Billy & Moon, Pondok Kelapa Jakarta 13450, Indonesia Tel: +62 218 644756 ext: 118 & 123 Fax: +62 218 650963 Email: info@indolivestock.com Web: www.indolivestock.com

7th - 9th June 13

*

8th International Rice Milling and Machinery Expo 2013, Ludhiana,Punjab, India Contact: Bhupesh Gupta, #D-56, First Floor, Rose Garden Market, Patiala – 147001, Punjab, INDIA Tel: +91 92162 99124 Email: info@businessempiregroup.in Web: www.indiariceexpo.com

7th - 9th August 13

IGC Grains Conference 2013, Queen Elizabeth II Conference Centre, London, UK Contact: Ann Knowles, 1 Canada Square Canary Wharf, London E14 5AE, UK Tel: +44 2075 131122 Fax: +44 2075 13 0630 Email: conf@igc.int Web: www.igc.int/en/conference/confhome.aspx

3rd International Symposium on Gluten Free Cereal Products and Beverages, Flemings Hotel Wien Westbahnhof, Neubaugürtel 26-28, A-1070 Vienna, Austria Contact: Roland Poms, ICC, Marxergasse 2, A-1030 Vienna, Austria Tel: +43 170 772020 Fax: +43 170 772040 Email: roland.poms@icc.or.at Web: http://gf2013.icc.or.at

12th - 13th June 13

24th - 26th September 13

25th - 26th June 13

•*

24th - 26th September 13

*

7th International Conference “Flour Mill – 2013”, 20, Pervy Shchipkovsky pereulok, Moscow, 115093, Russia Contact: Dr. Vladimir I. Dashevsky, 20, Pervy Shchipkovsky pereulok, Moscow, 115093, Russia Tel: +7 495 9 596669 Fax: +7 499 2 354281 Email: dashevsky@grainfood.ru Web: www.grainfood.ru

*

25th - 26th September 13

*

64th JTIC International meeting, Reims Congress Center, 12 boulevard du Général Leclerc, 51722 Reims Cedex, France Contact: Nelly Duprat, 268 rue du Faubourg St Antoine, 75012 PARIS, France Tel: +33 1 47 072069 Fax: +33 1 44 245625 Email: aemic@wanadoo.fr Web: www.jtic.eu

*

University of Nottingham Annual Feed Conference, School of Biosciences University of Nottingham, Sutton Bonington Campus, LE12 5RD, UK Contact: Sheila Northover, School of Biosciences, University of Nottingham, Sutton Bonington Campus, LE12 5RD, UK Tel: +44 1159 516100 Fax: +44 1159 516099 Email: sheila.northover@nottingham.ac.uk Web: www.nottingham.ac.uk/feedconf

13th - 16th July 13

*

Livestock Asia 2013 - Asia's International Feed, Livestock & Meat Industry Show, Kuala Lumpur Convention Centre, Kuala Lumpur, Malaysia Contact: Ms Michelle Ha / Ms Rita, Suite 1710, 17th Floor, Plaza Permata, 6 Jalan Kampar, Off Jalan Tun Razak, 50400 Kuala Lumpur, Malaysia Tel: +603 40 454993 Fax: +603 40 454989 Email: livestockasia-my@ubm.com Web: www.livestockasia.com

Cereals Event, Boothby Graffoe, UK Contact: Rebecca Dawson, Haymarket Exhibitions, Wroxton Business Centre, Bragborough Farm, Welton Road, Braunston, Daventry, Northants, NN11 7JG, UK Tel: +44 1788 892039 Fax: +44 1788 892038 Email: rebecca.dawson@haymarket.com Web: www.cerealsevent.co.uk

VIV Turkey 2013, Istanbul Expo Center Istanbul, Turkey Contact: Hande Bieber, HKF Trade Fairs Barbaros Bulvari 163/2, 34349 Besiktas, Istanbul - Turkey Tel: +90 2122 164010 Fax: +90 2122 163360 Email: hande@hkf-fairs.com Web: www.viv.net

*

Livestock Philippines 2013 – International Livestock Nutrition, Health And Production & Meat Industry Show, SMX Convention Centre, Pasay City, Manila, Philippines Contact: Ms Michelle Ha, Mr Michael Blancas, Suite 1710, 17th Floor, Plaza Permata, 6 Jalan Kampar, Off Jalan Tun Razak 50400 Kuala Lumpur, Malaysia Tel: +603 40 454993 Fax: +603 40 454989 Email: lvphilippines-my@ubm.com Web: www.livestockphilippines.com

*

12th - 14th June 13

13th - 15th June 13

Segregation, Degradation and Caking, The Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich Central Avenue, Chatham Maritime, Kent, ME4 4TB, 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 2083 318646 Email: wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com

5th - 7th June 13

*

11th - 11th June 13

1st - 3rd October 13

*

Overview of Particulate Handling Technology, The Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich, Central Avenue, Chatham Maritime, Kent, ME4 4TB, 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 2083 318646 Fax: wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com

*

Institute of Food Technologists Annual Meeting and Food Expo, Chicago, IL, USA Contact: IFT, 221 N. LaSalle St. Suite 300, Chicago, IL 60601-1291, USA. Tel: +1 3127 828424 Fax: +1 3127 820045 Email: info@ift.org Web: www.ift.org

* See our magazine at this show • More information available

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Grain

Events VIV Russia May 21-23, 2013, Moscow, Russia

Guus van Ham, project manager VIV Russia, VNU Exhibitions Europe, Netherlands talks to GFMT’s Alice Neal about what to expect at this year’s show and the opportunities in the Russian feed market

What’s new for VIV Russia 2013?

We're further extended the CropTech-FeedTech theme at VIV Russia in 2013. CropTech-FeedTech was developed at VIV Asia in 2011.

With CropTech-FeedTech a lot of emphasis is put on the production of quality feed. The combination of quality technology and a high level conference, offers extra value to the visitors of VIV Russia.

Together with the emphasis on this theme at the trade show floor itself, a technical seminar and economical conference will be organised. The presented topics will handle the latest technologies, on how to manage commodity price volatility in feed production in Russia. And the feed safety and feed quality challenges in Russia will be addressed by both international and Russian specialists on this field.

What are the main challenges in Russian meat production?

The main issues are on the animal health and feed production. On the feed side, the Russians have some challenges related to the high costs of commodities for the past year and they have difficulties in keeping the feed quality and feed safety on a high standard.

This is all related to knowledge.

At this moment in time it is very difficult to find well-educated people to work in the livestock industry and to keep them in the

&feed milling technology

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companies for a longer period of time. There is a lot of investment power in the Russian market but there is a lack of good knowledge.

VIV Russia takes up its position as a knowledge-providing event for the whole Russian industry.

But cutting the conference up in different topics for different audiences we think we can provide hands on knowledge for CEOs, farm managers and technical managers / veterinarians.

Which areas do you think have the greatest potential for development in Russia?

The dairy sector and pig sectors have a hard time to become profitable again. The pig sector suffers from new import tariffs as a result of the entrance of Russia to the World Tr ade Organization.

Poultr y on the other hand, does not face these problems.

Production is growing and it has a good profitability still.

What role does animal feed play in this?

There is still a shortage of quality feed in Russia, so investments in feed mills are on a high level still.

What we have seen in the past two years is that a lot of integrations are further investing in their own feed mill facilities.

Anything else you’d like to tell Grain and Feed M i l l i n g Te c h n o l o g y readers about?

It is clear that Russia is still a top five market in the world for our industry and it will remain in this position for the coming decade.

So it is a market to keep an eye on and to follow. But you have to be in Russia to get a feeling of the opportunities. So I would like to invite your readers to take up the opportunity to further investigate the opportunities in this market by visiting VIV Russia.

More Information: Website: www.vivrussia.nl

March - April 2013 | 55

Events

Indo Livestock 2013 Expo & Forum Preview

June 5 – 7, 2013, Bali, Indonesia

B

ali is welcoming the 8th Indo Livestock Expo & Forum, June 5 -7, 2013, Nusa Dua Convention Center, Bali, Indonesia.

Formed in 2002, Indonesia’s biggest livestock, feed, dairy and fisheries industry show will bring together trade buyers representing integrators, farmers, feed millers, meat and egg processors, veterinarians, impor ters, distributors and retailers to view the latest technology, get updates on the latest issues, network and do business.

Indo Livestock 2013 Expo & Forum will attract 12,000 trade visitors and delegates. More importantly, over 400 exhibitors from 40 countries are expected to once again participate in this year Indo Livestock Expo & Forum. Seven country pavilions have confirmed to attend this three-day show, including Indonesia, Taiwan, South Korea, Europe, United States of America, Singapore and China.

The Ministr y of Agriculture re cog ni se s h ow i m p or t a n t this show is, “Indo Livestock Expo & Forum is a platform for the Ministry of Agriculture to expand the information regarding the technologies of modern agriculture and animal husbandry as well as to introduce a range of current research and development of new technologies in agriculture and animal husbandry,” says a government representative.

Brilliant Bali This is the f irst time the show will take place in Bali.

Bali is known as a centre of industry, commerce and world famous tourism destination.

Strategically situated along the east Indonesia province, Bali is the main gate to enter the market of eastern Indonesia.

E a ster n I ndone si a h a s high potential in the field of tourism, livestock and fisheries. Ninety percent of national economic

56 | March - April 2013

growth comes from the outside areas of Java Island.

An incorporated show Incorporating Indo Feed, Indo Dairy and Indo Fisheries 2013 Expo & Forum, Indo Livestock 2013 Expo & Forum is hosted by the Directorate General of Livestock and Animal Health, Ministry of Agriculture of the Republic of Indonesia. Indo Livestock 2013 Expo & Forum is today a 'must attend' event for decision makers and buyers across Asia.

This show consists of Expo, Conference, Technical Product Presentation, Indonesian Livestock Industry Award and SDTI Campaign Programme.Indo Livestock 2013 Expo & Forum is proven to be the preferred venue for trade buyers to source for new technology and equipment and where industry professionals get update on the latest technological advances and industry trends.

Industry issues Key issues affecting the industry including feed management and production, virulent disease management , bio-security implementation, modern farming systems, meat processing t e c hnolog y, m ar ke t ing and financing will be discussed at the 8th Indonesian Livestock Industry Conference.

Co-located with Indo Livestock 2013 Expo & Forum, it will be attended by the top feed millers, f ar me r s , ve t e r in ar i an s and retailers - making it the most important gathering of the year.

The international conference will feature experts and industry captains who will share their views and visions on the future trends of the Livestock industry and its impact in the region.

Product Present ation room facilities are made free for exhibitors at Indo Livestock 2013 Expo & Forum. As a value added service, exhibitors will be provided with free 45 minutes

usage of the rooms and will have seating for up to 40 participants.

Presentation rooms are allocated on a first- come-first-served basis.

ready to present their topic of interest, discuss on latest trends and issues, and examine the new technology and processes to improve on livestock productivity, feed production and management, animal health and nutrition, slaughtering facilities, packaging technology and many more.

The 2013 event is expected to be the only Indonesian show covering the complete spectrum of the livestock, feed, dairy and fishery sectors. It is also perfectly timed to coincide with the improving economic and political climate in Indonesia. Indo Livestock 2013 Expo & Forum will feature the biggest livestock, feed, diary and fishery industry exhibition of the year in Indonesia.

The Indo Livestock Expo & Forum is expected to be a top priority to get an update of livestock industry and technology development in the Asia Pacific region, as well as a platform to enhance business cooperation, though the development of animal husbandry technolog y and ser vices in Indonesia.

"The Indo Livestock Expo & Forum 'shows off' and 'campaigns' its poultry ability in Indonesia, which has been shown to support selfsufficiency of poultry food products in order to always grow in harmony.

It is also involved the cooperation between the poultry doers along with the government, researchers, press and public," says Don P Utoyo, head of the Indonesian Poultry Society Federation.

Local recognition As an appreciation of local districts and cities government that have a high commitment in the development of animal husbandry in order to support the development of Indonesian Livestock, KPUPI (Indonesian Communit y of Livestock Enterprises Developer) gladly presents the Adi Praja Satwa Sewaka award. It is presented to one of districts or cities in the west, middle and east zone in Republic of Indonesia.

The award is decided based on creativity programme, the level of involvement of breeders and communities, the impact of the programmes, as well as its sustainability.

The SDTI (Milk, Meat, Egg and Fish) programme supports the campaign for the increasing of animal protein and Indonesian farming products consumption.

The campaign aims to educate and increase people awareness of the impor tance of animal protein, par ticularly for people who have yet lack of underst anding about animal protein consumption.

About Indo Livestock Indo Livestock Expo & Forum is designed to be a strategic marketing springboard in order to achieve maximum return-of-investment in the industry. Major integrators, processors, veterinarians and farmers across the region are

More Information: Website: www.indolivestock.com

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Events NGFA 117th annual convention:

Review

agribusiness offers greatest growth opportunity

C

hris Policinski, president and chief executive officer of Land O’Lakes told attendees of the National Feed and Grain Association’s (NGFA) 117th annual convention that “agriculture, agribusiness and the food industry offer the greatest growth opportunity of our era”.

In addition, the convention opened with presentations from Rep. Jim Costa, D-Calif.; U.S. Department of Agriculture Deputy Under Secretary Darcy Vetter; and Bart Chilton Commodity Futures Trading Commission commissioner.

All present ations from the convention can be found online.

Policinski’s keynote address closed out this year’s convention in San Francisco, which had more than 600 attendees who represented all sectors of the grain industry, including country, terminal and export elevators; feed manufacturers; cash grain and feed merchants; end users of grain and grain products, including processors, flour millers, and livestock and poultry integrators; commodity futures brokers and commission merchants; and allied industries.

In his presentation, Policinski provided an industry outlook and touched upon challenges and opportunities for agriculture as well as the advantages of

improvements in productivity.

A s Po l i c i n s k i se e s i t , t h e opportunities for agriculture boil down to an increasing world population that is expected to grow to more than 9 billion by 2050, which equates to a 70 percent increase production to meet higher demand. The majority of that growth will come from emerging markets – such as China and India, which will account for 40 percent of that growth.

However, all oppor tunities come with challenges. Policinski said, “we must produce more food, with fewer resources and less environmental impact”.

Specifically: • At most, only 12 percent more arable land is available globally; • Only 5 percent more land is projected to be cultivated by 2050; and • Demand to outstrip water supply by 40 percent by 2030.

These are surmountable hurdles, Policinski said, through the adoption of modern business and production management practices on the farm, and the application of safe, proven agricultural technologies.

Market opportunities Like Policinski, Vetter’s speech focused on opportunities, and how “changing market forces

can lead to new opportunities.

But in order to adapt to these changes and capitalise on these opportunities we need to be willing to invest, to diversify and to engage,” she said.

For investment, she said that U.S. “infrastructure is absolutely vital to ensuring future growth in exports and – indeed in our economy as a whole”.

“We need to continue to diversify our markets, both in terms of what we sell and who we sell it to,” she said. “Right now, the greatest opportunities for growth in U.S. food and farm exports are in value-added products.”

Finally, she called upon the industry to continue to engage – but in different ways – particularly in the trade arena. She said, “our trade capacity building efforts continue to be important in developing markets of tomorrow”.

Efficient and effective markets In Chilton’s speech focused

on ensuring that markets are e f f i c i e n t a n d e f f e c t i ve . H e said, “while futures markets have worked exceedingly well since ( t he l ate 18 0 0 s ) , we a re se e i n g so m e o f t h e new prospectors having an inf luence which can be problematic”.

As such, he has called upon Congress to: 1. Register the “cheetahs,” which is his term for high frequency traders.

2. Test trading programs before they are put into live production.

3. Ensure trading systems have a “built-in kill switch,” which would shut the program down and prevent “flash crashes.”

4. Increase penalties for all market participants who break the rules.

More Information: Website: www.ngfa.org

Annual Feed Conference 25 th 26 th June 2013 The following papers have already been confirmed:

News

NAMA to co-host 54th annual corn dry milling conference

T

he 5 4t h A nnu al Cor n Dry Milling conference i s sc h e d u l e d fo r M ay 15-16, 2013 in Peoria, Illinois.

Jointly sponsored by NAMA and t he n ation al ce nt re for agricultural utilisation research ( N C AU R ) , t h e c o n f e r e n c e focuses on the corn dry milling industr y, including the latest advances in milling, product testing technologies and the scie nce of cor n produc t ion technology.

The conference begins with a banquet on Wednesday, May 15, at the Embassy Suites East Peoria hotel in Peoria. NAMA members will meet at the hotel on May 15 immediately before the banquet.

Presentations will be made the following day from 8:30 am – 5 pm at the NCUAR, which is also located in Peoria.

For those who need overnight accommodation, hotel rooms have been reserved at the East Peoria hotel.

&feed milling technology

Grain

RUMINANT S Low protein diets for dairy cows -­‐ Kevin Sinclair, University of Nottingham Nutrition, health and fertility in dairy cows -­‐ John Mee, Teagasc Mineral requirements and supply on dairy farms -­‐ Liam Sinclair, Harper Adams University College -­‐ Nigel Kendall, University of Nottingham Global milk and feed price trends and influences -­‐ John Allen, Kite Consulting NON-RUM INANT S Environmental impact from poultry operations: influence of nutritional inputs -­‐ Ilias Kyriazakis, Newcastle University Home grown proteins in pig and poultry diets -­‐ Jos Houdijk, SRuC Nutritional quality of soya products for non-ruminants.

-­‐ Julian Wiseman, University of Nottingham; Mick Hazzledine, Premier Nutrition

For further details visit: www.nottingham.ac.uk/feedconf

March - April 2013 | 57

Events Cereals 2013

Preview

June 12-13, 2013, Boothby Graffoe, Lincolnshire, United Kingdom

C

ereals 2013 is gearing up for another year of arable innovation at Boothby Graffoe, Lincolnshire. With an expected attendance of over 25,000 farmers and industry experts, the event provides the UK arable industry with valuable technical expertise, new products and dedicated business advice.

The 64 -hectare site is home to m any dif ferent sec tions including crop plots, machinery

GEAPS Exchange review

G Review

ra i n a nd Fee d M i l l i ng Technology’s Tom Blacker heads to Louisville, USA for the GEAPS Exchange 2013

June 5-8, 2013, Krakow, Poland

F

EFAC president Patrick Vanden Avenne and IZBA president Adam Tanski, invite all partners of the European and international feed and livestock chain to join FEFAC’s Congress in Cracow to find out how to stay profitable in volatile times.

Keynote speakers from the European Commission, including deputy director general Jerzy

58 | March - April 2013

to help farmers growing for both the feed and flour markets.

Jon Day, event director for Cereals says that despite the difficulties of last season farmers are keen to look to the future; mitigating any losses by clever marketing, improving storage potential for this year’s crop and looking for alternative markets when it doesn’t all go to plan.

“With increasingly volatile weather it’s even more important to find technological ways to maintain what has been produced in the field. Meeting the manufacturers and asking the experts direct at Cereals is the ideal way to do that,” says Day.

Post Harvest Technology. Other companies across the site also offer contributory products and services

www.cerealsevent.co.uk

Fourth Street entertainment area and The Muhammad Ali Center.

Three days inside seeing and meeting the people behind large and small innovations in milling was very interesting and enjoyable. We found a mixture of the broad coverage that GEAPS as fascinating as ever.

One benefit from participating at this event would definitely be the expansion of American members into the IMD. Some have even passed on good design changes we are sure to implement as well as a more comprehensive and reliable array of listings.

Regular and new members of the IMD loved getting complimentary copies we had set for distribution at GEAPS. It really gave us confidence for publishing the upcoming 22nd edition!

We’re sure to be back next year when the GEAPS Exchange travels to Omaha, Nebraska, USA.

and Tom Blacker became an interest in themselves to attendees; before the milling publications were talking points.

The vast hall of the International Conference Center in downtown Louisville was a good location. It

The GEAPS (Grain Elevator and Processing Society) Exchange came around a month after IPPE in Atlanta and at the same as WAS Aquaculture 2013 in Nashville so Perendale's familiarity with US shows is at quite a high.

Fortunately, the GEAPS Exchange opened with aplomb and Grain and Feed Milling Technology (GFMT) and its sister publication the International Milling Directory (IMD) were flying off the shelves. Six boxes of IMDs and hundreds of the latest issue of GFMT became a real talking point between exhibitors, students and interested visitors. As the only UK-based exhibitor Roger Gilbert

XXVI FEFAC Congress

News

arable conference, renewables and working demonstrations.

However, the area of most interest to Grain and Feed Milling Technology readers is the Post Harvest Technology area.

The section within the Cereals Event is always well represented and is a key area for visitors keen to maximise their yield quality and profit potential. This specialised area features a range of companies and products, including grain drying, processing, storing, weighing, transporting, testing and marketing. To date over 440 companies are booked to attend Cereals 2013 including 42 who are specifically focused on

was actually on the second floor of a large complex near the famed

Bogdan Plewa, the Polish Ministry of Agriculture, global financial institutions, market and food chain partners, and academia will present their views on how to maintain a vibrant livestock economy in a volatile market and political environment. They will discuss with the congress audience on how our industry can meet both European and global consumer demand while ensuring the economic viability of livestock producers and value chain partners.

At a time when the CAP reform proposals are moving to the final

since EU enlargement and how they plan to make the new CAP work for the benefit of Polish agriculture”.

FEFAC President Patrick Vanden Avenne says, “the only certainty we have today is that volatility is here to stay – our industry needs to support and encourage swift policy and market actions to develop the new financial risk management tools that allow our sector to stay profitable in the years ahead reaping the benefit from growing global consumer demand for products of animal origin”.

stage of the political negotiation process under the Irish EU Council Presidency, FEFAC’s Congress will provide a unique opportunity to take stock of the key measures which could help improve competitiveness of the EU livestock sector, including new initiatives for innovation and sustainable development in livestock agriculture.

Adam Tanski says, “FEFAC’s Congress delegates will discover with their own eyes how the Polish feed and livestock sector managed to take advantage of new business opportunities in the past decade

www.fefaccongress2013.eu

&feed milling technology

Grain

The GFMT interview

Since its formation in 1967, the Muyang Group has grown into a prestigious corporation, whose activities cover the whole process of feed manufacturing. From design and development to fabrication and installation of the machinery, Muyang has it covered. Over the years, the company has developed more 100 different series of feed and grain processing machines, which includes an impressive 600 different models.

Headquartered in the famous historical and cultural city of Yangzhou, China, Muyang currently has over 4000 employees, including 1000 technicians and engineers who work across all departments. As one of China's big three equipment suppliers, Muyang is now looking for its share of the international marketplace.

GFMT met up with Mani Qian, assistant president of Muyang at the IPPE show in Atlanta, USA where his company was promoting its range of feed manufacturing equipment. Mani Qian is a dynamic and forthright individual. When you meet him he captures your attention with his ideas and enthusiasm for all things milling.

Mani Qian Assistant president, Muyang

What makes Muyang special?

Animal feeding and aquafeed processing are very different. For aquafeed we are number one when supplying integrated systems for aquafeed manufacture. From fine or micro pellets to extrusion for shrimp and floating fish feeds we are recognised, even for slowsinking fish feeds. We also provide reliable, stable vacuum coating and dryers. In summary we are recognised for being reliable and flexible.

Do you supply your customers with more than just equipment?

Yes, we take the farmer from start to finish, from sales through control to after sales service including nutritional backup. We do all the civil work, the design concept, wear housing, building authority work - the complete integrated package. We are the only ones able to supply all the equipment for aquafeed production. This is our selling point - being reliable and flexible.

How do you support sales in many countries?

We have 50 sales networks worldwide. Our marketing share for 90 percent of CP Group (Aquafeeds) is made by Muyang machinery. We also service the biggest aquafeed producer in Latin America (GISIS).

We also have over 90 percent of the market share in aqua feeds. Our focus is on Latin America and Russia and BRICKS and N11 countries.

In Asia we are already over 90 percent of the market in aquafeeds and that’s a peak, so we are now focusing on Latin America in particular - Brazil, Ecuador, Venezuela and Peru. We are looking towards Chile 60 | March - April 2013

as it has great potential for us in terms of salmon feeds. We are also working for the Honduras Aquafeed Company and with extruded pet foods for Industrias Bachoco Mexico.

However, Muyang is more than just aquafeed equipment. What makes Muyang special in animal feeds?

What separates us from others is the advantage we have in being more experienced in turnkey projects. We can start with bare land and complete the finished product. In animal feeds we have a new philosophy: ‘from farmers to fork’. It means we make machines for harvest machinery, silo storage, feedmills, rice milling and after that chicken farming equipment, slaughter houses, food processing equipment through to packaging, etc, and even oil pressing, extraction and refining.

We are very diverse and in the food processing for human foods we supply equipment for meat processing and even equipment for the alcohol industry. This is all through the food chain. We make all the relations work within the food chain from special orders and specific requirements all according to the customer's needs. That's why we have to be flexible.

How has this approach impacted your company's performance?

In 2012 we reached US$1000 million turnover with exports accounting for US$300 million. That was up by 20 percent for the whole group, but for exports specifically, we were up by 54 percent.

&feed milling technology

Grain

Watch the interview on your smart phone Simply download the Aurasma light app, and then subscribe to our channel at http://auras.ma/s/1shRr Point your phone at the image below and watch it come to life with the full interview

Classified section Equipment for sale

Bulk Storage The right storage solution starts with the right advice.

• Automation Products, Inc. Specialists since 1976 in the Design, Supply, Installation and Commissioning of: • Bulk Storage and Handling Systems • Pneumatic and Mechanical Conveying • Weighing and Batching • Screening and Magnetic Protection • Bag Filling and Discharge • Aspiration and Dust Control • Turnkey Projects Tarvin Mill, Barrow Lane, Tarvin Chester CH3 8JF Tel: 01829 741119 Fax : 01829 741169 E-mail: admin@croston-engineering.co.uk Web: www.croston-engineering.co.uk

Block 10 Todd Campus West of Scotland Science Park Acre Road, Glasgow Scotland G20 0XA Tel: +44 141 945 2924 info@r-biopharmrhone.com www.r-biopharm.com

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• Blo-Tech Ltd Extruders • Cargotec Sweden AB CL_Handling_techniques.indd 1 class_vigan.indd 1 30/11/2012 10:51 • Schenck Process UK Limited • Dynamic Air Inc

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Condex (UK) Ltd

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Customised industrial bags for quick filling and reliable protection of your goods.

Material Handling & Electronic Components for all Applications

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• Elevator Buckets & Bolts • Belts & Fasteners

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62 | March - April 2013

• Hazard Monitors • Level Controls

19.03.13 12:51

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www.brabender.com

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15:36

Classified section Feed processing

Mill Design & Installation

Valves

• Converteam UK Ltd • RED-BERG s.r.l.

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

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Process control

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

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Ottevanger Milling Engineers Moerkapelle and Aalten - Holland Tel.: +31 79 593 22 21 E-mail: mkp@ottevanger.com

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For maximum control and efficiency call:

01473 829188 www.suffolk-automation.co.uk

Recruitment • AGRI-Associates Wynveen International b.v.

Tel: +31 (0)26 479 06 99 info@wynveen.com

Packaging • Arodo BVBA

www.wynveen.com Versatility in feed processing

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Grinder hammers

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Silos Yingchun Group

Used around all industrial sectors.

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

Visit us! www.pipe-systems.eu

Grain Silo Manufacturing Tel: +86 546 8313068 Email: ycgbc@silo86.com

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John Staniar & Co.

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

www.silo86.com &feed milling technology

Grain

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March - April 2013 | 63

Schenck Process appoints domestic sales manager for air filtration products

Gareth Hine

Gareth Hine has joined Schenck Process, UK as the new IBS light domestic sales manager for the new range of air filtration products aimed at the food, chemical, plastics and pharmaceutical sectors. The new range of air filtration will build on the extensive experience of Mac Process in the USA who over the last fifteen years has sold their filtration products into Europe via Clyde Process.

Bringing with him a wealth of technical sales and business development experience, Hines also has over 16 years experience in the dust control and industrial ventilation industries, working with blue chip clients on major environmental control and process improvement projects.

Schenck has also appointed Phil McHale as a proposals engineer to work alongside Hine. McHale has extensive experience with the Nederman/ Danthern group specialising in air filtration projects. www.schenckprocess.com

Alltech searches for next extraordinary minds in science

Graduate student Qian Wang received the graduate Alltech Young Scientist Award in 2012 for her research on preventing greenhouse gas emissions (nitrous oxide) from invading agricultural soil

The search is on to select the next winner of the Alltech Young Scientists Awards. The 2013 competition is now open to undergraduate and graduate students who are interested in submitting experimental research or scientific review papers.

Cover topics can include veterinary science, animal nutrition, feed technology, sustainability, agricultural management, marketing, environmental science and economics. During Alltech’s 30th International Symposium in 2014, eight finalists will be invited to compete. Dr Pearse Lyons, president and founder of Alltech says, “Every year, more and more students send us their research with hopes of standing out in a crowd of candidates representing countries from around the world. Alltech is proud to provide an avenue for future leaders in diverse fields of science to compete at the highest level?”

In May, the regional finalists will travel to Lexington KY to compete in the final during the 29th International Symposium. The winning graduate and undergraduate students will receive a $10,000 scholarship and a $5,000 scholarship respectively. Dr Inge Russell, director of the Alltech young scientist competition says, “Our Young Scientists are in a class above the rest – their research sheds light on how science steers our world to a better future.” www.alltech.com

Change is sales structure at Vortex

Laurence Millington

Vortex has undergone a change in its European sales management structure in order to support its continued growth as a solution provider in components for bulk material handling.

As part of the restructure, Laurence Millington has been appointed European sales manager. In his new position, Millington will be responsible for the development of sales and the coordination of marketing activities for Vortex throughout Europe. He has over 16 years of extensive experience in the industrial process equipment industry and previously served as Vortex’s Regional Sales Manager for the UK, Ireland, Scandinavia, and Benelux.

“Laurence has been a great asset to Vortex over the past four years,” says Travis Young, vice president of Global Business Development. “His experience, technical knowledge, integrity, and dedication to customer service will be a major benefit to our growing client base throughout the continent.” www.vortexvalves.com

John Brown Scholars take part in Novus programme Novus International, USA welcomed the University of Missouri College of Agriculture, Food, and Natural Resources John Brown Scholars to its global headquarters on January 14, 2013.

Sixteen Agricultural majors were invited to visit agribusiness firms in the St. Louis area. Keen to participate in a programme that highlights the corporate side of agribusiness, the students were invited to take part in meetings with top executives, tours and training.

Each student selected a host company to suit their future career choice in the agricultural industry. Three out of the four plan to have a career in Ag Business and Ag Marketing, while the fourth has chosen a career in Biochemistry and Ag Economics.

The four Novus scholars spent a full day with Novus executives to discuss Novus’s role as a global nutrition and health company.

They also shadowed members of the Novus staff and took part in industry tours. These included: AMR Management Services, Anheuser-Busch, The Donald Danforth Plant Science Center and the St. Louis Zoo. Biochemistry senior Olivia Harrison says, “Participation in the Novus programme allowed me to see how science and business can collaborate and work together firsthand.” www.novusint.com

INDUSTRY FACES

by Marnie Snell

PEOPLE

INDUSTRY FACES

Leave nothing to chance. With WinCos Care, the Service Management System of Bühler, you will put your maintenance work in order. The system, which is customized by Bühler to precisely fit the specific needs of your production system, takes charge of the entire planning and administration of all your maintenance jobs. This ensures efficient processes and maximum plant uptime.

Bühler AG, Grain Processing Customer Service, CH-9240 Uzwil, Switzerland, T +41 71 955 30 40, service.gp@buhlergroup.com, www.buhlergroup.com

WinCos Care Service Management System – Unrivaled Efficiency.

Maximum uptime: Prefabricated job cards are based on service hours or calendar intervals as well as individual job planning.

Plug & Play: Efficient processes and customerspecifically programmed software for all plants.

Always up to the minute: Automatic online updates and data backup.

All in one system: Extensive documentation, among other things for certifications (e.g. International Food Standard).

Innovations for a better world.