Nov | Dec 13 - Grain & Feed Milling Technology

November - December 2013

first published in 1891

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Fit-for-purpose grain and feed packaging: an environmental perspective

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Organic feeds: the future for sustainable poultry farming?

In this issue: •

Single or twinscrew extruder: what are the options?

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Animal feeding in the future: reaching genetic potential through smarter nutrition?

PORTS: VIGAN industry report

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Market-aware farming: commodities training at Writtle College

INCORPORATING PORTS, DISTRIBUTION AND FORMULATION

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

GRAIN &

FEED

MILLING

News:

FAO: Typhoon-hit farmers ‘need urgent assistance’ New Biomin premix plant opens in Vietnam UK lupins trial plants seeds of protein security FEFAC calls for action on EU feed supply Egypt expands grain storage capacity VIV Europe organiser launches North African mission Bühler container mill offers Africa small-scale solutions Associations round-up

TECHNOLOGY November - December 2013

Published by 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

Features:

Fit-for-purpose grain and feed packaging: an environmental perspective Single or twin-screw extruder: what are the options?

Animal feeding in the future Organic feeds: he future for sustainable poultry farming?

Market-aware farming: commodities training at Writtle College PORTS: 70 guys in Nivelles: VIGAN Engineering industry report INDUSTRY PROFILES 2014

Publisher Roger Gilbert Tel: +44 1242 267707 rogerg@perendale.co.uk Deputy Editor Richard Sillett Tel: +44 1242 267707 richards@perendale.co.uk

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10 16 20 26 30 34 38

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

industry events Campden BRI branches out with new feed seminar IPPE opens doors for international audience REVIEW: IAOM MEA 2013 Conference and Expo

Circulation & Subscriptions Manager Tuti Tan Tel: +44 1242 267707 tutit@gfmt.co.uk International Marketing Team Darren Parris Tel: +44 1242 267707 darrenp@gfmt.co.uk Lee Bastin Tel: +44 1242 267707 leeb@gfmt.co.uk

52 52 53 54

the gfmt interview Andreas Flückiger, Middle East and Africa region president, Bühler AG

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industry faces

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GLOBALG.A.P. appoints new director Lesaffre feed additives strengthens team AFIA’s new position filled Veterinarian joins antimicrobial leader New appointment at feed ingredient firm

Tom Blacker Tel: +44 1242 267707 tomb@perendale.co.uk 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 India Marketing Team Assocom-India Pvt Ltd Tel: +91 47 675216 india@perendale.co.uk

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

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THE

volume: 124 number 6

issn No: 1466-3872

Guest - EDITOR’S OBSERVATIONS

Guest editor - Paul Davies, Royal Agricultural University

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eing invited to guest edit Grain & Feed Milling Technology is much appreciated, having known and enjoyed this iconic magazine for many years.

It gives me a welcome opportunity to pass comment on the many opportunities, challenges and threats which continue to influence our global food and feed supply chain. An increasingly complex industry, but a more and more essential one, which affects us all. Drivers for change in our worldwide agri-food business are many, and more various, than in times past.

Drivers for change in our worldwide agri-food business are many, and more various, than in times past Excellent work by the International Feed Industry Federation (IFIF) – working closely with the UN Food & Agriculture Organisation (FAO) and Codex – during the last decade has ensured that the animal feed industry has become safer, and an integral part of the global food supply chain so essential to health and wellbeing – not to mention our food security. Many of you know the significant contributions to improving animal feed supply and safety made in recent years by such contributors as Andrew Speedy (previously FAO), Roger Gilbert (Perendale Publishers and previously IFIF), Eric Miller (Cambridge University), together with Reg Preston, Ron Leng, Freddy Ib and many others worldwide. All credit to them.

I'd also like to take the opportunity to comment on key issues and concerns currently affecting the animal feed business. Of particular interest to me personally was being able to contribute to the excellent Bridge2Food congress held in Rotterdam in September, the 6th Protein Summit 2013: Platform for Future Supply, Health and Technology meeting. Not to be missed next time, if you get the chance to go. It provided me, especially, with the opportunity to make comparisons with progress reported previously at the FAO conference 'Protein Sources for the Animal Feed Industry', held with great success in Bangkok in 2002. What has not changed is the demandled 'livestock revolution' worldwide, and the continuing demand for even greater quantities of animal feeds.

Increasing demand for meat, milk, eggs and other livestock products continues to drive up global animal populations – not to mention the substantial expansion we are seeing in aquaculture. If available, and if we can afford to buy them, most of us are consuming more and more of these products. Of course, this growing demand for high value protein foods is being driven most of all by population growth, rising incomes and urbanisation.

Although the rate of population growth is slowing down, we could still reach 10 billion by 2030 from today's 7.2 billion global citizens. A growing demand, for sure, but with 1 billion hungry today (the same as in 1950) and 1 billion more reported to be suffering from 'hidden hunger' from nutritional imbalance, not all can enjoy it.

Overall demand for livestock products could reach 376 million tonnes by 2030, an increase of 50 percent since 1997. Looking further ahead, it is even predicted that by 2050 over 326 million tonnes of meat products will be demanded in developing countries alone, and milk

2 | November - December 2013

consumption will have doubled to 585 million tonnes. For which, say prediction models, we will need an additional 1 billion tonnes of cereal grain for animal feed. Which, nevertheless, augers rather well for the future of our industry.

However, one noticeable difference between the feed conferences in 2002 and 2013 are the increasing concerns being voiced about the impact of higher livestock numbers and modern approaches to animal husbandry. There are ethical concerns, relating particularly to the increasing replacement of mixed smallholder farms with intensive, specialist, industrialised livestock facilities, but also worries about environmental impact.

These were highlighted in the FAO book Livestock's Long Shadow, which many will know. Concerns have also mounted over human health, as large numbers Professor Paul Davies, Vice of domesticated animals Principal and Professor of (especially those near urban Agricultural Systems, Royal centres) pose to us an Agricultural University, UK increasing disease risk.

Quite clearly, a much more holistic approach to livestock farming is required if we will ever achieve greater sustainability of future production – greater sustainability 'from plough to plate'.

Technically, two critical issues continue to make a serious impact on our global food and feed system: the source of animal feed nutrients (especially protein), and the efficiency of feed conversion. We need more available protein sources, as was highlighted during the recent Rotterdam meeting; this could include such sources as algae, insects and microbial products in the future. In addition to this, we must of course continue to look for and develop a greater diversity of plant protein crops for feed. We are still having to live with an unacceptable – and unsustainable – protein deficit in Europe for animal feed manufacture, which relies on the importing of more than 75 percent of its protein-rich material (mostly soybeans).

Soybean prices have doubled in recent times, and fishmeal prices have also increased considerably. This makes the feed industry highly vulnerable, not to mention substantially increasing the cost of livestock rearing in Europe. For the sustainable intensification of farming, we also need to keep chasing greater efficiency of feed conversion, for the sake of the security of our future food and feed supply. It's said that a hectare of rice crop could feed 19 people a year, but the same area devoted to beef production could only feed one individual.

There will be much to consider from a sustainability perspective in future years, if we are to deliver greater benefits to the industry. Against the backdrop of increasing climate change on an ever more fragile planet, all this assumes a much greater significance.

&feed milling technology

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www.tapcoinc.com *Statement based on our current level of knowledge and covers the above mentioned material produced by Tapco Inc. at the date of issue. Since conditions of use are outside of Tapco’s control, Tapco makes no warranties, express or implied, and assumes no liability in connection with any use of this information. Tapco Nylon resin meets U.S. Food and Drug Administration (FDA) Regulations Title 21 CFR177.1500, 21 CFR175.105, 21 CFR178.2010 and 21 CFR177.300. © 2013 Tapco Inc.® All rights reserved.

November - December 2013

NEWS

FAO: Typhoon-hit farmers ‘need urgent assistance’ A blog dedicated to professionals - including nutritionists - in the transportation, storage and milling of grains, feedstuffs, rice and cereals, globally.

Hello Millers The Global miller has seen an influx in animal feed related news lately. In the global quest to feed 9 billion people by 2050, it is important to consider how livestock feed affects animal health, and by extension, the health of everyone who consumes these animal products Supporting the link from food to feed Earlier this year, an industry association was set up to promote the use of recovered food waste in animal feed. The European Former Foodstuff Processors Association (EFFPA) focuses on the interests of businesses, which specialise in the processing of former foods for use in animal feed in all EU member states. http://bit.ly/1ciNRMZ Cargill’s new animal nutrition feed additive American animal nutrition corporation Cargill has announced it is to introduce PROMOTE™, a new global brand of feed additives. Feed additives play a prominent role in animal nutrition as livestock producers strive to enhance performance, keep up with consumer demand and improve feed conversion. As a trusted advisor and source of innovation, PROMOTE™ is a significant step forward in Cargill’s commitment to serve its customer. http://bit.ly/1g1We2U Harnessing the benefits of the Cassava crop In October, top international researchers along with decision makers, business people and a range of stakeholders working in the cassava sector met at the International Institute of Tropical Agriculture (IITA) in Ibadan, Nigeria. Cassava is the fourth most important source of food energy in the world after wheat, maize and rice. Both the roots and leaves can be directly fed to livestock or used in producing commercial feed. http://bit.ly/1gAJQV7 Soy-yeast supplement for piglet feed The Department of Animal Science, the agriculture research division of the University of Arkansas, USA recently studied the effect of a new supplement for use in piglet feed. Developed by Hamlet Protein, a global supplier of soya protein products for the animal feed industry, HP 800 Booster is a soy-yeast supplement developed specifically to boost the food intake of underweight piglets. http://bit.ly/1beLZ3o Global animal feed market International market data leader Research and Market has announced the addition of a new global animal feed report. Designed for companies who want to gain a comprehensive perspective on the global animal feed market, Global Animal Feed Market to 2017 - Market Size, Growth and Forecasts in Over 70 Countries is a comprehensive package that enables readers to evaluate the world market for animal feed. http://bit.ly/19eri80

http://gfmt.blogspot.com This month we have added our pictures from IAOM MEA 2013 to our Facebook page - take a look at: http://www.facebook.com/GrainFeedMillingTechnology

H

undreds of thousands of farmers struck by Typhoon Haiyan need urgent assistance to restore their livelihoods, warns the United Nations Food and Agriculture Organisation (FAO).

The typhoon, which has killed more than 5,000 people and displaced over four million, hit the central area of the Philippines as the annual rice harvest was well underway, causing estimated losses of 900 000 tonnes. It is likely that along with disrupting the harvest, the cyclone also destroyed cereal storage facilities and their contents.

Planting for the 2013-14 secondary rice season, which ends in late December, has also been severely disrupted, meaning that the effects of any food shortages caused by the disaster will continue to be felt next year. The FAO predicts ‘severe food security and livelihood problems’ in central regions, should the planting not go ahead. As a result of the typhoon around 2.5 million people in the central Philippines are already in need of food assistance.

The FAO has called for US $24 million in immediate intervention aid, in order to mitigate the damage to the secondary harvest. It will provide farmers in the crisis-hit area with rice and maize seeds, tools, fertiliser and small irrigation equipment to allow them to resume their crop planting while they still can.

Dominique Burgeon, Director of the FAO’s Emergency and Rehabilition Division, was clear that immediate action is required to prevent a wider disaster. “Initial estimates reveal that hundreds of thousands of hectares of rice and other key crops like coconut have been affected due to the typhoon.”

“Planting of the secondary season, mostly irrigated rice, was well underway and it is expected that crops are severely compromised.

If we want to avoid entire regions of the country having to rely on food aid, we need to act now to help vulnerable families to plant or replant by late December.”

In the longer term, the FAO has also identified the need to clear storm debris from farmland and rebuild storage and irrigation facilities.

Alongside the US$119 million of crop losses to the typhoon, US $42 million of damage has been inflicted on agricultural facilities and infrastructure.

DAILY UPDATES For more industry news, try our daily news service - The Global Miller. Find it at: www.gfmt.blogspot.com

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News

News

November - December 2013

NEWS

New Biomin premix plant opens in Vietnam

G

lobal animal health and nutrition experts Biomin has continued its expansion into Southeast Asia, opening a 4.7 hectare premix plant in Binh Duong, Vietnam.

The new facility, which utilises energy-conserving technologies including solar panels and walls made of autoclaved aerated

UK lupins trial plants seeds of protein security

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ritish-grown lupins are being fed to laying hens as part of a new feed trial organised by A b e r y s t w y t h U n i v e r s i t y, UK.

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concrete, consolidates the A u s t r i a - b a se d c o m p a ny 's presence in the region. Asia Pacific CEO Jan Vanbrabant said the new plant “allows us to capitalise on the growth in demand for safe and reliable nutrients for animal feeds in Vietnam.” “ With our plant in Hanoi already running at full capacity, the additional 60 tonnes per

day capacity at Binh Duong will definitely ease production pressure and allow us to im prove le ad time s w it h our customers,” he added.

“We have also installed the latest technologies, including liquid chromatography mass spectrometry, which is capable of detecting up to 300 different mycotoxins.”

The October opening ce re m o ny s aw 2 50 V I Ps , customers and government officials invited to the facility, and featured speeches from Biomin founder Erich Erber and Le Thanh Cung, president of the People's Committee for Binh Duong.

Biomin are continuing their plans to expand their Asia Pacific footprint, with a new facility in development in Jiangsu province, eastern China. www.biomin.net

Carried out in conjunction with university egg supplier Birchgrove Eggs, the 18-week commercial trial will replace the usual soya protein in the layers mash with edible yellow lupins, which can be grown across the UK and Europe.

Previous trials with laying hens have found no adverse effects on feed intake, growth, weight, health or eg g production compared to the traditional soya meal. Currently European animal feed producers’ vast

demand for soya necessitates l arge - sc ale impor t s from South America, leading feed experts to raise concerns over sustainability and the distortion o f t h e s u p p l i e r re g i o n’s agricultural sector.

Nigel Scollan, principal investigator for the project and Waitrose Chair of Sustainable Agriculture at the university was very optimistic about the potential benefits of lupin-based feeds.

“The UK and Europe have

major issues with protein security within the livestock sec tor and are he avily dependent on impor ted soya. We need to find ways of incre asing t he amount of protein that can be grown on-farm in the UK. Our research studies have demonstrated the potential for lupins in laying hens, and it is excellent to have this work taken forward in a large commercial-scale study with Birchgrove.”

November - December 2013 | 5

November - December 2013

FEFAC calls for action on EU feed supply

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ew FEFAC president Ruud Tijssens has warned against the “unlevel playing field” caused by EU feed legislation drifting too far from regulations elsewhere in the world.

Tijssens expressed dismay that the EU, which consumes 15 percent of the animal feed produced worldwide, is concentrating on food safety, GM crops and sustainability

Egypt expands grain storage capacity

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g ypt ’s troubled agricultural sector was given a boost by the announcement from Supplies Minister Mohamed Abu Shadi that the country will expand

VIV Europe organiser launches North African mission

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lobal livestock trade show organiser VIV is opening doors in the 175-million-strong North African market thanks to a new trade mission launched in November.

Although primarily a networking event for industry leaders and national governments in the region, it doubles up as a preview for its centrepiece VIV Europe event, to be held in Utrecht, the Netherlands, in 2014. In recent years the emerging Nor th African agricultural market has been a significant feature of European industry shows, and VIV’s fivecountry mission will deepen the level of cross-Mediterranean collaboration.

“The reason we are paying so 6 | November - December 2013

at the expense of continuing access to the global feed materials market.

Mentioning Europe’s aflatoxins crisis earlier this year, the European Feed Manufacturers’ Assocation president noted that while a large consignment of contaminated maize from southe astern Europe was de e med unf i t for anim al consumption, that batch was eventually exported to the United States, where relatively relaxed regulations allowed it to be processed for use in cattle feeds. “ T h e E U re m a i n s h i g h l y dependent on imports for the supply of several critical

commodities, such as proteinrich feed materials and essential minerals like phosphates,” Tijssens wrote in the FEFAC newsletter.

“Our feed industry is faced with an increasingly complex supply of feed materials when doing business with its trading partners, as our companies operate in the same global market as emerging powers such as China and India , who don’t demand the same specifications. The EU has already lost preferential buyer status for many key exporters as a result.”

Earlier this year the EU lifted its longstanding ban on processed

animal proteins ( PAPs) in aquaculture feeds and entered discussions with member states over the possibility of re-introducing them into pig and poultry diets from 2014.

Tijssens’s column alluded to the move, but emphasised that more must be done to promote their safe use, as well as greater investment into the local production of vegetable protein.

Tijssens’s comments follow a pattern set down by his predecessor, Patrick Vanden Avenne, who spoke of the need to “restore some common sense and pragmatism” to European food and feed policy in 2011.

its grain storage capacity to 4.5 million tonnes, a 50 percent increase on current levels.

24 silos are already complete and 26 more h ave begun construction, and more still are in the planning stage.

Abu Shadi maintained that high food prices following president Mohammed Morsi’s decision to drastically reduce wheat imports were a key reason for his ove r t h r ow. E g y p t i s t h e world’s largest importer of

wheat , and its huge bread subsidy programme left the government highly exposed to a subsequent 900 000 tonne shortfall.

Egypt’s current wheat supply is expected to last until early March, following the recent addition al impor t of 2 . 3 million tonnes over a period not specified by the Supplies Ministry.

The government hopes its s i l o - b u i l d i n g p ro g r a m m e , which will take place with assistance from foreign states including the United Arab Emirates and Italy, will be complete before the end of its fiscal year in June 2014.

much attention to North Africa is because these countries are on the threshold, or are in the middle of, a major turnaround – in some cases this turnaround is already complete,” commented VIV Europe promoter Didier Nech.

“Although in some cases there is still political instability, we expect that our exhibitors and knowledge specialists can help these countries to develop and build their animal protein sector. These are countries with a total of around 175 million cosumers, where a lot of investments will be made in the coming years in response to their growth.”

The VIV road show will visit Morocco, Algeria, Libya, Tunisia and Egypt between November and January. Highlights include a visit to Morocco’s Dawajine poultry breeding exhibition, and conferences in Tunisia and Egypt held in conjunction with national poultry associations GIPAC and WPSA. Due to the security problems in much of the country the

Libyan leg of the mission will African producers, they mark a be limited to Tripoli, although continuation of the technical companies from other parts of programme provided at VIV the country have been invited Europe proper, including the to the meetings with business Croptech-Feedtech conference associations and government chaired by GFMT publisher and former IFIF director-general ministries.

“In most countries we have to Roger Gilbert. work extremely circumspectly VIV Europe will be held in and comply with the formal Utrecht, the Netherlands, on procedures,” said Nech. “We 20-22 May, 2014. www.viv.net have direct contact with the g ove r n m e n t t h r o u g h ministers and other highly-placed government officials, giving us better Use of grains for access to the top people. industrial products’ Around a thousand prominent individuals 320.2 million tonnes - forecast will be invited to our world industrial use of grains in 2014 road shows, followed by a personal invitation to 2.5 million tonnes - industrial use of Utrecht in May 2014.” grains in 2012-13 down from preceding A big at t r ac tion for season the VIP delegations is the progr amme of 164.5 amount that ethanol will masterclasses and account for in 2014 seminars taking place as part of the trade mission.

36 million tonnes - the expected Giving the global livestock amount of grain used in brewing in 2014 industry the opportunity Source: The International Grains Council to share ideas with North (IGC), UK 2013

NUMBER CRUNCHING

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NEWS NEWS

November - December 2013

Bühler container mill offers Africa small-scale solutions

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complete maize mill squeezed into two shipping containers is the latest innovation to hit food producers in SubSaharan Africa.

N amed Isigayo af ter an old South African word for the grinding process, Bühler's compact mill hasa capacit y of t wo tonnes per hour and is preassembled at the factory.

NEWS IN BRIEF A historic day for the agricultural world saw the first ever bulk shipment of US sorghum to China unloaded at the Guangzhou Port Facility, South China. The 60,000 tonne shipment reinforces the continuing modernisation of China's feed industry. Staff from the US Grains Council, representatives of buyers and sellers, port officials and US government representatives were present at the leading coastal hub port.

Global exchange company CME Group was at the centre of a controversial trial on Monday following a decision to consider electronic trades when settling grain prices. Terrence Duffy, executive chairman of CME defended the digital move, stating the decision was "the right thing to do." The

The standard production p ro ce s s o f b a g i n t a ke , cleaning, conditioning and de-germination, grinding and sif ting, and manual bagging of the end product is replicated on a small scale to provide farmers and star t-ups a versatile and investment-light way into food processing.

“Isigayo will help transform the market value chain by aiding new entrepreneurs to become millers at a com munit y leve l ,” s aid B ü h l e r S o u t h A f r i c a' s h e ad o f s a l e s R a p h ae l Krucker. “This is in line with the South African gove r n m e n t 's p l a n s t o

digital change follows a centuryold tradition of settling futures prices for crops like corn and soybeans based on transactions executed in the pits.

The US soy industry has launched a Sustainability Assurance Protocol which includes soy export documentation to support 'responsibly, environmentally, socially and economically' grown soy products. During a visit to several western European countries, United Soybean Board director Laura Foell assured importers that US agriculture is farming in more responsible and sustainable ways, and that since 1980 US farmers have produced higher yields with less energy consumption and less environmental impact.

Western Canada's transport systems are under strain as a result of record grain

s t re ng t he n r ur al economies.”

30 percent of maize flour is lost bet ween har vest and production in southern Africa's conventional value chain. By allowing maize to be processed much closer to where it's har vested, the significant losses incurred during storage and transpor tation to large milling cooperatives can be avoided.

Other Bühler innovations for Africa were on display in November at the IAOM 's annual Mide ast a n d A f r i c a c o n f e re n ce and expo, held in Sousse, Tunisia. Most notable was t he new I ns t ant M aize product, the result of an optimised milling process allowing southern Africa's staple maize mash to be cooked in as little as two minutes.

An interview with Andreas Flückiger, President of Bühler's Middle East and Africa division, can be found on page 59.

harvests in Canada's prairie regions. Shipping terminals in Vancouver and Prince Rupert are running at capacity, prairie grain elevators are full and elevator operators require double number of current rail cars provided in order to get the waves of grain off farms. "The situation this year is unprecedented," said Wade Sobkowich, executive director of the Western Grain Elevators Association.

South Korea has halted beef imports from the US after finding traces of the feed additive zilpaterol in a meat shipment. The substance, which is banned in the country, was detected in a 22-tonne shipment from Colorado-based Swift Beef Co. in September 2013.

According to the Ministry of Food and Drug Safety, South Korea has asked the US to investigate the matter.

W

ith the wrapping up of 2013, it's natural to look back as well as forward for the International Milling Directory. We have been involved in some great events this year, forged ever-closer ties with the magazine and completed a redesign Tom Blacker of our 2014 Directory which was published online last month.

Thank you to all who came back with positive responses.

You can always email me at tomb@ perendale.co.uk to do the same!

The number of industry visits our staff have made this year has been impressive once again. Alongside our regular subscribers, the Directory reached many more managers and executives in offices and events. 2013 has been a landmark year for the expansion into countries like Turkey, Taiwan, South Africa and Russia, and interest in our plans for next year has been consistently high. IMD Online has generated more online hits than forecast, owing in a large part to great web traffic coming from millers in China and India.

Our other online offering, Millinginternational.com, is my way of keeping you up to date about what I'm doing and the events we're bringing the Directory to. A lot of this job is about promotion and communication, and the blog is a great tool to reinforce that, as well as (I hope!) a great read.

So where are we bringing IMD 2014?

In the next month, the new edition will see its first company outings with IPPE in Atlanta, USA and the LAMMA agricultural equipment show in the UK. Perendale staff will be on hand at these two very different sides of the agricultural business, to take you through the Directory and perhaps even tempt you with a copy.

The redesign is not only limited to the printed directory. The monthly newsletters have also been refurbished, which means that what drops into the inboxes of its 10,000 plus readers will be clearer and more attractive than ever before.

IAOM members are due to receive a free copy of the new edition, bringing the Directory to more of the right people than ever before. IPPE, IAOM, and many more events will again be visited by the leading industry guidebook for Grain & Feed Milling Technology magazine.

November - December 2013 | 7

www.internationalmilling.com

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ASSOCIATIONS

Rice

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The Federation of European Rice Millers (FERM) Europe

USA Rice Federation USA A global advocate for the US rice industry, the USA Rice Federation is a representative organisation and leading entity with a mission to promote and protect the interests of the US rice sector.

Comprising of four primary organisations – the USA Rice Producers’ Group, the USA Rice Millers' Association, the USA Rice Council and the USA Rice Merchants' Association – the federation is a united voice, committed to strengthening the industry in the US. The collaborative theme of the federation provides financial support to the industry, as well as harnessing the wealth of experience and expertise of its members.

Made up of producers, millers and industry representatives, the federation’s board of directors provides direction to the USA Rice staff, which implements programmes and policies. www.usarice.com

As the voice of the European rice milling, representing over 90 percent of Europe’s milling capacity, the Federation of European Rice Millers is made up of 21 company members from across Europe, as well five national rice milling associations including Italy, Spain, Portugal, France and Germany.

As an authoritative voice that represents the interests of the industry, FERM aims to provide support to the European Institutions in all aspects of policy and legislation that affects the supply, milling, processing, marketing and sale of rice in the European Union.

Statistics: The European Union currently ranks 17th as a world rice producer, milling the equivalent of 1.53 million tonnes. In 2000, rice was cultivated on European Union farms on a total of about 410, 000 ha.

According to EU statistics, the average rice consumption in Europe equates to 5.2 kg per capita annually. The average rice consumption in Asia is 77 kg per capita.

Top European rice-producing countries: Italy - 221,000 ha Spain - 111,000 ha Portugal - 31,000 ha Greece - 27,000 ha France - 19,000 ha

At a press conference in Bangkok, Mr Henk van de Bunt, general manager, Victam International BV, announced the launch of the first Asean Feed & Grain Symposium, the first Asean Feed Summit and the first Asean Rice Summit. He then went on to report of the progress of FIAAP Asia, VICTAM Asia & GRAPAS Asia 2014.

To see the full story visit: http://bit.ly/1cZAfob

http://gfmt.blogspot.com 8 | November - December 2013

Who imports EU rice?

Four main suppliers currently account for more than 80% of EU imports: USA - 36% Thailand - 22% India - 13% Guyana- 10% The EU also exports to a large number of countries in the Middle East and Central and Eastern Europe. www.ferm-eu.org

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Rice Growers’ Association of Australia Inc. (RGA) Australia

Thai Rice Exporters Association (TREA) Thailand

Established in 1930 during the early years of the rice industry, from small beginnings the Rice Growers’ Association of Australia has grown into a leading force in the rice sector.

Initially, the RGA focused on building infrastructure to enable growers to mill and market their own rice. This focus was a driving force in the development of the Ricegrowers’ Cooperative in 1950 - now the grower owned company SunRice - and the Leeton mill, which opened the following year.

Today, the Ricegrowers' Association of Australia Inc, which represents over 1500 voluntary members, provides a strong, united voice for the rice industry. The RGA provides a service to its members, ensuring they have the knowledge and means to provide a legacy for their children, create employment and above all grow quality rice.

RGA fulfills this role by representing and leading growers on issues affecting the viability and sustainability of their businesses, the industry and their regional communities.

At the forefront on a range of policy issues affecting rice-growing businesses, RGA is currently working to develop a harvest mass management scheme that recognises the needs of the industry.

Statistics: - Australian rice growers produce more rice per megalitre of water than anywhere else in the world - The country boasts the highest medium grain yields globally - The Australian rice industry averages 9.7 tonnes per hectare and the 2013 crop averaged 10.3 tonnes per hectare - Australian rice growers surpassed the international average production of 5.4 tonnes per hectare 45 years ago - Traditionally, Australia exports 20-25 percent of the world’s medium grain trade

With 199 exporter members and 35 directors, the Thai Rice Exporters Association boasts a long and proud history.

Founded in 1918 as the Siam Rice Association, TREA is a significant entity in Thailand’s rice industry. The association is crucial in its role in developing the rice trading. Together with the government, TREA works relentlessly to promote the rice industry.

In 1927, the Siam Rice Association changed its name to the Rice Traders Association and continued the activities into the Second World War. During that period, the names of the association, along with all of the members and the location were changed several times.

The association is crucial in its role in developing the rice trading industry both domestically and internationally. Together with the government, the association works relentlessly to promote Thai rice globally. It has a role in promoting Thailand as a world famous rice producer and reliable rice supplier for the world’s population. www.thairiceexporters.or.th

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FEATURE

Fit-for-purpose grain and feed packaging: an environmental perspective

by Michael Bonin packaging technologist Campden BRI, UK

G

rain and grain product spoilage is an important global food security issue. I recently spoke to the director of an international freight company who had lost over 4 000 tonnes of rice due to the poor quality of woven polypropylene sacks that had been used for packing. The weave had loosened and separated due to defects in the polypropylene strands. This, combined with heavy manual handling in tropical conditions, had resulted in product spillage, moisture ingress and insect infestation.

These kinds of problems are not isolated.

According to UN estimates, more than 40 percent of losses occur in developing countries during post-harvest handling and processing where the packaging of grain and grain products is a major challenge for producers. In financial terms, grain losses in sub-Saharan Africa could represent as much as US$ 4 billion (Gustavsson et al, 2011).

On a global scale, cereal production is projected to keep up with an estimated annual demand of 2 600 million tonnes by 2020 (OECD-FAO, 2011), but with a growing world population expected to reach 9.1 billion by 2050, a 70 percent increase in global food production will be required – including an increase in cereal production to 3 000 million tonnes per annum (UN FAO, 2009).

While multifaceted solutions and approaches are required to solve these problems, packaging plays a major role in ensuring food security and safety and is crucial in reducing loss and wastage at all stages of the grain and grain product supply chain in both developing and industrialised regions.

Although much of the grain produced glo-

10 | November - December 2013

Case study

Arodo

by Bob Berghans, Arodo BVBA. Belgium The objective of any producer is to set up an efficient line that meets quality, time and economic objectives to be able to maintain its competitive position in the market. A flour producing company in the Antwerp region thought exactly that, and was looking to install a packaging line for its new plant. Keeping that in mind, they began searching for the best possible solution.

After conducting general market research and having drawn up a short supplier list, it was the Belgian firm Arodo that offered the most appropriate answer to their specific demand, a filling, palletising and stretchhooding line. At the first stage the empty flat bag is labelled and attached to the filling spout. The flour drops from the silo through a screw dosing and gross weighing system in order to fill the bag to exact specifications.

Tight fastening to the filling spout prevents waste and any escape of dust.

The pinch bag is conveyed to the closing section using a unique transport device to guarantee accurate and reliable presentation of the stretched sack top. At this stage it is closed in three different steps while being continuously held by the gripping sledge arms. The top is folded, and then the glued bag top is first heated and then cooled to make a seal. From there, the conveyor belt takes the bag through the metal detecting device and on to the palletising section.

In palletising, different options can be offered depending on the stacking required. In this case, the best solution was a system combining the advantages of a robot and a conventional palletiser in one. It is ideal for overlapped palletising of different sack dimensions caused by fluctuating weighments and product densities. Furthermore, a stable pallet is created through the overlapped sack positioning that also enables pallet layers to be formed on coordinates inboard of the pallet, helping reduce damage caused by overhang. Put simply, every layer of bags lying on the ‘table’ is gently put onto the underlayer by opening the table layer.

A very precise and secure finished pallet is also achieved by applying side and top pressure.

Additionally, each empty pallet is given a plastic layer to prevent any ingress of moisture.

Last stage in the line is stretchhooding the pallet. It is absolutely waterproof and therefore gives optimal protection against all weather conditions, as well as localised dust ingress. Stretching the hood utilises ‘film memory’, which provides pallet load stablisation for safer transportation.

Arodo was founded 25 years ago by Henk Marien and Diet Doormaal, and now employs over 120 people specialising in engineering, drawing and construction. The Belgium-based company has a reputation for expertise in the design and production of customised packing machines, which are sold worldwide.

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FEATURE bally is handled in bulk, a significant proportion still needs to be packaged and therefore requires packaging that is fit for purpose.

Grain and grain product spoilage factors can be grouped into three main categories: • Physical losses caused by spillages, which occur due to the use of faulty or underspecified packaging materials • Physiological losses including moisture absorption, heating and respiration due to exposure to high humidity, temperature and oxygen, as well as physical taint and taint from odours • Biological losses due to micro-organisms, insects and rodents The basic functions of any packaging for cereal and cereal products include: • Containment – to protect the contents from spillage • Protection against external environmental conditions such as humidity • Protection from insect infestation and pests • Protection from external odour and taint • Ability to withstand mechanical hazards during transportation • Ease of handling and stacking to optimise the use of available space In addition, the packaging should be economical and may be required to help promote brand awareness through the addition of graphic designs and printing processes.

Figure 1: Potential environmental impacts of underpackaging and over-packaging

Over recent decades, developments in grain and feed packaging have gone a long way towards fulfilling these functions. We have seen advances in materials from sacks made from traditional jute and natural fibres, multiwall paper, high density woven polyethylene or polypropylene sacks, to packaging made from advanced polymers which have allowed down-gauging (reducing the amount of material used) and weight reduction of materials while maintaining equivalent package strength.

Environmental factors as drivers for development The main drivers for these developments have generally been cost reductions

and performance improvements of materials and sealing systems, which have advanced alongside the development of high-speed filling lines. Major cost reductions have also been achieved through the use of efficient packaging, which has helped to reduce product spoilage and wastage during distribution and storage.

However, in recent years an additional and growing set of drivers have emerged which may influence the choice of packaging.

These drivers are the environmental concerns surrounding packaging in all production sectors. Environmental issues have now become drivers in their own right, due to increased regulation, greater public awareness, and an increased recognition from

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FEATURE producers that these are issues which every industry must tackle.

While it may be very tempting to make intuitive assumptions as to which type of packaging will be “greener”, these are at best merely guesses which can often include myths based on an incomplete understand-

Case study:

Robotic packing transforms production at G Owen & Sons

by Bev Small, Pacepacker Services, UK A pre-owned robotic solution has increased the production efficiency of copackers G Owen & Sons by 100 percent, bringing them a fully automated production and enabling the Wales-based company to meet their customer’s tight delivery timeframes. Pacepacker Services installed the FANUC 420 Blu-Robot, which is now stacking over 4,000 bags of animal feed per day and has overcome previous issues of inaccurate stacking due to different density levels caused by the wide range of feed types being bagged. As pre-owned models are typically half the cost of a new robot, G Owen & Sons will see a return on investment in less than 12 months.

On an annual basis G Owen & Sons contract pack over 30,000 tonnes of animal feed for distributors to sell direct to farmers or merchants across the UK. The feed, which is predominantly for farm animals, is offered in a range of up to 100 different types, and is packed within bags from 20 to 25 kg in weight. However, the vast range of food types used causes filled bags to distend differently, which resulted in inaccurate stacking by the original layer palletiser. Company director Murray Owen explains: “Although it could meet our output requirements, the layer palletiser was having difficulty in neatly stacking our wide range of products and as a result we were having to manually align the bags to ensure that we had well-presented stacks of up to 50 bags per pallet. With the additional demand from customers for next day delivery, it was essential that we replaced the palletiser to make the line more efficient.”

Pacepacker, a FANUC strategic partner, had installed a robot onto one of G Owen & Sons’ coal packing lines over a decade before. As a result they renewed contact with them with a view to replacing the existing palletiser and overcome the stacking issue. To meet G Owen & Sons’ budget constraints, Pacepacker came to the solution of a Blu-Robot (a pre-owned FANUC 420) was installed within the factory.

“The original layering palletiser, while having the ability to run at the desired

12 | November - December 2013

ing of the issues. A key question which must be addressed from the outset is how is it possible to quantify and compare the environmental profiles of different packaging materials?

Even if we assume that different packaging formats are capable of performing the speed, created issues due to the inaccuracy of the stacking which was caused by the differing densities within the packed bag,” explains Pacepacker sales manager Chris Francis. “To overcome this problem we fitted a gripper arm onto the robot which has the added benefit of being able to effectively grip and neatly place the bags onto the pallet.”

“The end effecter also offers the robot the added ability to switch easily between stacking different bag sizes, dependent on the product option selected from a pre-programmed list of recipes which we implemented prior to installation.”

Not only has line’s efficiency improved by 100 percent, the installation of the BluRobot has eliminated the need for manual labourers to manipulate the stacked pallet, resulting in a fully automated line.

“Within our budget constraints, we wanted a versatile robotic system that would increase the efficiency and presentation of our packing line, which with little human intervention would quickly switch between the different bag sizes dependent on our customer demands,” says Murray Owen. “At half the cost of a new system, Pacepacker’s pre-owned FANUC has provided us with an affordable solution; we should see a return on our investment in just under 12 months.”

An active member of the British Automation and Robot Association (BARA), Pacepacker launched the economical Blu-Robot in support of the association’s Automating Manufacturing Programme, which aims to increase robot uptake in the UK, and is aimed at automation-shy small to medium enterprise manufacturers and seasonal packers. The pre-owned FANUC 420 installed within G Owen & Sons is approximately 10 percent of the way through its expected operational lifespan of at least 100 000 hours.

Pacepacker’s Chris Francis is positive about the potential of pre-owned solutions. “Through the Blu-Robot G Owen & Sons has received a solution which has 90 percent of its minimum expected lifespan still left in the tank. As a testament to the longevity of the robots, Pacepacker installed a FANUC robotic palletiser within their own factory over a decade ago, and the company has recently recorded a palletising weight achievement on this robot of one million tones.”

same functions, the empty packs may have different weights (with associated transport implications), different recycled and recyclable contents, and be capable of different filling line speeds which may require a varying number of filling lines to achieve an equivalent level of production.

In fact, no packaging material has a monopoly on environmental virtues.

Provided it is fit for purpose in helping prevent product spoilage, all packaging can make a positive contribution to sustainability. It is obviously in nobody’s interest to over-package grain products and so in this respect the producer and environmentalist are in full agreement. However, while lightweighting and down-gauging can improve the environmental profile of packaging up to a certain point, under-packaging will not if the result is increased product wastage, spoilage or a reduction in product quality, then this under-packaging will not deliver the benefits. Figure 1 shows the spectrum of over-packaging and under-packaging plotted against potential environmental impacts.

Figure 1 illustrates that there is an optimal level of packaging required, above which excess materials are wasted with associated transport and disposal impacts.

Below this optimal level, under-specified packaging materials may not fulfil their protection or preservation functions and so could be completely wasted if their contents are spoiled.

More significantly under this scenario, any product losses occurring as a result of underpackaging include all the embedded environmental impacts (energy, water use, emissions to air and land etc) associated with grain production. While it could be argued that these production impacts will occur whether the grain is wasted or not, if a food resource is disposed of and fails to reach its intended consumers then more food will have to be produced to replace it. In addition, disposal impacts from grain losses may include carbon dioxide and methane emissions, both of which are global warming gasses.

That situation is described by the curve to the left of the optimal point in Figure 1.

It rises much more sharply than the curve to the right, reflecting the greater potential environmental impacts of under-packaging.

Therefore, packaging technologists generally err on the side of caution, preferring to specify packaging toward the upper end of the optimal range rather than under-specifying and risking product wastage, which would increase both cost and environmental impacts significantly.

Clearly the environmental issues surrounding grain packaging are just as complex as those of any other sector and we should be wary of over-simplification. Methods to systematically quantify the environmental profiles of different packaging systems do exist, but these can be time-consuming and costly to conduct.

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Life cycle assessment

Figure 2: The LCA methodological framework according to ISO 14040:1997

Life-cycle assessment (LCA) is a family of tools and techniques underpinned by the ISO 14040 series of standards, designed to assist in environmental management and sustainable development in the long term. LCA is generally considered to be one of the most important environmental analysis tools for evaluating aspects associated with products, processes or activities throughout their entire life cycles. In the case

of packaging, LCA can encompass all associated activities, from extraction of raw materials to processing, manufacturing, use and re-use, right through to final disposal.

The LCA methodology is a structured framework that specifies the required data, methods of calculation and the procedure of its interpretation. This involves description of the system to be assessed, production of an inventory of inputs and outputs associated with that system, translation of this inventory data into potential environmental impacts, and finally, evaluation of the results in order to facilitate decision-making. Figure 2 gives a broad overview to the technique, illustrating the separate stages of the LCA methodolog-

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FEATURE ical framework. The double-headed arrows shown in Figure 2 indicating that LCA is an iterative process, which feeds back upon itself throughout its separate stages.

To a considerable extent, LCA studies rely on the quantity and quality of data used at the inventory stage and this is naturally reflected in the quality of the final LCA results. Often, both published and site-specific data are used to develop an inventory. However the data are obtained, the inventory analysis is generally the most time-consuming stage of LCA studies and is often a limiting factor for wider LCA application. For this reason, the majority of those conducting or commissioning LCA studies are generally large, well-resourced organisations with the greater ability to actively aim for longterm development of their businesses.

Whether grain producers and packers have the time and resources to conduct complex LCA studies on which to base their choices of packaging materials and methods will vary from organisation to organisation. However, both in terms of economic and environmental performance, ensuring that packaging is fit for purpose is essential for all organisations of any size. While over-specified packaging may be both environmentally and economically wasteful, it is not nearly as wasteful as packaging which turns out to be under-specified.

Thus a balance must be struck in order to optimise packaging.

Packaging testing Achieving an optimal packaging balance requires some understanding of the properties of the packaging materials and the integrity of the filled package. These specifications may come from the packaging suppliers and can be tested by packaging testing laboratories which conduct examination and assessment in multiple aspects of packaging to ensure that it performs to specification and is fit for purpose. Food processing and packaging are increasingly viewed as an integrated whole and consideration of that collective as well as each individual aspect is essential in assuring product quality and safety. Not only must the packaging retain its integrity and have the correct physiochemical properties to fulfil its functions, but it must also ensure that the quality of the product is not impaired by taints.

Campden BRI’s Packaging Testing Laboratory specialises in all types of food packaging and works in close conjunction with other disciplines within the organisation, such as food microbiology, microscopy and migration (food contact) testing. This multidisciplinary approach provides analyses and solutions across all areas of the food industry. Our expertise in all these food packaging areas provides a holistic approach while viewing packaging innovations in the context of wider industrial developments. As well as advising on packaging suitability we

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have a range of packaging analysis facilities that include all aspects of mechanical testing and also chemical and sensory taint analysis capabilities. The objectives of this work are to assist in achieving the correct balance of fit-for-purpose packaging for our clients, which in the broader sense helps to reduce the environmental impacts of packaging and food production.

References: Available on request

About the author Dr Michael Bonin is a Packaging Technologist at Campden BRI with a research background in the properties of starch-based plastic foams and their commercial application. He has experience in package transit testing which provides a practical understanding of the relationship between packaging materials and their distribution environment. Michael also has experience in environmental profiling of renewable and biodegradable materials by means of life-cycle assessment (LCA) methodology. Michael’s main research interests are in the field of packaging for the food industry and environmental technology.

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FEATURE

Single or twin-screw extruder: what are the options?

by Dr Mian N Riaz, director, Food Protein R&D Center, Nutrition and Food Science Department, Texas A&M University, USA

S

electing an extruder can be a confusing process for buyers. Many options are available in the marketplace when selecting extrusion systems for product.

For example: is a single- or twin-screw extruder required? Should it be a "wet" or "dry" extruder? Should it have internal steam locks or a single face die plate?

Should it have continuous or interrupted flights, and so on. Appropriate selection depends on several factors: • Physical and sensory properties of the end product • Formula ingredients: their physical nature (i.e. whether the product will utilise high levels of fresh meat), moisture content, whether they are constantly available or only during certain seasons, and the potential for occasionally using substitute ingredients.

• What kind of product do you want to extrude? Is it food grade, or feed or pet food? Should each piece be multicoloured or centre-filled? Is the shape general, exotic, or detailed? What is the target bulk density? In the case of feed, how much fat needs to be added to the formula? How much can be applied to the surface?

• What is the production rate? The size of an extruder depends on market size, since extruders function best when operating at full throughput per hour.

• What is the energy source? For product heating, will steam or electricity be more economical where the extrusion plant is built? If it is a small operation in a developing country, would a tractor power take-off drive be more suitable?

• What about capital availability and the recovery date target? Would a used extruder fill a start-up operation’s needs better?

16 | November - December 2013

Segmented screw/barrel singlescrew “wet” extruders Segmented screw/barrel single-screw extruders are the most widely applied cooking extrusion design in the food, pet food and feed processing industries. “Wet” means that steam and water can be injected into the barrel during processing. Typically, the barrels of these machines are also equipped with heating and cooling jackets. They can process more tonnage of extruded products than any other extruder design, and can produce a range of products, from fully cooked, light-density corn snacks, to dense, partially cooked and formed pastas.

A typical single-screw extruder consists of a live bin, feeding screw, preconditioning cylinder, extruder barrel, die and knife. The live bin provides a buffer of raw material so the extruder can operate without interruption.

Typically, the height of raw material in the bin is kept within defined limits by high- and low-mounted sensors which activate a conveyor supplying the bin. The bin is designed to prevent the bridging of its contents, and the blocking of the feed screw leading to the preconditioner. The speed of the feed screw to the conditioner or extruder must be variable, in order to ensure a continuous uniform supply of raw material. This is crucial to ensure the consistent and uniform operation of the extruder.

Because single-screw extruders have a relatively poor mixing ability, they are usually supplied with premixed material, which often has also been preconditioned with added steam and water. Generally, preconditioning prior to extrusion enhances extrusion processes which benefit from higher moisture content and longer equilibration time. Preconditioning of the raw material typically improves the life of wear parts in the extruder several times over. Although the weight of ingredients in the extrusion

system is increased, preconditioners are relatively inexpensive to build for the volume they hold and the time they add to the process. Perhaps most importantly, product quality can be greatly improved by preconditioning the raw ingredients.

Application The first major commercial application of the single-screw extruder in the food processing industry was the conversion of semolina flour into pasta using solid screws.

This low-shear, low-temperature forming process first found commercial production in the 1920s and 1930s, and remains a standard process even though equipment has improved. Several recent developments in the single-screw extruder have further increased its efficiency and versatility. A brief list of the products made by single-screw extruders can be found in Table 1.

Twin-screw extruders Recent years have seen increasing requirements for new products with intricate shapes and small sizes, which are beyond the capabilities of single-screw systems. Twinscrew extruders can fill some of these needs.

The term “twin-screw” applies to extruders with two screws of equal length, both placed inside the same barrel. Twin-screw extruders are much more complicated than single-screw extruders, but at the same time provide much more flexibility and better control. Twin-screw extruders are generally categorised according to the direction of screw rotation and to the degree to which the screw intermeshes.

In the counter-rotating position the extruder rotates in the opposite direction, whereas in the co-rotating position the screw rotates in the same direction. These two categories can be further subdivided

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according to the relative positions of the two screws (intermeshing and non-intermeshing).

The non-intermeshing twin-screw extruder is like two single-screw extruders sitting side by side, with only a small portion of the barrel in common. These types of extruders depend on friction for extrusion, just like single-screw extruders. In non-

intermeshed extruders, neither pumping nor mixing is positive. Their design does not provide a positive displacement action for pumping the product forward.

In intermeshing twin-screw extruders, the screws partially overlap each other in a figureeight barrel track, resulting in positive pumping, efficient mixing and self-wiping action (although only in co-rotating machines: mixing is limited in counter-rotating machines).

This is what differentiates these types of extruders from non-intermeshing and singlescrew machines. These extruders are like a positive displacement pump, forcing material in the barrel between the screws to move toward the die by the rotation of the screw.

Co-rotating self-wiping types of extruders are most commonly used in the food industry. When they were developed, these extruders significantly increased the variety of products that could be made using extrusion technology.

The twin-screw extruder consists of several sub-components very similar to singlescrew extruders (live bin, feeding screw, preconditioning cylinder, extruder barrel, jacketed heads and rotating screw). The bearing assembly in twin-screw extruders is much more complicated because more components (such as drive and torque dividing gears) are required. Twin-screw extruders also have three processing zones: feeding, kneading and a final processing zone

very similar to single-screw extruders. These zones were described in the single-screw extruder section above.

Applications Twin-screw extruders became popular in the food industry in the mid-1980s to the mid-1990s. Originally developed for processing plastics, food companies began using twin-screw extruders for products like sticky caramels and candies that could not be made with single-screw machines.

Very soon, twin-screw extruders became popular with food manufacturers for many specialised food items.

However, new developments for singlescrew extruders are beginning to change the relative advantages of the two technologies.

Variable speed drivers now give single-screw extruders a flexibility approaching that of twin-screw machines. Improved gravimetric feed systems and mass flow meters allow for the more precise measurement of recipe components. These recent improvements, along with systems for computer control, have made it possible to process several foods formerly made with twin-screw, possibly limiting the market for twin-screw extruders.

Single-screw vs twin-screw Single-screw extrusion has been successfully employed in food and feed production

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FEATURE

for the last 60 years. Because of consumer demands for innovative food products in the market, extruder manufacturers adopted and developed twin-screw extruders around 30 years ago.

Twin-screw extruders have greater ability and flexibility for controlling both product and process parameters. They are a flexible design, permitting easy cleaning and rapid product changeover. Because of the ability to better match the desired shear, the twin-screw extruder has more control over product variability. Screw speed can also be used to compensate for some variations in the properties of the starting material. Because screw speed is such an influential variable, the twin-screw extruder is a better choice for plants producing a wide variety of high-value products at low volume.

Single-screw extruders limit formulas to a 12-17 percent fat level. Fat content above that level reduces friction due to lubrication, and does not help the hardware transform mechanical energy into heat for cooking purposes. On the other hand, the fat level for recipes designed for twin-screw extuders can be as high as 18-22 percent and still maintain the required mechanical energy. This is only possible due to the greater number of screw configuration options provided by twin-screw extruders, compared to singlescrew machines.

In single-screw extruders, with the help of steam injection a fat level as high as 17 percent can be achieved. However, the addition of steam injection to twin-screw extruders allows the product to be processed more consistently, which as a result 18 | November - December 2013

allows better binding of the fat and reduces its leakage from the products during handling and packaging.

Moisture content is very critical during the extrusion process for starch gelatinisation and protein denaturation. The average moisture content of a typical formula ranges from 20 to 28 percent. Moisture, in the form of steam or water, is added to the preconditioner and extruder barrel to help soften raw ingredients and reduce their abrasiveness. Twin-screw extruders have the ability to run equally under narrow or wide ranges of moisture.

Ultimately, processors should consider using twin-screw extruders in situations dealing with: • Frequent product changeovers • Products with a high internal fat content (more than 17 percent) • The addition of a high level of fresh meat in the product (up to 35 percent) • Uniform product size and shapes • Ultra-small product sizes (less than 1.5 mm) • Products made with low density powders • Special formulations (e.g. products with high levels of protein and fibre, or which require a high level of moisture, or require the use of sticky raw materials like soy isolates or wheat gluten)

Table 1: Single-screw extruder products Direct expanded corn snacks Texturised vegetable protein Ready-to-eat breakfast cereals Full-fat soy Pet foods Floating and sinking aquatic feed Baby foods Rice bran stabilisation Precooked or thermally modified starches, flours and grain Breading

Table 2: Twin-screw extruder products Co-extruded snacks and other food items Precooked pasta Noodles, spaghetti and macaroni Third-generation snacks Texturised vegetable protein (soy and wheat) Semi-moist food Pet treats Meat analogue Rice bran stabilisation Multicolour food and snacks Cereals and corn flakes Corn chips and tortilla Loose fill (packaging material) from starches

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Animal feeding in the future: reaching genetic potential through smarter nutrition?

Feed focus

POULTRY

by Aidan Connolly, Vice President, Alltech Inc. and Dr Alexis Kiers, poultry health consultant, Washington, DC, USA

I

n the last decade, animal protein production has faced all-time record high commodities prices, the occurrence of serious diseases such as avian influenza (e.g. H7N9), porcine epidemic diarrhoea (PED), food scares, salmonella in dairy farming and campylobacter in chickens.

Each of which is related to the increased intensification of farming, but can be mostly attributed to authorities' ability to analyse for contaminents at even lower levels.

Indeed, the ability to detect polychlorinated biphenyls (PCBs), heavy metals and mycotoxins in feedstuffs has never been more sensitive, making us aware of risks we never used to imagine.

Against this backdrop, the increased restriction on the use of growth promoting compounds such as subtherapeutic antibiotics (AGPs) has been a worldwide phenomenon. New limits on the incluson of AGPs in animal diets are now in place in the 28 European Union countries, the Middle East, Turkey, Japan, Chile, India and South Korea, and the United States will soon follow. Its Food and Drug Administration (FDA) is on course to implement restrictions in late 2016, either by removing antibiotic compounds from the market completely or by requiring their re-registration for therapeutic use, with veterinary oversight and prescription. It may seem that the only constant for those involved in the production of meat, milk and eggs is that these changes will continue to occur at an even greater rate.

In the meantime, the genetic improvements in animals continue to astonish even the hardiest of observers. While farm productivity yields have improved in the last seven years at half the rate of the previous 50 years, we continue to see extraordinary leaps in the ability to get more from less.

Historically, broiler producers talked

20 | November - December 2013

about the ideal of '2:2:42', which meant profits, that target may be difficult to envigrowing a two kilogram bird, with a feed sion. Animal protein producers are already conversion ratio of 2:1, in 42 days. With efficient; for example, broiler integrated continued genetic advances, and a rhythm of operations are reaching two kilogram marimprovements of 50 grammes or 2 percent ket weight in 36 days, attaining an 85 extra weight for the same age per year, will it percent yield, and achieving a 1.45 FCR. be possible to achieve that same weight with So where are the gaps between genetic potential and real animal performance? Is just one kilo of feed by 2025?

In a global context, this means we could reaching a 1:1 FCR by 2025 in poultry, or use 30 percent less grain to produce 100 2:1 in pigs a dream, or a reality?

The possibility of a 1:1 FCR was first probillion tonnes of broiler meat, or produce 45 percent more meat with the same feed, posed by Foulds in 20052, and more recently making chicken meat even more economi- by Brazilian nutrition and feed management cal, and thereby assuring its availability to consultant Ronei Gauer. The industry is, a growing population. When we look at however, still struggling to reach that taregg, turkey, duck, pork, dairy and even beef get. At Alltech's 29th Symposium, speakers production, we see similar advances, albeit highlighted five obstacles in poultry that are sometimes harder to quantify because of estimated to represent as many as 40 points the multitude of feed sources used, and the of lost feed conversion (0.40) in poultry. less homogenised nature of their production systems. If genetic improvements can bring Gut health about a 30 percent reduction of the entire Gut health plays a vital role in poulindustrial feed market approaching one bil- try production. Dr Peter Ferket of North lion tonnes', they have significant implications for the sustainability and availability of affordable food.

With the world's population closing in on eight billion by 2025, and set to exceed nine billion by 2050, the critical importance of continuing to improve food production efficiencies is clear. Sometimes, however, the short-term focus takes precedence.

Amid our current state of battling $350 per ton Figure 1: US agricultural output, inputs, and total factor productivity, 1948-2011 (USDA, Economic feed costs, and downResearch Service) ward pressure on bird prices pulling down

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POULTRY Carolina State University pointed out that only a healthy gut can digest and absorb the maximal amount of nutrients. If the digestive system is compromised, its requirements for energy and protein increase sharply. This can severely diminish the nutrients available to the bird for growth, slowing weight gain and leaving a plunge in feed efficiency. In addition, most intestinal challenges will lead to reduced feed intake that can further impact bird performance.

Three components are important for a healthy gut and improving FCR: ecological environment, nutrient balance and symbiotic microbial stability. Poor intestinal health can increase moisture content of the excreta, negatively affecting litter conditions, increasing ammonia levels in the house and leading to respiratory problems. Wet litter has also been shown to increase footpad dermatitis, hock burns, processing downgrades and condemnations. Runting, stunting and other viral diseases can also be exacerbated by a poor house microflora.

With these repercussions, every poultry operation should be fine-tuning their gut flora management programmes. Recommended steps include seeding the gut with favourable organisms, preparing the environment for digestion, excluding pathogens, enhancing resilience and decreasing feed passage. This involves applying a probiotic or competitive exclusion product as soon as possible after

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hatching. In the absence of antibiotics, a key factor in maintaining an optimal gut microflora is to control the flow of nutrients down the gastrointestinal tract. Diet digestibility should be maximised by ingredient choice and enzyme use, thus avoiding excessive substrate for bacterial growth. Also, consider the use of an appropriate organic acid in the diet and drinking water. Application in water can specifically address critiFigure 2: Recent FCR evolution of broilers cal phases, such as brooding (Ronei Gauer, 2013) or later in production, when the risk of necrotic enteritis is particularly high. Lastly, the gut flora management programme should ery to seed the gut, while feeding beneficial include blocking the attachment mechanism bacteria with organic acids in the water, as of unfavourable organisms with a type-1 fim- well as enzymes to reduce non-digestible feed bria blocker, thereby reducing their ability to fractions that may cause the proliferation of contend with favourable organisms within clostridia, and weeding harmful type 1 fimbria the gut. The Alltech gut health programme bacteria (such as E.coli and salmonella) using is now being implemented by 25 companies a mannan-rich fraction of yeast carbohydrates worldwide, with half of those participating in (ActigenTM). In the absence of antibiotics, a key factor in maintaining an optimal gut microNorth America.

D Steve Collett of the University of Georgia flora is to control the flow of nutrients down demonstrated the advantages of a program the gastrointestinal tract. called 'Seed, Feed and Weed' in improving gut health and FCR. The programme consists Quality control of using lactobacillus probiotics in the hatchConsidering the implications of poor

November - December 2013 | 21

Table 1: Summary of live performance results from broiler trials with negative control (nCON) versus Actigen-supplemented (ACT) diets Age

Actigen

Body wt or gain, kg FCR or F/G ratio

days

g/tonne

nCON

ACT

nCON

ACT

nCON

ACT

42

800/400/200

2.382

2.501

1.947

1.852

4.83

4.46

Mathis (2009)

42

400

2.081

2.134

1.825

1.784

3.69

4.77

Kill et al. (2010)

42

400/200

2.763

2.865

1.872

1.82

5.6

3.8

Kill et al. (2010)

42

200

2.37

2.516

1.74

1.66

13.9

12.5

Kill et al. (2010)

40

800/400/200

2.37

2.552

1.74

1.66

13.9

11.5

Nollet and Kay (2010)

42

200

2.37

2.441

1.74

1.7

13.9

17.4

Perić et al. (2010)

42

400

3.317

3.437

1.746

1.708

5.56

3.89

Perić et al. (2010)

42

800

2.066

2.065

2.02

2.01

6.25

6.25

Perić et al. (2010)

35

400/200

2.066

2.234

2.02

1.95

6.25

2.3

Venkatesh (2010)

49

400

2.066

2.151

2.02

1.96

6.25

4.93

Corneille (2011)

42

400

2.521

2.657

1.636

1.603

4.3

6.2

Gernat (2011)

42

400/200

1.877

1.901

1.658

1.654

4

4

Gernat (2011)

42

200

2.515

2.847

1.741

1.694

6.67

6.67

Gernat (2011)

1

2

3

4

5

Mortality, %

Reference (Year)

42

200

2.515

2.677

1.741

1.729

6.67

3.33

Lea et al. (2011)

42

400

2.515

2.749

1.741

1.725

6.67

5

Lea et al. (2011)

42

800

Lea et al. (2011)

1.6

1.65

1.89

1.87

5

5

34

6

800/500/300

2.743

2.825

1.942

1.939

3.34

5.5

Lausten et al. (2011)

34

800/500/3006

2.469

2.478

1.79

1.75

8.51

4.07

Lausten et al. (2011)

42

800/400/2007

2.469

2.468

1.79

1.75

8.51

5.99

Mathis (2011a)

52

400

2.469

2.451

1.79

1.77

8.51

4.46

Mathis (2011b)

42

800/400/200

2.165

2.2

1.52

1.49

5

6.4

Munyaka et al. (2011)

32

400

2.118

2.135

1.61

1.56

3.9

3.3

Nollet (2011)

49

800/400/2005

2.79

2.799

1.96

2.02

6.3

7.6

Sasou & Corneille (2011)

42

400

2.349

2.346

1.75

1.72

5.3

3.79

Guo et al. (2012)

42

800/400/2008

2.349

2.264

1.75

1.76

5.3

3.79

Guo et al. (2012)

42

200

2.397

2.383

1.83

1.83

4.39

3.72

Ivkovic et al. (2012)

42

400

2.397

2.392

1.83

1.79

4.39

2.7

Ivkovic et al. (2012)

52

800/200

2.832

2.992

1.846

1.772

0.83

1.04

Mathis (2012)

35

800/400/200

2.541

2.699

1.494

1.481

8.3

8.3

Swick et al. (2012)

29

29

29

29

29

29

2.396b

2.476a

1.792a

1.759b

6.41a

5.61b

8

9

Comparison (n=) Mean P value

<0.001

<0.001

0.031

Difference

+0.080

-0.033

-0.8

Diff. from nCON, %

+3.34

-1.84

-12.5

Average age was 41.72 days (number = 29). 2Actigen in starter 0-21 days, grower 21-35 days, and finisher 35-42 days unless otherwise stated. 3Actigen at 400 g/tonne from 0-21 days and at 200 g/ton from 21-42 days. 4Actigen in starter 0-10 days, grower 10-25 days, and finisher 25-40 days. 5Feed phase ages not given.

6 Actigen in starter 0-7 days, grower 7-28 days, and finisher 28-34 days. 7Actigen in starter 0-17 days, grower and finisher 17-52 days. 8Actigen in starter 0-7 days, grower 7-21 days, and finisher 21-42 days. 9Actigen in starter 0-10 days, grower 10-24 days, and finisher 24-35 days.

1

gut health and the challenges crops faced this year in the field, finding good feed sources has become even more important to poultry production. Poor feed quality will always negatively impact intestinal health and the overall efficiency of the digestive 22 | November - December 2013

tract. Recent data shows that some types of mycotoxins can weaken the intestinal barrier and thus increase the risk of invasive microbes like Salmonella enteritis passing the gut wall and entering the bloodsteam. The extremely hot and dry growing season of

2012 was a precursor for Aspergillus, the mould responsible for aflatoxins. If the corn was further damaged or stressed by insects or hail, the chance of aflatoxin contamination is greater still.

Poor feed quality will always negatively impact intestinal health and overall efficiency of the digestive tract. Feed quality is affected by many factors, including the way the grains and proteins have been grown and processed, and the way in which feed is manufactured. For example, more than 500 types of mycotoxin are known to induce signs of toxicity in avian species, and it is estimated that 25 percent of the world's crop production is contaminated.

Gary Gladys, former CEO of US poultry producer Allen Farms, mentioned that the main component of water management is making sure your birds are actually getting water. Dr Aziz Sacranie, poultry health director with Alltech, also spoke on the benefit of good water quality, often overlooked in terms of its impact on bird performance and FCR. Effective chlorination and acidification are essential, given that 70 percent of final bird weight is water. As mentioned above, the brooding phase is critical for water acidification, as are later stages in production when the risk of necrotic enteritis is particularly high.

The value of feed Near infrared technology offers the ability to properly determine the actual feeding value of the ingredients in the feed. With current corn and soybean prices at record highs, and easily influenced by market speculations, real time, accurate nutrition is at a premium. Gladys and Dr David Wicker of Fieldale Farms, USA, both highlighted the difference between real feeding values and the book values for raw materials. Variations in protein analysis, starch and moisture are just three examples. The FCR losses represented by inaccurate or variable nutritional values can be considerable, and the use of NIR can clearly play a role in capturing value and eliminating losses. Feed materials need to be cleaned, ensuring that both broken grains and dust have been removed.

Enzymes, especially those produced through solid state fermentation, can also address these variations.

Cocci control Coccidiosis control has always been a key concern in poultry farms, but was also mentioned by eight of the ten Alltech symposium speakers when discussing FCR, particularly given the growing demands to produce antibiotic-free broilers. Any programme must address the question of whether to use a chemical, antibiotic or vaccine option. Natural control compounds are arriving in the marketplace, but it seems that natural solutions will involve multiple active ingredients and not any one single ingredient.

The development of necrotic enteritis is a

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POULTRY

innOVaTiOn DisTinguishes BeTween a leaDer anD a FOllOwer.

—Steve Jobs

How are you going to navigate the ever-changing dietary landscape?

Today’s dietary demands are literally all over the board. While some consumers are demanding nutritious foods that are quick and easy to prepare, others desire protein-rich food that fits a low-carb or vegetarian lifestyle. Still others are simply looking for enough affordable food to feed a growing population. At Wenger, we partner with food companies to develop the processes and products they require to meet world consumer’s specific nutrition demands. Within our world-renowned Technical Center, we provide unmatched expertise for development challenges, whether it be for foods that are ready-to-eat, gluten-free, protein enhanced, heart healthy or have a low-glycemic index. And the list goes on.

Contact us now. With new concepts and fresh initiatives, we’re ready to help you meet the everchanging requirements of the food industry.

Turning ideas into opportunities.

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Taiwan

Brasil

China

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inDia

5/30/13 4:42 PM

November - December 2013 | 23

Table 2: Global timeline for restrictions on antibiotic growth promoters and bans on their use for food animal production Year

Legislature

Growth promoter

1972-74

European Union

1986

Sweden

Ban on antibiotics use for growth promotion in agriculture, as requested by Federation of Swedish Farmers

1988

Sweden

End of use of all general prophylactic medications

1995

Denmark

1995

Canada

Ban on tetracycline, penicillin and streptomycin for growth promotion use

Ban on routine prophylactic use of antimicrobials, ban on use of avoparcin for all agricultural purposes Carbodox banned due to being a human carcinogen

1996

Germany

Avoparcin banned

1997

European Union

Avoparcin banned

1997

The Netherlands Olaquindox and carbadox banned

1998 1999

Denmark

Virginiamycin banned

Denmark and Switzerland Ban on all subtherapeutic AGP in feed

1999

European Union

1999

Sweden

2000

Philippines

2000

Taiwan

2001

European Union

Olaquindox and carbadox banned, suspension of authorisation for bacitracin, tylosin, spiramycin and virginiamycin Ban on use of remaining AGPs flavophospholipol and avilamycin Olaquindox, carbodox, nitrofurans and chloraphenicol banned Avoparcin banned Avilamycin, bambermycin banned

Chile, Brazil, Japan and Middle 2001 Avoparcin banned Eastern countries 2005

Turkey

2006

European Union

2006

Thailand

2010

Bangladesh

2011

South Korea

Complete ban on subtherapeutic AGP use in feed Complete ban on subtherapeutic AGP use in feed All AGPs banned in line with European Union All AGPs banned in new Feed Act All AGPs banned

2012

India

Official ban with AGP withdrawal periods

2013

USA

Ban on the use of roxarsone, carbarsone and arsanilic acid in poultry and pig feeds

2013

China

Without official regulation, Ministry of Agriculture has announced a forthcoming ban on AGPs in animal feed

2013

Japan

Monitoring AGPs but no clear timeframe

2013

USA

Preventing Antibiotic Resistance Act of 2013. Dateline of end of 2016 / early 2017 has been clearly stated

secondary concern, and the gut microflora management programme was demonstrated as essential by Dr Collett and Dr Ahmad Mueez of Neogen, Inc. Diet digestibility should be maximised by ingredient choice and enzyme use, thus avoiding excessive substrate for bacterial growth.

Feeding the genes Studies have indicated that it is possible to imprint the genes of a bird at a very early age, and turn it into a more efficient animal later.

One way of doing this is through in ovo feeding.

Administration of highly digestible nutrients into the amnion of embryos can bring an improvement in chick quality, increased glycogen reserves, advanced gut development, superior skeletal health, advanced muscle growth, higher body weight gain, improved feed conversion and enhanced immune function. Using nutrigenomic data, almost 30 percent of genes expressed different activity over time by in ovo feeding (Oliveira et al. 2008).

Dr Karl Dawson, vice president of research at Alltech, presented data showing that limiting nutrient intake posthatching is another way to imprint genes at a very early age. Production traits, such as 24 | November - December 2013

tolerance to immunological, environmental or oxidative stress, or energy and mineral utilisation, can be imprinted by adaptive conditioning of gene expression. During the first 24 hours post-hatching, the small intestine, liver and pancreas develop at a faster rate than body weight. The chick needs to be fed as soon as possible to provide substrate for gastrointestinal development, weight gain and immune system development. High quality ingredients, mannan-based oligosaccharides, nucleotide-rich ingredients, mycotoxin adsorbents and organically complex minerals can generate significant FCR changes.

Nutrigenomics enables the bird's response to a feed product or diet to be recorded, by detecting and measuring the change in expression of several thousand genes all at the same time. This allows a far more comprehensive understanding of how diet affects the metabolism and health of the bird. Among the many changes in gene expression observed, a general carbohydrate was seen to regulate intestinal enzyme production, and reduced both cell cycling and heat shock protein production when tested in a challenge model with increased intestinal viscosity.

Conclusions A new frontier is being reached in animal production, with increased feed prices and a global movement towards antibiotic restrictions. A healthy digestive tract is the new West to be conquered, and is the only way animals can reach their full genetic potential. Animal protein operations need to optimise the basics of hygiene, management and feed programmes in order to properly take care of the gut microflora, while looking towards new technologies to improve gut health, increase feed efficiency and maximise performance. The implications of bridging the gap between genetic potential and actual performance represent as much as onethird of the feed required to produce a kilo of meat, milk or eggs today, with a commensurate effect on the costs of production. With the challenges of a burgeoning global population alongside the opportunity of continued genetic advances, bridging this gap and attaining the much awaited 1:1 in feed efficiency has never been so important.

References available on request

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informstion:

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Organic feeds: the future for sustainable poultry farming?

by Tony Little, Organic Centre Wales; Cliff Nixey, Poultry Xperience; Rachel Marsh, Capestone Organic Poultry

M

ost poultry producers identify feed issues and feed costs as one of their biggest challenges. Part of the problem is that the UK poultry industry depends heavily on imports, leaving producers at the mercy of global commodity prices for key feed ingredients. For organic farmers, the problem is even more acute; organic, and indeed non-GM, soya is getting harder to come by and therefore more expensive.

There are also the principles of the organic movement to consider. self-sufficiency and the idea that stock should be fed, as far as possible from the farm, is one of the cornerstones of organic thinking. However, a report prepared by the Soil Association in 2010 shows that a significant proportion of feed ingredients come from as far afield as Russia, Australia, Ukraine, Kazakhstan, South America and China. Clearly there is some way to go. If we want to build resilience into our farming systems, if we want quality, traceable feed at prices we can control, and if we want to reduce the environmental burden of our feed system, then it seems logical that we need to produce more of it at home.

Organic Centre Wales has been working on poultry feed issues for several years.

With funding from the Welsh government through the Better Organic Business project and Farming Connect, we have taken three different approaches to the problem:

26 | November - December 2013

Table 1: Nutritional analysis of entire and dehulled peas and beans Peas Nutrient % Crude protein

Entire

Beans

Dehulled

19.7

20.2

Hulls only

19

Entire

27.4

Dehulled

29.9

Hulls only

11.9

Crude fibre

4.8

2.5

14

10

5.4

42.1

Moisture

15.8

15.8

14.2

15.1

14.5

13.6

Oil (B )

1.98

1.9

2.21

1.55

1.57

0.83

Lysine

1.57

1.78

1.3

1.46

1.92

0.4

Methionine

0.2

0.24

0.2

0.16

0.22

0.03

Sugar

3.28

2.55

3.91

2.85

2.7

2.2

Starch

45.8

66**

28.5

29.6

33.6

5.9

M.E. MJ/kg (calculated)

11.81

12.5

8.97

11.14

3.4

10.09

Meth.+ Cyst. (calculated)

0.48

0.59

0.4

0.49

0.58

0.12

Threonine (calculated)

0.75

0.92

0.62

0.87

1.04

0.22

Tryptophane (calculated)

0.19

0.23

0.16

0.2

0.24

0.05

Arginine (calculated)

1.76

2.16

1.46

2.3

2.74

0.57

• Growing better quality cereals and fostering direct relationships between arable and poultry producers • Improving the quality of our homegrown protein crops such as peas and beans by dehulling the grain

Table 2: Opportunity prices of dehulled peas and beans in various rations

Peas entire (£/t)

Turkey starter

Turkey grower

Broiler finisher

Chicken layer

391

439

274

307

Peas dehulled (£/t)

440

514

383

359

Beans entire (£/t)

343

395

101

221

Beans dehulled (£/t)

414

514

255

302

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Table 3: Field observations

• Exploring opportunities for growing new crops such as sunflowers

Naked oats as a quality poultry feed Naked oats are varieties that thresh free from their husks during combining, increasing the density of nutrients and offering real advantages to pigs and poultry. They have a high energy content (over 16ME in new varieties) and crude protein values at up to 14.8 percent, but it is perhaps their amino acid profile, which closely matches the requirements of the birds, that makes them so attractive as a feed. So can they be successfully grown in Wales, and are the nutritional benefits realised under its conditions?

Oats are good competitors against weeds, tend to be disease resistant and thrive under lower fertility conditions, all of which makes them particularly well suited to organic systems in marginal growing areas.

The growers we worked with had positive experiences on the whole, although the poor summer of 2012 meant that some had to take the grain unripe and crimp it, or even take it as wholecrop silage for ruminants.

However, the main drawback is yield; oats generally have lower yields compared to other cereals, the absence of a husk means that the yield of naked oats is only about two-thirds of husked varieties. The lower yield, however, can be offset by an increase in nutritional value – by establishing direct links between arable and poultry producers it is possible to recognise and reward this. At the same time, these direct relationships can improve the supply of quality, traceable organic feed from Wales, reduce the carbon footprint of the enterprise and bring the production systems closer in line with organic standards.

Improving our protein crops Dehulling improves the quality, and therefore the inclusion rates, of homegrown protein crops such as peas and beans. It is certainly not a new idea, but we

25 September

2 October

10 October

16 October

Most flowers still yellow. A lot of the seeds white inside & immature. Larger heads were dryer and therefore easier to sample.

Flowers rapidly becoming browner.

Bigger heads are starting to droop.

Great variation in head size. Sampling much easier as seeds become drier.

Flowers have developed a lot; very few yellow petals left. Seeds detached very easily. Foliage yellowing but still very leafy and lush.

Most flowers brown and ready to be harvested. Some have lodged. Stems are becoming yellow. Many flowers were missing their outer brown layer.

Seeds detached flowers very easily

wanted to look at it in the context of farmers processing their own crops. We analysed the nutritional content (Table 1) of entire and dehulled grains and used this information to calculate the opportunity price in ‘least cost’ formulations for different poultry rations (Table 2).

We confirmed that dehulling does indeed increase the nutritional value of peas and beans as a feed ingredient, especially with respect to key amino acids. At November 2012 prices for feed ingredients, the associated economic benefits varied between diets. They were greatest in turkey diets (which are higher in protein) and broiler diets and more marginal for layers.

Two things could increase the attractiveness of dehulling. Firstly, the likely prospect of a medium-tolong-term increase in organic soya prices, and secondly the development of a market for the separated hulls. This could be as a ruminant feed or poultry litter to replace wood shavings, which are becoming increasingly expensive.

The cost of purchasing dehulling and seed cleaning equipment (in the region of £15,000 to achieve through-

put of 1.5-2.0 tonnes per hour) and the running costs of the machine, estimated about £19 per tonne, also need to be factored into the calculations. Structures to enable farmers to share facilities, for example machinery rings, could help to bring down the cost of the former.

Sunflowers as a feed crop Wales does not often appear on the list of sunflower producing countries so this

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November - December 2013 | 27

Grain

AD_o&j.indd 1

21/11/2012 15:08

Table 4 Nutritional content of sunflower seeds over the ripening period Sample 1 (25/09/2013)

Sample 2 (01/10/2013)

Sample 3 (10/10/2013)

Sample 4 (13/10/2013)

NDF

4.6

6.1

6.3

Crude protein

1.8

2.3

3.1

3.6

Crude fibre

3.2

3.3

3.6

Moisture

86.9

82.5

73.4

71.8

Total oil (B)

2.06

0.73

13.09

Sugar

1.31

1.1

0.27

Starch

0.4

2.3

2.7

Phosphorus

0.09

0.13

0.16

Non Phytate P

0.05

0.07

Lysine

0.18

0.21

0.15

Methionine

0.06

Cystine

0.03

0.05

0.04

Threonine

0.1

0.14

0.11

Arginine

0.13

need the long, hot, dry ripening period, and if that is the case, can it be grown in useful quantities here?

We ran a simple trial, funded by Farming Connect, to help us decide whether or not the idea merited further investigation. There was no replication, no statistical analysis and only one site; a quick ‘look-see’, to use a very un-technical term. Capestone Organic Poultry in Haverfordwest planted 2 hectares of sunflowers on their land. We took samples of 20 heads at weekly intervals between

may, at first, seem an odd choice of crop to look at. This is because practically all sunflowers are grown for their oil, most of which is synthesised during a long, hot, dry period at the end of the crop’s development.

But if the primary purpose of growing the crop is for feed, then a number of different factors come into play, potentially allowing us to grow sunflowers under a much wider range of conditions. Oil is produced partly at the expense of the protein so, from a feed perspective, the ideal time to harvest is when it is slightly unripe. This means that we don’t

Table 5: Nutrient content adjusted to 12% moisture compared to sunflower meal Sample 1 (25/09/2013)

Sample 3 (10/10/2013)

Sample 4 (16/10/2013)

Sunflower meal (oil extracted)*

NDF

30.9

20.18

19.66

43

Crude protein

12.09

10.26

11.23

28

Crude fibre

21.5

10.92

11.23

28.5

12

12

12

11

13.84

38.81

40.85

2.6

Sugar

8.8

3.64

0.84

4.5

Starch

2.69

Nutrient

Moisture Total oil (B)

7.61

8.43

3

Phosphorus

0.43

0.5

1

Non Phytate P

0.17

0.22

0.27

Lysine

0.69

0.47

0.98

Methionine

0.3

0.17

0.63

Cystine

0.17

0.12

0.46

Threonine

0.46

0.34

1.02

Arginine

0.86

0.53

2.24

16.65

17.27

6.2

Calculated ME

8.22

* Published data. Source Premier Atlas 2011

28 | November - December 2013

25 September and 17 October 2013, made field observations on each occasion (Table 3) and analysed each batch for nutrient content (Table 4).

In the event, 2013 was not a good year for sunflowers. They need a warm soil (6-8 °C) to plant into, and in a ‘normal’ year you would expect the UK to get up to those temperatures in late March/early April.

With March 2013 being the second coldest on record, it was mid-May by the time temperatures had become high enough. Even the warm summer could not make up for the lost time, and we were not able to get the grain harvest we had hoped for. Even so, the experiment yielded some important and interesting data.

Results Our biggest problem was high moisture content, still over 70 percent on the final sampling date. Indeed, Sample 2 deteriorated so rapidly it was only possible to get limited data from it. Had we been able to plant the crop in early April, the ripening period would have coincided with the warm, dry months of August and September and the moisture content would have been much lower. Even so, growing for feed instead of oil implies harvesting unripe, so even in ‘good’ years, moisture content is likely to be higher than cereal crops and the crop will usually need to be dried after harvest. Alternatively it could be crimped and fed as whole grain.

In terms of nutrient content, the high moisture levels depressed the proportion of other nutrients. In order to draw comparisons with commercial sunflower meal, we adjusted the nutrient levels to be consistent with a 12 percent moisture content (Table 5), presuming that the crop would be dried after harvest.

Levels of protein in the seeds were significantly lower than that of commercial meal, even when adjusted to a 12 percent moisture content. The crop from which the meal was derived was probably dehulled, and this could account for some of the difference, but even so, it seems unlikely that growing sunflowers will contribute much to increasing the supply of home-grown protein.

But if they were disappointing with respect to protein, they were surprisingly promising with respect to energy. Adjusted for 12 percent moisture, the oil content was up to 40 percent by the final sampling date, much higher than we had anticipated under Welsh conditions. Starch, for reasons that are not immediately obvious, was nearly three times that typically found in meal.

On the final sampling date the seed had an estimated ME of 17.3 MJ/kg, compared to 6.2 MJ/kg for meal.

This nutrient profile means that sunflower would really complement field beans: whereas sunflower is high in ME, beans are low; sunflower is strong in methionine and weaker in lysine whereas the opposite is true for beans.

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Table 6: Opportunity cost for Sunflower seed (£/tonne) Diet

Full fat trial seed

Meal from trial seed (oil extracted)

Commercial meal (oil extracted)

Broiler Finisher

734

381

531

Turkey Grower

210

226

435

Chicken Layer

303

235

337

We attempted to put an economic value on sunflower as a feed by calculating the opportunity cost (Table 6). We calculated this for three diets (broiler finisher, turkey grower and chicken layer) and for three products: the seed from the trial adjusted for 12 percent moisture, a hypothetical meal from the trial after oil extraction, and a commercially available meal.

The broiler finisher diet, with its high ME requirement, would benefit most from the inclusion of sunflower seed. The benefit is less clear for the other two species, although it could have a role in layer rations due to their higher requirements for the essential fatty acids (a determinant of egg size) found in the oil. If offered in least cost formulations in conjunction with field beans or peas, the opportunity price of each would be increased because, as stated earlier, they complement each other.

A more in-depth study, using several different sites and fully replicated experiments on each location would confirm this or otherwise. In any case there are a number of issues that need to be tackled or considered.

• The moisture content needs to come

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down to around 12 percent, and even in more favourable years, there is likely to be some requirement for drying, because the seed is harvested before it is fully ripe • In the context of small producers in particular, some sort of cooperative structure will be needed to reach the tonnages that will justify the necessary equipment and facilities • The crop would also appear to be valuable for ruminant nutrition. It also produces a considerable amount of stem and leaf material which could perhaps be converted into silage.

• The unexpectedly high oil content means that it could be economical to extract at least a proportion of the oil.

Organic vegetable oil is in short supply and expensive • The material remaining after harvesting the seed can provide green manure if chopped and ploughed in. Sunflowers have deep tap roots which will bring phosphorus and potassium to the top soil Although there are no magic bullets or overnight solutions to offer, there are plenty of ideas worthy of further consideration and development. There will come a time when the UK will have to rely less on imports and move towards lower carbon feed systems: that is inevitable.

The sooner we start, the less painful that transition will be.

More

informstion:

www.organiccentrewales.org.uk www. capestone.co.uk

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November - December 2013 | 29

513634_GrainFeed-MillingTechnology_47x270_gb_4c_RZ.indd 22.10.13 08:36 1

FEATURE

Market-aware farming:

commodities training at Writtle College

by Henry Matthews, Seniour Lecturer in Agriculture, Writtle College, UK

T

raditionally farmers are poor at marketing, being predominantly concerned with producing the crop to the best of their ability within the constraints of soil type, climate and utilisation of inputs. Beyond the farm gate was of little concern. This approach was encouraged by a subsidy system put in place at first in the UK after the Second World War though the Agriculture Act of 1947, and then by the European Union through the CAP after Britain joined the Common Market in 1973.

Systems of price support, grants and tax relief were all put in place to increase production and, with the emphasis on yield and producing more, the market was guaranteed. Husbandry improved as fertiliser use increased, varieties were improved and fungicides and pesticides were developed to enable crops to fulfil their potential. Farmers were very successful and yields doubled from their 1960 level.

However, by the early 1990s concerns over the environmental impact of the system, the existence of grain mountains and the increasing cost of the policy led to a reappraisal, and the result of this was the ‘set-aside’ policy through the McSharry reforms of 1992. The biggest shift in policy then came with the introduction of the Single Farm Payment Scheme in 2003. Under this regime agricultural support was no longer linked to production but to the land. Farmers received a payment for the land they farmed, not what they produced, requiring a different mindset and approach to their businesses.

No longer was it sufficient to produce crops and think about where to sell them afterwards. Farmers instead had to consider the market and adjust management and agronomy according to the requirements of the market.

In practice, cropping has changed little but farmers now are now aware – and have to be – of commodity prices and events in 30 | November - December 2013

Case study

Business view, W & H Marriage & Sons W & H Marriage, a flour and feed miller founded in 1824 and situated close to Writtle College in Chelmsford, has always believed in sourcing cereals from local farmers and building relationships with them. This has ensured that over the years both have benefited from the certainty of knowing that what is being grown has an ultimate market destination. The importance of meeting the right specifications for the right market is crucial for the success of both farmer and miller. For example, Marriages supply a wide range of specific flours to the leading artisan bakers and this requires excellent and above all reliable performance from wheat and flour.

As with all businesses which have a long history, the company has had to adapt and evolve to meet changing markets. The recent acquisition of a pet

food company has diversified the animal feed part of the business while Marriages has continued to offer bespoke rations for specific species from free-range turkeys to parakeets.

Family member James Marriage, currently responsible for managing farm livestock feed accounts, is keen to maintain the close link between the company and local farmers that both supply raw materials and consume feed. James says that this will help maintain the standard of quality assurance and good service required to thrive within niche areas of the market. He welcomes the introduction of this module at Writtle College and the way it highlights this important link.

Marriages currently employs several former students of the College and hosts student visits to reinforce the message of quality for markets and to demonstrate how the checks are carried out on grain arriving at the mill. The company has also supplied the College farm with animal feed for the pig and turkey enterprises.

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FEATURE

4 - 7 FEBRUARY

&feed milling technology

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November - December 2013 | 31

FEATURE

Case study

A student’s experience Leanne Eyre BSc (Hons), Agriculture I came to Writtle College with a basic level of agricultural knowledge. I now work in assurance, but I could not have got there without the guidance, dedication and knowledge from my lecturers at Writtle College. I studied a BSc Honours degree in Agriculture and it covered livestock, arable and agribusiness aspects. I learnt what quality agriculture really is and what goes into farming in today's world. I now use my knowledge every single day in my job.

I learnt that a quality crop is not only about the physical product at the end of the process, but is also about everything that went into producing that product from the beginning.

For my job I need to know about seed, environment management, chemical control, competency, harvesting, storage, vermin control, machinery, traceability, haulage and legislation. At Writtle College, I learnt about all of these. I was taught the whole system, beginning with preparation, harvest and storage, to the marketing and selling of grain.

I learnt about a variety of crops including cereals, sugar beet, fodder beet, potatoes, OSR, linseed, beans, peas and many other crops from the UK and abroad. I learnt about what makes a good quality crop and how to measure this. This included learning about critical timings and

other parts of the world. Where previously a farmer would be interested in what was happening in the next parish he now is aware of the problems surrounding the maize harvest in the US, wheat plantings in Australia and the prospects for the soya crop in Argentina.

Writtle College in Essex was established 32 | November - December 2013

growth stages, cultivations and machinery choice, soil and nutrient management; both natural and artificial fertilisers, disease and pest management; insecticides, fungicides and herbicides. I learnt about looking after the environment including water, soil and air quality. It also included learning about integrated crop management (ICM) and entry-level/higher-level stewardship (ELS/HLS) schemes and good agricultural practices.

I was taught that a quality crop can be measured in many ways. I remember from college learning that the quality is set by the end market, so it’s important to meet your specific market targets to get the level of quality that they want – an aspect one person regards as a measure of quality, others may not regard so highly. I spent many hours learning about the measures of quality for different crops, for example milling wheat and Hagberg falling numbers and Thousand Grain Weights. Other crops have other points that determine quality, for example, sugar or oil contents, digestibility levels for fodder, potential seed quality and so much more – it’s amazing it all sunk in!

Writtle promoted a very ‘hands-on’ approach and I remember spending time in fields walking crops, digging soil pits and making my own weed guide. I also went on many trips to see real life situations and studied different systems, learning as I went about how important it is to find your own niche in the market and about the many ways to make your crops achieve a higher quality so as to receive a positive differential to other producers.

in 1893 to meet the training needs of local farmers – something it has continued to do throughout its 120-year history. The change in policy brought about a change in the curriculum taught to undergraduates.

A new module was introduced for those studying crop production called ‘Quality

Assurance and Markets’, which runs alongside an ‘Introduction to Agronomy and Cropping Systems’, with the purpose of teaching students about the world market, the requirements and quality issues associated with each crop.

During the year, the main crops covered include wheat, rape, barley, oats, beans, peas, potatoes and sugar beet as well as speciality crops such as borage, sunflower and soya.

In the same week that students learn about the agronomy of a crop, they are taught and given insights into the local, European and world markets for that crop. As part of this, market requirements and standards are discussed as well as how these might be achieved by good agronomic practice such as appropriate variety choice and targeted use of pesticides and fertiliser. The delivery of the module combines the traditional lecture/seminar approach with visits and external speakers. The College has good links with the local miller, W.H Marriage and Sons, and two graduates are among the staff employed there. Students also visit Clarksons at Ipswich Docks, a major importer and exporter of agricultural commodities.

The module is taught by three Writtle College staff, both with academic and practical agricultural backgrounds. Dr Chris Bishop is an authority on post-harvest technology and consults around the world on storage and processing on a variety of agricultural and horticultural products. The Writtle postharvest unit has a national and international reputation for its work with both NGOs and commercial companies in the areas of storage, and the maintenance of crop quality between the producer and the consumer.

Work has also been carried out on behalf of UK supermarkets on shelf life and packaging of fruit and vegetables.

Dr Clive Beale, also part of the post-harvest team, lectures on the quality of cereals using his scientific background and commercial experience, while Henry Matthews, the module leader, has practical farming experience in the UK and Eastern Europe.

Students are partly assessed on a presentation on a crop market of their choice.

They are expected to be able to articulate the main requirements of the market for the crop of their choice and to be able to suggest strategies which might enable this to be achieved. While the popular choices are wheat and rape, other crops such as poppies and palm oil have been chosen.

The key to giving students the skills they need to be attractive employees in the agriculture industry is flexing the curriculum according to the sector’s needs. Writtle College has been proficient in reflecting the changes in the agriculture industry for decades – indeed our stand at Cereals 2013 celebrating our 120th anniversary was visited by alumni who are now among the leaders in the agricultural economy – and we intend to continue this over the coming years to keep pace with this ever-changing industry.

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PORTS

70 guys in Nivelles: VIGAN Engineering industry report

by Richard Sillett, deputy editor

P

ulling up at Vigan’s gates in Nivelles, just outside Brussels, there is not much initially to catch the eye.

Other than the company name and logo above the entrance, and the knowledge gleaned from its website that the facility contains 10,000 m2 of floor space, there is little to give away what kind of company lives and works within.

Entering the factory, which doubles up as Vigan HQ, what it is that sets the company apart becomes apparent. The building’s office space, corridors and meeting rooms are dominated by photographs – floor-toceiling in some cases – of the many projects the company has taken on at ports around the world since 1968. A map of the world on Vigan’s website tells a similar story: details, images, technical drawings and addresses of over a hundred of the company’s 1,200 total projects are marked across Europe, Asia, Africa and the Americas. It demonstrates that although they are based in Brussels and within easy reach of some of Europe’s biggest ports, Vigan is not only a regional player.

It also demonstrates a level of transparency and willingness to credit the customer first that is rare in any industry. “A few things are crucial for Vigan,” explained managing director Nicolas Dechamps. “We put ourselves in our customer’s shoes, we’re not hiding from anyone. We know all our customers by name, we know the machine that’s at their port, and we know the people who operate it. We’re just 70 guys in Nivelles, but we’re reaching out to the world.”

Agribulk specialists Vigan Engineering operates in the highly specialised field of agribulk handling in ports.

Their core business – though not their exclusive one – is manufacturing unloaders for ships and barges in grain terminals.

Corrosion is enemy number one for port equipment. Most parts are hot-dip galvanised, but for larger pieces where that would be impractical – like the crane cabins – the metal is shot-blasted and treated with anticorrosion paint before the final colour layer is applied.

Vigan components are shot-blasted prior to painting 34 | November - December 2013

The Engineering Department builds detailed 3D drawings for customers Each port is different in terms of geography, capacity, and the markets they serve, so each job demands a different approach, and a bespoke design from Vigan. Smaller ports, like many European canals, only require Vigan to cater for smaller ships and barges.

These require shorter booms, which in turn does away with the need for a counterweight. The machinery can be lighter, cheaper and simpler, and the need for a mobile gantry is usually removed.

Finished components after painting

&feed milling technology

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Vigan equipment is pre-assembed on site before shipping Larger ports can contain larger ships, which means longer booms and counterweighted unloaders. Gantries are a must to raise the unloading equipment to the height required, which brings the additional question of how many. Port authorities have been careful to try to save money by loading high capacity machinery on the smallest gantries possible, in order to maximise the unloading efficiency and to reduce tie-up delays.

major competitors, the company provides both pneumatic and mechanical systems for unloading. The solutions aren’t only different in terms of technology, and when used effectively they can have distinct and complementary functions.

Vigan’s mechanical unloaders work by the combination of a feeder and two belts which sandwich the grain. The feeder consists of a central paddle wheel, with side screw con-

Towers in the process of pre-assembly: they will be broken back down and prepared for transportation And which agribulk material is passing through the port? Grain is abrasive and dusty, and pneumatic unloaders require significant filtration. Substances like urea are quite sticky, and can only be coaxed into flowing freely with mechanical action. These are all worries which port operators hope to be able to pass on to their bulk handling specialists.

Pneumatic vs mechanical?

The problem of sticky and non-free flowing cargo also serves to highlight a strength of Vigan’s core product range. Unlike its

&feed milling technology

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veyors making sure it receives a continuous flow of grain. Upward pressure is applied by the feeder to bring the grain away from the vessel and towards its destination. Pneumatic unloaders, which form the vast majority of the company’s sales, use turboblowers direct-driven by high-speed electric motors.

These create a 0.5 bar vacuum to suck the product out of ship holds. It’s a maritime vacuum cleaner: indeed, Vigan has brought well-known brands of domestic vacuum cleaners and industrial turbines into the factory to strip down and test.

The unloader's cabin is pre-assembled before shipping to the customer So what’s the difference? At peak level mechanical has a much greater flow rate (up to 1,500 t/h, compared with a current maximum of 600-650 t/h for pneumatic), and is more energy efficient, since the conveying system acts directly on the grain, rather than on the surrounding air. However, this doesn’t tell the full story. Peak loads are one thing, but pneumatic races back into contention at the end of the process, during hold cleaning when most of the grain has been picked up. The mechanical device must work at full power trying to scrape up the last bits of grain, and afterwards the vessel still requires cleaning. The pneumatic system, meanwhile, is optimised for these situations.

Taking an average across the whole process, Vigan believes that their pneumatic system is in fact more energy efficient.

“Think of a small spoon and a big spoon,” commented Dechamps. “You go with the big spoon first, but you still need a small spoon at the end.”

There are other engineering challenges to getting the most out of pneumatic conveyors. The pipes must be telescopic while maintaining an airtight seal between inner and outer pipes, to allow effective suction.

Across 25 metres of very hard steel, this is a unique undertaking for designers and fabricators alike. Air speed must be kept down in order to keep the grains in pristine condition. A change to boom design allowed wider pipes, which maintained the suction force on the grains while reducing the stress placed upon them. Although the greater complexity and number of moving parts in mechanical unloaders increases the likelihood of breakdowns, pneumatic unloaders suffer from wear more, which creates its own maintenance and logistical challenges.

Ultimately, some customers require a mechanical solution, often because of the need to integrate unloading technology with other equipment already on site.

Dechamps is willing to keep a foot in both camps, as a look at Vigan’s product range will indicate.

“People are always asking, ‘pneumatic or mechanical?’ We say ‘pneumatic and November - December 2013 | 35

PORTS Factory philosophy It is the philosophy within the factory that Dechamps believes sets his company apart from competitors. One reason for Vigan’s huge facility is that all equipment is pre-assembled there before being shipped to their destination (usually having been broken back down again into their constituent parts). “It’s a huge amount of work,” he Managing Director Nicolas Dechamps (left) with explained, “because we do a colleague from the production line the job twice.”

“We’re unique because mechanical. If you have a port, use both. The we control everything here at the factory. From drawing, to welding, to the final two can complement each other.”

Vigan fights hard for market share with on-site assembly, everything comes through the likes of Bühler and Neuero, who favour here. It’s a pain when you have to make mechanical and pneumatic solutions for changes here, but a bigger pain to make the continuous vessel unloading respectively. changes on site. We’re not just sending a The decision to supply both reflects a larger set of parts to be assembled in Africa, Asia split in port handling between continuous or anywhere else around the world. Our and discontinuous unloaders, such as grabs. customers know what they’re buying.”

Sitting around the table at Vigan HQ, Versatile, relatively low-tech and suitable for a wide variety of bulk goods, salesmen Dechamps appears genuine in his desire to for all those companies have a job on their build his company around his customers’ hands to emphasise the efficiency and loss- needs. After all, he’s in the business of feeding the world. A recent project in Djibouti minimising benefits of continuous systems.

There’s a huge silo and a huge vessel. And we are the link in between involved an unloading facility handling 85 percent of Ethiopia’s wheat imports.

“The people coming to IAOM have a mission to mill and to feed, and we’re proud to be part of that chain. Our growth markets are where the population is growing and where the population is hungry. We are very proud to be part of such a ‘good’ business.” Dechamps points to a photo of a ship docked by an unloader. “There’s a huge silo and a huge vessel. And we are the link in between. And that part of the chain has to be reliable.”

b site e w ou r Vi sit vigan.com www.

VIGAN manufactures dry agribulk materials handling systems:

Latest references

• Portable pneumatic conveyors or grain pumps (100 - 250 tph); • Pneumatic Continuous barge & Ship Unloaders (160 - 800 tph); • Mechanical Continuous Ship Unloaders (up to 1,500 tph); • Mechanical loaders (up to 1,200 tph). as well as complete storage systems in ports and the agricultural industries.

PYEONGTAEK PORT South Korea 1 NIV 400 tph On rails with cable reels

LATTAKIA PORT Syria 2 Mobile T200 2 x 250 tph

From project design to complete turnkey bulk handling solutions and port terminals with mechanical and/or pneumatic reliable and cost effective equipment.

SWINOUJSCIE Poland (BUNGE GROUP) 1 Loader 600 tph

An affiliate company of VAN DE WIELE group.

VIGAN Engineering s.a. • Rue de l’Industrie, 16 • B-1400 Nivelles (Belgium) Phone : +32 67 89 50 41 • Fax : +32 67 89 50 60 • Web : www.vigan.com • E-mail : info@vigan.com 36 | November - December 2013

Ann A5 victam 0212.indd 1

&feed milling technology 21/02/12 15:37:04

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In the footsteps of Broomhall

FROM OUR ARCHIVES

In the footsteps of Broomhall

I

n celebration of the festive season, this fixture of Broomhall brings you a collection of our favourite Christmas news stories extracted from our archives. This year, we look back 60 years at a selection of stories originally published in our ancestral Milling publication back in 1953. From all here at Grain & Feed, we wish you a Merry Christmas!

1953 The Christmas Spirit Among the many precious maxims left to us by Shakespeare there is one that states “one half of the world does not know how the other half lives.” We have numerous examples of this maxim annually at Christmas time.

Not withstanding the competitive prices that were frequently detrimental to the well-being of the industry, when there were crises such as famine, the milling industry was always among the foremost in the necessary response.

Food and drink What thoughts are uppermost in the minds of the [people at this time of the year? Our guess is food, with a capital F, with maybe a capital D for drink running a close second.

As to the first, our mouth has already begun to water at the thought of well-stuffed turkey and pork, succulent capons, and so on- if it is one’s fortunate lot to be able to afford such annul luxury. |And it is a sad thought that such blowouts are only an annual luxury for many folk.

Christmas thoughts Whether the timing was or was not deliberate, the United States have shown themselves in their most generous mod by presenting India with 1.5 million tons of wheat and a credit of fifty million dollars for fertilizers. It is indeed a munificent Christmas gift. India has had a bad rice harvest and her food grain deficit for 1954 is estimated at around eight million tons.

The Dawn “What means this Christmas spirit, That gives the heart new birth?

It means that love is greater Than any power on earth.

What means this song of angles Above the din of wars?

It means the dawn is glowing With peace the stars of stars.”

38 | November - December 2013

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COMPANY PROFILES 2014

As an international supplier of micro-ingredients to the animal feed industry, AB Vista has become internationally renowned for its technical expertise, application of technology and use of independent research trials to demonstrate product efficacy. AB Vista is confident in reinforcing its position as the innovation leader in the feed ingredients market with more than 100 staff globally, 10 support offices worldwide and sales in over 50 countries.

A strong focus on research has allowed AB Vista to push product development beyond previously accepted boundaries, setting new standards in many areas, such as feed enzymes, product assays and technical support services. The company’s Quantum Blue phytase, for example, is the latest generation of enhanced E.coli phytase, and has been specifically optimised to degrade phytate in the plant-based feed ingredients used in monogastric diets.

“The launch of Quantum Blue represents a significant step forward for phytase performance and reliability, and offers end-users a larger and more consistent return on investment than previous generation products,” states AB Vista’s Managing Director, Richard Cooper. “These results have been proven time and time again, both in numerous independent research studies and in commercial-scale on-farm trials.”

It has been estimated that the anti-nutritional influence of phytate on nutrient utilisation and feed efficiency could be costing the industry as much as €2 billion/year in lost performance. As a result, the use of phytase feed enzymes has become almost ubiquitous within the monogastric feed industry in recent years.

“It is what sets AB Vista apart,” Mr Cooper concludes. “Better research leads to more advanced products that deliver more consistent benefits to the end user. Backed by the latest technology and a portfolio of customer support services that can really make a difference, it means that AB Vista is set to continue leading the way for many years to come.”

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BESTMIX® feed formulation software is used by more than 500 feed mills worldwide, and encompasses feed formulation, ration calculation, recipe management and lab data management services. With multiblend, ingredient allocation, advanced labelling, bulk blending among its features, users can adapt instantly to volatile material costs, fluctuating ingredient stocks and purchasing positions, all automatically synchronised with labelling and safety data. The Lab Information Management System (LIMS) allows operators to automate the processing of analyses and optimise sample management to ensure quality control, risk management and compliance with regulations.

MILAS® provides ERP solutions specific to the agriculture, feed and food industry, based on the industry-standard Microsoft Dynamics AX platform.

Features include enterprise resource planning and management for logistics and financials, sales and purchasing, warehousing and production, and minerals administration.

Early 2013, the cloud-based “Formulation as a Service” was launched as part of Adifo’s BESTMIX® product line. The collaborative platform is bound to revolutionise the information interchange between nutrition experts, internal departments and the outside world. Securely implemented in the cloud, FaaS gives users online access to part of their nutrition company’s database, improving collaborative interaction and formulation functionality between all parties in the nutrition company’s value chain.

2014 will see Adifo expand its presence in China and North America with a new deal to distributre its Gold Certified BESTMIX® software. Working in collaboration with AMTS, Adifo will incorporate Cornell University’s Net Carbohydrate and Protein System to bring operators a predictive model for the feed demands of cattle.

For its cloud solution, a number of new phone apps will soon be launched.

www.adifo.com

COMPANY PROFILES 2014

Establishing plants at any desired capacity, Alapala is a company that exports 95 percent of its current production today and has hundreds of references in over 75 countries in four continents including developed industrial countries such as Belgium, France, Italy, Canada and the USA. Alapala continually develops and expands thanks to its superior technology infrastructure, perfectionist staff and management, and its quality and customer-oriented approach.

It renders the best before- and aftersales services with its staff specialised in their industry, overseas representatives, strong service networks and spare part stocks. Alapala helps its customers obtain the best efficiency by manufacturing quality and high performance machinery in production facilities containing the most developed and state-of-the art technology.

Alapala’s lines of business: Wheat flour mills, semolina mills, corn flour mills, rice processing plants, feed mills, cereal storage systems, weighing, conveying, packing equipment, harbour facilities under the licence of Tramco Inc-USA.

www.alapala.com

Brabender GmbH & Co. KG was founded in 1923 as Brabender Elektromaschinen GmbH by Carl Wilhelm Brabender. Today, the Brabender group, which has generated a steady growth in recent years, employs about 400 people.

As a leading supplier, Brabender develops, manufactures and distributes instruments and equipment for the testing of material quality and physical properties in all areas of research, development and production, worldwide, for the two application areas of Food and Plastics.

The product range includes instruments suitable for a variety of task areas, whether as a single unit or complete system. However, “hardware,” and thus machinery, is not the only important factor. Appropriate, user-friendly software also determines the utility value of a testing and measuring device today. Therefore, the focus is on the development of customized software for the instruments.

At the company’s headquarters in Duisburg, there is a technical applications laboratory available in which customers can also test the instruments themselves.

Development and production are very highly integrated at Brabender.

Therefore, the family run group can guarantee “Made in Germany” quality, because the research, development and production of the instruments take place exclusively in Germany.

The Group has a presence in over 116 countries with 80 distributors and an export share of about 80%. In addition to Europe, the major export regions are the United States, China and Russia.

www.brabender.com 40 | November - December 2013

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COMPANY PROFILES 2014

F

rom the local iron foundry founded in 1860 to the global corporation of today Bühler delivers leading technology and solutions for processing grain into safe and healthy finished products. Bühler stands for straightforward and cutting-edge solutions. State-of-the-art process technology, innovative plant engineering and a deep knowledge of the related processes maximize both quality and product yields. But there is even more to it: Bühler knowhow also enables customers to create the most cost - and energy-efficient process solutions from stand-alone machines to complete plants.

Innovation. One of the key terms in this connection is innovation based on the art of engineering. Without an additional healthy dose of enthusiasm and persistence, the spirit of discovery so typical of Bühler would never have thrived. Time and again, this spirit has enabled the organization to roll out firsts in the global marketplace, for example in the field of roller mill development.

Quality leadership. This attribute is manifested in quantifiable and transparent quality targets which are defined in an open dialog with our customers so that promised performance is achieved and the edge in confidence can be further increased.

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

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

Focus on solutions. Focus on solutions means to center all efforts on our customers’ profitability. This requires an understanding of and a capability to improve their complete value chains and thus to offer our customers an edge in performance over pure equipment manufacturers.

Global reach. Bühler has been a global player for many decades, with a multicultural team and a local presence extending across all the major markets of the world. This edge in availability, whose significance will further increase in the future, pays off in the results it allows to be achieved.

www.buhlergroup.com Innovations for a better world.

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20.03.2013 14:24:32

Measuring Moisture in Grain, Nuts and Pulses Controlling moisture in grain, nuts and pulses throughout different stages of processing can be one of the biggest problems for manufacturers. Many factors affect the moisture level in the raw product and they will have a contributing factor in the amount of moisture that either needs to be added or evaporated during processing. Hydronix sensors successfully measure moisture in all types of grain, whole kernel corn, wheat or maize as well as cut maize and flaked oats.

Benefits • Reduce the amount of energy required for drying • Reduce the amount of wasted materials • Consistent, repeatable end product Correct moisture control during the drying or conditioning of the grain enables a direct cost reduction in terms of energy consumption and an efficient use of raw materials. Knowing the precise moisture content of the material also reduces the likelihood of product waste due to microbial growth.

Microwave moisture measurement provides an easy method for the producer to precisely measure the moisture content of the material and to make real time adjustments to optimise the process. Microwave sensors are not affected by dust and vapour and have proved easy to use, reliable, accurate and cost effective.

Hydronix range of sensors can be positioned in many different locations. The Hydro-Probe XT can be installed inside a bin, underneath the gate, or in the material on a conveyor, and takes measurements as the material flows over the sensors measuring surface. For applications with a high ambient temperature, the Hydro-Probe Orbiter can be mounted above belt conveyors, taking measurements as the grain or other material flows around it. Finally for applications that use a screw conveyor, chute or mixer, the Hydro-Mix is a flush mounted sensor that enables the material to pass across the faceplate without impeding the flow of material.

www.hydronix.com &feed milling technology

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November - December 2013 | 41

COMPANY PROFILES 2014

Since the foundation of the company in 1896, Satake has been working for mankind’s three staple foods – rice, wheat and maize. Today, Satake serves 150 countries through 13 manufacturing and marketing operations in 10 countries.

Satake is dedicated to serving the needs of customers wherever they may be, in countries both large and small. When customer satisfaction leads to trust in Satake, our dream is fulfilled.

In the field of rice, Satake has always been one step ahead. Satake invented Japan’s first power-driven rice milling machine in 1896 and has continued to respond to customers’ demands as they change over time.

The global standard of modern rice milling has been established by Satake through its ability to continually develop innovative products and processes. Today, Satake focuses on the value-added functionality of rice to increase the profitability from rice.

In the field of wheat, Satake has developed the spirit and technology of Robinson Milling Systems (formerly Henry Simon Ltd) since 1991. Satake adopted its rice milling technology to Robinson’s/ Simon’s wheat processing systems and launched its PeriTec wheat debranning system in 1996, much earlier than others. Today, Satake’s capabilities include the ability to design, manufacture and install complete flour mills.

In the field of maize, Satake also adopted its rice milling technology for maize. Maize degermers and Corn Fractionators are based on vertical rice milling machines to efficiently separate bran and germ from endosperm. Satake offer a Modular Maize Mill which produces first class finished products, but also has the benefits of fast installation within a very small building footprint.

And others. Satake’s technology cultivated through grain processing and optical colour sorting is now widely utilised not only in pulses and nuts, but also in industrial applications such as plastic pellet polishing and sorting, and car bumper recycling. In 2008, Satake opened the Sorting and Processing Integrated Centre to help our customers find solutions to all of their sorting and processing problems. At the centre, Satake performs sorting and processing tests on a wide variety of materials, from rice and wheat to food products and industrial plastics.

When you think something new, think Satake.

www.satake-group.com

In 2013 Silos Cordoba has followed the same stable path as in previous years: a continuous and safe growth of the company.

We have grown in several aspects: It’s not only sales that have been going well in 2013. Our team is bigger due to the introduction of a new member for Maghreb region, giving a wider and better service in these countries; new members in our technical team, aftersales services and quality department; the creation of an R&D department which is focused on research, product redesign and innovative solutions; construction of a silo plant for testing our equipment and silos, and getting valuable data about the useful life of our products – the wear of the parts, corrosion time, etc. And last but not least, our new factory. The idea is to start work on the factory in 2014 and we estimate it will be operational by 2015.

During this year Silos Cordoba accounts around 82.5 percent of turnover to come from exports on average, we are selling in 30 countries per year, which means that we are a permanent supplier in those countries.

These new steps will bring competitive differences to Silos Cordoba, which will lead us to leadership in our sector. We have always focused on development and innovation to be competitive abroad and provide comprehensive solutions for the storage and preservation of cereal.

www.siloscordoba.com 42 | November - December 2013

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COMPANY PROFILES 2014

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SUPER EUROBUCKET ™

Symaga, a Spanish company specializing in the design, manufacture and supply of steel silos for storing seeds, cereals, malts, oilseeds, grains and pellets, rice and, in general, for agriculture, agro-industry, biofuels and biomass. With more than 30 years’ experience and over 15 million m³ of storage space Polyethylene worldwide, our Elevator capacity is Bucket sure to be able to tackle any project.

Also available in Urethane & Nylon Symaga supplies a wide range of silos, flat bottom up to 25,000 m³ and hopper silos, reaching 12 metre diameter with 45° hopper and 2,643 m³ •Ability capacity, to absorb impact and “give”andorwith “yield” completely galvanised double welded compression ring. We provide Z600 gr/m² galvanisation, ensuring the highest service life of to bypass obstruction – andinvesting return intoresearch their and development, allowing us to develop new products to reach customer needs, including ventilated thean market.

We continue originalcones shapeand– to on working fullykeep perforated floor. for you.

•Injection-molded from highest grade resins to guarantee very dense, long wearing surfaces.

•Directly interchangeable with existing pressed steel buckets.

www.symaga.com

Replace your steel buckets with Tapco – the bucket with a memory.

ELEVATOR BUCKETS & BOLTS

T: +1From 314a739 9191 • F: +1 314 739 5880 small facility in Keokuk, Iowa, USA, founded in 1974, to a 92,000 square foot manu-

facturingwww.tapcoinc.com facility in St. Louis, Missouri, USA, Tapco Inc. is a global leader in elevator buckets.

Tapco continues to develop innovative products and create safe, top-quality solutions for the grain processing industry.

Engineered designs, state-of-the-art technology and comprehensive expertise in material handling processes help Tapco’s customer facilities increase quality and productivity. Nine in-house injection-molding machines allow us to make our entire range of buckets in the most expedient manner and with the greatest quality control. The extremely high pressures required to make injection-molded buckets guarantee very dense, long wearing surfaces.

Tapco buckets are known worldwide for their strength and precise discharge characteristics.

Tapco stocks 900,000 elevator buckets in 93 sizes manufactured in polyethylene, nylon, polyurethane, aluminum, ductile iron and fabricated steel. Standard styles include CC-HD (HEAVY DUTY), CC-XD (XTREME DUTY) and Super EuroBucket. Tapco nonmetallic buckets have strong, thick walls that “give” and “yield” to withstand hang-ups and return to their original shape. The XTREME DUTY bucket is molded with 35-50% MORE resin, making it a thicker and stronger version of the classic style CC-HD. Super EuroBuckets replace steel buckets and provide equal or greater capacity for your elevator.

Tapco bucket performance and productivity consistently exceeds customer expectations, lasting longer and wearing better than other nonmetallic buckets. That may be why 75% of Design Engineers, Contractors and Bucket Elevator Manufacturers in the USA specified Tapco buckets* on new or expanded facilities since 1986.

Tapco maintains 15 million elevator bolts in 54 sizes in six styles, along with a large inventory of abrasion-resistant sheeting, hanger bearings, drag flights and belt splices.

With a team of bilingual representatives, and stocking distributors located strategically throughout the world, Tapco has what you want, when you need it.

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Polyethylene Elevator Bucket

Also available in Urethane & Nylon

•Ability to absorb impact and “give” or “yield” to bypass an obstruction – and return to their original shape – to keep on working for you.

•Injection-molded from highest grade resins to guarantee very dense, long wearing surfaces.

•Directly interchangeable with existing pressed steel buckets.

Replace your steel buckets with Tapco – the bucket with a memory.

ELEVATOR BUCKETS & BOLTS

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

*As reported by GRAIN JOURNAL, Country Journal Publishing Co., Inc., Decatur, Illinois, U.S.A.

www.tapcoinc.com &feed milling technology

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November - December 2013 | 43

COMPANY PROFILES 2014

VIGAN, a reliable partner in dry bulk handling Belgium-based VIGAN Engineering SA designs and manufactures handling equipment for dry agribulk cargo: grain pumps, ship unloaders and loaders (pneumatic or mechanical), reaching capacities up to 1,500 tons per hour.

Widely recognised worldwide as an expert in pneumatic bulk handling technology, VIGAN also delivers turnkey projects for port terminals that include conveyors, silos, warehouses and bagging lines.

Since its foundation in 1968, VIGAN has sold more than 1,200 machines all over the world.

Successful 2013 - Basically, the sales pattern has been similar to previous years. The interest in VIGAN technology in ship unloading remains important, with numerous inquiries from existing ports or new facilities. We have also seen a growing demand for ship unloaders with larger capacities.

VIGAN has recently been awarded several contracts in North Africa and nearby countries, as well as in other regions such as Europe, the Middle East and the Far East. It is also evaluating projects on other continents. These order confirmations should make this a quite good year by its end.

A reliable solutions provider - For more than four decades, VIGAN has forged its reputation by offering reliable equipment adapted to the customer’s requirements: technical characteristics most suitable to each particular project with value-for-money machines.

To remain competitive, VIGAN offers a highly professional technical assistance, a strong after-sales service and the guarantee of long-term supply of spare parts from most well-known suppliers. Moreover, VIGAN maintains permanent technical development, keeping in mind major concerns: the environment, dust suppression, safety, efficiency and reliability.

A bright 2014 - With several long-term projects in the pipeline, VIGAN is confident for next year. The demand for grains remains strong. As grains are a basic staple food in many countries, governments and private companies are both continuing to invest in handling equipment.

www.vigan.com

Always Changing To Meet Customer Needs Back in 1935, when Wenger was established as a local manufacturer of mixers and feed milling machinery, the company’s main objective was to add value and palatability to lowquality feed. Today, as the world’s leading supplier of aquatic and pet food processing systems, Wenger is helping customers meet a new, more timely list of objectives, like increasing production rates, lowering energy costs and expanding viable recipe options.

In 2010 alone, Wenger introduced 23 new innovations and was issued 11 new patents in response to rapidly changing needs in the industry.

New Wenger SX-1480 shrimp feed extruder

Innovative designs Available in both single screw and twin screw configurations, Wenger extruders boast capacities as high as 22 tonnes per hour. Two new innovations – Wenger’s diverging cone screws and oblique die technologies – make extrusion the superior choice for production of even high capacity micro aquatic feeds.

Knowledge, research, training and support Wenger customers have access to the 2,500-square-metre Wenger Technical Center for testing ideas and formulas.

Wenger technical support also includes pre- and post-installation engineering assistance, operator training and onsite attention to quality control and operational needs. Extensive inventories of replacement parts are maintained for prompt shipment to customers. Service after the sale is standard with Wenger products.

Operating around the globe Wenger’s engineering, manufacturing, research and administrative facilities are located at the company’s Sabetha, Kansas, USA headquarters. Plus, Wenger extension research sites are available at a number of universities and research centres around the world. Sales and service is available through Wenger offices in the USA, Belgium, Taiwan, Brazil, China, Turkey, and India, as well as independent agents in strategic locations around the world. In fact, Wenger serves hundreds of different agri-food producers in more than 90 countries.

www.wenger.com 44 | November - December 2013

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COMPANY PROFILES 2014

At Westeel, we pride ourselves on manufacturing grain storage products that are considered among the most innovative in the market today. Our storage solutions are engineered to suit your application: from smaller on-farm bins to large-scale commercial systems. Personalised service, superior quality, innovation, design and long-term value signify the Westeel name.

From our pioneering work to introduce the steel grain bin to farming in the 1920s, to our subsequent efforts to perfect and popularise its use through the subsequent decades, no company can claim more experience or innovative thinking in the field of steel sided storage than Westeel. All our products are manufactured to ISO 9001 requirements, and throughout the manufacturing process we employ the latest in computerised design and production technology.

Undertaking storage projects on six continents, Westeel offers a range of flat bottom and hopper grain bins as well as handling and unloading equipment, monitoring systems and aeration solutions. Full aftersales service is also included, ensuring customers receive the support they need to keep bins in peak operational condition.

At Westeel we offer products of superior quality and long-term value – products that represent the finest in on-farm and commercial grain storage.

www.westeel.com

Zhengchang is the feed machinery manufacturer and complete project contractor in China. Established in 1918, it owns 16 subsidiary companies and over 30 offices overseas. It has obtained the European CE and Russian GOST-R certificates, as well as being designated a “Chinese well-known brand”, and one of China’s “national key high-tech enterprises”.

SZLH1068: China’s largest capacity pellet mill Developed and manufactured by Zhengchang, the SZLH1068 pellet mill is one of China’s key science and technology support projects of its eleventh five-year plan. Its 44-55 tonne per hour capacity is the largest of any in China, and it will be put to use in the 160 ton per hour feed factory for the Hewei company.

The successful manufacture of the SZLH1068 has laid a solid technological foundation for the massive and intensive development of the Chinese feed industry. The adoption of the SZLH1068 pellet mill will greatly reduce the cost of investment, production and management for feed factories, and add value to their products.

Advantages: • Variable-frequency feeder: a variable-pitch double screw ensures even feeding of the product • The main motor works at a stable current, and the round screw barrel protects against upcoming steam • Extended and lengthened conditioner ensures longer conditioning time and better performance • Multiple inlets ensure even addition of steam • External pneumatic discharger releases feed automatically in case of blockage, and magnets at chute inlet removes impurities • High quality bearings in drive system and adopting of thin-oil cooling and lubrication ensure long-term reliability • Greater capacity and better pellet quality due to increased die speed • Hydraulic lifting carrier makes it easy to disassemble the die and roller • Optimised design, advanced heat-treatment technology and high quality steel fabrication give the gear and shaft a longer life and more reliable drive

www.zhengchang.com &feed milling technology

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November - December 2013 | 45

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.

Huge corn supplies will anchor feed costs

Recovering ‘Black Sea’ (former Soviet country) crops may now live up to, even exceed, their early promise in terms of tonnages but there may be some quality issues after wet harvests for the latter stages of Russia, Ukrainian and Kazakh harvests. The latersown spring wheat and corn crops will be most at risk.

46 | November - December 2013

M

ORE good news this month for feed raw material consumers’ costs: The world supply outlook for maize seems to be getting looser by the month, pushing prices down to yet more historical (33month) lows as we go to press. Not only has the US crop turned out even bigger than expected in our last review; the second largest consumer of maize, China, now appears to be using considerably less than estimated earlier. Top outlet for maize, the USA might also need less than expected as we move into 2014 after proposals to roll back targets for renewable fuel use.

Markets had been bracing for a bigger US crop number after consistently stellar yield reports from the gathering harvest during October and the latest figure didn’t disappoint – 355m tonnes will be 81.5m bigger than last year’s crop and even that might not be the end of this story.

The Chinese news, on the other hand, came more or less ‘out of the blue’ for a market that has grown used to ever-expanding estimates of this county’s feed demand. The lower than expected forecast was made in the latest global supply/demand estimates from the US Department of Agriculture which cut 5m off its demand in 2012/13 season (ended Sep 30) and a further 6m from 2013/14t. The net effect was to raise the USDA’s forecast for China’s end-season stocks from 54.8m to 67.5m tonnes – equal to about 40% of the world total carryover.

As a result, world corn stocks next September are seen rising to about 17.6% of global consumption

needs compared with around 15% over the previous three seasons. China will be the largest stockholder (compared with an estimated 48m tonnes in the US, no mean total either!). However, these large Chinese supplies are seen mostly ‘off-market,’ held in the vast strategic reserves that the government there likes to hold for lean crop years. Some western analysts even doubt that China’s stocks can really be that high, or, if they are, whether much of is still in a useable conditions, some carried over from several crop years past. Nonetheless, this evident loosening in its internal supply could indicate that China’s import needs may not be quite as large - or as urgent - as markets had assumed during the summer months when it was first tipped to jump from joint tenth place (with Indonesia) to number 5 in the world import league.

Caution towards bullish Chinese maize import forecast was also demanded by two further developments. One was its rejection in November of an arriving US cargo that contained an unauthorized variety of genetically modified maize, sparking fears that this could happen again (not many years back, readers may recollect, there was a lengthy break in trade caused when unauthorised ‘Starlink’ GM maize was found in US cargoes). As we went to press, China had bought almost 4.85m tonnes of US maize but shipped less than 1.5m tonnes of that. Another factor was a higher Chinese crop estimate from forecasting body Lanworth - 220m tonnes compared with the USDA figure of 211m.

Russia’s maize crop has also been increased, from 9m to 11.5m tonnes which some observers see releasing maybe as much as 3.5m tonnes of exports (against 2m in recent years and very little before that). However, the much bigger factor in that region remains Ukraine whose record 29/30m tonne crop is expected to allow exports of at least 18m, compared with 12.7m last season and its normal average 5m tonnes in recent years. Ukraine has already exported around 5m tonnes

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COMMODITIES

from a crop that has barely finished harvest and during November, shipped its highest weekly total ever at 969,500 tonnes. Like the Latin American countries throughout the past few months, Ukraine has set the price bar low for other feedgrain exporters. However, the drop in US futures prices has now made the traditional largest supplier of corn competitive on fob terms with most of its rivals for first quarter 2014 shipments onward.

As noted in our last issue, the corn crop bounty has extended to the EU too, where production is expected to expand by about 6.5m tonnes to over 65m. So far this has had less effect than might have been expected in bringing down EU corn prices, mainly because the French harvest has been slowed by excessive rain. Even in mid-November, this had reached just 58% completion versus 88% at the same time last year. Once the harvest is done and attention turns fully on the Ukrainian competition, prices here may well come under further downward pressure..

At this stage, EU corn consumption in 2013/14 is seen more or less level with last season’s around 70m tonne. Imports – again with a heavy emphasis on Ukrainian supplies – are expected to drop by about 3m tonnes but will remain relatively high compared with recent years at some 8m.

Like other consumers, Europe will remain tempted by corn prices that have recently undercut feed grade wheat on world import markets by as much as $60 per tonne. The gap between wheat and maize prices is even wider on the US futures markets – over $2.20 per bushel or about $72/tonne on the spot months compared with just $20 this time last year.

US maize prices have been pushed down by the large domestic crop, the foreign export competition and a past season of lower demand in its own feed and ethanol sectors.

Both were expected to show some revival

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in 2014 in response to the halving of corn costs and higher renewable fuel use mandates set some years back. During November, the US government confirmed it was proposing to lower these, including a cut in next year’s RF mandate. Although the breakdown in cuts for fuel types is not yet clear, some trade houses offered initial calculations that this could put US maize consumption for ethanol 7.5/15m tonnes below what the market assumed from the earlier targets. However, others have played down the impact, suggesting the changes will have greater impact on so-called ‘advanced’ biofuels like soya diesel, rather than corn ethanol.

Better profitability in the bio-ethanol sector after the drop in the corn price (and a rise in ethanol values to five-month highs) may also continue to support production that has been buoyant recently by these factors, along with the industry’s ambitions to export more. In summary, the outlook for corn ethanol use is a bit of a grey area, if a potentially bearish influence.

Latin America’s contribution to global corn exports is seen smaller in the coming year by the USDA which pitches the Argentine crop 500,000 tonnes lower at 26m but Brazil’s 11m smaller at 70m on the assumption that producers have sown/will sow more soyabeans and that Brazil is unlikely to get the unusually high yields it had from its Safrinhas (second-sowing) crop maize. Despite that, the Brazilian figure is probably too cautious. Local analyst Safras e Mercado, for example, recently put the crop at 75.2m. It might also be remembered that the USDA started out estimating last season’s crop at 70m too. It ended up at 81m. Either way, though, there will be no shortage of maize in the season ahead, when world export trade is expected to reach a record 109m tonnes, (up 10m) even as the global carryover stock piles up.

The tail end of the maize supply outlook might be a little less bearish. Many analysts

are currently predicting US farmers will cut plantings next spring in response to the price drop and consequent better returns from soyabeans (which will move into this empty land). Weather will, as always, also play a part in that sowing campaign, good conditions favouring early sowings and larger maize areas, weather delays favouring more soyabeans, which can be planted later. On the other hand, Russia and Ukraine have land left vacant by unfulfilled winter wheat planting intentions, the bulk of which is expected to go to maize. That suggests an even bigger contribution from the CIS countries next year, weather permitting.

In the meantime, futures markets are not pre-empting any shortages arising from lower US or South American plantings. As far out as December 2014, the maize price is trading around $4.60/bu or about $180/tonne. That’s less than 8% over the current very low spot price.

It has been an odd couple of months for the wheat market which, despite a surge in October to four-month highs of near $7/bu ($257/t) on the CBOT futures market has also been frequently tempted to test the low side, ranging down to the $6.30’s ($235/t).

On the supply side of the market, the main changes in recent weeks have centred on the expected trimming of CIS crops after rain delays to their harvests. Russia’s is now assumed to be down by about 2.5m from earlier forecasts at 51.5m while Kazakhstan’s has been cut by 1.5m to 15.5m. However, these, in combination with Ukraine’s, are still good crops compared with last year’s very disappointing results (the three in total at 89m tonnes are up by about 16m allowing exports of 34m compared with last year’s 25.5m tonnes. Their combined wheat stocks carried into next season are also expected to rise by about 2m tonnes to around

November - December 2013 | 47

compared with as low as $245/250 back in the late summer months. Ukraine has also been getting well sold, its export offers also moved up with Russian wheat, allowing EU, US and other exporters to grab a larger share of the going import business (see below). However, India has a huge exportable surplus this year, poor storage and another probable record crop on the way.

With world prices now coming within its reach (its domestic prices had been too high to export without subsidy), it has begun to release more wheat and will likely prove a formidable competitor in the months ahead, probably filling any Russian or Ukrainian gaps and helping to slow the Page 1 ascent in international prices.

Other notable developments since our last review include a big uprating of the Canadian crop, now seen at a record 33.2m tonnes versus last season’s 27.2m. This makes the USDA’s forecast of a 3m tonne increase to 21.5m in this season’s Canadian exports look a little conservative.

The EU crop has also outdone all the early forecasts and is now rated by the USDA at 143m tonnes versus last year’s 133.6m although some 16.5m. That’s still way under the 27m carried in private forecasts for 2013 are several million from the bumper 2011 harvests but welcome tonnes larger still. nonetheless to the bear camp.

However, the rise in prices that the wheat Russia does seem to be running low on market saw in October was less of a response to old crop news than to delays in sowing the adequate export quality wheat now and has embarked on a state purchasing programme next batch of CIS wheat crops for harvest 2014. to rebuild its depleted stocks. This has allowed At one stage, things looked pretty grim amid its export prices to creep up in recent weeks talk of major cutbacks to sowings across the to around $285/tonne for Black Sea ports region and late sowings at greater risk of poor FIAAPisland:Layout 1 30/8/13 14:26 or non-germination and high ‘winterkill.’

However, planting estimates have improved with drier weather in the last few weeks and will not be as far under the 2013 totals as earlier expected.

Also a spell of unusually mild weather after all the rain has got sown crops off to a rapid start across the CIS region.

The longer this continues, the better chance of reasonable survival rates into the spring although the lack of snow cover was beginning to make a few observers fret as we went to press.

8 – 10 April 2014 . Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand If the CIS countries are to make a smaller contribution to next year’s wheat supplies, there will be some mitigating factors. In the USA, the largest exporting country, winter wheat sowings are estimated to have risen by about 3-4%, while crops are in far better condition than at this time last year, when large areas of the wheat belt were suffering droughts (at one stage recently, almost twice as much wheat was rated ‘good/excellent'). If the weather stays favourable over the next six months that could mean big yields and a bumper US crop. EU winter wheat sowings are also estimated to have increased for harvest 2014 and are similarly blessed with largely favourable weather – certainly no lack of rain in the main western European grain belt and a relatively late start to cold weather, promoting good growth pre-dormancy.

FIAAP Asia 2014 is the only dedicated trade show and conference organised specifically for feed ingredients, additives and formulation within the dynamic and growing region of South and South East Asia.

Southern hemisphere crops have presented a slightly more bullish story.

New for 2014 Supported by A combination of low sowings (blamed Now including the first The Thailand Convention on government export controls) and ASEAN Feed Summit and Exhibition Bureau unfavourable weather is expected Specialist conferences Co-located with to prevent Argentina – once one of The exhibition will be supported VICTAM Asia 2014 by its own specialist conferences. www.victam.com the ‘Big five’ regular wheat exports – They will include: improving much on last year’s unusually Contact details The FIAAP Conference 2014 For visitor, exhibition stand poor 9.5m tonne crop. Some estimates Petfood Forum Asia 2014 space and conference are even under 9m, a few still around Aquafeed Horizons Asia 2014 information please visit: 11m but most expect exports to drop The Thai Feed Conference 2014 www.fiaap.com

Asia’s foremost exhibition and conferences for the ingredients and additives used in the production of animal feeds, aquafeeds and petfoods

48 | November - December 2013

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COMMODITIES to as little as 3.5m. from last year’s 7.5m and the year). previous season’s near 12m tonnes.

This rapid rate This gap in southern hemisphere supply of disappearance has already turned Argentina’s customers – is one of the main especially Brazil, the world’s second largest factors holding up wheat importer – to North America for prices on both the supplies, with supportive effect on US/Canadian US and EU markets, hard wheat export prices. especially the latter.

Australia’s harvest results to date (around Even so, the relative 20-30% complete) have also been a bit adequacy of overall disappointing, achieving lower than expected supply – and the lack of a major weather threat to 88.66m. Planting of the next Latin American proteins (one forecast saw two thirds of yet to 2014 global output is at this stage allowing crops, for harvested first quarter 2014 has the harvest grading 11.5% or lower). Some the distant futures price of wheat to run at only progressed under favourable conditions.

Australian sources also expect more of this a small premium to the spot market – the EU’s Record large areas are being sown there and season’s surplus to go to rebuilding stocks that even portraying slightly cheaper prices into 2015. ideal weather has got things off to a flying were used last year to maintain strong exports Finally onto oilmeal markets, where all the start. The USDA sees regional output rising in a year of lower production. Crop estimates supply news so far is no less encouraging for to 156m tonnes from last year’s 146m (and have ranged from as much as 28m (probably consumers. The US soyabean crop estimate just 112m in 2011/12) while some local analysts far too high now) to 23.5m tonnes. Yet evenVICTAMisland:Layout has recently been raised1 by30/8/13 almost 3m tonnes expect1the total to exceed 160m. With the 14:22 Page the lowest figure would, be bigger than last year’s and large enough to maintain a full export programme.

Overall, there should be no shortage of wheat supplies going forward which is just as well in a season when global trade is expected to expand by about 4-5m tonnes to 152m – its second highest level ever.

The main factor, as outlined in our earlier reviews, has been the explosion in Chinese import needs from less than 3m over the past two years (little more 8 – 10 April 2014 . Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand than 1m before that) to a forecast 8-9m tonnes this season. Demand has also been forecast higher into the top importer Egypt (9.5m vs last year’s 8.3m tonnes and a more normal 10/5/11m before its political/economic crisis). Iran may also take more wheat with the easing of trade sanctions in the wake of its recent nuclear nonproliferation agreement.

Aside of these seasonal forecasts, there has recently been a lot of evidence that international buyers are already finding wheat better value since it forsook the $350/450 (soft & hard wheat respectively) levels of this time last year for prices closer to $280/340 (see charts).

The past month or so especially has seen strong demand from the Middle East especially, but no lack of suppliers keen to get this business. For the US and Europe, this demand surge has VICTAM Asia 2014 is the largest trade show within South and South East Asia for displaying the latest equipment and technology used in the production of animal feeds, aquafeeds and dry petfoods. propelled exports far ahead of the needed pace. The EU in total has New for 2014 Supported by already sold 10.6m tonnes of soft wheat Now including the first The Thailand Convention compared with 6.8m this time last year ASEAN Feed Summit and Exhibition Bureau – a 56% increase compared with the Specialist conferences Co-located with seasonal forecasts of a less than 10% The exhibition will be supported FIAAP Asia 2014 and by its own specialist conferences: GRAPAS Asia 2014 rise. The US has meanwhile sold 37% www.fiaap.com / www.grapas.eu The FIAAP Conference 2014 more than last year (forecast plus 8%) Petfood Forum Asia 2014 Contact details which is almost three quarters of its Aquafeed Horizons Asia 2014 For visitor, exhibition stand space and seasonal projection with six months The Thai Feed Conference 2014 conference information please visit: still to go (seven for the EU marketing www.victam.com Biomass Pelleting Asia 2014

Asia’s largest exhibition and conferences for animal feed, aquafeed and petfood production

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November - December 2013 | 49

bigger US crop that puts world soyabean supply up by 16-20m tonnes, equal to an additional 12.5/16m tonnes of soya meal if all were crushed. The USDA currently sees meal output up by a more conservative 11m tonnes, the rest of the extra soyabean supply going to build global stocks carried into 2014/15. At a record 70m tonnes these will be more than Brazil has produced in some recent years.

This surplus may not yet been fully factored into soyabean prices at $12/13 per bushel.

But either way, if consumers need more meal

than currently estimated, the supplies should be there to crush.

Other oilseed crops have also turned out higher than expected. The world sunflowerseed output estimate has been raised by 1m to 42.8m tonnes, rapeseed by 1.5m to almost 68m, putting total world oilseed production at 280m tonnes or about 25.5m over last year’s. Not surprisingly, the forward futures markets point to lower prices in this sector with both beans and meal seen about 13% cheaper next autumn

than now. Soyabeans are already 25-30% cheaper than the record peak prices they reached in the autumn of 2012 (just under $18/bu).

KEY FACTORS AHEAD – WHEAT Will ‘Black Sea’ (former Soviet countries) crops have a normal, mild or harsh winter?

Planted areas are down and a lot of the crop went in late but it has been mild so far and there is no lack of soil moisture – unlike some recent years. Provided they get some snow protection, production may not be so far under this year’s adequate level.

50 | November - December 2013

How much more of their 2013 crops will Black sea countries want to export? A brisk early season sales campaign, some emergent quality deficiencies in Russia, Moscow’s plan to rebuild reserve stocks - plus some unease in government circles about next year’s crop after late, downsized plantings - might all conspire to encourage a cautious export policy from now on. That would mean less price discounting to win foreign deals.

But if the CIS countries do go into export retreat, India should be able to fill a lot of any

gaps resulting in world supplies. It may not have top quality but it does have an awful lot of surplus wheat – much of it in risky poor storage – and another probable record crop on the way. So Indian exports could help cap rallies in international wheat prices.

Europe’s breakneck early-season export campaign shows no sign of letting up as we go to press. But at this stage, there seems no danger of the domestic market running out of wheat.

Plantings for next year’s crop are up, weather so far promising.

Cheap corn competition from Ukraine especially, $60/80 per tonne under feedwheat, should also help cap the low quality end of the wheat market. A record world maize crop will keep wheat use in feeds below the peak level of two years ago.

But food, bio-fuel and other outlets will still add about 3.5%, or 24m tonnes to world total wheat consumption in 2013/14. That continues to mean only modest stock growth but the global wheat inventory will still be more than adequate as a percent of consumption.

The USA, Canada, Australia, even Argentina, with its weather problems, all still have wheat to export going into the second half of the 2013/14 season. So importers do have choices.

Markets could get excited again about Chinese imports taking more of the world export supply. China’s own crop needs more rain and its domestic prices are at record highs, way above the world price of wheat.

Iran could import a lot more with the easing of

trade sanctions but top buyer Egypt’s demand is uncertain amid its financial problems.

Quality remains a potentially live issue.

Canadian, Australian and French proteins may be below average in a year when Argentine wheat availability is halved. But so far, benchmarks like the North American hard wheats are holding prices steady at levels considerably cheaper than at this time last year.

COARSE GRAINS The US maize crop is much larger than expected and this will loosen both US and world carryover stocks considerably over the coming year – but there are some wild cards on the consumption side.

US exports are running ahead of USDA forecasts. If that pace continues, stocks may not be quite so large but may still be burdensome enough to depress US and world prices.

US feed use of maize is expected to recover somewhat in the year ahead. January quarterly stock figures will shed some light on the extent of this trend.

US ethanol demand for maize (40% of consumption) was expected to rise 5.4% this season – before the government proposed curbing bio-fuel blending.

Strong exporter competition will continue for maize import trade – from Ukraine and Russia initially and, into first quarter 2014, from South American crops – whose potential might be under-rated – but weather there needs to be watched in the months ahead.

The US is expected by many observers to sow significantly less maize in 2014 in response to this season’s surplus, the near halving of prices and the relatively better returns to be had from soy beans.

But CIS countries could sow more in the spring on failed winter wheat lands, raising export supplies to new rercord levels.

Will China remain a key maize importer, helping to soak up some of the world surplus?

The biggest crops opf barley and sorghum for four and five years respectively add to this season’s abundant feed grain supply.

OILMEALS/PROTEINS Latin American soya crop weather will be the main focus in the months ahead. If it stays as favourable as recently, crops will be record large and should pressure prices lower for soya meal and the entire oilmeal complex.

China will remain top factor on the demand side of the soya/oilmeal equation but its purchases are likely to switch soon from US to cheaper Latin American new crop supplies.

Big EU and CIS rapeseed and sunflowerseed and Canadian canola crops are adding to the abundance of oil meals implied by record soyabean production. But will these producers grow less in 2014?

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Empower your employees with tools and problem-solving skills at IAOM’s Fundamentals of Milling I and II courses, offered at Ocrim’s International School of Milling Technology in Cremona, Italy.

Fundamentals of Milling I: March 17-21 Fundamentals of Milling II: March 24-28 Technical training courses that combine lectures and discussions with hands-on laboratory and pilot-scale milling exercises.

Experience this unique learning environment where classroom, lab, manufacturing plant, and pilot mill all come together.

visit us at Fruit Logistica 2014 5-7 February 2014, Berlin, Germany Stand D-07 in Hall 5.2 Don’t miSS our newS ConFerenCe at Fruit LoGiStiCa!

International Association of Operative Millers 10100 W. 87th Street, Suite 306 Overland Park, KS 66212 USA T: +1 913-338-3377 | F: +1 913-338-3553 E: info@iaom.info

For more information, visit: www.iaom.info/education

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Date: time: Place:

6 February 2014 12:00 a.m. - 1:00 p.m.

Berlin Fairgrounds, Press Center, Hall 6.3, room B Check out our website for events happening near you! www.tour2013.org

November - December 2013 | 51

Events 19 – 24 January 14

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24th Annual Practical Short Course on Feeds and Pet Food Extrusion, Texas A&M University, College Station, USA Contact: Dr Mian N Riaz Tel: +1 979 845 2774 Email: mnriaz@tamu.edu http://foodprotein.tamu.edu

20 – 24 January 14

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Bühler Feed Milling Electrical Maintenance Training, Uzwil, Switzerland Contact: Bühler AG Tel: +41 71 955 19 14 Email: service.academy@buhlergroup.com www.buhlergroup.com

21 – 22 January 14

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Myanmar Agribusiness Investment Summit (MAIS), Inya Lake Hotel, Yangon, Myanmar Contact: Gwendoline Yap Tel: +603 4045 5999 Email: gwendoline.yap@confexhub.com www.myanmaragribusinessinvestmentsummit.com

23 – 25 January 14 Livestock 2014 Myanmar Expo, Tatmadaw Exhibition Hall, Myanmar, Asia Contact: Dliana Sahadan Email: Dliana.Sahadan@ubm.com http://www.livestockmyanmar.com

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* Bühler Feed Milling Mechanical Maintenance 27 – 31 January 2014

International Production and Processing Expo (IPPE), Georgia World Congress Center, Atlanta, USA Contact: Gwen Venable Tel: +1 7704 939 401 Email: Gvenable@uspoultry.org http://ippexpo.com

4 – 6 February 14 AgroFarm Russia, All-Russian Exhibition Center (VVC), Moscow, Russia Contact: Dr. Olga Hunger Tel: +49 0 69 247 882 71 Email: o.hunger@dlg.org http://www.agrofarm.org

For more event information, try our Event Register at www.perendale.com la Av a i b l e H

Cereals, Mixed Feed and Veterinary Exhibition, (Held in conjunction with 1st Russian Milling Conference), All-Russia Exhibition Centre (VVC), Moscow, Russia Contact: Tatiana Sokolova Email: ts@expokhelb.com www.expohleb.breadbusiness.ru/eng

5 – 6 February 14 Oilseed Congress Europe / MENA 2014 Hotel Arts Barcelona, Spain Contact: Sule Basa Tel: +90 542 434 4044 Email: sule.basa@gmail.com http://www.cvent.com

11 – 13 February 14

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13 February 14 Ildex Thailand on the move, Chiangmai, Thailand Contact: Nalinrat Ananamnuaylap Tel: +662 670 0900 ext. 118 Email: nalinrat.ana@vnuexhibitionsap.com http://www.ildex.com

GEAPS Exchange, CenturyLink Center, Nebraska, USA Contact: Rose Miller or Samantha Kukowski Tel: +1 952 928 4640 Email: conferences@geaps.com www.geaps.com/exchange

3 -5 March 14

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Campden BRI Seminar: Safety and Quality of Livestock Feed, Campden BRI site, Gloucestershire, UK Contact: Nick Saunders Tel: +44 0 1386 842104 Email: nick.saunders@campdenbri.co.uk www.campdenbri.co.uk/livestock-feedseminar.php

12 – 14 March 14

ILDEX Vietnam Saigon Exhibition and Convention Center (SECC), Ho Chi Minh City, Vietnam Contact: Nalinrat Ananamnuaylap Tel: +662 670 0900 ext. 118 Email: nalinrat.ana@vnuexhibitionsap.com http://www.ildex.com

8 April 14

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2014 Purchasing & Ingredient Supplier’s Conference (PISC), Caesars Palace, Nevada, USA Contact: American Feed Industry Association (AFIA) Tel: +1 703 524 0810 Email: afia@afia.org www.afia.org

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K food and drink research centre Campden BRI have made a foray into animal nutrition with the announcement of its ‘Safety and quality of livestock feed’ seminar, to be held at their Chipping Campden base on 6 March, 2014.

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Using as a starting point the increasing demands placed on manufacturers by global feed markets and changes in livestock production, the seminar will explore animal feed issues from a number of different perspectives. A packed programme covers a varied range of topics, from feed safety regulations and food chain nutritional studies, to focuses on developments in the poultry, ruminant and aquaculture sectors.

Renowned feed journalist and Grain & Feed Milling Technology publisher Roger Gilbert will chair the discussions. Gilbert maintained that the seminar represents a golden opportunity for the industry.

“If we are ever going to feed 9 billion people by 2050, then the quality and nutritional value of feed ingredients, not to mention how we source them, must be a central concern. For many this statement will be a matter of course. However, maintaining high levels of quality in ingredients while ensuring they are sustainably managed is becoming a major challenge. “ H aving be e n a founding member of the International Feed Industry Federation and having served as its SecretaryGeneral for more than 20 years, this topic is extremely close to my heart. It is a privilege to work in close collaboration with as innovative and forward-thinking an organisation as Campden BRI, and I look forward to playing a part in keeping these issues at the forefront of feed research and development.”

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GRAPAS Conference (held in conjunction with Victam Asia) Bangkok International Trade and Exhibition Centre (BITEC) Bangkok, Thailand Contact: Andy West Tel: +44 0173 776 3501 Email: Andrew.west733@ntlworld.com http://www.victam.com

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Victam Asia Bangkok International Trade and Exhibition Centre (BITEC), Bangkok, Thailand Contact: Andy West Tel: +44 0173 776 3501 Email: Andrew.west733@ntlworld.com http://www.victam.com

8-10 April 14

Pig, Poultry & Dairy Focus Asia Queen Sirikit National Convention center Bangkok, Thailand Contact: Panadda Kongma Tel: +662 670-0900 Ext. 204 Email: panadda@vnuexhibitionsap.com www.positiveaction.info/conferences.php

6 March 14

Turkish Flour Industrialists' Federation Celebration of 10th Foundation Anniversary and International Congress and Exhibition Titanic Deluxe Belek, Antalya, Turkey Contact: Turkish Flour Industrialists Federation (TFIF) Tel: +90 312 440 0454 Email: bilgi@tusaf.org http://www.tusaf.org/EN

8 – 10 April 14

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Campden BRI branches out with new feed seminar

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13 - 16 March 14

19 – 21 March 14

Agro Animal Show/Grain Tech Expo/ Fruits, Vegetables, Logistics, Kiev Expo Plaza Exhibition Center, Kiev, Ukraine Contact: Friederike Arnz Tel: +49 0 6221 13 57 12 Email: f.arnz@ifw-expo.com www.ifw-expo.de

22 – 25 February 14

Training, Uzwil, Switzerland Contact: Bühler AG Tel: +41 71 955 19 14 Email: service.academy@buhlergroup.com http://www.buhlergroup.com

28 – 30 January 14

4 – 7 February 14

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FIAAP Asia Bangkok International Trade and Exhibition Centre (BITEC) Bangkok, Thailand Contact: Andy West Tel: +44 0173 776 3501 Email: Andrew.west733@ntlworld.com http://www.victam.com

8-10 April

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GRAPAS Asia Bangkok International Trade and Exhibition Centre (BITEC) Bangkok, Thailand Contact: Andy West Tel: +44 0173 776 3501 Email: Andrew.west733@ntlworld.com http://www.victam.com

23 – 25 April 14

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VIV India 2014 Bangalore International Exhibition Centre (BIEC) Bangalore, India Contact: Manuel Madani Tel: +31 30 295 2608 Email: Manuel.madani@vnuexhibitions.com http://www.viv.net/en

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our magazine at this show * See • More information available

52 | November - December 2013

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Events IPPE opens doors for international audience

2

014’s International Production & Processing Expo (IPPE) is set to provide the world’s poultry, meat and feed producers with another show to remember this January. Held in the United States at Atlanta, Georgia’s World Congress Center, the expo is on target to match its 2013 offering of 1,189 exhibitors and 40,000 square meters of stand space, which made it one of the 50 biggest trade shows in the United States.

E ac h o f t h e e x p o’s t h re e integrated events is backed with its corresponding national body: the US Poultry & Egg Association sup por t s t he I nt e r n at ion al Poultry Expo, the American Feed Industry Association (AFIA) the International Feed Expo, and the International Meat Expo is sponsored by the American Meat Institute. Aside from being a place for attendees to network and make contacts with exhibitors, these industr y associations bolster IPPE’s credentials as a leading educational event for the global food and feed processing industries. The diverse range of educational forums is free to attend and includes sessions on traceability, human health, marketing and the future direction of the industries.

AFIA’s programme of events includes the International Feed Education Forum and IPPE’s first-ever export seminar. The education forum, which takes place on January 29, features three AFIA speakers discussing regulator y topics such as the recent U S Food S afet y M oder nis at ion Ac t , h a z ard identification requirements for feed producers and the latest environmental and health and safety directives. Also on the 29th, the export seminar has a similar focus, designed to help IPPE’s 5,000-strong international contingent navigate the complex proce s s of e x p or t ing fe e d ingredients into the United States.

“Over the years AFIA has seen an increased interest and curiosity by IPPE participants in

expor ting food and feed ingredients to the United States,” said Gina Tumbarello, AFIA manager of international trade.

“The seminar is designed to address this growing demand by providing a variety of information from a diverse panel of speakers.

If you are currently exporting to the US, or thinking about it, this seminar will serve as an excellent resource.”

On the poultr y side, IPPE’s conference programme offers much of interest in the linked

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GRAPASisland:Layout 1

f ie ld s of su s t ain a bili t y and animal health. The ‘New Approaches to Ground Poultry P at h oge n Re d u c t i o n’ b i ll e t features former US government official Dr Richard Raymond.

Dr Raymond ser ved as Undersecretary of Agriculture for Food S afet y under t he George W Bush administration, and will give conference-goers a summary of current practices and shor tcomings in poultry inspection.

The sixth annual Animal Agriculture Sustainability Summit is sponsored by the US Poultry & Egg Association and

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will contain a diverse series of talks on subjects including ingredient sourcing, corporate responsibility and consumer engagement. Six regional winners for the association’s Family Farm Environmental Excellence Award will be honoured at the end of the summit.

Last but not least, the International Rendering Symposium returns to IPPE for another edition. Covering topics as diverse as quality assurance, consumer perception and aquaculture feeds, it is likely to set the tone once again for 2014 in slaughterhouse by- and co-products.

8 – 10 April 2014 . Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand

Asia’s premier rice & flour milling and grain processing exhibition and conference

GRAPAS Asia 2014 is the only dedicated trade show and conference organised specifically for rice & flour milling, grain storage, preservation & processing, noodle, breakfast cereal and extruded snack production within the dynamic and growing regions of South & South East Asia.

New for 2014 Now including the first ASEAN Rice Summit

Supported by The Thailand Convention and Exhibition Bureau

Specialist conference The exhibition will be supported by its own specialist conference: The GRAPAS Conference 2014

Co-located with VICTAM Asia 2014 www.victam.com Contact details For visitor, exhibition stand space and conference information please visit: www.grapas.eu

November - December 2013 | 53

REVIEW - IAOM MEA 2013

Group shot of all participants Frank Braeken Operating Director, Simbi Capital

Alfonso Garrido - Sales Manager at Symaga and Hicham El Kasri Gitri from Symaga Dirk Janssens Director, Nutrex

Melinda Farris, Vice President of IAOM with a group of delegates from the Romanian Millers Association

Stephane Cochet Export Director, Chopin Technologies with an Infraneo®

IAOM MEA 2013 Conference and Expo

by Tom Blacker, events correspondent

H

igh-level executives, managers and CEOs came together in Sousse, Tunisia from 5–8 November 2013 for the International Association of Operative Millers' (IAOM) annual conference and exhibition of its Mideast and Africa region. The show's heading, ‘Cultivate the Earth’s Wealth and Nurture People’s lives’ was a lofty one, but in reality it boiled down to some interesting challenges paradoxes and discussions, and inspirational solutions that left the delegates and exhibitors looking ahead into the future with plenty of food for thought.

Promotion had started well before the event, with exhibitors like Silos Cordoba sending out blog posts and the IAOM releasing its final exhibitor and attendee list.

The atmosphere of the week was building from the moment of stepping foot in Tunisia: IAOM's event organiser was present at Tunis Airport assisting with arrivals and shepherding them over to Sousse, some 150 km south of the capital.

The Mövenpick hotel in central Sousse became the central point for the event.

Registration was in the reception of the hotel, where keen IAOMers collected all conference and expo material, Tunisian gifts and more. Amongst their winnings was of course a copy of Grain & Feed Milling 54 | November - December 2013

Technology magazine for every delegate!

The hubbub and chatter of the business opportunities only just becoming clear in Africa – with modern equipment, improved feed conversion rates and wireless communication leapfrogging wired communication – all came round eventually to very specific, detailed and technical discussion. It was great to see a variety of expert delegates from across the region. There were flour millers from Iran, Libya and Sudan; feed formulation experts from South Africa, France and Turkey and equipment manufacturers from the USA, Brazil and Lebanon.

Inside the marquee exhibition hall – set up on the resort's own beachfront – there were fantastic new products such as the Bühler Atta flour mill machine and great new companies from across the world, from the USA to South Korea. The expo was built on sand, but the knowledge and expertise was in the products, that had been carefully carried by truck into the exhibition tent! Footfall was highest at the very beginning and end of the exhibition days between Tuesday and Friday. Associations from Romania to Iran had sent groups of millers that dovetailed the opening and closing ceremonies.

Opening ceremony Four speakers represented Tunisia's milling industry during the opening ceremony, giving delegates a rounded overview of the past, present and future of cereals in the country. Kamel Belkhiria, CEO of specialist millers La Rose Blanche focused on the tradition of wheat milling in Tunisia. He focused on the challenges of storage methods, production and marketing, and above all on the significant opportunity for growth presented by the North African country.

Merzad Jamshidi, district director of the

IAOM's Mideast and Africa district praised the enormous diversity, strength and growth potential of his region's milling industries, as well as the acumen and range of local participants. He also took the opportunity to publicise his organisation's educational courses, held in conjunction with Kansas State University and growing all the time.

The Tunisian government was represented by Minister of the Economy Ridha Saidi, who noted that his country's 1.2 billion dinar (US$700m) milling industry has historically been boosted its high consumption of cereal products. As the first IAOM meeting to be held in Tunisia, Saidi stated his belief that the “new Tunisia” can capitalise on the event by upgrading its milling equipment and increasing the quality of its products. He rounded off with a statement confirming Tunisia's regional leadership in the milling sector.

“On behalf of everyone in Tunisia, we are proud to host this prestigious event. Tunisia consumes over 200 kg of cereals per capita every year, whereas the international figure is only 157 kg. The cereals board of Tunisia is working hard to guarantee the rights of everyone, with growth in production opening up huge opportunities for investment and development. Our focus has been on food safety and sustainability, in which we are proud to say we are a leader in African countries.”

Finally, Wided Bouchamaoui, president of the Tunisian Union of Industry, Trade & Craft (UTICA), was adamant that human concerns should not disappear from the discussion of economic development and business opportunity. Recalling Tunisia's historical role of providing the Roman Empire with cereals, she reaffirmed the country's role in maintaining food safety and battling poverty and malnutrition for the benefit of

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(L-R) Gorkem Alapala Strategy Director and Kemal Ozdemir from Alapala

VIPs and speakers of the Opening Ceremony Sousse Archaelogical Museum on the final night

Tomas Kisslinger Managing Director and Touraj Goudarzi - Sales Manager from Neuero Industrietechnik humanity. As this can only be done with greater investment and greater emphasis on sustainability, she called on exhibitors and visitors to consider the “fantastic wealth of resources” present in Tunisia.

After this, a large group photo took place outside on the grass. The event was officially open and the exhibition hall admitted the speakers and VIP delegation to tour every stand.

Conference interest Grain & Feed Milling Technology magazine heard presentations for some very insightful principles and concepts around Africa. Emphasised again and again was the fact that Africa is not merely one continent.

It is a collection of regions, with local needs for local challenges.

IAOM conference began on the afternoon of the first day with a session titeld 'Management and Marketing Africa'.

These talks were not given by millers, or aimed at them. Focusing on the bigger picture, they made for an interesting and business-led way of opening the conference.

From the keynote speaker, writer and media guru Mike Walsh, on, all speakers reiterated the opportunities presented in the MEA region by the growth of the middle classes, population increase, technological advances and the development of an investmentfriendly culture.

Walsh related an interesting story about Chinese innovation. A washing machine was donated to a rural village by the Chinese government, and as the villagers began to use it the manufacturer's call centre started to receive many complaints. A field engineer was deployed to sort this out. The reason for the complaints was determined to be too much dirt in the moving parts of the machine. It turned out the machine was not

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Andreas Flückiger and team from Bühler being used to wash clothes, but freshly dug potatoes before cooking! The management of the manufacturer heard about it, and ordered for the machine to be modified to allow more effective potato-washing. The new version went on to be incredibly successful for other customers. This showed a different model of customer-led innovation particularly suited to emerging markets, which could easily be applied to the prestigious old industry of milling feed and flour.

The 'What’s New' session and market outlooks gave delegates a vision of future trends in technology and business. US journalist Paul Roberts gave the keynote speech on the pressures put on the Middle East and Africa by major grain exporters such as the United States and Europe. His 2008 book, The End of Food, was welcomed by Nature magazine as “a call to arms” against the uncritical acceptance of intensified food production in the face of diminishing returns and rapidly expanding demand. The conference had a great structure and the trilingual headsets provided by the organisers allowed maximum participation among the delegates.

The unique setting on the beach brought a relaxed air to the exhibition. The number of stands at the expo, 126, was a record for IAOM Middle East and Africa district meetings since their inception.

Evening Entertainment The opening night's cocktail party in the Mövenpick hotel was a pleasant affair, facilitating networking opportunities between millers, manufacturers' representatives, conference speakers, media and show organisers.

The other nights’ entertainment were very interesting, with a cultural evening at the Jinene Khadij sponsored by La Rose Blanche, and the final night at the Sousse Archaeological

Museum sponsored by US Wheat Associates.

The historic venue was full of delegates as the conference drew to a close. Attendees were treated to a fireworks display at the hotel patio over reflections from the Mediterranean, and over on the party floor some of the dancing from the IAOM's American contingent was truly extraordinary.

Closing ceremony At the closing ceremony, La Rose Blanche had the stage for a prestigious talk. This influential company in the North African milling industry demonstrated their belief in the IAOM's concept with a huge presence at the show, and as with the opening ceremony, CEO Kamel Belkhiria gave a speech to delegates. The packed conference room also heard Damon Sidles, Vice President of IAOM (USA) thank the organisers for the team effort to ensure the size and success of the event.

There was one surprise in store for delegates. As Sidles announced the host nation for the IAOM's 2014 MEA gathering, gasps echoed around the conference hall. A lastminute change saw Cape Town, South Africa substituted for the expected choice of Kigali in Rwanda. The change had been kept confidential within the Oman-based IAOM Mideast and Africa organisation. Officially, the move was made to build on the success of the 2010 edition, also held in the South African capital.

“We have listened carefully to our members,” said an IAOM spokesperson. “All agreed that the best ever exhibition was in Cape Town in 2010: it has the infrastructure and experience to deal with all our delegates.”

The exhibitors themselves on the whole seemed positive about the news, and, like GFMT, are looking forward to the 2014 edition with anticipation.

November - December 2013 | 55

IAOM PRODUCT SHOWCASE The expo hall at IAOM was full of high-calibre products and high-calibre figures from the companies and organisations that provide machinery and services for millers in Africa and Middle East regions. Grain & Feed Milling Technology took a closer look at the stands of some exhibitors ...

STIF is a specialized manufacturer of components for the bulk material handling industry. It is a French company with locations in Europe (Spain), Asia (Singapore, China and Indonesia) and has just opened a new office and warehouse in Panama to serve all the Central American customers. Main components for Bucket Elevator include JET pressed steel and plastic elevator buckets, elevator belts, sensors (under speed monitor, belt alignment), monitoring and VIGILEX explosion vent panels for the safety of the Bucket Elevator.

The other important product range are EURAC compression coupling (for pneumatic handling), slide-valve and diverter valve (grain handling), safety valve and manholes.

Regarding the bucket elevator, the strategy of the company is to provide the same offer worldwide, in term of product and service, with stock of buckets and belt cutting and punching holes service in Europe, China and Panama. In 2013 the company has launched new products: - A Very Low Elongation elevator belt - A new compression coupling EURAC HL - A new belt alignment system VIGIBELT TOUCH - A flam arrestor Vigilex Quench

www.stifnet.com Guttridge were delighted to demonstrate the company’s expertise in grain and flour handling at the prestigious IAOM Mideast and Africa Conference & Expo for a second year.

Guttridge experts from the MENA office in Riyadh were pleased to discuss with visitors the Guttridge range of equipment, focusing on the heavy duty, high capacity machines that reliably deliver grain throughputs of well over 1200tph frequently required for centralised grain storage facilities. Of particular interest to many stand visitors was a belt conveyor grain handling system recently supplied by Guttridge to a major port.

We are really looking forward to the next IAOM MEA in South Africa. Hope to meet you all again Darren Parris, GFMT

Imas brought a Supersense Purifier product to the exhibition tent at Sousse, Tunisia. Their large double stand in the centre of the exhibition drew many visitors.

The requirements of visitors to the stand ranged from complete upgrades of mechanical handling systems to new storage projects as well as many enquiries about the spares service offered, and Guttridge were pleased to welcome to the stand new visitors from a range of countries including Egypt, Libya, Sudan and even Slovakia, with whom they hope to build foundations and contacts moving forward.

With 50 years of experience in the design and manufacture of grain handling machinery, Guttridge have a proven ability to deliver “right first time” solutions and are a trusted partner for milling projects ranging from single pieces of equipment to fully integrated conveying systems.

Mr Hasan Tosun, Sales Manager, and Abdallah Ghandoura, Area Sales Manager, attended the show to provide the mainly Tunisian, Middle Eastern and African visitors with information leaflets.

www.guttridge.co.uk

www.milleral.com

56 | November - December 2013

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An international market leader in the field of bucket elevator and conveyor components and electronic monitoring equipment, 4B Braime Elevator Components has a long history in serving the milling and agricultural industries.

4B has the world’s largest range of elevator buckets, including the popular Starco / Super Starco and CC-S buckets. 4B is also the world’s leading manufacturer of elevator bolts, producing all the original Ref70 Bolts, Euro Bolts (Din15237), Easifit and Fang bolts in their UK factory. 4B also supplies a complete range of highest quality elevator belting.

4B’s drop forged conveyor chains are of the highest quality and suitable even for heavy duty and highly abrasive applications. 4B's chain is made of special heat treated high grade alloy steel, case hardened to Rockwell C57-62 with a ductile core hardness of Rockwell C40.

Our company Bastak Gıda Makine Medikal Paz.Ith.Ihr.San.Tic. Ltd.Sti. established in 1999, Ankara, Turkey. After this time our company has begun to produce flour additives and quality control apparatus. To be the leader in this matter that is rather difficult and sensitive to comply with the innovations of the age has become our only target. The fundamental principle of our company is the satisfaction of our valuable clients. For this purpose, all investments are made for new technologies.

Our company participates in domestic and foreign fairs as participator and visitor in order to follow the developments in the world every single year and introduce our own innovations.

www.bastak.com.tr

4B chains are supplied either with standard welded flights, or with bolt-on flights (Bolt ‘n’ Go system).

4B's electronic division specialises in hazard monitoring systems that prevent downtime and reduce the risks of explosions in hazardous areas.

The range includes bearing temperature sensors, belt and pulley misalignment sensors, (under)speed switches, level and choke switches and combined monitoring systems.

All 4B components meet the highest standards, certified to meet ATEX, CSA, IEC-EX and GOST regulations.

www.go4b.co.uk

Lambton is a manufacturer of galvanised material handling and grain storage equipment since 1965. Some of our equipment consist of our grain silos, hopper tanks, bulk feed tanks, flat bottom, L-type and u-trough chain conveyors, screw conveyors and elevators up to 1,500 tonnes per hour which include a variety of accessories (like distributors, valves, conveying loop system, grain cannons, gravity and drum precleaners, catwalks, unload augers and much more).

Chief Industries UK as part of the Chief Industries Group exhibited at IAOM MEA 2013 in Sousse Tunisia to show the participants their range of storage, drying and handling equipment. Chief manufactures one of the largest ranges of corrugated steel silos in the world with capacities from 30 to 30 000 tons, grain dryers capable of throughputs of 4 – 400 tons per hour and conveyors and elevators with capacities up to 1000 tons per hour. This exhibition enabled Chief Industries to promote the range of brands to regional visitors.

We also manufacture a variety of feed equipment including pellet mills, mixers, screeners, crumblers, coolers and hammer mills, etc.

www.chief.co.uk

www.lambtonconveyor.com

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November - December 2013 | 57

REVIEW - IAOM MEA 2013

New developments in bag closing technology

by René A. Bontemps, Viviane Mpinga and Tarek Zakaria, Fischbein LLC

E

agle-eyed conference delegates in Tunisia will have noticed a significant absence from the 'What's New' session organised by the IAOM's Education Committee during 7 November.

Owing to medical reasons the talk due to be given by bagging specialists Fischbein never occurred. We caught up with marketing manager Viviane Mpinga in their Eastern Hemisphere HQ in Brussels, and in a GFMT exclusive can publish here the full text of her talk.

Ladies and gentlemen, it is a great pleasure and honour for me to speak here in Sousse in Tunisia.

Most agricultural products in solid form, like grains, rice and flour, must be put in a bag or sack once or even several times during the transport, handling and sales process.

Sewing continues to be the most popular technique to close open mouth bags, from manual up to automatic operations.

It remains the ideal solution to close bags of all kinds of material: cotton, jute, burlap, polyethylene, paper, woven polypropylene and even net bags. It offers today the flexibility to change bag materials and also several possibilities for the appearance of closures to satisfy all needs: First of all, plain sewing: the very simple and well-known kind of closure with one or two threads. For manual operations, the portable sewing machine remains a very useful tool. More than 600,000 units have been sold worldwide since its development 58 | November - December 2013

by Dave Fischbein. This durable, compact, extremely robust machine features a special non-corrosive finish, a reinforced feed mechanism, a presser foot lifter and a lubrication system with oil pump and reservoir guaranteeing a long lifetime.

Other options include: • Sewing including folding at the top of the bag, ensuring minimal product leakage • Sewing with crepe paper, possibly with filler cord to plug the small holes created by the needle • Sewing with easy-open tape, allowing the final customer to access the contents of the bag quickly and easily • Tape over sewing: to meet the customers’ new requirements for the attractiveness of the bags and the

siftproofness of the closure, Fischbein has recently designed the new TOS 3000 In the TOS 3000-SW, the bag must first go through a specially designed and separate sewing system called MOS. The top of the bag will be trimmed and then sewn, the sewing head realising the very short tails of the thread. Then the bag, caught by an infeed, immediately enters the deep throat of the TOS 3000-SW. There, a 60 mm wide paper tape is applied instantly over the top and on both of the bag's sewn sides. The reactivation of the tape is undertaken as the bag passes through a section containing two radiant heaters. The tape is firmly pressed onto the bag by two pressure rollers. It provides a closure that is always strong, clean, durable and sift-resistant.

&feed milling technology

Grain

Another new evolution in sewing technology is the twin-needle sewing machine, which provides two parallel sewn lines on the face of the bag. The stitches between the two lines are offset to further minimise or eliminate product sifting through the sewn closure. The twin needle sewing system must hold four thread cones and must have routing for all four threads to the twin needle head: two for the needles, two for the loopers. This new type of sewing closure is used when the end user wants to reinforce protection against leakage, breakage and theft.

Key sewing head characteristics Always remember that the most important element for sewing is the sewing head itself. Basically, the key characteristics of an excellent sewing head are: • To be completely sealed in oil, avoiding dust and dirt. A filtered self-lubricating system ensures long life of moving parts, reducing maintenance and costly downtimes, and consequently avoiding loss of money • Variable speed, and a adjustable by pulley • Low weight, simple thread diagram for the operator • Variable stitch length • Easy adjustments of thread tension • A high performance rotary knife. Being able to cut cleanly the thread chain close to the needle in one shot really is a great improvement!

For automatic lines, sewing systems must also integrate infeeds. An infeed is a motorised system designed to bring the top of the bag into the sewing head automatically – that is, with no manual input from an operator.

The motor of the infeed is equipped with an adjustable pulley, allowing an easy synchronisation with the sewing head and the conveyor belt speeds.

The front section must be hinged and spring-loaded for the passage of various bag thicknesses and to allow adjustable belt tension, as well as for the operator’s safety.

Fischbein can also offer a full range of high speed sewing systems, with high speed sewing heads fixed on a double leg pedestal to decrease vibrations, for performances up to 1,600 closed bags per hour. These fast speeds can now be reached thanks to significant research and development efforts, including new in-depth studies of mass movements, the redesign of some parts and of the internal oil flow, new metallurgic composition, special surface treatments previously seen in motor sport applications, and the highperformance rotary knife allowing a better cut of the thread chain.

Sewing remains a very good (and less expensive!) technique to close open mouth bags, offering various types of safe closures.

Three new developments – tape over sewing equipment, the twin needle head and specially-adapted high speed systems – bring great new possibilities to the customer.

&feed milling technology

Grain

Closing open mouth bags by sealing

or automatic handling of the bag is required immediately after sealing • Bag-top trimmer, to get a nice appearance in line with the seal, regardless of how the bags are fed or presented to the sealer. A trimmer makes the feeding much easier since the operator does not have to control the height of the bag-top prior to entry • Validation of all sealing parameters can be provided, preventing sealing unless all conditions are met

Sealing applies to polyethylene bags, coated or laminated bags, and even complex bags with a polyethylene inner liner.

For industrial operations, the whole Saxon range of continuous sealers responds to the most sophisticated and demanding of requirements. Their action is based on some of the principles of heat transfer by convection (hot air sealers), conduction (band sealers) and radiation (heating elements).

Convection with hot-air sealers uses ambient air, which is transmitted to specially Conclusion designed heating capsules. The hot air is then Fischbein has developed new features blown onto the polyethylene bags to pro- like the TOS-3000, the twin needle sewing mote the sealing process. head, the high speed sewing systems and the Conduction applies to band sealers, where Saxon sealers to meet the new requirements fixed heating elements heat the bags by direct for closing open mouth bags: efficiency, qualcontact. The contact bands have high thermal ity, reduced downtime, flexibility, appearconductivity and move in synchronisation with ance of the bags and siftproofness to avoid transport belts. The minimum width of the environmental contamination, losses or theft. seal is 10 mm, and extends to a generous 14 Fischbein is committed to continuing to mm for the high-end sealers. provide its customers with solutions to specifRadiation is used when the bag moves ic bag closing requirements from an extensive between a pair of heating elements. It is range of top quality equipment. Developed required for special applications, like paper using the latest proven technology and capabags with a polyethylene coating or inner ble of delivering worldwide service from its liner, or even bags with header cards. large distribution network and just-in-time Saxon sealers offer many very interesting delivery of spare parts and new machines, and useful features, such as: Fischbein stands for quality products.

• A large variety of crimp wheels. The Ladies and Gentlemen, thank you for seal pattern and width can then be your attention. chosen to suit the characteristics of the bag 4th Sports & Performance material and Nutrition 2014 product.

Sometimes the selection may simply be for aesthetic reasons • Air wash bagtop cleaner, to clean the mouth of the bag immediately prior to sealing.

This prevents dust from being included in the seal, guaranteeing strong and siftproof closures 1 & 2 April 2014, Cologne (Germany) • Bag-top cooler, International Speakers from Optimum Nutrition, Fitness First, Capsugel, to rapidly FrieslandCampina DMV, The Nielsen Company, PhD Sport Nutrition, decrease the Cologne University, Innova Market Insights, CRI Collagen Research, temperature ESSNA, Marche Polytechnique University and many more.. after sealing.

This is very useful, particularly for high speed lines where For information on partnerships & exhibiting, contact: Sandra Roefs either manual sroefs@bridge2food.com | ph: +31 30 225 2060 | www.bridge2food.com November - December 2013 | 59

The GFMT interview Andreas Flückiger is president of the Middle East and Africa region of Switzerland-based industry leader Bühler AG. He took up his current position in 2011, having led Bühler South America for the previous 10 years.

Andreas Flückiger Middle East and Africa region president, Bühler AG

What was your background before you came to Bühler?

My father had a big flour mill in Africa, in the Belgian Congo where I grew up. Being a Swiss native, I found it very interesting and enriching to grow up in Africa. I started to work for Bühler in 1978 in the Swiss apprenticeship program where I learnt the millwright profession.

What happened then?

After completing the apprenticeship program, I was appointed as an installation supervisor working mainly for Bühler in Africa.

I attended the Swiss Milling School after several years of practice in and outside of Switzerland, followed by studies at MBA level.

In 1990 I was delegated to Morocco where I spent 10 years in the Maghreb region before I went to Paris to take on the milling division where I stayed for four years. Next I headed to Buenos Aires, Argentina, where I was in charge of South America's five southernmost countries. Two years into that assignment I took over the responsibility for the entire continent.

How is business in South America for Bühler?

It’s a very important market for us reflected by our huge market share. We have a lot going on with soya plants in the vegetable oil business, flour milling, port terminals for cereal export and with the biggest feed plant in the world in Brazil.

Recently, we opened an additional factory in Joinville, Brazil – where the head office of the South American region is located – to respond to local needs How do you see the flour milling market developing in Africa?

The market requirements for finished products are very different for different parts of the continent.

Understanding the ethnic and cultural diversity is a challenge for us all. Our vision is to be as close as possible to the market to understand the requirements of our customers. Based on their requirements, we develop specific solutions. Two of those solutions, for example, are a compact maize mill and ‘instant maize flour’.

We have developed a compact maize mill that comes in the form of two shipping containers and we named it ‘Isigayo’. It can mill two tonnes of maize per hour, and is very easy to transport and install. The mills are manufactured in South Africa for the Maizeconsuming market. This solution is more for small-scale millers and it provides affordable and flexible processes to sustain the small rural food production in the region over and above the traditional industrial high capacity mills.

The Instant Maize solution was based on research conducted in the Southern African region, where the nutrition often consists of pulped and cooked maize flour and takes about 30 minutes to cook. After much research on how we can simplify this process, we developed an innovative milling process solution to reduce the cooking time to two minutes. This is what makes it instant. The 60 | November - December 2013

solution was introduced to the markets earlier this year, so it is still very new.

It is important for Bühler to know how the traditional foods in a typical village taste and also to recognise the importance of food and energy in Africa. When we started the Instant Maize Flour project, it was imperative that we remain true to the authentic taste and feel of traditional dishes, especially with new innovative techniques of preparing them.

What particular challenges does Africa pose?

One of the biggest challenges in Africa is to find skilled people – both as industry leaders and as Bühler staff. For this reason we facilitate training directed to our clients to help them use their machines optimally, and also to expand our customer care services.

We offer different courses at our training centre in Johannesburg to improve human resource skills, building competence to serve our customers’ needs.

Furthermore, there are many mills in eastern and southern Africa that require expert millers; hence we are currently building a milling school in Nairobi, Kenya. This will offer young people the opportunity to learn the milling trade from the very beginning. The school will be operational at the latest by the first quarter of 2015.

How important is customer service to you?

At Bühler, the customer is always the main focus of everything we do. As mentioned above, our vision is to be as close as possible to the market in order to understand the requirements of our customers. My regional team all share a vision – which is the key to measuring what we do and how we do it. We only have one yardstick: “Is the customer experiencing excellence in dealing with us?”

We are committed to making the customer happy and to learning from our mistakes. This is a continuous learning process and as a result we have developed a strong customer support base, helping us deliver solutions much closer to our clients.

This year, for example, we launched customer service stations in Kenya, Zambia, Mozambique, and two stations in South Africa.

These are additional to our 12 well-established sales and services hubs in the Middle East and Africa region. On a regular basis, we conduct training and share new learnings from each other’s site visits. This way we are all on one page and can offer the same standard of service to our clients. We have also recently launched a Test Bakery in Johannesburg where flour correction services are conducted.

People buy from people. All our efforts are so that we can know our customers well and to have that burning question answered regularly – “Is the customer experiencing excellence in dealing with us?”

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

&feed milling technology

Grain

"Our vision is to be as close as possible to the market to understand the requirements of our customers"

Classified section Analysis

Certification

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

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November - December 2013 | 63

GLOBALG.A.P. appoints new director

Markus Philipp

GLOBALG.A.P. recently expanded its team with the appointment of Markus Philipp as the organisation’s new director of operations.

As a member of the executive management team, Philipp will be responsible for the overall business development, financial optimisation and IT structure of the company.

As well as 15 years' experience working for a multinational chemical corporation, Philipp also holds a Process and Environmental Engineering degree from the University of Applied Sciences in Offenburg, Germany. He is currently studying towards an EMBA/MBA dual degree in general management. www.globalgap.org

Lesaffre feed additives strengthens team

Dr Frédérique Clusel

Lesaffre Feed Additives (LFA), a division of Lesaffre Nutrition & Health, a French leader in probiotic and yeast-based product applications for animal feed, recently announced a new addition to its team.

Dr Frédérique Clusel, will take over as the new managing director of LFA. She will be based at the Lesaffre headquarters in Marcq-en-Baroeul, France.

Clusel graduated as a doctor of veterinary medicine in 1993 and holds a master’s degree in business administration (MBA) from HEC Executive Education, a leading academic institution in Paris, France.

With over 20 years’ experience in the animal health sector, Clusel has expertise in management functions worldwide, particularly in Europe, the Middle East, Africa and Asia Pacific regions. www.lesaffre.com

AFIA’s new position filled The American Feed Industry Association (AFIA) welcomes W. Henry Turlington, Ph. D., as its new director of quality and manufacturing regulatory affairs. The position title is a newly created role at AFIA. Turlington’s duties will be heavily involved in the Food Safety Modernization Act (FSMA) feed rule comment development process as part of AFIA’s legislative and regulatory team and in conjunction with member working groups. He will also focus on the overall quality and technical leadership for AFIA’s third-party certification programs alongside Keith Epperson.

“We are pleased to welcome Henry as the newest member of the AFIA team,” said AFIA President and W Henry Turlington CEO Joel G. Newman. “His feed industry experience in the quality assurance sector will make him a Ph. D valuable asset to AFIA’s staff while wading through the feed rule and other industry challenges to come.

Henry will broaden and strengthen our total team expertise in serving our members.”

Turlington holds a doctorate from Kansas State University and a master’s degree in animal nutrition from the University of Kentucky. He obtained his bachelor’s degree from North Carolina State University in animal sciences. www.afia.org

Veterinarian joins antimicrobial leader

Shane Brookshire

Pathogen control specialist Anitox of Georgia, USA has appointed Shane Brookshire to drive its North American commercial operations.

Prior to his new role, Brookshire – a veterinarian with private practice experience - held a senior commercial role at multinational animal health company, Merial Animal Health.

He joins Anitox at a time when the animal and human food safety sector is evolving fast.

"Anitox has a detailed scientific understanding of how pathogens survive and thrive. That understanding enables us to deliver effective control systems that guarantee value and security," he explained.

Speaking of Brookshire’s appointment, Roger Mann, vice president of Anitox said: "This is our second high-level commercial appointment in as many months, and it signals our commitment to grow and increase service levels in all regions.” www.anitox.us

New appointment at feed ingredient firm

Dr Svetlana Peganova

Continuing to strengthen its global operations, AB Vista has appointed Dr Svetlana Peganova as a new technical manager in the Europe, Middle East and Africa (EMEA) region.

Dr Peganova’s primary role will be to oversee AB Vista’s technical activities in the German-speaking countries of the EMEA. With over ten years’ experience in product development within the German feed industry, plus an academic research background in poultry nutrition, Dr Peganova brings a wealth of expertise to the AB Vista EMEA team.

“We are delighted to have Dr Peganova joining the team,” states Dr Rob ten Doeschate, AB Vista Technical Director in EMEA. “With experience and knowledge of both product development and the feed industry, she has exactly the combination of skills we need to build lasting relationships with customers.” www.abvista.com

INDUSTRY FACES

by Marnie Snell

PEOPLE

INDUSTRY FACES

Built by feed millers for feed millers. Equipped with the industry‘s most efficient drive system, the new Bühler pellet mill Kubex™ T saves up to 30% of energy – while boosting line capacity to up to 80 tons per hour. With the Kubex™ T you save costs, reduce the release of CO 2 and make your operation even more productive. Gaining competitive advantages has never been easier. For more information please visit www.buhlergroup.com/kubex-t

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

Innovations for a better world.

IPPE 2014 in Atlanta, Georgia January 28 - 30, hall A2, booth 1739