SEP 2020 | Milling and Grain magazine

September 2020

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In this issue:

Gentle drying of soybeans • Roll measurement • Bringing innovation to the milling industry • Wheat flour fortification in Egypt

IN A

IN G R AI N

SO E M B ER F N ABI M

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S T E D M I LLI N G M A G A

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• Launching a new generation of molasses mixers

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#1 M

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Milling and Grain . Volume 131 . Issue 09 . September 2020

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• Toward the Smart Mill

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Volume 131 Issue 9

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VOLUME 131 ISSUE 9

September 2020 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 darrenp@perendale.co.uk Fred Norwood Tel: +1 405 834 2043 fredn@perendale.com Asia Marketing Team Dante Feng Tel: +886 227930286 dantef@perendale.com Latin America Marketing Team Iván Marquetti Tel: +54 2352 427376 ivanm@perendale.com Pablo Porcel pablop@perendale.com Oceania Marketing Team Peter Parker peterp@perendale.co.uk Nigeria Marketing Team Nathan Nwosu Tel: +234 8132 478092 nathann@perendale.com Egyptian Marketing Team Mohamed Baromh Tel: +20 100 358 3839 mohamedb@perendale.com Turkey, Eurasia and Middle East Marketing Team Mehmet Uğur Gürkaynak Tel: +90 537 3646457 mehmetg@perendale.com Managing Editor Vaughn Entwistle vaughne@perendale.co.uk Features Editor Rebecca Sherratt rebeccas@perendale.co.uk International Editors Dr Roberto Luis Bernardi robertob@perendale.com Professor Wenbin Wu wenbinw@perendale.com Mehmet Ugur Gürkaynak mehmetg@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

62 - Toward the Smart Mill with Pluto PCS ISSUE HIGHLIGHTS

8

NEWS FEATURES

40 Roll measurement 44 Bringing innovation to the milling industry

44 The future of rice processing 48 Chicken fed with insect oil go on sale

FACES

10-30 52 Wheat flour fortification in Egypt

56 Packaging pioneers prove their expertise in the food industry

62 Toward the Smart Mill with Pluto PCS

114 People news from the global milling industry

PRODUCT FOCUS

38

CASE STUDY

94

66 Launching a new generation of molasses mixers 68 Scales: The heart of the next generation mill 74 Current status of rice consumption in China and outlook of rice cooking industry

EVENTS

102 Event listings, reviews and previews

78 Extrusion systems for aqua feed and pet food STORAGE

82 Simplicity drives malt conveyor specification at Madrid brewery 84 Gentle drying of soybeans

TRAINING

34 IAOM-KSU Basic Milling Principles

COLUMNS millingandgrain.com ISSN No: 2058-5101 ©Copyright 2019 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

10 The Global Miller 22 Mildred Cookson

8 GUEST EDITOR Halil Yirtimci

100 MARKETS Rebecca Sherratt

116 INTERVIEW Professor Li Dongsen

COVER IMAGE: Gentle drying of soybeans: Cyclone with connected rotary valve for the removal of fine particles - page 84

Flaking technology and its nutritional benefits Highly nutritious grains for feed, such as barley and corn, have been rationed for all animal species for many years. Crushing and flaking technology has increased the digestibility of barley in sheep feeding and has demostrated significant benefits in Feed Conversion Ratio (FCR). In the flaking process, steamed grains are flaked with roller balls after steaming at 88-100˚C. The starch is gelatinised, whilst the integrity of the barley is preserved. Fermentation is achieved at the same time as bacteria is eliminated. The risk of dusting is very low in the crushing process.

Halil Yirtimci

For many years, the consumption of grains that have been subject to crushing has been a key method of ensuring the public receive metabolism-regulating and nutritious food. The

Session 7

Raw Material Receiving and Storage

August 26

reason why grains are recommended as part of a healthy diet, especially during breakfast, is because the acid in the starch does not form in the stomach. Grain flakes prove to be much healthier than other carbohydrates. The consumption of whole grains is often utilised in animal fattening programmes due to the proven increase in FCR. The primary role of technology that crushes the grain is to ensure the homogeneous distribution of heat and moisture during the pre-steaming of the products and the preservation of all the essential nutrients when forming flakes. Post-flake drying and cooling is also essential to ensure the optimal end product.

Yemmak solutions implement a steam injection method at varying pressure and flow rates in different layers. This is a direct result of the company’s extensive experience in flake processing. The design and rotation speeds of the rollers in flaking machines guarantee precise processing without any product breakage and damage. Single-point hydraulic or mechanically supported adjustment systems guarantee equal thickness and shape for each and every grain.

Halil Yirtimci, Board Member, Yemmak

Session 8

Other Supporting Equipment

September 2

WHEAT

Gentle drying of soybeans

Soybeans going to be treated in an oil press need to have a remaining moisture content of about 10 percent. Typical moisture content before a drying process comes close to about 13 percent.

During the COVID-19 pandemic, the uncertainty of supply chains, increased premix prices, and trade restrictions have led some countries to scale back efforts to fortify grains.

SCALES

YOUR GLOBAL PARTNER

SOYBEANS

Wheat flour fortification in Egypt: During a pandemic

PAGE 52

www.onlinemillingschool.com

PAGE 84

FOOD

STORAGE

FEED

PROCESS

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The heart of the next generation mill

A family-owned mill in eastern Germany thrives on its expertise and passion for milling as well as state-of-the-art technology. The introduction of Bühler’s Tubex Pro marks an important step towards the mill of the future.

Chicken fed with insect oil go on sale in French supermarkets

Insect farming has recently gained significant attention, as insects continue to broaden our understanding of natural and sustainable animal feed.

PAGE 68

PAGE 48 Annual Subscription Rates Inside UK: UK£100 Outside: US$150/€133 Milling and Grain has a cooperative partnership with COFCOET

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

Milling

News

Milling and Grain’s official video platform, MAG TV, which can be accessed via our official website, hosts a variety of videos from various companies in the industry that help provide more insight into the services they offer and many success stories from their customers.

One such selection of videos available on MAG TV is a collection from Turkish milling innovators, Yenar. Yenar have been producing processing solutions for the food industry since 1995 and are especially renowned for their roller mill rolls.

Yenar’s workshop One interesting video on MAG TV from Yenar is an insight into the running of their workshop. This video showcases the everyday running of the Yenar facilities, giving customers access to their production line and seeing the hard work being carried out by Yenar’s dedicated operators. There is a key focus on machinery used to make fluting rolls and viewers can see the machines running smoothly and efficiently, with minimal human intervention needed. myMAG.info/e/910

Yenar’s Sand-blasting machine In this video, we are given an understanding of Yenar’s unique Sand-blasting machine. The solution is opened up and made available to view, followed by an opportunity to see the solution in operation. Using the Sand-blasting machine, rolls can be smoothed in just under 15 minutes and the process is efficient, professional and simple. The digital screen and viewing window ensures that operators can monitor every stage of the smoothing and sanding process, from start to finish. myMAG.info/e/911

Yenar’s Combined fluting and grinding machine The Combined fluting and grinding machine is a Yenar innovation that has received widespread acclaim for its innovative features and this video goes into more depth to showcase the engineering behind this solution. The video takes viewers through each section of the machine, showcasing its many features and optional accessories.

Viewers can see the machine in running, highlighting how easily the operator can completely control the fluting and grinding process via a digital touch screen and controller. Cutting depth is automatically calculated and the multi-tool system allows for unique, specialised grinding and fluting options. myMAG.info/e/912

10 | September 2020 - Milling and Grain

The Mills Archive column in this month’s Milling and Grain was one that proved to be of great interest to our team, as, this month, Mildred Cookson takes a look at older issues of Milling and Grain magazine, back in 1891 when our publication was known as The Miller. Milling and Grain magazine has, unsurprisingly, gone through a plethora of changes and revisions over the many decades, and we are pleased that our publication continues to innovate and overcome any challenges that it faces.

Back in the 1800s, The Miller focussed primarily upon flour milling and specialised in food production processing, but the publication has now evolved into a selection of stories and news that caters to all aspects of food and feed production, as well as storage solutions and machinery on an international level. The development of the aquaculture industry also led to our publication covering aqua feed for some time, before we branched out and established our sister publication, International Aquafeed, approximately 20 years ago.

The Miller continued to be published and be a wealth of information for members of the milling sector, and this continues to be the case today. Our publication is being archived as a historical document for the milling industry at The Mills Archive in Reading, UK, and our future issues will also be archived, as a record of the milling sector and its evolution throughout the years.

Despite the impressive history of our publication, we have never seen such a unique situation akin to that of COVID-19. The pandemic is truly unprecedented and its effects on the milling sector are still being discovered.

Milling and Grain continues to dedicate itself to producing a reliable source of information for readers who wish to better understand the pandemic and its effects on the food and feed industries. We will be monitoring the situation at every stage and ensuring to provide our readers with the crucial information they need to know to stay safe and operate efficiently.

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Milling News

T

Zheng Chang complete installation of Belarusian Agro-Industrial Complex project he site manager of the CITIC Belarusian Agri-Industrial Complex Project has happily announced that Zheng Chang have completed their project with great success. Zheng Chang have successfully installed 35 silos on the site, with a capacity of 12,500 tonnes.

In order to ensure completion of the project and a great final result, the site manager worked with members of the elite Zheng Chang team to develop the

engineering project with a strict time frame in place, as well as considerable focus and attention paid to key points of the project, and various contextual considerations.

At every stage, the site manager meticulously inspected the project, to optimise quality and efficiency. So far, the team have passed 3,000 inspections and tests of multiple key quality points and areas. Extensive collaboration has also taken place with the Belarusian

12 | September 2020 - Milling and Grain

engineering team to further ensure optimal results when integrating the silos with the proper ventilation panels, wiring, fan assembly, temperature measurement systems and control panels. This is the latest in a long line of successful turnkey projects installed

by Zheng Chang, and the company express their pleasure to continue to be able to continue such impressive work, despite the challenges presented by COVID-19.

Milling News

COFCO and World Bank’s IFC partner for more sustainable soy in Brazil

C

OFCO International and the International Finance Corporation (IFC), a member of the World Bank Group, are partnering to help improve the sustainability of soy farming in Brazil’s Cerrado Biome.

IFC will support COFCO International’s subsidiary in Brazil to develop a more traceable and sustainable supply chain in the Matopiba region, including direct and indirect non pre-financed suppliers. The work will focus on screening soy farms in Cerrado’s vulnerable Matopiba region to ensure compliance with key environmental and social criteria and build farmer capacity to apply more sustainable farming practices.

Although Cerrado’s soy-related land conversion has been decreasing since 2001, the Matopiba region, comprising the states of Maranhão, Tocantins, Piauí and Bahia, has experienced higher land conversion rates linked to rising global demand for soy, Brazil’s main export commodity.

The screening will use farm contours, satellite imagery and other geographical information and official data. The aim is to ensure that supplying farms are free of forced labour, are not located on indigenous land, conservation units or embargoed areas, and are in compliance with the Amazon Soy Moratorium.

The project will also establish land conversion profiles for individual farms and assess supplier compliance

with the Cadastro Ambiental Rural (CAR), a mandatory electronic registration which combines geospatial data of rural properties with their environmental information, including legally protected areas.

COFCO International and IFC expect the project to cover 85 percent of COFCO International Brazil’s direct suppliers in the Matopiba region by 2021, and to fully cover the region by 2023.

Agrosatélite, a Brazilian company specialising in remote sensing satellite images and geographic intelligence, has been selected as the project’s technical partner.

This partnership follows COFCO International’s recent announcement that it expects to achieve full traceability of all soy purchased directly from Brazilian farmers by 2023.

It will help COFCO International to build on its work on traceability.

“Traceability was never our final destination but rather a tool to go further,” says Wei Peng, Head of Sustainability with COFCO International. “With this project we will be able to further screen non pre-financed suppliers for key sustainability criteria and identify those with whom we want to engage more closely.”

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FEFAC elects new president

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EFAC has elected Mr Asbjørn Børsting as its new President, for the term 2020–

2023.

Børsting, a graduate of the University of Copenhagen (in Agricultural Economics), served as CEO of The Agricultural Council & DLG. He is now Director of DAKOFO, the Danish Grain and Feed Association and Variety Denmark. He’s also Chairman of the Danish Bio-Economy Panel.

In a press release, Asbjørn Børsting states, “I look forward to the launch of the FEFAC Feed Sustainability Charter 2030 at the occasion of our FEFAC Congress on 24-25th September, 2020, in Antwerp, co-hosted by our Belgian members. Our Charter will contain concrete actions to promote animal nutrition solutions, increasing nutrient efficiency, reducing greenhouse gas emissions linked to feed production (through use of PEFCR Feed Category Rules & the GFLI Database) and help reduce the need for antibiotics at farm level.

We will also promote responsible and deforestationfree soy sourcing and new technologies to increase EU production of vegetable proteins.”

FEFAC have also recently launched a new website to facilitate access to information about the European compound feed and premixtures industry and any relevant FEFAC initiative to support the sustainable development of livestock production in Europe.

The FEFAC XXIX Congress is confirmed to take place physically in the Queen Elisabeth Centre Hall in Antwerp on September 24-25th, 2020. The event location is large enough to accommodate all necessary COVID-19 safety measures and social distancing rules.

The Congress will be held in partnership with the Belgian Feed Association (BFA). The main theme of the Congress, ‘Towards carbon-neutral feed and livestock production’, provides the reference for the launch of the FEFAC Feed Sustainability Charter 2030, responding to the EU Green Deal targets for the EU livestock and aquaculture sectors. FEFAC has invited keynote speakers and panellists from the EU institutions, COPA/ COGECA, and other value chain partners, NGO’s and scientists.

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Milling News

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Satake develop new gluten-free rice flour bread

S

atake Corporation has developed a unique bread production method, using rice flour, capable of producing an equivalent texture to wheat flour bread without using any of the seven main allergens, such as wheat, along with 21 other food products in Japan.

Bread from rice flour has been studied and developed throughout Japan. Traditionally, however, bread made with rice flour alone has a lower viscosity than that with wheat flour, therefore, it needs to be mixed with wheat-derived gluten to make the dough rise sufficiently to achieve a wheat bread-like texture.

Satake has been working to develop a new method for producing rice flour bread that is as tasty as those based on wheat, in an attempt to contribute to further expanding rice consumption in Japan. As a substitute for gluten, Satake focussed their research on the thickening polysaccharide.

After repeated research to ensure its effectiveness and safety, Satake has established a manufacturing method to produce bread that is as expansive as regular wheat flour bread. The production method is currently patent pending.

This unique bread production method uses only rice flour, sugar, salt, oil, yeast, and thickening polysaccharide.

Since the bread does not contain any of the 28 ingredients currently mandated or recommended by the Japanese Consumer Affairs Agency to be listed on the food product packaging, consumers with food intolerances, such as wheat allergy, can enjoy eating without worries. When baking, the dough rises to the same level as wheat flour bread and has a fluffy, light, and delicious texture. This allows families or even the food and hotel industry to serve the bread without concerns about allergic reactions.

Furthermore, the rice flour bread dough is softer than that of wheat flour, and rises in a shorter time, meaning the production time can be shortened by about fifty percent when compared to that of wheat flour bread, approximately 120 minutes from mixing to finished baking.

Satake plans to provide the method and technology to bread producers to promote rice flour bread for hotel/ restaurant meals, school lunches, emergency rations, and a sixth industrialisation by utilising locally grown rice.

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Milling News

Vortex donates equipment to University of Illinois Feed Technology Centre

V

ortex Global has recently announced the donation of slide gates and diverters that will optimise operations within the new Feed Technology Centre at the University of Illinois and the College of Agricultural, Consumer and Environmental Sciences. The facility, currently under construction, will be a national hub for new discoveries and advancement in animal management, nutrition, and production.

The US $20 million state-of-the-art project, located at the University of Illinois South Farms, USA, will accelerate advancements and expand horizons in technology and scientific discovery in feed ingredient utilisation, new processing technologies, and improved efficiency of food production.

“Vortex is proud to support the University of Illinois on this project,” says Vortex CEO, Travis Young. “The impact the Feed Technology Centre will have on research, innovation, and process efficiency will be tremendous for many generations to come. We thank the university for the

18 | September 2020 - Milling and Grain

opportunity to partner on this.”

Included in Vortex’s donation to the Feed Technology Centre are a total of 32 slide gates and diverters. Among these are the Vortex Gravity Vee Diverter, Vortex Titan Slide Gate, Vortex Seal Tite Diverter, Vortex Aggregate Gate and various accessories, controls and switches to increase valve performance and life span.

“We are incredibly grateful to Vortex for this generous gift. The equipment is vital to the everyday operations of the facility and, therefore, will allow our faculty and students to continue our tradition of innovation in the animal nutrition space,” said Rodney Johnson, Head and Professor in the Department of Animal Sciences at Illinois.

When it opens, the facility will drastically expand the capabilities of the more than 40 faculty members and hundreds of students, whose work and research depend on the Feed Technology Centre. Testing and calibration of equipment is expected to take place this summer with the goal to be fully operational by October 2020.

Milling News

Lebanon to receive 50,000 tonnes of flour from the World Food Programme following port explosion

A

recent United Nations report has stated that the World Food Programme (WFP) is set to send 50,000 tonnes of wheat flour to Lebanon after a devastating blast occurring at Beirut’s port on August 4th destroyed its only silo, with all the private stocks held there. The UN Office for the Coordination of Humanitarian Affairs (OCHA) report said the flour would be sent “to stabilise the national supply and ensure there is no food shortage in the country”.

A Reuters report on August 7th said Lebanon’s government held no strategic stockpile of grain before the explosion and all privately held stocks at the country’s only grain silo were destroyed. Current flour reserves in Lebanon were estimated to cover market needs for six weeks.

“An initial shipment of 17,500 tonnes is due to arrive in Beirut within the coming 10 days to supply bakeries for one month,” the report said.

“Lebanon consumes between 35,000 to 40,000 tonnes of wheat a month. With no large grain silos to store wheat 杂志广告20200316.pdf 1 20-3-16 下午4:02

in, sending the shipments as flour is more efficient,” said Hesham Hassanein, Regional Grain Consultant based in Cairo. “Flour comes in bags and is ready to distribute to be baked to bread versus wheat that needs to be milled.”

According to the UN report, the damaged port is not able to be repaired for at least a month.

“A temporary bulk receiving facility is needed for grain imports to ensure adequate national stocks,” the report said.

The French millers’ association have also said they were shipping 500 tonnes of wheat flour to Lebanon as a donation from their stocks. A first consignment of 250 tonnes left the southern French port of Toulon on August 9th aboard a navy vessel, and the rest of the flour is due to be shipped from France on August 11th, the association said in a statement.

France’s wheat growers association, meanwhile, is in talks with grain companies to assemble 25,000 tonnes of wheat to send as aid to Lebanon, says President Eric Thirouin.

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Milling News

A collage of the production process

How Milling was printed

by Mildred Cookson, The Mills Archive, UK

O

Milling journals of the past at The Mills Archive

ver the last few months of lockdown I have been increasingly impressed by how smoothly the publication of Milling and Grain proceeds. Working from home, digital communication supports us in many ways; thank goodness it also enables the production of high quality printed journals. This train of thought set me thinking about the early days of Milling, the ancestor of today’s issue.

An interesting well-illustrated article in the August 15th, 1903 issue of Milling described how the journal was printed in the days when digital only meant “of the finger”. The first issue of Milling appeared in 1891, published by The Northern Publishing Company Ltd. The magazine was the brainchild of George James Short Broomhall, described by John Maynard Keynes as the “greatest practical statistician of our age” when he died in 1933.

His stable included the Liverpool Corn Trade News, which first 22 | September 2020 - Milling and Grain

appeared in December 1888, renamed The Corn Trade News in 1890 and Broomhall’s Corn Trade News in 1895.

Based in Liverpool, the early editions strongly featured Lancastrian companies. Milling was quite unique as scarcely any trade papers were printed by the proprietors; most were sent out to printing works to be set up and printed. The offices and printing works were in the busiest part of the city, close to the port. Facing the River Mersey, the offices were situated midway between the newly erected White Star Line and St Nicholas Church. The building was part of a group of warehouses known as the Goree Piazza. Named after the former slave trading island off the coast of Senegal, West Africa, the warehouses were built 11 years after the courts ruled that every slave became free as soon as their feet touched English soil.

The warehouses were demolished following bomb damage during the Second World War. The buildings had been very firmly built, as evidenced by their housing the heavy printing machinery that was installed in No 17. The roofs were low and the floors very extensive; all the upright pillars which supported

An early issue of Milling

Operating the Lanston keyboard

Operating the linotype machine

the beams were of expensive woods and as hard as iron. By 1903 two modern machines, the Linotype and the Monotype, had been introduced, driven electrically rather than relying on a gas engine.

The Linotype machine, so called because it cast the type in lines, was introduced around 1899 and was protected by no less than sixty patents. Described as the most remarkable machine of the century, it marked the first and, at the time, the only successful departure from using moveable type and hand composition.

The revolutionary step involved creating from machine-made matrices, independent type lines or ‘slugs’ now known all over the world as ‘linotypes’.

The other improvement was the introduction of a device in which the linotypes were produced instantly and ready for use on the press “by the mere fingering of keys as on a typewriter”.

The keyboard was operated by just one person to produce and assemble lines of type ready for the press at the rate of ten to

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Milling News

The linotype machine

The keyboard of the Lanston Monotype

fifteen thousand letters-per-hour. It also allowed the face or style of type to be changed at will and allowed the operator to read and correct his material as he proceeded. Every issue of Milling was printed from new type, the previous being thrown into the melting pot and cast into blocks for another occasion.

The Lanston Monotype was installed just prior to the article being written and was said to be very difficult to describe. The linotype machine cast lines of type, whereas the Monotype cast separate types. The machine, as illustrated, was in two parts, a keyboard which had rolls of paper perforated to represent the setting out of the copy and a casting machine to which the paper was fed after perforation and which automatically cast the type and assembly in the galley ready for the printer. It was the only

The casting machine of the Lanston monotype

machine having the full English font of 220 characters, with Roman upper and lower case, italic upper and lower case and numbers and fractions.

Colour printing was a specialty and used to great effect to establish Milling as a superior looking, high-quality magazine full of much which is still of interest today.

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Milling News

W

Recent survey finds 27 million Brits baked during lockdown

ith homes across the country full of the aroma of banana breads, a new survey commissioned by The National Association of British and Irish Millers (nabim), undertaken by YouGov, has revealed just how much Britain turned to baking throughout the lockdown period.

The survey found that over half (53%) of respondents baked between the start of lockdown and mid-May, equating to 27 million UK adults, 34 percent of which had used two or more bags of flour since the start of lockdown.

The survey also showed what Britain has been baking, with bread emerging, perhaps surprisingly, as the most popular bake overall, with 37 percent of home bakers adding this to their repertoire – whilst seven percent have attempted sourdough loaves. Cookies came in second place, with 34 percent of these home bakers indulging in the sweet treat. These were most favoured by those aged 18-24 and 45-54, with 40 percent of these age groups having baked them.

The survey also asked about peoples’ future baking intentions. Almost five times (33%) the number of people who made sourdough between the start of lockdown and mid-May (7%) are looking to bake it in the future, and with 59 percent of these respondents intending to bake breads, this proves a love of bread baking has been reinvigorated nationwide. Having been bitten by the baking bug, home bakers are also wanting to broaden their range, with chocolate cake (59%) and cookies (58%) next up on the baking schedule as we emerge from lockdown. It is clear the upturn in baking as a hobby over the lockdown period has inspired a nation to switch on their ovens, with the trend not looking to ease greatly any time soon.

Baking is now popular with adults of all age ranges, with three in five (60%) of 18-24-year olds baking during 26 | September 2020 - Milling and Grain

the early lockdown period, 19 percent of 25-34-year olds having invested in new baking equipment, or planning to invest soon and 47 percent of 35-44 year olds saying they believe it’s a good activity to do with children.

Over one-quarter (26%) of respondents say they find baking to be relaxing and therapeutic, whilst 40 percent of 18-24-year olds say that baking has helped with their stress levels during the uncertainty of the lockdown period.

Earlier this year, nabim set up The Easy Peasy Baking Campaign, which was designed to simplify baking and cut through common misconceptions that stop non-bakers putting their aprons on. Through regularly sharing new recipes, baking tips, equipment swaps and friendly advice for new bakers, the campaign aims to prove baking is for everyone, and show that it can be simple, quick, cheap and use minimal amounts of equipment. With this new YouGov research, the campaign aims to support the many new UK bakers on their baking journey.

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INTUITIVE AND FAST PROGRAM SETTING

The Rex Wailes Collection Wind powered sugar cane mill in Barbados at work ca 1900

Windmills and steam power in Barbados

by Mildred Cookson, The Mills Archive Trust, UK By the late 1960s, Rex was being invited to survey and report on mills in many places around the world. As an engineer he made great use of his contacts before starting on such an expedition.

His planned trip to Barbados was carried out for McGill University in Canada, ably assisted by fellow engineer Sir Frank Hutson of DM Simpson & Co Ltd of Bridgetown. He first visited Simpson’s offices just off Trafalgar Square, where the engineers there dealt very largely with sugar mills and worked closely with the Central Foundry in Barbados. Rex was shown catalogues of machinery there, manufactured by Fletcher & Stewart Ltd, a firm in Derbyshire. Rex visited the Foundry and saw for himself the machinery and steam engines which delighted him no end.

Rex’s survey, carried out in January 1969, was subsequently written up in the Transactions of the Newcomen Society as a very detailed account with drawings and photographs of the many mills he visited.

Sugar mills have existed in the West Indies and South America for three centuries. Rex noted that they were first driven by animal power and waterwheels, later by tidal power, but particularly by windmills in Barbados. The focus on power source and technology was natural to an engineer and the technical details are of great interest, particularly as he recorded much in sketches later drawn up as detailed measure drawings.

He also related anecdotes that bring to life his visits, such as his account of his visit to the Morgan Lewis sugar mill, now restored by a UK millwright for the Barbados National Trust.

“A Mr Lewand called for me at 7:15am and took me out to Morgan Lewis Mill. I had been there an hour, taking exterior photographs and struggling with flash, which kept shorting, probably because of the high humidity. At the next site was a derelict tower mill, but still with the machinery inside. Whilst there, quite a number of taxis drew up with tourists. Only one man went to the top of the mill, and one woman entered the lowest floor. None of the visitors put any money in the collection box, which was perhaps hardly surprising as it was in an insignificant position with a curled-up notice, hardly legible.”

Rex’s image of a worker moving the tailpole, so that the windmill faced the wind, is a reminder that when these mills were originally built they were operated by slaves, and the sugar they exported helped to fuel that trade until the British outlawed it in 1833, after a previous failure to abolish it.

Sketch of Kirton, St Philip pumping mill, Barbados

Turning the sugar mill with the tailpole

28TH EDITION OUT NOW internationalmilling.com

28 | September 2020 - Milling and Grain

Milling News

EXTRUSION AND EXPANSION TECHNOLOGY YOU CAN TRUST With the Expander AL300 Which improves the quality of finished feed as well as a more efficient Process.

The Almex expanders have a reliably and sturdy design and are equipped by an unique Active Disk system (AD-system) in order to control exact product input and assure the quality of the product.

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Milling and Grain - September 2020 | 29

Milling News

AFIA leadership to serve on US Agricultural Trade Advisory Committees

Constance Cullman, CEO, AFIA

T

he American Feed Industry Association (AFIA) has announced that Constance Cullman, AFIA’s President and CEO, and Mallory Gaines, AFIA’s Manager of Market Access and Trade Policy, have been appointed to serve on the US Department of Agriculture Foreign Agricultural Service’s Agricultural Policy Advisory Committee (APAC) and Agricultural Technical Advisory Committee (ATAC) for Trade in Animals and Animal Products, respectively.

“Just like many industries, the US animal food manufacturing industry depends on the sale of its products to international markets. By having Constance, Gina and Mallory participating in these various trade advisory committees at USDA, it allows for the animal food industry to have a voice at the table as trade agreement and policy issues are discussed,” stated Scott Druker of Church & Dwight Company and AFIA Board Chair.

Congress established the advisory committee system in 1974 to ensure that US agricultural trade policy objectives reflect US public- and privatesector commercial and economic interests. The US Department of Agriculture and the USTR manage the committees.

Mallory Gaines, Manager of Market Trade and Policy, AFIA’

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Mill

TRAINING

Milling and Grain magazine, along with Progressus Agrischools, has set up the Online Milling School. It is currently hosting a series of two-hour sessions discussing various critical aspects of the feed milling operation.

The Online Milling School upcoming sessions announced The next upcoming courses offered as part of the Online Milling School discuss raw material receiving and storage, other supporting equipment, and quality assurance and control, taking place online on August 26th, September 2nd and September 9th respectively.

“This is a key initiative by both Progressus and Perendale to bring learning and knowledge sharing to the factory floor and to the locations of those who might otherwise not have access to a better understanding of processes,” says Roger

Through hands-on training in the Kansas State University milling facilities and classroom discussions at the IGP Institute, this course will help participants develop a conceptual understanding of the milling process with a focus on mill balance, understanding critical control points in the milling system, and milling different wheat classes.

IAOM-KSU Basic Milling Principles Participants will be provided with a greater knowledge of Through hands-on training, participants will learn quantitative tools and practices to influence and impact theeveryday running of the mill, as well as managing optimal machine adjustment, milling efficiency and flour quality. Expanding on topics from the Basic Milling Principles course, this course also explores quantitative techniques and tools to analyse and improve the process flow; understanding the variables that impact production efficiencies and enhancing troubleshooting skills of mill personnel to optimise mill efficiency.

IAOM – KSU Advanced Milling Course Topics in the course include wheat kernel characteristics; understanding cleaning systems and equipment for optimal The objectives of this course are to gain a general understanding of the principles of the milling process, from wheat receiving to finished product distribution; understanding the relationship between wheat quality and the effects of the milling process; gain knowledge of different wheat types and what products each can produce; gain knowledge of flour functionality and baking performance of different flours; and learn the role each department plays in the success of the milling industry. Participants will discuss all aspects of the flour milling process, from wheat selection to milling, to flour blending and baking functionality.

IAOM – KSU Introduction to Flour Milling Topics for the course include an overview of the US milling industry; wheat production; supply and demand; wheat classes, 34 | September 2020 - Milling and Grain

Gilbert, Publisher of Milling and Grain Magazine and CEO of Perendale ONLINE Publishers Ltd. MILLING “Each course will be held on a SCHOOL CR Wednesday live at 14:00 Bangkok EDO Time (10:00 CEST) and repeated in a re-broadcast to reach North and South American students on Fridays at 14:00 CDT. “Course content is developing as we progress and we hope to provide an incentive for those in the feed milling sector to begin a lifetime of learning, starting with an online introduction through the Online Milling School. We wish to work with established milling learning centres and will encourage students to go further over time,” he adds.

Whether you’re starting out in feed milling, advancing your understanding of milling processes or refreshing your knowledge based on certain aspects of the milling process to meet ongoing operational requirements, the OMS has something to meet that need.

the milling process and controls that are influenced by the raw material and the milling systems including cleaning, conditioning, milling, and finished products.

Topics to be covered include wheat classes and uses; wheat testing practices and methods; wheat cleaning and conditioning systems; the importance of wheat quality and preparation; milling process specifics and associated equipment; basic flowsheet terminology and understanding; advantages of wheat and flour blending; granulation curves; flour and dough quality testing; and practical hands-on experience in the Hal Ross flour mill and KSU milling labs. grain quality; processes, equipment and flow design, and steps of conditioning and tempering; in-depth analysis of mill flow sheets and design; mill balance and product distribution; in-depth study of functions, design and optimal set-up for roller mills, sifters, purifiers, detachers, dusters, and other milling equipment; cumulative attribute curves and their uses; understanding starch damage and it’s influences.

Milling engineers, operation managers, production managers, shift managers, head millers, professionals with theoretical or applied milling background will all gain significant benefits from undertaking this course. Having a theoretical milling background (milling school, university or other milling training) and some experience with practical work in a flour mill or other completed milling training is required. This course will take place September 21–25th, 2020. uses, and basic wheat chemistry; wheat cleaning and conditioning; gradual reduction process overview; milling math (extraction, tempering and blending); principles of mill flow sheets; an overview of the general milling process and major milling equipment; flour and practical hands-on experience in the Hal Ross flour mill and KSU benchtop milling and baking laboratories.

Staff members wo will benefit from this course include new mill employees, mill HR staff and managers, grain and ingredient procurement managers, feed and flour sales representatives, production schedulers, warehousing and QA personnel, R&D staff, wheat breeders, grain inspection personnel, food program administrators, international wheat/ grain traders, journalists, extension agents, wheat commission staff/board members, and agricultural and business economic analysts. No previous milling experience or theory is required. This course will be held January 4-8th, 2021.

We are now accepting enrolments

for the 2020 flour milling distance learning programme

Mill

TRAINING

OUR NEXT SESSION: Session 8: Other supporting equipment September 2, 2020

EDO

CR

ONLINE MILLING SCHOOL

major feed integrators and commercial feed millers Jon Ratcliff, an honour graduate from Reading University, joined the national UK feed company J Bibby Agriculture as a Poultry Nutritionist in 1981. He has considerable experiences in feed mill systems across the world and provides seminars and training on HACCP and GMP specifically for feed mills Olaf Naehrig is Amandus Kahl’s Senior Area Manager, responsible for Asia-Pacific markets. He is very familiar with all expects of the use of expanders in feed milling, such as improved feed digestibility, increase of pellet quality/capacity, hygiene, as well as the reduction of anti-nutritive factors for pig, poultry and cattle feeds.

Malcolm Gresswell has spent his entire career in milling of flour and animal feeds in Australia and Canada. He combines qualifications in Mechanical Engineering and Flour Milling, with 46 year’s experience at all levels of management in feed milling, flour milling, starch and glucose industries.

Roy Kazen is an SMEI-Certified Professional Salesperson and is also a Bachelor of Business Engineering and a Bachelor of Automotive Engineering. He has worked for Ottevanger and Asia Pentair Fairbanks Nijhuis.

Join Milling and Grain’s e-learning series: Online Milling School In July and August 2020, Milling and Grain magazine and Progressus Agrischools have run seven of its highly successful Credo Online Milling School e-learning experiences, specialising in topics such as pelleting processes, mixing, conditioning and grinding operations.

These cutting-edge training webinars are part of Milling and Grain magazine’s ongoing commitment to supporting all aspects of the milling industry. These webinars provide attendees with the need-to-know skills to optimise your feed processing solutions and make the most out of your machinery and ingredients.

“This is a key initiative by both Progressus and Perendale to bring learning and knowledge sharing to the factory floor and to the locations of those who might otherwise not have access to a better understanding of processes,” says Roger Gilbert, publisher of Milling and Grain Magazine and CEO of Perendale Publishers Ltd. “Course content is developing as we progress and we hope to provide an incentive for those in the feed milling sector to begin a lifetime of learning, starting with an online introduction through the Online Milling School. We wish to work with established milling learning centres and will encourage students to go further over time,” he adds.

• • • • •

The Online Milling School sessions are aimed at: Feed mill plant owners, managers and plant operators Quality assurance and maintenance staff Nutritionists and feed formulators Feed additive and animal health suppliers Industry advisors and technical consultants.

Each session is presented by an expert moderator with years of experience in the industry and followed by a Q&A session that allows attendees to ask questions directly to an expert and receive an immediate answer.

Milling and Grain still has plenty of content on offer: the series comprises of a total of twelve sessions, the eights onwards taking place throughout September. But that’s just the beginning, due to the huge popularity of these online sessions, more editions will be taking place in the future to provide millers with invaluable information.

Course presenters include:

Ryan Alan Celis, a Mechanical Engineer by training. A graduate from the University of the Philippines, he earned his Certificate in Advanced Military Training in 1985. He placed sixth in the 1987 Mechanical Engineering Licensure Examinations.

At present, his company also operates a feed mill plant in the southern Philippines, doing contract manufacturing for various

Your moderators

Roger Gilbert, Publisher of Milling and Grain has worked in the milling sector globally as a journalist and publisher since 1983, with a focus on feed, flour, rice milling and aquaculture feeds processing, and has been the publisher of Milling and Grain magazine since 2000. He is a New Zealander and believes that new milling technologies and applied science-based nutritional research is the way forward in providing safe and affordable food.

Yiannis Christodoulou is currently engaged with Progressus, Agentis Innovations and Athene Consulting, all companies which he co-founded in 2011. Yiannis graduated from the Scottish Agricultural College in Poultry Production and Management and from Wye Collage-University of London with a BSc in Animal Agriculture and currently is about to receive his MA in Leading Innovation and Changes in Organisation from York St John University, UK. www.onlinemillingschool.com

Upcoming Online Milling School sessions: • • • • •

Session 8: Other supporting equipment, September 2nd Session 9: Quality assurance and control, September 9th Session 10: Feed mill management, September 16th Session 11: Digitalisation and automation, September 23rd Session 12: Design and construction, September 30th

Register now to secure your place: myMAG.info/e/886 Tickets cost US $30 per session with a complete course fee of $330. If you have missed a course, attendees can still gain access via re-broadcasts.

Zheng Chang SZLH 1208 Pellet Mill

PRODUCT FOCUS September 2020 In every edition of Milling and Grain, we take a look at the products that will save you time and money in the milling process.

In the 1970s, Zheng Chang developed China’s first-generation particle feed pellet mill. Over the past 50 years, the company has accumulated rich manufacturing experience, mastered advanced manufacturing technology, and developed various types of pellet mills with different outputs, including livestock and poultry feed, shrimp feed and biomass particles, to provide customers with personalised design and solutions to meet different market demands. The result is the innovative SZLH 1208 Pellet Mill.

The external oil cooling and lubricating system can cool the oil and key bearing down. The automatic oil lubricating system also adds oil regularly and consistently to relevant parts to ensure optimal processing and product quality. The SZLH 1208 Pellet Mill is available in capacities of up to an impressive 75 tonnes-per-hour.

myMAG.info/e/908 www.zhengchang.com

Hammer Mill 1900

Vigan Simporter 600

Bastak Instrument’s Hammer Mill 1900 is used to prepare samples for gluten analysis, falling number analysis and NIR analysis.

The hammer mill motor works at 16,800rpm and can utilise many different sieve sizes to ensure ease of use and a wide variety of applications. Users can grind wheat, barley and corn using the Hammer Mill 1900.

After processing the first sample there is no need to clean the machine before preparing for the second sample, significantly speeding up rate of analysis. The solution is a compact size at 640x620x450mm and 51kgs heavy with an impressive grinding capacity of 300g in 30-50 seconds.

The Simporter 600 is ideal for the bulk handling of any kind of cereals, seeds, nuts, animal feed stuffs and delicate cargoes such as malt, barley, rice, feed pellets and cocoa. Vigan vertical screws can also be implemented to create a smooth flow and more efficient feeding with the Simporter.

The solution can transport up to 1500 metric tonnes-perhour and can quickly and efficiently discharge to quayside conveyors, trucks and rail wagons. The Simporter ensures clean and efficient unloading operations with totally environmentally friendly conveying and no dust pollution (as the material is totally enclosed within the belts). There is also no noise caused by the conveying elements and no product damage, as the products are gently transferred along the belts.

myMAG.info/e/905

PDF  myMAG.info/e/906

www.bastak.com

www.vigan.com

Yemmak Flaking roller mill

Magnum ST Extruder

Yemmak’s Flaking roller mill is mostly used for the crushing of small grains that have been steamed, to ease digestion of the high starch levels. Due to the solutions high diameter rolls, it is now much easier for grains to be effectively gelatinised. The grain is thoroughly gelatinised at the roller mill outlet. Rolls are hardened by heat treatment and resistant to abrasion. Roll intervals can be adjusted according to the desired flake thickness.

With hydraulic pressure controls, stable flake thickness is ensured via constant pressure and a fixed ball spacing. Thanks to the drum feeder on the machine, the rollers are regularly fed and a stable grain flow is provided. The optimum rotation speed of the roller crusher minimises product dust from the machine outlet.

Yemmak offer a variety of models of the Flaking roller mill with different roll diameters, as well as varying capacities of between three-to-ten tonnes-per-hour which can attain between 0.8-1mm flake thickness.

The Magnum ST Series by Wenger Manufacturing redefines versatility for smaller extruders, with no loss of capacity. The ability to use higher Specific Mechanical Energy (SME) settings to take extruded products to the next level makes this solution especially innovative.

Wenger’s extruder boasts speeds of up to 1,200rpm and power levels to 165kW hr/t SME at volumetric capacity. Benefits of the Magnum ST Extruder include potential for lower bulk density, higher absorbency levels of liquid coating, smaller cell structure, enhancement of textural properties and higher cook levels.

myMAG.info/e/917

myMAG.info/e/907

www.yemmak.com

www.wenger.com

38 | September 2020 - Milling and Grain

FOCUS

SPECIAL FOCUS

Extru-Tech introduces Self-Adjusting Die/Knife Cutter System

Dramatic reductions in maintenance costs and downtime are just two of the benefits of a new Self-Adjusting Die/Knife Cutter System from Extru-Tech, Inc. Equally important, the new advanced feature cutter head can be used across their full spectrum of wear plates.

According to John Menold, Field Service Manager for Extru-Tech, the new die/knife cutter system offers a cleaner cut than cast blade configurations due to a “precision” pressure pack and individually replaceable blades, which can be sharpened up to three-tofive times.

“Not only can they be re-sharpened, but the new blades have been reported to last from 2.5-10 times longer than cast blades,” Menold adds. “This translates into lower overall cost, particularly when you consider the automatic adjustment feature allows one cutter head system to be used on multiple dies. The cutter assembly is easily secured and automatically set parallel to the wear plate with just one bolt.”

Menold notes that the self-levelling feature also allows the system to accommodate non-perpendicular die stubs and worn plates.

For additional ease of maintenance, the self-adjusting die/ knife cutter system is rated for wash-down and utilises high temperature, sealed bearings for longer life. The single cutting edge of the blades also minimises the risk of injury to employees and personnel.

Extru-Tech, Inc, headquartered in Sabetha, Kansas, currently produces and markets one of the industry’s most complete lines of extrusion processing systems, along with a full line of ancillary equipment and customised equipment solutions for specialised processes. Since 1985, Extru-Tech has installed extrusion systems worldwide, designed for the production of human food, pet food, aquatic feed and animal feed products.

myMAG.info/e/909 www.extru-techinc.com

www.goudsmitmagnets.com Milling and Grain - September 2020 | 39

F

ROLL MEASUREMENT

A

15,000 measuring points over 15 millimetres

by Martial Wüthrich, Managing Director, Diavite AG, Switzerland lways more precise: Modern production processes have to meet ever higher quality requirements.

Accordingly, the demands on the measuring technology used to determine the quality of the products are also increasing. This also applies to the measurement of surface roughness, such as the surface of rolls used in the milling industry. The corresponding measurement devices must meet ever higher demands on accuracy and also be as versatile as possible. In addition, end users of measuring instruments are increasingly demanding special solutions for automated, process-accompanying quality control systems.

Wear equals loss

In the milling industry, the condition of the surfaces of the smooth and corrugated rolls is of decisive importance for the profitability of a mill. In modern mills, the roller mills, as the central production unit, run practically around the clock. Since the grinding process is basically purely mechanical - coarse becomes fine by grinding - even modern rollers made of special alloys are subject to a certain amount of wear. Experienced millers know this, and numerous measurements and studies by mill manufacturers prove it: The degree of wear of the rollers has a direct influence on the quality of the products, the yield, the energy consumption, on moisture losses and also on the stability of the grinding process. The bottom line is that the higher the degree of wear, the higher the losses, in tonnes and dollars.

Various control options

These correlations explain the importance of regularly checking the condition of all smooth and corrugated rolls “working” in a mill. These checks can be carried out in various ways. The simplest, but also rather inaccurate, is the visual inspection, where the experienced miller uses a dome to inspect the condition of the rollers. A second possibility is the analysis of the products 40 | September 2020 - Milling and Grain

in the laboratory. This mainly involves determining the particle sizes, moisture loss and/or ash content of the intermediate and end products. Finally, monitoring energy consumption and yield can provide indications of roll wear. The most accurate way to determine roll wear is to measure the surface condition.

Service station or on-site?

The service stations operated by a number of globally active suppliers of milling systems are equipped for such measurements of the surface condition of the grinding rolls. However, this means that the rolls must be removed, replaced by replacement rolls and transported to the service station for inspection and any necessary machining. The whole procedure is very timeconsuming and expensive.

The ideal solution is to measure on-site. However, for reliable measurements in the mill, good spatial, hygienic and bright conditions must be available. For the measurement itself, the various suppliers present different measuring equipment. There are two basic types of equipment. One works optically, the other measures tactilely, i.e. “touching”.

Optical or tactile?

Optical measurements are performed with no physical contact, typically with light or laser. In principle, the reflection of the light/laser by the surface and, thus, its condition is measured.

The surfaces must be very clean and there must be no disturbing light sources. At best, even anti-reflection pastes must be applied.

In tactile, i.e. contact measurement, a standardised diamond tip is pulled over the surface to determine the surface condition.

Tactile devices are, “all-rounders”. In the case of smooth rollers, the surface is scanned by a diamond stylus and the Ra-value (roughness value) is determined. With corrugated rolls, the contours are measured with a needle stylus.

Advantages of tactile measurement

The advantages of tactile measurement are mainly in its simplicity. The application is not complicated: Simply place the stylus, start measurement and read the result. For measurement,

F either so-called diamont stylus or needle stylus are used. They measure according to different principles. With diamont stylus, a skid is pulled over the workpiece, which usually surrounds the probe tip at the side.

The recorded signal thus has the surface of the skid in the immediate vicinity of the probe tip as a reference. Macroscopic waviness or angular deviations of the surface are largely suppressed. The recorded signal describes the microprofile. In contrast to this, with the free stylus, only the probe tip is in contact with the workpiece, so that all geometric features of the test piece, such as waviness or angle errors to the reference plane, are represented in the measurement signal.

The rollDetect system

The Swiss company Diavite, in cooperation with Bühler, has developed a portable tactile device for measuring the surface condition of smooth and corrugated rolls.

The rollDetect system has been in use for several years and has proven itself worldwide. It is used in Bühler service stations and also by Bühler specialists on the road for periodically checking the surface roughness of grinding rolls in flour milling, feed milling, and brewing industries. It consists of a scanning device that can be freely positioned on the rollers and an evaluation unit. The values determined are with great accuracy by means of 15,000 measurements over a 15mm measuring path. Smooth rollers are measured using a diamont stylus, while corrugated rollers are measured by a needle stylus, showing the effective

The two different stylus used for rolls; Diamont stylus for smooth rollers and needle stylus for corrugated rollers

surface structure of the examined roller. The values are then directly evaluated in a special evaluation device.

The initial result of the evaluation, the tecReport, shows the current condition of the roll graphically as a deviation from the target condition and, in a traffic light system, evaluates the condition of the roll as “green = ok”, “orange = to be observed”, or “red = critical”. A further function of the software creates the so-called ecoReport for each individual roller, which interprets the data determined, and taking into account all factors of economy, determines the optimum time for the inspection of the roller - not too early and not too late, but just at exactly the right moment. www.diavite.com

Milling and Grain - September 2020 | 43

F

Bringing innovation to the milling industry

S

by Balaguer Rolls, Spain

earching for new technological improvements to be applied to the food processing industry is in Balaguer Rolls’ DNA since its establishment, over 100 years ago. As a leading company in manufacturing centrifugal chilled cast rolls for the milling industry, Balaguer Rolls has applied its knowledge to develop machines for the sector which help its customers to reduce both the time and costs associated with the fluting process.

It is for this reason that Balaguer has become the global and sole distributor of Rodomach, an expert company in manufacturing and installing high-quality robotic machines and systems, specialising in CNC machinery. Robomach has developed a machine which reduces fluting time by almost 40 percent.

The strategic association of both companies gives rise to the fastest fluting machine in the market, achieving the incredible return speed of 105m/min, drastically reducing the fluting time in order to increase mill productivity.

This competitive advantage has been achieved by completely redesigning the fluting machine. Changing the intricacies of the system and maintaining the bench, with the roll fixed all the time, during the fluting process and only moving the support with the

44 | September 2020 - Milling and Grain

fluting tool leads to optimised results. This principle reduces the moving weight and the cycle time of the system. As a result, the machine only uses 2kW of electrical power. Moreover, the new R-F300/1500 has the most compact design in the market, by reducing the machine size by 30 percent and ensuring easy installation in any mill or workshop.

Fluting speed: The new fluting machine R-F 300/1500 is the fastest machine in the market, having a cutting speed of 30m/min and a return speed of 105m/min. Thus, the machine reduces the fluting cycle time by up to 38 percent, by drastically increasing the machine’s productivity. All this is carried out without increasing power consumption. Due to the unique orientation of the cutting tool, the R-F 300/1500 doesn’t need to utilise compressed air for chip removal on the roll. Both of these features reduce operational costs dramatically.

Compact: The R-F 300/1500 is 30 percent smaller, with a unique compact design. Launched as the fluting machine with the smallest measurements on the market, and weighing in at only 4.5 tonnes, the start-up is simplified, and the transport costs are reduced.

Lower speed in and out fluting: By lowering the tool speed when making contact with and moving away from the roll surface, the machine achieves optimised roll care and increases

F Rodomach R-F300/1500 Roll specifications Body diameter

Speed Body length

Weight kg

Flute inclination

Cutting speed

Return speed

m/min

m/min

mm

feet

mm

feet

Min.

100

0.328

250

0.82

0

Max.

300

0.984

1500

4.921

30

Remarks

feet/ min

Length

feet/ min 0%

9.1

105

Cycle time 38% faster

the lifetime of the tool. In addition to this, the solution achieves fewer break outs of material and preserves the roll shape.

Single- and multi-tool system: The new FL300/1500 is prepared for operating with both single- and multi-tool systems, as well as for adapting to the customer’s needs under any unique circumstances. Moreover, the machine makes it possible to quickly change tools by using a state-of-the-art VDI tool holder.

Live visual process control: By assembling the most advanced control panel in the market, the worker can see the fluting process at all times, directly through the high-definition camera installed next to the fluting tool. Thus, the worker has clear visual information readily available for making sure, during the whole fluting process, that the machine achieves a perfect flute. This software also ensures workers can detect tool wear, in order to sharpen or change rolls at the right time.

Intuitive software: The software developed guarantees the shortest and easiest work preparation, allowing all users to get the most out the machine in only few quick and easy steps. The

Machine dimensions

32

Width

Height

mm

feet

mm

feet

mm

feet

3500

11.5

2210

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machine also allows remote access via mobile phone or PC, in order to control the fluting process remotely.

Optional features: The new R-F 300/1500 also includes the Optical Fluting Test 2.0 (OFT 2.0), the world’s only device able to check rolls profiles by optical vision without roll contact. The OFT 2.0 allows for quick and accurate checking of the flutes in the roll. The machine also offers the possibility to include additional features such as the steady rest with digital read-out or automatic length compensation.

The new fluting machine R-F 300/1500 brings about a technological leap in the milling industry, since it achieves a fluting speed and return speed never seen before. As a result, the fluting machine by Rodomach reduces the fluting time significantly, so time and cost are both reduced, offering a dramatic increase in productivity.

Its operation speed, its compact size and its ease of use makes the R-F 300/1500 fluting machine the most powerful machine in the market. www.balaguer-rolls.com

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CHICKEN FED WITH INSECT OIL GO ON SALE IN FRENCH SUPERMARKETS

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by Gregoire Belegaud, InnovaFeed, France

nsect farming has recently gained significant attention, as insects continue to broaden our understanding of natural and sustainable animal feed. Thanks to the collaborative efforts of an entire value chain, a new landmark has been achieved: for the first time, consumers can eat chicken whose diets were enriched with insect oil. This is an exciting breakthrough as insect oil products reduce the environmental impacts of animal husbandry.

InnovaFeed’s insect oil, SaniNovaTM, has indeed achieved an 80 percent lower carbon footprint than imported soybean oil. The launch of this new insect-fed value chain demonstrates, once again, the full potential of the insect sector.

Demonstrated zootechnical performance and improved animal welfare

Between March and June, a batch of chickens raised in France received a feed enriched with InnovaFeed’s insect oil, SaniNovaTM. This world premiere confirmed the results of previous trials done by InnovaFeed at a smaller scale. Chickens were raised in Label Rouge conditions (free range for 85 days) with the exception of insect oil replacing 100 percent of soyabased oil in the diet. Zootechnical performance was closely monitored during the entire rearing period.

Insects are a natural part of poultry diets, and this is reflected in the performance of the animals fed enriched diets. Regarding animal husbandry, insect oil had a positive impact on animal welfare: lower levels of stress response were measured. Chickens were calmer, less afraid of human contact and pecking between individuals was reduced. All of this combined meant their plumage was considered by farmers to be more beautiful, softer and fuller.

More generally, poultry demonstrated a strong appetence to the product and positive trends in regard to feed conversion ratio (FCR). This allows for a steady weight growth to meet the farmers’ high standards. Chicken fed with insect-enriched feed also happen to have higher litter quality, making it both drier and easier to crumble.

Based on these results, a request has been made to include insect oil from black soldier fly larvae in Label Rouge specifications.

Insect oil: A natural and sustainable alternative to vegetable oils

Insects can be bred sustainably, the process being both zero-

48 | September 2020 - Milling and Grain

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F waste (the insect is used entirely) and circular (insect bodies are used as organic fertiliser for the agricultural by-products that will feed the larvae). Yet, InnovaFeed has developed an even greener process, based on co-localisation of its production facility with existing industrial players. The biotech company thus valorises co-products of a local starch manufacturer to feed its larvae and captures waste energy from a nearby renewable power plant.

Thanks to this unique industrial symbiosis model, the company is able to raise its insects (which like warm temperatures) at a very low environmental cost, reducing the CO2 footprint of insect oil by 80 percent, compared to vegetable oils.

In the wild, insects make up to 50 percent of a standard poultry diet, meeting their nutritional needs. Replacing vegetable oil with insect oil in poultry diets, therefore, constitutes as both a natural and sustainable choice.

“By upcycling local cereal co-products and repurposing insect waste as an organic fertiliser, InnovaFeed’s products truly have a positive environmental impact,” says Clement Ray, Chief Executive Officer at InnovaFeed. “We’re also able to have a positive impact on climate change by saving 57,000 tonnes of CO2 emissions-per-year with each 10,000-tonne production unit by feeding insect meal to animals. That is equivalent to travelling 5,800 times around the Earth.”

From farm to fork: Consumer-driven sustainability

The commercialisation of insect-fed chicken, a world premiere, results from the close collaboration of the entire value chain, from farm to fork. Players have combined their know-how and expertise to provide consumers with natural and sustainable poultry, whose traceability is 100 percent secured.

According to a Kantar consumer survey, insect-fed chickens

answer a customer’s needs, as 87 percent of consumers want to reduce the environmental impact of their food.

The entire value chain worked together to offer and explain this pioneering product to the end-consumer. The feed formulator Nealia, an expert in animal nutrition, has developed an innovative recipe in which soybean oil is replaced by insect oil. These freerange chickens were then raised at a farm in Champagne, France and processed by Les Eleveurs de la Champagne. Finally, Auchan renewed its commitment to sustainable and natural value chains, leveraging insects as feed. This was a successful bet, as they are the first to bring to market these insect-fed chickens. All these players have worked together in order to feed tomorrow’s world.

By highlighting the insect-based origins of these products through clear and informative labelling, this value chain approach empowers customers to make an informed decision about the impact that their diets have on the planet. Indeed, the launch of insect-fed poultry has been supported by a strong communication in stores and online, in order to emphasise insect oil benefits for consumers: primarily that of naturality and sustainability.

The final result of this operation is a consumer, surprised but interested by the product.

It is not the first time that InnovaFeed’s new value chains are highlighted; they had already launched insect-fed trout in 2018 at Auchan. The objective for the poultry sector is to convert this new value chain into a sustainable industry by the end of the year.

By placing innovation at the heart of modern food systems and offering SaniNovaTM, its insect-based product, InnovaFeed offers a clear and relatable solution to drive local, sustainable, ethical and high-quality products to the market, in line with customer needs. https://innovafeed.com

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Wheat flour fortification in Egypt:

During a pandemic

D

by Jessie Genoway, Food Fortification Initiative, USA

uring the COVID-19 pandemic, the uncertainty of supply chains, increased premix prices, and trade restrictions have led some countries to scale back efforts to fortify grains with vitamins and minerals that strengthen individual health and whole economies. Yet, the Egyptian government’s commitment to the health of its citizens is clear: despite challenges posed by a pandemic, Egypt is pushing ahead with the Food Fortification Initiative’s (FFI) support to restart the country’s wheat flour fortification programme, save lives, and bolster the economy.

Food fortification, sometimes referred to as food enrichment, is when food producers add essential vitamins and minerals, also known as micronutrients, missing in a population’s diet to food that people eat every day. Food is fortified to prevent micronutrient deficiencies that can limit a child’s academic achievement, reduce adult productivity, and cause disabling or fatal birth defects.

Fortification: A weapon against COVID-19

Malnutrition from micronutrient deficiencies is a pressing public health issue in Egypt: 20-30 percent of women are anemic; birth defects are three times what they could be if women had adequate intake of folic acid and losses in gross domestic product due to vitamin and mineral deficiencies are over US $800 million annually.

But the potential for fortification to dramatically improve Egyptians’ nutritional status is even greater: 90 percent of the population (90 million people) is reached by industrially processed wheat flour that can 52 | September 2020 - Milling and Grain

F

be easily fortified, providing a tremendous opportunity for Egypt to address persistent health and economic challenges.

More than ever, flour fortification with iron, folic acid, and other essential nutrients is a life-saving intervention vital to reducing the risk of malnutrition before, during, and after pandemics. The frontline of every country’s health system is the immune systems of its people. Several micronutrients, including folic acid and iron, may influence the susceptibility of a person to infectious diseases and the course and outcome of such diseases.

Good nutrition helps boost the immune system, lowers the risk of becoming critically ill with infectious diseases, and supports faster recovery when infected. While more data needs to become available on the role of nutrition to the severity of COVID-19, the role of micronutrients in the optimal function of immune systems is well established.

Furthermore, fortification is an adaptable intervention wellsuited for the social distancing requirements demanded by the COVID-19 pandemic: large-scale fortification does not require

direct person-to-person contact to deliver micronutrients to beneficiaries.

Bread builds life

Egypt’s former national fortification programme provided fortified baladi bread, a staple food consumed by a majority of Egypt’s low-income population, at a subsidised cost. In classical Arabic, baladi means ‘life’. Through this programme, lifesaving amounts of folic acid and iron reached approximately 50 million Egyptians. However, due to the Arab Spring uprising in 2011, the country’s fortification programme came to a halt.

In 2018, the Government of Egypt launched 100 Million Healthy Lives, an initiative that emphasised the critical role of nutrition in health and economic development. To help Egypt’s 100 million citizens access essential micronutrients, the government decided to restart the national wheat flour fortification programme. In April 2019, the government requested FFI’s technical support. Once a partner agreement was drafted,

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F realistic plan for implementing fortification. Although Egypt had required the fortification of baladi bread through the national subsidy programme, this requirement did not include wheat flour produced for the open market. One of FFI’s first recommendations is that the government enact mandatory fortification for wheat flour sold on the open market, an improvement that will ensure fortified wheat flour reaches at least 90 percent of the population.

From planning to implementation and monitoring, FFI and the Government of Egypt remain committed to the work of rebuilding a smarter, stronger, and healthier future for Egypt, one baladi bread at a time.

About FFI

FFI completed a comprehensive situation assessment. The assessment mapped the opportunities and challenges for flour fortification that lay ahead and helped the government take its next step in planning a successful programme.

A stronger future

Building on the assessment and subsequent discussions with stakeholders including government, wheat millers, and consumers, FFI is working with the government develop a See more Milling and Grain content about flour fortification FEATURE: Fortification: Excessive nutrient risk calls for thoughtful approach

mymag.info/e/895 M&G_gennaio.pdf

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The Food Fortification Initiative champions effective grain fortification so people have the nutrition they need to be smarter, stronger, and healthier. FFI helps country leaders plan, implement, and monitor fortification of industrially milled wheat flour, maize flour, and rice. Established in 2002, FFI is the only global group that focuses exclusively on these commonly consumed grains through public, private, and civic partnerships.

References

World Health Organisation. The global prevalence of anemia in 2011. 2015.

Blencowe, H., et al. Estimates of global and regional prevalence of neural tube defects for 2015: a systematic analysis.

Annals of the New York Academy of Sciences. 2018.

Egypt World Bank. Nutrition at a Glance. Accessed 12 February 2020. http://www.ffinetwork.org

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Packaging pioneers prove their expertise in the food industry

S

by Mira Ulz, Marketing Assistant, Statec Binder, Austria

tatec Binder continuously manages to successfully apply its expertise as a bagging and palletising specialist of bulk materials on a global scale. With its flexible and customer-oriented packaging technology, the Austrian company is represented on the international market, placing itself among the leading suppliers of high-performance open-mouth bagging machines. The wide-ranging product portfolio offers customised solutions of the highest quality for products used in a variety of industries.

Statec Binder packaging machines pack a wide range of animal feed and food products on a daily basis. Whether flour, rice or animal feed and additives, the bagging and palletising expert offers the right system, fully automatic or manual, to meet high standards and requirements of customers. Numerous references in these industries speak for themselves – Statec Binder stands as a strong and reliable partner and can draw on years of experience

56 | September 2020 - Milling and Grain

and in-depth knowledge.

Included in the broad product portfolio, the packaging system CIRCUPAC is installed in the global food sector. The highperformance bagging carousel is particularly developed for flour and powdery products. The special feature of the packaging machine is the continuously rotating carousel, which allows the entire process to be carried out without a start-stop system to achieve a maximum output. In 2018, one of the world’s largest flour producers gave Statec Binder the chance to prove the highperformance capacity of the CIRCUPAC bagging system.

In moving from semi-automatic bagging systems to fully automatic lines, several manufacturers were in the closer selection as potential partners for the project. The customer’s requirements of 1200 demanded bags-per-hour, each bag containing 25kg flour, proved to be quite challenging for many manufacturers. With the prioritised aim of increasing the previous output significantly, the flour producer finally made the right decision. Statec Binder was able to win the bidding process, especially the high machine performance and provided accuracy in weighing and dosing were decisive factors. Additionally, the technical implementation and the project setup encouraged the company to place its trust in the Austrian specialist. Three fully automatic CIRCUPAC bagging carousels and three highperformance PRINCIPAL-R robot palletisers were ordered.

Additionally, quality control equipment such as checkweighers and metal detectors were supplied.

As part of the packaging line, a long conveyor system was installed to guarantee a smooth transition from the bagging to the palletising process. A special feature of this system is the bag detection equipment, which can identify the category of the bag according to the bag’s imprint, to convey it to the corresponding robot palletiser. The customer further attached great importance to a clean layer pattern, which is easily achieved with the

F PRINCIPAL-R. Moreover, via a control system, the customer can always monitor the machines’ performance, productivity, and efficiency.

After the installation of the packaging lines, on-site acceptance tests were successfully carried out over six shifts. The products to be filled were used to test each machine on two separate shifts, with one lasting over six hours. As the customer paid particular attention to the overall achieved output capacity, the filled bags on the finished pallets were counted as part of the acceptance test.

Throughout the single phases of the project, a cooperative partnership could always be remained. Wolfgang Kober, Division Manager Project Management at Statec Binder, explains his experience with the customer, “We had a common goal in mind, namely the successful completion of the project and consequently to enable perfectly running production processes. This and the constant exchange of information with the customer’s team significantly contributed to the accomplishment of all project objectives.”

Knowing that the same customer, one of the most renowned flour producers worldwide, is placing its trust in Statec Binder competencies again with another project, proves the quality of the offered technology and the company’s knowhow. The placed order is currently in the final phase of assembly, and after a successful acceptance test, the packaging equipment will soon be shipped to the customer.

In addition to the CIRCUPAC and the Principal-R, also other

Statec Binder bagging and palletising solutions can be ideally used in the food sector, but also for the packaging of animal feed and pet food. Depending on the specific product requirements and the desired output, Statec Binder offers three open-mouth bagging machines to choose from: the PRINCIPAC and the CERTOPAC, both high-performance packaging machines, and the ACROPAC. Previously installed bagging machines of the series are successfully used worldwide for the packaging of food and feed products.

The fully automatic high-performance bagging machine CERTOPAC can pack any type of free-flowing bulk material in pillow bags and gusset bags with a filling weight between 5kg and 80kg at incredibly high speed. In addition to the

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“standard version”, the packaging machine is also available as CERTOPAC-S and CERTOPAC-L. The differences between the versions are the bag magazines (rotating bag magazine or push magazine), the different filling weights and sizes of the bags.

Particularly the CERTOPAC-S, abbreviated for CERTOPACSMALL, has been a great success for Statec Binder in recent years.

The machine was developed especially for the packaging of maize meal in the South African market, which has always been an important source of food for the South African population.

In the past, the dusty product was packaged in large paper bags with a filling weight of up to 80kg. However, the packaging requirements for maize meal, including bag sizes and used materials, have changed considerably. As a result, the bagging of the product in large bags, which used to be quite common, was no longer preferred by the purchasing population. In addition, paper as the used bag material became more and more of a problem because producers had to deal with many complaints and returns, as the material often broke during transport.

“As a company, we reacted with the development of the CERTOPAC-S. With the technical features of this machine, we were able to perfectly address these trends in South Africa at the right time,” says Josef Lorger, Managing Director at Statec Binder.

The CERTOPAC-S uses polypropylene (PP) as a bag material to ensure sufficient resistance, and at the same time packs maize meal in small bag sizes, usually with a filling weight of only 5kg.

Statec Binder was, thus, the first manufacturer on the South African market to develop a product especially for maize meal.

“Thanks to our rapid response to market requirements, Statec Binder has achieved a great deal of recognition in all of South Africa with our machine. We are now the key supplier for this industry with an extremely high market share of 85 percent for automatic packaging with PP bags,” says Josef Lorger. The potential for the CERTOPAC-S is great, since maize meal is an important product not only in South Africa, but on the entire African continent. The demand is expected to remain high in the future. Only in a recently completed project, a maize meal producer was supplied with four packaging machines, and due to the high level of satisfaction, a follow-up order for a further CERTOPAC-S packaging machine has already been placed.

However, Statec Binder has more highly efficient packaging solutions to offer. Standing as the most efficient machine out of the broad product portfolio of Statec Binder, the PRINCIPAC is a packaging system prepared for a wide range of applications.

As an ideal system for those who want to make the move from manual or semi-automatic packaging to fully automatic packaging or require rather low capacity, Statec Binder offers the product Acropac. Moreover, also Form-Fill-Seal (FFS) packaging solutions are offered for these industries. The FFS machine

SYSTEM-T is particularly suitable for the fast packaging of bulk materials and can fabricate pillow bags and gusset bags with a filling weight between 5kg and 50kg. On the other hand, the SYSTEM-F, a fully automatic vertical FFS machine allows easy and quick adjustability and only requires little space.

Statec Binder further ensures precise weighing and dosing in product feeding by equipping bagging machines with highperformance net weighers. Moreover, the company ensures a secure and precise bag closure through Statec Binder bag closing systems. For instance, the patented bag closing system “Over Tape Bag Sealer” is especially suitable for PP bags. The hot air of the machine, which is produced by a heating unit, seals the bags airtight and makes sure that they are completely odourless.

The packaging process of animal feed and food products is optimally complemented by fully automatic high-performance palletising systems. Besides the robotic palletising solution PRINCIPAL-R, customers can choose from high-level and portal palletisers.

Thanks to proven technology as well as continuous developments and optimisations, the company serves as an internationally recognised partner to many. Expert consulting services, a high level of service competence and support for any concern provide additional reasons for this. The fullest satisfaction of customers has always the highest priority. www.statec-binder.com

Milling and Grain - September 2020 | 59

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Toward the Smart Mill with Pluto PCS

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by Gernot Ruppert, Program Manager Smart Mill and Silvan Trunz, Senior Sales Advisor Automation and Digital Solutions, BĂźhler, Switzerland

rom the earliest automation through to full-scale digitalisation and connection to the cloud, milling is evolving fast.

BĂźhler offers the technology and support to manage the transition. Pluto PCS is one basic but important step on that journey.

Today’s young people are the first true digital natives. They have never known life without smart phones and

Two solutions for different requirements

62 | September 2020 - Milling and Grain

total connectivity and their choices and expectations reflect this.

As they enter the job market, the consequences are being felt nowhere more so than in industries like milling that have relied in the past on traditional craft and expertise. As a result, businesses that demand manual craft and skill are experiencing difficulties attracting younger people.

Even if the effects of these changing expectations among young people are not yet felt, mills should be prepared. This is vital because the milling industry is as important today as it

F ever was, may be even more so. With the world’s population growing, the industry needs to ensure it is equipped to meet the increasing demand for quality milled products – and that means embracing digital technologies.

Technology moves on, so does milling

In fact, the milling industry has always developed with the world around it. From wind and water powered mills, through mechanisation, to electrically powered mass production and basic automation – milling technology has evolved at an increasing pace.

For an industry rooted in tradition, craft and skill, today’s digital revolution is occasionally met with some reservation. “This is understandable, the pace of change has been incredible. Some people fear losing control,” says Gernot Ruppert, Program Manager Smart Mill. “However, the benefits of digitisation are clear and proven: improved safety and security, more efficient processes, cost savings, enhanced asset utilisation and increased productivity.”

In today’s high-tech mills, user-friendly controls and steering systems guide staff through processes ensuring the smooth operation of the plant. As the technology continues to evolve, Internet of Things (IoT) – the infrastructure that connects physical entities with virtual items – is transforming the business of milling yet further.

The vision

Bühler has created the Smart Mill Program to explore all the opportunities these new technologies offer to milling. The goal is to provide more and better guidance for millers and their teams, and a concise overview of processes for management.

“Our goal is to develop the fully autonomous mill. That is our vision. This can be achieved in steps starting with simple assistance and later in the process with more sophisticated systems that enable operations to fully benefit from digitisation and IoT technology,” says Silvan Trunz, Senior Sales Advisor Automation and Digital Solutions.

Pluto PCS is one of the latest additions and complements the automation portfolio.

As the name suggests it is a Process Control System (PCS) designed with small and medium sized operations in mind. Easy to use and with all the necessary functionality, it is the natural replacement for old relay-based systems and is an upgrade on the LiteCoS automation system. For millers running simple processes that do not require sophisticated functionalities, Pluto PCS is the perfect fit.

Its sister system Mercury MES, the successor of WinCos, represents the next step.

It is a Manufacturing Execution System developed for more complex operations with many different functionalities and add-on’s.

Bühler is raising its entire suite of systems to today’s state-of-the-art digital technology and best practices. As a result, like other Bühler web-based systems, Pluto PCS and Mercury MES are accessible via browser on any device, including PCs, laptops, tablets and smart phones.

Pluto PCS: Functionality and features

Process visualisation: Pluto PCS visualises the entire production process, from the grain input to the milled output. Operators can control, start, stop, and suspend the process via a user-friendly interface Orderly control: For mills that are upgrading from older relay systems the benefits are significant. Pluto PCS not only automatically steers the process and switches machines on and off in the correct order, it also visualises the status and online values of every machine and scale Milling and Grain - September 2020 | 63

User-friendly web-based interface: The web-based technology means that Pluto PCS can be flexibly accessed via multiple devices, from PCs, to tablets and smart phones.

This is a huge advantage in comparison to old setups where operators had to move between control room and shop floor losing valuable time rectifying problems Intuitive usability: The intuitive interface follows best usability practices by displaying the entire process in an easy to understand flow. The principle is to represent the process from left to right and top to bottom. This provides ideal guidance even for less trained staff Dependable and reliable: The system’s hardware is built for the typical conditions found in a mill with robust components that can withstand the challenging environment.

Switching to Pluto PCS

When is the optimal time to upgrade? “A simple but important call to action is outdated hardware,” says Trunz. “The benefits of up to date hardware and software justify the investment. At the same time outdated technology always poses a risk. And in terms of recruiting young people into the industry, offering web-based applications makes the profession more attractive. The technology is also easier to use, which provides for gains in efficiency.”

The most basic upgrade builds on existing machinery. With the high-end MES solution Mercury MES customers can connect to any machinery independent of manufacturer. It is completely configurable even to an entirely “non Bühler” plant.

In contrast the PCS system Pluto PCS is designed to connect mainly to Bühler machinery. The entire Bühler product portfolio is set up to connect with Pluto PCS quickly and easily. If required, some adaptations can be made. However, the focus is on swift implementation with minimal downtime.

At the miller’s side throughout

The transition from a legacy to a new system requires close management. Bühler provides the guidance and expertise to successfully deploy new systems, from overall project management to technology consulting, built on a deep understanding of the specific requirements in the milling context. This ensures reliable implementation within the shortest timeframes.

“It depends on the customer’s setup and other factors how long a transition will take. But this is really one of our core skills. We deliver more than machinery and software. Our customers have access to our accumulated experience and expertise within the industry,” says Ruppert. “If you take the retrofit for Grand Mill in Abu Dhabi as an example – here we managed the entire retrofit from grain silos to mill and finished products with a minimum of downtime in just 48 hours. I don’t think anyone can do it quicker.”

Since the launch, Pluto PCS has been successfully installed and operated at pilot plants in different parts of the world. Feedback from customers underlines the main success factors of the system: it is reliable and easy to operate. “This is important because for many customers this is the first step towards digitalisation,” says Trunz.

With the control room at their fingertips wherever they are in the mill, the way staff work together can change. “I occasionally ask customers if they still need the control room at all,” says Trunz. “In a modern mill it no longer plays such a key role. It could be used instead as a meeting room for staff. Even with automation, personal contact at work is still very important.”

The future

Pluto PCS is one of the basic elements of a smart mill. It is a journey that has only just begun. In the future IoT will connect every mechanical and electronic device in the mill to the Bühler Insight platform. The platform allows storage and analysis of valuable information and data from the mill’s operations. “There is still a long way to go to the fully developed smart mill concept, but we have made great progress already,” says Ruppert.

As digitisation and automation drive change in the milling industry, the role of the people that work in it will also evolve. Key to attracting young digital natives is showing them that the industry not only offers the opportunity to work with these technologies, but also that they have a decisive role to play in the future. After all, technology is there to serve humans, but in the end, it is still the people that make a mill successful. www.buhlergroup.com/pluto Milling and Grain - September 2020 | 65

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Launching a new generation of molasses mixers

by Famsun, China

M

ixing is an essential unit operation within the process of feed manufacturing. It turns individual ingredients into nutritionally balanced and homogeneous blends of feed for all varieties of animals and livestock.

The mixer enables further agglomeration steps, such as pelleting or extrusion, if desired and, ultimately, it ensures healthy and efficient animal growth.

Mixing molasses with other vital ingredients for ruminant feed is often essential, but always challenging. Molasses is an excellent low-cost energy source for ruminants, especially during times of drought conditions and roughage shortages.

According to the Food and Agriculture Organisation (FAO), beef production in Australia may have fallen by almost five percent in 2019 due to a large-scale drought-induced slaughter.

Millions of wild and domesticated animals have been lost in the Australian bushfires since it began in October 2019. During one single event, dry lightning reportedly caused numerous fires between the Victoria and New South Wales border on December

66 | September 2020 - Milling and Grain

30th, 2019. This devastating incident forced ranchers to euthanise an estimated 12,000 head of cattle and 6,000 head of sheep.

Elsewhere in 2019, hot and dry weather conditions also caused forage shortages in both Europe and Africa.

Climate change-related uncertainties have pushed many ranchers in various parts of the world to shift from grass-fed to grain-fed production. Additionally, the growing demand for highvalue nutritious protein is also driving the global beef production system to make other feeding regimen adjustments.

No matter the driving force, we have witnessed greater demand for specialised molasses mixers. The Famsun molasses mixer is explicitly developed for ruminant feed production and the challenging properties of molasses. The latest generation of Famsun STHJ Molasses Mixers (See Table 1) are now available for higher mixing efficiency, fewer residues, easier maintenance, and better product quality.

Highlights of the new machine include:

• Improved mixing efficiency: Compared to the previous versions of the same model, the production capacity of the new generation is improved by 15-20 percent. The adoption of a belt drive ensures stable and reliable transmission, and the

F Table 1: Technical parameters of molasses mixer Rotor speed (r/min) Mixing homogeneity (cv%)

STHJ35x200

STHJ40X250

STHJ50X275

788

660

528

10

10

10

Maximum molasses level

10%

10%

10%

Capacity (t/h)

10-20

20-25

25-30

Motor (kW) Matched mixer

30

37

45

SLHS2

SLHS4

SLHS7

Table 2. Technical parameters of molasses screw feeder

•

•

•

•

•

Molasses Screw Feeder 25

Molasses Screw Feeder 32

Molasses Screw Feeder 40

Speed reduction ratio

17

17

17

Handling capacity (m3/h)

40

80

120

Motor (kW)

3

4

5.5

Frequency-variable

Yes

Yes

Yes 2000

Centre-to-centre distance

2000

2000

Between inlet and outlet (mm)

1200

1200

1200

Length of feeding inlet (mm)

STHJ35x200

STHJ40x250/ STHJ50x275

(Under development)

service life of a belt for the new STHJ mixer is expected to be more than one year of working time Better mixing homogeneity: Molasses is injected into the mixer by a compressed air-atomising device, which creates a uniform distribution of molasses particles and allows them to make uniform contact with other feed ingredients. The paddle arrangement on the mixing rotor includes optimised angles to achieve reinforced mixing effects and excellent quality products.

The product, when discharged from the molasses mixer, is of uniform colour and has no agglomerations in the mixture Fewer residues: Thanks to structural optimisation, the rotating paddles can create a continuous spiraling trajectory along the shaft during production.

Together with the small gap between the paddle tip and the inner wall of the mixer, the paddles can more effectively push the feed mash out of the discharge chute. Because of the minimal remaining residue, the troublesome agglomerations that usually coat the paddle and the inner wall of the mixer are now eliminated Wear resistant paddles: Tungsten carbide coated mixing paddles improve wear resistance and extend the replacement cycle to over 8,000 tonnes of feed production. Re-use of the worn paddles is made possible by adding new layers of tungsten carbide, significantly lowering maintenance costs Easy cleaning: The new generation molasses mixer is also equipped with a heat preservation device to prevent hardening and accumulation of feed particles on the inner wall of the mixer, which facilitates periodic cleaning work More precise feeding: The mixer includes a standardised molasses screw feeder that matches the size of the unit. Sensors at the molasses feeder provide critical feedback and feed delivery information to the control system. This approach prevents molasses from injecting without feed flow, thus avoiding further agglomeration problems. For the technical parameters of the molasses screw feeder, please refer to Table 2. www.famsungroup.com See more content about feed ingredients FEATURE: The future of feed ingredients

mymag.info/e/919 Milling and Grain - September 2020 | 67

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Scales

A

The heart of the next generation mill

by Bühler, Switzerland

family-owned mill in eastern Germany thrives on its expertise and passion for milling as well as state-of-the-art technology. The introduction of Bühler’s Tubex Pro marks an important step towards the mill of the future.

In the eastern-most region of Thuringia, in Germany, the town of Wünschendorf marks the furthest reach of the ice shield that once covered the region nearly 500,000 years ago. It is an old country and the 1000-year-old St. Veits church stands testimony to its rich heritage. Here on the confluence of the rivers White Elster and Weida, waterpower has provided the driving force for mills for centuries.

To this day, the Otto Crienitz mill puts the water flow to good use for its own energy requirements and even feeds electricity into the national power grid. The family-owned and managed mill is deeply rooted in the region’s history.

Built in 1900, the mill has undergone many changes. Technical innovation has altered production processes in 25-year cycles.

During the formation of the German Democratic Republic (GDR), the family was dispossessed but regained control over the mill after the fall of the Berlin Wall.

Since then they have developed the business and successfully adapted to new market requirements, focusing increasingly on deploying innovative technology to achieve the highest standards in quality, productivity, hygiene, and environmentally friendly production processes. The business has grown fast and extended its customer base, two thirds of which are larger industrial customers and one third smaller artisan bakeries.

Scales make the difference

Quality, price and automation are the main ingredients for a successful milling operation. Managing the flow of produce accurately plays an important part in operating the mill efficiently, maintaining high quality standards and reducing cost.

Detecting changes, understanding yields, and identifying and rectifying problems quickly is essential.

“This is where precise and reliable weighing comes in,” says Scharf. “Improving the accuracy of our scales is one of the main levers we have in the mill to increase profitability.”

The Scharf family has always embraced technology. The introduction of Bühler’s Tubex Pro scales marks an important step towards the digitisation of production processes. The data provided by the system is extremely accurate, allowing for precise control over the production process and optimised profitability.

Saving energy

Key indicators such as kilowatts of electricity consumed per tonne of milled flour provide robust figures on the overall energy balance of the mill. Breaking energy consumption down to each individual unit delivers a full picture. The old pneumatic scales 68 | September 2020 - Milling and Grain

F at the Otto Crienitz Mill were operated with pressurised air to move the scales’ cylinders.

“We use pressurised air in many ways, it’s common practice,” says Scharf. “But this practice is costly. By avoiding pressurised air, we save a lot of energy, both in comparison to the machinery we used before and in terms of what we see from the competition.”

Hygiene, reliability, and low maintenance

The mill’s customers demand excellent food quality and a commitment to highest food safety standards is essential. One key question when it comes to hygiene and maintenance is the required manpower. Every system needs cleaning.

It depends on the design of machinery where and how much deposits build up.

Materials used also play an important role.

The new scales use high-grade stainless steel and food- approved materials. The lean system design minimises the amount of deposits and reduces maintenance efforts and downtime.

By avoiding small mechanical parts, such as screws, getting into contact with the produce, the risk of contamination is eliminated. At the Otto Crienitz Mill product changeovers are less of an issue. But the system is designed to facilitate changeovers with minimal downtime.

Moving to Milling 4.0

Six Tubex Pro scales are in operation at the mill, one for input and five for output. Their precise load cells work in conjunction with intelligent algorithms providing accurate measurements on each cycle. The scales are already set up to connect to Bühler Insights, a cloud-based platform that includes a growing portfolio of digital services.

Through Bühler Insights, process data like real-time tracking of the scale condition, current and historic throughputs, alarms, warnings, recipes and jobs, is transformed into reports to aid decision-making.

The Yield Management System (YMS), one of the digital services available on

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Bühler Insights, combines the data captured by input and output scales, and measures not only the overall yield but also the yields at subprocess levels, giving the customer the information needed to fine tune the operation.

Scharf looks forward to moving operations to the next level, “We are about to start a test phase with Bühler Insights. This is an interesting project requiring input from both sides to train the system for best results,” he says.

The mill in your back pocket

As Otto Crienitz moves toward the next generation of mill, increasingly the system can be operated remotely. This has many benefits.

“Our staff appreciate flexible working time. No one needs to be at the mill when there is nothing to do. This is valuable time that can be spent with the family at home,” says Scharf. “With operation data accessible via handheld devices you can access all the information you need remotely and at any time: I simply carry the mill in my back pocket.”

Increasing automation also provides many benefits, helping to maintain quality standards, reduce cost and facilitate cumbersome and error-prone processes so that trained staff can concentrate on working where they are really needed.

Scharf’s view is clear; “A miller’s job is to control the overall quality and processes. All processes that can be performed by machines should be performed by machines,” he says. “And with fewer young people training to enter this industry, we have to deploy staff in the best and most efficient way.”

Sustainability, partnership, and innovation

For Scharf, sustainability is a matter of common sense. “It makes sense to plan transport efficiently, to avoid waste and use resources carefully,” he says.

See more content about sustainably sourced grains FEATURE: Enabling access to better grain

mymag.info/e/897 72 | September 2020 - Milling and Grain

This approach holds true: the team at Otto Crienitz plans deliveries carefully. As a business focused on local markets, routes do not exceed a 200-kilometre radius. Deploying up-todate technology such as the energy efficient Tubex Pro scales is as important.

In the end, all these actions together lead to an improved carbon footprint.

Over the past two years the Otto Crienitz Mill has worked with Bühler on several successful projects.

“After visiting the mill, Bühler consultants provided us with a complete assessment of the entire plant and made excellent suggestions for optimisation that required no investment at all.

That really convinced me that we were in good hands,” says Scharf.

“The Bühler team understand the complete system rather than selling individual components. It is also a very innovative company – we enjoy discussing ideas collaboratively. This is how we develop new solutions for the mill together.”

Ready for the next generation

For the future, Scharf is convinced that concentration trends within the industry will continue. Specialisation will also play an important role over the coming years.

Otto Crienitz intends to keep up with the pace. This is only achievable with commitment and the best technology in place.

The strong partnership with Bühler will help the mill move ahead towards a milling operation 4.0.

“As long as we keep looking for the best solution, we will always find our place in the market,” says Scharf. Past performance proves his point. Over the decades the mill has gone from strength to strength.

Today, two generations of the family work together at the mill.

Scharf has great plans for the future and a dream, “I hope that the next generation of our family will want to work in the business too and continue to develop the mill in the coming years,” he says. “That would be fantastic.”

For more information, please contact maximiliano.moreira@ buhlergroup.com www.buhlergroup.com

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F

RICE

Current status of rice consumption in China and outlook of rice cooking industry

I

by Motonobu Kawano, PhD, Deputy Representative, China Operations, Technical Division, Satake Corporation

n 2019, China produced 210 million tonnes of paddy (accounting for 28.9% of global production) and consumed 194 million tonnes (81.6% of which is for staple food). For about a thousand years, China has been eating rice as a staple food, and today, about two-thirds of the entire population (1.4 billion) are eating rice as staple food. As the standard of living improves in line with social and economic development, the need for rice consumption has shifted from an emphasis on quantity to taste, convenience, and health benefits. Particularly in urban areas, traditional home-cooked rice and home-made lunchbox practices have been gradually decreasing. Instead, the use of ready-made rice dishes or lunch at workplace are increasing.

From the end of the 1990s to the beginning of the 21st century, the Chinese rice cooking industry entered a period of growth along with the rapid increase of the fast food and school lunch industries. In recent years, factory-cooked rice usage spread to various industries and even a production line for an astonishing 100,000 meals a day has been built. Commercial factory-cooked rice is now used in company cafeterias, lunches at hospitals and schools, catering services, bento boxes at convenience stores, and Chinese fast food dishes. The economic scale of the factorycooked rice is said to reach approximately 300 million yuan a year.

74 | September 2020 - Milling and Grain

However, many company cafeterias and restaurants still cook rice using steam cooking equipment in their shops, so not only is the efficiency of cooking low, but also the texture of the cooked rice is poor, and the quality unstable. Since the rice cooking industry is a part of the rice industry chain, it is influenced by upstream cultivation, dry storage, rice milling, and downstream distribution and consumption. The rice cooking industry in China seems to experience the following problems: • The production, storage, and distribution of rice depends on government policies, and the cost of polished rice as a raw material for cooking rice is high • The quality of raw materials for polished rice is unstable.

For example, the moisture content of raw paddy is kept low and dried in order to reduce the degradation of quality due to long-term storage and, as a result, there is much polished rice produced with a moisture content of 13 percent or less.

Excessive polishing, through seeking too much gloss in the final product, has also become a common issue • The quality of cooked rice is unstable, and it is necessary to establish a quality control method to standardise this • In order to ensure food safety and security, it is necessary to establish an information traceability system from raw materials.

Satake Machinery (Suzhou) Co., Ltd., a subsidiary established

by Satake in Suzhou, China in 1998 has not only been

F

The Power of Phytogenics!

• Increases feed intake and supports digestibility • Helps to maintain flavor profile across diet changes • Beneficial for all stages of growth and development • No negative side effects or manufacturing rice processing facilities for the Chinese market, but has also been providing profit improvement solutions for improving the quality of rice products and reducing production costs, based on the concept ‘From the field to the table’. Through the provision of various technologies, Satake helps solve problems faced by the Chinese rice cooking industry, such as: • Offering a paddy rice growth diagnosis system for the purpose of controlling and sorting the protein content of rice in cultivation • An optimum drying control system for preventing the occurrence of excessive drying of unhulled rice and cracking of the body • A rice polishing system that can be automatically controlled to an appropriate degree of polishing • A GABA rice processing system with enhanced health functionality and a pressurised IH rice cooking system that can optimally cook rice for multiple purposes • Inspection equipment that can be used for quality control such as appearance quality, taste quality, and safety quality in production processing.

Since the pressurised IH rice cooking system from Satake performs pressurised rice cooking at 1.2 atmospheric pressure (atm) and 106°C, and the inside of the pot is uniformly gelatinised, the texture of the rice is good, and there is little change in quality with time after rice cooking. Satake’s ricecooking system has reached an operating rate of over 80 percent, and the rice produced is used in boxed lunches and rice balls sold at convenience stores. Satake’s rice cooking system for food factories is used for in-flight meals at major airlines. To control the quality of the rice, Satake’s “Food Taste Appraisal Group” is also available in addition to the rice cooking system.

withdrawal periods • Increases profitability

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Outlook for the rice-cooking industry

Approximately two-thirds of the 1.4 billion people in China eat two meals a day on average, and the amount of rice consumed outside the home is increasing, along with changes in eating

Naturally ahead

Milling and Grain - September 2020 | 75

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F

and drinking habits. Together, with the promotion of staple food industrialisation by the government, rice cooking by food factories in a central kitchen system is expected to increase more and more in the future. As living standards improve, the need for consumption of cooked rice for safety, security, good taste, and health will become more and more integral, which will offer good opportunities for technological innovation and development in the Chinese rice cooking industry.

Examples of such innovations we may desire short-term include: • Rinse-free rice processing and blending technology for raw

material polished rice, helping to stabilise and improve the quality of cooked rice • IH rice cooking systems that can be used to cook rice in one pot, promoting a comfortable work environment • Use of rice quality measuring devices (Rice cooking taste meters, hardness stickiness meters, etc) that are indispensable to control the quality of cooked rice.

Satake contributes to the development of the rice cooking industry in China by making use of the know-how it has accumulated throughout the entire post-harvest process. www.satake-group.com

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Milling and Grain - September 2020 | 77

F

EXTRUSION SYSTEMS FOR AQUA FEED AND PET FOOD

Single- or twin-screw?

T

by Diego Clivio, Clivio Solutions, Argentina

he extrusion process is a thermomechanical process that consists of forcing a product to pass through one or more holes of a specific size under pressure and temperature thanks to the Archimedes screw concept (also known as “endless screw”).

The extrusion processes in the processing of extruded pet food and aquaculture aim to cook a mixture of raw materials and ingredients, giving it the form of croquette (pellet/kibble) that facilitates its subsequent handling.

The most important processes that take place inside an extruder is the gelatinisation of starches and texturisation of proteins. Both processes help aid in greater digestibility, as well as to form a structure and texture that hosts other ingredients, minerals and fats in a stable and uniform way.

For a good gelatinisation of starches and texturisation of proteins, moisture is needed (which is added in the form of liquid water and steam in pre-conditioning and/or extrusion). Suitable temperatures are also needed, which can be provided through the addition of steam, as well as being produced by the mechanical work and friction produced by the screws. Mechanical energy is also needed, granted by the shearing action of the screws.

Today, there are two technological forms of extrusion, singlescrew (SSE) and twin-screw (TSE). In this article we will talk about the features, advantages and disadvantages of each of these technologies.

78 | September 2020 - Milling and Grain

Single-screw extruders

In single-screw extruders we observe as a characteristic that the screw moves the materials through the channel by developing a “drag flow”, the speed of which is directly proportional to the speed of the screw. Due to the constraint of the die in the discharge of the extruder, there is a “backpressure flow”, which goes in the opposite direction to the drag flow. Therefore, the flowrate in single-screw extruders is equivalent to the drag flow rate minus the backpressure flow rate.

The flow dynamics in the screw channel shows us that the fluid particles travel at different speeds and that they do not interact in their entirety, resulting in a dispersion of dwell times and an uneven mixture.

Consequently, the heat transfer, as well as the entry of mechanical energy in the cooking section, are very limited. In addition, the length of the shear depends on the space, which generates heterogeneities of the melting properties (cooking duration, temperature and pressure).

• In short, single-screw technology features: • A single processing section • A unique dependence on performance and screw speed • A single operating point (performance combined with maximum screw speed and die opening area) • Limitations in mixing, which limits heat transfer, mechanical energy input, and generates heterogeneities in particle fusion (cooking duration, composition, temperature and pressure) • The higher the screw wear, the lower the extruder performance.

A reduction of 10-20 percent can be observed during the life of the screw

F

Milling and Grain - September 2020 | 79

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F • ‘Lubrication factors’ in the composition of the mixture generate runoff, which reduces the performance of the extruder and the addition of mechanical energy.

See more content about extrusion FEATURE: Twin-screw extrusion in aqua feed

Twin-screw extruders

Twin-screw extruders have multiple processing sections, (melting/cooking, vapours/gas extraction, vapours/positive displacement pumping), thanks to the different restrictions generated by the work of the screws.

In twin-screw extruders, very thorough mixing is observed in the coupling area of the screws (via the use of macro-mixing and micro-mixing).

Consequently, the heat transfer coefficient in these sections is very high. Homogeneous fusions can be obtained with an optimised linking of lipids. Expansion develops consistently, leading to an excellent density, texture and shape of the final product, as well as a uniform density and colour.

In short, twin-screw technology involves: • Multiple processing sections • The performance and speed of the screw are unlinked.

Therefore, for a formulated mixture, twin-screw extruders are characterised by their many operating points. In addition, the screw profile can vary extensively to modulate the addition of mechanical energy • The mixing process is very thorough, providing great additional benefits in relation to the quality of the product • The slippage of the mixture is compensated by the positive displacement pumping of the screws • Less sensitivity to changes in raw materials • Increased tolerance to changes in moisture, fibre aggregates and fats

mymag.info/e/695

• Better quality and consistency of final product • Greater overall process flexibility.

In aqua feed production, the best possible uniformity and high level of degassing decreases the chances of floating pellets when sinking aqua feed is produced. Thanks to the action of the two screws, twin-screw extrusion allows us to produce micro-pellets of up to 500 microns (0.5 mm).

In the particular case of extrusion experts Clextral, significant energy savings in drying are achieved by their ability to work with two-to-three percent less humidity. This results in much improved end products.

Conclusion

Both extrusion technologies are widely used in the pet food and aqua feed production sector. Single-screw technology typically requires a lower investment cost and lower spare parts costs.

While twin-screw extruders require a higher investment, this investment brings the possibility of working with a wider range of raw materials with more fibres, more vegetal proteins and higher fat content. www.cliviosolutions.com

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Milling and Grain - September 2020 | 81

S

F

STORAGE

Simplicity drives malt conveyor specification at Madrid brewery

E

by Flexicon Europe, UK

stablished in 2017, the Cervecera Peninsula craft brewery in Madrid, Spain brings a taste of the New World to the heartlands of Spain with its hoppy American-style beers.

Operated by a father and son team, the company needed to move grain from the milling room to the brew tank and decided on a flexible screw

82 | September 2020 - Milling and Grain

conveyor from Flexicon Europe. The needed components were available via Flexicon’s Quick Ship programme, which provides rapid delivery of frequently specified systems such as this.

“In the beginning, we had to do everything ourselves,” says Roman Jove, Cervecera Peninsula Founder and Head Brewer.

“We were putting in the grain by hand. We needed certain processes to be very simple. I had looked at many options, but Flexicon was recommended by brewer friends in the US.”

STORAGE

Moving milled grain to the mash house

The brewing process begins in the milling room where milled, malted grain is conveyed from a 225 litre (7.9 cubic feet) capacity floor hopper to a brew tank by a 6.5m (21ft) long flexible screw conveyor. As it rotates, the screw self-centres within the 67mm (2.6 inch) diameter polymer tube, providing ample space between the tube and screw wall to avoid grinding of the milled grain.

The mill produces two 400kg (880lb) batches-per-day of either malted wheat or a malted wheat-oat blend, all of which is transported directly to the brew tank by the conveyor. The design of the conveyor screw was specifically selected to efficiently transport the various free-flowing materials. With the drive motor located beyond the discharge point, the material does not contact seals or bearings.

F

Keeping things simple

Sr Jove describes installation of the conveyor as “very simple.”

It is cleaned after every five batches, a procedure that consists of reversing the screw to evacuate residual material, and in-place flushing of the interior. Alternatively, the screw can be removed through a lower end cap for sanitising.

The conveyor meets Cervecera Peninsula’s requirements for gentle handling of the malted grain with no separation of wheatoat blends.

“It moves all the material together at the same speed,” says Sr Jove. The enclosed tube also eliminates dust and spillage, as well as contamination of the product or plant environment. He concludes, “It takes a lot of the work out of brewing and that’s something we appreciate.” www.flexicon.uk.com

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F

STORAGE

Gentle drying of soybeans

S

Carouseldryer T200.4 right after final commissioning

by Ulrich Grahn, Consulting Manager, Germany

oybeans going to be treated in an oil press need to have a remaining moisture content of about 10 percent. Typical moisture content before a drying process comes close to about 13 percent. In order to reduce retention time in a dryer, soybeans are cracked either to half or just a quarter bean size.

Paying attention to an increasing demand of typical soybean-based oil, an Austrian company decided and finally chose to adopt a carousel-dryer system. As available installation ground was limited, a carousel-dryer with a round cylindrical body offered the best solution. Additionally, the dryer guarantees very uniform and gentle drying. From the first inquiry

84 | September 2020 - Milling and Grain

up to putting the solution to function, less than a year took place.

The T200.4 carousel dryer is doing extremely well, as of June 2020.

Carousel-dryers have a basic design of a cylindrical crosssectional area containing a modular case. In its centre, a vertically fitted main shaft is driven by a frequency-controlled bevel gear box. Fitted onto this shaft, either 12 or 16 single installed screen trays compose the closed drying area. Depending on a number a customer requirement such as water evaporation, throughput rate, etc, up to seven different drying options are available through the tailormade carousel-dryer.

A rotary valve serves as the carousel dryers production inlet, which avoids sucking in unwanted ambient air. Product to be dried enters first drying area whilst the inner design is continually

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Product layer height of approximately 9cm

Product discharge into dryer outlet with moisture measurement sensor in the background

rotating. Installed product distributors generate uniform distribution on all installed drying areas. Each of the installed screen trays are pivoted and open or tilt with a special tilting mechanism after approximately 90 percent of the revolution.

Product is then discharged to the next subjacent drying area. This process is repeated by the number of chosen drying areas and is released via an outlet box, followed by another rotary valve.

Based on the carousel-principle operating dryers, a typical convectional process takes place. Hot process air, either generated

Cracket soybeans after drying

by steam or hot water entering the dryer, not only vaporises moisture from the products’ core, but transports evaporated moisture via outlet ducts into the atmosphere.

In order to generate processed air, ambient air gets sucked into dryer’s case, passing heat exchangers which are installed at dryer’s bottom. A radial fan takes care to suck processed air into the dryer and, finally, blow waste air out of the carousel-dryer.

Continuously operating carousel-dryers can offer a homogeneous process flow going along with uniform and gentle

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Milling and Grain - September 2020 | 87

F

Typical advantages of a carousel dryer

Input touch screen TP700 for controlling the dryer via PLC S7-1215FC Safety

drying. On top of this, carousel-dryers are ideally used when energy saving is a requirement by customers.

If, in addition to pure drying, subsequent cooling is also required, the combination of drying and direct cooling results in an almost ideal energy reduction. The warm exhaust air extracted from the cooler sector is fed directly (or also indirectly, depending on the dust load) to the dryer sector.

Exhaust air temperatures of a cooler are approximately 4555°C. After cleaning the exhaust air (if required) by means of a pocket filter, the treated air is not released into the atmosphere, but is fed to the thermal unit in the dryer area. The energy savings at the heat exchanger are obvious: depending on the climate conditions, between 15-20 percent of primary energy can be 88 | September 2020 - Milling and Grain

saved here.

The T200.4 carousel dryer has a nominal diameter of 2,000mm and consists of a total of four drying floors. On a total installation area (including heat exchanger with ring channel) of only approx.

6.3m2, the T200.4 produces a drying surface of approximately 11m2. Improving the cleaning possibilities, an additional window is installed on each drying floor.

All parts in contact with the product are made of stainless steel.

The transport weight of the solution is approximately 3,500kg.

The carousel dryer is equipped with four crane eyelets on the upper dryer cover to allow easy delivery by means of a crane truck, even at high altitudes.

The entire scope of supply also includes a heat exchanger, a

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Cyclone with connected rotary valve for the removal of fine particles

Radial fan for generating process air

dust separator (cyclone), a radial fan, and the electrical control system, which also includes a microwave moisture measuring sensor that transmits reliable final moisture data to the PLC via intelligent online measurement. The fan, supplied by an Austrian company, is equipped with a frequency converter that reliably masters all air resistance even at low frequencies (with low process air flow).

A bevel-helical gear unit with a motor output of 0.18kW is mounted on the carousel dryer, which generates an output torque of around 5,000nm. To achieve long residence times, the gear unit

Carousel-dryer T200.4 shown with process air generation

is equipped with an additional external fan.

Saturated steam generates the required process air whilst a heat exchanger, upstream of the dryer, generates a drying temperature of approximately 100°C. Steam control is ensured by means of innovative control components. A smart digital positioner supplies a permanent control signal of 4-20mA to the connected PLC. This then automatically controls the heat quantity or drying temperature required, depending on the dryer capacity.

The dryer is controlled by a PLC from Siemens S7-1215FC Safety. All essential drive units required for control are equipped

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F with frequency converters.

An additionally installed microwave moisture measuring sensor allows an almost self-sufficient operation of the plant. The amount of required processed air, as well as the temperature, are variably adjustable and are Microwave moisture sensor fitted controlled by the intelligent to dryers outlet box Steam control with digital positioner PLC. In a total of three test runs, the performance of the dryer could be proven at the first attempt. In addition to the selected size of the carousel dryer, proof was provided that the specified product layer height of approximately 9cm, as well as the heat quantity and Loaded truck in the port of Genoa-Italy process air quantity, meet the before continuing towards customs performance specifications. clearance German border Switch cabinet with input touch screen Due to the local structural conditions, the units this article, whilst the manufacturing was carried out by Idah in downstream of the carousel dryer, such as the cyclone and fan, Taiwan. The transport of the solution from Taiwan to Austria was were placed on the upper floor. Pipe transitions, that are as round carried out without any problems, an impressive feat in light of as possible, ensure that the air flow is only slightly reduced. the current pandemic, with special thanks to a transport company The design of the carousel dryer was uniquely produced to based in southern Siegerland, Germany. meet the customer’s specifications. Fulfilment of the order and www.carouseldryers.de subsequent commissioning was carried out by the author of

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www.gimetech.com Milling and Grain - September 2020 | 93

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Industry Profile

SGS America

T

The grain inspection experts

he grain inspection experts SGS America came from humble beginnings, from a simple yet innovative concept first identified by a young Latvian in 1878. Whilst watching the ships load and unload upon the docks of Rouen, France, this young man realised that grain exporters were losing a significant amount of money because they were not adequately represented at the port of destination.

Traditionally in the nineteenth century, importers would only pay for the amount of grain that was received, not taking into consideration the amount that was being shipped. As a result of this, the grain volume that was inevitably lost in transportation due to loading, unloading, shrinkage or theft, often resulted in losses for the exporter.

Recognising this problem, the young man decided to establish his own business defending the rights of the exporter. How would he do this? He would provide a service wherein he inspects and verifies the quality and quantity of the grain upon arrival with the importer. For this service he would receive a commission from the exporter, based upon the value of the shipment.

After some preparation, the business soon came to fruition and word spread of the man who was helping profits boom in the export sector. The business rapidly expanded, and the company

96 | September 2020 - Milling and Grain

soon had three offices in France’s largest ports: Dunkirk, Marseilles and Le Havre. It didn’t take long before the company was inspecting 21 million tonnes of grain-per-year across an impressive network of offices throughout Europe.

This company has now evolved into SGS America, a leading company in the grain inspection, verification and testing sector.

With over 2,600 offices, laboratories throughout the world and more than 94,000 employees, that one man’s consideration at the docks of Rouen has evolved into a global industry.

SGS America now offer four main services as part of their company: inspection, certification, testing and verification. SGS offer a variety of solutions and services for companies to ensure their grain is properly inspected. This process also enables exporters to ensure that their produce meets all the applicable regulatory requirements across different regions.

The company also offer opportunities for various exporters to certify their services in accordance with national and international standards. In addition, their testing facilities provide resources for companies to assess their produce quality, safety and performance.

Working at every stage of the value chain, from harvest to final product, SGS America ensure that food and feed quality around the world is always optimal to ensure a healthy population. www.sgs.com

F CASE STUDY

CASE STUDY

Upgrading older types of steel elevator buckets for modern efficient types of polymer elevator buckets

4

Discharge chute – Before modifications

4B Group’s modern polymer buckets

B Group’s modern polymer buckets are a great solution for companies looking to enhance their existing elevator bucket solutions.

Customers of the company had undertaken a continuous improvement programme of upgrading older types of steel elevator buckets for modern efficient types of polymer elevator buckets. The older style fabricated steel buckets were of a similar geometry to CC type buckets. Trials commenced utilising several types of CC poly buckets, all of which proved to be inefficient and backlegged rice so significantly throughput was decreased by 40 tonnes-per-hour (tph) and wear damage to the casings had occurred through the recirculation of materials.

4B was contacted and asked to consult and were engaged to provide a solution, which included providing suitable system belt speeds, adjustments to outlet chutes and selecting a suitable polymer style bucket that would not compromise the capacity of the system and operations.

The solution came to light via a complete and thorough evaluation being undertaken of belt and pulley speeds, discharge efficiencies and actual volumetric filling factors of individual buckets. This was then assessed against the existing discharge

Old style fabricated steel bucket & CC type bucket

98 | September 2020 - Milling and Grain

Discharge chute – After modifications

SPS buckets installed

chute design, which favoured the older style steel fabricated buckets.

In particular, the actual centripetal acceleration that was expected to occur with the modern polymer buckets was calculated and then cross referenced with the vertical and horizontal distances available within the existing discharge chute.

The combined results provided 4B engineers with the exact information required for selecting a suitable bucket, adjusting the angle of the outlet chute and applying a belt speed reduction. This increased individual volumetric filling and reduced backlegging.

The result was a versatile SPS bucket which provided the best results due to a wide range of speeds that it can be utilised on most elevator applications. In this instance, the elevator had been designed around an old bucket that was now considered inefficient in performance and costly to manufacture.

The 4B solution was able to deliver the benefits the customer was looking to achieve with their continuous improvement programme, namely the elimination of backlegging and chute wear whilst maintaining original design capacity.

RECORD-BREAKING INCREASES IN WHEAT AND CORN PRODUCTION

by Rebecca Sherratt, Features Editor, Milling & Grain

World wheat production is continuing to increase as many countries get back into the swing of things following the initial surge of the COVID-19 pandemic

Global wheat production has now hit a record-breaking 766 million metric tonnes (mmt), with production seeing a sharp increase in Argentina, Russia and Canada. The EU and United States are not experiencing this same increase but continue production at a steady level. Across the globe, countries are producing record amount of wheat, especially India and China, which is surprising, considering that they are countries not traditionally known for record levels of wheat export.

Global ending stocks are at a record high, at an estimated level of 317mmt. Should this estimate come to fruition, this volume would be a five percent increase compared to the 2019/20 harvest year. In contrast, US ending stocks are currently the lowest in six years and expected to decrease another 11 percent this year.

The US has seen lower imports and higher exports in recent months. Imports of wheat have lowered by 10 million bushels in August to 130 million. Food use in 2019/20 has lowered slightly to 962 million bushels. This is estimated to decrease slightly to 960 million bushels in 2020/21, due to the closure of restaurants and eating out services as a safety precaution against COVID-19.

Other countries experiencing production drops include Kazakhstan and Turkey, both experiencing 1mt drops.

US production and export of feed ingredients such as soyabeans is seeing some growth as exports to China continue to increase. US corn production has increased by 278 million from the July projections, up to 15.3 billion bushels, coming mainly from Minnesota and South Dakota.

Corn imports have also seen a marked increase in the EU, Thailand and Canada. Many feedstuffs are being subject to larger harvests at lower prices.

Rice levels fluctuate amid extreme weather conditions Whilst some countries have seen an increased demand for wheat, following a surge of home baking whilst many have remained in lockdown, rice usage remains constant, with slightly reduced export rates. Long-grain rice production is forecast at 159.1 hundredweight (cwt), whilst both short-grain and medium-grain production is expected to reach 59 million. China’s rice

100 | September 2020 - Milling and Grain

production has decreased slightly, possibly in part due to record rainfall experienced in the Yangtze River Valley in June and July, resulting in reduced harvesting areas and intense flooding. In contrast, a remarkably dry season has also limited harvests in Vietnam and Thailand.

Asia continues to experience much of the demand for rice imports and exports but, despite this, there is a slight decrease in rice exports. Exports of rice in 2020/21 are expected to decrease to 97 million and projected ending stocks are expected to reach 44.3 million cwt, which is 44 percent higher than 2019/20.

Brazil have experienced a strong past few months in regard to rice exports, which makes up for the past month of reduced rates. Their export market continues to be diverse, ranging from both eastern and western markets and Brazil is expected to remain one of the top rice exporters in 2020/21.

Oilseeds US soyabean supply experienced lower beginning stocks in 2020/21, with higher production rates, exports and estimated ending stocks.

Production in 2020/21 is expected to increase to 4.425 billion bushels, a 290 million increase compared to 2019/20.

Supplies are, therefore, expected to see an increase this year of 13 percent to a record 5.1 million bushels.

On a global scale, US production increases are somewhat offset by a decrease in many other countries. Rapeseed and sunflower seed crops especially are seeing decreases in production in countries such as Russia, Ukraine, Kazakhstan and Moldova. Soyabean trade is seeing marked increases this year, especially in exports from Brazil, the US and Argentina. Countries experiencing an increased rate of soybean import demand include China, Argentina, Egypt, India and China.

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101 | September 2020 - Milling and Grain

INDUSTRY EVENTS 2020

2020

September 2-3 Black Sea Grain 2020 Kyiv, Ukraine www.ukragroconsult.com

9-12 TUSAF 2020 Antalya, Turkey http://tusaf2020.org

8-10 Livestock Malaysia 2020 Malacca, Malaysia www.livestockmalaysia.com Postponed from 7-9 April 2020 to 24-26 August 2021

4-5 JTIC 2020 France www.jtic.eu

15-18 SPACE 2020 http://uk.space.fr CANCELLED, next event taking place 14-17 September, 2021

17-19 VIV Qingdao 2020 Qingdao, China www.viv.net

2021

9-12 Eurotier 2021 Hanover, Germany www.eurotier.com

5-7 Livestock Taiwan 2020 Taiwan www.livestocktaiwan.com

☑ 20-23 GEAPS Exchange 2021 Columbus, Ohio, USA www.geapsexchange.com

October 1-2 3rd Agrifood International Congress Port Tarragona, Spain www.agrifoodporttarragona.com

25-3 Interpack 2020 Düsseldorf, Germany www.interpack.com

1-3 NAMA Annual Meeting 2020 White Sulphur Springs, USA www.namamillers.org

2021

10-13 Mill Tech Istanbul 2021 Istanbul, Turkey www.milltechistanbul.com 2020

December

17-18 Solids Dortmund 2020 Dortmund, Germany www.easyfairs.com Postponed from 24-25 June to 17-18 March

9-11 ☑ Ildex Vietnam 2020 Ho Chi Minh City, Vietnam https://www.ildex-vietnam.com Postponed from 18-20 March to 22-24 July 2021

6-8 16th ICC Cereal and Bread Congress Christchurch, New Zealand www.icbc2020.icc.or.at

21-23 FIGAP 2020 Guadakajara, Mexico www.figap.com Postponed from 21-23 October to 24-26 August 2021

26-28 IPPE Atlanta, Georgia USA www.ippexpo.org The International Production & Processing Expo (IPPE) continues to evolve and grow to meet the needs of its attendees and exhibitors.

For 2021, IPPE will again be in all four halls and will bring together more than 1,400 exhibitors and 32,000 visitors in Atlanta, Georgia.

IPPE focuses on innovation, bringing together buyers and sellers of the latest technology, products and services to make your business successful. Education is also key, with the opportunity to learn from the experts in free- and fee-based world-class programs on topics that cross industry interests.

102 | September 2020 - Milling and Grain

18-20 IDMA and VICTAM EMEA 2021 Istanbul, Turkey www.idmavictam.com

January

14-16 Agritechnica Asia 2020 Bangkok, Thailand www.agritechnica-asia.com

FIGAP 2020, now in its ninth edition, is renewed and once again puts itself at the forefront as the most important forum of the livestock sector in Mexico and Latin America, with international recognition.

FIGAP 2020 will have the largest areas of specialisation in the livestock sector, where attendees can see the latest trends and technological innovations, with new approaches in research and development

March 10-12 VIV Asia 2021 Bangkok, Thailand www.vivasia.nl/

14-16 Vietstock 2020 Ho Chi Minh City, Vietnam www.vietstock.org Postponed from October 14-16, 2020 to 13-15 October, 2021

☑ = Meet the Milling and Grain team at this event

February

Industries des Céréales (JTIC) is intended for professionals in the grain industry. Organised by AEMIC, this event is a unique opportunity to present your expertise to a specialised audience in search of concrete solutions for all your milling needs. Several conferences and seminars will again take place at the venue, as well as many opportunities for business networking

15-17 AFIA Liquid Feed Symposium 2020 Chicago, Illinois, USA www.afia.org

2020

November

2021

April 11-13 PIX AMC Gold Coast, Australia www.pixamc.com.au 13-16 125th Anniversary IAOM Conference and Expo Little rock, Arkansas, USA www.iaom.info/annualmeeting/

2021

June 23-25 Indo Livestock 2020 Jakarta, Indonesia www.indolivestock.com

THE BUSINESS NETWORK LINKING PROFESSIONALS FROM FEED TO FOOD VIV WORLDWIDE FULL EVENTS CALENDAR 2020-2022 VIV QINGDAO 2020

Qingdao China, September 17-19

POULTRY AFRICA 2020

Nairobi, October 14-15

VIV ASIA 2021

Bangkok, March 10-12

VIV MEA 2021

Abu Dhabi, November 22-24

VICTAM AND ANIMAL HEALTH AND NUTRITION ASIA 2022

BY VICTAM & VIV

VIV EUROPE 2022

Bangkok, January 18-20 Utrecht, Amsterdam

30 min, May 31- June 2

PARTNER EVENTS SUPPORTED BY VIV WORLDWIDE Moscow, October

MEAT & POULTRY INDUSTRY RUSSIA 2020 ILDEX VIETNAM 2020

Ho Chi Minh, December 9-11 Istanbul, June 10-12

VIV TURKEY 2021 ILDEX INDONESIA 2021

Jakarta, September 15-17

STAY SAFE & MEET ON VIV ONLINE 24/7, UNTIL WE SHAKE HANDS AGAIN!

WWW.VIV.NET

Online 24/7 knowledge networking from feed to food

EVENT ROUND UP PIX AMC The 2021 Poultry Information Exchange (PIX) and Australasian Milling Conference (AMC), PIX/AMC 2021 will be held at the Gold Coast Convention and Exhibition Centre, April 11-13th, 2021.

The conference will provide a comprehensive programme with the latest in innovation and information, featuring knowledgeable industry experts from both Australia and overseas. The program will cover a variety of topics such as chicken meat, egg production, free range and organic farming, flour milling and feed milling for all livestock species, including beef, dairy, pigs and others. There will be topics of interest for each and every delegate.

Workshops on numerous special interest areas encompassing all aspects of the poultry industry will also be on offer. For the more technically minded, the Australasian Veterinary Poultry Association (AVPA) will again be holding a scientific meeting after the conference.

The highlight of the conference will be the trade display area, which is the industry’s largest and most extensive to-date. With over 250 booths on display, exhibitors will be on hand to demonstrate their latest products and equipment.

Early bird registration will open in September 2020 and close December 2020. Standard registration closes in March 2021.

VIV Asia 2021 With almost 1,250 international exhibitors and over 45,023 visits from 120 countries registered, the VIV Asia 2021 exhibition offers a unique selection of companies, including global market leaders and regional, as well as national, Asian players of growing importance.

Professionals active in the production of pig meat, fish, dairy, poultry meat and eggs from Feed to Food, including the downstream part of the supply chain, all have numerous reasons to meet once more in Bangkok and be part of the premium show in the heart of Asia.

For more than 20 years, VIV Asia has been organised in Bangkok. The event started as a small convention in Queen Sirikit National Convention Centre (QSNCC) and then moved to BITEC, which offered more space to grow the show until 2019.

VIV Asia 2021 will expand even further. More business profiles will be covering the whole supply chain from Feed to Food in one place. A new venue with bigger exhibition ground and enhanced and modern facilities supports this strategic development to lift-up the show to the next level.

VIV Asia 2021 will be taking place March 10-12th, 2021 in Bangkok, Thailand at IMPACT exhibition centre.

16th ICBC Cereals and Bread Conference The 16th ICBC Conference will be held in Christchurch, New Zealand on January 6-8th, 2021 and is continuing the established ICBC event series. The International Association of Cereal Science and Technology was formed in 1955 at the 3rd International Cereals and Bread Congress and is the foremost international organisations in the field dedicated to international cooperation, the dissemination of knowledge, and the improvement in safety and quality of cereal-based foods.

The association has its headquarters in Vienna, Austria but has members represented from all five continents, including industry and academia.

The conference will feature plenary sessions; concurrent sessions embracing the challenges and opportunities facing the cereal science community; poster displays and competitions; a networking dinner for all our contributors to develop long lasting collaborations throughout the world; industry focused workshops; a trade display for equipment and food manufacturing; and, of course, the opportunity to participate on study tours to acquaint yourself with the culture, food and environment of New Zealand.

Themes for the conference include cereal nutrition for healthconscious consumers, food safety and security, sustainable agricultural technology systems, milling and bread making technology and much more. Confirmed speakers include Ke Bian from the Henan University of Technology, Marina Carcea of CREA, Bruce Hamaker of Purdue University and Witoon Prinyawiwatkul of Louisiana State University, to name but a few.

104 | September 2020 - Milling and Grain

Webinars hosted in August:

• August 5th,12th,19th and 26th: Sessions 4-7, The Online Milling School - myMAG.info/e/866 • August 20th: Electromagnetic waves, GEA - myMAG.info/e/915

• August 25-28th: New trends and technologies: The modular mill concept, Ocrim - myMAG.info/e/914 • August 27th: Pasta production and processing technologies, Alapala - myMAG.info/e/913

Upcoming webinars in September:

• September 2nd,9th,16th,23rd and 30th: Sessions 8-12, The Online Milling School – myMAG.info/e/866 • September 24th: Stone milling: Timeless technology, Alapala - myMAG.info/e/913 • August 17th-September 23rd: AFIA Feed Industry Institute - myMAG.info/e/920

• September 16-18th: Women in Agribusiness Summit - myMAG.info/e/921

• September 30th: Agrifood Virtual Meeting - myMAG. info/e/922 • October 20-22nd: IAOM MEA Virtual Milling Forum - myMAG.info/e/923

Elevator & conveyor components 4B Braime +44 113 246 1800 www.go4b.com

To be included into the Market Place, please contact Tuti Tan at tutit@perendale.co.uk

Air products Kaeser Kompressoren +49 9561 6400 www.kaeser.com

Amino acids Evonik Nutrition & Care GmbH +49 618 1596785 www.evonik.com/animal-nutrition

Bagging systems FAWEMA +49 2263 716-0 www.fawema.com Statec Binder +43 3112 38 5800 www.statec-binder.com TMI +34 973 25 70 98 www.tmipal.com

Bakery improvers ERKAYA +90 312 395 2986 www.erkayagida.com.tr Mühlenchemie GmbH & Co KG +49 4102 202 001 www.muehlenchemie.de

Bulk storage NACHI EUROPE GmbH +90 216 688 4457 www.nachi.com

Bulk storage Bentall Rowlands +44 1724 282828 www.bentallrowlands.com Chief +1 308 237 3186 agri.chiefind.com Lambton Conveyor +1 519 627 8228 www.lambtonconveyor.com Silo Construction & Engineering +32 51723128 www.sce.be Silos Cordoba +34 957 325 165 www.siloscordoba.com Sukup +1 641 892 4222 www.sukup.com TSC Silos +31 543 473979 www.tsc-silos.com

Cereal and pulse conditioning Vibrafloor +33 3 85 44 06 78 www.vibrafloor.com

Henry Simon +44 0161 804 2800 www.henrysimonmilling.com

Colour sorters

Lambton Conveyor +1 519 627 8228 www.lambtonconveyor.com

Bühler AG +41 71 955 11 11 www.buhlergroup.com Cimbria Srl +39 0542 361423 www.cimbria.com

Maxi-Lift Inc +1 972 735 8855 www.maxilift.com

Gime Tech Company Limited +86 1351037 2500 www.gimetech.com

Tapco Inc +1 314 739 9191 www.tapcoinc.com

Satake +81 82 420 8560 www.satake-group.com

Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Computer software Inteqnion +31 543 49 44 66 www.inteqnion.com

Enzymes ERKAYA +90 312 395 2986 www.erkayagida.com.tr

Coolers & driers Chief +1 308 237 3186 agri.chiefind.com

JEFO +1 450 799 2000 www.jefo.com

Consergra s.l +34 938 772207 www.consergra.com FrigorTec GmbH +49 7520 91482-0 www.frigortec.com Geelen Counterflow +31 475 592315 www.geelencounterflow.com Grain technik +91 114608 9500 https://graintechnik.com FAMSUN +86 85828888 www.famsungroup.com Soon Strong Machinery +886 3 9901815 www.soonstrong.com.tw Sukup +1 641 892 4222 www.sukup.com Wenger Manufacturing +1 785-284-2133 www.wenger.com Yemmak +90 266 7338363 www.yemmak.com Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Elevator buckets 4B Braime +44 113 246 1800 www.go4b.com Maxi-Lift Inc +1 972 735 8855 www.maxilift.com Tapco Inc +1 314 739 9191 www.tapcoinc.com Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

PLP +39 05 23 89 16 29 www.plp-systems.com

Extruders Almex +31 575 572666 www.almex.nl Andritz +45 72 160300 www.andritz.com Extru-Tech Inc. +1 785 284 2153 www.extru-techinc.com Manzoni +55 19 3765 9331 www.manzoni.com.br Wenger Manufacturing +1 785-284-2133 www.wenger.com Yemmak +90 266 7338363 www.yemmak.com Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Feed nutrition Adisseo + 33 1 46 74 70 00 www.adisseo.com Biomin +43 2782 8030 www.biomin.net Evonik Nutrition & Care GmbH +49 618 1596785 www.evonik.com/animal-nutrition

JEFO +1 450 799 2000 www.jefo.com Nutriad +32 52 40 98 24 www.nutriad.com PHIBRO +1 201 329 7300 www.pahc.com Phileo +33 320 14 80 97 www. phileo-lesaffre.com

Feed milling Dinnissen BV +31 77 467 3555 www.dinnissen.nl FAMSUN +86 85828888 www.famsungroup.com Kay Jay Rolls +91 9878 000 859 www.kjrolls.com Milltech Tel: +90 332 502 13 00 www.milltech.com.tr Ottevanger Milling Engineers +31 79 593 22 21 www.ottevanger.com PLP +39 05 23 89 16 29 www.plp-systems.com Wynveen +31 26 47 90 699 www.wynveen.com Van Aarsen International +31 475 579 444 www.aarsen.com Viteral +90 332 2390 141 www.viteral.com.tr Yemmak +90 266 7338363 www.yemmak.com Zheng Chang +86 2164184200 www.zhengchang.com/eng

Grain handling systems Chief +1 308 237 3186 agri.chiefind.com Cimbria A/S +45 96 17 90 00 www.cimbria.com Lambton Conveyor +1 519 627 8228 www.lambtonconveyor.com

Hammermills Alapala +90 212 465 60 40 www.alapala.com Aybakar AS +90 312 398 0247 www.aybakar.com.tr Bühler AG +41 71 955 11 11 www.buhlergroup.com

Vigan Engineering +32 67 89 50 41 www.vigan.com

Mill design & installation Alapala +90 212 465 60 40 www.alapala.com ASG Group (Değirmen Makine) +90 342 357 01 50 www.degirmen.com

Dinnissen BV +31 77 467 3555 www.dinnissen.nl

Bühler AG +41 71 955 11 11 www.buhlergroup.com

Ottevanger Milling Engineers +31 79 593 22 21 www.ottevanger.com

Genç Degirmen +90 444 0894 www.gencdegirmen.com.tr

Selis +90 222 236 12 33 www.selis.com.tr

Golfetto Sangati +39 0422 476 700 www.golfettosangati.com

Soon Strong Machinery +886 3 9901815 www.soonstrong.com.tw

Henry Simon +44 0161 804 2800 www.henrysimonmilling.com

Viteral +90 332 2390 141 www.viteral.com.tr Van Aarsen International +31 475 579 444 www.aarsen.com Wynveen +31 26 47 90 699 www.wynveen.com Yemmak +90 266 7338363 www.yemmak.com Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com Zheng Chang +86 2164184200 www.zhengchang.com/eng

Laboratory equipment Bastak +90 312 395 67 87 www.bastak.com.tr ERKAYA +90 312 395 2986 www.erkayagida.com.tr Gime Tech Company Limited +86 1351037 2500 www.gimetech.com Perten Instruments +46 8 505 80 900 www.perten.com Tekpro +44 1692 403403 www.tekpro.com

Loading/un-loading equipment

Sukup Europe +45 75685311 www.sukup-eu.com

Dinnissen BV +31 77 467 3555 www.dinnissen.nl

Tapco Inc +1 314 739 9191 www.tapcoinc.com

Golfetto Sangati +39 0422 476 700 www.golfettosangati.com

Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Neuero Industrietechnik +49 5422 95030 www.neuero.de

IMAS - Milleral +90 332 2390141 www.milleral.com Ocrim +39 0372 4011 www.ocrim.com Ottevanger Milling Engineers +31 79 593 22 21 www.ottevanger.com Sangati Berga +85 4008 5000 www.sangatiberga.com.br Satake +81 82 420 8560 www.satake-group.com Selis +90 222 236 12 33 www.selis.com.tr Silo Construction & Engineering +32 51723128 www.sce.be Wynveen +31 26 47 90 699 www.wynveen.com Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com Zaccaria +55 19 3404 5700 www.zaccaria.com.br

Moisture measurement Hydronix +44 1483 468900 www.hydronix.com Vibrafloor +33 3 85 44 06 78 www.vibrafloor.com

Mycotoxin management Adisseo + 33 1 46 74 70 00 www.adisseo.com

107 | September 2020 - Milling and Grain

Biomin +43 2782 8030 www.biomin.net

Zheng Chang +86 2164184200 www.zhengchang.com/eng

Inteqnion +31 543 49 44 66 www.inteqnion.com

Packaging

Yemmak +90 266 7338363 www.yemmak.com

Scalling

Fundiciones Balaguer, S.A. +34 965564075 www.balaguer-rolls.com

Sifters

Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

ASG Group (Değirmen Makine) +90 342 357 01 50 www.degirmen.com

Pelleting Technology Netherlands (PTN) +3 73 54 984 72 www.ptn.nl Soon Strong Machinery +886 3 9901815 www.soonstrong.com.tw

Dinnissen BV +31 77 467 3555 www.dinnissen.nl Filip GmbH +49 5241 29330 www.filip-gmbh.com

Roller mills Alapala +90 212 465 60 40 www.alapala.com

Pellet press

ASG Group (Değirmen Makine) +90 342 357 01 50 www.degirmen.com

Statec Binder +43 3112 38 5800 www.statec-binder.com

Yemmak +90 266 7338363 www.yemmak.com

TMI +34 973 25 70 98 www.tmipal.com

NorthWind +1 785 284 0080 www.northwindts.com

Shandong Jintai Rolls Co., Ltd +86 533 3058815 www.jintai-rolls.jssytm.com

Statec Binder +43 3112 38 5800 www.statec-binder.com

Statec Binder +43 3112 38 5800 www.statec-binder.com

Vibrafloor +33 3 85 44 06 78 www.vibrafloor.com

Rolls

FAWEMA +49 22 63 716 0 www.fawema.com

Palletisers

Reclaim system

Ottevanger Milling Engineers +31 79 593 22 21 www.ottevanger.com

Aybakar AS +90 312 398 0247 www.aybakar.com.tr

TMI +34 973 25 70 98 www.tmipal.com

Fundiciones Balaguer, S.A. +34 965564075 www.balaguer-rolls.com

Process control

Neogen Corporation +44 1292 525 600 www.neogen.com

Dinnissen BV +31 77 467 3555 www.dinnissen.nl

Roll fluting

Genç Degirmen +90 444 0894 www.gencdegirmen.com.tr IMAS - Milleral +90 332 2390141 www.milleral.com Henry Simon +44 0161 804 2800 www.henrysimonmilling.com Milltech Tel: +90 332 502 13 00 www.milltech.com.tr

Gazel +90 364 2549630 www.gazelmakina.com Selis +90 222 236 12 33 www.selis.com.tr

Silos Behlen Grain Systems +1 900 553 5520 www.behlengrainsystems.com A/S Cimbria +45 9617 9000 www.cimbria.com CSI +90 322 428 3350 www.cukurovasilo.com

Ocrim +39 0372 4011 www.ocrim.com

Lambton Conveyor +1 519 627 8228 www.lambtonconveyor.com

Viteral +90 332 239 01 41 http://viteral.com.tr

Pelleting Technology Netherlands (PTN) +3 73 54 984 72 www.ptn.nl

MYSILO +90 382 266 2245 www.mysilo.com

Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Pingle +86 311 88268111 www.plflourmill.com

Obial +90 382 2662120 www.obial.com.tr

Selis +90 222 236 12 33 www.selis.com.tr

Silo Construction & Engineering +32 51723128 www.sce.be

Soon Strong Machinery +886 3 9901815 www.soonstrong.com.tw

Silos Cordoba +34 957 325 165 www.siloscordoba.com

Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Soon Strong Machinery +886 3 9901815 www.soonstrong.com.tw

Yemmak +90 266 7338363 www.yemmak.com

Plant Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

108 | September 2020 - Milling and Grain

Sukup +1 641 892 4222 www.sukup.com

Symaga +34 91 726 43 04 www.symaga.com

Tanis +90342337222 www.tanis.com.tr

Top Silo Constructions (TSC) +31 543 473 979 www.tsc-silos.com

Temperature monitoring Inteqnion +31 543 49 44 66 www.inteqnion.com

Training BĂźhler AG +41 71 955 11 11 www.buhlergroup.com IAOM +1 913 338 3377 www.iaom.info IFF +495307 92220 www.iff-braunschweig.de Kansas State University +1 785 532 6161 www.grains.k-state.edu nabim +44 2074 932521 www.nabim.org.uk Ocrim +39 0372 4011 www.ocrim.com

28TH PRINT EDITION

OUT NOW! PERENDALE PUBLISHER'S INTERNATIONAL MILLING DIRECTORY 28 IS NOW ON AVAILABLE. With close to 30 years of publication behind it, the International Milling & Grain Directory (better known as the IMD) is a high-visibility, high-prestige directory for your company to appear in if you are selling products or services to millers.

The IMD enjoys a global reach of more than 23,400 readers.

New for IMD 28 you will find fascinating articles drawn from our sister publication, Milling and Grain. These articles provide real world examples from each different milling specialty, including interviews with leading industry figures, case studies based on visits to flour mills, feed mills and grain storage and handling manufacturers around the world.

Contact the team: Tuti Tan tutit@internationalmilling.com Mehmet Ugur GĂźrkaynak mehmetg@perendale.com

Member news Evonik invest in SmartAHC technology company with the goal to ensure healthier livestock farming and reduced risk of infection in animal farming Extru-Tech announce the introduction of their latest cutter head, the Self-Adjusting Die/Knife Cutter Head Leiber, in collaboration with Ghent University, have published a new study in the Journal of Animal Science (JAS) concerning the prebiotics effects of yeast cell walls within the canine gastrointestinal tract Ocrim recently hosted their new webinar series in early August to great success. The series of four webinars was dedicated to the modular mill concept

The International Milling Directory is free to join.

List your company, products and services today at:

internationalmilling.com

Vibrators Vibrafloor +33 3 85 44 06 78 www.vibrafloor.com

internationalmilling.com

Weighing equipment PLP +39 05 23 89 16 29 www.plp-systems.com TMI +34 973 25 70 98 www.tmipal.com Vibrafloor +33 3 85 44 06 78 www.vibrafloor.com

Yeast products Leiber GmbH +49 5461 93030 www.leibergmbh.de Phileo +33 320 14 80 97 www. phileo-lesaffre.com

Milling and Grain - September 2020 | 109

myMAG PRODUCTS AND SERVICES FEATURED IN THIS ISSUE

What is The Market Place The Market Place is a collaboration between Milling and Grain magazine and our sister titles, The International Milling Directory and The Global Miller.

The Market Place aims to connect the print and the digital world, bringing more content that will be of interest, as well as direct links to the content that you want to see.

Throughout this edition of the magazine you will find QR codes and myMAG links that can link to various content from all three publications.

MAG TV MAG TV is Milling and Grain magazine’s video channel.

Featuring content about new products, interviews with industry professionals, industry event content and much more

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Advertised products in this issue

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4B Braime Elevator Components Ltd

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AGI

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Alapala Makina Gida San. ve Tic. A.S.

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PROFILE

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Jiangsu ZhengChang Cereal Oil and Feed Machinery Co.,Ltd

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Lambton Conveyor Ltd

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15

Myande Group Co., Ltd.

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Nabim

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Obial

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Pavan Group

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Behlen Mfg Co

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Biomin Holding GmbH (Austria)

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PLP Liquid Systems srl

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116

Buhler (Switzerland)

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PTN

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Cimbria (Denmark)

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Satake (Japan)

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Cimbria (Italy)

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Saygili Rulman

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COFCOET (Xi'an) International Engineering Co., Ltd

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Consergra

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CSI

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Degirmencioglu Makina San. Tic. Ltd. Sti

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Dinnissen

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85

Erkaya Laboratory Instruments Co

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Evonik Degussa (Germany)

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Extru-Tech Inc

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FAMSUN

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FAMSUN

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FILIP GmbH

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Fundiciones Balaguer

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Gazel Degirmen Makinalari San. TIC. LTD. STI.

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Guttridge

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Hydronix

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Imas

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SCE

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Selis Makina Endustri VE TICARET LTD. STI.

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Shandong Jintai Rolls Co.,Ltd

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Silos Cordoba

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Siwertell AB

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87

Statec Binder GmbH

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Sukup Manufacturing

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Symaga (Spain)

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9

Tapco

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TSC

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TekPro

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The Essmueller

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Van Aarsen International B.V.

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Vibrafloor

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16

Vibronet Graef

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Vigan Engineering

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71

Wenger (US)

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12

Yemmak

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14

Yemtar

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13

Yenar Döküm A.S.

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91

Wynveen

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Milling and Grain - September 2020 | 111

the interview

Professor Li Dongsen, President, Zhengzhou Golden Grain Mechanical Engineering Co Ltd

Professor Li Dongsen is a professor at Henan University of Technology, China. From 1977-1981 he studied at the Grain Engineering Department of Zhengzhou Grain Institute (now formally known as the Henan University of Technology). From 1981-2017, he has taught students about grains and oil as part of the Food College within Henan University of Technology. He has been engaged in teaching, scientific research and technology development within cereal sciences and engineering. Professor Dongsen has also served as Deputy Secretary General of the China Wheat Association.

Professor Dongsen also serves as the Founder and Chairman of Zhengzhou Gold Grain Mechanical Engineering Co Ltd. How did you come to be involved in this industry?

Entry into this industry was, initially, a national necessity.

I was born in 1957 and was one of the first batch of students admitted, after the resumption of the college entrance exam in China. Due to various reasons, my admission notice was sent late, and I was finally able, after a short delay, to enter Zhengzhou Grain University to study. Although entering this industry was originally arranged by the state, I still feel a sense of pride as a witness of the development of China’s flour industry over the past three or four decades.

What do you see as a possible challenge that the grain industry may face over the next five years and how will your company play a part in prevention or solving it?

From the perspective of the grain processing industry and the development of the Chinese flour industry, it can be concluded that flour-based innovations are only relevant for a short time before new innovations are required to keep up with the technology. This seems to be an ongoing situation and I, personally, think there are a few topics that we need to think about over the next few years: Product development: Domestic flour competition is very fierce, as in the buyer’s market there has been an issue with oversupplying for many years. Short-term, enterprises must conduct in-depth research on product development and comprehensively consider the market demand, their own advantages and their own technological skills. This is also the professional advantage of our company. We will help customers avoid mistakes in product development as much as possible, through conducting analysis with our unique solutions.

Personnel training mechanisms: For the grain industry, the key to developing lasting development plans and whether enterprises can continue to grow is having the right people.

Retaining talent and setting up the training for this talent can prove challenging for many small and medium-sized flour enterprises. My experience as a teacher has resulted in Zhengzhou Golden Grain recognising this talent and knowing how to best promote this growth. Our company also provides a role similar to industry headhunting. Every time we discuss plans with our customers, we will also offer some suggestions regarding the enterprise’s personnel structure.

Intelligent manufacturing: The last five years have seen the dramatic evolution of 5G development. 5G is a new starting point for technology, and it is exciting to think about the opportunities and challenges that this network revolution may bring.

For the industrial field, 5G will bring a huge impact once it is popularised. It is possible to bring revolutionary influences to the production efficiency of enterprises, once 5G can be utilised in product production.

Our company is also building its own Internet of Things (IoT) platform. Through its existing electrical automation, we can add more sensors to our solutions to provide certain reference for big data analysis. In a later stage, we will also conduct in-depth research on the application of intelligent

112 | September 2020 - Milling and Grain

manufacturing.

The impact of genetic modification (GM) technology: GM may not be a challenge per se, but it may be one of the most important transformative factors for the future of flour.

Although the risks associated with GM are different, it can be said that GM technology itself is the inevitable next step to ensure human survival and development in the future.

With complete decoding of a genetic map of grain, it can be expected that there will be more genetically modified grain products in the future, which will bring profound changes to the production of the grain processing industry.

This new evolution is certainly something which Zhengzhou Golden Grain are paying great attention to.

How has China’s flour industry developed in recent years?

The development of China’s flour industry is difficult to generalise. Since the reform in the 1980s, there has been much phased development taking place. First of all, after the reform, the market economy began to eliminate some state-owned enterprises. Due to the change of the market demand structure, the domestic grains market was opened up and the price of wheat decreased for some time, and the profit gained from produce rose. In the main wheat producing areas, tens of thousands of new flour milling companies emerged. According to the statistics, in 2010, there were nearly 40,000 flour processing enterprises in China, among which there were more than 200 large and mediumsized flour processing enterprises with a wheat processing capacity above 400 tonnes-per-day (tpd).

After China’s entry into the World Trade Organisation (WTO) the price of wheat and the profit made within the flour milling industry was almost zero. These conditions made it inevitable to readjust the flour market in China. This readjustment will take several years but will further improve each and every link within the industry chain, ranging from farmers, to depots, processing plants all the way through to the final production factory. Eventually we hope China can form a group of large flour milling enterprises that is resilient against risks sand fluctuations, to efficiently and securely serve the Chinese market.

What makes your company stand out from its competitors? Do you have any projects or plans that we should look out for over the coming year from you and your company?

For Zhengzhou Golden Grain, the most important factor in what makes us unique is our understanding of the processing technology itself. Our impressive industry experience has given us great support when development new innovations.

Other product development and talent training services are inseparable from this core advantage.

Of course, the development of our company is also a result of how the living standard of the Chinese people has greatly improved. The food market in China is based upon grain as a staple food. New trends are emerging constantly, ranging from convenience to the concept of leisure food.

Zhengzhou Golden Grain is dedicated to the continuous

research and improvement of the comprehensive flour milling process, to take on any and all opportunities for development within the market. Despite the fierce competition among grain machine equipment manufacturers, our company has been able to survive. This is, in part, due to our continuous research regarding flour milling.

Over the course of the next year, we will continue to play to our unique advantages to bolster growth. We will continue to provide our customers with the most advanced processing designs and concepts, providing high-performance products. At the same time, we will focus on software and launch software products that can improve production efficiency, combined with 5G innovations.

What are you most proud of since founding Zhengzhou Golden Grain?

Personally, I am proud that I have witnessed the evolution of China’s flour industry, from being somewhat unorthodox in its production methods to becoming a leading flour producing country. As one of the participants in this evolution, I have left my own mark in this development of the industry.

From the perspective of entrepreneurship, our company has developed into a solution supplier for the food industry, offering such a great variety of solutions for all manner of processes. I think our company contributes to the development of society and improves society as a whole.

I am also very proud of our ability to train our personnel, producing professional engineers, marketing teams and more.

This is the biggest driving force of our company’s pride.

PEOPLE THE INDUSTRY FACES Ardent Mills hires Angie Miller as Vice-President of Sales

A

rdent Mills LLC has announced the appointment of Angie Miller as Vice-President of Sales. Ms Miller will oversee the company sales team and strategies, and join the experienced and dedicated senior leadership team.

“Angie has extensive experience building and leading high-performance sales organisations,” said Angie Goldberg, Chief Growth Officer at Ardent Mills. “With an eye toward strategic growth and sales effectiveness, we welcome Angie’s dedication to further drive our vision of being a trusted partner and nurturing our customers, consumers and communities through innovative and nutritious grain-based solutions.”

“Bringing Angie on board aligns with our commitment to our people and our investment in our customer focused strategy,” said Daniel Dye, Chief Executive Officer of Ardent Mills.

“Angie brings with her a wealth of experience, and we’re thrilled she’s joined our team.”

Ellen Zimmerman joins the USGC

E

llen Zimmerman has been selected as the US Grains Council’s new Director of Industry Relations. In this exciting new role, Zimmerman will provide direction to the council and their engagement in regard to the agribusiness industry and domestic markets. She will also be working towards the refinement of the USGC’s global market development programme.

“Ellen brings with her a solid connection with and great knowledge of the checkoff system so important to the council’s daily work. She comes to us with an abundance of positivity and creativity and will quickly incorporate her skills into what is already a very solid and trusted team at the council”, says Ryan LeGrand, USGC President and CEO.

Jim Raben elected Chairman of US Grains Council

T

he delegates of the US Grains Council (USGC) elected Jim Raben, a farmer from Illinois representing the Illinois Corn Marketing Board, as chairman of its Board of Directors at its 60th Annual Board of Delegates Meeting.

“It’s always been my way to cultivate relationships because together we are stronger, our collective voices are heard more loudly, and we can work together to achieve our common goals,” Mr Raben said in his incoming remarks. “The Council works around the clock and around the globe to find and expand new pockets of demand for the products we offer. That’s why I’ve chosen for my theme Building Relationships, Building Trade.”

Mr Raben has been working on his family farm since 1973, more recently with help from his two sons. He spent nine years on the Illinois Corn Marketing Board before joining the Council’s board in 2015 as an at-large member. Mr Raben has also previously served as the Board liaison for various USGC Advisory Teams.

Woo Kyun Kim receives Poultry Nutrition Research Award

W

oo Kyun Kim, PhD, has received the American Feed Industry Association (AFIA)’s Poultry Science Association (PSA) Poultry Nutrition Award.

“Dr Kim’s breadth of experience and research in the area of gut health make him an excellent recipient of this award,” said Paul Davis, PhD, AFIA’s Director of Quality, Animal Food Safety and Education. “The field of poultry nutrition is better off thanks to his passion and dedication.”

Dr Kim, an Associate Professor and Poultry Nutritionist in the Department of Poultry Science at the University of Georgia teaches feed and feeding, poultry nutrition and vitamins in animal nutrition. He also serves as a Section Editor for Poultry Science.

Mr Asbjørn Børsting joins FEFAC as new President

M

r Asbjørn Børsting has been elected as the new President of FEFAC, effective 2020-2023.

When discussing the new role, Mr Børsting states, “Our Charter will contain concrete actions to promote animal nutrition solutions, increasing nutrient efficiency, reducing greenhouse gas emissions linked to feed production and help reduce the need for antibiotics at farm level. We will also promote responsible and deforestation-free soy sourcing and new technologies to increase EU production of vegetable proteins.”

Børsting is currenrly also the Director of the Danish Grain and Feed Association and Variety Denmark (DAKOFO) as well as Chairman of the Danish-BioEconomy Panel. He has a degree in Agricultural Economics from the University of Copenhagan.

114 | September 2020 - Milling and Grain

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