MAY 2017 - Milling and Grain magazine

May 2017

YOUR GLOBAL PARTNER

In this issue:

World record wheat harvest • The next generation of enzymes • Using phytogenic feed additives in growerfinisher pigs • POWER SAVING: How to reduce animal feed plant power consumption by more than half • IAOM 2017

Event review millingandgrain.com

Volume 128

Issue 5

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VOLUME 128 ISSUE 5

April 2017

Perendale Publishers Ltd 7 St George’s Terrace St James’ Square, Cheltenham, Glos, GL50 3PT, United Kingdom Tel: +44 1242 267700 Publisher Roger Gilbert rogerg@perendale.co.uk International Marketing Team Darren Parris Tel: +44 1242 267707 darrenp@perendale.co.uk Tom Blacker Tel: +44 1242 267700 tomb@perendale.co.uk Mark Cornwell Tel: +1 913 6422992 markc@perendale.com Latin America Marketing Team Iván Marquetti Tel: +54 2352 427376 ivanm@perendale.co.uk Nigeria Marketing Team Nathan Nwosu Tel: +234 805 7781077 nathann@perendale.co.uk

72 - Power saving How to reduce power consumption in an animal feed plant by more than half

Editorial Team Rhiannon White rhiannonw@perendale.co.uk Zasha Whiteway-Wilkinson zashaw@perendale.co.uk Matt Muller mattm@perendale.co.uk Peter Parker peterp@perendale.co.uk International Editors Professor Dr M Hikmet Boyacıog ˘ lu hikmetb@perendale.co.uk Dr Roberto Luis Bernardi robertob@perendale.co.uk Professor Wenbin Wu wenbinw@perendale.com Design Manager James Taylor jamest@perendale.co.uk Circulation & Events Tuti Tan tutit@perendale.co.uk Development Manager Antoine Tanguy antoinet@perendale.co.uk ©Copyright 2016 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. More information can be found at www.perendale.com Perendale Publishers Ltd also publish ‘The International Milling Directory’ and ‘The Global Miller’ news service

Grain & Feed Milling Technology magazine was rebranded to Milling and Grain in 2015

ISSUE HIGHLIGHTS

2

NEWS FEATURES

6-43

PRODUCT FOCUS

46

CASE STUDY

90

48 An intensive twoday exchange of knowledge and ideas

56 The next generation of enzymes

66 NIR analysis to reduce feeding costs

54 Understanding the role of heat treatment of flour

62 Using phytogenic feed additives in grower-finisher pigs

70 Expander technology

50 Does wheat make us sick?

FACES

58 Poultry: applying a Dutch approach in Mexico

124 People news from the global milling industry

68 Grain quality control and mycotoxins

72 Power saving

STORAGE

80 The highs and lows of noncontact level sensors

84 Why choose Hopper-bottom silos?

76 Efficiency

EVENTS

100 Event listings, reviews and previews

TRAINING

45 Food protein course 2017

COLUMNS

14 Mildred Cookson 20 Raghavan Sampathkumar 29 Tom Blacker 30 Christophe Pelletier 36 Chris Jackson

4 GUEST EDITOR Mervin Poole

94 MARKETS Matt Muller

122 INTERVIEW Volkmar Wywiol

COVER IMAGE: New Zealand: Ashburton farmers Eric and Maxine Watson have entered the renowned book of Guinness World Records after producing the world’s highest yielding crop of wheat. Image courtesy of Bayer New Zealand - www.bayer.co.nz

ISSUE HIGHLIGHTS SYMPOSIUM An intensive two-day exchange of knowledge and ideas

Flour millers are notorious for wanting to remain in their mills, overseeing the milling process.

PAGE 48 FLOUR

WHEAT

HOPPER-BOTTOM

Does wheat make us sick?

Why choose Hopper-bottom silos?

If we find out that what we eat currently contains too much gluten, and that it is making everyone sick, then we need to look into and modify the food chain or alter the gene in wheat that is producing the gluten.

When purchasing a storage solution for your farm or commercial enterprise, there are many important factors to consider before you choose the type of silo that will fit your needs and budget.

PAGE 50

PAGE 84

Understanding the role of heat treatment of flour

Flour Heat Treatment (FHT) is a process designed to modify the properties of flour, germ and bran. FHT can be divided into two basic processes: hydrothermal treatment and thermal treatment.

SENSORS Non-contact level sensors

Grain storage facilities and millers find non-contact level sensors attractive for a number of reasons. Of course, since nothing comes into contact with the material, there’s no risk of equipment interfering with the process or rogue parts breaking off and getting stuck in equipment or contaminating grain. Plus, they provide continuous level measurement for optimising inventory and preventing bins from running empty. With commodity prices where they are, inventory accuracy is important to the bottom line of every grain and milling operation.

PAGE 80

PAGE 54

FOOD

STORAGE

FEED

PROCESS

EXPANDER Expander Technology

The global growing demand for high quality feeds made of a wide range of available raw materials is to the advantage of the expander

PAGE 70

PIGS Using phytogenic feed additives in grower-finisher pigs

POWER SAVING

Grain quality is of the utmost importance, and if it’s not something you’ve been paying close attention to then you could be putting your supply chain and reputation at risk.

Since 2011, UFA’s Sursee poultry feed mill built in 1965 has been one of only a few unmanned feed mills in the world. The mill runs from 9pm until 5am without any operating personnel

Applying a Dutch approach in Mexico

The poultry industry is undoubtedly the most dynamic livestock activity in Mexico, accounting for 63.6 percent of it in 2016.

Phytogenic feed additives (PFAs) comprise a wide range of plants like herbs, spices, and other plant-derived products such as essential oils and oleoresins (Windisch et al., 2008). Although this kind of feed additive has been known for a long time, its use is not yet as common as feed enzymes or pre- and probiotics.

PAGE 68

PAGE 72

PAGE 58

PAGE 62

MYCOTOXINS Grain quality control

How to reduce power consumption in an animal feed plant by more than half

2 | May 2017 - Milling and Grain

POULTRY

The things we produce today were utopias yesterday.

Our task is to give shape to new ideas and innovate what once was magic.

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Guest

Editor

Expecting the same product every time, but better, new and innovative I am delighted to have been invited to be Guest Editor of this edition of Milling and Grain.

I joined Heygates as Chief Chemist in April 2015 with responsibility for leading the development of the laboratories. Heygates is a family owned flour-milling business, serving its customers from its base in central England. It produces a comprehensive set of bespoke and open market flours to meet the needs of their customers.

The experience I gained before starting at Heygates was diverse and complementary, allowing me to interact at all levels relevant to the business. I read Genetics at the University of Newcastle before continuing on to complete a MSc. and PhD. at the University of Nottingham.

Subsequently, I worked in the Universities of Oxford, Warwick and Nottingham as a researcher on pre-breeding plant genetics for advanced crop traits, before managing the Milling and Analysis section at Campden BRI. I am currently a member of the Cereals and Cereal Applications Testing working group (CCAT), the American Association of Cereal Chemistry International (AACCI) technical committees, nabim Technical and Regulatory Affairs Committee (TRAC) and the British Standards Institute subcommittee, AW4. This keeps me abreast of national and international developments in assuring quality and safety of food. My experience allows me to lead research programmes, manage a strong and experienced team at Heygates, interact with breeding programmes and support customers with in-depth knowledge about flour for their products and processes.

Since my career in industry began, I have observed an increasing focus on flour quality. The emphasis on quality seems to be driven by consumers expecting to receive the same product every time, but also expecting better new and innovative products. In addition, the producers are under constant economic and environmental pressure which challenges their sustainability. Consequently, the expectation is that millers will support their customers by

®

12 September 2017 www.buildmyfeedmill.com

producing bespoke flour types that better meet the needs of specific or optimised processes.

Millers have a range of quality control tools at their disposal.

The miller will assess the rheological quality of gluten as the wheat is received at the mill intake point. Along with the well-established near infrared spectroscopy (NIR) systems, the UK relies on varietal segregation, wet gluten extraction and examination and SDS-sedimentation to assess gluten quality. Other regions rely on the Mixograph and the Chopin-Alveograph test where the wheat is milled on a CD1 mill to reduce the impact of grain hardness on the results.

During milling, the miller will employ rapid spectroscopy based tools to provide rapid responses to variations in milling parameters which can include protein, moisture and bran content whilst also establishing relative quantities of damaged starch. In total, vast amounts of data are generated and together, millers have a comprehensive view of the products they are producing and can react quickly to maintain consistency. However, millers are challenged with supporting producers to meet further quality control challenges.

Producers are continually striving for minimal waste, improved products and higher throughput. The miller is challenged to embrace the broad range of data generated, make best use of multi-variate statistics and determine the parameters that lead to less waste, improved products or meet the demands of higher efficiency for processing plants.

The key is to create flours that are robust in processes because the optimal flour is well defined. The milling business needs to interpret these parameters to a format millers can use to balance their milling process and apply them consistently.

I am delighted to see Milling and Grain continues to address the complex technical issues and provide practical solutions. The conciseness’s of the articles continuously suit professionals working under time pressures. Included in this issue, are a range of insights into technical issues and practical tools to support the complexity of delivering ever more appropriate flours.

Mervin Poole

Build My Feedmill is a new conference concept brought to you by the team at Milling and Grain magazine. It aims to bring you the latest technological and process developments by the most forward thinking speakers and companies, in a format based on the process flow chart of a feedmill. The quick fire presentations will bring you right up to date with the latest thinking for all the key areas in the feed milling process.

The first Build My Feedmill conference was held at VIV Asia in 2017, and we would like to invite you to join us for the next installment to be held as part of Asia's largest and most influential grain, rice and feed event - CICFO 2017

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More Information www.millingandgrain.com http://gfmt.blogspot.co.uk

News

MAY 17

Milling

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CM

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Production has started at Henry Simon

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lapala and Satake partnership initiated the production of the milling legend Henry Simon. The pre-launch meeting was held between April 23 and 25, 2017 in Alapala’s headquarter in Çorum, Turkey.

The new Henry Simon milling machines will be introduced at the 121st Annual IAOM Conference & Expo held April 10-14, 2017.

This take off will be a prologue to the new era of global milling sector. Japan’s first power driven rice milling machine inventor Satake and 60 yearlong global grain milling technology provider Alapala had signed a strategic partnership agreement in 2015.

Both companies had combined their production, R&D, sales, marketing and aftersales forces in the scope of this agreement.

As a second and a further step of the agreement, the companies are regenerating the oldest and the best-known, legendary brand of milling technologies.

The German engineer Henry Gustav Simon founded the Henry Simon milling company originally in England in 1878. More than 400 Henry Simon branded mills was established all over the world, with innovations such as the first double roller mill and the first PLC automation system.

One of these 400 Henry Simon branded mills was “Hatap Un” which was established in Çorum in 1961. Also Mehmet Alapala, the founder of Alapala, entered to the sector by producing wooden sifter for “Hatap Un” mills.

Following years, joining with Robinson Milling Company, Henry Simon brand was sold to Satake in 1991.

By the year 2017, Alapala and Satake resubmit the Henry Simon brand to the market.

Alapala’s capacity increasing investments, spare parts supply and aftersales services ally with Satake’s active sales network and gigantic R&D team to revive Henry Simon brand.

With the force of Henry Simon brand and Satake partnership, Alapala will move up its worldwide power by reaching new more 55 countries in addition to its existing experience of more than 600 turnkey projects in 100 countries.

6 | May 2017 - Milling and Grain

This month Milling and Grain magazine gives you a varied collection of articles and features that we hope you find informative, compelling and educational as we do.

We focus firstly on NIR (Near Infrared Reflectance), which can be used to reduce animal feed costs. Software developers and manufacturers use this technology to gain a chemical profile, which allows the composition of animal feed to be changed based on the needs of the farmer and the nutritional need of the livestock.

We are excited to share with you our very own Group President, Darren Parris’ experience of IAOM in New Orleans from mid April.It is very exciting and a great honour for our team to be able to go to these conferences and shows and share with you, our readers, just how much there is to be enthusiastic about in the coming year for the industry.

Vis-à-vis poultry, we include a feature this issue explaining who AgriMex Holanda are and how they benefit the production of livestock. The private partnership includes businesses, Government institutions and vital knowledge to cover the entire production chain.

With such care being taken into the milling process, it is important to consider ways in which the tasks we face can be made as enjoyable and efficient as possible, with that in mind, we look at UFA’s Sursee poultry feed mill, which was built in 1965.

It is one of the few all automated mills in the world meaning it can reduce the cost of power consumption by more than half.

We finish with a historical insight into Perry of Oakley Limited. Established in 1947, they have just celebrated their 70th year anniversary as one of the UK’s most experienced manufacturers of materials handling and drying equipment.

On a final note, the UK Government (the Conservative party) has called a General Election on the June 8, 2017. Not too long after the controversial “Brexit” vote, it is an apprehensive time here in Britain as to how the outcome may or may not affect national and international agriculture alike. A potential government change, especially at this affluent point of the harvest year, could spell possibly large consequences for the industry, particularly small or family owned businesses.

The food industry is the biggest employer in the UK, agriculture and aquaculture are fundamental building blocks of our society. They positively manipulate the economy, health and general well-being, as well as our environment Whatever the next Government does, it will set the path and legal foundations for possibly decades to come.

If you have any views on how you or your business may be affected by this unexpected political upheaval (including the upcoming election in France), we would be really interested here to learn about it. Please get in touch with our editorial team.

GF

MT

gfmt.blogspot.com

Milling News

Ashburton farmers Eric and Maxine Watson have entered the renowned book of Guinness World Records after producing the world’s highest yielding crop of wheat

New Zealand couple break world record wheat harvest

A

shburton farmers Eric and Maxine Watson have entered the renowned book of Guinness World Records after producing the world’s highest yielding crop of wheat.

The couple produced a staggering 16.791 tonnes per hectare, beating the previous record of 16.519 tonnes held for two years by a UK farmer.

On average, irrigated wheat yields in New Zealand are around 12 tonnes per hectare, demonstrating how remarkable the new record is.

The crop was planted almost a year ago in mid-April 2016 and harvested mid-February this year.

Eric says it’s a big relief to have achieved the record, especially after coming close in previous years.

“We’re absolutely delighted to have set a new record – I feel a bit overcome in a way, it’s quite an achievement.

He continues, “It’s a very good feeling after all these years of achieving high yields to get the World Record, after all, it’s what we set out to do. Possibly one of the things that will come out of this is recognition of the New Zealand Arable Industry. It’s very small but there are some good farmers out there and it’s good to have the record back in New Zealand again.”

Eric puts his success down to his partnership with Bayer and Yara. Bayer for its agronomy advice and range of crop protection herbicides and fungicides; and Yara, for its nutrition input.

8 | May 2017 - Milling and Grain

“I couldn’t have done it without them – they made me realise I could do it. I suppose I needed a shove in the right direction.

He adds, “We’ve been achieving high yields for several years but have never bothered about the world record. The record definitely became harder to achieve after the 16.5 tonne barrier was broken in the UK harvest of 2015.”

Bayer New Zealand Crop Science Country Manager, Scott Hanson, says the record is not only an important achievement for the Watsons, but for New Zealand as a whole.

“For me, the record demonstrates the skill set that we have in New Zealand in the arable industry. The New Zealand grain and seed industry is an important part of the global seed market. Farmers like Eric and Maxine demonstrate what New Zealand can do at a global level truly promotes our industry to the world.

He concludes, “In particular, the Canterbury region is demonstrating that it not only has the best arable growing conditions in the world, but also the best and most knowledgeable arable farmers in the world. Our aim is to make New Zealand the highest yield producing country in the world.”

As for the future, Eric believes he can do even better.

“It is an exceptional yield, but I could always do better and that’s my aim. There were things I saw when I was out there in the combine harvester and I thought, yeah, I could do this a whole lot better.”

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Milling News

Highlighting the importance of holistic value

C

ombining financial and sustainability reporting for the first time has highlighted the importance of creating holistic value.

Olam International Limited (“Olam’’) has merged its Annual Report with its Corporate Responsibility and Sustainability Report for the first time, reflecting the interdependence of economic, social and environmental performance for the global agri-business and the importance of creating value across all three fronts.

The FY2016 report’s theme, ‘Maximising Value and Purpose’ reflects the building blocks of an enduring business, according to Co-Founder and Group CEO, Sunny Verghese, “The macro changes that the world is experiencing have long-term implications for how businesses are led, organised, managed and financed. At Olam, we must continue to maximise shareholder value while pursuing a purpose-driven model, providing consistent transparency, advancing sustainability and engaging with an ever-broadening community of stakeholders.”

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He continues, “We remain focused on executing our differentiated strategy, aligned with our core purpose of Growing Responsibly. To seize the opportunities from the rise of digital disruption, we are also creating a ‘digital first’ culture at Olam by evaluating various initiatives.”

Commenting on the strong year-on-year net profit growth for 2016, A. Shekhar, Executive Director and Group COO, highlights the significant uplift in volumes and sales revenues for Africa, “Given our depth and breadth of experience across the continent, Africa is a strategic vertical for the business. We are confident that our investments in Africa and across our prioritised platforms will contribute further to our success moving forward.”

On Olam’s social and environmental performance, JeanPaul Pinard, Chair of Olam’s Corporate Responsibility and Sustainability Board Committee, said, “For anyone investing in the agricultural sector, understanding the external aspects of the business is fundamental. Olam’s activities depend on the quality of the soil, the availability of water, and the dedication of people to grow, harvest and process quality crops. Combining sustainability reporting with business performance is therefore an important step.”

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Milling News

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MOU on responsible soy n January 2017, Aprosoja-MT, ABIOVE, FEDIOL, FEFAC and IDH signed a Memorandum of Understanding (MoU) to stimulate the production and trade of Brazilian responsible soy.

As a follow-up to this agreement, a first steering group meeting with approximately 20 people was held in São Paolo on April 6-7, 2017 to discuss and evaluate individual actions and projects that can feed into a joint strategic working plan for the Brazilian and European soy supply chain partners.

The partners updated each other on their respective initiatives since the signing of the MoU. Aprosoja briefed the partners on the progress made on Soja Plus, a rural property management programme for soy farmers taking into account financial, social and environmental elements.

They raised attention to “Geocloud”, a system that allows tracking technical visits to farmers in real-time and optimises the report sharing with farmers.

Another development is the project “Referência”, which focusses on the financial management of properties and facilitates the integration of the Soja Plus programme.

Aprosoja highlighted the development of a pilot project in Mato Grosso, with financial and technical support from IDH, which aims to incentivise the recuperation of degraded land by farmers.

ABIOVE emphasised its ambition to implement the Soja Plus

12 | May 2017 - Milling and Grain

programme in the states of Piauí, Maranhão and Goiás as well as further expand the coverage in Minas Gerais and Bahia.

They reminded the partners that more than 50 percent of deforestation in the Legal Amazon takes place on property owned by the government and cannot be tackled by the private sector.

IDH highlighted its ambition to work this year on the stimulation of supply chain systems that facilitate the connection between sustainable production and its respective market demand.

A supply chain model that allows capturing the value generated by the Soja Plus programme is an example. They informed the partners about the US$400 million investment by the World Economic Forum to stop illegal deforestation in tropical areas, which will facilitate reforestation and boost farming.

IDH also marked the importance of PCI (Produzir, Conservar e Incluir – Produce, Conserve & Include), a development strategy in the fight against climate change to attract investments to the state of Mato Grosso to pool and integrate the different parties involved to obtain investments and tools to reach consolidated objectives as regards good agricultural practices.

FEFAC informed the partners that it wants to increase the responsible production of raw materials used in animal feed. They also highlighted the progress being made on the preparation of the benchmarking of the Soja Plus programme against the FEFAC Soy Sourcing Guidelines, which would be essential for its recognition as a responsible soy programme to the EU feed industry.

We take looking after grain very seriously

www.bentallrowlands.com E: info@bentallrowlands.co.uk

Joseph Rank’s Premier Flour Mills, Victoria Dock, London

Roller flourmill buildings in London continued

Milling journals of the past at The Mills Archive

by Mildred Cookson, The Mills Archive, UK In my previous article, I introduced mills owned by Seth Taylor and JH Robinson based in what is now referred to as London’s Dockland.

A little further up the Thames there were a series of mills on the Embankment in the region of the Albert and Battersea bridges. Visits to these mills were organised as part of nabim’s London Convention in 1887, as reported in The Miller on June 6th.

The first of this group mentioned in the report was the Albert Bridge Flour Mills at Battersea. Built for Messrs. Marriage, Neave & Co, they were built on the south bank of the Thames between the Albert and Battersea bridges. They opened for work on 9th July 1884. The building was divided into three main portions, but in reality seven independent sections, separated by fireproof walls.

It was built in the Queen Anne style and with its octagonal tower it had quite a baronial appearance.

The architect responsible for this building was Mr F Bath, ARIBA, FSI of London and Salisbury.

As well as designing a most economical internal arrangement, his exterior of the building caught your eye from every angle viewed. The engravings capture the magnificent architecture, supplemented by an illustration 10 years later from the Simon catalogue.

The octagonal tower consisted primarily of a chimney shaft, with a spiral staircase winding round and enclosed by the octagonal outer wall. This allowed easy access to each of the floors by galleries which were outside the three buildings and provided the only communication between them. On top of the tower was an iron water tank that held 25,000 gallons of water in case of fire. From the tank to the ground a main pipe ran with hoses on each landing that could be coupled up in case of fire.

This arrangement was supplemented by an abundant supply of buckets!

The roller floors on the first and third floors were described as having six sets of the largest four-roller mill type for the breaking process, the remaining rolls were smooth for the reduction of the semolina and middlings into flour, a process effected in ten 14 | May 2017 - Milling and Grain

operations. The wheat and its resulting semolina and middlings passed through 42 pairs of rolls, 30 and 31 inches in length, before it appeared as flour at the three “Eureka” flour packers on the second floor. The plant was installed by Mr H Simon and was said to produce a product of good quality.

The final mill mentioned on the list of convention visits was the Royal Flour Mills on the Albert Embankment. These were situated near the southeast end of Vauxhall Bridge, and were the property of Mr Peter Mumford. ‘The Miller’ regarded the eternal

The Royal Flour Mills on the Albert Embankment

An 1898 view of the Marriage & Neaves’ Albert Bridge Mill from the Henry Simon catalogue

The Cooperative Wholesale Society Silvertown Flour Mill in London

view of the mill as presenting unusually good architectural features and described it as an imposing feature on the Albert Embankment. The building had a 76 foot frontage to the River Thames and was 80 feet high from ground to the ridge of the roof. On the river frontage there were two lucams of two storeys for loading and unloading the barges and hoisting to the top floor.

Another lucam was on the south front for hoisting from wagons.

In 1875 only two years after ‘The Miller’ started publishing, it gave a full description of the mill on the millstone system.

The division on the eastern side of the party wall, which had a frontage of 40 feet to the river, was the mill proper, and the section on the western side of the party wall was the warehouse.

The six floors were supported in the mill by three rows and in the warehouse by two rows of iron columns on substantial foundations of Purbeck stone. On the ground floor were 14 sets of Ganz’s roller mills, with four horizontal grooved rolls, 25 inches by 8.5 for granulating the wheat on a system of six breaks.

On the first floor roller mills were placed in three rows, for the reduction of semolina and flouring the middlings. This was done on Ganz smooth three-high roller mills, four Houghton smooth roller mills with a single pair of rolls and two Herbert & Law roller mills with two smooth chilled iron rolls.

The sound of millstones was not silent here, and these were kept running to be used by some London millers to produce millstone flour for their customers who preferred it to the roller mill system!

Other machines used in the mill were by George Smith middling purifiers, Haggenmacher gravity purifiers for semolina, Fenwick’s sieve purifiers and two Gray’s gravity purifiers.

On the sixth floor were twelve centrifugals, six scalpers, one Richmond brush machine for offal and two Staniar’s bran dusters.

As we have just rescued the archive of Gelder and Kitchen, architects to Joseph Rank from well before 1900, I intended to end this article by showing an engraving of the proposed Rank “Premier Flour Mills” at Victoria Docks. The design envisaged a wheat receiving house, silo, granary, wheat cleaning house, flour mill and, extensive warehouses with engine and boiler house. The mill would cover an area of around 7,000 square yards and have a frontage of 400 feet. Henry Simon was to be engaged as the milling engineer. However, having just received this engraving of the CWS Silvertown (London) flourmill, I have included that as the final illustration and would be pleased to hear if anyone knows more about its history.

The geographical and historical spread of our holdings at the Mills Archive mean that I can only provide snapshots; if you would like to know more please email me. mills@millsarchive.org

Marriage & Neaves’ Albert Bridge Mills as seen from the River Thames

The Rear View of Marriage & Neaves’ Albert Bridge Flour Mills

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Milling and Grain - May 2017 | 15

Milling and Grain supports the aims and objectives of the Mills Archive Trust, based in Reading, England.

The history of milling no matter where it has taken place - is being archived by the Trust.

For well over 100 years milling technology has been global with many magazines serving or having served our industry from flour and food to feed and oilseed processing and now to fish feeds.

A most recent contribution to the Trust’s collection is a complete century of past edition of the now out-of-print ‘NorthWestern Miller’ from the United States.

We are proud to present here, front cover illustrations from this valued and longserving publication as a visual reminder of the importance contribution past magazines provided to our industry.

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Australian lentil crop doubles

Milling News

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ustralia is strengthening its position as a major exporter of lentils following a bumper crop.

Latest figures from the Australian Bureau of Agricultural and Resource Economics and Sciences (ABARES) show lentil farmers down under harvested a record 620,000tonnes of mainly red lentils late last year, double the previous record of 310,000tonnes set in 2010.

The majority of the crop was grown in South Australia (420,000tonnes), which increased its yield to 2.95tonnes per hectare in 2016/17 from 1.58tonnes per hectare in 2015/16 thanks to excellent winter rainfall.

The record result was also helped by an 11 percent increase in hectares planted in South Australia and Victoria, the only lentil-producing states, to 253,000 ha.

Australia is now among the biggest producers of the soup-and-curry pulse behind India, the biggest lentil consumer, and Canada. More than 90 percent of Australia’s lentils are exported to countries including India, Bangladesh, Sri Lanka and Egypt.

Nick Goddard, CEO, Pulse Australia said high global prices in recent years driven by poor seasons in India and low wheat and barley prices had convinced more Australian farmers to plant lentils. He said although prices had fallen from the recent spikes of more than AU$1000 a tonne in 2015 they remained above long-term averages.

He explains, “They are still an attractive proposition for growers in Australia relative to wheat and barley. Last season was certainly a record in Australia by a long shot … the extra rain had a very positive affect in almost doubling the yield.”

South Australia is well suited for growing larger red lentil varieties that are proving popular in India and Sri Lanka.

He continues, “We compete head-on with Canada on the medium size but there’s a large variety called Jumbo we produce that really does have a strong place in the market over there.”

Farmers in Australia are also turning to pulses as a means of improving soils while rotating fields away from traditional cereal plantings. The United Nations declared 2016 as the International Year of Pulses sparking a campaign to increase domestic consumption, including the launch of Australia’s first lentil beer.

Australian lentils are harvested and processed in November and December, taking advantage of a window between the Canadian (August/September) and Indian (March/April) harvests.

AGT Foods Australia is a leader in value-add processing of pulses. CEO Peter Wilson said although prices had stabilised to about AU$650 a tonne, they were at a level where they were trading internationally, which was “a good thing”.

He comments, “The great thing about red lentils is that they have fairly broad and deep markets around the world.

The red lentils are relatively stable at the moment. We’ve got to be striving for really good quality all the time so we encourage farmers to continue to invest in the product to ensure we can position it to the highest paying market.

He summarises, “I think we’ll continue to see good growth based on profit – farmers are going to plant things that are going to make them money, that’s the bottom line.”

Milling and Grain - May 2017 | 17

Milling News

Action taken to support quinoa growth

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rdent Mills, the premier flour milling and ingredient company, is launching its Great Plains Quinoa™ with the largest quinoa growing network in North America.

This will bring transparency, ground breaking scale and the consistent quality needed to support the mainstream growth of quinoa with consumers, food manufacturers, bakeries, retailers and restaurants in the US and Canada.

Joe Dutcheshen, quinoa farmer explained, “We are very excited about the relationship we now have with Ardent Mills. We have seen the positive impact their commitment to double organic wheat acres has had on North American farmers and the organic wheat supply and know that level of commitment will have a similar impact in the quinoa market.”

Bill Stoufer, Ardent Mills Chief Operating Officer remarks, “Ardent Mills is joining forces with North American quinoa farmers to ensure both supply and predictable pricing for quinoa whether as an entrée, side dish, in artisan-style bread or in many other culinary applications.”

He continues, “We are always looking for ways that grains can nourish what’s next for communities, customers and consumers. We are applying our leading food safety standards, operations expertise, grower and customer relationships to support the growth of this great tasting and nutritious food.”

Both the Dutcheshen family and Ardent Mills have a long history with quinoa in North America. Joe Dutcheshen began evaluating different varieties of South American quinoa seeds on his family farm in 1992. 15 years on Ardent Mills began promoting quinoa as the star of its Ancient Grains line in 2007.

Mr Dutcheshen expounds, “Quinoa is recognised as a true superfood. As a pharmacist and multi-generational farmer, I was looking for a crop that was healthful and could provide a value-add from the farm to the consumer. Quinoa does both!

Quinoa is in the same plant family as other nutritious foods – spinach, beets and amaranth. Through traditional selective breeding over a period of 15 years, we have produced a North American quinoa that is acclimated to the cooler climate, has a variety of natural resistances and a shorter growing season.”

Leading the movement in ancient grains, quinoa usage has shown double-digit growth in entrées, sides and kids’ menus, according to Technomic Inc.’s MenuMonitor 2016 Left Side of the Menu: Soup & Salad Consumer Trend report. From 2012 to 2016, sales from products containing quinoa have grown sevenfold.

Quinoa continues to surge in usage and is increasingly included in nutrition bars, ready-to-eat cereal, oatmeal, gluten-free foods, tortilla chips, crackers, snacks, prepared dinners and side dishes, all in a variety of packaging.

Mike Veal, Ardent Mills Vice President of Marketing summarises, “The quinoa market is often affected by South American supply challenges and spikes in pricing. With all the unique aspects and certainty of this program, we are introducing locally grown quinoa under our new Ardent Mills Great Plains Quinoa™ brand. This will help clearly define our quinoa as grown in North America along with all the assurances that are available from Ardent Mills.

Assurances include supporting North American family farms in the program and our commitment to food safety, quality, supply and transparency. We are also committed to price predictability and can offer up to a two-year price guarantee.”

Sports and Active Nutrition Awards entry

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versatility in feed processing 18 | May 2017 - Milling and Grain

ridge2Food Sports and Active Nutrition Awards will celebrate the innovators creating the next generation of categories, products, beverages and ingredients to delight an increasingly health conscious consumer.

For your chance to win, enter by April 30, 2017.

Examples of current nominees include, OmniMind, Nootropics, which are defined as supplements that improve cognitive function and brain health, TruEnergy Sport Shot, a pre-workout drink infused with ten vitaminsm antioxidants and five electrolytes from coconut water, and thirdly Royal Green Magnesium, the first product worldwide to present in certified 100 percent organic form originating from a special sea lettuce.

According to Euromonitor International, the sports nutrition market is forecast to grow at an average of eight to 10 percent year on year by the end of 2021. The global value for sports nutrition beyond the bodybuilder to an audience interested in the social, physical and health benefits of exercise and nutrition.

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The Raghavan Report Asia’s food future: A fresh perspective Beer, Brexit and blockchain

by Raghavan (‘Ragha’) Sampathkumar When talking about diversity, Asia is really endowed with its diverse food culture and traditional practices.

Similarly, it is extremely diverse in terms of agroclimatic zones that help produce a great variety of crops and some (e.g. cassava) that have great potential to be included in a wide variety of foods are not known well outside the region. Lately, protein gained enormous attention and particularly vegetable sources (e.g. pulses) have become quite popular across the world. Ever since the UN announced 2016 as the International Year of Pulses, globally interest from different industry stakeholders grew exponentially, specifically on how to use pulses as sources of protein and also for other special (e.g. gluten-free) products. Recently I stumbled upon one of the most surprising innovations and it is revealed at the end of this column.

While the next most talked about issue globally was Brexit and what happens next for the countries that trade with EU ASEAN countries, which export huge quantities of seafood to the EU. As the call to exit has been sounded, it remains to be seen whether the countries will realign their positions and trade relationships during the process which is said to be taking at least a couple of years. Largely, there has been an understanding that the trade relationships with UK will remain unaffected, if not grow.

One of the indicators of such a move came from China, who are trying to rebuild the erstwhile “Silk road” that flourished during the Han dynasty, linking the country with its Asian and European neighbours. The first freight train carrying UK’s export products such as whisky, baby food and pharmaceuticals was flagged off last week and started its 7500-mile journey to Zhejiang in Eastern China. This perhaps partly explains the way the world’s multilateral trade is getting realigned as countries look to strengthen bi-lateral ties or agreements with fewer countries with mutually-rewarding trade pacts. On the other hand, UK seems actively looking to cement its place in global trade, as it is known as the hub for many industries including finance.

The next buzzword happens to be blockchain technology and its applications in agricultural commodity trade. While it is still under the experimentation stage with a limited-scope, the “distributed ledger” principle is said to have the potential to greatly improve some of the persistent problems of the agricultural supply chains. These include things such as lack of transparency, time delays, propensity for malpractices and limited information capture and use by the value chain entities. While there are some companies in Australia already pursuing the technology to make their supply chains efficient, its application in Asia with its majority small fragmented landholders needs to be studied.

Well, its time perhaps to reveal the answer to the question. A South-Australian brewery recently launched a beer made from mixing lentils (30%) with barley (70%) giving it a unique earthly flavour. Indeed, as a food and agribusiness professional, it is exciting for me to see the food industry that is abuzz with innovations!

Raghavan (‘Ragha’) Sampathkumar is a seasoned food and agribusiness professional with 360 degree understanding of the complex political, socioeconomic, environmental and cultural perspectives of the Agri-Food value chain.

He has more than 13 years of experience working in various subsectors of food & agribusiness including agro commodities, international trade, agri-inputs, biotech, and animal nutrition sectors across Asia-Pacific.

20 | May 2017 - Milling and Grain

Profit Value Calculator app launch

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new tool that helps customers calculate feed mill profitability improvements has been released.

Kemin, a global nutritional ingredient company that uses science to create solutions for half the world’s population, has launched the MillSMART™ Profit Value Calculator to help feed mill professionals easily evaluate the economic returns of incorporating the programme into their operations.

The programme preconditioning solution uniformly disperses and penetrates feed, providing a positive impact on feed mill production parameters and significant economic benefits.

Carmen Coetzee, Associate Product Manager, Kemin Animal Nutrition and Health explains, “We created the Profit Value Calculator to help feed mill professionals visualise the economic benefits the programme can provide their business.”

She continues, “With just one click, the tool provides a complete picture of the programme’s collective impact and individual key performance indicators (KPIs), such as feed weight, pellet durability index, energy and throughput.”

To use the tool, users simply enter their feed mill and lab parameters for both a control treatment and MillSMART. The app provides a side-by-side comparison of the net savings and individual KPI savings.

KP Philip, President of Kemin Animal Nutrition and Health boasts, “This is an ideal way to show the tangible potential the programme offers feed mill producers. With this app the feed mill is no longer seen as a cost centre, but a tool to optimise the feed value and quality while optimising feed mill processing productivity.”

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Milling News

T

Nutriad opens new plant in China raditional Chinese dragon dances were on display when Nutriad, together with local partners, opened its new palatability factory in Nantong, China.

The ribbon cutting ceremony was attended by government officials, industry leaders and local staff.

A pioneer in flavour and sweetener solutions for livestock applications in China, Nutriad invested in a new state of the art production facility allowing the introduction of the most recent product development from their laboratories in Europe.

The new factory, with a 10,000 Mt capacity/year, will operate under the FFI (Feed Flavour International) brand.

Building on strong experience in swine nutrition, the new plant will also service ruminant and aquaculture applications.

Erik Visser, CEO Nutriad stated, “As the Chinese industry has developed, both government regulations as well as customer demands have changed over the years.

This new factory is in full compliance with the latest environmental and safety regulations and brings together our years of experience from producing and servicing customers across the world.”

The new 4,150 M2 facility, will see production capacity increased and incorporates lab facilities that were built following European quality standards.

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and introduction of ERP software will support supply chain improvements.

The opening ceremony was follow by a seminar that hosted speakers from Chinese universities and international industry expert and concluded with a dinner attended by industry leaders from all over China.

Mr Visser concluded, “China is a dynamic and growing country. We are proud to be investing in this market and in our relation with local producers. We are confident that we will continue to be successful as we have shown to be able to convert global knowledge into practical local solutions helping producers to overcome feed intake challenges.”

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Milling News

The effects of residual herbicides on fall-seeding cover crops

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over crops are attracting widespread attention for the benefits they provide in crop rotations, especially for soil health. However, many growers of corn and soybean crops know it can be challenging to establish fall-seeded cover crops.

An article featured in the journal Weed Technology provides important insights into why. The authors have discovered that residual herbicides applied as part of a notillage system or to control glyphosate-resistant weeds can inhibit cover crop growth.

A team from the University of Missouri conducted field studies over three consecutive years to evaluate the impact of more than two-dozen residual herbicides on eight cover crops, including Austrian winter pea, cereal rye, crimson clover, hairy vetch, Italian ryegrass, tillage radish, winter oat and winter wheat.

Four weeks after emergence, researchers examined each cover crop for stand and biomass. They determined that the severity of the impact produced by residual herbicides depends on the weather, the species of cover crop and the specific herbicides used.

Pyroxasulfone was found to reduce Italian ryegrass and winter oat biomass by about two-thirds in both the corn and soybean experiments. Flumetsulam-containing products resulted in the greatest carryover symptoms in the corn experiment. In the soybean experiment, products containing imazethapyr and fomesafen resulted in the most severe stand and biomass reduction.

Rainfall was found to be an important variable. During two of the three study years, more rain fell between the time of herbicide application and cover crop seeding. As a result, there was less herbicide carryover and less impact on cover crops.

Researchers found that Austrian winter pea was the most sensitive of the cover crops to residual herbicides remaining in the soil. Cereal rye was the least sensitive, with only four of 27 herbicides adversely impacting its establishment.

Kevin Bradley, Ph.D., University of Missouri explains, “Previous research has shown that cereal rye has several agronomic benefits, including a reduction in soil erosion, weed suppression and an increase in soil organic matter.

Now we know cereal rye can be effectively established in rotation with corn and soybean crops, even following the use of most residual herbicides.”

The results from this research will help growers choose cover crops that are compatible with herbicide use in the previous crop, enhancing the benefits of incorporating these plant mixtures into crop rotations.

Milling and Grain - May 2017 | 25

Milling News

Advanced Feature Dryer

Summer is upon us

The Complexity of Balancing Sanitary Drying and Efficiency

Tom Blacker, International Milling and Grain Directory It is May already and summer is upon us, meaning a busy time for the industry.

IDMA, the International Flour, Semolina, Rice, Corn, Bulghur, Feed Milling Machinery & Pulse, Pasta, Biscuit Technologies Exhibition, is due to take place shortly in Istanbul, Turkey. The exhibition, which is held every two years, has a strong focus on grain and pulses processing technology. It is unique because of the sheer breadth of participants from across the industry. Professional visitors from 144 different countries will be attending, and it is the ideal opportunity to meet and expand investment opportunities, and market share.

The event is being held from the May 4-7, 2017 at the Istanbul Expo Center and you can visit http://www.idma. com.tr to find out more information and to book tickets.

Milling and Grain magazine will be there, so please stop by to say hello.

Speaking of Turkey, I have just got back from visiting, TUSAF that was held in Antalya at the Sueno Deluxe Hotel Belek. The event, which was supported by the Turkish Industrialists Federation, looked to showcase Wheat and Flour trade, trends and innovations within the Bakery sector. I found the atmosphere friendly informative and am hopeful IDMA will be the same.

I am happy to report that our membership to the Milling Directory keeps growing. We have had many renewals in the past few weeks, which will go on to consolidate the directory as one of the biggest and best within the industry. One noteworthy renewal is from Brabender.

They renewed their advertising and membership at the same time via the website in one quick and easy process.

Now is the ideal time to do this, and we urge our other members to consider renewing as Brabender did.

The Milling Directory highlights companies from Europe, America, Asia and even Africa, which make it a global network. This should be the first place to look if you need a service or assistance with a project. If you have not joined already, visit internationalmilling. com and sign up. It is free, quick, and allows you access to a vast directory of invaluable information.

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Milling and Grain - May 2017 | 29

1/7/16 2:11 PM

The Pelletier Column The accordion, the contrarian and the robot

by Christophe Pelletier Although change happens all the time, in some areas human nature demonstrates great constancy. One of these areas is how Pavlovian we react to market fluctuations. Agriculture knows many cycles, most of which are as much the result of human nature as the mechanics of economics.

In the time of high commodity prices that preceded and followed the Great Recession of 2008, one of the main questions I was asked about the future of agriculture was to give predictions about prices and profitability of agriculture. This is a tricky exercise if there is any. So many factors can influence both supply and demand that it is unrealistic to believe someone could predict with certainty future prices. Price predictions would only be meaningful by predicting costs at the same time. Despite the difficulty, many economists venture in the exercise.

The levels of accuracy are disappointing. Past research on economists’ and gurus’ predictions has shown accuracy levels of 47 percent on average. In other words, tossing a coin would statistically be more accurate by a margin of three percent.

When “predicting” the future, it is more useful to focus on patterns rather than trying to miraculously try to pull the right numbers. Human nature is rather predictable.

When prices and profitability are good, suppliers want to produce more, because they expect the result to be even higher profits. It is intuitive, and it would work fine only if the competitors did not follow the same thinking.

Unfortunately, they do and the result is an increase in supplies. As it takes two to have a supplier-customer relationship, the flip coin of the high price medal is that buyers are less warm to buy more of what increase their costs.

I like to compare value chains to an accordion. There is only so much money that flows between the two ends of the entire chain, and all the links must share that money. One end is the consumer market and depending on prices, consumers switch foods when prices reach a pain threshold. Since the amount of money entering value chains actually come from the consumer end, consumer resistance limits the elasticity of the entire chain. Thus, depending on the relative supply and demand between the individual links of the chain, some see their profitability expand while others see it shrink.

The FAO knows the conundrum. High food prices put the economically vulnerable into food insecurity, while 30 | May 2017 - Milling and Grain

low food prices put many small farmers in economic difficulties, and into food insecurity. There is nothing like a food shortage causing high prices to encourage farmers to produce more. Following high price years, they have done exactly that, and that is why prices have fallen, sometimes to the point that entire sectors suffer dramatic losses. Low prices will give an incentive to those who will survive to boost their production, and the cycle will continue.

The counter intuitive approach is to be a contrarian and to supply tomorrow products that have low price and low profitability today and reduce exposure to today’s attractive products. It is easier said than done, because natural conditions limit the choice of products a farm can produce and heavy investments for one kind of production can limit flexibility.

Nonetheless, the contrarian approach is a good one from a planning and forecast perspective. Market swings happen because forecasts tend to be made with today’s prices in mind and assume that the system is static. It is not. Forecasts must take into account the big picture and project what all actors of the value chain will do, as well as in what shape other value chains are and will be. The tools have been here for a while. The exercise then comes down to technical analysis, which is a very common method used by traders. It uses historical data and the predictability of human behaviour to give an indication of which direction prices are most likely to go in the future.

Unfortunately, too many actors in value chains do not use that tool for their forecasting and miss on the most likely picture of the future. Some help might be coming, though.

The development of software, robotics and artificial intelligence will come to the rescue by eliminating the intuitive and preference of the present of human nature by more rational analysis and forecasting than is the case today. Price setting and negotiations will increasingly be automated and carried out by machines, squeezing out the human factor, especially for undifferentiated commodities. Wall Street is already working on this.

Earlier this year, Goldman Sachs indicated that they were going to replace traders by software engineers to achieve this very change, and also to reduce their costs, as a software engineers cost them four times less than a trader.

Christophe Pelletier is a food and agriculture strategist and futurist from Canada. He works internationally. He has published two books on feeding the world’s growing population. His blog is called “The Food Futurist”.

Milling News

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New paper-based bag solutions t the upcoming interpack trade fair Mondi, an international packaging and paper group, will present paper-based bag solutions.

These bags will protect sensitive powdery filling goods, prolong product shelf life, meet the highest safety and hygiene standards as well as being easy to handle.

Being marketed as ‘interpacks that pack more than

34 | May 2017 - Milling and Grain

expected’, the company will showcase customer solutions for three industries including food and beverage. The one of particular interest to agriculture will be the ‘Hot Lock Bag®’ which boasts high hygiene and safety standards as required by the food sector.

PE-inliner bags with Hot Lock Bag® sealing are Mondi’s solution for the particular needs of the food industry. Food producers require packaging that meets stringent health and hygiene standards. Produced under strict hygienic conditions, these open mouth bags combine functional features for easy closure, reliable storage and convenient opening.

The bag acts as a moisture barrier for hygienic and safe packaging and optimal protection. It can be sealed separately after filling for increased protection. The sealing technology ensures reliable closing under strict hygiene standards. In regards to sustainability, the inliner can be easily separated from the outer paper ply for optimal recyclability.

Another product of which they are keen to show off is the ‘Splashbag’. Displayed at the show ‘Interpack’ May 4-10, 2017, Düsseldorf, it is aimed primarily for moisturesensitive building and construction material from rain, although it’s talents are perhaps transferable for the storage needs of the milling and feed industries.

Developed in collaboration with cement producer LafargeHolcim, it is particularly suitable for protecting moisture-sensitive filling goods. It is made from wetstrengthened, machine-finished Advantage Protect sack kraft paper, and is formulated to maintain high tensile strength even in wet environments.

As a result it absorbs less moisture than conventional paper bags whilst maintaining the integrity of the product quality, while at the same time matching the filling speed of standard paper bags.

Even after two hours of direct exposure to rain, Splashbag can still be moved, handled and emptied without difficulty. This significantly reduces bag breakages rates, leading to cost savings through reduced waste, lower vehicle and site cleanup costs, fewer trips from warehouse to site and time savings for logistics and site managers.

EU protein balance sheet

Tradition and modernism in agriculture

by Chris Jackson, Export Manager UK TAG Following on from last months column I have been visiting some of the family farms in Australia, where farm visiting is a constant reminder to me of the importance of farming and food production - something that in the western world our political leaders take for granted.

Without food and water not one of us can exist, something our political elite should be reminded of before their complacency causes a real problem.

When I am visiting established farms it is a salutary reminder, that apart from the New World, the same land has been tilled and farmed through many hundreds of generations. This practice will continue to be so through future generations, so it is imperative that each generation of farmers leaves the land in good condition for future generations.

This must be a primary focus, but at the same time we need food so we have to look to science and genetics to improve yields. This will allow farmers and their advisers to be the final arbiters on their production techniques. After all, they are the ones with the vested interest in efficient production.

This can be done quite successfully without the need to destroy precious rain forests, however we will need a more enlightened political elite to overrule political lobbyists. Those who would have us farming with 500 year old technologies, no fertilisers and no crop protecting sprays, meaning of course most of the world would then be hungry.

Of course we must be sure that toxic chemicals do not enter the supply chain.

Farmers have an overriding responsibility to ensure safe food; criminals will be unscrupulous for money so efficient policing is essential.

Going back to my farming background 36 | May 2017 - Milling and Grain

also serves as a useful reality check in this world of high technology. Whilst I was in Australia, Queensland was hit by a devastating tornado. Much was made in the media of damage to houses and property, but for a country, whose agricultural industry is key to the economy not a lot was said about crop losses.

Houses can be mended quickly but when a crop is lost it takes another year to replace, in national terms the losses were quite small but devastating to the farmers.

It reminded me that one thing that the world’s food producers have in common, is that they are all at the mercy of the weather. Without sunshine and water nothing grows.

However with technology farmers are able to reduce time taken for growth, both in livestock and crops with a commensurate reduction in inputs, all good for the environment, production and food security.

As I left Australia the rice harvest was in full swing with average yields, but of course, the scale of operation is vast in field sizes. Thailand and Vietnam still have far greater outputs grown on very small family holding’s using manual labour, but even here we are seeing small machines being developed, taking some of the drudgery from the workers.

In the vast fields of Australia I was introduced to modern farming with the tractors using satellite navigation to steer them up and down the fields, cutting out wasted energy by having no overlap. I was also reminded as I fly often how the pilots use the computers. In the dust I could not see anything of the land that needed work, but the SatNav kept me on course and the tractor straight, something I found quite bizarre but the younger generation often take this technology for granted!

As I come back to the UK I will leave autumn behind and come to spring with all of growth beginning again.

We do live in a truly remarkable world. @AgrictecExports

T

he European Commission published for the first time on April 10, 2017 a comprehensive EU protein balance sheet. The sheet, 2015/2016 is an overview of total EU production, consumption and trade of all marketable sources of proteins used in animal feed production.

Next to well-known protein-rich materials such as soybean meal, rapeseed meal and pulses, the balance sheet includes sources with lower protein content like cereals.

It also shows the total protein needs in the EU, with EU production of cereals and oilseeds (i.e. derived rapeseed and sunflower meal through domestic crushing) providing the bulk of raw protein requirements.

Also confirmed is the strong need to import protein-rich sources such as soybean meal and soybeans for EU crushing. It should be clear that the different vegetable protein sources have different nutritional profiles and cannot be substituted for each other.

Reacting to the publication, COCERAL, Copa-Cogeca, FEDIOL and FEFAC appreciated the Commission efforts to develop a dedicated, independent tool to monitor the balance of demand and availability of protein crops in the EU, which will contribute to market transparency and help operators to better understand market developments.

This allows for informed discussions and an assessment of potential changes to the agricultural sector and the Common Agricultural Policy (CAP), non-agricultural uses like biofuels, phytosanitary and trade and antidumping policies which could affect the availability of protein sources for EU livestock farmers as well as increase dependency on imports.

Assured and predictable access to a strategic supply of proteins to meet demand and to feed farm animals is crucial for the competitiveness and resilience of the EU feed and livestock sector.

The Commission has indicated that a second EU protein balance sheet will be published after the summer of 2017 once data are available for the whole marketing year 2016/17, which will contribute to the discussions within the scope of the European cereals, oilseeds and protein crops market observatory.

Milling News

Digital moisture sensors launched

H

ydronix are launching two new microwave moisture sensors at the IDMA show in Istanbul.

Using digital technology the sensors are manufactured from food safe materials, those that are specifically for use in animal feed, grain, rice, nuts and liquids.

The Hydro-Mix HT is a high temperature sensor that will measure moisture in materials that have a process temperature of up to 120 degrees Celsius. This is to ensure maximum potential for installation before or after dryers or in mixing systems.

The Hydro-Mix XT is a digital moisture sensor that comprises a single unit, containing all on-board Hydronix are launching two new microwave moisture sensors at the IDMA show in Istanbul

functionality such as signal processing, smoothing and averaging. This sensor has an external seal, enabling it to be installed in dusty or liquid processes or applications, from one-bar vacuum to five-bar pressure.

Both of the sensors come with fixing plates that make them easy to install flush with the internal wall in drying, ducting, conveying and mixing systems.

Hydronix also offer the HydroProbe XT sensor. This is designed for applications that require the sensor to be placed into the flowing material such as the outlet of a silo or in the neck of a storage bin.

All Hydronix sensors are designed for use in flowing materials with readings being taken 25 times per second as the material passes across the ceramic sensing face. With digital input or output, a choice of measurement modes, free configuration and calibration software and a global sales and support network, Hydronix is already the supplier of choice for many OEM equipment manufacturers, system integrators and end-users.

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July 2015 | 63

Milling News

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US Secretary of Agriculture announced onny Perdue has been sworn in as the 31st US Secretary of Agriculture on April 25, 2017.

Administered by fellow Georgian and Associate Justice of the US Supreme Court, Clarence Thomas, his wife Mary was by his side as he took the oath of office in the US Supreme Court Building.

The ceremony was brief and the vote was confirmed by a ration of 87-11 by the Senate. After he took the oath of office, he addressed employees at the US Department of Agriculture (USDA) before getting started on his first day of work. This was simultaneous to the USDA launching his official Twitter handle: @SecretarySonny.

40 | May 2017 - Milling and Grain

Perdue commented on his appointment, “The only legacy that I seek is the only one that any grandparent or parent seeks – to be good stewards, and to hand off our nation, our home, our fields, our forests, and our farms to the next generation in better shape than we found it.”

He continued, “Making sure that Americans who make their livelihoods in the agriculture industry have the ability to thrive will be one of my top priorities. I am committed to serving the customers of USDA, and I will be an unapologetic advocate for American agriculture.”

Perdue’s policies as U.S. Secretary of Agriculture will be guided by four principles informing his decisions.

Maximising the ability of the men and women of America’s agriculture and agribusiness sector to create jobs, to produce and sell the foods and fibre and to reap the rewards of their labour.

Prioritising customer service every day for American taxpayers and consumers.

As Americans expect a safe and secure food supply, USDA will continue to serve in the critical role of ensuring the food we put on the table to feed our families meets the strict safety standards we’ve established. Food security is a key component of national security, because hunger and peace do not long coexist.

Finally, he will remember that America’s agricultural bounty comes from the land. And those land resources sustain more than 320 million Americans and countless millions more around the globe. His father’s words still ring true: We’re all stewards of the land, owned or rented, and our responsibility is to leave it better than we found it.

Sonny spoke of his ambitions of his new role, “As secretary, I will champion the concerns of farmers, ranchers, foresters, and producers, and will work tirelessly to solve the issues facing our farm families. I am proud to have been given this opportunity and look forward to rolling up my sleeves and getting to work as we continue to move the USDA and our nation forward.”

Upon nominating Secretary Perdue in January, President Donald J. Trump said, “Sonny Perdue is going to accomplish great things as Secretary of Agriculture. From growing up on a farm to being governor of a big agriculture state, he has spent his whole life understanding and solving the challenges our farmers face, and he is going to deliver big results for all Americans who earn their living off the land.”

Additionally, he recognises that American agriculture needs a strong advocate to promote its interests to international markets. The United States is able to produce more than its citizens can consume, implying that we should sell around the world.

As a youngster growing up on a dairy and diversified row crop farm in rural Georgia, when he was a young boy feeding the calves and ploughing the fields, he was an integral part of the workforce on his father’s farm.

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A book review by Tony Evers

S

canning the contents list of this book, readers may be surprised to note that one chapter is devoted to durum wheat! With a world production of over 30 million tonnes, one might ask how the inclusion of durum wheat is justified in a book on neglected cereals. The same might be said of millets (the more so as the authors include sorghum in this category) as these are staples for many millions of people throughout the world.

It is only on reading the text that it can be appreciated that the authors are very much concerned with a German perspective and that their contention is that there is potential for increasing production of non-mainstream crops in their country. In accord with this observation it is also notable that a large proportion of the references cited are in German publications or by German authors. This is not to say that the book has little relevance outside Germany, nor does it imply that more widely applicable principles are absent from the text. The book was originally written in the German

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42 | May 2017 - Milling and Grain

2017

Book Review

Neglected Cereals

Meet the authors at FVG Select - GRAPAS Conference in Köln

language, but has been translated by Charlotte Grill into pleasurably readable English.

The authors observe that there are 380,000 known species of plant, of which 30,000 are edible. Only 150 species are used for human consumption today and only 30 of these account for 95 percent of calorie requirements of the world’s population. Wheat, rice and maize alone contribute 50 percent of those requirements.

A consequence of this is that the world food supply is somewhat vulnerable to disease, predation and climate change. Diversification thus offers a potential benefit, providing that the alternative crops are sufficiently different from the current dominating species in their requirements and susceptibilities.

About half the book’s text is devoted to consideration of agronomic, nutritional and technological properties of lesser cropped species of wheat, the main ones being emmer, einkorn and spelt, ancient types of which many readers are aware, but the lesser known species Khorosan wheat (Triticum turgidum ssp turanicum) is also considered, as are wheat types of various species that produce coloured grains, thus offering potential for novelty products. St John’s rye and other perennial grasses with crop potential are also discussed and the historical, agronomic and nutritional aspects of the better-known pseudocereals: buckwheat, quinoa and amaranth are briefly considered.

The full title of the book includes the phrase ’From Ancient Grains to Superfood’ from which it can be inferred that at least some of the neglected crop plants included offer nutritional or medicinal properties superior to those that are more widely grown, and indeed such claims are made with supporting evidence. Chia (Salvia hispanica) otherwise known as Mexican sage is little known in Europe but may become more familiar as a result of being promoted as a ‘superfood’ based on claims of health promoting properties as well as its high protein content.

The chapter entitled ‘Does wheat really make you sick and thick?’ is more relevant to conventional wheats because of their wide consumption by most people, than to those described as neglected in the book’s title. However, it offers a welcome detailed assessment of the hazards, and more particularly the absence of hazards, associated with gluten consumption; refuting, with sound scientific evidence, the more emotive objections, that have become fashionable, to the consumption of cereals-based foods.

Many readers will appreciate the frequent text boxes that provide summaries of salient points discussed in the main body of text and while academics may be disappointed in the limited bibliography and incomplete references throughout, the publishers’ declared target audience of farmers, traders, millers and bakers as well as consumers, will find much of interest between the covers of ‘Neglected Cereals’.

Mill

Training This specialist course ran by Bridge2Food is being run for the 12th time in the USA and will run from June 28-30, Las Vegas (USA) after IFT. Food Proteins: Properties, Functionalities and Applications will give a fantastic theoretical and practical overview of 10 new vegetable and animal proteins for food applications and will provide hands on information about their properties and functionalities.

Food protein course 2017 The proven format of the course provides a unique combination of lecturers and hands-on experience. Theoretical lectures by leading industry professionals on protein functionality, nutrition, digestibility, hydrolysis, combined with practical hands-on experience, is unique. After three days, all delegates will have seen, touched and smelled the different proteins, experienced in model systems and final applications.

Some of the leading industry experts who will discuss these topics include: • Soy – Dupont Nutrition and Health • Pea – Roquette • Potato – Avebe Solanic • Canola – DSM • Pulses – Ingredion • Whey – Milk Specialties Global • MPC and MCI – Milk Specialities Global • Gelatin and Collagen Hydrolsates – Rousselot • Egg Albumin – Rembrandt Foods In the theoretical sessions, participants will learn about protein properties and functionality and the relative importance of proteins in food applications, processing and legislative context.

They will understand more about the nutritional and health benefits as well as denaturation, agglomeration, stabilisation, emulsification and modification. Focus will be on both animal and

Milling

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vegetable proteins including egg albumin, whey, milk, collagen and gelatine as well as the topics listed above.

The practical sessions will focus on functional properties and applications. Various protein gels and foods will be combined with different proteins to evaluate and learn about thermodynamic properties, gel colour, strength, flavour and elasticity.

This course is designed for all who are active in the food industry and want to learn more about the properties, functionalities and applications of a broad range of plant-based and animal-based proteins, and wish to obtain hands-on know-how and know-why.

A protein industry networking opportunity, the 12th Food Proteins Course 2016 will be held in Las Vegas, USA. www.bridge2food.com

The Training Register operates on the same platform as the highly successful internationalmilling.com Events Register.

Our vision is to produce an easily accessible hub which will list both milling and aquaculture related training courses, workshops and educational opportunities from around the world, much the same as the Events Register does for conferences and expositions.

“If you, your company or organisation is organising a milling or aquaculture course we would love to work with you. No training course is too big or too small for any of our readers to attend.”

Milling and Grain - May 2017 | 45

UltraPoly Rice Polishing Machine DRPG

PRODUCT FOCUS MAY 2017 In every edition of Milling and Grain, we take a look at the products that will be saving you time and money in the milling process.

A term often used for describing the talents of products is “setting the standard”, although, perhaps in this case a term not used lightly. The UltraPoly by Bühler sets a new standard for rice polishing and boasts to supply the highest quality end results.

Coming equipped with the latest technological advances and features, the machine delivers optimum polishing performance whilst maintaining a constant low processing cost per ton. Not to mention that the high head rice yield process allows uniform milling and higher yields of head rice.

The UltraPoly also benefits from maximum capacity. Its unique geometry of sieves with reverse bends allows a better polishing performance. In addition to this, it has an extremely efficient energy operation.

Firmly fixed screens restrict unnecessary vibration whilst helping to maintain a uniform gap between the sieve and the cam. In short, this innovative technology

www.buhlergroup.com

Cast-iron Roller Mill The Roller Mills frame provides an optimal base for high grinding performance in 24-hour continuous operation.

Sanitation is guaranteed through the use of stainless steel and other food-safe materials. The wide inlet and the variable speed of the feeding roll ensure even feeding across the entire length of the grinding roll, contributing to consistent product quality.

The modern sensor technology ensures that the rolls are always ideally positioned and running at optimal speed. The Roll Quick Pack allows both rolls to be quickly exchanged, reducing the duration of required maintenance and downtime. In addition grinding solutions can be individually tailored to specific requirements.

One company that addresses the needs of all millers, no matter the material being milled or the product produced, and exhibiting its technology throughout the world, is the Swiss engineering group, Bühler.

We are pleased to report several of its updated and new offerings in this month’s Product Focus section!

www.buhlergroup.com

Tubex scales: New generation

Air Cleaner LAIA

With Tubex, the hopper scale boasts reduced energy costs, high food safety and instead of pneumatic cylinders the drives of the bottom and the inlet slide gates operate with an electromagnetic drive.

The ASU 200 and ASU-100/-150/-200 aspirators are used for pre-cleaning processes. They feature two fans for enhanced air distribution, and can be adjusted to accommodate product differences. The aspirators comply with explosion protection requirements of the EU Directive 94/9/EC and are suited for plants that deal with grain or other bulk materials.

Super-capacitors save energy in-between driving cycles and supply sufficient starting power, reducing energy costs by 90 percent.

A completely closed scale, it has no false-air opening. Differential pressure sensor measures the internal pressure fluctuations, and the algorithms of the control system process the measurement values and compensate for the influence on the measurement accuracy.

Internal radii and product touching parts are made of stainless steel, reducing the risk of product build up or cross-contamination.

The measuring technology monitors all operating and service parameters, while the diagnostic system detects problems at an early stage.

www.buhlergroup.com 46 | May 2017 - Milling and Grain

The ASU is cost effective and eco-friendly. The exhaust system and recirculating air principal give great results at a fraction of the cost, it also minimises dust emissions. An optimised construction gives an infinitely adjustable regulating flap, which in turn distributes the product optimally across with entire width of the working area. This increases the amount of throughout with as little space requirement as possible.

Flexibility is a key factor of the ASU aspirator. The adjustable flap combined with the vertical sifter allows an optimised clean, and is available in three sizes: 100m 150 and 200 to satisfy the requirements of space and capacity.

www.buhlergroup.com

FOCUS

SPECIAL FOCUS Bühler’s high-precision ring dies and roller shells formed part of the company’s display at EuroTier 2016 in Hannover, Germany, offer a vast range of designs suitable for all types of pellet mills and brands.

Supplied worldwide, these products are marketed as of a superior quality, easy to mount, starting easily and lasting longer.

The process begins with the selection of the material, often dictated by the customer’s raw material formula and selected to resist the high abrasive and corrosive forces within the pelleting process.

The warehouses are stocked with high quality forged blanks, the CNC machining centres for high precision and there is no limitation of hole patterns thanks to the latest gun drills.

Steel qualities for roller shells commonly used are 20MnCr5 or 100Cr6. The shells may be corrugated, dimpled, open or closed ends matching the different characteristics of the raw material to be pelletised.

In addition they may be case hardened or through hardened resulting in a more bridle or flexile material.

The right roll shell design makes a difference when it comes to lifetime and throughput. For the majority of the applications the X46Cr13 alloy is the first choice for ring dies.

There is different counter drilling

Ring dies and roller shells for different products; the counter drillings enhance pelleting performance. The quenching and tempering occur in a vacuum and nitrogen atmosphere, while a low dimensional distortion and smooth surface ensure quality assurance. This is due to the measuring of hardness and dimensions and the quality data recorded for traceability.

Every hole is spaced so that they wear evenly. For obtaining uniform die quality the hardening and tempering process is of utmost importance. Bühler uses the latest vacuum furnace technology for hardening the ring dies. Each product checked again for hardness and dimension and all data are recorded for traceability purposes. The running-in process for de-burring of ring dies and shells means that they are delivered readyfor-use.

A specially developed hole pattern is used to increase throughput and save electrical costs. Compared to non-optimised patterns a significant capacity increase has been measured. In addition, the so called parallel hole pattern reduces the forces between rollers and die which lowers the risk of die breakages and results in a more uniform wear.

The counter drilling design also has an influence on performance and should be matched to the pelletised product formula.

From straight to cone design there are hardly any limits to the counter drilling design.

Roman Inauen from Buhler

www.buhlergroup.com Milling and Grain - May 2017 | 47

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05

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An intensive two-day exchange of knowledge and ideas

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by Roger Gilbert, CEO, Perendale Publishers Limited

lour millers are notorious for wanting to remain in their mills, overseeing the milling process. It’s only natural after all, when you consider the importance of the products they produce and the demands placed upon them in terms of time, attention to material detail, monitoring processes and ensuring the products produced satisfy discerning customers and consumers on a daily basis.

Therefore, it was surprising, and gratifying, to see a large number of millers represented among the 300 delegates attending last month’s Global Millers’ Symposium held in Hamburg, Germany.

What drew them to Hamburg and two full days of presentations at the Bucerius Law School, which was the venue for the symposium?

It was the quality of the presentations on offer and the opportunity to engage with not only other millers but with a significant number of European and international grain and cereal organisations.

In fact, this the sixth edition of the Global Millers’ Symposium was jointly hosted by Mühlenchemie and the International Association for Cereal Science and Technology (ICC) and attracted millers and others in the industry from 54 countries to listen to 40-plus presentations delivered by experts from more than 12 countries. This year’s event was also partnered by leading industry suppliers, such as AkzoNobel, BASF, Brabender, Chopin, SGS, Perten and Diosna.

Setting the scene

Volkmar Wywiol, the chairman of Mühlenchemie, expressed his pleasure when welcoming delegates to the largest event held so far.

“You will hear many presentations over these two days,” he told the gathering.

“Knowledge transfer is the focus of this symposium. The exchange of ideas and the renewing of old friendships is also important. My model in life is that business is to make friendships. Please do this.”

He explained that Mühlenchemie has a proud 94 year history of assisting the development of flour milling around the world with a focus on the “white gold” products that match the demands of both customers and consumers alike who rely on bread and pasta.

“Like no other company in this area, we have been assisting the flour milling for generations.”

His company serves more than 2000 mills in 120 countries and they in turn rely on the company’s range of specialist products, its expertise 48 | May 2017 - Milling and Grain

Volkmar Wywiol, the chairman of Mühlenchemie, expressed his pleasure in welcoming delegates to the largest event held so far. For more from Mr Wywiol see our interview on page 122

and its innovations, he added.

Dr Hamit Köksel, President of ICC, the International Association for Cereal Science and Technology, which was founded in 1955 on the occasion of the 3rd International Bread Congress in Hamburg, Germany as the International Association for Cereal Chemistry, is one of the foremost organisations dedicated to international cooperation, the dissemination of knowledge and the improvement in safety and quality of cereal-based foods. ICC is headquartered in Vienna and has 24 country members.

“With a growing world population the network of cereal scientists and technologists has never been more critical in providing food security and sustainability,” he told the audience.

He praised the opportunity the symposium provided for networking and the exchange of ideas from a number of countries.

He spoke about the need to address misinformation concerning gluten and the avoidance of recalls due to salmonella and other bacteria.

“These kind of food safety issues can be devastating for the reputations of companies as well as challenging for the health and safety of the consumer. Therefore, food safety must remain a priority for the foreseeable future.

“ICC is dedicated to the advancing of knowledge and understanding of cereals science through research, education, training and networking. ICC can only achieve this working with all stakeholders such as Mühlenchemie,” he concluded.

"Millers and others in the industry from 54 countries listened to 40-plus presentations delivered by experts from more than 12 countries" A full schedule

Presentations came fast and thick with little time for questions or discussion outside coffee and lunch breaks on the first day.

The opening session on Markets presented keynote speakers such as Vito Martielli an analyst for grains and oilseeds at Rabobank’s RaboResearch Food and Agribusiness who spoke on Global Outlook for Wheat.

F Martielli was followed by Bernard Valluis the president of the European Flour Millers Assocaition who spoke on New Regulations for Wheat Futures and Options.

While both these speakers outlined impending changes facing the milling sector it was Merzad Jamshidi of MD KFF Mills and district chairman for IAOM MEA to put the millers perspective to market conditions.

While baking trends were dealt with by Mühlenchemie speakers, the first session concluded with an award presented by the President of the Russian Union of Flour Millers, Arkadiy Gurevich, to the ICC. We learnt in this brief presentation, that Russia has 295 mills in production with capacities ranging from 200 to 1700 tonnes per day and currently utilising between 50-60 percent of its capacity to produce some 10 million tonnes of flour - including nine million tonnes from wheat and the rest from rye annually. Mr Gurevich said there were some 3000 small mills producing up to 20 tonnes of flour per day throughout the country.

The Russian Union of Flour Mills represents 70 percent of all flour and cereals processed in Russia. Mr Gurevich, who has been the Union’s president since 2005 was responsible for the development of the private sector moving into the baking industry.

After a brief coffee break the Secretary General of the ICC, Michaela Pichler took over proceedings and introduced the Grain Research & Quality session of three presentations.

They included: Developing wheat varieties for the future: challenges and opportunities, by Klaus Oldach, Team Leader Breeding Technologies Cereals, KWS LOCHOW GMBH; The potential of growing wheat in sub-Saharan countries and other regions, by Hans-Joachim Braun, CIMMYT, Director Global Wheat Program & CRP WHEAT and Protecting the quality of grain by Ralph E. Kolb, FrigorTec GmbH. Dimitrios Vasilakopoulos, Head of Laboratory, Mühlenchemie chaired the session on Quality Determination Tools that saw four of the ‘partner’ companies involved in hosting the event explain their latest developments (MAG will be reviewing each of these products in turn within our Product Focus pages in upcoming editions). For example one such company, BioAnalyt explained how its new iCheck testkit can reduce testing times for vitamins to just a few minutes and at one tenth of the current cost.

Bucerius Law School, which was the venue for the symposium

87. Annette Büter of Mühlenchemie said that while fortification and iron digestibility is all-important, anyone consuming less than 75g of flour per day has to look to other forms of supplement.

Twenty countries in Africa suffer malnutrition with two billion people suffering iron and zinc deficiency and a further half-a-million going blind through Vitamin A deficiency.

Subsistence farmers for example is one group that misses out on these benefits, as they do not have access to commercial flour.

And while we consider developing countries in most need, we should not overlook that fortification is also needed in developed countries, such as the USA and throughout Europe, added another speaker.

We heard good reasons for both why wheat is suitable for Africa and why it will ultimately fail in terms of local growing conditions.

With the right weather however, soil and technological inputs yields could be as high as 16.8 tonnes per ha, the world record achieved in New Zealand in February 2017 from an 11ha field.

The second day

The second day presented a further 17 speakers with the focus firmly on two themes; culture, cultivation and climate, and flour quality, processing and improvements. Several of these presentations will be reported in future editions of Milling and Grain.

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The heat of the event

But it was the Health and Fortification session that proved to be the heat of this event. MAG reports in this issue the presentation

by Professor Fred Brouns of Maastricht University on: Does Wheat make you sick?

We were updated on six years of progress in grain fortification, functional flour for improved health and the benefits to be gained from FeNa-EDTA, Vitamin A, technical aspects of flour fortification, implication for taste and regulatory challenges for vitamins in food under the heading of ‘Catch me if you can’.

An extremely moving presentation by the President of the International Federation for Spina Bifida and Hydrocephalus (IFSB), Margo Whiteford, took on the task of outlining why flour production in Europe should be fortified with folic acid. Her presentation received the full support of all present.

We were also told that the impact fortifying food is not immediately seen and that it takes at least five years to detect the reduction in diseases.

“Today consumers want personalised nutrition in order to optimise their health and we all need rapid tools that assess the health of human beings,” says Simone Frey of BioAnalyt. She told millers, “how we act impacts the whole of the food production chain.”

Scott Montgomery, director of the Food Fortification Initiative told delegates, “it is millers who fortify and not governments” and said that the number of countries that mandate fortification had risen to

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Milling and Grain - May 2017 | 49

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DOES WHEAT MAKE US SICK? The hazards of gluten and gluten intolerance

I

Professor Fred Brouns is the co-ordinator of the ‘Wow’ or ‘Well on Wheat 2017-2019’ project, which is an international research consortium for the study of wheat types, their processing and impact on consumption, intolerance and wellbeing f we find out that what we eat currently contains too much gluten, and that it is making everyone sick, then we need to look into and modify the food chain or alter the gene in wheat that is producing the gluten.

That’s the response Professor Fred Brouns of Faculty of Health, Medicine and Life Sciences at the School of Nutrition, Toxicology and Metabolism (NUTRIM) at Maastricht University in The Netherlands opened with when tackling the subject ‘Is wheat making us sick’ at last month’s Global Millers’ Symposium in Hamburg, Germany.

Professor Brouns has 25 years experience in research, health and nutrition. He had been invited to speak at the symposium, hosted by Mühlenchemie and the ICC, which was supported by a number of industry supply companies.

With many books now being published that challenge wheat as a healthy food choice, such as ‘Wheat Belly’ by Dr William Davis, ‘Grain Brain’ by Dr David Perlmutter, ‘The Paleo Diet’

by Dr Loren Cordain just to name a few, the industry took the opportunity to ask Professor Bouns to respond to their claims.

All the above, says Professor Brouns, culminate in one medical doctor claiming that modern wheat “is a perfect, chronic poison.”

“All of these authors identify gluten content as the problem, he says, yet “a doctor trained in the US spends just 23 hours on nutrition in his six years of training.”

Professor Brouns says wheat and gluten avoidance is now a global issue.

However, he believes the food industry’s production chain produces healthy grain for global nourishment.

“There is a need for healthy food and we need to adapt our food supply chain for our health if it is not provided.”

Yet the popular press and social media, plus major TV celebrities, are together establishing gluten as the new sick-maker and gluten-free as the new, healthy option.

Since 2013 there has been a global spreading of the “glutenwheat free diet” with 30 percent of US consumers in 2014 asking

50 | May 2017 - Milling and Grain

Professor Fred Brouns, Faculty of Health, Medicine and Life Sciences at the School of Nutrition, Toxicology and Metabolism (NUTRIM), Maastricht University, The Netherlands, points out, “On one hand, we have a need for healthy food products. On the other, we have what we see in our field. That’s why we need to select the best crops for health. If current crops are not optimal then we should optimise them.” specifically for gluten-free food and meals. And this has resulted today in gluten-free menu cards in restaurants, he adds.

In addition, Professor Brouns reports that sportsmen and women are talking of gluten-free diets without sufficient knowledge or understanding and only the number one tennis player Andy Murray, who experienced a gluten-free diet for a three-month period, has apposed the trend by saying he lost weight and lost strength that almost compromised his playing ability.

Grain consumption

Some of the media hype being put forward by professionals which claims eating wheat makes you fat and sick are based on the assumption that humans have only been eating wheat for 10,000 years - too short a period to adapt to it without getting ill.

They also claim that modern wheat has been genetically modified and contain more “ill-making components” than ancient grains.

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Professor Brouns responded to these claims with facts.

“Have grains been consumed for only 10,000 years? Very interesting. Now what are the facts?”

He showed his audience clear evidence of large-scale processing of wild cereal grains at Ohalo II campsite in Israel more than 23,000 years ago and that almost 45,000 years ago micro-particles in human dental enamel proves the consumption of plants and cooked meals in Neanderthal diets that contained dates, vegetables, roots plus wheat, rye and barley.

“Have we been eating wheat for only 10,000 years? No, we have been eating wheat for at least 45,000 years.

“Did humans eat grains more than 45,000 years ago? That question cannot be answered however the absence of evidence is no evidence of absence,” he stated.

However, where there is evidence is in fossil findings that show grains, not dissimilar to modern day wheat containing starch and protein and what had been living then would have been eating from it, of over 300 million years old have been found in a geo-park in Araripe, Brazil.

Concerning the question of wheat modification, Professor Burns laid out the essential wheat varieties from wild

crossbred to the selection for yield that have taken place over the past 150,000.

Over time we have selected grains for harvest yield and disease resistance, from the wild cross-breeds to modern varieties. The yield of early Einkorn is only 25 percent of our modern bread wheat, he says.

“If we wanted to go back to Einkorn wheat we would have to increase the area planted by four times, and that’s impossible.”

His take-home messages for delegates here, include the surprising fact that yields of bread-making wheat are up to 300 percent higher when compared to ‘ancient wheats’ and that wheat, rye and barley have been used as local staple foodstuffs for at least 45,000 years and that modern bread wheat ‘was born’ about 11,000 years ago as a wild natural hybrid.

Milling and Grain - May 2017 | 51

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GMO wheat

Dr Davis et al and social media sources claim that bread wheat is now GMO and contains more gluten and ‘sickmaking’ components than ancient wheat. Professor Brouns asks, “What are the facts supporting this claim?”

He reported studies of major projects - one being the European Consortium called Health Grain - that used grain bank wheat genomes of Diploid: AA Einkorn (T-monococcum); Tetaraploid: AABB (Emmer, Durum, Rivet and Khorasan and Hexaploid: Modern wheat - broadsheet (Triticum aestivum sap. aestivum and spelt (T. aestivum sap Spelt).

Over time starch content has risen while protein content has gone down. “There is less protein in modern bread wheat and more starch,” he says. ‘There is very little differences in nutritional composition between bread wheat of today and ancient wheat. However, there is some differences in dietary fibre content, very small and not important differences in most bioactive components and colour selection (based on the higher content of Lutein or carotenoid) in Einkorn, Emmer and Khorasan compared to today’s bread wheat.

“But there is no evidence to support the claim that ancient wheat are healthier than modern wheat,” he says.

Do they contain more gluten? The answer from Professor Brouns is no, as protein content has fallen over time reducing the content of gluten in wheat, he adds.

“You cannot say that older types of grain have less gluten.

In Durum wheat for example, the highest levels of gluten - almost double - are recorded in the ancient Graziella and Kamut varieties than in their modern-day equivalents.

“And therefore we should not advise that older grains are more suitable for those people with the celiac condition.”

Additional take home messages at this point included: 1. Modern bread-wheat resulted from natural cross-fertilisation and from farmers selecting based on economic reasons 2. There is no GM-wheat on the global market today 3. All gluten-containing grains cause health problems in susceptible individuals and the majority of the global population - that is, over 90 percent - develop appropriate oral tolerance with no problems 4. Grains are a high-quality food when eaten whole Modern milling separates the wheat stream into wheat bran/ germ and the flour, taking out the oil.

“But if you take out the bran and the germ you also take out nutrients.

“That’s why we say that ‘white flour’ is empty calories. The micronutrients are in the bran and germ and they have the 52 | May 2017 - Milling and Grain

health benefits.

In a 14-year study that followed 367,442 individuals and their whole grain and cereal fibre consumption, recorded against the group’s mortality that occurred, concluded from the 46,067 deaths that the consumption of whole grain and cereal fibre reduced disease risks and all causes of mortality such as cancer, cardiovascular disease, diabetes, respiratory disease and infections, etc and that the risk reduction was most related to cereal fibre intake suggesting that the fibremicronutrients complex was a prime factor.

“This is a very, very powerful message.”

For example, cardiovascular disease mortality can be reduced by 20 percent by consuming one serving per day of whole grain.

“That is the reason we put so much emphasis on whole grain and we need to go back to whole grains and for industry to make more whole grain products that are more tasty,” he adds.

Food intolerance common

Food intolerances exist in many individuals, from lactose intolerance, to nut and other allergies and even to food such as pepperoni and resulting gastric acid reflux.

Wheat allergy by comparison is only in 0.3 percent of the population and celiac disease is about one percent of the population.

“What we know now, is that some people develop an intolerance to wheat through some kind of inflammation that does not have celiac disease nor wheat sensitivity - that’s about three-to-five percent of the population.

“And we know this because recent tests done before and after wheat/gluten avoidance is prevalent in people who have Irritable Bowel Syndrome (IBS).

“20-30 percent of people with IBS are intolerant to wheat or gluten containing cereals. This needs further research.

In conclusion, Professor Brouns says whole grains, including gluten, are excellent food sources for the majority of the population; that white flour-based foods are less healthy due to the lack of fibre and micronutrients; that in small portions of the population gluten-wheat containing foods can cause health problems; that there is a need for transparency and clear consumer information.

“If you can do anything as a miller, don’t just think about fortification of the flour, think about what’s being provided by nature that can offer consumers health benefits.”

“We want to know what we need to be telling the farmers to grow in their fields in future to provide the most nutritious food products based on wheat flour.”

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Understanding the role of

heat treatment of flour

F

by Dr Mahmoud Riad, Egyptian Milling Society Secretary General, Egypt lour Heat Treatment (FHT) is a process designed to modify the properties of flour, germ and bran. FHT can be divided into two basic processes: hydrothermal treatment and thermal treatment.

Applications for FHT products can be applied in a large number of different ways in the food industry. This is because coatings where hydrothermally treated flour is excellently suited for preparing batters for coating fish, meat and vegetables.

Thanks to its optimised cold viscosity batters or breadings adhere perfectly to the food and dripping of the batter is reduced.

In bakery products thermally treated flours are used for cakes with high sugar and fat contents. These flours are characterised by their strengthened gluten properties and fine granulation.

In order to achieve a long shelf life of fresh dough, raw materials with low microbiological contamination are required.

Heat treatment sanitises the flour by inactivating a large proportion of the microorganisms.

Binders

FHT flour is applied, among other things, as a thickener for soups and sauces.

Heat treatment increases the hot viscosity of these flours, dries the product to prevent moisture from migrating to the other substance components while inactivating microorganisms and enzymes.

Other applications

The FHT process allows bran, germ - that is from wheat - as well as rice bran to be stabilised, enabling them to be preserved by essentially inactivating fat-splitting enzymes, reducing a large proportion of the microorganisms by heat and optimising the product moisture.

These grain by-products can, for example, be used in muesli mixes or in cereal bars.

Hydrothermal flour treatment involving moisture and heat is a hydrothermal process. The term ‘hydrothermal process’ refers to the treatment of flour by heat and moisture in the form of water and steam.

The goal of this process is to modify the flour substance components such as starch and gluten.

In addition, enzymes and microorganisms are inactivated.

The principle

FHT is a continuous process with a throughput capacity up to 2500kg/hour.

54 | May 2017 - Milling and Grain

Hydrothermal flour treatment can be divided into three steps: • Injection of steam and water into the flour, followed by a retention time in the heat retention screws • Gentle drying by hot air in thermopneumatic conveyors • Removal of agglomerated particles by sieving, which are then ground The goal of hydrothermal treatment is to increase the hot and cold viscosity by gelatinizing the starch while improving the water solubility by denaturing the gluten and inactivate enzymes in grain byproducts such as germ and bran to improve the shelf life.

The ‘thermal process’ of flour treatment involves heat and retention time.

The term ‘thermal process’ refers to the treatment of flour by heat, followed by an appropriate retention time. This process is less intensive than the hydrothermal process. The flours thus retain their baking characteristics. The heat acts particularly upon the gluten and the microorganisms.

The principle involved in the ‘thermal process’, which allows a throughput capacity up to 2000kg/hour of product. The process can be divided into the following discrete steps: • Gentle heating in a current of hot air in thermopneumatic conveyors • Temperature retention in heat retention screws • Moisture addition to adjust the water content • Screening and grinding to adjust the particle size Unlike hydrothermally treated flours, thermally treated flours retain their baking characteristics. Such flours are applied as cake flour with strengthened gluten framework, for cakes with very high sugar and fat contents, plus soup flours with increased hot viscosity and low moisture content.

Overall process

System types: The core components of all FHT systems (heat retention screws and thermopneumatic conveyors) for the ‘hydrothermal’ and ‘thermal processes’ are identical.

The two processes can be combined in one single system. This produces maximum production flexibility, since it is possible to produce flours with gelatinised starch, baking flours with strengthened gluten, dried flours and stabilised germ and bran.

A single system may also be designed to meet specific process requirements. The system capacities are related to the specific product and may vary according to the process used - thermal/ hydrothermal - the heat retention time in the retention screws and the intensity of treatment.

The process and the system size are matched to the customer’s specific needs.

References available upon request.

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THE NEXT GENERATION OF ENZYMES:

How the Feedase effect improves overall feed digestibility

W

by Pierre-AndrĂŠ Gergert and Olivier Guais, CERN-Adisseo, France

ith innovative new enzyme combinations, the overall digestibility of feed is increased, including energy, phosphorus and amino acids.

RovabioÂŽ Advance is a Feedase and has been designed to address the main anti-nutritional factors present in cereals, arabinoxylan chains. The actions of xylanases and the de-branching enzymes arabinofuranosidases are key. Their synergistic action efficiently breaks down the fibre structures, making nutrients more available for both endogenous and exogenous enzymes to work on.

Energy is provided in poultry and swine diets by the carbohydrates found in cereal grains. They also contain nonstarch polysaccharides (NSP), a type of dietary fibre that reduces feed digestibility. As poultry and swine do not naturally produce NSP degrading enzymes they are not able to digest them. Consequently they have a negative effect, including increasing the viscosity of the intestinal contents and reducing the availability of other nutrients within the cereals.

Anti-nutritional effects

NSP are polymers, present mainly in the cell walls of the endosperm but also in the bran. They include cellulose, hemicelluloses and pectins. These can also be divided according to their nutritional value, into water-soluble and water-insoluble fractions. Soluble NSP are known to possess anti-nutritional properties by either encapsulating nutrients and/or depressing overall nutrient digestibility, through enhanced viscosity and changes in digestive microbiota.

The cell walls of the outer tissues of the cereal kernel mainly contain cellulose and complex xylans, together with significant amount of lignin. The cell walls of the endosperm however, contain almost exclusively arabinoxylans and beta-glucans.

Arabinoxylan is one of the main NSP component in cereals. It is composed of a beta (1-4) linked xylose backbone carrying 56 | May 2017 - Milling and Grain

arabinose residues at the C(O)2 and/or C(O)3 positions of the xylose residues (Figure 1). Ferulic acid or even more complex side chains can also substitute the xylose residues: including (feruloylated) arabinofuranose, xylose, galactose and glucuronic acid.

Enzymatic activities

Polysaccharides can be degraded by hydrolytic enzymes, which are part of a larger group called Carbohydrate Active enZYmes (CAZy). They have been classified into five groups: glycoside hydrolases (GH), glycosyltransferases, polysaccharide lyases, carbohydrate esterases and finally auxiliary activities, according to their functional domains and catalytic modules. They are each involved in the degradation of the different polymers present in the plant cell wall.

Figure 1: Schematic biochemical structure of an arabinoxylan. Each positioning of the arabinose side chains on the xylose backbone induces a specific enzyme activity to breakdown the link.

Figure 2: The synergistic effect of Arabinofuranosidase (ABF) and endo-xylanases. When ABF is added to feed alongside xylanase, the xylanase activity is improved.

F The affinity of xylanases to specific xylan-like substrates and conformations can vary from one group to another, for example GH 10 and 11. Various endoxylanases produced by the fungus Talaromyces versatilis have been identified. They differ in their molecular size and optimum pH; as well as selectivity or affinity to insoluble or soluble substrates.

Improving feed digestibility

The unique combination of naturally compatible enzymes produced by Talaromyces versatilis was exploited to create Rovabio® Advance. It contains many different types of xylanases, ß-glucanases, pectinases and cellulases. This innovative profile of fibrolytic enzymes most importantly contains arabinofuranosidases, essential debranching enzymes, which ensure the optimum degradation of arabinoxylans.

Due to their narrow specificity towards a given bond, distinct enzymes are required for the degradation of arabinoxylans.

While xylanases hydrolyze the xylose backbone, their activity is frequently hampered by the presence of arabinose branches, which prevent access to the central xylose chain. Arabinofuranosidases, also known as debranching enzymes, are able to cleave arabinose from the backbone. Removing the branches greatly helps the xylanases gain access to the xylose backbone.

Synergistic action

To improve the efficacy of Rovabio® Advance an original molecular biotechnology approach has recently been developed.

The basis of the method was not to express one particular arabinoxylan-degrading enzyme but rather to over express a

transcription factor (XlnR). In turn allowing stimulation of a series of GH genes resulting in an improved expression of various new xylanases as well as new arabinofuranosidases.

Of the different endoxylanases from Talaromyces versatilis, Xyn D belongs to the GH 10 while XynB and XynC belong to the GH 11 families. Due to their narrow specificity towards one linkage, different enzymes are required for the degradation of the arabinoxylans. Figure 2 shows the synergistic effect of removing the substitution with the arabinofuranosidases to degrade arabinoxylans as measured by the viscometric method.

When considering any of the single xylanases (Xyn B, C or D), by adding only one arabinofuranosidases (Abf 51a) the xylanase activity is improved.

The Feedase effect

The complexity and variety of anti-nutritional factors in common feedstuffs requires a large range of enzyme activities.

In this way their negative effects are reduced and their nutrient content is more available. To be effective in vivo a wide spectrum of different xylanases are required to function all along the digestive tract, alongside a range of arabinofuranosidases, to efficiently break down cereal cell walls.

Poorly digested feed impairs animal performance and increases feed costs, which lowers profitability. The ability of efficient enzyme solutions to improve the global feed digestibility is known as the Feedase effect. RovabioÒ Advance utilises arabinofuranosidases to enhance the efficacy of xylanases. The result is improved availability of all nutrients in feed, including energy, amino acids and phosphorus.

References available upon request.

Milling and Grain - May 2017 | 57

F

POULTRY: APPLYING A DUTCH APPROACH IN MEXICO

T

by Alex De Kerpel, Agrimex Holanda Representative, Mexico City

he poultry industry is undoubtedly the most dynamic livestock activity in Mexico, accounting for 63.6 percent of it in 2016. At the same time, it accounted for almost a full percentage point of the national GDP (compared with circa 2 percent product contribution from the much boasted automotive industry). The sector generates 220,000 jobs in 18 Mexican states and, with a reported 4.6 percent in 2016; it maintains a steady annual growth actually doubling that of the national GDP (2.3 percent).

Last year the Mexican egg industry registered a 6.2 percent growth rate (32bn pieces), whereas chicken meat registered a 3.1 percent growth (A 6m tonnes combined output of chicken/turkey). Prospects are excellent too, considering Mexico is the leading consumer of egg on a global scale (with a 23kg annual consumption per capita) and one of the most dynamic chicken meat markets (32 kg per capita). Despite its own enormous productive capacities, Mexico remains an importer of egg (24,000 tonnes from the US in 2015), whereas the chicken meat imports (which nowadays equal 13 percent of local production), registered a growth rate of 14.4 percent in the same period (≈481,340 tonnes, mostly inbound from the US and Brazil).

According to the National Poultry Association (UNA), the industry consumes 15.5m tonnes of balanced food, of which 63 percent are fodder grains (corn and sorghum with a combined 9.8m tonnes). Feed actually accounts for 66 percent+ of the poultry products’ related production costs. Mexico’s dependency on imported fodder grains keeps growing. A partial annual estimate figure for yellow corn imports stood at 10,8m tonnes (Oct 2016), of which at least 50 percent correspond to the poultry industry.

The poultry industry (and particularly the egg production) traditionally concentrates in the Bajio region, the Center and Western States of Mexico (76.7 percent of total output in just 10 states). This pattern is now being challenged as the recent outbreaks of HPAI (of which the H7N3 2012 contingency represented a fall exceeding 7 percent of all poultry production) increasingly make companies opt for relocation to the East and Southeastern areas, which are less exposed to the North American southbound migration/ transmission corridors. This trend altogether represents for some companies the opportunity to modernise their existing processes and equipment.

Companies are highly integrated, and a handful of them are responsible for most of the production. At least two of them, which are 100 percent Mexican owned, are leading protein producers, true references on a global scale.

The challenges ahead

The recent years’ experiences with HPAI convinced the Mexican producers and authorities to move towards the creation of a national center for poultry research on which, amongst other topics, more adequate detection/contention measures in case of HPAI outbreaks will be discussed. Closely related to this, the creation of additional compensatory funds to the affected producers is now being studied by the poultry associations themselves (rather than as a result of reinforced policies at government level).

This is of course all positive in itself, as long as the larger picture is kept within sight; the design and implementation of a comprehensive policy on biosecurity including the upgrade of the logistics and transport conditions for the poultry products on a national scale.

In the past few months, the local poultry industry has shown keen interest on Animal Welfare. The producers are very aware of how this subject will become a market trigger in the years to come, and initiatives on the matter have already 58 | May 2017 - Milling and Grain

F been introduced at the Federal Congress towards what might well become a General Law in the near future.

Unsurprisingly, the Mexican poultry industry has attentively followed the events and policy decisions announced North of the border from mid-January this year. The National Poultry Association (UNA) has already stated its intention to remain close to the negotiating team of the Mexican Ministry of Economy all through the upcoming process hopefully leading to a revamped version of the NAFT Agreement which by the way, in its poultry chapter, exclusively concerns trade between Mexico and the US (having Canada opted-out since the original negotiations).

As negotiation rounds could well start before mid-year, Mexico recognises its growing dependency on fodder grain imports, hatching eggs and genetics, and actively searches for alternative suppliers of these items in other regions, starting with Brazil and Argentina in its own hemisphere. This is also the reason behind Mexico’s given priority to the conclusion before the end of this year, of the on-going negotiations towards a new FTA with the European Union, where no agricultural products are in principle excluded, in contrast with the currently operating treaty signed in July 2000.

Consumption-growing trends and the continued low prices of grain and other commodities seem to ensure the ongoing expansion of the Mexican poultry industry for the years to come. On the other hand, the possible adoption by the US administration of increased tariffs or other barriers to agricultural products in the framework of a new bilateral trade regime might probably damage the US producers more than it would their Mexican clients in this sector. In the face of the upcoming challenges, Mexico will at all times reaffirm its staunch commitment to Free Trade.

UPGRADE THE WEIGHT CLASS!

The Dutch integrated chain approach

AgriMex Holanda is a public private partnership uniting expertise of eleven Dutch businesses, governmental institutions and knowledge providers, covering the full chain of the poultry industry, which mid-2014 gathered to define a common strategy towards the described, promising Mexican market.

This Partners for International Business (PIB) project launched by the Netherlands Enterprise Institute (RVO), is rooted in more than 50 years of experience from some of the member companies, which are already well-recognised references on a global scale. The Agrimex Holanda Smart Poultry approach offers solutions to international producers including (comprising) incubators, hatchery automation, climate control, multi-tiered group housing systems, egg transportation and handling, lighting technologies, meat processing line equipment, waste water treatment, containerised pelleting lines, bulk feed transportation trailers, feed additives and manure treatment technologies.

The partnership equally comprises a world-renowned institution on quality management systems addressing food safety issues and the animal feed industry. Likewise, Agrimex Holanda counts within its ranks an international training centre specialised in poultry, pig and feed production, offering custom made trainings and consultancy in a real-life business context.

The partnership operates from its office located in Mexico City (in the premises of the Embassy of the Netherlands), while the general coordination takes place near Barneveld, the capital of the poultry industry in the Netherlands. For the past two years, the group has attended the most prominent congresses and tradeshows of the industry in Mexico and Latin America, not to mention our attendance at the 2016

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F and 2017 editions of the IPPE tradeshow in Atlanta, USA, where we presented a booth acting as a counter from which to direct visitors toward our nine present members’ own spaces (networking hub).

A relevant item in our annual program concerns the animal production roadshow, organised around selected States, which has allowed us to visit and introduce our members to globally recognized Mexican poultry producers, always at General Director level, who normally will receive our members surrounded by a team of production and logistics managers. Agrimex Holanda takes care of the preliminary work, introductions and the timing of the meetings.

It is of course up to the member company’s reps themselves to then make the most of While AMH attends the most relevant breeding their assigned slot. In industry events in Mexico, our members will meet in most others, in the Americas and many cases, individual worldwide invitations/meetings follow the general session.

Whilst member companies primarily focus on the sales work and turnover, the partnership has the explicit objective of promoting the Holland brand as a whole. G-to-G, and knowledge initiatives have taken place under the PIB umbrella. In this context, it is worth mentioning the participation of Dutch experts, only European representatives,

as the key speakers at the roundtables characterising the 2015 and 2016 annual congresses by the Unión Nacional de Avicultores (Mexican Poultry Association), an event that gathers the top directives of the industry. The Mexican producers and sector specialists attentively followed the Dutch experiences in fields such as detection and measures adopted in the case of Avian Influenza outbreaks, or lately, Animal Welfare. In some cases, our guest speaker afterwards presented a more extended conference at the Veterinary faculty of the National University of Mexico.

These cooperation initiatives along with the Holland branding strategy, all tend to consolidate the presence of the poultry expertise of the Netherlands in Mexico and the region for many years to come. Since the support of the Dutch government to a PIB project has a life span of three years, Agrimex Holanda already plans a memorable closure at the upcoming Congreso Latinoamericano de Avicultura, hemispheric tradeshow that is to take place in Guadalajara, Mexico, September 26-29, 2017.

In view of the good results obtained but especially the excellent perspectives open for the Mexican poultry sector, many of our members have already signaled their intention to continue common action afterwards. A new, reconfigured partnership might very likely then take shape.

References

UNA Compendio de Indicadores Económicos 2016 Congreso UNA, Huatulco, Nov. 2016 Grupo Reforma “ Piden avicultores cautela en TLCAN”, 31/1/17 El Economista, notas de Carlos Rubio Bezies, Panorama Agroalimentario. Avicultura 2016, BdM/FIRA, 28p.

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WHY IT MAKES SENSE

USING PHYTOGENIC FEED ADDITIVES IN GROWER-FINISHER PIGS

P

by Ester Vinyeta, Species Leader Swine, and Kostas Syriopoulos, CTS Swine, Delacon Biotechnik GmbH, Austria

hytogenic feed additives (PFAs) comprise a wide range of plants like herbs, spices, and other plant-derived products such as essential oils and oleoresins (Windisch et al., 2008).

Although this kind of feed additive has been known for a long time, its use is not yet as common as feed enzymes or pre- and probiotics. A recent survey on the usage of PFAs published in Sciences & Solutions, Phytogenics (2017) indicates that from a total of 1140 responders (36% poultry producers, nine percent swine producers, 14 percent feed milll operations, 29 percent consultants and 13 percent other), 51 percent are currently using phytogenic feed additives in their feeding programs, being slightly higher in EU (57%) compared to other regions.

Based on the survey, PFAs would be applied in five percent of total worldwide livestock feed tonnage per year. Among several reasons for using PFAs, the main ones are digestibility enhancement, antimicrobial effects linked to AGP replacement strategies, improved FCR and higher feed intake.

Digestibility enhancement, citing the survey means more complete use of feed, resulting in improved feed efficiency and lower emissions that accompany a reduced environmental footprint“. This, in turn, is linked to a growth promoting effect and improved FCR. Furthermore, the survey summarises the main benefits that customers value in PFAs, which were (in decreasing order):

1: Enhanced feed efficiency/better FCR 2: Reduced medicinal costs 3: Enhanced growth (carcass yield) 4: Enhanced reproductive performance 5: Better uniformity

6: Increased feed intake 7: Better meat quality 8: Nutrient-sparing effect 9: Emissions reduction (e.g. ammonia)

Focusing on the phase of growing-finishing pigs (20-115kg BW), which represents 60-70 percent of total cost of pig production, the main reasons why customers might use PFAs and most desired benefits are a digestibility enhancement and an improved FCR (and better meat quality), alongside with simultaneously reduced medicinal costs. A reduction of emissions is definitely a strong reason in some regions due to environmental concerns. Although the latter arguments have been important in the EU and US for quite some time, it is becoming increasingly important in Latin America as well as North and South East Asia. Finally, production costs and ROI are always in the spotlight.

Effects of Fresta® F as Delacon’s zootechnical additive for piglets with proven effects on performance and piglet homogeneity are not dealt with in this article.

Aromex® ME and Aromex® Pro are phytogenic feed additives, fully using synergistic effects of plant-derived active substances. They feature a carefully selected composition of phytogenic active substances, like essential oils and other plant extracts, perfectly aligned to the needs of growing-finishing pigs. They consist of a blend of microencapsulated essential oils.

Delacon added a unique blend of saponins to reduce ammonia and odour emissions accompanying the digestibility enhancement. Moreover, these saponins were shown to increase nutrient transporters on the enterocytes, further improving nutrient digestibility.

To realise the full growth potential of fattening pigs, they need optimal nutrient supply adjusted to their respective phase of life. The combination of active ingredients in Aromex® (ME and Pro) achieves slower passage rates of digesta 62 | May 2017 - Milling and Grain

F without negative effects on feed intake. In combination with a higher nutrient uptake as well as an enhanced utilisation and retention of dietary energy and protein supplies, this will lead to an increased animal growth, and thus, to a higher profitability. Furthermore, the additives enhance stress tolerance due to the high antioxidant power of the used plant ingredients.

Moreover, Aromex® Pro contributes to an inhibition of ammonia formation, which arises in the course of pig fattening.

Increased digestibility results in enhanced feed efficiency Many aromatic plants, spices and essential oils are shown to be potent to stimulate digestive secretions (saliva, mucus), pancreatic enzymes production and bile secretion in the intestinal tract, being beneficial to the animal (Franz et al 2010, Platel and Srinavasan, 2004 and Van der Klis & Vinyeta, 2014).

As a result of increased digestive secretions and enzyme production, together with a healthier gut mucosa, nutrients are better digested and absorbed and several studies (Maenner et al, 2011; Li et al., 2012; Ahmed, 2013) have reported an increased ileal and fecal digestibility of dry matter and crude protein due to a supply of phytogenic feed additives.

The effects of essential oils, herbs and spices on improved performance in pigs were quantified by Franz et al. (2010) based on 26 piglet trials, showing 2.5 percent improved body weight gain (ranging from -5% to +9%) and three percent improved feed conversion ratio (ranging from +4% to -10%), whereas feed intake was not affected (ranging from -9% to +5%, average +0.5%).

This results in an improved performance index and an increased nutrient utilisation (higher body weight gain at a similar feed intake in piglets). The same authors described that the primary mode of action of growth promoting feed additives is the beneficial effects on the ecosystem of gastrointestinal microflora by controlling potential

pathogens. Hence, animals are less exposed to microbial toxins or other undesired metabolites, e.g. ammonia and biogenic amines, and therefore the pigs will benefit by an improved intestinal health. This latter effect has positive impact on pig uniformity.

In an experiment conducted by Freie Universität Berlin, the effects of Aromex® Pro (100ppm) were evaluated on nutrient digestibility and performance in 25-50kg BW pigs. The supplementation of pig diets with PFA improved apparent ileal digestibility of crude protein and amino acids > 3.0% (Figure 1). Moreover, Figure 2 demonstrates that supplementation increases production performance (daily weight gain: 5.2%, P=0.004; feed conversion ratio: 3.6%, P<0.001) as well as faeces consistency (data not shown).

When looking more closely, the data of body weight at the end of a trial at Delacon’s Performing Nature Research Center (42 days trial period; castrated males and females pigs: average BW 30-80 kg at start and end of trial period, respectively; 12 replicates per treatment; 3 pigs/replicate), it was clear that not only body weight gain was improved. Data presented in Figure 3 clearly show that pig body weight distribution was improved by Aromex® Pro treatment

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www.norwoodandco.com Milling and Grain - May 2017 | 63

10/02/2015 17:30

F compared to Control treatment.

Although it is a difficult parameter to confirm in field trials, because it’s almost impossible to weigh pigs individually at commercial farms, it is definitely a parameter to consider as homogeneity has a big influence on farm management costs. Moreover, the aforementioned survey (Sciences & Solutions, Phytogenics, 2017) indicated uniformity as one of the main benefits of PFA that customers value most.

Dietary supplementation of essential oils shows antioxidant and anti-inflammatory activities as described for essential oils in recent reviews (e.g. Saleh (2010), Brenes and Roura, 2010; Miguel, 2010; De Cassiada Silveira, 2013, Zeng 2014). Cai et al. (2004) showed a clear relationship between radical scavenging capacity and the phenolic nature of essential oils. In Saleh (2010), from a total of 248 essential oils belonging to 18 botanical families of medicinal, herbal and wild flora, only 7 percent were found to have high antioxidant and radical (reactive oxygen species (ROS) and reactive nitrogen species (RNS)) scavenging activities, being related to components like oxygenated monoterpenoids, monoterpens hydrocarbons and monoterpene phenols.

In addition, essential oils have indirect antioxidant activity by upregulating the intracellular production of antioxidant enzymes, like SOD and GSH-Px (Franz et al., 2010), for both phenolic (like oregano and thyme oil) and non-phenolic essential oils (like turmeric and rosemary oil).

According to Mueller et al (2012), phytogenic feed additives upregulate the antioxidant system of piglets either by direct or by indirect antioxidant effects and they may thereby improve animals’ health status. Among the labiatae oils, oregano oil has a high direct antioxidant potential, whereas rosemary potently induces antioxidant enzymes.

Aromex® ME and Pro, thanks to its unique blend of essential oils, has a high antioxidant power, as shown in a piglet trial performed in Nanjing Agricultural University (China), shown in Figure 4.

Antioxidant effects have positive consequences in animal health and final product quality: they may improve the dietary nutrient value and lead to a better oxidative stability and longer shelf life of fat, meat and eggs (Franz et al 2010).

Reduced ammonia emission

Ammonia is one of the main emission gases from livestock production. It negatively affects the environment, human and animal health by damaging respiratory epithelium, making the animal more susceptible to infections. Moreover, ammonia enters into the blood and requires detoxification. The reduction of ammonia emission in Aromex® Pro is achieved by: • Nutritional effects: increased protein digestibility, resulting in less protein available at large intestine and better protein utilization (improved N balance) • Saponin effects: Inhibition of ammonia formation, reducing activity of proteolytic bacteria at large intestine, ammonia binding and inhibition of urease activity.

As an average, supplementing pig diets with 100ppm Aromex® Pro, ammonia emission is reduced by 20-25 percent depending on BW range of growing-finishing pigs (Table 1) and ventilation rate as key variables at optimal crude protein content in the diet.

Figure 1.

Aromex® Pro improves ileal digestibility of crude protein and amino acids in pigs

Figure 2: Aromex® Pro improves production performance in growing finishing pigs, summary of 7 trails.

Figure 3.

Aromex® Pro improves pig’s body weight distribution

Figure 4.

Aromex® increase anti-oxidant enzymes and decrease lipid peroxidation in piglets

Table 1: Effect of Aromex® Pro on ammonia emission in growing finishing pigs, as measured in three experiments that were conducted in climate chambers at Delacon’s Performing Nature Research Center.

64 | May 2017 - Milling and Grain

Trial 2

Trail 3

47-62

115-130

12.9 MJ ME/ kg, 15.5% CP, 9.6 g d.lys/kg

13.8 MJ ME/ kg, 17.8% CP, 11 g d.lys/kg

13.7 MJ ME/ kg, 16% CP, 6.6 g d.lys/kg

Length of period of NH3 measurments, days

72

14

14

Reduction in Arommex PRO vs control diet

24%

25%

20%

Diet1

Costs and Return of Investment

The economic benefits when improving FCR by 2.5 percent (from 2.57 down to 2.50) in growing-finishing pigs (BW 20-107kg), using average feed costs of 254 €/MT, and assuming 4 percent mortality and medication costs 2€/pig (commercial data from SIP Consultors, 3tres3.com, Mar 31, 2017), the margin per sow/year increases by 36€. This represents 4.60€ benefit per MT of growing-finishing feed.

When to this improvement of 2.5% FCR, a reduction of mortality (1%) is also applied (from 4 to 3%) and reduced medications costs (from 2 to 1€/pig) -as average improvements of Aromex® Pro compared to a control diet- the margin per sow/year increases up to

Trial 1 45-115

BW range pigs, kg

All diets were based on wheat, barley and soybean meal as major feedstuffs, and based on the ideal amino acid profile

1

64€ and the benefit per MT of feed is up to 9.2€. ROI may range from 2.5 up to 4.5 depending on the feedstuffs costs.

With Aromex® ME and Pro, Delacon is ready to bring the benefits that customers expect from a phytogenic feed additive in profitable and sustainable pig production.

F

NIR analysis to reduce feeding costs

N

by Dr Sophie Parker-Norman, Global Technical Manager, AB Vista

utrition continues to be one of the most critical factors of animal production, with feed costs accounting for up to 80 percent of the total variable costs.

Least-cost feed formulation software allows nutritionists to construct a diet that meets the requirements of the animal and considers feed ingredient cost and nutrient content.

However, there is considerable variation of nutritional quality within an ingredient due to several factors including cultivar, soil quality and growing, harvesting and post-harvesting conditions. The extent of this variability and its potential economic impact is a challenge for feed manufacturers and producers.

Traditional analysis methods are costly and time consuming

The cost of wet chemistry analysis is prohibitive to large numbers of samples and as such it may not address the question of ingredient variability. Variability of nutritional quality of raw materials presents a risk of under or over estimating nutrients, leading to economic losses and/or poor animal performance. In addition to the cost of wet chemistry there is an average 1-2 week turnaround time to receive results after ingredient submission.

Published references (NRC or Feedstuffs ingredient analysis table) are another resource nutritionist used to assign ingredient nutrient values. However, published references only present an average nutrient value and do not provide knowledge of ingredient variability, compositional differences between batches or changes over time.

New developments in NIR technology

With increased focus on ingredient knowledge and quality control, near infrared reflectance (NIR) manufacturers and software developers have introduced new products into the market that are able to help the modern day nutritionist better understand feed ingredient quality and variability. NIR uses near infrared reflectance to obtain a chemical profile of an ingredient sample and thus predict parameters such as moisture, starch, protein and fat. However it is also possible to build NIR calibrations beyond the usual proximate analysis to include analysis of reactive lysine, in vivo energy values and phytic-P. Such analysis has the potential to bring cost savings through formulation, supplier selection and ultimately animal performance. Hardware advances such as portable NIR devices can be used on-farm or in the feed mill, allowing greater flexibility, and software developments have allowed web-enabled analyses and programs that transfer NIR data directly into feed formulation software.

66 | May 2017 - Milling and Grain

Measuring phytate levels to maximise phytase use

Phytate varies within raw materials and if this is not accounted for in formulation it has the potential to lead to variable phytate content of complete feeds. In Figure 1, it is clear that some raw materials are more variable than others, particularly those that we know to be inherently variable such as bakery meal. NIR technology can analyse phytate content, giving the nutritionist values for formulation and confidence that there is enough substrate for a phytase enzyme to act on in the complete feed.

NIR can be used as a tool to check the potential substrate for phytase in complete feeds, as demonstrated in figure 2. The presence of higher levels of phytate in broiler feeds means there is greater opportunity to make the phosphate in this phytate available by use of higher doses of efficient phytases.

Corn variability analysis

Advances in NIR technology can be used to predict the AME of cereals, including corn, which has been shown to vary by as much as 360 kcal/kg. NIR can help nutritionists better understand their corn variation, to optimize diet formulation and monitor incoming corn from suppliers. As shown in Figure 3, this technology can help track changes in nutritional value, for example in corn used in different countries. It also enables analysis results to be generated rapidly, allowing formulations to be adjusted in real-time to account for corn quality variation.

Thereby delivering improved accuracy of formulation, greater consistency of nutrient supply and potentially substantial cost savings by reducing the need to â&#x20AC;&#x2DC;over specifyâ&#x20AC;&#x2122; diets.

The data in Figure 3 is broken down by country, using a box and whisker plot to show the full extent of the predicted AME variation. It highlights the extent of variation experienced in some countries and the differences between countries.

Potential for cost-savings

The potential for economic improvement comes when the total AME variability is large, such as in Argentina, where the range was found to be up to 400 kcal/kg. In those countries that are not corn producers, such as Indonesia, the variation could be representative of importing from different countries and is particularly interesting to not only the nutritionist but the raw materials buyer as well. Yet it is also important to recognise that even the 50-100 kcal/kg differences measured in countries such as Bolivia still represent considerable potential wins if effectively accounted for during diet formulation.

The reduced cost, quicker turnaround time and ease of use with NIR allow much more frequent analysis of cereal quality leading to greater strength in the numbers from which cost saving decisions can be made.

F

Figure 1: Variability of Phytic P levels in raw materials (n>78000).

Source: AB Vista

3000S In Line Analyser

Figure 2: Variability in Phytic P in broiler complete feeds (n>11500).

Source: AB Vista

   

Figure 3: Figure 2 – Box and whisker plot showing the large variation of poultry AME content in over 43,000 global corn samples (88%DM, kcal/kg). The narrow grey bar shows the full extent of variability (excluding outliers), the wide grey box the range for the 50% of samples closest to the median and the white line indicates the median. Source: AB Vista, 2017, n=43,412

Lysine content

Heat damage during processing of protein meals can also affect the precision and cost effectiveness of diet formulation. As lysine is heat-processed, it loses its nutritional value through the formation of Maillard products. Reactive lysine can be measured

by NIR as an indicator of heat damage; with reactive lysine content being reduced with over-processing. Whilst it is not currently possible to formulate to reactive lysine requirements, it is certainly a tool that could be used for supplier selection.

Making NIR easily accessible

NIR technology can be used to determine the nutrient content of feedstuffs and feeds in a cost effective and timely manner. Latest software and hardware developments can help nutritionists better understand their feed ingredients.

Emerging technologies such as centrally maintained on-line calibrations, pay-as-you-use calibrations; portable NIR and affordable in-line NIR installations are making NIR technology more accessible across the entire feed industry. The subsequent expansion in the number of NIR-analysed results available for industry-wide interpretation brings additional potential benefits, as the main trends in feedstuff variability become both clearer and more accurate.

Continuously monitor grain Protein, Oil and Moisture data Blending and outloading Ideal for: Flour Mills Stockfeed Manufacturers On Farm Storage Bulk Handlers Grain Containerisation

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www.nextinstruments.net sales@nextinstruments.net Milling and Grain - May 2017 | 67

F

Grain quality control and mycotoxins

G

ACCURATE, REPEATABLE AND TRUSTED RESULTS WITH BIOCHIP ARRAY TECHNOLOGY

rain quality is of the utmost importance, and if it’s not something you’ve been paying close attention to then you could be putting your supply chain and reputation at risk. Grains and seeds are highly volatile, and their quality can be influenced by a number of key factors, such as the environment, weather conditions and propagation techniques.

Not only this, but grains are also susceptible to moulds during cultivation and storage which can pose as a great risk to quality.

Mycotoxin development

For readers who may not know much about mycotoxins, they are a group of naturally occurring toxins produced by certain fungi, commonly known as moulds, which are harmful to humans, domestic animals and livestock. They can develop on grain and seeds during cultivation (Fusarium species) and some types can remain in the soil around infected grains. However, it should be noted that they could also develop during storage (Penicillium species) especially when levels of moisture are heightened.

They can be found in a wide range of foods and feeds, particularly in areas with climates of high temperature and humidity. Mycotoxins can then enter the food or feed chain through contaminated crops, in particular via cereals, but also nuts, beans, spices, dried fruit, oil seeds, coffee and cocoa, poultry meat and kidneys, pig kidneys and pork sausages.

Contamination may also occur post-harvest during storage, transport, and processing stages of the food or feed supply chain.

Mycotoxin prevalence and effects

The prevalence of mycotoxins varies significantly across the globe, yet they can be classified into six main groups – aflatoxins, trichothecenes, fumonisins, zearalenone, ochratoxin and ergot alkaloids. Each of these different groups has different physiological effects on human and animal health. Typically, they have an immunosuppressant effect, which can lead to a reduced ability to fight disease and infection, but they can also have multiple other side effects. Mycotoxins range in their level

Figure 1: Biochip Carrier and Discrete Test

68 | May 2017 - Milling and Grain

Figure 2: Evidence Investigator

of toxicity and can affect humans and animals in different ways depending on the level of exposure and age of the individual. Many can be carcinogenic, so their prevention is of key importance to grain producers.

Grain storage has a direct impact upon frequency. Poor storage conditions or fluctuations in temperature/humidity can increase the risks of mycotoxins developing. Often termed as the ‘invisible enemy’ as in many cases they are not easy to identify with the exception of Ergot Alkaloids, which alters the structure of the grains. As a result, quality control of grains needs to be completed within a laboratory setting and highlights the importance of frequent grain screening, as not all are visible to the naked eye.

Recent research has shown that co-occurrence is becoming more prevalent, meaning that multiple mycotoxins can infect a single grain or batch. Co-occurrence poses as an additional threat to feed and food producers as they can have a negative synergistic effect on human and animal health. This surge in the co-occurrence of mycotoxins within grains means there has never been a more important time to begin multi-mycotoxin screening, ensuring that grains are not being wrongly approved as free from mycotoxins.

Preventative mycotoxin screening

You’ll now be aware that mycotoxins are a growing threat and pose risks to both animal and human health. As noted you can’t always tell if grain will contain them or if they fall in line with global regulations, which means that accurate multi-mycotoxin screening is paramount in ensuring that your grain is safe. Even with excellent management, low levels may still exist in grains.

Having the right technology is key to ensure that they’re detected quickly and adequately monitored.

Randox Food Diagnostics have been transforming the landscape of conventional mycotoxin screening by developing and manufacturing high quality, reliable screening solutions for the global feed and food industries. Randox Food offers a unique solution to provide multiple results from a single sample. Our patented Biochip Array Technology (BAT) offers users the ability to run one test, which provides quantifiable results for up to 10 compounds from a single sample. This novel product reduces the

Figure 3: MycoFlex Array

F labour requirements associated with traditional ELISA screening and provides accurate, repeatable and trusted results to help reduce affected grain entering the supply chain.

Biochip Array Technology from Randox Food

Based upon a competitive immunoassay format, similar to that of traditional ELISA technology, each Biochip is arrayed with up to 10 assays, which are called discrete test regions (see figure 1). Each 9mm2 Biochip’s direct test regions are pre-coated with generic antibodies, which can detect multiple compounds, including metabolites of the drug family.

Regions

Once the prepared sample is applied to the biochip, reagents and conjugates are then added which allow the sample to bind with the antibodies if there are mycotoxins present within the sample. Next, Luminol and Peroxide are added which begins the chemiluminescent reaction and the biochip carrier is placed into the Evidence Investigator where the results are read and quantified by the analyser.

Grain screening solutions with the evidence investigator

The Evidence Investigator provides simultaneous analysis of up to 10 mycotoxins from a single, undivided sample. Consolidated testing allows a high throughput with 45 samples being screened and quantified in 2hrs 30mins. The Evidence Investigator is a semi-automated bench top analyser that is used with Biochip Array Technology to detect and quantify mycotoxins and drug residues within feed samples. The analyser comes as a complete package including computer, barcode scanner, thermoshaker and comprehensive training.

The MycoFlex Array

The MycoFlex array from Randox Food offers the simultaneous screening for up to 10 of the world’s most prevalent mycotoxins from a single sample. This customisable Biochip allows the user to predefine the mycotoxins they need to screen for, offering a tailored, flexible solution for mycotoxin analysis.

All of the mycotoxin arrays from Randox Food are validated across a range of matrices including maize, wheat, rye, soya and finished animal feeds such as TMR and haylage. We have a full range of mycotoxin arrays including three, five, seven and 10 offering users total flexibility to suit their screening needs.

About Randox Food Diagnostics

With over 30 years’ experience in the diagnostic market, Randox Food Diagnostics continue to transform the landscape of conventional drug residue screening and wine analysis, by developing revolutionary high quality products to improving the global food safety chain. Our versatile range of kits includes an extensive list of drug residue ELISAs and biochip arrays, as well as our dedicated enzymatic kits for the wine and beverage markets.

Within Randox Food Diagnostics we offer remarkable tools for the screening of antimicrobials, growth promoting hormones and drugs of abuse in animals and produce. Offering superb limits of detections and simple sample preparations, Randox Food Diagnostics has an extensive and expanding range consisting of 38 ELISA’s and 16 multiplex screening platforms.

Our comprehensive range and trusted screening solutions are intertwined with continually improving the standards of global food safety.

Milling and Grain - May 2017 | 69

F

Feeder Mixer Conditioner

Expander

EXPANDER TECHNOLOGY

Pelletmill

“An absolute addition to a modern feed mill” Counterflow cooler

by Almex, Triott Group

The global growing demand for high quality feeds made of a wide range of available raw materials is to the advantage of the expander

S

everal scientific studies and proven results at clients such as UFA, Deuka, Fanon, Agravis, Vitelia, Mironovsky and others show that expander technology is an absolute addition to a modern feed mill as a tool to fulfill the wide range of needs at clients to supply different feedstuffs for the different life stages of animals. Besides traditional meal and pellets, farmers ask for crumbled feed, expanded pelleted feeds and mono-components that have been treated with expander technology for example for use in TMR feeding.

In the fields of nutritional value, digestibility and feed utilization interesting results have been achieved with expander technology in feed for high yielding dairy cattle, broiler and pigfeed. (Table 1) A recent trial at the well-known UFA-Bühl research farm showed interesting results in daily gain in advantage to expanded feed compared to traditional meal.

One such company who provide this kind of technology is “Almex”. Almex has been a leading supplier of expanding technology since the early 1970’s. Since 2014 they have been a part of the Triott group, and as such, can now supply complete pelleting lines including automation.

The designs of the distinguished Almex Expanders are considered reliable and notably robust. These are just a few of the many unique selling points of the product, such as the Active Disc System and the lower energy costs.

The lower energy costs can be explained by the power input for the expander, depending on the type of feed. In general this power input is between 8-15 kW per ton. For special applications such as by-pass protected protein energy input can even be up to 20-30 kW per ton. This is important at these applications, as is that the counter flow cooler is oversized to ensure the proper cooling of these types of products.

The Almex expander is equipped with the unique Active Disc system in order to control the product output and to

70 | May 2017 - Milling and Grain

Table 1: An overview of specific energy consumption and temperature Source: Extruders and Expanders in Pet Food, Aquatic and Livestock Feeds

by Mr. Mian N. Riaz

Layer feed

Property

°C Conditioner

°C Expander

kWh/t Expander

kWh/t Pellet Mill

Not pelleted

75

95

8-10

-

Broiler fattening feed

Rich in fat

75-80

100-105

12-15

2-3

Broiler starter feed

Low in fat, structurized

80-85

100-105

10

-

Piglet starter feed

With milk powder

60

80

8

2

Pig fattening feed

Expandat structure

80 - 85

100 - 105

8 - 10

-

Pig fattening feed

Pellets

80 - 85

100 - 105

10

2-3

Cattle feed

Rich in crude fibers

75 - 80

105 - 110

15

2-3

Dairy cattle feed

By-pass protein pellets

80 + steam in expander

130

15 - 18

2-3

130 - 140

15 - 18

-

120 - 130

20 - 30

-

130

15 - 25

-

By-pass Dairy cattle protein 80 + steam feed expander for in expander TMR Starch modification

>60%

80 - 90

By-pass UDP 80 + steam protein soya/ increase in expander rape meal

Table 2: Range of Almex Expanders Type

Main motor (Kw)

Motor slide adjustment (Kw)

Expander barrel diameter (mm)

Capacity (ton/hour)

AL150

45-75

0,55

150

1-6

AL200

75-132

0,55

200

5 - 10

AL300

132-315

0,75

300

10 - 30

AL350

315

0,75

350

30 - 45

F Various applications of expander technology

Standard expander

Expander with optional cutterhead

Active disc system

Dieplate with cutterhead

13 - 20 moisture 90 to 135ºC

12 - 22% moisture 100 to 145ºC

Pelletmill and cooler

Cooler and crumbler

Oversized cooler

Expanded pelleted feed

Feed in form of expanded crumbled feed

Special products such as by-pass protected proteine Starch modification Special feed pellets

Flow 1: Expanders for different applications in the compound feed production

Figure 2: Active Disc System Almex Expander Design: mixing pins, screw segments, AD Active Disc (slide) outlet, crusher (shear and pressure)

Expander Pelleting line equipped with Feeder, Conditioner and Counterflow cooler taken at Feed Design Lab

assure the quality of the product. The slide of the Active Disc enables introduction of shear forces and frictional heat into the product. This enables the expander to eliminate heat sensitive bacteria (salmonella). The AD system is designed together with Feedmill operators, as users they are happy with the performance and easy access to the system for maintenance and exchange of wear parts.

The expander can be used for the production of expanded crumbs in combination with a crumbler. Or in a feedline with or without a pellet mill or with a by-pass in the production line (Flow 1.) In cases where retention time is required, an expander can be used in combination with a RTB (Retention-Time-Barrel).

To summarise, difficult raw materials that in the past only could be handled by double pelleting can now be processed easily by means of an expander. Higher fats and liquid inclusions are possible. The die of the pellet mill can be thinner and in general less wear costs arise at the pellet mill in combination with expander.

Containerised Mills outputs 1 - 45 ton/h

» All components reliable and tested » Assembled and checked in factory before dispatch » Container sized support frame included » All electric components included » Low freight costs and easy handling

Modular solutions for: › Compound feed production › Pet food › Aqua feed › Cereal processing plants › Soybean processing › Premix / concentrates plants Type: C30-15-15

www.ottevanger.com Milling and Grain - May 2017 | 71

A Triott Company

» Saving on civil & building cost » Minimum installation time on site » Proved concept with many outstanding references

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POWER SAVING

M

How to reduce power consumption in an animal feed plant by more than half Since 2011, UFA’s Sursee poultry feed mill built in 1965 has been one of only a few unmanned feed mills in the world. The mill runs from 9pm until 5am without any operating personnel

72 | May 2017 - Milling and Grain

echanical engineer Peter Hofer is a member of management and responsible for the entire production of UFA, the Swiss agricultural company specialising in animal feed.

Using power as efficiently as possible for UFA’s large production volume is important for him and the company – for reasons of cost and for the sake of principle.

He stresses, “You can do a lot to use energy efficiently if you analyze the processes accurately.”

Working with the Bühler Technology Group, UFA has been particularly successful in optimising processes at its Sursee feed mill. The energy savings mean the investment pays for itself in just a few years.

Until the beginning of 2015, an aspiration ventilator was installed with a conventional 75kW induction motor. This ventilator dehumidifies and cools the steamed, pelleted feed before it is packed. For this, it draws the air through the material to be dried from the 10th floor of the production tower. The ventilation was controlled simply via a flap with the motor directly coupled to the power grid and always operating at fixed speed.

This ventilation system, which was state of the art when it was installed in the 1980s, needed to be replaced. “I read a technical article about a ventilation system at

F

University Hospital in Zürich where, during a renovation, a new, highly efficient synchronous reluctance motor from ABB with a variable speed drive was used. I was impressed by the figures that showed how much less energy it used,” remembers Hofer.

Precise motor design saves space and costs

Peter Hofer sat down with experts from Bühler to explore the potential efficiency improvements that renovating the

ventilation system with an ABB drive package could bring.

Together, they first thoroughly inspected the process and measured the power of the motor. The new plant was finally precisely designed along with specialists from ABB and Bühler.

50 percent power saving

A 37-kilowatt (kW) ABB synchronous reluctance motor

There is strength in numbers.

Perhaps the only thing more reassuring than having the extrusion leader work on your behalf is having their dedicated subsidiaries work for you, as well.

Anchored by Wenger and their nearly 80 years of process experience, the Wenger Group includes Corporate Project Services – specialists in complete project planning and food safety requirements; and Source Technology – innovators of inline sampling and analysis equipment, fully integrated with Wenger’s automation for total system communication.

Rally the power of three to address the entire scope of your extrusion-based project. You’ll experience the dedication, ingenuity and responsiveness of the one and only Wenger Group.

corporateprojectservices.com

Wenger14.Wx3-210x147.indd 1

sourcetechnology.dk

wenger.com

Milling and Grain - May 2017 | 73

12/18/14 6:11 PM

F was installed for the drive of the new aspiration ventilator, controlled by an ABB ACS880 variable speed drive.

The commissioning was carried out together with an ABB engineer and a Bühler process expert in April 2015. The ventilation system has proven itself completely. It runs five to six days a week around the clock, all year round. The results are convincing. On average, the motor draws an electrical output of 14 kW from the converter. “That pays off!” emphasises Peter Hofer. “We save around 50 percent power compared to the previous system. It’s around 300 megawatthours in this system. At approximately 120 Swiss francs ($118) per megawatt hour for industrial electricity, that makes 36,000 Swiss francs ($35,400) a year.

The drive package pays for itself quickly. And the reduced CO2 emissions are also considerable.” Additional positive side effects, such as a reduced need for cooling in the control cabinet, reduced space requirements, and savings due to the smaller size of the motor, have not yet been considered in this analysis.

Synchronous reluctance motors - a trendsetter for power efficiency

Synchronous reluctance motors are equipped with a rotor consisting of packets of geometrically optimised oriented electrical sheets. As a result there are almost no losses in the rotor. For example, compared to a 75kW induction motor, total losses measured in a synchronous reluctance motor of same capacity are 3kW instead of 4.8kW. This reduction in losses by more than a third brings the overall efficiency of 94.0 percent up to 96.2 percent, which corresponds to the highest efficiency class, IE4. In addition, the motor heats up less, which prolongs the life of the insulation and extends the lubrication intervals.

Synchronous reluctance motors have already been retrofitted in the UFA plant in St. Margrethen and two more are installed in the Herzogenbuchsee plant.

ABB is a pioneering technology leader that works closely with utility, industry, transport and infrastructure customers in roughly 100 countries. Continuing more than a 125-year history of innovation, ABB today is writing the future of industrial digitalisation and driving the Energy and Fourth Industrial Revolutions.

ABB’s Robotics and Motion division provides products, solutions and related services that increase industrial productivity and energy efficiency. These include motors, generators, drives and robotics that provide power, motion and control for a wide range of automation applications in the food and beverage industry.

Electric motors consume around 28 percent of the world’s energy, making them a clear target for energy improvement measures. Traditionally, motor speeds are controlled by mechanical techniques such as throttling the output of a pump to achieve the desired flow rate. However, this can lead to significant loss of energy as the motor continues to operate at full speed.

Adopting variable speed drives (VSDs) will not only optimise the operation of pumps and fans, they also achieve energy savings in conveyor systems that transport solid materials and products from one place to another. VSDs regulate the speed and torque of electric motors and even a small drop in motor speed can offer major savings. For example, a 20 percent drop in speed of a pump can reduce consumption by half. And these savings are further enhanced when a VSD is used in combination with a high efficiency motor.

74 | May 2017 - Milling and Grain

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3D Belt feeding system easily removable for cleaning and maintenance operations

What does efficiency really mean?

A

by Imeco, www.imeco.org

s per the main agricultural area, in the heart of the livestock Italian market, and as per its experience, Imeco has had several experiences in dealing with one of the terms often used by a plant manager. That’s the reason we would like to discuss the concept of efficiency with both data and suggestions in this article.

Everybody knows how animal feeds play a leading role in the global food industry, enabling economic production of products of animal origin throughout the whole world. They may be produced in industrial feed mills or in simple on-farm mixers.

These feeds may be called ‘industrial’, ‘formula’, ‘blended’ or ‘compound’ feeds. Feed millers use their knowledge to grow or maintain animals for food, fibre and other products under a wide range of farming conditions and necessities.

Commercial production or sale of manufactured feed products takes place in more than 120 countries and directly employs more than a quarter of a million skilled workers, technicians, managers and professionals. Currently, there are an estimated 8,000 plants for manufactured feed production with capacities greater than 25,000 tonnes per year, along with other production facilities, including premix and specialty plants producing lower volumes of high-value products.

Together, these plants manufacture more than 620 million tonnes of feed products annually (FAO data).

76 | May 2017 - Milling and Grain

The everyday concept

Underneath every aspect, we analyse the feed milling art with the most important word in every process stage being ‘efficiency’. The meaning of this word must be searched in its latin origin efficientia, derived by efficĕre that means “to accomplish” or “to fulfill”. Of course, not in a general and superficial way, but at a deeper level. Using that word or even thinking to have reached it doesn’t mean that we know how to have it. It doesn’t matter if you live and work in a super industrialised area of the world or in a country whose industrial revolution is still happening: efficiency is something that needs to be reached every day, with every batch, in every slot of production. So the question remains, how?

Technology can help us all in becoming more efficient. Besides technology, the Imeco philosophy is to sit next to the client, investigating the best solution tailored to their real necessities and helping to find the correct balance.

In animal husbandry, feed conversion ratio (FCR) or feed conversion rate is a ratio or rate measuring of the efficiency with which the bodies of livestock convert animal feed into the desired output. For dairy cows, for example, the output is milk, whereas in animals raised for meat (such as beef cows, pigs, chickens, and fish) the output is the flesh.

The meaning and scope is exactly the same in order to know if the production plant is efficient. Everybody knows its output, in terms of loaded trucks, bags, liber, kilos or even bushel, but usually the knowledge of the in-load product is roughly calculated in volume or occupied space in the silos.

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Process scales

An approximate knowledge of the in-load product gives an approximate calculation of the efficiency also.

First level of knowledge

This is why Imeco suggests having in-load bulk scales as a first step of measuring in each plant.

The necessities of measuring the incoming raw products clashes sometimes with the other necessities that rise up in in these operations, often done during the nighttime when all the trucks want to discharge their loads in the shortest possible time.

Imeco in-load scales have been engineered whilst taking this into consideration. The CSE/p scales model finds their main application in dry bulk ports where speed and precision are strongly required, that’s why they find their perfect application also in every (feed) mill plant. The CSEp concept allows a nonstop flow of the incoming products to be weighed.

Thanks to a dual weighing hopper fed by a diverter, the product

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flows continuously passing from a hopper to the other without being stopped for a total batch acquisition, and doing this operations adding the single container batch to the following and so on. Each container is suspended on three load cells, which due to their position, reads the entire amount of weight with high accuracy and reliability.

The twin hopper design also brings a constant flow of product with smaller batches and in almost double the speed compared to classic design scales. All of this leads to lower running costs because it has a mixed mechanical and pneumatic movement rather than just a pneumatic one with a huge air consumption.

Moreover, receiving raw materials like bran and rice husk to classic design scales brings big problems such as “product bridges” because product flow-rate is very low and the weighing process needs to stop the product to acquire the batch.

Similarly, in a warehouse, in order to avoid forced operations in transferring the product from one silo to another, it is crucial that

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F management and internal transfers have the correct information on the amount of product at the inside. We all know that it happens and it happens because operators do not acquire the amount of the present product constantly. This can be avoided with an in-load bulk scale that does this job for you. It measures, calculates, and sends the data to your control room through many different languages that are available on the market today: Modbus, RS-485, Profibus DP or analog communication interfaces.

This concept can be considered mandatory in other phases of the production process and the engineering technology applied turns out to be ideal in these cases and it is called process flow monitoring. After all, accurate weighing processes help to address some of the most demanding challenges of the feed industry increasing animal health, productivity, and competitiveness.

Litmus landmark

By the intake accounting process, we can jump directly to the end of the production process and highlight Imeco’s bagging technology.

Besides the amazing performances in terms of accuracy and speed of production, Imeco would like to shed light upon its reliability for an industry where cleanliness is just a utopia.

Anybody who has visited a feed mill can attest to the visible dust on the equipment and in the plant. Dust can have a negative effect on the equipment (due to abrasive effects); on animal health with the risk of cross contamination; and on plant cleanliness. With fewer and well-protected movement parts, ABF and ABP automatic Imeco baggers, have easy access to maintenance and cleaning operations. Baggers are an important part in the end of production process whilst at the heart of the

output is the important and fundamental role played by the scales.

Because of its particle size range, 99 percent of the feed bagging scales have a belt feeder, able to handle semi-free flowing materials such as molasses-based products, soils, range cubes, flour products and many others.

Feed scales: your reliable buddy

With our CSB/e scales, able to manage from 2.2lbs up to more than 220lbs per batch, accuracy, consistency and reliability is granted. But what really makes the difference in a working scale? To run it every day for many, many hours, can cause some problems in terms of having time to maintain it. So where is the advantage? Our experience brought us to pay greater attention to your job and to enhance your time, understanding that maintenance operations as well as reparations must be done in the shortest time as possible.

Compared to other belt feeder scales, Imeco CSB/e scales are so easy to maintain that you won’t even believe it. In less than half an hour, everyone could be able to open the two small side doors and actually remove the belt system for every kind of operation.

From there you’ll also have easy access to the weighing container to clean it as you would your dining table. All of this can be done without touching the scale mainframe and especially on site, just like as shown in the picture.

Imeco are able to grant perfectly functioning equipment but what a 4.0 industrialised plant really needs is true communication among all of the machines installed. This we are also able to provide.

Everything mentioned is a brick in the ‘efficiency’ wall needed to build its own close-to-perfection plant.

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The highs and lows of non-contact level sensors: Comparing laser, 3D scanners and radar

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by Jenny Nielson Christensen, MBA, VP of Marketing, BinMaster, USA

rain storage facilities and millers find non-contact level sensors attractive for a number of reasons.

Of course, since nothing comes into contact with the material, there’s no risk of equipment interfering with the process or rogue parts breaking off and getting stuck in equipment or contaminating grain. Plus, they provide continuous level measurement for optimising inventory and preventing bins from running empty. With commodity prices where they are, inventory accuracy is important to the bottom line of every grain and milling operation.

Today’s most popular non-contact technologies in the grain industry are 3D scanners, radar, and lasers. The sensor that might be best for your application is determined by a number of factors including the material being measured, the amount of dust in the environment, the size of the bin, and the desired inventory accuracy. Communications options for getting your needed data can also vary, as well as the price of the sensor, its mounting, wiring, and installation costs.

See through Bin Walls with 3D Scanners

Using a 3D scanner level sensor is like having Superman’s x-ray vision. With its dust-penetrating technology, you can actually see the topography of what’s inside the bin using the graphical option. The 3D scanner is mounted on top of the bin at an optimal 80 | May 2017 - Milling and Grain

location recommended for superior surface coverage, so the scanner can “see” the utmost material surface. It sends acoustic pulses that sound like chirping crickets to the material surface in a 15°, 30°, or 70° beam angle depending on the model. It then measures and maps the material surface at multiple points to detect uneven topography.

Distance is calculated using advanced algorithms that convert the difference between the timing the echo was sent and received to a distance. Data is sent via 4-20 mA or RS-485 output to software, or if you prefer an HMI/PLC. The included software records the data and calculates level, volume, and mass, whilst creating an optional 3D visual of bin contents. 3D scanners come in a variety of models, which are generally chosen based upon the vessel size, the desired accuracy, the need for 3D visual, and the operation’s budget.

The 3D scanner is the only level sensor that measures multiple points on the material surface to account for irregular topography. To your operation, that can convert to precise volume measurement within 1-3 percent of total stored volume. For the grain industry, it offers the added benefit of detecting cone up, cone down, or sidewall buildup. When the MV or MVL models are used, 3D scanners are the only sensors that offer a 3D visual of bin contents. The visual can also be used to indicate where buildup is occurring and alert for the need for bin cleaning or excessive buildup that could lead to structural damage or collapse of the bin.

A key advantage of 3D scanners to operational efficiency is

volume accuracy in very large bins or domes. When bins are over 45 feet in diameter, more than one 3D scanner can be used on a single vessel. For example, three to four 3D scanners will provide very good volume accuracy on a 105-foot diameter bin depending on the bin height. The software takes into account measurements taken by multiple sensors and aggregates it to a single volume and single 3D visual. This can also be very useful in domes or any very large vessel. Multiple 3D scanners can also be used in flat storage warehouses for more accuracy than a single point measurement device, as it scans the material surface to detect irregularities caused by conveying grain into the structure or removing it using loaders.

Redundancy is also an insurance of reliability. 3D scanners use three independent frequencies to transmit and receive to ensure accuracy. With self-cleaning transducers, they require minimal maintenance. An optional Teflon-coated sensor can be used if materials such as flours are excessively clingy or sticky.

MultiVision software for managing multiple bins is also available for grain operations that have multiple bins or multiple locations where they want to monitor inventory throughout the entire operation.

Precise accuracy comes with a few considerations. The 3D scanner must be installed in the recommended location on the bin roof to obtain the best accuracy results. This may require a new eight-inch opening on the roof for installation. Although sensor installation is fairly routine, it’s recommended that a trained technician do the startup and system configuration.

This requires a site visit or temporary remote access to your company’s network. A 3D scanner will have a slower update rate and tracking speed versus a laser or radar; scanners taking a few

minutes versus the others less than a minute.

Avoid installing 3D scanners where there is excessive noise that may interfere with the acoustic technology.

They also are not recommended for very narrow bins that have corrugation. If there’s excessive internal structure that may interfere with operation, a neck extension or alternative sensor technology will need to be used. Due to its robustness, there is no loop power option.

The new reality of radar

Non-contact radar has become increasingly popular in the grain industry since the recent introduction of 78GHz to 80GHz frequency radar level sensors to the market. Unlike the 26GHz radar, radars using these high frequencies are quite reliable in dust. Their principle of operation is the same, but they are less prone to erratic data or lost signals that were common in older models. They have a 4° versus 10° beam angle for better

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STORAGE

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precision and a substantial 393 foot measuring range.

Radar works by emitting an electromagnetic pulse through the antenna where the emitted signal is then reflected off the material and received by the antenna as an echo. The frequency of the received signal is different from the emitting frequency with the frequency difference being proportional to the distance and the height of the material being measured. The difference is calculated using special algorithms contained in the sensor’s electronics, where the material height is converted and output as a measured value. Or to vastly simplify this explanation, these high frequency radars use the same basis of technology as self-driving cars.

Since high frequency radar works in high dust, it’s quite reliable for measuring inventory of just about all types of grain at any stage of processing. It is suitable for corn, soybeans, wheat, rice, oats, barley, sorghum, and rye as well as milled flours that can be excessively dusty.

Since it is powerful across long ranges, it can be used in very tall, narrow bins for single point level measurement at distances of up to almost 400ft. With its 4° beam, it can be used in segmented bins with narrow compartments. It is also proven to work in bins with excessive noise created during filling, extreme dust, or high temperatures. Radar is ideal for bins where precise aiming is needed to avoid internal structure, the flow stream, or sidewall buildup.

It can be mounted over piled material, on dome roofs, or in storage bunkers. In large grain operations, radar is used over conveyors belts to prevent overloading or detect when belts are running empty.

One of the things that grain operators like best about the newest models of non-contact radar is their ability to work in dust. High frequency radar is able to track levels despite excessive dust generated during the filling process. The narrow beam can be targeted to avoid measuring internal structure such as ladders versus the material in the bottom of the bin. The signal is not affected by corrugation, if material is stored in such a vessel.

Fast reaction and updating times allow for the tracking of filling or emptying activity. Radar is also versatile enough for use in solids or powders and it offers loop power capability to simplify installation.

The potential downside of non-contact radar is that it measures only a single point, as does laser. Therefore, it is not the recommended instrument when very precise volume accuracy is needed for inventory management. Since it can’t detect topography of material such as uneven piling or cone up or down, inventory accuracy will be similar to dropping a tape measure at a single point on the material. In extreme conditions where there’s both harsh dust and excessive humidity, an air purge may be required for optimal performance. In that case, between the cost of running compressed air lines and paying for compressed air, 82 | May 2017 - Milling and Grain

preventive maintenance costs can add up quickly.

The lowdown on laser

A laser sensor is mounted on top of the bin using an adjustable 10° mounting flange for aiming the laser to the desired location, generally toward the output of the cone. During configuration, the minimum and maximum distances are set using 4 and 20 inputs configured on the sensor. The sensor sends timed laser pulses to the material surface. The distance to the materials is calculated using complex algorithms that convert the laser pulses to a data output. A compensation for “slant range” is made based upon the angle of the beam to ensure accurate level measurement.

The laser is not always ideal for the grain industry because it is best suited for low or no dust environments. However, because of its very narrow beam, it is a good option for level control in narrow vessels containing solids, so long as it’s not used on high dust materials. It can also be used for plugged chute detection or restrictive chutes and hoppers where precise targeting is needed.

For materials that don’t flow freely, it can be used for monitoring buildup when installed above the monitoring point or directed toward the sidewall.

Some of the advantages of laser are that its adjustable, swiveling mounting flange is flexible up to 10 degrees. This may allow for use of an existing mounting location and eliminate drilling another hole in the bin roof. The laser’s extremely narrow beam can be directed to avoid obstructions that could interfere with sensor operation. It is easily configured in the field using a USB port, while configuration can be performed without filling or emptying the vessel. The laser has a fast update rate of eight times per second and also features integrated dust protection for minimal maintenance.

The laser’s major disadvantage is that it is not recommended for use in dusty environments. This limits its application in the grain industry. Plus, it only measures a single point in the bin, which could be problematic for materials that don’t flow freely or pile unevenly in the bin. It can be subject to interference from falling materials that can temporarily render the readings inaccurate. If used in a bin with any dust, it may need an air purge option to keep lenses free of buildup for reliable performance.

When it comes to non-contact level sensors, one size doesn’t fit all. In fact, many grain operations use a combination of sensors – both continuous and point level – to keep their facilities running smoothly. Different size bins, different grains, and different material management objectives will all come into play when selecting the right sensor solution for your grain or milling operation.

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From rice to animal feed:

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Why choose Hopper-bottom silos?

By Anna Marie Martin, SCAFCO Grain Systems, USA

hen purchasing a storage solution for your farm or commercial enterprise, there are many important factors to consider before you choose the type of silo that will fit your needs and budget.

Hopper bottom silos stand out from other storage and handling systems because they are often easier and less problematic to unload. Opening just one discharge gate on a hopper silo can allow grain to flow out by gravity, with no mechanical equipment required.

The biggest advantage of hopper bottom silos is they allow total cleanout by gravity without the use of sweep augers. There is less material handling equipment, less electricity needed for unloading, and much less maintenance required. Foundations for hopper bottom silos are more economical compared to flatbottom silos, because they can be erected without subterranean trenches. Hopper silos with larger storage requirements can also be stiffened for extra security, expanding their capacity.

Hopper bottom silos have long served as working silos for repetitive receiving and discharge of grain. This application is especially useful for holding wet grain or rice before it enters a grain dryer. Also, these silos can be elevated on a structure, allowing the truck driver to drive up underneath the silo for ease of loading, without the need for expensive turnarounds.

Hopper bottom silos are the best choice if your operation meets the following criteria: • You need a short-term storage solution • You need ease of loading and discharge of stored materials • You require a quick transfer of stored materials to a truck or train SCAFCO Grain Systems, a leading US manufacturer of steel

84 | May 2017 - Milling and Grain

storage systems and grain handling equipment since 1961, sees a trend toward customer interest in hopper bottom silos. The company has supplied hopper silos at numerous facilities where in years past, only flat-bottom silos would have been considered.

SCAFCO hopper bottom silos are available in capacities from 3MT to 1,500MT (130 bu. to 55,000 bu.) in a wide variety of sizes. They maintain a high level of performance because of G-115 (min. 350 gr/m2 zinc) coated steel on all their roofs, support structures and steel sheets. These corrugated sheets have a 67mm (2 ⅔ in) pitch. With support structures made from hot-dip galvanised structural steel, they are ready for years of maintenance-free service. Hopper bottom silos can be built with support structures rated for earthquakes, which ensure a proper foundation for structures in areas with frequent seismic activity.

SCAFCO engineers work with customers to meet their needs for storage with a versatile array of hopper silo features and accessories. From companies that require massive storage, to customers with much smaller needs like microbreweries, the following installations illustrate a wide variety of applications.

Wheat

This expansive grain railroad terminal, pictured above, in Eastern Washington State, USA, has three SCAFCO 10,000 MT flat bottom silos, and three SCAFCO 1,500 MT (55,000 bu.) hopper bottom silos for a total of 34,500 MT of storage.

The hopper bottom silos stand 25.9 meters (85 ft.) tall and are 11 meters (36 ft.) diameter. For train transport, 110 car shuttle trains can be loaded with 16,000 MT (587,904 bu.) of grain in 10 hours. This facility is a long-term investment in the future of Washington State wheat production and distribution.

We have also custom engineered taller hopper bottom silos without the need to lay down expensive concrete pilings. Standard hopper bottom silos have a clearance height of 1 meter (39 in.),

F but Scafco has made structures with a 1.2-meter (48 in.) discharge height. Leg support structures can be created significantly stronger than standard supports to fulfill customer requirements, especially where high wind or seismic loads may be a factor.

Rice

Hopper silos are vital in getting rice ready for market. Unmilled rice, known as â&#x20AC;&#x153;paddy rice,â&#x20AC;? is usually harvested when the grains have a moisture content of 22 percent. Paddy rice needs to be dried to bring down the moisture level to no more than 12-14 percent for milling. Drying has to be carried out slowly to avoid cracking the rice.

Properly equipped hopper bottom silos are essential to the paddy rice drying and tempering process. After removing approximately three percent of moisture from the wet paddy, the rice is placed into the hopper bottom-tempering silo for at least eight hours. This tempering allows moisture inside the rice kernel to move toward the outer husk where it can be removed in the next drying pass. The process is repeated two or three times before the rice is dried down to its optimal storage moisture.

Day silos adjacent to the rice mill also utilse hopper bottom structures because of their ability to discharge the grain using gravity. No expensive sweep augers are required and there is minimal damage to the rice kernels.

White milled rice can also be stored in corrugated, galvanised steel hopper bottom silos, although the environmental requirements are a bit stricter due to the high value of the product. Seed letdown ladders on the interior of these silos gently drop the milled rice to the bottom of the silo. These letdowns are designed to reduce damage to the stored product by allowing a smooth flow through a series of chutes.

Lentils

Hopper bottom bins can provide seed letdowns for grains that are more fragile. This process slows the descent of the grain at

100 MT/hr. as it is discharged from the filling top conveyors, allowing it to fall more softly into the silo.

Organic animal feed

Recently, a pioneer in the organic animal feed industry in Washington State, USA, turned to us for their entire storage system: silos, elevators, conveyors, catwalk, and towers. The complete system called for maximum efficiency and flexibility.

When our customers have complicated storage and handling system requirements, SCAFCO engineers promptly use the latest modeling and analytic techniques to propose accurate, efficient and economical solutions. SCAFCOâ&#x20AC;&#x2122;s staff boasts decades of combined experience in a wide variety of storage, handling, and processing applications. From our plant in Spokane, Washington State, USA, we create superior designs that are crafted exclusively from U.S.-sourced prime mill certified steel.

Whether your storage requirement is large or small, SCAFCO Grain Systems are meeting the demand for hopper bottom silos and other versatile storage systems. www.scafcograin.com

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Industry Profile

Perry of Oakley Ltd reflects upon 70 years of innovation

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by Abi Young, Perry of Oakley, UK

stablished in 1947, this year marks the 70th anniversary for Perry of Oakley Ltd, one of the UK’s most experienced manufacturers of materials handling and drying equipment.

During those 70 years, it has witnessed firsthand the evolution of the agricultural industry.

Perry of Oakley Ltd was founded by Tom Perry, a farmer’s son, who offered a mobile repair and manufacturing service to local farmers and businesses in the Oakley, Basingstoke area of Hampshire.

In 1949, Tom Perry designed and built Perry of Oakley’s very first belt and bucket elevator with a capacity of 5tph. These early cleaners were equipped with mechanical sieves and aspiration to lift off dust and light rubbish. Today, Perry’s range of belt and bucket elevators are suitable for agricultural and industrial use and are available in capacities up to 1000tph at heights of up to 30m.

1949 also saw the introduction of Perry’s first grain cleaner. These early cleaners were equipped with mechanical sieves and aspiration to lift off dust and light rubbish. Today, Perry offer aspirator pre-cleaners and rotary drum cleaners, ensuring there is a solution for every customer’s needs.

During the early 1950s, many new farm mechanisation aids were designed by Tom Perry and manufactured in Oakley. These included tractor mounted buck rakes, trailers, dust reduction systems for combine harvesters and jog trough grain conveyors driven by petrol engines or electric motors. These conveyors had capacities of up to 5tph; as capacity requirements increased the first chain and flight conveyors were developed. These conveyors were the fore runners of the conveyors that Perry’s currently design and manufacture with capacities up to 1000tph.

Since 1950, Perry of Oakley has sold over 18,500 machines, which averages at over 1.2 machines per day, every day, every single year 88 | May 2017 - Milling and Grain

since then. Their machines have handled and dried everything from standard cereals to digestate, pellets, minerals, dust, woodchip and even waste fish! Perry is so confident in the capabilities and longevity of its machines that it is now offering a 10-year guarantee on its standard agricultural conveyors (T’s & C’s apply).

Tom grew the business from a mobile repair service, to employing engineers to build and design handling equipment in a converted greenhouse, to eventually in 1952, the first factory was built in Oakley measuring 60 foot x 40 foot.

Tom’s son, Nigel Perry joined the business in 1972 and shortly after Pat, Nigel’s wife also came on board.

Under Nigel’s leadership Perry’s expanded to such a degree that in 1974 a brand new, purpose-built factory was built in Oakley to house the company. By 1990, the business had expanded again and required an even larger premises and Nigel made the decision to relocate the business down to Devon on to their current site.

A year after moving to Dunkeswell, David Perry, Nigel & Patricia’s son, joined the company having achieved a First Class Honours degree in engineering. David worked with his parents for 16 years until he took over as Managing Director in 2007, although Nigel and Patricia are still spotted around the factory 10 years after they retired.

David Perry has continued to expand the business and plans for the future. He has invested in his staff, the latest technologies, manufacturing capabilities, research and development projects.

Since David has been the Managing Director, Perry’s have released several key products including Ezi Quote, a revolutionary online quoting system that allows customers to obtain quick and easy quotes direct to their inbox. He also released the Perry CentriKleens, a system that catches 97 percent of all dust and chaff emitted from driers. These can be fitted to both Perry driers and other manufacturers driers.

Since 1955, when Perry’s first grain drier was manufactured with a

Industry Profile capacity of 5tph, their grain driers have become the front-runners of continuous mixed flow driers. This year has seen the release of their Savannah series drier, which is capable of capacities of up to 150tph. The Savannah series is billed as a commercial specification drier, accessible and affordable to small farms.

Last year saw Perry release their Belt Drier, which has proven itself on a variety of products and was their most significant product release in over a decade. The Perry belt drier is one of the most popular and versatile driers available on the market for non-free-flowing products.

David has not just focused on the grain & industrial handling, he has also developed a whole range of handling, drying and storage equipment specifically designed for Biomass.

All Perry products are designed and manufactured in Perry’s purpose built facility in the West Country using a depth of knowledge acquired during 70 years of business. Perry of Oakley in-house team now provides expert technical support for its machinery globally.

David Perry comments, “Over the years there have been many changes but some things have remained consistent. We have always worked to a high specification and standard of manufacture, we aim to provide excellent customer service and support, we ensure that all of our customers have direct access to key design and engineering personnel and, we continue to fund research and development programs to ensure we provide the very latest technologies to our customers. I am sure this is why over 90 percent of our customers buy from us repeatedly.”

He continues, “I am really proud of how this company has developed over the last 70 years. As well as major product releases, we constantly tweak and improve our products so the product range is always expanding and improving. We are incredibly proud to have been awarded the SHAPA Exporter of the year and also to be in the UK’s top 100 SME’s.

Being a family run business means that each generation passes down knowledge and improves on the last generations designs, but most importantly it means that we are really driven to see the business be successful, after all, it is literally my name above the door!

The future brings the prospect of new products, new challenges and new technologies, which we embrace and enjoy! Embracing new technology and maintaining our market position is really important to us. We need to make sure that our products are the market leaders in technological advances, which they are.

We have a fourth generation of Perry’s in waiting. I’d like to think that my children, Tom & Abi, will continue to fly the Perry flag to bring our customers the same great service and products that they are used to in years to come, but we are a way off of that yet!”

Milling and Grain - May 2017 | 89

CASE STUDY

New feed plant boosts local development AWILA Anlagenbau GmbH has erected a plant in Bangladesh for flexible animal feed production next to fish and crab breeding ponds in the rural, yet densely populated region in the north of the country

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any Third World countries and newly emerging markets are increasingly trying to add value, generate more production and create new jobs in their own region, in order to become more independent of expensive imports. These countries are however, often dependent on technology from industrialised nations for their development.

One example is Bangladesh. As one of the most densely populated countries in the world, Bangladeshâ&#x20AC;&#x2122;s development is

90 | May 2017 - Milling and Grain

additionally complicated by regular floods, which occur as a result of the unfavorable geographic location in the deltas of large rivers, only a few meters above sea level.

Agriculture in Bangladesh is characterised by many small farms, which produce mainly for their own needs. That way, even without industrial livestock farming, a high density of farm animals such as poultry, pigs, fish, and also cattle are still used for fieldwork.

To meet these special local requirements, the German technology supplier Awila Anlagenbau GmbH has erected a plant for flexible animal feed production next to fish and crab breeding ponds in the rural, yet densely populated region in the north of the country. In this plant, two independent production lines can be used to produce a wide variety of fodder for different livestock, also in small batches.

The new feed plant consists of two identical pelletizing lines with a production capacity of 10 t/h each. Depending on the used raw materials and the desired final product, it is possible to grind, mix, pelletise and crumble in a flexible way. In front of the production line, there are located two storage silos, a grain dryer and a premix system including scales and numerous silos for the dosing of various additives.

At the end, both lines have a partially automated bagging system.

The raw materials for the production of the fodder are mainly cultivated in the nearby surroundings. The manufactured products are made both for the local market and exported to neighboring countries. On this basis, the project provides local added value and thus contributes to the agricultural

CASE STUDY F

projects, as well as plant extensions, with the company.

The machines can be distinguished by their high reliability, robustness and operability. In order to maximise the availability of the technology a special attention is given to a simple and fast maintenance. The machinery is being continuously developed and optimised according to experience and customer feedback.

An example of this are the pellet presses, which are built in various sizes, containing among others a heavier cast

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development of the region, also by creating new jobs in the built facility. In addition, the nearby farmers benefit from a more extensive and cost-effective supply of high-quality feed.

The AWILA Anlagenbau GmbH, active worldwide for more than 100 years, plans and builds tailor-made technology for the production of animal feed. For this purpose, the machines are mostly manufactured according to the wishes of the customers directly in the workshops at the company headquarters in Lastrup near the Dutch border. The area known as “Oldenburger Muensterland” is located in the region with the highest livestock density in Germany.

Many well-known, internationally active companies for agricultural technology are based here. Due to the close proximity between the companies and their suppliers, it can be produced in a very efficient way.

Especially in the last 40 years, hundreds mainly turnkey projects with production capacities of up to 120 t/h have been carried out.

Furthermore, Awila is known as a subcontractor of machines and supplier of wear and spare parts and have been able to continuously expand its customer base over the years.

The concept of looking at the customer as a partner and placing its satisfaction in the foreground has paid off so that customers have subsequently also implemented their new

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Milling and Grain - May 2017 | 91

F CASE STUDY

iron base and a die-pick-up rotor made of solid steel. This ensures a special calm run, resulting in reduced wear at a constant high throughput.

In the case of the different hammer mill models for capacities of up to 40t/h, the sieves can be simply changed from the front without stopping the mill. The exchange time of the hammers is minimised by a quick-change device to a few minutes, thus achieving a very short downtime.

In the case of other machines manufactured by Awila, such as mixers, countercurrent coolers, through chain conveyors, elevators,

screens, and transport augers, etc., attention was paid to such details in the constant further development of the technology.

In this way, Awila Anlagenbau GmbH has become one of the leading companies in the field of animal feed technology over the last decades. Thanks to its numerous representatives and experience also far away from Europe, optimal project implementation and technical support throughout the later operation of the plant can be ensured, in order to continue to win many more customers as partners and support them at their challenges in the future.

Your global technology process supplier for the animal feed industry ANDRITZ is one of the world’s leading suppliers of techno­ logies, systems, and services relating to advanced industri­ al equipment for the animal feed industry. With an in-depth knowledge of each key process, we can supply a compatible and homogeneous solution from raw material intake to finished feed bagging.

ANDRITZ Feed & Biofuel A/S Europe, Asia, and South America: andritz-fb@andritz.com USA and Canada: andritz-fb.us@andritz.com

92 | May 2017 - Milling and Grain

www.andritz.com/ft

Annual overview With the end of the first quarter of 2017 passed, it is an ideal time to review how trading has faired, and give an overview of what is predicted for the rest of the year.

by Matt Muller

Another winner in Q1 of 2017 was rice.

The price of all grains is driven by demand, and given population increase; rice has enjoyed a stable presence in the market. To put this into context, in 1960 the global population was less than three billion, today it is around 7.4 billion, more than double in the last 57 years.

Grain Grain continues to be driven into a buyers market as prices continue to slide. This in part is down to four years consecutively providing huge yields, and large suppliers able to fulfill that demand. A breakdown of the grain market shows it was down 2.89 percent in 2016 and the overall industry fell by 14.48 percent in 2015, and 12.18 percent in 2014. This quarter, this sector posted a gain of 1.37 percent; in terms of global scale this is minimal.

It is important to stress that while prices are dropping due to supply being bountiful, the grain market does not seem to suffer the same price volatility of other commodity markets.

There will always be factors, affecting the production levels of crops. The drought in 2012 elevated the price of commodities to a sky-high status. In 2014 much more favorable conditions provided a sharp rise in production levels, a trend which followed on in 2015 and 2016. Even thought prices took a tumble in 2016, the increasing demands for food security around the globe.

Soybeans The same cannot be said for Soybeans, which continue to fall in price, reported by the Chicago Broad of Trade to their lowest level in a year. This is a direct result from the US Department of Agriculture’s plantation report. The report illustrated that Soybean sowing is expanding at a huge rate.

Richard Feltes, RJ O’Brien is quoted on the market site ‘agrimoney.com’ as saying that the market was, “framed by negative equity/interest rate outlook, a much improved US hard red winter wheat precipitation outlook, eroding South American soy basis and general cautiousness ahead of one the year’s most important USDA releases.”

However, the estimates for Soybeans keep rising. One report has estimates for South American Soybean yields up to 111 million metric tonnes, which is up three million in Brazil, whilst Argentina was increased to 57.5 million, up 2.5 million. This is irrespective of rainfall, which has slowed harvest, and gives traders some hope of a slight price rise in the short term at least.

Rice Another winner in Q1 of 2017 was rice. The price of all grains is driven by demand, and given population increase; rice has enjoyed a stable presence in the market. To put this into context, in 1960 the global population was less than three billion, today it is around 7.4 billion, more than double in the last 57 years. There is a reported 8.09 million rise in rice production globally from 472.04 million tons of 2016. US rice producers are utilising the Turkish/Russian political situation to take advantage and fill the gap after Egyptian export bans.

Greg Yielding, a representative for the private rice association U.S. Rice Producers was quoted in the Times of India as saying, “Some Russian rice was going into Turkey and now there are problems, so we see it as an opportunity to sell more into Turkey.”

He added that, “Turkey is a huge market, and even rough rice goes to Turkey, which is paddy rice.”

The figures speak for themselves; Turkey imported around 71,000 tons of paddy rice from the US in 2015/2016.

Whilst traders can always rely on staple commodities like rice, the Russian diplomatic unease has affected Wheat market trades. Wheat is typically quiet during Q4 of

94 | May 2017 - Milling and Grain

2016 and Q1 of 2017 and it wasn’t until the previously mentioned plantation report was released, that a more accurate picture of yields could be obtained.

some late seasonal rain would sedate jitters for predictions, and therefore elevate the crop as a stable and viable choice for investment and trading.

Wheat US wheat planting were down 46.1 million acres, a comparative fall of four million compared with 2016. Winter wheat was at 32.7 million, down 3.42 million on last year. However amid the bullish scenario, western markets have the Russian Rouble to thank for a rebound in price. The recovery in oil prices, which is primary for the currency, rebounded from a weak 86 roubles for US $1, to around 55 roubles per US $1 for the first time in nearly two years. This relates to the wheat market because of the rising cuts in the competitiveness of Russian exports, particularly for agriculture. Russian overall grain shipments for 2016 were marginally lower year on year also.

France is currently on a hot streak. FranceArgiMer, the French government crop agency, rated 90 percent of their soft wheat as being in good or excellent condition as we finish Q1. It bodes well for the year with trading breaking new lows of €163.25 a ton. In addition to good quality crops in the EU, there is increased availability, which is pressuring prices to be lower.

The International Grain Council forecast that the EU would yield 150.3 million tons, up 5.6 tons compared to last year. The only blot on the French copybook is that there could be more rainfall.

High temperatures in spring have boosted production, however

Cocoa & Sugar Cocoa has historically remained at an eight-year low and the crop has finally seen some signs of recovery. Analysts cite the potential growth in developing markets such as China and India.

Prices were down in New York 27 percent year on year despite the production rating of ratings agency, Moody’s, which placed the Cote d’Ivoire and Ghana as resilient producers.

Sugar likewise has hit new price lows. In a timely measure, the Brazilian harvest is upon us and predictions of increased production at the expense of ethanol seem to be the buzz around traders. In New York sugar futures are down an 11-month low at 16.29 cents a bushel. The biggest question remains on the choice between sugars over ethanol. Supply is high and the general opinion of analysts seems to be that the market needs to halt production. However it is believed that this will not happen unless sugar falls below 15 cents a pound.

Moving into the rest of the year, it seems obvious that the weather will once again play a key role in trading. Big stock levels will be limiting prices and the US will be producing less the expected, which may in the short term, have a knock on effect. The market can be buoyed by the planting season due to arrive in Q2, which should kick into high gear and offset some of the shortfall.

96 | May 2017 - Milling and Grain

New event

13 â&#x20AC;&#x201C; 14

JUNE

2017 . KOELNMESSE, COLOGNE, GERMANY

FVG Select 2017 is a new event which will be organized by Victam International BV. The event will focus on a series of high quality industry conferences and matchmaking with colleagues and clients in the animal feed processing, grain processing, ingredients & additives, aquafeed, petfood and biomass pelleting industries.

The event will be complemented by an industry expo for a select group of companies.

THE CONFERENCES AND DELEGATE PROFILES Tuesday 13th June

Wednesday 14th June

1. PETFOOD FORUM EUROPE Production technology and specialist ingredients for dry petfoods.

Organizer: WATT Global Media Delegate profile: CEOs, directors, mill and plant managers, head and senior nutritionists, formulators from dry petfood production plants.

1. FIAAP ANIMAL NUTRITION The use of specialist additives and ingredients used within the production of animal feeds.

Organizer: WATT Global Media Delegate profile: Head and senior nutritionists, feed formulators, CEOs, directors, mill and plant managers from commercial feed production plants, integrators, specialist feed producers, etc.

2. THE GLOBAL MILLING CONFERENCE WITH GRAPAS Processing technology and additives used within flour milling and grain processing.

Organizer: Perendale Publishing Delegate profile: CEOs, directors, mill and plant managers, nutritionists from flour mill, rice mills and grain processing plants.

3. VICTAM FEED PROCESSING CONFERENCE Production technology and equipment used within the animal feed production processes.

Organizer: Wageningen University and IFF Delegate profile: CEOs, directors, mill and plant managers, head and senior nutritionists, feed formulators from commercial feed production plants, integrators, etc.

A cocktail party on the evening of Tuesday 13th June will be organised for exhibitors and delegates.

2. AQUAFEED HORIZONS Production technology and specialist ingredients for aquaculture feeds.

Organizer: Aquafeed.com Delegate profile: CEOs, directors, mill and plant managers, head and senior nutritionists, feed formulators, integrators, specialist aquaculture feed producers, etc.

3. BIOMASS PELLETING Production technology for the pelleting of bio-degradable materials for biomass pellets.

Organizer: AEBIOM (The European Biomass Association) Delegate profile: CEOs, directors, mill and plant managers from biomass pelleting plants.

A fee of â&#x201A;Ź95 per person (valid for two days) will be charged to each individual attending the event, both exhibitors and visitors, and includes lunch, two coffee and tea breaks a day, the cocktail party and access to our matchmaking service. A separate fee will be charged for each conference.

More details can be found on our website.

THE INDUSTRY EXPO

EVENT ORGANIZERS

There will be 9m2 and 18m2 standard shell scheme booths available during the two day event. The expo will take place in the adjoining hall to the conference rooms and will also be the venue for all the refreshments.

Victam International BV P.O. Box 197, 3860 AD Nijkerk, The Netherlands T: +31 33 246 4404 F: +31 33 246 4706 E: expo@victam.com

www.fvg-select.com

Industry events MAY n 17 - 19/05/17 - INDOLIVESTOCK Indonesia WEB: indolivestock.com

nn 21-24/05/17 - 1ST ICC ASIA-PACIFIC GRAINS CONFERENCE China WEB: icc.or.at

n 23 - 25/05/17 - VIV RUSSIA Russia WEB: vivrussia.nl VIVworldwide VIVworldwide

n 24 - 26/05/17 - LIVESTOCK PHILIPPINES 2017 The Philippines WEB: livestockphilippines.com

n 25 - 27/05/17 - BIOFACH CHINA China WEB: biofach-china.com

nn 25 - 27/05/17 - 6TH GLOBAL SUMMIT ON AQUACULTURE & FISHERIES Japan WEB: aquaculture.global-summit.com

n 25-28/05/17 - 35TH A.I.B.I. CONGRESS France WEB: www.aibi.eu

nn 31/05 - 04/06/17 - SEAFOOD SUMMIT

Drying Theory Put to Practice: 2017 seminars Bühler Aeroglide, thermal process engineering and technology for food, feed, and industrial materials giants have announced their 2017 drying seminar series.

The dates and locations include: Wuxi, China – May 23-25, 2017 Braunschweig, Germany – June 20-22, 2017 Raleigh, NC – October 10-12, 2017 Joinville, Brazil – November 7-9,2017 This event will be where each participant learns the principles and techniques for optimal drying, regardless of their make or model. Past participant Miriam Villen Rodriguez talks about her experience in Food Australia.

“As a chemical engineer with Stahmann Farms in Queensland-a tree nut processor using many drying technologies to produce premium quality products--I was interested in a course that would help me make real changes to the business.“ Sponsored by the Australian Institute of Food Science and Technology she continues by identifying her top takeaways related to moisture uniformity, dryer evaluation and airflow, “I believe that to improve processing capacity, product quality and energy efficiency, it is important to understand the foundations of the technology you are using.”

USA WEB: seafoodsummit.org

MAY n 4 – 6/06/17 - 40TH ANNUAL SOSLAND PURCHASING SEMINAR USA WEB: purchasingseminar.com

nn 6/06/17 - IGC GRAINS CONFERENCE 2017 UK WEB: igc.int

n 07-10/06/17 - BIOFACH AMERICA LATINA, BIO BRAZIL FAIR Brazil WEB: biofach-americalatina.com

100 | May 2017 - Milling and Grain

The African Extrusion Seminar Aquaculture without Frontiers CIO UK’ is supporting a one-day extrusion seminar hosted by Wenger Manufacturing of Sabetha, Kansas in the USA and International Aquafeed magazine and which will be held during the up-coming World Aquaculture 2017 Conference in Cape Town, South Africa.

The venue is the Cape Town International Convention Centre, Cape Town, South Africa from 12:00-18:00 on Monday June 26, 2017.

Joe Kearns, Wenger Manufacturing explains, “This is a unique opportunity for African fish feed producers to gain additional indepth knowledge while attending the Cape Town Conference.”

Discussions on African aquaculture, extrusion cooking, drying, coating and related functions for production for all types of aquatic feeds centered firmly around improved profitability, he says.

He continues to say that, “Feed ingredient selection, grinding, methods of producing floating, sinking and slow-sinking feeds will be included on the program. In addition, related products including petfoods, ingredient creation, breadcrumbs for fish coating before frying, will provide a full review of extrusion possibilities.”

Before adding finally, “Places will be limited.”

If you’re interested in attending, please register on the International Aquafeed website at: “The Wenger company and IAF are making their contributions in organising and running this event free-of charge to attendees, however a donation towards AwF CIO’s work in Africa, which is aimed at assisting small fish farmers adopt more modern practices that support fish heath and productivity while reducing environmental impact would be much appreciated,” says Roger Gilbert, publisher of International Aquafeed magazine.

PLANÈTE ÉLEVAGE RENNES PLANET LIVESTOCK FRANCE PLANÈTE ÉLEVAGE RENNES RENNES PLANET 12-15 PLANÈTE LIVESTOCK ÉLEVAGE September FRANCE RENNES PLANET LIVESTOCK FRANCE PLANET LIVESTOCK FRANCE RENNES FRANCE RENNES FRANCE

More than 1.400 exhibitors (1/3rd international)

More than 100.000 trade visitors,

An exhibit area of 156.000 sqm.

380 journalists, including 98 international.

700 animals on show.

Free farm visits program.

in 11 halls and 250 booths outdoors.

including 12.000 international.

SPACE 2016 figures

INTERNATIONAL VISITORS,

e.fr

pre-register on: www.spac

SPACE: THAT THE EXPO PLETE COM OFFERS A RODUCTS P F RANGE O ES FOR ALL IC AND SERV : POULTRY, S R O T SEC ), AIRY, BEEF (D E L CATT D EEP AN SWINE, SH S. RABBIT @SPACERennes @SPACERennes #SPACE2017 #SPACE2017

SALON INTERNATIONALDES DESPRODUCTIONS PRODUCTIONS ANIMALES LE LE SALON INTERNATIONAL ANIMALES INTERNATIONAL EXHIBITIONFOR FOR ANIMAL ANIMAL PRODUCTIONS THETHE INTERNATIONAL EXHIBITION PRODUCTIONS @SPACERennes @SPACERennes #SPACE2017 #SPACE2017

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2017

Industry events

J

oin us in Cologne, Germany on 13th June for a full day of informative and innovative presentations from the milling industry’s best and brightest! The event is co-located with FIAAP and VICTAM, to form the exhibition you know as FVG Select 2017.

Exhibitors

The latest technology used within a rice or flour mill/food processing plant will be displayed. Also on show will be a wide and varied display of ancillary equipment and systems – silos, elevators, magnetics, conveyors, bagging, trucks etc. There will also be specialist technology used within the preservation and storage of grains.

Visitors

The senior international executives that attend GRAPAS will comprise of CEO’s , directors, mill managers, plant managers, transportation managers, nutritionists, etc. These influential visitors will have come from rice mills, flourmills, food processing plants, storage facilities, port terminals, etc.

Speakers

Milling and Grain Magazine is excited to share with our readers the latest line up industry voices that will present on the day among the topic of ‘Milling Materials’, ‘Global Milling’, and ‘Milling Innovation’. Read below to find out more about our exciting line up.

Thomas Ziolko, Product Manager Industrial Milling, Bühler

“Ensuring food safety in the milling process” Thomas Ziolko is product manager at Bühler’s Grain Milling Business Area. He is responsible for various grain milling product groups including weighing, packing, online sensors and quality monitoring.

104 | May 2017 - Milling and Grain

Achieving great synergies between milling sectors as the world wakes up to the challenge of feeding 9.5 billion people by 2050

Alexander Waugh, Director, NABIM

“Training the millers - Are we providing enough trained mill leaders?”

Alexander Waugh is the Director General of the UK flour millers’ association, NABIM, and Secretary of the Rice Association. He has a long involvement in the grain world, having worked in the farming sector before joining nabim in 1987. Alexander is a Council member of the Campden and Chorleywood Food Research Association and a member of the Executive Committee of the European Flour Millers Association. He is a former vice-President of Euromaisiers, which represents EU maize millers, and has also been a board member of HGCA Ltd (now AHDB Cereals and Oilseeds), an organisation which brings together UK farmers, grain traders and processors to promote the wellbeing of the grain sector.

Clifford Spencer, Chairman, Milling4Life CIO

“The future importance of lesser known grains to global milling” During a distinguished 40 year farming career Clifford achieved several UK crop yield records and acted as the leading nucleus seed producer to all the major European plant breeders. He has produced over 60 species of plants at farm level on a global basis, was previous Chairman of a regional Farming Group for the UK Sustainable Strategy in Farming and Food, and is an Honorary Member of the Department of the Environment, Food and Rural Affairs (DEFRA) Plant Varieties and Seeds Tribunal.

Clifford was a senior Agriculture and Bioenergy adviser to the United Nations Foundation (UNF) and has served as an expert adviser to the Food and Agriculture Organisation (FAO) and the International

Fund for Agricultural Development (IFAD).

He is now a Goodwill Ambassador for the African Union, a director and Chairman of Milling4Life, a UK Charitable Incorporated Organisation. He is listed in “Who’s Who in the World 2016” and is also currently liaising with senior scientists, universities and centres of learning, government offices and industry in designing and producing principally land-based projects involving innovative science.

Nicholas Trounce

“Internet of things: Sensors and online measurements for milling” Title: Head of Product Management, Industrial Milling, Bühler Bio: Nicholas Trounce is head of product management at Bühler’s Grain Milling Business Area. He is responsible for various grain milling product groups including roller mills and optical sorters.

Dr Wen-bin Wu, Head, Institute of Grain Machinery

Originally receiving his PhD from Dalian University of Technology, professor Wen-bin Wu is now a visiting scholar at the Norwegian University of science and technology and leader of the Grain and oil Machinery Research Institute at Henan University of Technology. His research focuses on the modern design of milling and grain machinery and manufacturing technology.

Aside from his research, Professor Wu is also a member of the China Grain and oil council, vice secretary of Food Machinery and Equipment on China’s Food Standard Commission, and committee member for the special processing branch of the Chinese mechanical engineering association.

To register, please visit: www.fvgselect.com

F

Industry events

Darren Parris, Martha Cornwell and Mark Cornwell from Milling and Grain at Buhler Reception

IAOM 2017

Kansas State University attend the Buhler Reception en mass

As the sun sets over the city that never sleeps, we reflect on yet another successful IAOM exhibition in New Orleans.

T

by Darren Parris, Group President, Milling and Grain Magazine his year was the 121st Annual IAOM Conference and expo and what a show it was. There were more than 900 delegates in attendance from 23 plus countries, showing this North American chapter of the IAOM has an ever-increasing global reach.

As the leading organisation for professionals in the grain milling industry, this annual get together furnishes those attending with the opportunity to stay up to date with new innovation and good practices available, thus partaking in the comprehensive educational program.

This year I counted 145 exhibitors, showcasing their newest equipment and services in 213 booths. Many of the booths scheduled in informative and educational Product Showcases which included Chopin Technologies new LabMill, which gives a completely new approach to laboratory experimental milling. With this unique product a miller can test wheat and produce results that are representative of results from industrial milling in terms of flour quality, extraction, ash and starch damage. When compared to a reference mill, more than 87 percent of extraction rates on various varieties of wheat were correctly predicted, within one percent, while maintaining representative ash values. Other product showcases included a 108 | May 2017 - Milling and Grain

Christian Jordan and Lambton Team with Johannes Karcher and Frigortec team

Mike from Lambton, Nick from Buhler and Joesef from Seafar at Buhler reception

Fengcheng Wang Ph.D. from Henan University of Technology with a local Delegation at Buhler Reception Pete, Andy and Bulent from Henry Simon and Ozan from Gazel Makina

Peter Marriott from Henry Simon and friends at BĂźhler Reception

Industry events

Mr Pereira and Rogerio from Sangati Berga

Anthony from 4B Braim

Bill and Bill from Corbion

Bill and Brian from Bullseye Products with Quick Patch

Suzanne from Bastak and Darren from Milling and Grain Magazine

110 | May 2017 - Milling and Grain

Eliseo Senpere from Balaguer Edward, Randy and Aaron and Fabio from Vomm from Pepper Maintenance

Industry events

Strong Seed.

Healthy Grain.

PETKUS.

Thomas, Luke and Frank from Fawema

Diwakar Mokadam, Seyit Ali Topac, Chad Joyce and Gary Billups from Imas North America

View of the Buhler Stand Wade from Maxi Lift

Grain Logistics â&#x20AC;&#x201C; Solutions from PETKUS. Transforming grain terminals into perpetual motion microcosms. PETKUS Engineering is more than silos, conveyors & cleaners, but a network of know-how, precision engineering, customized design & high quality technology.

www.petkus.com TECHNOLOGY | INNOVATION | ENGINEERING | SERVICE

Eli from Sesotec

Milling and Grain - May 2017 | 111

Industry events

Gerry Richardson, Mike Richardson and Chris Richardson from CETEC USA and Fabrizio Baccinlli and associates from OCRIM Italy

Mark Gist from Bird Be Gone talking with Mark Cornwell from Milling and Grain

Karen and Shauna from Charm Science Inc.

Mehmet and Ozan from Entil - Making Quality Rolls since 1964

food safety management application form Dekra, Antimicrobial composite material from OCRIM Spa and a Halo Automatic Metal detection testing system from Fortress Technology.

In addition to the product showcases from Vibronet-Gräf Gmb and Co and Buhler, there were four educational tracts happening simultaneously. We will have in-depth coverage of the talk given by Edward Lapreze from Pepper Maintenance, "What is reliability and why do you need it" as well as John Putnam’s talk entitled "RF pasteurisation and the wave of the future" in a upcoming edition of Milling and Grain.

So, with well-attended product showcases and full educational programs we can confidently say IAOM 121st in New Orleans was an outstanding success and missing out could cost you thousands in mill operations. Well done to Melinda Farris and her team at IAOM and a big thank you to Brad Allen in his role as President this past year.

One of the many highlights for me at the expo was seeing first hand the Quick Patch product

by Bulls Eye Products. Quick Patch is a very unique and easy to use UV or sunlight activated, self-adhesive repair patch. These patches are effortlessly impressive, and if you’re a head miller it would seem to make tremendous sense to invest in one in the same way you would invest in first aid kits for your staff. These Patches range in price from USD $15 to USD $50 and are sold in multi packs. They are something you should regard as first aid kits for your mill. They can

Mike from Electro-Sensors Paul and Sarah from Bliss

Milling and Grain - May 2017 | 113

Front row, Left to right: Veronica Soto, Kaoru Kawate, Koji Yamamoto, Moreno De Marchi Back row, Left to right: Walt Tisdale, Peter Marriott, Gorkem Alapala, Hajime Harada, Andy Bailey, Peter Matthews

Henry Simon launch

The Henry Simon brand was officially launched at the 121st Annual IAOM. With an impressive stand, Henry Simon really stood out at IAOM and the excitement and interest in the rebirth of arguably one of the globe's forerunners in Milling Machinery was the talk of the show. It is no secret that Alapala and Satake have partnered up to initiate the production of the milling legend that was Henry Simon.

The pre-launch meeting was between April 23-25, 2017, in Alapala’s headquarters in Corum, Turkey. The new Henry Simon milling machines were then subsequently introduced at the annual conference and expo here in New Orleans.

One of these 400 branded mills was “Hatap Un” which was established in Corum in 1961. Also Mehmet Alapala, the founder of Alapala, entered into the sector by producing wooden sifters for “Hatap Un” mills. In the following years, after joining with Robinson Milling Company, the Henry Simon brand was sold to Satake in 1991.

By the year 2017, Alapala and Satake resubmit the Henry Simon brand to the market. Alapala’s capacity increasing investments, spare parts supply and aftersales services ally with Satake’s active sales network and gigantic R&D team to revive the Henry Simon brand.

With the force of the brand and the partnership, Alapala move up their worldwide power by reaching a new 55 countries in addition to their existing experience of more than 600 turnkey projects in 100 countries.

SOLIDS SOLIDS EUROPEAN SERIES

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10 – 11 May 2017 | Messe Westfalenhallen Trade show for granules, powder & bulk solids technologies In parallel with: RECYCLING-TECHNIK Dortmund 2017

Get your free ticket with code 4066 at www.solids-dortmund.com

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114 | May 2017 - Milling and Grain

Industry events

Sun Su from Taixing Xiqiao Roller Factory in China

Mike and Jason from Laidig

patch up any broken pipe, silo or conveyor in minutes; one patch can save you thousands. These patches will set rock hard and be a permanent fix.

A superb conclusion to the conference was the IMEF auction reaching its goal of raising $1,000,000. Thank you to all who contributed and bid. Keep an eye out for the technical reports form the show that will follow in our June and July editions of Milling and Grain magazine.

Bühler reception

As with every IAOM event, it would not be the same without the premium reception evening hosted by Buhler.

This year was a full turn out with food and drinks courtesy of Buhler allowing over 900 delegates and 500 exhibitors to mingle and network prior to the official opening of the expo.

IMEF reaches the million-dollar milestone

Terrence from Brabender Sean from Seedburo Susanna and Johannes from Frigortec

Richard, Sean and Dan from Flock Free Bird control systems

When the auctioneer’s gavel fell on the final winning bid during the annual IAOM Conference and Expo in New Orleans, the International Milling Education Foundation had raised over $81,000, which pushed the endowment past the one million dollars mark. At its fall 2016 meeting, the IMEF board of trustees had set a goal to reach the milestone in 2017. The joint live and silent auction held during the annual IAOM Conference & Expo is the largest fundraising event of the year for the Foundation. The total includes winning bids and pledged donations.

“We are so excited to have reached our goal of one million dollars during the conference,” stated Stephen Doyle, IMEF president at the conference. “The milling industry has shown tremendous support for this annual event. This year we had a record number of items donated to the auction by our

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Industry events allied partners and milling companies. We wouldn’t have been able to reach our goal without everyone’s participation and support.

“The funds raised have been used to help Kansas State students and professionals further their education, as well as to develop content for a vocational training program and a website to help promote the milling industry as a great place to make a career,” Doyle explained.

The donations ensure that IMEF will be able to continue to inspire leadership and achievement within the milling community as the Foundation supports learning and knowledge resources.

One of the recent projects funded by the IMEF endowment was the development of a Milling Technician certificate program, which is currently under way at Cowley College in Arkansas City, Kansas. The Milling Technician certificate program is a fully online college credit program, which allows anyone in the world to enroll in the program. The program is completed with a 250-hour internship at a flourmill. The program will have its first graduates in August of this year.

In addition, IMEF funds a scholarship program for milling science students at Kansas State University, as well as professionals in the industry to take the IAOM Correspondence Course in Flour Milling and resident milling courses. One USD $3,000 scholarship and one USD $2,500 scholarship were presented to K-State students during the IMEF Breakfast at the IAOM Conference for the 2017-18 academic year.

Santiago from Bruker Brad Carr and John Sanders from Sonic Aire

Sylvia Gräf at Vibronet Cagil from Genç Degirmen

Bill from Blower Engineering

Summary

To end my report, I shall just say for a final time how thoroughly enjoyable, noteworthy and fascinating this year's IAOM Conference and Expo was. To have been privileged enough to attend the 121st anniversary is an honour in itself, and I would without a doubt say that I look forward to seeing you there next time, both for yourselves and your companies.

Begum from Erkaya

Julie Sundgaard BSc and Jeffery Rich BSc from Romer Labs with customers View of the Buhler Booth

116 | May 2017 - Milling and Grain

Steve Hernandez, Neil Veron, Vince Kintzle Ardent Mills Regional Manager,Mike Branson, John Hultman - Ardent Mills Mill Superintendent Joe Klingler from SEFAR

Yemtar Feed Mill Machines +90 266 733 85 50 www.yemtar.com

Elevator & Conveyor Components 4B Braime

To be included into the Market Place, please contact Tom Blacker +44 1242 267700 - tomb@perendale.co.uk

+44 113 246 1800 www.go4b.com

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118 | May 2017 - Milling and Grain

iness, ce is crucial. me in ours.

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119 | May 2017 - Milling and Grain

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internationalmilling.com

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120 | May 2017 - Milling and Grain

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the interview

Volkmar Wywiol

There’s more to Volkmar Wywiol than meets the eye. While he’s passionate about his flour museum, it is his commitment to the development of the Stern-Wywiol Gruppe – with 11 specialised independent companies including Mühlenchemie and numerous alliances throughout the world – that has made him an industry icon. Now over 80, for decades he has worked tirelessly to provide an economic supply of ingredients and additives to improve flour.

37 years ago Wywiol bought a small Hamburg-based company and developed it into a world market leader for lecithin, an important food ingredient, along with many other ingredients including enzymes and stabilisers. Today, the Stern-Wywiol Gruppe provides a range of key ingredients for the food and feed industries. Its companies Mühlenchemie, DeutscheBack and SternEnzym with their broad line-up of products, cover every sector of the milling and baking industries in a significant number of countries.

When did you start your company, and why?

I started my company Stern-Wywiol on January 1, 1980.

Before that I was the general manager of an ingredient company called Lucas Meyer, which made soy lecithin, an emulsifying agent. I was there for 25 years, but when a new generation came in with different ideas on company policies, I decided it was time to go into business for myself.

I bought a very small company that had revenues of just DM 300,000 per year. It was really quite small. From that DM 300,000 or €150,000 in 1980 we have grown into a group turning over €500 million.

Do I understand it rightcorrectly that you started the company as a one-man show?

Yes, I started the company with very few products but a lot of enthusiasm and ideas. My company was originally not involved with lecithin at all; it concentrated on one small technical product. However, I saw an opportunity to bring my old product to the fore, and with this enthusiasm and my new ideas I developed soy lecithin into the number one lecithin in the world today. Soy lecithin is now a very familiar ingredient.

Did you focus solely on the European market at the time or did you see a wider reach for your product?

I always saw the world as my market. I am an individual who looks at the wider world and its future. We started in Germany but quickly expanded throughout Europe and worldwide. Personally I was very interested in international business, seeing other cultures and building up other partnerships. I also found other young people who shared my passion for the development of new products and for new markets.

Was your philosophy simply the development of new markets or did you feel like there was a nutritional need outside Germany and Europe that needed to be met?

There was. I was brought up with lecithin, which is an important functional as well as nutritional food additive. It was in this direction that I wanted to go, and from the first day I said to myself that I had to go into the food industry and focus on nutritional products by providing application service. I was also very keen to improve animal feed in the right way.

122 | May 2017 - Milling and Grain

Were your products accepted in the marketplace straight away, or did it take time to convince people of their benefits?

I started off as a one-man show and I had to convince each customer every time. Even though I was widely known as a lecithin specialist I had to really prove that I was an expert in the eyes of my customers. It was not easy. But I received a lot of guidance and support from friendly customers so in the end it was a success.

Mühlenchemie are known for milling ingredients and food fortification. Are you more focused today on this company?

No, Mühlenchemie is just one of the specialised companies within the Group. It is a very important company, but we also have Hydrosol (stabilising agents), SternVitamin (vitamin and micronutrient premixes), and SternEnzyme (enzyme systems) among others. In Germany we have a total of 11 companies plus 16 affiliates worldwide. So today we are a big group.

Mühlenchemie is just part of that, but it is a leader in flour improvers and fortification.

A professor in the USA has called flour millers heroes.

Your company makes the improvers that millers rely on to achieve quality end products. Do you consider yourself a hero when it comes to flour quality, especially in terms of nutrition for consumers in developing countries? Does it make you proud?

Hero is a very strong word. We are leaders in the production of ingredients for the flour industry. But yes it does make all of us very proud. The key to our success is our world-class milling and technology centre. We build quality into flour, and more than 2000 millers depend on our expertise every year.

Where do you see the future?

We see a lot of future in Mühlenchemie, especially in the flour and pasta industry. We have seen that the market for flour is growing, including baking, biscuits and pasta, and there are a lot of possibilities. There is much more work to be done. We started with bread flour but now we also make products to improve pasta flour, plus additives and vitamins for rice. So Mühlenchemie will be getting bigger and stronger.

Our thanks go to all the millers of the world who day after day and year after year make the ‘white gold’ that is mankind’s most important staple food. As for me, I love this company, I love our team and I love our customers for the products they make.

PEOPLE THE INDUSTRY FACES Stephen Doyle appointed as 113th IAOM President

S

tephen Doyle, vice president at King Milling Company in Lowell, Michigan, became the 113th president of the International Association of Operative Millers, IAOM.

Highlighting the importance of education and training, Doyle annouced the theme for his presidency, “Education is the Key”. Having been an active member of IAOM since 1987, he stressed the importance of the development and training of a new generation of millers to replace the anticipated 50 percent of the workforce that will retire within the next decade.

Stephen Doyle

Doyle is a native of Lowell, Michigan. He earned a bachelors degree in milling science at Kansas State University, in Manhattan, Kansas. Following graduation, he returned to Lowell to work at his family’s mill, King Milling Company, where he has worked for 30 years.

David Jansen elected IAOM Treasurer

D

avid Jansen, plant manager at Siemer Milling Company in Teutopolis, Illinois, was unanimously elected 2017-2018 treasurer of the International Association of Operative Millers (IAOM).

As treasurer, Jansen will be responsible for overseeing preparations for the Association’s 2018 and 2019 conferences in Atlanta, Georgia, and Denver, Colorado, respectively. Jansen has been an active member of IAOM since 1995.

David Jansen

While serving as IAOM treasurer, he will also be vice president of the International Milling Education Foundation (IMEF).

He is a 2016 graduate of the Illinois Agricultural Leadership Program, and received a certificate in 1996 from Kansas State University and IAOM for the Advanced Operative Millers Short Course.

Jeff Hole elected IAOM Vice President

J

eff Hole, director of milling at Grain Craft in Overland Park, Kansas, was unanimously elected 2017-2018 vice president of the International Association of Operative Millers (IAOM).

As vice president, Hole will be responsible for overseeing preparations for the Association’s 2018 conference in Atlanta, Georgia. Hole has been an active member of IAOM since 1994.

While serving as IAOM vice president, he will also be president of the International Milling Education Foundation (IMEF).

Jeff Hole

Hole is a native of Wichita, Kansas. He earned a bachelor’s degree in milling science and a master’s degree in agribusiness at Kansas State University, in Manhattan, Kansas.

Gretchen Sosenheimer joins Brock Grain Systems

G

retchen Sosenheimer has joined Brock Grain Systems as the Business Support Group Manager.

Ms Sosenheimer is a graduate of the College of Charleston, South Carolina, she holds a Bachelor of Science degree and has over 20 years of experience working in customer

service.

Gretchen Sosenheimer

Upon joining the company she will be responsible for the “A to Z” of sales order administration, logistics coordination with dealers and the company’s internal shipping teams, and process improvement for those areas.

CEO Ali Habaj moves on after nearly two decades of service

A

fter 17 years with Oman Flour Mills and Atyab Investments, Ali Habaj has decided to take on a new opportunity as CEO of one of Oman’s major industrial companies.

During Habaj’s tenure in OFM, the company’s workforce grew from 220 to 1,500 employees. It was under his leadership that Atyab Investments was created.

Ali Habaj

This development built Oman’s largest industrial bakery and successfully turned around the country’s major poultry farms- broiler and layer facilities.

124 | May 2017 - Milling and Grain

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