JAN 2021 - Milling and Grain magazine

January 2021

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In this issue:

World Flour Day and The Milling Hall of Fame • BioSecurity & Design in the Food and Feed Industry IN A

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#1 M

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• The future of feed milling

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Milling and Grain . Volume 132 . Issue 01 . January 2021

• Arrius: A groundbreaking grinding system

• mycotoxin risk • NIR technology: for raw material and feed analyses goes mobile Proud supporter of

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Volume 132 Issue 01

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VOLUME 132 ISSUE 01

January 2021

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 Jasmine Parker jasminep@perendale.com Nigeria Marketing Team Nathan Nwosu Tel: +234 8132 478092 nathann@perendale.com

92 - Bühler technology helps Andean Valley’s expansion into the Chinese market

Egyptian Marketing Team Mohamed Baromh Tel: +20 100 358 3839 mohamedb@perendale.com Turkey, Eurasia and Middle East Marketing Team Mehmet Ugur Gürkaynak Tel: +90 537 3646457 mehmetg@perendale.com Managing Editor Vaughn Entwistle vaughne@perendale.co.uk Editorial Manager Peter Parker peterp@perendale.co.uk Sub-editor Andrew Wilkinson andreww@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 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

ISSUE HIGHLIGHTS

8

NEWS FEATURES

38 BioSecurity & Design 44 Digital conversion era ahead for our industry 48 Arrius: A groundbreaking grinding system

52 An automatised solution for traditional paddy pre-cleaning

FACES

10-29 56 Most national mandatory flour fortification standards need review

60 Taking the alternate route to our destination 64 The mill of the future: what will it look like?

70 Triple-action protection in feed biosecurity

74 Formulating ruminant health for improved profitability

138 People news from the global milling industry

PRODUCT FOCUS

36

CASE STUDY

118

78 Mycotoxin risk

82 Improving feed quality and breeding increases income

88 Automation of a paddy parboiling plant 92 Bühler technology helps Andean Valley’s expansion into the Chinese market 96 NIR technology

EVENTS

124 Event listings, reviews and previews

STORAGE

100 An air-tight heatinsulated steel silo for longer-term grain storage

104 BinMaster’s compact non-contact radar with bluetooth setup 106 Centralised, independent and combined aspiration systems

TRAINING

32 Industry training news

COLUMNS

10 The Global Miller 22 Mildred Cookson 26 The Rex Wailes collection

8 GUEST EDITOR Roger Gilbert

120 MARKETS John Buckley

COVER IMAGE: Details count when designing a grain handling system - page 74

136 INTERVIEW Prof. Wang Weiguo

nabim-to-UK Flour Millers The transition from one year to the next is a time of sad farewell balanced by a bright expectation of what the future year may hold. Not so this year.

We are leaving behind a year of turbulences, anxieties and sadness; with a clear understanding that while the world is more connected it’s more open to volatility and that anything that may happen anywhere can, in an instance, influence us.

We all know now that our food supply chain needs to be robust in terms of supply, safety and bio-security, and that we will be put under increasing pressure to provide more food to more people.

Millers and the milling industry will be at the forefront of meeting food demand through the supply of both cereal-base food products and animal protein products.

However, millers are adopting rapidly as several stories and features in this edition imply. Our factories of the future will be driven by big data, block-chain technology and intelligent equipment - in fact, in a digital world more information equates to greater intelligence. To get to this new future successfully we need to attract and develop the skilled labour and talent that wants to work in and develop our production processes.

The African Milling School represents the focus we must put on

Roger Gilbert

training our flour millers while the Online Milling School (that Milling and Grain supports) represents the feed industry’s desire to improve its skill base in feedmills across borders.

Our Interview this month features Professor Wang Weiguo from Henan University of Technology in China who talks about the challenge of skills and talent and notes that ”… only Kansas State University of USA has the specialty-feed science and management course. In China, now only two universities - Henan university of Technology and Wuhan Polytechnic University - educate bachelor students with a feed engineering basis in animal science.”

It is vital that in this fresh start to another year, and under the restrictions an uncontrolled virus has brought about, that we recognise the bigger challenge we face and that we use the knowledge and experiences from other industries to enhance our milling processes to provide those much needed food products – whether that be flour, rice, oilseed, feed or other milling process – that consumers have come to rely upon us for.

Finally, I must mention the up-coming World Flour Day – which is happening on March 20th. It’s important that we take the opportunity of this day to inform our customers and consumers in general that March 20th is a special day in the annual calendar when we pay tribute to all those involved in the production of this food staple – Flour!

It’s up to everyone one of us to spread the word and if possible organise an activity to acknowledge the hard labour and skilled work that goes into producing our daily bread, and all those other baked products, etc that rely upon milled grains. Tell us what you plan to organise and we will report it!

Happy New Year

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FLOUR

STEEL SILOS

An obsession for milling Where flour means power means life

An air-tight heat-insulated steel silo for longerterm grain storage

An interview by Roger Gilbert, Milling and Grain with the founder of the FlourWorld Museum and the initiator behind World Flour Day.

PAGE 14 GRINDING

COVID-19 is breaking stable food supply chains around the world. Many countries in Africa and Asia are facing food crises due to COVID-19 and compounded by locust infestations, which impact national food security.

PAGE 100

FOOD

STORAGE

FEED

PROCESS

FEED

Arrius: A ground-breaking grinding system

Improving feed quality and breeding increases income

Lower energy consumption, faster installation, maximum food safety, highest operating reliability, and best grinding performance: Arrius, the integrated grinding system from Bühler, offers an impressive array of innovations and tangible benefits for customers.

Following 40 years of development, China’s chicken industry has achieved global attention.

PAGE 82

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

As we all step forth with much trepidation into the vast expanse of the great unknown that is 2021, we can be forgiven for welcoming the back of it’s predecessor, which was undoubtedly a difficult year for our industry.

Dr Hamady Diop, the Head of Technical Co-operation & Advisory Services for the African Union Development Agency’s NEPAD (New Partnership for African Development) talks to Roger Gilbert, publisher of Milling and Grain magazine about the opportunities for commercial development in the areas of grain storage and feed production in Africa, whilst also discussing the various policies that are in place for national governments to develop programs that can be supported by NEPAD across numerous African countries. mymag.info/e/1030

Express yourself!

The Rongorongo Live Video Studio is a platform where industry representatives can talk about issues that concern them and which need greater exposure. Topics can cover issues that confront the milling industry and where opinions can be expressed to a wider audience than to just colleagues and other in your local industry.

Awareness is everything - and Milling and Grain magazine believes that informed governments, consumers and industry on issues that challenge us is vital if we are to meet the food challenges of the near future which involves the supply, safety, environmental impact, sustainability, health and nutrition of our food chains.

So if you have something to add to the ‘conversation’ or there is an issue that you want to raise for debate, then please connect with our publisher Roger Gilbert by emailing rogerg@perendale.co.uk.

Interviews can be conducted over Skype, Zoom or Teams.

Milling Hall of Fame The 2021 inductee into the Milling Hall of Fame (MHoF) will be announced on March 20, 2021 on World Flour Day. The individual will be honoured with: his or her image and details displayed in the new Milling Hall of Fame area at the FlourWorld Museum in Wittenburg, Germany; their career details and achievements recorded in the UK’s Mills Archive Trust and presented with a bronze sculpture which we proudly dedicate our January 2021 magazine cover to.

The sculpture is by the German artist Sibylle Waldhausen and stands at 25cm tall. It conveys the challenges millers face in turning grains and other ingredients into valuable food products and reflects the balancing act involved in producing consistent, safe and affordable products for the food chain that feeds the world’s growing population - all driven by men and women with commitment and vision.

10 | January 2021 - Milling and Grain

If there is one thing to be learned from last year, it’s that nothing in this world can be taken for granted, a statement that holds no truer case than with food.

In spite of the pandemic, the most recent 12 months has seen the production of 493,126 tonnes of rice worldwide, according to recent figures published by Statista.

This is not a one off either as global consumption of rice has seen a slight increase over the last several years. For example, during the 2018-19 crop year, approximately 486.62 million tonnes of rice was consumed worldwide, an increase of nearly 4.9 million tonnes from the 437.18 million tonnes yielded in 2008-09.

To meet this increasing demand, producers have been seeking to invest in much more efficient and safer working practices and equipment, whilst also taking steps to ensure that as much of the crop is getting from paddy to plate as possible.

As the most popular foodstuff in the world, the irrigation and cultivation of rice is arguably one of humanity’s most enduring achievements.

A most versatile grain may go some way to explaining the burgeoning high demand.

In terms of its nutritional value, compared to maize, wheat and potatoes, raw long-grain white rice is a relatively good source of energy, carbohydrates, calcium, iron, thiamin, pantothenic acid, foliate and vitamin E. However, rice contains no vitamin C, vitamin A, beta-carotene or lutein and is also very low in fibre.

Beyond rice, the processing of all grains will be key to keeping the world fed as the world’s population continues to increase. And this is why Bühler’s compact milling solution Arrius could not have come at a better time – and why we are talking about it so much. By streamlining the entire milling process, centred around reduction, to an unprecedented micro level, the speed and ease that mills can now be set-up and process may make all the difference in future years. gfmt.blogspot.com

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The second World Flour Day in March will honour a staple food, an industry and the people behind it

The Milling Hall of Fame moves into the FlourWorld Museum

The second World Flour Day will be celebrated on March 20, 2021. This day is dedicated to one of the staple foods of humankind, a staple that has nourished people every day for millennia, contributing to health, well-being and prosperity. It has had enormous influence on the political, economic and cultural development of societies. This commemorative day was inaugurated by the FlourWorld Museum in Wittenburg, Germany.

Founded in 2008, the museum illuminates the cultural history of flour and the epochal effects it had on people between the neolithic and industrial revolutions, and will have in future.

It also houses the world’s largest collection of flour sacks. The illustrations on the over 3600 sacks from 140 countries tell the story of the many things that grain, flour and bread mean to the people of the world.

The second World Flour Day will be celebrated in a special way by the FlourWorld Museum.

In addition to honouring the history and the product, this year the focus will be on the people behind the success story of this food. The Milling Hall of Fame was established by Milling and Grain. On the occasion of the first World Flour Day last year, the Hall of Fame inducted personalities who, from historical and contemporary perspectives, have made important contributions to the development of milling.

“The development and importance of flour would be inconceivable without the individuals and personalities who every day ensure that the product is made and gets out to people,” says Roger Gilbert, publisher of Milling and Grain.

“The creativity and innovation that go into this are unfolded with great personal commitment and passion. Without these lifetime achievements, milling would not have the significance that it does today.”

In future, each year an independent committee formed by Milling and Grain, the British Mills Archive Trust and Flour World Museum will select new members of the milling industry and induct them into the Hall of Fame.

Volkmar Wywiol, founder of the FlourWorld Museum, adds, “It very quickly became clear to us that the Milling Hall of Fame should have a physical space in the FlourWorld Museum.

“Here, we place personal achievements in the context of the importance of this staple food. We are very thankful to be able to 12 | January 2021 - Milling and Grain

collaborate with Milling and Grain on the long-term development of the Hall of Fame, and give it a permanent residence.”

In order to create a physical symbol of the distinction, this year the induction will include an artistic interpretation.

Well-known Berlin artist and sculptor Sibylle Waldhausen has created a bronze sculpture that symbolises a millstone. This will be awarded to the new members of the Hall of Fame.

“Our new space will tell the story of grain through the people.

This will make the historical dimension of the subject that much more tangible. Prepare to be surprised by who joins the Hall of Fame on 20 March 2021,” says Mr Wywiol.

LET´S CELEBRATE!

How will you celebrate World Flour Day 2021?

MARCH 20 - WORLD FLOUR DAY Please feel free to share your thoughts contact@worldflourday.com

www.worldflourday.com

20. 03.

W O R L D F L O U R D AY

An obsession for milling Where flour means power means life An interview by Roger Gilbert, Milling and Grain

Mr Wywiol, you’re a Mühlenchemie shareholder, founder of the FlourWorld Museum and the initiator behind World Flour Day. Your passion for milling is unmistakeable. What has driven your 30-year commitment to the industry?

I’m part of the postwar generation. Back then, flour and bread were important.

I would almost say they were the gold standard of survival. So as owner of the almost century-old Mühlenchemie, it went without saying that I would also be attentive to the cultural aspects of flour.

Flour has become a great passion of mine, almost an obsession! Not for nothing do we call the upper floor of the FlourWorld Museum ‘Flour. Power. Life.’!

Inspired by World Flour Day on March 20, our editors will induct a new member into the Milling Hall of Fame every year on this date. In doing so we want to honour individuals who have made special contributions to milling.

I’m glad that Mühlenchemie has agreed to give us practical help with that. What do you plan from your side?

Roger Gilbert, thank you for this wonderful idea! We’re devoting a dedicated room to the Milling Hall of Fame in the FlourWorld Museum and will publicly honour the inductees there. Right now we’re putting together a committee of millers, mill builders and baked goods producers. Each year this committee will 14 | January 2021 - Milling and Grain

award a suitable candidate from industry, science or technology.

Let’s take a look at the international milling business, which is changing at a breathtaking pace. Companies are under a lot of economic pressure, and must constantly adapt to new situations and challenges. What support does Mühlenchemie as a flour treatment specialist offer businesses in this challenging field?

In milling, efficiency, rationalising and quality are key. But grain is a natural raw material with changing product characteristics. We at Mühlenchemie specialise in evening out these variations.

At our Stern-Technology Centre we have a pilot mill with rheology, bakery, wafer and pasta production facilities. Here we can replicate all the products of the flour-processing industries, to offer our customers bespoke solutions for flour standardisation, while taking into account regional processing methods and recipes.

‘Enzyme design’ is the core competence of Mühlenchemie. Are enzymatically improved high-end flours really the universal solution for raw material problems of all kinds?

Yes, enzymes play a vital role.

Mühlenchemie was already working in this area as early as the 1960s. No other materials are as multifaceted and

multifunctional or as sensitive as enzymes are. As enzyme designers we recognised early on that what matters is the ‘complex,’ the interaction and synergistic effect of different enzymes. We tune these compounds in detail to meet the individual requests, which are getting ever more specific.

What are the requirements in practice?

Flour standardisation is naturally one of the biggest challenges. Mill customers want flour properties that remain consistent over months or years. We help mill operators meet these expectations, even when weaker wheat batches enter the picture.

Another demand, for example, is for special flours. Processors want solutions for making flours for special bread varieties, or mixing with high-starch milled products like cassava, maize or rice flour.

The food industry is a reliable seismograph of societal changes. What nutritional trends are reaching all the way into flour treatment?

One aspect is the shelf life and freshness preservation of baked goods. Processors increasingly expect flour to have a positive influence on the fresh-keeping of baked products.

For example, flatbreads and sandwich breads are expected to stay soft and

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moist for a long time, and not get dry and hard after only three or four days. We offer functional concepts for this.

Another global food trend is pasta. With its long shelf life, dried pasta has become a product in high demand from end users. But durum wheat is not always available to make it with. Our applications technologists in the Pasta laboratory know what enzymes can improve the consistency, cooking tolerance and colour of pasta to the point where soft wheat can be used to make it.

Not just eating habits, but also growing conditions are changing. Many producer countries are battling drought, heat or extreme rainfall – and these environment factors have an immediate influence on grain quality. What answers does Mühlenchemie offer to the effects of climate change?

Well, let’s look at drought for example.

The resulting deficit in flour enzymes has to be compensated; otherwise there will be problems in the bakery. With Deltamalt we’ve developed an especially innovative system that can improve the rheological values as well as the baking properties of flour. Before now this combination was not possible in this targeted way.

‘Individual and tailored customer support’ is an integral part of the worldwide Mühlenchemie philosophy. But the international milling industry has a very multifaceted structure. Each country has its own framework conditions, and a high-performance mill with a daily capacity of 1000 tonnes of wheat flour has different problems from a traditional chakki mill. How does Mühlenchemie manage to please all of its customers in the face of this complexity?

Without question, this is the greatest challenge that our baking and pasta specialists and grain technologists face every day. Our central Applications Technology is located in Hamburg-Ahrensburg, but in many countries we have regional rheology and baking laboratories that speak the customers’ language.

Here, our staff can quickly analyse even the most complex issues quickly, while consulting with their colleagues in Germany at any time. With this individual service strategy we have gained a great reputation in the worldwide milling industry. I’m very proud of it.

Mühlenchemie is a member of the SternWywiol Gruppe, a family-owned company based on food ingredients. Does this

constellation result in synergies for the milling and baking industry?

Yes indeed, as an owner-operated food ingredient manufacturer with twelve specialist companies, we are unusually broad-based. We have over 100 people just in applications research, including specialists in hydrocolloids, lecithin, plant proteins, flavourings, chocolate pieces, dairy, deli foods, meat, baked goods and of course vegan alternatives. This variety, and the constant communication among our experts, gives us many advantages and naturally also results in remarkably creative solutions.

Can you give a specific example?

One of our specialist companies is DeutscheBack. It was founded 15 years ago at the request of several large mills in order to offer additional services to their customers, frequently bakers who need individually adjusted flours or active ingredients to improve their products or processes. Our expertise helps the millers deepen their customer loyalty. This ‘From Flour to Final’ service from a single source is unique.

Let’s look at the second core competence of Mühlenchemie, the production of flour fortification premixes with vitamins and minerals. In recent years many governments have instituted flour fortification programmes, but practical implementation often involves uncertainties. What does Mühlenchemie do to help mills in handling micronutrients correctly?

Flour fortification is much more than just a line of business for us. It is something that is dear to our hearts.

We operate our own compounding plant, and in our Baking and Pasta laboratories we do tests to better understand the reactions and retention of vitamins in flour. In collaboration with partner organisations like GAIN, FFI, Smarter Futures and SUN (Scaling Up Nutrition) we also offer workshops and seminars for mills.

When millers get more information on how important the added micronutrients are for public health and how best to store and process the sensitive premixes, they typically become as passionate about flour fortification as we are.

In two years Mühlenchemie will celebrate its 100th anniversary. What plans and projects are slated for implementation by 2023?

Right now we’re focusing our strength on meeting the challenges of the corona crisis.

But one thing is sure – we will continue to push digital communication, dialogue and knowledge transfer at all levels. And naturally we’re keeping an eye on the expansion of our international network and the Technology Centers.

Volkmar Wywiol, thank you for this engaging conversation. Your passion, or your obsession as you call it, for flour is obvious. We’ll continue to follow Mühlenchemie’s activities for the global milling and baking industry with interest.

Thank you for setting up the Flour World Museum and for supporting the establishment of the Milling Hall of Fame.

Nominate an inductee for the Milling Hall of Fame

If you know an individual who has made, or is making, a significant contribution to milling - be that in equipment provision; production of flour or other milled products; through research and/ or development; in training or education, engagement with retailers and/or consumers; advances in safety or environmental impact (the list is endless) - and you feel they should be recognised for their efforts, then nominate them to be considered as an inductee into the Milling Hall of Fame.

The first inductee was Volkmar Wywiol (see our interview with him on these pages), who has made a significant contribution to flour improvement throughout the world in addition to promoting the industry through his development of the FlourWorld Mesuem.

A committee of up to 15 milling industry representatives is being formed to evaluate nominations made by individuals, companies, organisations or governments for this honour. Candidates must be still working or recently retired to be considered.

Nominations can be made by emailing to request an application form. Additional information and references should be included along with the application. One or possibly two inductees will be made each year on World Flour Day - March 20th.

Please email info@perendale.co.uk in the first instance.

Milling and Grain - January 2021 | 17

Milling News

Factory upgrade supports sustainable future

I

ndependent feed additives manufacturer Anpario PLC, has invested UK£500,000 (US$675,000) in a series of upgrades within its UK-based production facility.

The project, which began earlier this year, involves three stages including: a new transfer system between the mixer and packing system on one of the key production lines; the installation of a fully automated pallet processing system and the installation of an innovative wrap round gantry which will also increase storage capacity at the site.

“The aim of the project is to further enhance operational efficiency whilst reducing the company’s carbon footprint,” explains Shane Bailey, Anpario’s operations director.

“For example, the new transfer system has reduced energy consumption when transferring products from the mixer to the packer by up to 90 percent and halved the amount of waste produced from operation of that line within the factory.

18 | January 2021 - Milling and Grain

“Not only does the upgrade reduce environmental impact, but it is also much more efficient, with the upgraded line running at up to eight times faster than the previous system,” says Mr Bailey.

“The addition of the fully automated pallet processing system is one of a range of measures and improvements at the plant over the past five years which have focused on increasing the output capacity for our products, including Orego-Stim and Anpario’s acid based eubiotic (ABE) range, in order to meet on-going sales growth,” explains Mr Bailey.

The investment has resulted in other benefits for Anpario, including building on quality assurance goals and improved health and safety of the operations team.

The project also supports the aspirations of the company’s ‘Green Team’ comprising individuals from each department who share the company’s ambition to minimise impact on the environment. The final stage of the project is scheduled for completion by the end of 2020.

“Anpario is fully committed to reducing the environmental impact of our operations and is working towards key milestones to deliver what our employees, customers, and stakeholders expect from us,” says Mr Bailey.

“We will achieve these targets thanks to the passion of our staff to reduce and conserve energy within the factory, and thanks to the ongoing investments aimed at making our operations environmentally sound and sustainable for the future.”

UK Government awards £21 million to farmers in bid to boost productivity

N

early 4000 UK farmers are set to benefit from UK£21 million (US$28.35 Million) in productivity-boosting equipment from the third and final round of the government’s Countryside Productivity Small Grants (CPSG) scheme.

The Rural Payments Agency notified successful applicants of their awards in late November and is now encouraging farmers to speak to their suppliers to confirm the items they wish to order are available before accepting their grant by using the acceptance portal on GOV.UK by January 18, 2021.

Under the scheme, farmers applied for grants of between UK£3,000 and UK£12,000 for them to invest in new and innovative equipment – from livestock monitoring cameras to precision farming technology – which will help businesses save time and money whilst also improving productivity.

Applicants have until midnight on May 31 to buy and install all of their items before submitting their claim for payment. This deadline has been extended by two months to allow for potential delays caused by the impacts of the coronavirus pandemic.

The announcement, which was made on December 15, 2020 means that UK£60 million has been allocated to farmers investing in technology to boost their productivity since the scheme opened in 2018.

Although the CPSG scheme is closing, government support for the investment in technology will continue as outlined in the Agricultural Transition Plan. As part of this, the government set out plans for the Farming Investment Fund which will support innovation and productivity.

The fund will provide targeted support to businesses so that they can invest in equipment, technology, and infrastructure that will improve their productivity and deliver environmental and other public benefits.

Two levels of farming investment There will be two level of farming investment funds, the: • Farming Equipment and Technology Fund: which will offer small grants to contribute towards the purchase of a list of specified items and the • Farming Transformation Fund: this will provide larger grants towards the cost of more substantial investments in equipment, technology or infrastructure. The hope is that this scheme will have the potential to transform business performance “It’s great to see that funding for all the eligible applications is being made for round three of this popular scheme. I would encourage all our customers to contact their suppliers early to ensure their items can be delivered ahead of the claim deadline,” says Rural Payments Agency Chief Executive, Paul Caldwell.

“Innovation and technology has real-life impact across the farming sector, so I’m delighted to be able to help unlock this potential for many farmers.” www.gov.uk/guidance/countryside-productivity-scheme

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Paris’ largest milling plant installed despite COVID-19 restrictions

D

espite the international SARS-CoV-2 restrictions, Omas has continued the construction of Paris’ largest wheat mill.

“Programming and organisational skills are our strong suits,” say Luigi Nalon, CEO of Omas of Giorgio delle Pertiche, Padova in Italy, when talking about the company’s approach to this unprecedented challenge.

The Omas team working on the Paris-based plant includes 22 specialised mechanics, who are completing the assembly of the mill despite the problems caused by the lockdown.

To protect their health, all Omas operators were tested for COVID-19 before leaving for Paris. This way, on July 27, 2020, they could start working safely.

At the end of November and after four months from the beginning of the works, 75 percent of this huge milling system had already been assembled, in line with the timetable.

An excellent result, considering the ongoing pandemic, says the company.

“We could achieve it thanks to the professionalism of our supervisors and expertise of our assemblers, whose priority was to meet the client’s goal to start up the mill on the agreed date.

“A handshake is even more binding than a contract! We at Omas comply with our agreements to provide our clients with excellent service” concludes Mr Nalon.

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Mr Green’s “Gold Belt” Roller Mills

William Green’s ‘Gold Belt’ Roller Mills, Brantham, Suffolk

by Mildred Cookson, The Mills Archive, UK

W

Milling journals of the past at The Mills Archive

system. Mr Green became convinced that to keep and extend illiam Green of ‘Gold his trade, a roller plant was absolutely necessary and ultimately Belt’ Brantham and ordered a four sack roller plant from ER Turner of Ipswich, less Raydon Mill was 42 years old when the Miller than 10 miles away.

Along with the roller plant, Turners installed a Jonval Turbine, contained a report on which was said to run with smooth and regular revolutions. him (June 4, 1894). He Apparently the nine-foot diameter crown wheel, made at St started out in agriculture Peter’s Works, Ipswich, ran as easily as if it the been the fly and moved on to become wheel of a toy engine and not a mass of metal weighing about a a flour salesman. He then ton and a half. decided he wanted not only to sell flour but to produce it.

Since the installation of the turbine, less work was required of Accordingly, in 1880 he rented Raydon Mill in Suffolk. Although without any previous milling experience, he soon showed that there the engine, which was of the compound beam type of 12 horse was no more enthusiastic miller in East Anglia.

In 1888 he purchased Brantham Mills, which at that time ran with five pairs of millstones driven by a breast shot waterwheel. The illustration of the exterior of the mills gives a good view of the entrance. In the deep red of the brickwork on the face of the mill was set a small white stone, bearing the simple inscription “I. P., 1778.” Mr Green enlarged the mill, adding a screening house and an engine and boiler house with a shaft within the 80-foot high chimney, as seen on the left of the exterior illustration.

The millstones were supplemented by smooth rolls for the conversion of middlings and for a few years, the mill was worked on a combination A Jonval Catalogue The Turner dustless purifier

22 | January 2021 - Milling and Grain

Cross section of the turbine

Longitudinal section of the mill

power. This was built by Wentworth of Wandsworth and proved a most efficient motor. The engine was supplied with steam generated in a Cornish boiler.

The roller plant was tested and with the engine alone, there was sufficient power for producing 120 sacks in 24 hours. This was a severe test for both the milling plant and the engine, considering the previous capacity was only four sacks an hour. Moreover, the 120 sacks were from a grist of all English wheat.

Grain storage

The warehouse was quite distinct from the mill itself, separated from it by a stout wall.

At the time of writing another building for storage of grain and flour was being constructed at right angles to the building on

the right hand side of the mill in the illustration. It was planned to come down to the edge of the River Stour with an elevator to discharge grain from the barges on the river.

The grain would be carried into the mill by a band conveyor. As the river communicated directly with Harwich and the seaboard, and inland was navigable as far as Sudbury, Mr Green reckoned he could bring in foreign grain to his mill at 1 shilling a quarter less than would be charged by the Great Eastern Railway.

The screen house of the mill was a distinct warehouse-like structure. After being automatically mixed, the wheat fell on a shaking sieve that separated impurities larger than the berries.

From this sieve the wheat passed to a “Vibromotor’ grader followed by a cockle and barley cylinder and finally a ‘Eureka’ vertical scourer and vibromotor.

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We engineer, manufacture, build and manage your complete project in the cereal processing industry. www.ottevanger.com Milling and Grain - January 2021 | 23

The roller system

The roller system had four breaks and eight reductions, the breaks being effected by two double roller mills fitted with rolls of 30 x 9 (inches.) while the eight reduction rolls were assigned to four double roller mills. In one mill the rolls were 15 x 8 (inches); two sets had rolls of 20 inches, while the dimensions of the remaining set Christy Brothers advertisement were 25 x 9 (inches).

Each roller mill was exhausted into a trunk passing a little above its hopper. The rolls and products were said to be remarkably cool, due to a good system of exhausting and lubrication. Each roller spindle ran in a film of oil in a long phosphor bronze bearing, aided by an ingenious but simple device maintaining a free circulation of oil is throughout the bearings.

The roller mills standing in one line were said to make a fine show, enhanced by the rich tones of their polished mahogany casings which were brought into sharp relief by the bright hue of the pine spouting and trunks above. The roller mills were driven by steel lay shafts form the basement that had been excavated especially. The four shafts separately powered the ground, the first, and the second floors.

The first floor, which housed the purifiers, held four ‘Turner’ dustless purifiers, two being double ones. The tin trays above the sieves worked well, and the action of the rotary travelling brush was gentle and effective. In one frame there were three break

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Cross section of the mill

scalpers of the type known as ‘inter-elevator reel scalpers’ which worked on the products of the first three breaks.

Underneath these reels were three of the popular pneumatic sorters to sort the overtails of the break scalpers and send them to the breaks for which they were best suited. A ‘Turner’ sifter worked on the overtails of the tailings reduction. On this floor the offals were taken off in a pair of ‘Turner’ packers conveyed by means of two spiral worms.

Messrs Christy Bros of Chelmsford fitted the mill out with an electric light installation, a dynamo stood in the corner of the roller floor next to a handsome switchboard.

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The Rex Wailes Collection A Man of Letters

by Mildred Cookson, The Mills Archive Trust, UK In my article on the Collection in February’s Milling and Grain, I included the 1900 photograph of the millwrights Wakes & Lamb replacing a sail on Coleby Heath windmill in Lincolnshire.

Much to my delight, we have discovered amongst Rex’s papers, a letter from the firm dated March 1930 - a few months after Rex joined the Society for the Protection of Ancient Buildings as Technical Adviser.

They were asking to be included on his list of specialised craftsmen, citing their 60 years of experience together with the number and geographical spread of their workforce.

Based in Newark on Trent in Nottinghamshire, their letterhead shows that they had won prizes overseas and had also manufactured wind pumps, another of my passions. Known as wind engines in the UK, and American Windmills in the USA, these simple structures were exported all around the world for irrigation purposes. We have many old catalogues of these machines dating back to the early 1900s; a number complete with what an American correspondent apologetically described as “mouse chew”.

Apart from the historical interest of the letter and its stationery, the letterheads often are works of art in themselves and we are keen to add more to our large collection. Frequently with designs unchanged for many years, they were used by engineering firms, mills and suppliers from over 100 years ago, in a way that always attracts attention when we hold an exhibition. Sadly many are now only available on eBay through dealers, a market we cannot afford to enter.

A second example from Rex’s collection shows how popular windmills were as an icon of a well-established firm. Dated December 1949, Smithdale and Sons were established over 100 years previously. Not only were they iron and Brass founders, they were engineers, millwrights and electrical contractors specialising in water supply and the drainage of marshes and fens.

I can only assume that their telephone number (Acle 71) no longer works!

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FIND WHAT YOU ARE LOOKING FOR - WITH THE INTERNATIONAL MILLING DIRECTORY ONLINE

internationalmilling.com Contact the team at: enquiries@internationalmilling.com

26 | January 2021 - Milling and Grain

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Milling News

B

Omas Industries to build first ‘Flexy Mill’ plant in in Central Europe

uilt in the district of Neamt, Romania, Omas Industries’ newly commissioned food complex facility will be operational in 2021.

The large milling plant of 150-tonne per 24 hours will enable the milling flow sheet to be modified according to the cereal quality, allowing the production of various types of final product automatically.

All this is able to happen thanks to the Fexy Mill, Direct Drive (DD) and the Omas Drive System (ODS) technologies.

Omas Industries were able to develop a tailor-made plant with distinctive elements allowing the widening of the finished products range by increasing the system’s ease of management and reducing costs.

The new milling plant will be able to produce six types of groats and three types of flour, each with their own unique grain sizes and characteristics.

Thanks to the DD and ODS systems, Omas Industries possess the capability to change the fundamental grinding parameters on the roller mills during the milling process.

They are also able to modify not only the distance

between the rolls, but also other grinding parameters such as the rolls working position and the cutting speed, as well as the differential between the grinding rolls.

These are very important factors for milling that become fundamental when the quality of the raw material changes, as well as when the changing needs of consumers demands very different products and percentages.

“We are honoured by this agreement and it’s a pleasure that our customer has understood the potential of our technology, unique in the world. We consider this Flexy Mill the first of a series of mills in Central Europe that, looking to the future, will choose Direct Drive machines to eliminate transmission belts and the problems they cause!”

Says Pietro Barbalarga, Omas’ Commercial Director.

Sergio Dipasquale, Chief Miller who has taken part in the commercial mission, comments “A taylor-made milling plant specific to the customer’s requests, which will obtain the flexibility and high yields required by large-scale distribution thanks to the DD technology. We are ready for this new challenge!”

Milling and Grain - January 2021 | 27

Milling News

Blockchain and the agri-food market

B

lockchain is in a slump, with almost half its 2018 market value wiped out in 2020. But the silver lining in that downfall has been the resiliency of industrial applications, not least in the Agri-Food market.

ABI Research, a global tech market advisory firm, expects industrial blockchain revenues to grow sixfold in the next five years, reaching US$2.1 billion globally by 2025. It’s analysis comes from a recentlycompleted Blockchain in Industrial Applications report “Supply chain implementations have been particularly successful and are having the greatest impact on the agrifood industry,” explains Michela Menting, Digital Security Research Director at ABI Research.

“Combined with digital transformation efforts and IoT technologies, numerous blockchain-based platforms are moving into the production phase, paving the way for adoption into manufacturing, retail, and utilities markets.

“Transportation, shipping, distribution and storage are key verticals for blockchain and especially as they concern supply chain management, logistics, location and tracking, asset and inventory management,” he says.

The blockchain market is still fairly young, with global revenues rather low, standing at US$374 million by the end of 2020. Industrial applications are only just emerging out of R&D and into production.

This would not be possible without the underlying R&D and support of the large enterprise IT providers, like IBM, Microsoft, Oracle and SAP. These providers offer the blockchain infrastructure to build and develop applications plus the ecosystem support through various consortiums and associations.

“There is no doubt that blockchain can offer real added-value to industrial markets, in line with the Industry 4.0 movement and associated technologies,” Mr Menting concludes.

These findings are from ABI Research’s Blockchain in Industrial Applications application analysis report. This report is part of the company’s Digital Security research service, which includes research, data, and ABI Insights. Based on extensive primary interviews, Application Analysis reports present in-depth analysis on key market trends and factors for a specific application, which could focus on an individual market or geography.

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IFIF and FAO launch new manual of Good Practices for the Feed Sector

T

he International Feed Industry Federation (IFIF) and the Food and Agriculture Organisation of the United Nations (FAO) launched the new manual of Good Practices for the Feed Sector: Implementing the Codex Alimentarius Code of Practice on Good Animal Feeding at their joint annual meeting 2020.

The manual was first published in 2010 and has been a valuable tool to increase knowledge and improve feed safety at the production level, and it is widely recognised and used in many countries around the world. This second publication is a fully revised, updated and expanded version of that manual and addresses recent developments in feed production and benefits from the latest scientific and technical knowledge.

The objective of the manual is to provide comprehensive information and practical guidelines to farmers, producers and all stakeholders along the feed value chain to comply with the requirements of the Codex Alimentarius Code of Practice on Good Animal Feeding.

The application of the Code is an important step for the expansion of international trade of feed and products of animal origin. Both feed/food exporting and importing countries can benefit from a greater and safer trade of feed and products of animal origins.

This manual is intended to guide managers of feedmills, the feed industry as a whole and on-farm feed mixers and producers. It will also be of value to national competent authorities, in particular those engaged in feed inspection, in

Milling News

their supervisory roles. It can also serve as a training manual and a guide to setting up national feed associations.

Daniel Bercovici, IFIF Chairman, highlights that, “This manual is a key result of the long-standing and strong collaboration between IFIF and FAO and serves as an important tool to promote feed safety, which is a key element in the sustainable production of food of animal origin: it is a prerequisite for food safety and human health, as well as a necessity for animal health and welfare.”

Daniela Battaglia, Animal Production Officer at the Animal Production and Health Division of the FAO, says, “FAO and IFIF have a long standing partnership.

“Together they also strive to promote feed safety globally as a component of access to trade, income generation and sustainability. In fact, feed is an integral part of the food chain and its safety has been recognised as a shared value and a shared responsibility.”

Alexandra de Athayde, IFIF Executive Director, adds “This new manual also serves as the basis of the IFIF Capacity Development Training Programme and the IFIF feed safety e-learning course. Both IFIF and FAO hope this manual will meet the expectation of a constantly evolving sector and will continue being an essential tool to support producers living up to their roles and responsibilities to ensure sustainable food production and feed a growing world population.”

The new manual is now available on the IFIF and FAO websites at the following links: https://ifif.org/our-work/project/ifif-fao-feed-manual/ www.fao.org/documents/card/en/c/cb1761en

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Presenting the next generation purifier 20-plus years of innovation has resulted in one of the most advanced pieces of equipment in the market.

The HP55 is the only purifier with four rows of superimposed sieves. While it boasts a 10% increase in purification surface, the overall machine footprint has been reduced by more than 10%.

Precision air-flow control is provided via four adjustment points per sieve length, for a total of 12 points.

Discover more about GEA Golfetto Sangati’s milling technology online at gea.com/milling

Mill

TRAINING

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.

IAOM – KSU Introduction to Flour Milling Participants will discuss all aspects of the flour milling process, from wheat selection to milling, to flour blending and baking functionality.

Topics for the course include an overview of the US milling industry; wheat production; supply and demand; wheat The European Union is a key, lucrative market for many countries around the world, and ensuring compliance with its requirements is a major issue for trade. The EU is also a leader in the establishment of effective food law and related control systems, with its legislation frequently being used as a basis for national and regional food laws.

AFTP Knowledge Nuggets - EU Food Law The impact of food law affects each and every aspect of the agrifood industries which makes this topic relevant to anybody working in the sector. To assist attendees with their understanding As several events continue to be postponed, moved online or cancelled altogether as a result of COVID-19 concerns in the United States, Texas A&M University (TAMU) has announced its 30th Annual Practical Short Course on Feeds & Pet Food Extrusion, will be held LIVE Online February 1-5, 2021.

30th Annual Practical Short Course on Feeds & Pet Food Extrusion - Febuary 1-5, 2021 A one week Practical Short Course on Feeds & Pet Food Extrusion will be presented on February 1-5, 2021 at Texas A&M University LIVE online by staff, industry representatives, and consultants. The program will cover information on different extrusion systems such as Dry extruder, Expander, Single and Twin Screw extruder, designing new feed mills and selecting conveying, drying, grinding, conditioning and feed

32 | January 2021 - Milling and Grain

classes, 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 4-8, 2021. of EU Food Law this course looks at various aspects of food laws such as a history of EU Food law through a short online video tutorials, plus associated core and support materials.

This course will also introduce attendees to the basic principles of EU Food Law, defining the space in which it operates, the kind of regulations that govern it, and the ways that laws come into being. Also explored is the way that science is factored into EU Food Law, including a summary of developments towards existing procedures, the role and current activities of the EFSA, and speculation on its future directions, as well as compliance and development of the Food and Feed Safety Alert System.

The course takes place at the University of Reading, UK and begins January 9, 2021. mixing equipment. Current practices for production of pet foods, preparing full-fat soy meal; recycling by-products and secondary resources; spraying and coating fats, digests and preservatives; use of encapsulated ingredients and preparation of premixes are reviewed. Reservations are accepted on a firstcome basis. For more information, programs and application forms, contact: Mian N. Riaz, Ph.D, CFS Holder of the Professorship in Food Diversity Food Science and Technology Department Professional & Continuing Education Texas A&M Engineering Experiment Station (TEES) Extrusion Technology Program Texas A&M University College Station, TX 77843 Tel: 979-845-2774; E-mail: mnriaz@tamu.edu https://teesedge.tamu.edu/extrusion/

Milling News

Register now for the Online Milling School for feed manufacturers If you think you’ve left it too late to join the 2021 Winter Course of the OMS for feed manufacturers - you haven’t.

We have made it possible for those signing up now, for the complete 12-week Course, to view missed weekly Sessions via our on-demand service in order to catch up.

Completing the Course results in a Certificate of Attainment which validates your achievement. Attending the full Course costs US$360 (while individual Session can be purchased for US$40/each). Visit www.onlinemillingschool.com for registration and Course details.

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Mixing Operations

In the most recent edition of the OMS, topics of ‘Mixer and Mixer Design’ and ‘Mixing Operations: Factor that impact mixing dispersion and homogeneity’ were covered.

The first section of the two-hour presentation sees Roy Kazen from Ottevanger discuss ‘Mixer and Mixer Design’ including points of attention in the mixing process, as well as the main mixer type, shapes and the mixing additions.

According to Mr Kazen, “One way to view mixing is as a method to cause separate ingredients otherwise independent from one another to interface as a result of an external force.

“Uniformity is most desirable. Yet, in the case of mixing highly viscous materials, achieving uniformity is often a difficult, but not impossible, challenge.”

The second section of this edition sees Feedmill Owner and Feedmill Engineering Consultant Ryan Celis examine the subject of ‘Mixing Operations: Factor that impact mixing dispersion and homogeneity.’

In his address Mr Celis covers a variety of relevant areas of this complicated process in great detail including testing for homogeneity, influences on mixing accuracy, whilst also mixer design considerations.

The experience that Mr Celis has yielded from many years of working on the frontline of our industry enables him to provide an unparalleled level of insight into how it operates.

According to Mr Celis, “The main function of the mixer is to ensure that every sample of feed within the batch is nutritionally balanced in terms of protein, energy, vitamins and minerals.”

More comprehensive reports in to both of these presentations will be published in Milling and Grain magazine over the coming months, so stay with us to enjoy the full benefit of the wisdom of these two industry experts.

If you have not done so yet, visit www.onlinemillingschool.com for registration and Course details.

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Milling and Grain - January 2021 | 35

Yemmak: Kubur Filter

PRODUCT FOCUS January 2021 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.

Yemmak’s Kubur Filter is designed to prevent the spread of dust that occurs during the unloading of goods from trucks in raw material receiving units. The filters lined along the sides of the intake chamber suck air through the filter cloths with the help of a fan. Dust remains in the filter cloths.

After the aspiration is finished, compressed air is periodically applied to the filter cloths with pulse valves. When the filter cloths are cleaned, the dust is then recycled back in to the system via the intake chamber.

All related environmental and human health considerations are a top priority for Yemmak, a factor that is reflected in the Kubur Filter’s design.

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Holmen NHP300 Pellet Durability Tester The Holmen NHP300 Pellet Durability Tester is ideally suited to a busy, quality-focussed mill.

Samples are automatically taken from the production line, tested, returned to the line, and a PDI result provided to the NHP300 control software, or to your current mill management software without manual input from the mill operator during the test phase.

Taking a sample from the process line enables changes to be made at a point that will maximise production, reduce cost, minimise waste and maintain pellet quality.

In addition to calculating the PDI, the number of dust/fines can be also be calculated.

Up to four pellet lines can be tested by one NHP300 with the option to return samples back to their original lines too.

Ottevanger: Progress MonoRolls HE Ottevanger’s Progress MonoRoll HE is an extremely stable, robust and well-balanced pelletiser. The partly patented innovations provide a unique price/ performance ratio. This technological concept guarantees an even distribution of the mechanical forces over the heavy main bearings and those of the intermediate shafts. The two-stage drive is delivered via V-belts and timing belts.

The robust RS frame in combination with the balanced drive guarantees a stable and vibration-free pelletiser during production. This makes the MonoRoll more efficient. The development of its new High Efficiency (HE) line not only focuses on higher performance and more hygienic design, but also on lower energy consumption. The new HE line provides excellent access to all maintenance areas. With this HE line, Ottevanger is taking a new step forward.

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Ocrim FLP-FLP/X high pressure air filter The FLP is particularly adapted for aspiration of single points like hoppers, casings and bins. The FLP is available in different versions based on the usable spaces and the required filtering surfaces. The fabric used for the filtering sleeves is particularly suitable for fine dust abatement. Sleeves are cleaned with high pressure air jets. Compressed air is accumulated in the tank placed on the upper section.

A built-in electronic timer permits adjustment of the cleaning air jets. The particular shape of the FLP allows easy maintenance and inspection. The filter is equipped with a pressure gauge that detects the efficiency and condition of the filtering sleeves. This type of filter can be supplied in both coated and stainless steel versions.

Omas Industries: Air-lock valve Virgilio Composed of a robust spheroidal cast iron structure with no welding, the air-lock valve Virgilio also features an inner rotor. Thanks to high coupling precision, the Air-lock valve Virgilio permits significantly reduced air dispersion and is excellent for separating aspired product from pneumatic air. This valve can also be equipped with glass spyholes and small cyclone scrubbers if required.

The technical features of the Air-lock valve Virgilio include a painted spheroidal cast iron structure, a painted carbon steel rotor with centre star and rectified outer rotor edges to guarantee excellent coupling with the static body. The absence of inner welding also enables perfect cleaning, which can be inspected through the valve’s sight glass. The Air-lock valve Virgilio is available with or without a motor.

myMAG.info/e/1028 www.ocrim.com 36 | January 2021 - Milling and Grain

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FOCUS

SPECIAL FOCUS

Flexy-Mill: Flexible grinding with a quality finished product

In recent years, consumption of organic grain and multigrain bakery products has increased by some 60 percent. This development is not the result of institutional campaigns however, but a completely spontaneous process.

The most used products for producing and mixing flours can be grouped into two categories.

The first of these groups includes various types of grains, such as durum wheat, soft wheat, rye, kamut, spelt, barley, oat, buckwheat and corn. With these grains, you can obtain wholemeal and non-wholemeal flours suitable for making bread, dried pasta, fresh pasta, biscuits, desserts, pizza and other standard products.

The second group includes a series of legumes, such as peas, chickpeas, lentils, broad beans, beans, etc. The flours obtained after grinding these legumes are used for producing dry flours, with which you can make soups, hummus, or crackers. Mixed with other flours, you can produce alternative food or even substitutes (vegan steaks) thanks to their high protein content.

Top-rated products

There are now more wholemeal and vegan products on supermarket shelves than ever before and these products are getting more and more popular, even at our table. This increase in consumption is due to two factors, with the first of these being health.

Today, wholemeal and vegan products are top-rated. Major food companies have even included them in their production lines and marketing campaigns.

Besides health we also have the multi-ethnic factor. Our societies are now becoming more and more multi-ethnical and the world’s markets are adapting to this change. Ethnic groups that cluster in the same environment bring their values, lifestyle, tradition and culinary habits together.

The art of grinding

On the subject of grinding grains and legumes, how can we obtain the best ground products with the best extraction percentage? As both grains and legumes have very different shapes, hardness and specific weight.

The art of grinding consists in obtaining the best ground products with the best extraction percentage. That’s why the characteristics of the rollers must be suitable for the product to grind.

The following is a list of the parameters that are essential for producing flours with different characteristics.

The first of these parameters, the number of grooves per cm, determines the semolina size and the amount of flour produced during grinding, whilst a further factor, operating angle, determines the percentage and size of the extracted semolina.

The percentage of semolina or flour produced and/or the size of the bran resulting from grinding if dictated by the operating

position: D-D – S-S – D-S – S-D, whilst the grinding rating between rollers, fluted rollers 1:2.5 and smooth rollers 1: 1.25, affects the size of the coarse bran when fluted rollers are used.

This parameter on smooth rollers is important when you want to change damaged starch values, which go hand in hand with water absorption. Increasing damaged starch increases the water retention capacity of the flour.

The cutting angle when the grooves intersect to produce more or less flour is determined by the tilting of the grooves, whilst the production capacity of every grinding step is either increased or decreased by the peripheral speeds of the fast roller.

The perfect configuration

By reading all of these parameters, one can only begin to understand how complicated it is to choose the perfect configuration of the rolling mill. Moreover, the operator (miller) has only one opportunity to calibrate the machine.

The team at Omas aims to exceed expectations and meet the requirements of both millers and the grinding market. The four grinding rollers are independent by removing the pulleys and idler belts that allowed the two pairs of cylinders to grind. Thanks to permanent magnet torque motors coupled with inverters, millers can adjust every roller and thus, modify the parameters that were impossible to change before.

With Omas’ Leonardo rolling mill the miller can modify the during the grinding process by adjusting the grinding ratio, the rollers’ operating position, the grinding gap, as well as enabling the miller to increase or decrease the peripheral speed of both grinding rollers.

The Leonardo also affords millers the opportunity to create grinding recipes that can be saved in the machine or systems control PLC. All of these operating parameters can impact the grinding operations as much as the gap adjustment.

Now that you can change them all, grinding will be quicker and more flexible. This way, the operator can adapt the mill to various types of grains and/or legumes without compromising either the grinding performance or the quality of the finished product.

www.omasindustries.com Milling and Grain - January 2021 | 37

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&

BioSecurity

Design

in the Food and Feed Industry

by Donald Hamm, Senior vice-President, Sales and Marketing, Zirconia Inc, USA Biosecurity after the COVID-19 pandemic might need to be re-defined. Donald Hamm looks at safety; safety in the workplace and safety that includes the product, the customer, the assets, the employees and the environment.

He suggests that the technology used in the past is necessarily the answer going forward. The food sector and millers in particular need to look to new technology and new answers to a 'new post-COVID-19 normal' era and suggests that what we have been doing might no longer be enough

S

afety and design have long been partnered together in the construction industry, and this pairing is the basis for many building codes that have been developed globally.

We have safety codes related to fire, physical safety of occupants and many more, but there has been little attention to biosafety in the design industry, with only a few exceptions up to now.

Most of these exceptions have been based around food chain production and health care, and are not the conversations many focus on, unless they are your specialisation.

Clearly, global awareness of this has become an issue and major

38 | January 2021 - Milling and Grain

changes are happening with the COVID-19 pandemic and the effect it has had across all industries.

What I am going to look at in this article is a shift in how we look at our projects and operations in terms of safety. When we talk about safety in the workplace, we need to make sure we include safety of the product, the customer, assets, employees and the environment. It is important that we not just assume the technology we have known and used in the past is the answer going forward. We need to look for new technology and new answers as our 'new normal' has shown what we have been doing is not enough.

Understanding contamination

First, we need to understand what we are talking about when we discuss biosecurity in regard to micro-organisms like bacteria, viruses and fungi.

For contamination to occur several things must be in place. The first is a transport method to move the organisms to a new surface and after air movement, that is usually us. Once a living organism is on a surface it needs several things to survive: food, water and habitat.

Anything that provides these three things is a host. Most porous

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F surfaces can be hosts, and once organisms are on the surface, they can multiply, mutate, and more importantly transfer to other surfaces or people and repeat the cycle. Nonporous surfaces, though they often are not hosts, can still be transfer surfaces.

Sars-Covid 19 has been shown to survive on most surfaces for days; in some conditions as long as 64 days in colder environments1. These types of passive touch surfaces are common in the food manufacturing industry.

Unfortunately, they are known to extend the life of microorganisms, by capturing and holding them passively.

Feed at the start of the food chain

Many people look at the feed industry as the start of the food chain and the point at which problems first start. This can be seen in China where there is a strong drive to improve food safety and thus they have focused on the feed level to do this.

What does that mean? Due to the increased regulation on safety in the industry, where there were once 20,000 feedmills in China, there are now fewer than 6000 and downsizing will likely continue.

So, what can we do at each existing and new plant to address the need for better biosecurity?

Each operation is different and the needs for each will be different, but some basics are identifiable. While we must continue to focus on prevention of contamination entering our plants, the truth is, we have no way to guarantee complete success of no contamination entering our facilities.

We have trucks entering our sites from farms and other areas with wild and domesticated animals that can transport many microorganisms. We have people that come into our operations on a daily basis that may be exposed and transport all kinds of infections.

What we do not want is to let contaminations get in because we know how hard they can be to get out.

Teams from Kansas State University and Iowa State University did a test at a research facility where they prepared one batch of grain that was contaminated with Porcine Epidemic Diarrhea Virus (PEDV) and even after four clean batches and routine cleaning between batches, it was still present.

Machinery one meter away and surfaces up to three meters away were contaminated.

Eventually equipment was broken down, power washed, sanitised and the mill heated to 140 degrees for 48 hours to eliminate it2.Who can afford to do this? Is there a better way to make these surfaces safer and less prone to contamination transfer?

Accepting that there is a problem

This is the problem we want to address here. We have traditionally put a majority of our effort, in clean room environments, into air handling and filtration which deals with the first part of the contamination cycle, which is transportation and is one of the key places we do need to address.

But what about contamination by contact or transfer?

Historically, we have turned to ‘cleanable’ surfaces such as low or non-porous substrates to reduce the habitat and food sources for microorganisms. But we are finding that this is not enough. Non-porous cleanable surfaces can still transfer virus’s and other microorganisms and allow them to survive because they are ‘passive,’ they do not do anything to break the cycle of transportation.

Just being cleanable is not enough. Even our preferred surfaces of stainless steel and plastic, because of their durability and

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F cleanability, allowed for longer survivability than on cardboard3.

So what do we do, now that we know our surfaces while being cleanable, are also potential hosts or transfer surfaces for the organisms we are trying to protect against and part of the cycle?

Creating active surfaces

As technology moves forward, we are going to need to look at options and technologies that are ‘active’ surfaces.

Traditionally, we have had passive surfaces like stainless steel that we can clean and then use disinfectants on to kill microorganisms. The problem is once the disinfectant is dry, the surface is again ready to be a host.

Once organisms are transferred to it, the cycle begins again.

Some surfaces like copper and silver are naturally ‘active’ surfaces. We have known for centuries that these surfaces are ‘healthier’ and with the advent of science we now know why.

They actively attack many of the microorganisms that come in contact with them and kill them.

Companies such as my own, Zirconia Inc, are developing coatings that are creating active surfaces. The technology was initially developed to make concrete and steel infrastructure more durable. The developers of the technology recognised that a lot of the failures of concrete and steel structures happened because of ‘microbial corrosion.’

This is what destroys concrete in sewer systems and other damp environments. What they have done is realise that the technology they have to stop microbial corrosion, can also actively work on microorganisms that are wanting to use surfaces as hosts or transfer surfaces.

Their first line of products are designed for concrete and other porous surfaces and provide a four-layer defense against microorganisms. This defense makes treated surfaces ‘Biologically Impervious,’ or in another words, microorganisms cannot make it a host and survive on contact.

The first layer of the four-layer defense is a layer of ‘nano swords’ or nano sized rods that are many times smaller than the smallest of viruses. Microorganisms are attracted to the swords by their positive charge since the organism’s membrane is negatively charged. Once contact has happened, the rod penetrates the membrane and releases its inherent static charge into the cell, destroying it.

The second layer of defense is the sealing nature of the coating.

It reduces the level of porosity so low that organisms as well as food sources for the organisms, can’t get past the surface and penetrate the surface. This means that it is very cleanable and durable. This in the past has been the one mechanism we have relied on for safety.

The third layer of defense is the same defense used by copper and silver, but in this case it is a non-toxic environmentally friendly element that is also oxidative. If a bacteria cell gets by a nano sword, the elements in our base coating will destroy the cells’ membrane and keep the surface free from any further attack or damage.

The final defense is that the coating is photocatalytic. This means that when it is exposed to UV light, it takes the moisture in the air that is in contact with it and breaks it down to OH and O2 or essentially a natural bleach. Testing has shown that this coating system and its individual components are effective in stopping microbial and viral attack.4

Treating existing surfaces

Zirconia Inc is also releasing a line of products that will allow companies to treat existing transfer surfaces in the workplace 42 | January 2021 - Milling and Grain

made of a variety of different substrates to create an ultra-high performance, general maintenance surface protectant. This surface defense system is ideal for reducing environmental contamination and transfer of disease on both porous and nonporous surfaces.

The system includes a prime coat that seals and eliminates porosity while providing the ultimate base for the nano sword technology.

This is intended for high contact surfaces where temporary treatments are worn or wiped away with repeated cleaning and disinfecting. The second part of the system is a renewable application of nano swords that can be fogged onto the primed and other surfaces to turn them into long lasting ‘active’ surfaces to eliminate the host potential of building, equipment and even vehicle surfaces.

Other options for millers

Along with new surface technologies, there are a lot of other technologies being developed that we need to look at and consider as we look at biosecurity in the milling industry.

With air filtration and management, we have new filtration systems coming online each year. We now have ionization that can be tied into our air handling that forces particles to be dropped out of the airstream reducing the load on filter systems or even reducing the complexity of them.

We can look at UV C systems which can be used to kill microorganisms on surfaces, again helping stop the transfer cycle.

While these are not safe around people and animals, they can be brought into systems safely and effectively.

What about air handling or mechanical systems that filter out larger particles, ionization in the air chambers that drop microorganisms to the surfaces and out of the air flow and then UV lighting that super activates coatings like Zirconia’s to actively deal with all microorganisms that make it to the surface.

Best from the past

As an industry and society, we need to now be looking not at how we have built and created our operations in the past, but what is the best from that past that we can continue using and integrate with new technologies that will help us work on safety and security.

We need to look at safety compliance as not just another threshold to overcome or meet but make it a key part of our culture. We want to make sure our products are safe whether we are milling for human consumption or for animals that will end up in our food chain.

We need to make sure that our customers, employees, facilities and our environment is safe. This is the challenge I want to give us as an industry in the coming years as we look at how we are going to do business in this new ‘normal.’

References

Riddell et al. Virol J (2020) 17:145 https://doi.org/10.1186/s12985-020-01418-7 2 Evaluating the Effect of Manufacturing Porcine Epidemic Diarrhea Virus (PEDV)-Contaminated Feed on Subsequent Feed Mill Environmental Surface Contamination http:// newprairiepress.org/ kaesrr/vol1/iss7/4 3 Aerosol and Surface Stability of SARS-CoV-2 as Compared with SARS-CoV-1 The New England Journal of Medicine.

Downloaded from nejm.org on October 12, 2020 For independent test results, contact Zirconia Inc. info@ zirconiainc.com, or 1-206-219-9236 1

F

Digital conversion era ahead for our industry

by Peter Marriott, Sales Manager, Henry Simon UK Peter Marriott, Sales Manager, Henry Simon UK looks forward to a future of digital development that goes beyond Industry 4.0 where ‘big data’ and ‘The Internet of Things’ provide more light-out manufacturing in the grain and milling industries

I

ndustry 4.0 was first announced in 2011 at the Hannover Exhibition in Germany and until now has brought serious changes to industry.

After the historical development steps of mechanisation, mass production and automation, today the new era has focused on higher productivity with digitalisation in industrial processes.

The industrial development had been almost singularly driven by web-based technologies in recent years.

And within the digital conversion, we started to hear about new

technological terms like ‘big data’, IoT, cyber security, machine learning and artificial intelligence, etc.

These terms are actually the fundamentals of a new generation of industrial systems. In this article, I hope to explain how we can benefit from them in industrial applications, by focusing on their definitions, principles and examples.

Internet of Things (IoT)

IoT network basically connects the physical world’s objects to each other in the web environment.

Today approximately six billion devices are connected to the web, whereas it is expected to raise up to 22 billion soon - with 5G technology.

IoT is expected to allow machines, systems and even plants to connect and communicate with each other for an integrated process management.

The new generation of controlled irrigation systems is an interesting example of IoT, with automated operation and process optimisation in agriculture. These systems carry out the irrigation process with real-time monitoring of the soil humidity by inground sensors. Moreover, these devices can receive the weather forecasts by wireless network connection and then schedule the irrigation periods accordingly.

Data Engineering

Today, many industrial devices are able to record their operating and processing data. This raw data stack can actually be analysed further to get a piece of meaningful information using data engineering methods.

This gives us important tips to improve our processes and develop new systems such as: data collection; data analysis; modelling; machine learning and decision making systems with AI. As the principles of data engineering are described above, they will provide a real insight for us to develop the artificial operating systems of the future.

Machine learning

Machine learning is a category of algorithms that allows software applications to become more accurate in predicting outcomes, without being explicitly programmed.

In other words, new generation machines will able to make predictions based on the learned data, to optimise their operating 44 | January 2021 - Milling and Grain

F conditions themselves. Machine learning algorithms are the basics of new programming methods in industry, which are expected to bring a higher self-managing ability for machines and systems.

As an example, silo systems are used to store grains under optimum conditions. Today, temperature and humidity values can be measured in silos to sustain the optimum storage environment.

Imagine if they could learn to adapt themselves according to the changing ambient conditions?

Machine learning examples can be extended for a very wide range of applications in all industries.

Artificial Intelligence

Artificial Intelligence is all about trying to make machines or software mimic and eventually, supersede human behaviour and intelligence.

Industrially, AI operating systems (AIOS) are expected to provide advanced management and operation abilities, with minimum intervention and maximum productivity advantages at the same time.

We have already started to talk about tomorrow’s ‘lights out’ manufacturing plants and it will be interesting for us ‘see’ all together how the grain milling industry will be affected by these technological developments. Robots are evolving in order to take on autonomous and flexible duties. Soon we will have industrial robots that can learn, decide and even interact with people.

Sensor technologies

At Henry Simon Milling, we have dedicated ourselves to develop intelligent milling systems.

For the first step of the digital conversion, we have implemented Advanced Sensor Technology™ which brings higher reliability,

better operational safety and consistent quality in milling process.

In this technology, sensors are responsible for real-time tracking of the machine’s operating status and environmental conditions, to detect any fluctuation during the operation.

HSRM Roller Mill has been equipped with 12 different special sensors (Main Roll Temperature, Ambient, Motor Load, Feed Roll and Main Roll Rotation, Vibration - PMD, Air Pressure, Stock Level, Hopper Clog Sensors etc). And the new HSQP Plansifter and HSPU Purifier will be also be available with Advanced Sensor Technology. info@henrysimonmilling.com

Milling and Grain - January 2021 | 47

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Arrius A GROUND-BREAKING GRINDING SYSTEM

by Nicholas Trounce, Head of Product Management, Milling Solutions Wheat & Rye, Bühler AG, Uzwil, Switzerland

O

Lower energy consumption, faster installation, maximum food safety, highest operating reliability, and best grinding performance: Arrius, the integrated grinding system from Bühler, offers an impressive array of innovations and tangible benefits for customers.

ne look at Arrius and it is clear – this is not just a facelift for an existing roller mill but a fundamentally new development.

And from the very beginning, the needs of millers were the focus of attention. They were involved in the development project from day one and their input has made Arrius what it is today - a machine that is both revolutionary yet familiar to millers.

Integration for efficiency

Arrius is not just a roller mill but the first integrated grinding system.

That might sound like a marketing slogan, but it makes total sense when you take a closer look.

Arrius is fully integrated, meaning the switch cabinet, the drive and gearbox and the web server, which provides the link to digital services, are all built in. These are all components that are separate in a conventional roller mill.

Integrating them brings significant advantages. It makes Arrius remarkably energy efficient, for example. The novel drive reduces energy consumption by up to 10 percent compared to conventional belt drives.

Furthermore, the integrated drive unit together with the direct suction means it is possible to save an entire floor when building a new mill.

The innovative design also allows the Arrius grinding system to be delivered to its destination as a ready-to-install module and to be flexibly positioned within the plant. Just connect three cables, compressed air and product inlet and outlet - and the grinding system is ready for operation.

This plug-and-play system considerably reduces installation and commissioning time. By using power busbars for the electric power distribution, installation time can be reduced by a factor of three.

48 | January 2021 - Milling and Grain

Optimised performance and hygiene

Bühler roller packs have stood out for their stability and precision for decades. In spite of – or perhaps precisely because of this – the company has continued to carry out intensive research in this area.

The roller pack with integrated grinding force measurement ensures outstanding grinding performance. Thanks to the prestressed rollers, up to 10 percent higher starch damage can be achieved compared to conventional roller mills.

The new gearbox enables parallel grinding force adjustment, which ensures uniform grinding over the entire length of the grinding gap. Moreover, by pre-stressing the rollers the gap remains stable over time. The grinding result can be adjusted directly and with ease.

Brushless scraper bars for corrugated rolls and self-adjusting scraper blades for smooth rolls contribute to perfect grinding with low maintenance requirements.

An important aspect in grinding is also the feeding of the product to be ground.

The complete inlet area of the feeding module is accessible for cleaning by opening the chamber door, taking hygiene to a new level.

A greatly simplified grinding chamber design and improved aspiration reduce product deposits, which further increases food safety. Also unique is the support on hygienic leveling feet, which allows easy cleaning under the machine. It goes without saying that all product-contacting surfaces on the Arrius are made of stainless steel or other food-compatible materials.

User comfort and safety

On the subject of cleanliness, swinging up the product chamber cover enables easy access to the entire grinding chamber. This not only simplifies cleaning but also maintenance work. Rolls can be changed in less than 45 minutes thanks to the easy access, the slidable roller pack, and quick plug-in connections.

With Arrius this can now also be carried out while grinding continues on the opposite passage - a unique feature in flour milling. The intuitive touch-screen operating unit allows easy monitoring and control of the grinding system.

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www.gimetech.com Milling and Grain - January 2021 | 49

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F Thanks to the integrated web server, Arrius can be operated via smartphone, tablet or PC within the mill. The user interface is extremely intuitive and can be understood within a very short time by personnel with milling experience.

Arrius also sets new standards in personal safety. The product chamber cover with electronic locking device completely closes off the grinding chamber and can only be opened when the rollers are completely stationary. In addition, the grinding chamber doors are each fitted with a hand guard to ensure safe sampling.

On the way to SmartMill

The Arrius grinding system is equipped with numerous sensors that continuously monitor the operating status. The sensors in the inlet of the feeding module detect product variations and the automatic feed control immediately compensates for fluctuations.

This ensures that the feed is always constant and that the ground material is distributed evenly across the entire grinding gap.

The novel force measurement of the roller pack enables close monitoring of the grinding process.

Should deviations occur in the absolute grinding force or between the measurements on each side, an error message is issued. This contributes to maintaining optimum grinding conditions in the individual grinding systems and thus ensures an efficient overall process.

The optional monitoring package includes additional sensors for monitoring the operating status including monitoring of the rollers, the product level in the inlet and the grinding gap position. The insights generated by these devices provide a solid foundation for future digital services under the umbrella of the SmartMill program.

Model range and options

The new grinding system Arrius is available as a four-roller and eight-roller integrated grinding system. For both models, roller lengths of 1000, 1250 and 1500 millimeters and diameters of 250 millimeters are available.

The following options are also available: roller temperature monitoring, bearing temperature monitoring, inlet monitoring, and grinding gap force measurement.

As with the Mill E3, Arrius improves efficiency in the areas of energy, building investment and installation time. In summary: • The direct drive reduces energy consumption by up to 10 percent • Energy recovery is achieved mechanically via the gear unit specially developed for Arrius • The integrated drive saves an entire floor structurally, which reduces investment costs • The integrated design allows Arrius to be wired and tested ready for operation in the Bühler assembly plant. Thanks to this plugand-play system, the time required for installation and start-up is significantly reduced.

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Milling and Grain - January 2021 | 51

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hina, India, Bangladesh, Indonesia and Vietnam are the worldâ&#x20AC;&#x2122;s largest rice producers. Traditionally the rice is harvested by hand with a scythe or sickle, but by and large most harvesting is now done using modern harvesting machines in the field.

After being cut and laid out for sun drying for a few days the paddy must be threshed to separate the grain from the stalk. Packed in bags, the harvested paddy is then loaded on trucks and transported to a rice mill for further processing.

Once the truck arrives at the mill the bags are manually slit open and tipped onto a huge sieve. In less automated mills, workers will then start to pick up the long impurities like bag strings or straw by hand. This first step in coarse cleaning is essential to all subsequent process steps, mainly because long impurities are a hazard for every downstream machine.

Elevators, dryers and cleaners can easily get clogged by straw or long bag strings and as soon as one machine clogs, the plant breaks down and the operation can only resume after the machine is manually cleaned.

Pre-cleaning advantages

Besides the prevention of downtime within a plant, paddy precleaning has many more advantages.

Overall rice quality will improve as rice-cleaning machinery works better when the grain contains fewer impurities. Thanks to fewer breakdowns and less time-intensive maintenance, the processing capacity is also increased, which in turn greatly increases mill profitability.

Lastly, pre-cleaning can significantly extend the lifetime of your machinery as long impurities in the grain continue to cause unnecessary wear in the machines.

Using equipment to replace manual labour during this essential pre-cleaning process step is becoming more and more 52 | January 2021 - Milling and Grain

AN AUTOMATISED SOLUTION FOR TRADITIONAL PADDY PRECLEANING common, as automatising the pre-cleaning process not only makes the rice mill more efficient but also safer for employees to operate.

With pre-cleaners, workers do not have to risk working on top of an open sieve.

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F As labour in some areas is becoming scarcer and more expensive as workers migrate to cities, automatising paddy precleaning is also a way for rice mills to reassign workers to less physically intensive tasks. This not only provides higher value for the mill but supports the upskilling and retention of the employee.

The pick-up cleaner

In response to this significant gap in the market, Bühler developed a state-of-the-art paddy pre-cleaner – the LALA pick-up cleaner.

The machine consists of two core components. The first is a vibrating sieve that separates long impurities from the freshly harvested paddy, while the second is a rake unit in the back of the machine that picks up the impurities at the end of the sieve, which prevents the sieves from getting frequently clogged.

The unique pick-up design allows the efficient removal of long impurities, making it the heart of the LALA pick-up cleaner.

With the highly automated LALA pick-up cleaner rice mills can save on manpower by reallocating workers previously assigned to picking up the impurities, and fewer full-time machine operators are required. This not only applies for the LALA, but also for downstream machinery.

The LALA pick-up cleaner also has a highly effective performance on wet paddy. For example, when processing product with a moisture level of 28 percent, the LALA can guarantee a throughput rate of 25 tonnes per hour.

Unlike other paddy pre-cleaners, the LALA has a fully-enclosed design that reduces dust emissions and assures workplace safety.

What’s more, the spacious design makes it extremely easy to clean and maintain.

Most importantly, however, the LALA successfully removes up

to 80 percent of long impurities like straws and bag strings from freshly harvested paddy, preventing costly downtime caused by clogged machinery.

For even more superior pre-cleaning results, the LALA pick-up cleaner can be combined with a Bühler SMA screening machine.

During a second pre-cleaning step the SMA then removes stones, broken grains and dust with its two sieve layers and aspiration.

These Bühler paddy pre-cleaning solutions – the LALA pick-up cleaner for long impurities and the SMA screening machine for smaller impurities – are essential to ensure the smooth running of all the subsequent process steps.

Milling and Grain - January 2021 | 55

Image courtesy of Dominic Chavez/World Bank

F

Most national mandatory flour fortification standards need review

by Food Fortification Initiative

F

Half of the countries that fortify maize and wheat flours with iron, zinc and vitamin B12 may need to update their standards to meet the World Health Organization’s (WHO) current recommendations, according to a recent study published in Food Policy.

or decades, many countries have recommended or required that their food industries produce fortified foods by adding small amounts of vitamins and minerals – micronutrients – into basic food staples and condiments which almost all consumers can afford.

For example, wheat flour with added iron or folic acid.

Food is fortified to prevent micronutrient deficiencies that can in turn boost a child’s academic achievement, strengthen maternal health and prevent disabling or fatal birth defects.

According to Food Fortification Initiative estimates, only 21 percent of industrially milled cereal grain was fortified in 2019.

Globally, 86 countries have legislation to mandate fortification of at least one industrially milled cereal grain: wheat, maize or rice.

This gap represents a tremendous opportunity for fortification to improve the lives of millions. Fortification improves a country’s productivity and reduces healthcare expenditures.

Fortification addresses several of the Food and Agriculture

56 | January 2021 - Milling and Grain

Organization’s (FAO) Sustainable Development Goals and can restore nutrients lost in crops as a result of climate change.

“While we continue efforts to increase accessibility to affordable, diverse and healthy diets, fortification of staple foods can provide populations – especially of the most vulnerable – with the vitamins and minerals that are the most difficult to obtain,” explained Dr Nancy Aburto, Deputy Director of Nutrition and Food Systems for the FAO and former World Food Programme (WFP) Chief of Nutrition.

To make sure people get the nutrients they need, countries set standards outlining the types and amounts of vitamin and minerals, as well as the optimal fortificant that millers and other food producers can use when fortifying food.

“Fortification standards must include the most efficacious vitamin and mineral compounds, in the right amounts, to safely meet their public health purpose.

“It is possible to accelerate progress towards reducing anemia and neural tube defects, and this paper shows key policy gaps that need to be addressed to do so,” stated Luz María de Regil, Head of the Unit of Multisectoral Action in Food Systems, WHO. In the study, country standards for wheat and maize flour fortification were compared to international guidelines for nutrient levels and compounds that deliver such nutrients. The intent of the study was to identify opportunities for countries to review their national fortification standards and ensure consumers receive the nutrients they need.

Out of the 72 countries analysed in the study, less than 50 percent had nutrient levels in flour fortification standards that

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58 | January 2021 - Milling and Grain

met the current WHO international guidelines for iron, zinc and vitamin B12. Conversely, most countries’ standards for vitamin A, thiamin, riboflavin, niacin and pyridoxine levels met or exceeded WHO recommendations for nutrient levels. The majority of countries included in their standards recommended compounds for all nutrients studied.

The study, which pulls expertise from leading institutions in nutrition including Emory University, WFP, UNICEF, US Centers for Disease Control and Prevention, WHO, Oak Ridge Institute for Science and Education and the Food Fortification Initiative, is the first to compare all national standards for wheat and maize flour fortification to international guidelines.

“Research such as this is incredibly useful in evaluating international alignment to the flour fortification standards outlined by WHO,” adds Katya Bobrek, from Emory University.

Image courtesy of Asian Development Bank

Image courtesy of Kate Tann

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Dr Aburto adds, “For fortification initiatives to have maximum benefit, data are needed to fine-tune policies and programs to meet population needs. This research sheds light on where and how national initiatives can be enhanced to ensure the most people get the most benefit to help eliminate hidden hunger.”

The researchers hope these findings will help countries create or update national standards that lead to a smarter, stronger and healthier future.

To view countries’ national standards, information on fortification and more please visit the Food Fortification Initiative’s website (https://www.ffinetwork.org) and the Global Fortification Data Exchange (https://fortificationdata.org/), available in English and Spanish (en español).

Find out more at: https://www.sciencedirect.com/science/article/ pii/S0306919220302025

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Milling and Grain - January 2021 | 59

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Taking the alternate route to our destination

by Constance Cullman, President and CEO, American Feed Industry Association Prior to the inauguration of US President-elect Joe Biden, Milling and Grain invited Constance Cullman, President and CEO of the American Feed Industry Association, to provide us with an insight into how the feed milling industry might confront the challenges of 2021 following the impact of COVID-19 over the past year. She looks back over the past year and projects what may lie in store for her members and for industry both at home and abroad in 2021, providing a much needed view for other national associations working an behalf of manufacturers around the world.

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hen I joined the American Feed Industry Association (AFIA) in late 2019, I expected to spend my first year as President and CEO on the road meeting with members at their facilities and at our education and networking events. Like many business leaders around the world, I could not have foreseen life as we knew it suddenly coming to a screeching halt, with the onset of the first coronavirus infections.

While 2020 may not have been the year we hoped it would be, it certainly gave us time to reflect and ‘reset’ for 2021.

The US animal food industry has responded remarkably well over the past several months to the coronavirus pandemic, making the necessary procedural and structural changes to keep the sector’s 944,000 employees safe.

The AFIA Board leadership and members have been highly engaged to ensure that the essential nature of our business is understood at the local, state and national levels, so that we may continue meeting our customers’ needs for feed and pet food, whilst also contributing to keeping food staples stocked on grocery shelves.

Although we have adapted to the new way of doing business, the pandemic further exposed the divide between rural communities and urban ones. In roundtable discussions with our members, we learned that rural access to rapid COVID-19 testing is still woefully inadequate and we expect that vaccines for our essential workers in the coming weeks may lag as well.

The high-speed internet that businesses in Silicon Valley enjoy that allows them to keep their employees safely working from home and their businesses afloat during this tumultuous time is lacking in rural America, where one in four people do not have access to this critical service. This makes it a challenge for our nearly 700 members to meet virtually with customers and suppliers or conduct their normal business operations. Not only that, America’s infrastructure – from railways to bridges to roads – is crumbling and requires attention if we are to continue supplying products from coast-to-coast.

The AFIA will spend 2021 working in concert with other agricultural coalitions to advocate for federal policies that

60 | January 2021 - Milling and Grain

promote the long-term economic viability of the US agricultural sector and provide solutions to address gaps in our food supply system.

Change of Presidency

With the change in presidential administrations, we expect that the regulatory landscape for our industry will shift as well. Much like the administration of the former President Barack Obama, which brought about the most sweeping food safety change in modern US history with the enactment of the Food Safety Modernization Act, President-elect Joe Biden has indicated his support for improving the US food safety system and addressing climate change.

The US animal food industry will urge the Biden administration to seek only science- and risk-based regulations that address real food safety threats and will seek to partner with the administration to be part of the country’s climate change solutions.

Our members are hard at work bringing new technologies to the marketplace that allow the animal agriculture industry to use antibiotics more judiciously and reduce the industry’s greenhouse gas footprint.

Unfortunately, our international counterparts continue to outpace us because the United States still does not have a mechanism in place at the US Food and Drug Administration to bring many of these products to market with appropriate labeling.

Given that our research and innovation in animal nutrition and metabolic processes continues to quickly progress, it is only fitting that our regulatory system should evolve as well. The AFIA will continue pushing for the FDA to have the resources it needs to review novel ingredients in an expeditious way and make the necessary policy changes to ensure they can be marketed appropriately to the customers we serve.

Customer dependent on support

Our customers – farmers and ranchers across the country – also depend on our support in mitigating animal disease risks through feed.

As we have seen with COVID-19, an epidemic in one region of the world can quickly become a widespread pandemic without adequate mitigation strategies in place.

One of these disease threats that currently keeps many of our members up at night is African Swine Fever (ASF), a virus that is lethal for pigs but not harmful to people.

Last May, Iowa State University found that should the ASF virus enter the US pork market, it could potentially result in upwards of US$50 billion in losses over a 10-year period. Not only would the virus devastate pig populations and farmers’

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F livelihoods, the latter of which is already suffering from the weakened economy, it would be detrimental to the food supply and further deteriorate the US economy.

Through the AFIA’s public charity, the Institute for Feed Education and Research, we have supported several research initiatives aimed at finding ways for the feed industry to stop the spread of the ASF virus in its tracks.

While feed may not be how the ASF virus enters the United States, it could be how it’s spread, which is why we are working diligently to improve our biosecurity methods. With the information acquired, we are working with our national leaders on a coordinated strategy to allow trade to continue uninterrupted in North America, should there be a contained outbreak.

Keeping our products moving in the marketplace through trade is critical. We were pleased that the Trump administration ushered several agreements across the finish line that will be beneficial for our industry in the years to come, including the US-MexicoCanada Agreement and China phase one trade agreement.

Though it may have been a bumpy road getting there, I believe that these agreements will be viewed as long-term success stories for our industry, allowing us to negotiate more modernised agreements in the future that are science-based, allow for innovation and are respectful of intellectual property.

There is still more work to be done in China to get more of our facilities registered for approval for export, but we are already seeing the benefits of the Asian country buying more pet food for its burgeoning pet food population.

The positive goodwill also opens doors for opportunities in other areas of the South-Pacific, including Vietnam, which boasts one of the fastest growing economies in Asia with three decades of over six percent annual gross domestic product growth.

In that same time period, Vietnam has risen from a food shortage situation to one of food abundance, with rising demand for animal protein and become an area where our industry is pursuing market access.

Free-trade agreements

President-elect Biden has stated his intentions to work with our allies and negotiate, or renegotiate, trade agreements that ensure our country’s manufacturers have a place in the world trade marketplace.

The AFIA would like to see the United States continue pursuing free trade agreements with the European Union and the United Kingdom, which are ‘full in scope,’ meaning they include agriculture, remove arduous, non-scientific barriers and support riskbased regulations and decision-making and the removal of tariffs.

The association is also looking at new areas of the world, including Kenya, which has a marketplace that is ripe for the high-quality technologies and regulatory expertise the US feed industry has to offer.

To achieve any of this, the Trade Promotion Authority will need to be reauthorised by Congress in the first half of 2021.

Our industry cannot continue to drive forward whilst looking in the rear-view mirror. 2020 changed our way of conducting business, but it did not change our drive to continue bringing innovations and technologies to the marketplace that will help our industry be more sustainable and provide affordable, abundant food to the marketplace.

Let’s think of it as the alternate route a navigation app provides us in route to our final destination - it may not have been the way we intended to go, but we learned a lot from seeing new ways of getting there.

Milling and Grain - January 2021 | 63

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‘The future of feed milling’

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The mill of the future: what will it look like?

by Andrew Wilkinson, Milling & Grain s we get to the end of an unprecedented year, our thoughts naturally turn to what’s in store for the industry in 2021 and beyond.

In an effort to find out, Triott is currently running a project called ‘Milling 2030’ that involves talking to customers, farmers and other industry figures in order to discover what would add the most value for them in future.

They then brought together their sister Triott companies within the group to brainstorm how they could achieve these ideals.

The aim of the company’s most recent digital episode of ‘Feed Forward’, is to give us an idea of what a digital and data-driven future could look like, as well as what it could actually mean on a practical level. This webinar also tries to answer the question of how we will all benefit and how long will it take to achieve those benefits?

With the help of some quick fire insights from their feed milling customers and experts, the webinar’s audience receives a glimpse into what the longer-term future could hold from Rene Ottevanger, Triott’s new Director of Technology and Innovation.

While they do not claim to have all the answers, Triott states that they are committed to finding them by working together with everyone in the industry (including all of us) and defines this as their New Year’s Resolution!

The current position

According to Rene Ottevanger, Triott is currently building turnkey feed mills for its customers, which means that they design and manufacture all of the machinery, deliver all of the 64 | January 2021 - Milling and Grain

electrics; including the control and automation.

However, Mr Ottevanger states that the company sees more value in the day-to-day processes of the feedmill, where they can help their customers. So they are helping feedmill customers to unlock more value from what they already have, as well as to get more value out of their machinery, their people and their total investment.

In this way, they are hoping companies will increase the quality of the product, increase their tonnages and of course, the overall profitability of their plants.

What does the feedmill of the future look like?

In principle the mill of the future will connect all of the elements of the plant at all levels, says Mr Ottevanger, a statement that extends to all mechanical, electrical and digital levels.

This comprehensive level of connection will then, in turn, allow them to look beyond the feedmill. From the field to the feedmill and then to the farm - all stages of the manufacturing process will be connected via The Cloud, adds Mr Ottevanger.

How can connecting at all of these levels actually benefit the feed mill owner?

Well the owner of the feedmill will be able to see what his plant is doing, so he can oversee the process, says Mr Ottevanger.

The operator will also have the ability to see, via their PC, tablet or phone, how much the plant is running, the quality of the feed being made and they can also see if their plant is running efficiently. They will be able to solve chokepoints and bottlenecks in their plant, for example. The operator is also able to see when the machinery is due for maintenance.

“That’s what we call data-driven milling,” adds Mr Ottevanger.

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A global perspective

General consensus during the webinar appears to support the view that more complexity and diversity in the feedmill will continue to present an increasing challenge that will require smart thinking to overcome. How do feedmills remain agile in order to address more complex processes?

The following are views from three continents on the subject of the future of feed milling to provide a more global perspective.

Wayne Cooper, USA - We do service first then we design mills to meet the customer’s needs. We do not do cookie-cutter mills, we communicate with the customer to design a facility that is specific to his needs and what he needs to produce for his customers. We are currently looking at automation within the mill, with the goal of turning the plant into a giant robot in the future.

Mario Ocampo, South America – He is looking at using alternative materials in order to be more sustainable and animal friendly. If we are adaptable and flexible, when it comes we will still be there in the future. Be adaptable, be flexible - be nice!

Albert Getkate, Europe - Aiming to use a more complete process that can be specifically tailored to address market concepts as well as being flexible enough to produce tailor-made products. The latter can lead to lower efficiency and higher cost per tonnage. Operators should be looking to redesign and adjust the layout of their mills and select the most profitable setup.

66 | January 2021 - Milling and Grain

Better decision making

With the ‘Milling 2030’ project, Triott is looking to the longer term.

The world’s population is growing fast, so therefore the demand for protein is increasing. With the demand on feedmills set to continue and become more complex, by connecting everything in the mill Ottevanger says it can create a ‘digital twin’, a completely computerised simulation of the proposed plant.

How does that work? Well, in principle the process gets rid of all of the drawings, as currently all technical decisions are based on technological drawings. The company can then create a fully operational virtual feedmill, where they can simulate every single process.

What are the actual benefits of the mill owner?

The virtual simulation will allow the mill owners to make decisions based on the simulated process. For instance, he will be able to try out different setups, different formulations, different machinery and can test all of that within the physical and financial safety of a virtual environment. The main benefit being that he can make better decisions based on the simulation of the feedmill, without having to make a lot of additional investment.

Together Triott companies are working on refining the concept to maximise the value to their customer. In fact, they already have

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a cloud-based platform, where they collect and analyse data and this is already running successfully at a production location in The Netherlands.

In addition to this, the company is already working on start-up ideas to get more added value to the platform and to more or less prove that the concept is a workable solution.

According to Mr Ottevanger, the company is not claiming to have all of the answers, of course there are feedmills around the world that already use these kinds of processes.

However, Mr Ottevanger believes that value can be added to customers’ existing setups with the addition of the company’s support.

The difference Triott can make is that it can provide technology with a depth of knowledge of the feed milling industry. According to Mr Ottevanger, mill owners should be concentrating on the what and the why, leaving Triott to focus on the how.

Milling as a service

Following the examination of the value that the company would bring to existing digitised facilities, Mr Ottevanger continues by discussing milling as a service.

In the most basic of terms, this proposal involves the entire production facility being leased or outsourced to companies such as Triott, who will then take care of the entire production process.

In this arrangement, the customer actually pays per-tonneof-feed produced. Mr Ottevanger then argues that milling as a service actually makes a lot of sense as other industries have done this for a long time. Manufacturers of photocopiers is one example of this, as customers are actually paying based on copies producted. Compressed air systems are also operated this way, based on the cubic compressed air used, he continues.

Mr Ottevanger then adds that if we really think about it, the milling industry started doing this centuries ago, when Triott began fixing windmills.

However, more obvious similarities exist between the proposed arrangement and how our ancestors brought bags of wheat to a local miller. The local miller would turn it into flour for a certain fee, so voila - milling as a service!

Mr Ottevanger believes that this will encourage millers to look to be more efficient, with the Triott companies more than happy to help them with this.

68 | January 2021 - Milling and Grain

Small investment - higher profitability

The final element of the webinar sees a discussion between Triott’s director of development, René Ottevanger, Marijn Laurensse (Inteqnion), Auke Markerink (Ottevanger) and Albert Getkate.

The general consensus between these assembled experts was that currently the market demands a very high range of flexibility and the need to prepare production teams for new technology.

In order to achieve this goal Triott believes that it has to provide its customers with the right tools to make the right feed in order to meet these predicted future demands. The panle added a word of caution however, by stating that, “We have seen some great ideas today but we have to remember that some mills are only just beginning the digitisation process.”

In its basic format, a customer buys a ‘workhorse’ that he need to make a living from. Therefore, his goal is to increase productivity and uptime. This can be achieved by adopting proactive maintenance practices for example.

By implementing a prevention rather than a cure approach, which means ‘fixing’ the equipment when we want to rather than when we need to, will reduce down time from unexpected stoppages. This approach, although by no means a new one, will have a positive impact on profitability.

One factor that also has a major effect on profitability is the size of the workforce required to keep the plant operational.

Will the feed mill run itself in the future? The answer is yes but this won’t be without a crew on site.

According to Triott, there will always be a need for skilled people in a mill - although in future they will require fewer operators on site. However, by using the data generated more effectively, the number of people needed to run a mill will reduce.

Going forward, Triott says it will be there to help its customers on this journey to a more data-drive and digital future and it looks forward to working with all customers in the future.

Salient advice

Albert Getkate then concludes the Webinar with some fairly salient advice for 2021, especially given how 2020 panned out, “Plan, do, act and check. Always be flexible and always be prepared for the unexpected!”

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A pHorce For Good

Triple-action protection in feed biosecurity pHorce is an acid based eubiotic (ABE) and is manufactured by UK-based, independent specialist feed additive producer Anpario plc. It is developed form a concentrated synergistic blend of pure liquid formic and propionic acids on a unique carrier system for optimal efficacy. Propionic acid helps to prevent fungal growth and reduces proliferation of moulds and yeast, whereas formic acid acts as a bacterial and fungal decontaminating agent, helping to control potentially pathogenic bacteria, such as E. coli and Salmonella.

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iruses are a threat to livestock health and performance and can be detrimental to the economic success of producers globally.

Feed ingredients have recently been identified as a potential risk for viral contamination and several studies indicate that certain feed ingredients may present a higher risk than others.

Those more likely to support the survival, and in turn transmission, of viruses include soybean meal, distillers dried grains with solubles (DDGS), lysine, methionine and vitamin D. The survival times of viruses in feed materials are variable, ranging from seven to more than 180 days. There are multiple factors which can play a crucial role in viral survival times, including environmental conditions such as temperature and humidity and also the type of virus and whether or not it is enveloped or non-enveloped.

70 | January 2021 - Milling and Grain

First line of defence

High-level biosecurity measures applied throughout the supply chain are the first line of defence in reducing viral transmission.

However, even with the strictest of biosecurity measures in place, if the proven risk associated with viral transmission in contaminated feed is not considered, the unit is still susceptible to viral outbreak.

Therefore, the established link of viral transmission via feed material is an additional area for producer to incorporate into existing biosecurity measures and programmes.

Treating feed with an effective additive which has proven antiviral action can help to mitigate the adverse effects of in-feed viruses.

A recent study conducted by Dr Scott Dee was undertaken at Pipestone Applied Research Facility in the United States. Having concluded in a 2018 paper that â&#x20AC;&#x153;contaminated feed ingredients could serve as vehicles for the transport of viral pathogens between regions, countries or even across continents,â&#x20AC;? this new

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trial was carried out to test the anti-viral efficacy of widely available feed additives on excessive viral loads in feed of common viral challenges in the swine industry.

The challenge

Pigs were challenged with Seneca Valley A (SVA), Porcine Reproductive and Respiratory Syndrome virus (PRRSv) and Porcine Epidemic Diarrhoea virus (PEDv). The feed was infected with these viruses using Dr Dee’s innovative ice block model and pigs were offered either the infected feed with no additives, or the infected feed supplemented with pHorce which was included at three kg per tonne of feed.

In the trial, pigs fed infected control diets had both a high infection rate and exhibited clinical symptoms of SVA, PEDv and PRRSv. However, there was no evidence of SVA or PRRS infection observed in the pigs consuming feed supplemented with pHorce, nor were there any clinical symptoms of any of these viruses.

The improved health and reduced incidence of viral infection in the pigs fed infected feed supplemented with pHorce resulted in additional performance benefits. Pigs exhibited a significantly higher average daily gain and a numerically lower mortality. Such performance benefits can provide economic advantages, helping to support producer profitability.

In principle, it can be assumed that agents based on formic acid which have demonstrated good efficacy under experimental conditions against enveloped DNA viruses are also likely to be effective against additional viruses, such as African Swine Fever (ASF).

“To find that pHorce, which is formaldehyde free, not only delivers effective anti-bacterial and anti-fungal action, but also successfully protects feed with proven anti-viral activity at a relatively low inclusion is massively important”, said Dr Wendy Wakeman, Anpario’s Global Technical Director.

“This finding will help in ensuring the biosecurity and safety of future feed and livestock production.

“Anpario have worked with Acid Based Eubiotic (ABE) feed additives for more than 30 years with a particular focus on pathogen control,” adds Dr Wakeman.

“The proven anti-viral activity of pHorce, specifically in the mitigation of the effect of PRRS, PEDV and SVA, highlights the effective triple action of the feed additive, which is also a well-established anti-bacterial and anti-fungal product.”

The importance of considering a viral mitigant

Whilst many of those involved in feed and livestock production are well aware of the risk posed by feed contaminated with moulds and bacteria and the impact they can have on feed quality and animal health and performance, the role of feed in viral transmission also needs to be considered.

Whilst feed has only recently been recognised as a vector for viral pathogens, high quality feed and raw materials are fundamental in reducing the outbreak of viruses in livestock production systems globally.

Therefore, a mitigant such as pHorce, which provides triple action benefits, is cost-effective and a low inclusion additive, is ideal for use in feed biosecurity programmes for the proactive protection against bacteria, fungi and viruses.

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Formulating ruminant health for improved profitability

by Robert Hamilton, Technical Sales Manager, Kemin Animal Health & Nutrition EMENA,

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alving is the most difficult and challenging phase in the life of the cow as it is where the animal’s body starts to prepare for the next lactation.

Without adequate nutrition and management at this stage, its health will deteriorate which will in turn compromise profitability.

Managing ruminant health often relies on treating health issues once they occur.

However, we must focus more on prevention by taking care of the daily nutrition, especially during the pre-calving and postcalving phases. Formulating for optimal health will prepare the cow for a smoother calving and for an improved lactation after calving.

By formulating for ruminant health, good daily performance will be achieved.

At Kemin, we work together with customers to formulate for ruminant health, based on expertise and scientifically proven nutritional solutions. We believe good animal health is the cornerstone of profitable dairy farming. In designing a ruminant health program, we focus on both the pre-calving and postcalving phases.

A critical time

A critical time in the dry period is the last three weeks before calving, also known as the ‘close-up’ period.

During this time, the cow is preparing to start the next lactation.

Without adequate nutrition and management, cows can calve and fade quickly, losing potential income. The ‘close-up’ dry period needs to be considered a high attention area that sets the stage for how well the cow will perform after calving.

We all know that dry cows should be moved to the ‘close-up pen’ before their due date, but where does this recommendation come from? For lactational success, the cow needs to mobilise calcium from her bones during this phase, which can take 10 to 15 days. Without adequate time for lactation preparation, milk fever can become a major issue.

Adapting the diet during the ‘close-up’ period, not only allows 74 | January 2021 - Milling and Grain

Graph 1

Graph 2

time for the cow to mobilise calcium, but also for the rumen to adapt to forage changes and a higher energy diet, which are essential for nutrient absorption and preventing post-calving issues.

Pre-Calving - The biggest concern today

The concern today is not only clinical diseases and associated treatment costs but more importantly, the ‘subclinical metabolic disorders’ which can be extremely detrimental.

Metabolic disorder, that is subclinical hypocalcemia (SCH), is considered as ‘a gateway disease’ because it is associated with increased risk of periparturient problems that have long-term consequences for production, reproduction and survival.

Research findings (Reinhardt et al 2011) (see Graph 1) clearly indicate that cows are more susceptible to hypocalcemia as the lactation number increases.

F Subclinical hypocalcemia beyond milk fever

In 2014, Martinez studied the impact of subclinical hypocalcemia beyond milk fever. They induced SCH through five percent ethylene glycol tetra acetic acid (intravenous infusion) treatment for 24 hours.

They reported that SCH significantly (*P<0.01) reduced dry matter intake, increased non esterified fatty acids (NEFA) concentration, reduced rumen contractions and decreases neutrophil functions as compared to normocalcemic cows.

Martinez et al (2012) also studied the effect of normocalcemia/ SCH and its effects on metritis incidences when a cow is in a high-risk situation. A high-risk situation was described as a cow being diagnosed with dystocia, twins, still born or retained foetal membranes (RFM).

Normocalcemic cows in a high-risk situation showed 20 percent incidences of metritis, whereas subclinical hypocalcemic cows showed 77.8 percent incidences of metritis in the similar highrisk situation (see Graph 2).

Formulating pre-calving cow health

A meta-analysis consisting of 42 randomised trials (Santosh et al, 2019) suggested that cows with cationic diets (diets having a positive charge due to higher concentration of sodium, potassium, calcium and magnesium) are more likely to suffer increased incidences of milk fever or hypocalcemia. Cationic diets are one of the strong triggers of subclinical hypocalcemia during the ‘close-up’ dry cow period.

Anionic diets (diets having a negative charge due to higher concentration of chloride, sulfur and phosphorus) promote a more acidic metabolic state (lower blood pH) which is associated with reduced incidences of milk fever.

Is your cows diet cationic or anionic?

It is likely that most diets are cationic in nature, based on typical dietary ingredients used in the ‘close-up’ period. One of the main reasons for this, is these ingredients are fundamentally cationic.

Turning your cows’ diets from cationic to anionic can create optimal acidification in the cows blood. These acidogenic diets minimise hypocalcemia by: 1. Changing the animals blood pH towards a slightly acidic condition, due to increasing the concentration of chloride ions 2. Mobilising more calcium from the bones to buffer the acid in the bloodstream 3. Achieving maximum calcium supply at the time of calving 4. Reducing incidences of hypocalcemia which occur due to calcium deficiency

Graph 3: Changes in the incidences of retained foetal membranes after the introduction of NutriCAB

Kemin offers on-site pH measurement kits for monitoring urinary pH in cows, which is critical for analysing potential pitfalls after calving, as well as dietary testing facilities in our laboratory to check the cation status. This way we can propose the most refined application of hypocalcemia control solutions and technologies.

Kemin’s solution is in formulating pre-calving cows health called NutriCABTM which contains incapsulated calcium chloride.

NutriCAB comes with the highest concentration (>80 percent) of calcium chloride in encapsulated form masks the bitterness of anionic salt and prevents intake issues, controlling hygroscopicity during application and storage, also ensuring skin safety when handling and improves the metabolic health for better animal performance.

Performance under field condition

Compromised immunity and decreased muscle tone due to calcium deficiency can be associated with increased incidences of retained foetal membranes in dairy cows.

Trials confirm that with good ruminant health programs for precalving cows (last 21 days before calving), whereby diets were made acidogenic with NutriCAB, the incidence of retained foetal membranes reduced from 28.7 to 5.4 percent (average of four farms - see Graph 3).

The pre-calving cow phase is an area of great importance that sets the stage for how well the cow manages after calving.

The outcome of this phase will directly impact profitability.

Hypocalcemia is known to be the main problem affecting calving.

Research studies indicate that in combating hypocalcemia, precalving cow diets should be made acidogenic.

Kemin’s experience and strategies will help resolve the challenges of the pre-calving process and optimise dairy farm profitability.

Milling and Grain - January 2021 | 77

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mycotoxin risk

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Alltech’s European Summer Harvest Survey shows moderate to high mycotoxin risk

eather patterns have been variable across Europe throughout the 2020 growing season and have had a direct impact on the presence of specific moulds and mycotoxins across different regions.

Mycotoxins are produced by certain species of moulds and are a concern for livestock producers due to their ability to negatively influence feed quality and subsequent animal health and performance.

Samples collected from across Europe as part of the Alltech European Summer Harvest Survey have been submitted to the Alltech 37+ mycotoxin analytical services laboratory, and analysis is indicating the presence of moderate to high levels of mycotoxin risk.

The results are based on 274 samples of barley, wheat, corn, corn silage, grass silage, alfalfa, haylage, grass, peas, oats, sunflower meal, triticale and soybean. These samples are collected from farms or animal feed production sites from 15 countries across Europe including Russia, Spain, Portugal, Denmark, Hungary, Germany, United Kingdom, Czech Republic, Estonia, Republic of Lithuania, Morocco, Greece, Belarus, Croatia and Kazakhstan.

Therefore the results of this survey offer a representative picture of the contamination risk in all regions, with an overall moderate to high risk.

Samples have shown an average of 4.4 mycotoxins, with 99.6 percent containing at least one mycotoxin and 96.4 percent containing two or more mycotoxins. Fumonisins were found in 80.7 percent of the samples, while 74.5 percent contained type B-trichothecenes.

78 | January 2021 - Milling and Grain

Emerging mycotoxins

A noticeable trend in recent years is the growing presence of emerging mycotoxins.

More than 75 percent of samples contained this group, which includes specific mycotoxins such as beauvericin, moniliformin, phomopsin A, alternariol and enniatin A and B. Zearalenone (ZEN), a mycotoxin that can have a significant impact on the fertility of most species groups, was detected in almost seven percent of samples.

Aflatoxin B1 (AfB1), a member of the Aspergillus species and a particularly harmful toxin, was detected in less than seven percent of the samples that have been analysed — a percentage that is potentially lower than expected considering the dryer-thannormal conditions across much of Central and Eastern Europe this year.

"Overall, the current results indicate a moderate to high mycotoxin risk across Europe this year, and producers must remain aware of how the risk and impact will vary between different species and animal groups, with breeding animals and youngstock being more susceptible,” says Dr Radka Borutova, European technical support manager with the Alltech Mycotoxin Management team.

“We know that feeding even low-level contaminated feeds has been shown to impact animal health and performance, so even in lower-risk scenarios, producers should not neglect the need to guard against the threat of mycotoxins.’’

Results by region

In Southern Europe (Portugal, Spain, Greece and Croatia), the results from this region show that 91.3 and 80.4 percent of all samples were contaminated with fumonisins and emerging mycotoxins, respectively.

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Welcome - Roel Schoenmaker and Roger Gilbert VIV and International Aqua Feed Magazine, UK

6.15 AM

How to Select an Extruder?

Dr. Mian Riaz, Texas A&M University, USA

6.50 AM

Guide to Modern Aquatic Plant Design Mr. Jonathan Iman, Corporate Project Services, USA

7.25 AM

Pulverizing of Raw Material Mr. Phil Erikson, Reynold Engineering, USA

8.00 AM

Break

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Making floating and sinking feed with twin-screw extrusion technology Hadrien Delemazure Clextral, France

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Optimization of Aqua Feed Quality Nicola Tallarico, Kemin Europe

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Twin Screw Extrusion Andritz, Peter Sønderskov Denmark

6.50 AM

Evolution of Extrusion Technology Spencer Lawson, Wenger Manufacturing, USA

7.25 AM

Common Aquafeed Drying Challenges and Practical Solutions for Improved Efficiencies James Laxton, Famsun, China

8.00 AM

Break

8.15 AM

What, When, Where, Why and How: A Proposition for Enzymes in Extruded Feed Dr Kabir Chowdhury, Jefo Nutrition Inc, Canada

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Q&A Session, End of the session

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F The average concentration of fumonisins was 1,195.88ppb, a concentration able to harm the health and performance of pigs. More than 86 percent of samples contained fusaric acid, which is frequently found in different feedstuffs, mainly in corn.

Fusaric acid gets into many mycotoxin interactions and has a synergistic effect with other mycotoxins like fumonisins and moniliformin. AfB1 was detected in less than six percent of the samples, and the maximum concentration of 8ppb was found in one of the Spanish samples. The maximum concentration of deoxynivalenol (DON) was found in Spain in corn silage, and the concentration was 4903.3ppb.

Central Europe (Germany, Hungary and Czech Republic): Samples show contamination of fumonisins of 86.7 and 73.5 percent with type B-trichothecenes. The average concentration of type B-trichothecenes was 463.5 ppb, a concentration able to harm the health and performance of pigs. More than 68 percent contained emerging mycotoxins, a group of with increasing relevance in the past few years. AfB1 was detected in less than four percent of the samples, and the maximum concentration of 3.6 ppb was found in one of the Hungarian samples. The maximum concentration of DON was found in the Czech Republic in corn silage with a concentration of 3,921 ppb.

Further afield

The Baltics and Eastern Europe (Estonia, Lithuania, Russia, Belarus and Kazakhstan): Of the samples analysed, 70.9 percent were contaminated with type B-trichothecenes, fumonisins and emerging mycotoxins. The average concentration of type B-trichothecenes was 454.9ppb. None of the samples from Eastern Europe were contaminated with zearalenone, a mycotoxin that can have a significant impact on the fertility of most species groups.

AfB1 was detected in more than 10 percent of the samples, and the maximum concentration of 27ppb was found in one of the Lithuanian grass silage samples. The maximum concentration of DON was found in the Republic of Lithuania in corn silage and the concentration was 4970.5ppb.

More results

In Northern Europe (Denmark), the results from this region show that 94 and 92 percent of all samples were contaminated with emerging mycotoxins and type B-trichothecenes, respectively.

The average concentration of emerging mycotoxins was 414.4ppb.

Interestingly, six percent of samples contained ergot alkaloids, while the average concentration was 695.4ppb and the maximum concentration was 2037ppb, found in barley.

AfB1 was detected in less than 2.5 percent of the samples, and the maximum concentration of 3ppb was found in wheat harvested in Denmark. The maximum concentration of DON was found in Denmark in barley, and the concentration was 1351.8ppb.

The average levels of mycotoxins identified fall below the EUrecommended levels for each of the mycotoxins when assessed individually. Only 0.36 percent of samples exceeded EU allowed concentration of AfB1 (20 ppb) in feed ingredients (Commission Regulation (EU) No 574/2011).

However, the risk level for productive species based on Alltechâ&#x20AC;&#x2122;s risk equivalent quantity (REQ) varies from moderate to high when the multiple-mycotoxin challenge is considered.

Recommendations

Pig producers should be aware that the risk level based on the average REQ for breeding sows and young piglets is deemed to be high When the mycotoxin contamination levels are applied to poultry, the mycotoxin risk for breeding birds is moderate, while in broiler birds, it is low to moderate In ruminants, the so far the results indicate a low to moderate risk in dairy cows There was a notable difference in the mycotoxin contamination levels of large grains (corn) and small grains (wheat, barley, oats).

The average number of mycotoxins detected in corn samples was 6.4, while in small grains, it was 3.6. This variance is reflected in the REQ and risk of feeding these ingredients to specific species and animal groups.

For instance, in sows and gilts, this yearâ&#x20AC;&#x2122;s corn samples represent a higher risk of mycotoxins, but when small grains are fed to the same animals, the mycotoxin risk is deemed to be lower.

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Improving feed quality and breeding increases income The secret of the Zhengchang 658 new generation success

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ollowing 40 years of development, China’s chicken industry has achieved global attention.

By combining the characteristics and development status of the domestic catering market and consumer market, China’s chicken industry is facing more opportunities and challenges.

Since 2019, the African Swine Fever (ASF) epidemic has continued to hit Asia, which is the continent of pork production and consumption, with China in particular suffering the most severe losses. China’s live pig inventory has dropped to its lowest point in 10 years. Poultry meat has undoubtedly become the best protein replacement.

Although the contribution of Chinese chicken in changing the dietary structure of the people, it is not as good as that being achieved in the United States, Japan and EU countries, despite it becoming the second largest source of meat protein consumption for the country’s people.

With the awakening of residents’ health awareness and the acceleration of the pace of life, low-fat healthy chicken suitable for fast food cooking will gradually replace its high-fat, highcholesterol pork counterpart.

Experts predicted that in 2020, the domestic pork production gap will further increase, with the capacity for chicken to replace pork, potentially increasing by more than 3.1 million tonnes. The required capacity will then need to exceed 2.1 billion boilers.

Of course, good broilers are inseparable from good feed cultivation.

In order to better serve customers and to help customers seize this historical opportunity, the industry is able to cultivate highquality broilers and further expand its market share and obtain gratifying benefits.

82 | January 2021 - Milling and Grain

Zhengchang‘s ‘Special Brought’ is the industry’s first thirdgeneration premium chicken feed system called 658 (or Dr Chicken) for its high-quality pelleting process.

The system is an excellent result determined by Zhengchang’s scientific research personnel and industry experts after four years of persistent research and development including several off-site experiments, repeated deduction of test data and joint trials with key customers in the final stage.

Feed-to-meat ratio

The system can successfully reduce the feed-to-meat ratio of broiler chickens - by increasing the chicken’s gizzards – through the use of green and safe feeds, ensuring the health and safety of grandparent hens and prolong life and laying periods. All of this whilst comprehensively improving the quality of feed and breeding.

If carried out effectively, making these adjustments can also greatly improve the efficiency of an enterprise.

Taking a 50,000 tonne-per-year feed factory as an example, it can feed about 10 million chickens, at 3kg per chicken and at

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10 yuan per kilogram. The feed-to-meat ratio is reduced by 0.05 which can increase the total income of a breeding enterprises by 9.47 million yuan per year.

At the same time, the system can also effectively reduce costs, increase operational value and help customers to build unique market competitiveness.

With the same ÎŚ3.5 ring die and with the ring die pressing ratio of 1:14, the Zhengchang 200kW granulator can reach 14.5 tonnes-per-hour, which is three tonnes higher than other counterparts in the industry and with a power consumption per tonne 3.6 degrees lower than counterparts.

That is to say, if the press runs a production per day o 20 hours and continuous production for 300 day with an electricity cost of 1 yuan/kWh, it can save 720,000 yuan, or US$11,000 per year.

Advanced process design

The system adopts the industry-leading process design, the whole process is temperature-controlled and tempered. The quality-adjustable time is every five-to-eight minutes,and the outlet material temperature can reach 70-90 degrees, which can completely remove salmonella.

The whole process of granulation is automated and intelligent and the gelatinisation degree of corn in the coarse powder state can be as high as 34.1 percent and the oil absorption is large (between seven-to-nine percent).

Under the same ring-molding ratio, the particle hardness can reach 50-60N (3min).

It also helps many customers win market development opportunities. The three advantages of cooked coarse meal, more fuel and harder pelleted feed can greatly improve the quality of the chicken and improve the breeding effect.

Zhengchang has been working hard on product development, design and process quality details in recent years.

Whether it is the upgrading of products and equipment, or to meet market needs, to relieve customersâ&#x20AC;&#x2122; worries or assiduously in technology research and development, Zhengchang insists on continuous research, development and innovation and is always at the forefront of industry development in order to meet the continuous improvement demanded by customers. It prides itself on enterprise development, the pursuit of high-quality products, with stable and reliable quality, in order to help its customers to move towards a broader future!

Milling and Grain - January 2021 | 85

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AUTOMATION OF A PADDY PARBOILING PLANT

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by Rajinder K Bajaj, Satake India Engineering Pvt Ltd he region of South Asia, which includes India, Pakistan, Bangladesh, Sri Lanka among others, boasts a combined population of 1.7 billion. Here, rice has traditionally been the most important staple foods in the region.

Satake India Engineering is located in the centre of this region and serving as one of the key suppliers of processing equipment for grains including rice, wheat, maize and lentils. It is also the principal distributor of Henry Simon brand flour milling equipment and technology for this region.

Paddy is being parboiled in India and South Asian countries for conserving its nutritional values and also for the taste factors. At

88 | January 2021 - Milling and Grain

present the system involves pre-cleaning, pre-steaming, paddy soaking in hot water and post-steaming, followed drying in a paddy specific facility.

All of the previously mentioned processes are currently being carried out using MS/SS tanks.

In these tanks, the main source of heat for attaining the required temperatures is largely steam. During this process the rice will be hardened, resulting in better yield during the milling process.

Also, the nutrition included in the bran will penetrate into the

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endosperm of the grain, which will remain in the final product.

Due to these advantages, parboiled rice is consumed not only in the South Asia, but is exported to various countries around the world.

Inconsistent results

Since the system is currently mostly manually controlled using available resources, there are many sources of variation, which causes inconsistent results.

As all of the process control points and parameters are adjusted manually, there are chances of error within the batch and even amongst the various batches of the same paddy lots.

The parboiled process applied for the wet paddy, which is received from the field during the harvest season. Therefore, in this case, the process can be continued for 24 hours a day, seven days a week for several consecutive weeks.

When all of the controls are operated manually, if the level of experience of the available labour is low, then this can provide a great challenge to the mill operators.

Uncontrolled operations make the paddy vulnerable to colour variation, Milling and Grain - January 2021 | 89

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F increased damage and burnt grains. Over cooking of paddy can also result in hardness and variations in moisture content, whilst uneven drying can also often causes yield loss in the milling process.

An automated parboiling process

Faced with these challenges, Satake India Engineering studied the current practices and developed a fully automated process for parboiling using the existing local infrastructure and Satake’s world famous precision instrumentation.

Satake’s main objectives are to: • Develop a fully automated parboiling system with minimal operator engagement.

• Target consistency and repeatability within batches • Improve error control and real time trouble shooting in case of alarms • Use warehouse data and analytics in order to enhance process capabilities • Implement an online feedback system to improve the batch operation process • Log colour control data and other grain related parameters for the miller Save energy due to automation and a reduction in breakdowns To achieve these targets, server-based PLC systems with embedded I/Os and SCADA systems are introduced to manage the control points, such as pneumatic slide gates, level sensors for paddy and water, control and on/off valves for steam and water, load cells, temperature and pressure sensors and transmitters and moisture sensors.

Remote viewing of the process is also enabled using IoT connectivity.

Unfortunately, the COVID-19 is still heavily hitting the wide area including South Asia region. The cross-border travelling is still restricted or limited between countries.

Therefore, it will be useful if millers were to upgrade their facilities with such a system, as technology can proactively alert and solve the problems/breakdowns over remote connections.

Data collection

All data is collected and stored by a system managed by a PLC system developed specifically to manage the system automatically, with screens in the following sections of the manufacturing process: • Pre-Steaming Section • Paddy Soaking Tanks • Post-Steaming Process + Pre-Drying • Paddy Drying Section With the help of the automation software provided, rice millers can now manage the parboiling process more efficiently and effectively. Satake India is also incorporating Next Stage Industry 4.0. technology into this application by integrating it with central cloud systems using IoT connectivity which will enable real-time monitoring of the system and its performance by the miller.

All corrections will be able to be implemented by millers in real time, allowing for the maintenance of consistent results.

Security and safety

A further feature added by Satake India is improved information security and operational safety with the employment of II-tier User Authentication system. The system’s biometric login facility will only allow authorised access to the operational control, with similar systems having already been installed in leading rice millers across the region.

As a result, uniform colour and controlled parameters in grains were observed in the mills using Satake Automation Software in the parboiling process throughout this region.

Yields were also improved by error control and automation in various batches.

Millers also reported that they observed a power and steam savings of us much as 30 percent, compared to their previous manually operated process.

As well as the operational improvements, the further additional benefits of the new Satake system, such as the digital analogue system data logging, ensure that the records are preserved for future reference. As a whole, capacity utilisation during the limited harvesting season, leading to an increased annual turnover of the mill.

The population in South Asia is still expanding, so is the demand for the food supply.

Satake India Engineering is committed to improving the efficiency and quality of food production, thus contributing to the brighter and more prosperous future for these countries. www.satakeindia.com Milling and Grain - January 2021 | 91

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Bühler technology helps Andean Valley’s expansion into the Chinese market

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olivia-based Andean Valley Corporation attributes its successful entry into the Chinese market to its investment in Bühler’s Sortex optical sorting technology.

Andean Valley Corporation has also seen a more than two-fold increase in its processing capacity, as well as ongoing expansion of its product portfolio and a significant improvement in its colour sorting.

Since the COVID-19 pandemic began, studies conducted around the world have shown a significant rise in depression and anxiety levels.

Medical professionals suggest physical activity and lifestyle changes as a first resort, including an increased intake of complex carbohydrates, fibre and protein-rich superfoods such as Quinea.

Superfood benefits

Quinea seeds contain all essential amino acids, iron and B vitamins, in addition to magnesium – known to boost levels of serotonin, or ‘the happy chemical’, in the brain. Their slow releasing energy and low glycaemic value ensure optimal blood sugar, while the presence of sleep-inducing hormone melatonin 92 | January 2021 - Milling and Grain

helps to ensure a good night’s sleep.

Javier Fernandez Villalobos, CEO, President and owner of Andean Valley Corporation says, “Our black Royal Quinea is particularly rich in lithium which can help to regulate depression.”

Royal Quinea, which is exclusively cultivated in the Andean region of Bolivia, is considered to be the highest quality of Quinea. At quadruple the size of other Quinea varieties, it contains a higher concentration of vitamins and minerals, as well as a distinguishable, nutty flavour.

Expanding portfolio

Established in 1998 and as one of the first companies to be certified ‘organic’ in Latin America, Andean Valley is committed to producing, processing and exporting organic food made with Royal Quinea.

The company is on track to process over 5700 tonnes of Quinea by the end of 2020 with the help of almost 500 farmers and 147 employees who work across three processing facilities covering 80,300 square meters located in La Paz. The company has developed a range of 50 organic, glutenfree and non-GMO, red, white and black Royal Quinea-based products.

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Mr Fernandez says, “One of the most important elements that has helped us in our product development, has been the support of companies like Bühler in furthering our technological development.

“By enabling us to perfect our de-stoning and cleaning of the grains, we can trust that we are producing the best quality in the market, so we are able to think bigger. The unmatched technology gives us the support and confidence that we need.

“As a result, our sales channel has evolved from supplying bulk containers of Royal Quinea to companies, to now providing restaurants, cafés and supermarkets with high quality, ready-to-eat Royal Quinea -based products.”

Boosting capacity

Since the COVID-19 pandemic began, Andean Valley has experienced a drastic increase in demand for its Royal Quinea, recording the highest sales in the company’s history.

“With our Sortex technology we have been able to meet this rise in demand,” states Mr Fernandez. With the highest capacity optical sorting solution for Quinea in the market, Andean Valley has more than doubled its processing capacity, from two to five tonnes per hour.

“Prior to investing in Sortex technology, if we wanted to ensure a high quality end product we had to significantly reduce capacity, this was costing us a lot of time and money. With Bühler we’ve been able to boost our quality and capacity, without sacrificing one for the other,” says Mr Fernandez.

With its expandable and modular structure, Sortex optical sorting technology enables higher product throughout without compromising on the accept product quality.

The flexible configuration allows the product to have multiple passes, enabling Andean Valley to obtain a much more concentrated reject.

Subsequently, the company has been able to recover approximately five tonnes of accepted quality Quinea every month.

Improved colour sorting

The main challenge that the company faced prior to its Sortex investment was detection and removal of immature pale green and overly mature pale pink grains, which are both very similar in colour to the main white Quinea.

With Bühler’s RGB camera sensors, Andean Valley is now able to detect very slight colour variations, with a clear image. The patented algorithm allows the operator to easily select which defect to remove, without touching any other colour.

Moreover, the Sortex machine continuously tracks the product colour, enabling automatic calibration of camera gains and background references.

The supplier’s program

The improvement in colour sorting aligns perfectly with Andean Valley’s Supplier’s Program, wherein the company purchases locally cultivated Quinea from almost 500 small farmers, most of whom lack advanced farming management.

Subsequently, their grains often contain defects, which would not be accepted by other Quinea processors in the region.

However, with its Sortex technology, Andean Valley is able to handle lower quality Milling and Grain - January 2021 | 93

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input material and so can successfully support its local farmers and provide them with a steady income.

“We set up our Suppliers Program so that small farmers are in a position to leave their businesses to their children, safeguarding their land and produce for future generations. This also involves strengthening their skills in pest control, sustainability and soil conservation,” Mr Fernandez adds.

The Chinese market

Not only has Sortex colour sorting supported small farmers in Bolivia, but also Andean Valley’s export markets. Currently the company exports its Royal Quinea to 13 countries.

However, without Sortex technology, Mr Fernandez states that it would have certainly failed to enter the Chinese market.

“The Chinese market demands a stringent separation of black, red and white Quinea; thanks to Bühler’s advanced colour sorting

we can guarantee that. Today we are able to comfortably fulfil our existing demand and also demand from China,” says Mr Fernandez.

The combination of the high speed and precise ejector system teamed with Bühler’s developments in digital image processing gives Andean Valley confidence that their Royal Quinea will continue to meet the toughest export requirements.

“With our Sortex stamp of high quality, we are looking to further expand into new markets that have an organic, high quality food interest. Additionally, we are in the finishing stages of installing our first gluten-free pasta line and a smoothie line,” states Mr Fernandez.

“We are also very excited to be boosting our sales potential with a brand new Research and Development department. Our aim is to continue developing our product range, so watch this space!”

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NIR technology

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for raw material and feed analyses goes mobile portable handheld near infrared spectroscopy (NIR) device, linked to a smart phone or tablet is capable of taking the standard laboratory test into the field. Rather than undertaking the laborious and time consuming task of taking and moving samples to the laboratory, Evonikâ&#x20AC;&#x2122;s AMINONIR Portable, a wireless device that is compact and robust, brings NIR technology into all areas of the feed industry.

NIR is a technology that is widely applied in the feed industry to either qualify or quantify macro components. In NIR spectrometry, invisible near infrared light is beamed at a sample, causing molecules in the sample to vibrate.

This interaction with the molecules consumes energy by absorbing elements of the light beam. In the case of liquid samples, residual light passes through the material, while solid samples reflect the light.

This light is measured with a detector and gives a spectrum. The spectral information is further used and evaluated for example to identify unknown samples (fingerprinting) or to estimate its nutritional composition via the application of NIR calibrations.

For feed mills and feed producers, Evonik launched its AMINONIR Portable service for customers in 1995 to analyse feed raw materials like corn, wheat and soybean meal for their amino acid composition. As of today, more than 800 units are using AMINONIR services.

The differentiating aspect of AMINONIR Portable is that it works apart from the typical assumptions of NIR spectroscopy.

Usually, NIR technology is used for samples that have a defined matrix, in order to determine the macro concentrations of analytes (>2 percent).

In contrast, AMINONIR is working in natural feed raw materials â&#x20AC;&#x201C; which are not a highly specific matrix â&#x20AC;&#x201C; and it

96 | January 2021 - Milling and Grain

determines amino acid concentrations, which are in the range of only 0.1-0.3 percent for some raw materials. Nevertheless, it is capable of giving precise results with a very low variation.

Regular improvements

Maintaining this performance level demands continuous monitoring, updating and validation of the NIR calibrations. This requires regular improvement and update processes, not only of the NIR calibrations but also of the chemo-metrical algorithms and the IT infrastructure.

Up to now, it is common practice in the feed industry to work with laboratory NIR devices, which are often located in a central lab. Thus, it is necessary to ship the samples from the feed mills to the central lab prior to their analysis.

This is causing extra work and a delay in time of up to a couple of days which slows down decision making in terms of storage, usage and adjustment of feed formulations, all of which is critical for the financial success of any feed operation.

AMINONIR Portable now takes the lab to the place where it is needed. AMINONIR Portable is using a hand-held NIR device, which is linked up to a smartphone or tablet. The wireless NIR device is extremely compact and robust. It is perfectly made for the rough environment of the feed industry.

Evonik developed NIR calibrations specifically for this robust handheld NIR device so that it can be used to evaluate the quality of finished feeds and feed ingredients. AMINONIR Portable enables you to quickly and reliably determine multiple parameters covering proximates, like crude protein, crude fibre, and energy values for poultry and pigs. In feed ingredients, AMINONIR Portable even samples and reports important nutrient levels, such as concentrations of amino acids.

There is no need for any sample preparation as feed or feed ingredient samples are directly filled into a holding cup attached to the NIR device, which are then scanned as they are. In order to get reliable results, no pre-grinding of the sample needs to be done.

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F Sample scans are sent to Evonik’s online analytics platform via smartphone or tablet where they are analysed and deconstructed into its nutrient values. The results are then made available to the user via Evonik’s Analytical Data Advanced Application within seconds. This application is password protected and provides a user-specific central access point to all their analytical data, which is particularly advantageous if the user is operating multiple NIR devices.

The analytical data can then be used for quality control right where it is needed, such as at the raw material reception area of a feed mill or even directly at farm level where local grains are used. AMINONIR Portable also facilitates timely decisionmaking and process improvements. For example, it can be used to separate and store raw materials according to their quality.

This will help to achieve a stable feed quality over time, as raw material homogeneity is increased.

Precise nutrient data

AMINONIR Portable delivers the necessary information to update feed formulations.

The precise nutrient data on the actually available feed ingredients cut out the guess work and make the use of table values obsolete. AMINONIR Portable enables for precise feed formulation, which also means that safety margins can be reduced and savings realised.

In addition to feed ingredients, AMINONIR Portable can also be used to measure finished feeds. Evonik developed NIR calibrations for Poultry, Swine and Aqua feeds. At feed mill level, usage of AMINONIR Portable should lead to improved and stable feed quality as mixing errors are much more likely to be detected in time and actions can be taken, before the feed

is shipped to the customer, which will in turn increase customer satisfaction.

Feeds, which match the targeted nutritional quality perfectly, are more likely to result in a stable animal performance and homogenous flocks. In addition, the environmental impact of husbandry is reduced as feed efficiency is increased. Aminonir Portable is the next level of professionally managing processes in the feed industry, says the company.

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www.almex.nl Milling and Grain - January 2021 | 99

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STORAGE

An air-tight heat-insulated steel silo for longer-term grain storage

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by Professor Wu Wenbin, MAG Editor – China Edition and Henan University of Technology OVID-19 is breaking stable food supply chains around the world.

Many countries in Africa and Asia are facing food crises due to COVID-19 and compounded by locust infestations, which impact national food security.

Therefore, more and more countries are attaching importance to the long-

term storage of food.

They hope to build more long-term grain silos and reserve more grain to ensure the stability of supply within their domestic grain markets and maintain national food security.

The steel silo is the main type of grain storage in the world nowadays. Due to the high and fast thermal conductivity of steel, it is difficult to control a silo’s inner-temperature.

In the high temperature season or in high moisture tropical regions, the silos’ temperature and humidity are too high, so the grain in the silos is easily deteriorating, which is not conducive to the long-term safe storage of grain.

Therefore, in the past and for a long time, the traditional steel silos could only be used as ‘transit storage’, or temporary storage of raw materials, finished goods and other short-term storage uses.

In order to solve this problem, the SRON company (in China) has researched and developed an air-tight, heat-insulated steel silo, which provides the possibility for the longer-term storage of grains in steel silos. Here, introducing its application in the long-

100 | January 2021 - Milling and Grain

term reserve depot for grains this structure-type and insulation conception of an air-tight, heat insulation steel silo can be shown

Insulation conception

The outer surface of the steel is assembled with an insulation layer made of polyurethane (thermal conductivity <0.024), which can isolate external temperature conduction The grain cooling machine blows the air upward from the wind net at the bottom of the warehouse to spread the whole warehouse. And the cool air scattered on the upper end of the warehouse is conveyed to the fan through the air outlet pipe for further recycling. When the temperature set by the temperature sensor is reached, the refrigerating compressor

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STORAGE will stop working and the fan will continue to work. When the temperature set by the temperature sensor II is reached, the fan will stop working and the cool air will be recycled to reduce the loss of cool air.

Advantages of air-tight heat insulated steel silos

Stable temperature change in the warehouse ensures long-term storage quality of grain - The temperature gradient inside the steel silo is smaller than that outside. Stable low temperature storage can ensure the stability of grain storage. Silos can be fumigated with our patented airtight technology.

Patented technology - SRON owns the patented technology of insulated steel silo. They have prevented the heat exchange between inside and outside of the silo. For a 10,000-tonne silo, the heat conduction area is only 0.18 square meters, or only two percent of that of the product from other suppliers. This technology significantly increases insulation performance.

Less investment - Compared with concrete silos, the investment of insulated steel silos is lower. The insulation effect is achieved by the insulation materials wrapping the silo, such as polyurethane foam, sponge rubber board and glass fiber.

Company advantages

SRON can provide safe and reliable single sheet steel silos with capacities of 200 - 10,000 tons, with advanced engineering technology systems including complete process design, civil engineering and foundation design. The company can also

provide upgrades, transmission, cleaning, magnetic separation, drying, measuring, temperature control, mites control, fumigation, cold storage, thermal insulation, ventilation and dust removal, automation control system solutions and EPC general contracting services.

Excellent team

SRON currently employs five senior engineers, eight firstclass constructors, 31 professional technicians with intermediate or above titles, nine technicians with Doctorates or Master degrees, 38 patented technologies and passed ISO9001 quality management system and SGS certification.

Strong production capacity - The company has three manufacturing and processing bases affiliated to it, with advanced production lines and an annual manufacturing capacity of 30,000 tonnes.

In Russia, Indonesia, Malaysia, Kenya and more than 30 countries and regions SRON have constructed more than 900 steel silo projects, the total reserves of three million tonnes of engineering achievements, well received by customers at home and abroad. www.grainsilo.com

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Milling and Grain - January 2021 | 103

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BinMaster’s compact non-contact radar with bluetooth setup

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inMaster’s new line of compact non-contact radar aka ‘CNCR’ level sensors puts 80 GHz of precision to work measuring simple and aggressive liquids.

Small in stature but big on features, these sensors set up simply using bluetooth and the wireless device configurator app loaded on a smartphone or tablet. The app can also be used to diagnose and change display parameters once the sensor is installed from up to 25 metres away.

The sensors have zero dead zone, measuring up to the sensor face, making them very accurate and ideal for smaller vessels and simple applications. The CNCR’s 80GHz technology measures through plastic vessel walls or lids, allowing it to be mounted unobtrusively and easily without cutting a hole in the vessel. CNCR sensors measure reliably through foam, vapour, and steam. The CNCR is not affected by fluctuations in temperature or condensation. The sensor enclosures are molded of PVDF plastic and feature FKM seal materials for exceptional mechanical strength and chemical resistance.

These devices are offered with 2-wire 4-20mA and 4-wire Modbus outputs. The CNCR sends measurement data to an HMI or PLC or to the BinView® web application or Binventory® software for viewing on a phone, tablet, or PLC. Level data can also be output to a digital panel meter or control console for local walk or drive up access.

The narrow beam angle is easily aimed to avoid obstructions

104 | January 2021 - Milling and Grain

or structure in the vessel that could interfere with performance.

Mounting is simple using one of four galvanised steel mounting brackets or one of four mounting plates offered in 0, 5, 10 and 30-degree angles. Alternatively, BinMaster’s swivel mount allows precise aiming with adjustability up to 40 degrees to perfectly point the sensor at the desired measurement location.

The CNCR-100 series wires quickly using a simple pigtail connection. There are four CNCR-100 models offered in measuring ranges from eight metres to 28 metres for general use or with optional hazardous location approvals. Enclosures are weather-resistant for dust and water ingress and have IP66/ IP68 ratings. The CNCR-200 series features three models that measure from 28 or 15 metres, with an optional LED display and push button controls. Great for basic liquid level applications in unclassified areas, the CNCR-200 sensors have IP66/IP67 NEMA Type 4X enclosure approvals and are often used to measure liquid levels through plastic tank walls or the lid of an IBC. These compact sensors are exceptionally versatile for use in all types of food stuffs for humans or animals, taking on the challenges of translucent, opaque, or transparent materials such as beverages, oils, fats, and sauces. The CNCR can be used in oils and fuels and all types of mechanical fluids. It can be used in many types of chemicals, fertilisers, colourants, or adhesives stored in bulk storage tanks, industrial bulk containers (IBCs), or drums. The CNCR can take on most any type of water application from drinking or purified water, to municipal water and sewage treatment, and industrial water and wastewater vessels. In open air applications, the CNCR can be used for monitoring sewer overflows, basins, dams, rivers and bridges.

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CENTRALISED, INDEPENDENT AND COMBINED ASPIRATION SYSTEMS Technological Tips by Ocrim

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s we are all still unable to meet face-to-face with any real convenience, Ocrim have chosen to make their know-how widely available by organising a series of webinars held by their best experts.

In the most recent edition, taking place on Thursday, November 26 and Friday, November 27, Ocrim continues to address the topic of High Efficiency Flow or HEF flowsheet, its pneumatic system application and the application of the flour silo aspiration concept to preserve the integrity of low ash flour.

Being very technical, the Ocrim webinar series is mainly designed for millers and production managers. However it may be appealing for all operators in the milling sector who like to be kept up to date, because after all, there is no such thing as possessing too much knowledge in our industry!

Designing for different passages

Part three of the series sees the return by popular demand of duo Marco Galli, Chief Technologist at Ocrim and Anna Buffa, the food entertainer and author of the Fornelli a Spillo blog, who was charged with introducing and moderating this edition.

The webinar begins with a discussion of Ocrim’s HEF Flowsheet, before moving on to the topic of pneumatic system application. On this subject, Mr Galli begins by describing how they are divided into two sub systems, those designed for clean passages and systems designed specifically for all other passages.

Those systems that are designed specifically for clean passages with low ash content are built with the sole intention of preserving the 106 | January 2021 - Milling and Grain

maximum amount of low ash flour passages from the sizing head to the middling group.

The pneumatic system for all other passages is designed to handle the remaining, lower quality passages.

According to Mr Galli, one of the key disadvantages of the standard system is that the nature of the design creates cross contamination, which in turn leads to a downgrade in product quality.

However, Mr Galli also says that with this new design also affords millers the ability to keep passages with low ash content segregated from the dirty ones, which in turn allows them to maintain its integrity and increase extraction on premium products.

On the subject of low ash pneumatic systems, this design keeps the ash valves of the cleanest products unaltered, with the result being the maximum recovery of the premium product yield.

That said, in mill designs that require a higher extraction on premium products, split pneumatic system may be needed.

If we are going to increase the level of investment, the next logical question that we are likely to be asking is, does the low

STORAGE ash pneumatic system offer any tangible economic advantage? Well according to Mr Galli, the answer to this particular question is “Certainly, yes.”

So now we have resolved the issue of whether or not it would be worth our while financially, the next step is establish whether adopting the system makes practical sense.

In order to ensure that this is the case, we would need to look at whether there are currently any technical solutions that would keep the low ash products separate from the low-grade product. Only then could pneumatic aspiration system be credibly assessed as a viable option.

Effective aspiration in flour silo

Following the assessment of the pneumatic system’s viability, Mr Galli continues by discussing the design of flour silos, as correctly designing the flour silos is essential, with aspiration is an important part of that process.

As well as the fairly obvious issues relating to storage, a flour silo also has to be designed according to the characteristics of the products that are being simultaneously processed across the various work cycles at the silo, such as the flow rates for products on the transfer line.

Whether the conveying system is either mechanical or pneumatic also needs to be decided, as well as which prevention measures need to be taken to avoid contamination.

All equipment should also be installed in line with all relevant standards and regulations. With all of the previously mentioned

factors taken into account, the next step according to Mr Galli, is to select an aspiration philosophy.

Flour silos can be designed with three different main philosophies in mind, with these being centralised, independent or combined.

Centralised aspiration system:Apparently lower costs

Described by Mr Galli as being one of the most commonly used solutions, centralised aspiration systems are most suited to silos without “excessive complications.” Centralised systems are also commonly used in facilities where the type of flour being processed in the silo is not so heavily governed by quality specifications.

In a centralised system aspiration is achieved by a single unit

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Milling and Grain - January 2021 | 107

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STORAGE that contains a filter and a fan that is equipped with a single manifold that connects to the various aspiration points via a network of pipes.

The segregation of the aspiration of the unused bins and/or aspirated points is obtained by butterfly valves with electropneumatic remote control. The aspiration is only guaranteed on these points foreseen by the simultaneity at that moment, based on the active cycle. Correctly identifying these cycles and simultaneities during the design phase are very important.

According to Mr Galli, although centralised systems may offer apparently lower installation costs, this saving is soon lost during the systems operation. Long term losses such as the high costs of electromechanical devices, loss of the aspired dusty products, higher frequency filter maintenance and higher energy costs, all mean that the centralised designed, according to Mr Galli is, “apparently the most economical solution.”

Mr Galli then continues by stating that in relation to standards and regulations, the centralised system is a borderline in terms of acceptability.

Because the product recovered from the aspiration filter is qualitative undefined, it is also difficult to reintegrate the dust into the production system, which is even more critical with the addition of additives or when the system has to consider a WWF processing.

In terms of quality and integrity of the final product, Mr Galli believes that in general terms, centralised aspiration systems have a negative impact on the overall handling process.

In terms of further limitations for centralised systems, Mr Galli offers the fact that the various aspiration points must be able to manage different products, problems in the handling of residual products collected by centralised filter and periodic filter maintenance that will require shutdown, as all being critical future issues.

Mr Galli also adds that the system is more complicated to balance due to ramifications, which will in turn result in the airflow rates involved not always being constant.

However, Mr Galli concludes by stating that this system has less flexibility if cycles have not been evaluated in the initial design, with initial low installation costs only masking the potential longterm financial impact.

Independent aspiration systems: reduced maintenance costs

The most commonly used alternative to centralised aspiration systems in flour silos is independent aspiration, which are becoming more common on an almost daily basis.

Mainly applied to the loading of flour bins, independent aspiration systems can also be used in other applications such as blowing line hoppers, flour mixers and scales or any in any situation where high volumes of air are aspirated.

Compared to centralised aspiration systems, the independent equivalent offers millers a solution with no contamination risk or quality product downgrade. This is mostly due to the system’s use of single filters that are allocated directly on the individual aspiration points.

Other than the cleanliness advantages, the independent aspiration system is also much tidier at the plant layout level, because fewer ducting runs are required throughout the plant.

This is reflected in the fact that independent systems meet every country’s standards and regulations as each individual bin is aspirated in isolation.

The isolated nature of the independent process also allows for different products to be handled simultaneously in the same flour

silo, whilst still preserving their respective characteristics.

With the issue of cross contamination presented by centralised systems seemingly dealt with, independent systems also afford millers lower running costs both on energy and maintenance as the whole system doesn’t need to be shut down if there is a problem with one of the units.

The most important advantage of this system is that there is no cross contamination of flour, therefore the integrity of the low-ash flour is preserved in its entirety. This aspect has an economic return, which according to Mr Galli will help to pay back your initial investment quickly. For example, if we were to assume that about 0.2 percent of low ash flour lost due to potential cross contamination, if this was prevented entirely, then the final result would be approximately €12,000 or US$14,500, a year for each cycle.

Combined aspiration: the best of both

The main advantages of the two systems that have been mentioned thus far have offered the advantages of a system that can be centrally controlled and cut cross contamination.

Both of these benefits can be achieved in a system that combines the independent aspiration system with the centralised one. Like the independent system, the combined aspiration system is also much more compact solution compared to the centralised one.

This system may also be used in almost every flour silo and even in flour silos with a medium to high degree of sophistication. The centralised aspiration also affords an increase in performance for the aspiration points, whilst the premium flour circuit is aspirated with individual filters that are separate from the system that manages products of lesser quality.

One option for supplementing a combined system further would be to upgrade the filters, with one option being the FLP highpressure system.

FLP High Pressure Systems

The FLP is designed specifically for aspiration of single points like hoppers, casings and bins and is available in different versions based on the usable spaces and the required filtering surfaces. The fabric used for the filtering sleeves is particularly suitable for fine dust management, with the sleeves cleaned with high-pressure air jets.

The FLP’s on board computer detects the efficiency and status of the filtering sleeves and a built-in electronic timer manages the cleaning air jets. Whilst an electronic panel adds a level of ease to managing both the frequency and bag cleaning time.

This type of filter can be purchased with steel and stainless steel versions allowing for increased hygiene, whilst the design of the FLP allows easy maintenance and inspection.

The FLP system uses the same principles as the traditional filters that are also used in single point aspiration system.

However, the main difference, according to Mr Galli, is that this system features an integrated fan that makes it an independent machine.

Returning to the subject of choosing which aspiration philosophy to adopt, the Webinar reached it’s conclusion by Mr Galli stating, “It is useless to take care of the details within the milling flow if we do not pay the same attention to all of the handling phases of the finished product.

“It is very easy to lose a few percentage points of premium flour only due to incorrect plant design.

“What today seems to be the least expensive solution, may not be in the medium to long term,” says Mr Galli.

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AUTOMISING THE BAGGING PROCESS

hen faced with the challenge of automising a bagging process there are some key facts to consider.

These key facts should include your required capacity for a fully automatic bagging machine and palletising system as well as the filling weight and type of your bags.

Also think about changing your bags as fully automatic bagging machines need a certain quality of the bag in order to handle it in the best possible way.

Moreover, you should define your requirements in regards to the weighing accuracy and the operation time of the machine (that is, hours per day).

Another essential aspect is the space required for a bagging system. Manual or semi-automatic bagging systems have lower space requirements than a fully automatic bagging machine. Therefore, is it crucial to talk with a bagging expert to find out if the machines will fit in the space you have reserved for it or if there are small modifications to the building that are necessary.

When you already know your required capacity, the production output as well as the budget for the machine, the next step should be to think of what your preferred supplier needs to know in order to offer you the right solution.

More detailed information

These eight questions are general ones and depending on your requirements there will be of course additional and more detailed ones.

STATEC BINDER believes that a detailed discussion with one of its bagging experts is vital for the success of a project.

110 | January 2021 - Milling and Grain

To better understand your needs and requirements, the answers of the following questions are important for the machine manufacturer: 1. What is your project time frame?

2. Details of your product a. Product form b. Bulk density c. Particle size d. Product temperature e. Product moisture f. Flowing characteristics g. Special characteristics 3. Details of the ambient conditions like temperature, air humidity, plant conditions, area execution and power supply 4. Do you use pillow or gusset bags or both? And what are the characteristic of the bag for example, block bottom, carrying handle?

5. Which bag material do you use?

6. How many different bags needs to be filled with the fully automatic packaging machine? The dimensions of the empty bags are also needed 7. Which closing method do you prefer?

8. Are there any other requirements like bag coding, labelling or tag application?

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F Therefore, their sales managers and experts will schedule a call or even a visit, if possible, to discuss the project in detail. During this discussion these experts will also give their advice to make sure you receive the best consultancy and your project will be a success.

It is essential that you know your status quo of course but even more important is that you have also thought about the future. The investment in a fully automatic bagging system or a whole bagging line should be well planned because the machines should last for at least 10 to 20 years. Therefore, the next paragraph covers some points which are important to know for the future.

Points for the future

Market requirements change from time to time. Therefore, keep an eye on trends and talk with your customers. Here are some questions to think of: • Are there any changes in regards to the preferred bag materials or sizes?

• Will the demand for your product increase so you also need to increase your production capacity?

• How flexible should your bagging and/or palletising system be?

Think also about the fact that flexibility could also affect the efficiency or capacity. For example, a machine for small bags, which should also fill bags with 50kg, has a small filling spout so that the small bags fit on it. Therefore, it then takes longer to fill a bag with 50kg, because it simply takes more time until the product is completely filled into the bag • Do you have already specific plans for a new product or bag which needs also to be handled with the new bagging system?

Following the trends

STATEC BINDER has customers all over the world in various industries. This allows it to keep an eye on different trends. So during a meeting with one of its experts, they will let you know which trends have been spotted and ask if they are also affecting your business plans.

This is not only important for customers but even more important for STATEC BINDER as machine manufacturer in order to be able to supply the best and of course the right solutions for our customers.

Manual to automatic

STATEC BINDER has supported a huge number of customers moving from manual or semi-automatic bagging to fully automatic bagging lines.

That is the reason why its product portfolio includes several open-mouth and FFS bagging machines for low, middle and high capacity requirements.

For powdery products the Austrian machine manufacturer developed the CIRCUPAC, a high-performance bagging carousel.

This packaging machine is the ideal solution for bagging up to 1200 bags per hour with high accuracy.

The extended filling time through six filling spouts and the continuous compaction of the product in the bag by special vibration plates result in a compactly filled bag.

This machine was developed due to demands on the market and for example has increased the output of a flour producer in SoutheastAsia significantly, who was automising the bagging lines.

Moreover, the palletising systems are the perfect complement to the bagging systems. For example, the PRINCIPAL-R, a robot palletising systems, can palletise up to 1400 bags or boxes per

hour and has low space requirements, which are the reasons why it is highly demanded for automation the palletising process since a high-level palletiser, for example, needs more space.

Flexible and customised solutions are the strength of STATEC BINDER. For more than 40 years it has been supporting customers in bagging and palletising tasks and this experience helps it today to provide better solutions for customers.

After the commissioning of a project the company’s customer service supports requests starting from spare part order to service visits and training for operators and maintenance teams as well as remote access service, imitate support should you face any problem and consultancy for adjustments of machines.

Milling and Grain - January 2021 | 113

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Industry Profile

Henry Simon

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Henry Simon Mustard Mill Project - Iconic brands come together

he iconic UK brand Colman’s Mustard, which has been produced in Norfolk for over 200 years, is one of the most recognised and respected food brands in the world.

So it is with great pride that Henry Simon announces the successful completion of a new state-of-the-art mustard mill for the company in Norfolk, UK. The new mustard mill, built on a site at Honingham in the east English county, is a collaborative partnership between Condimentum, Unilever and English Mustard Growers (EMG), with EMG being a UK farmer’s collective that supplies the mill with all its homegrown mustard seed requirements from local growing areas.

Established in 1878, Henry Simon Ltd, a British company, which went on to become a world leader in the flour milling sector, completes the new mustard mill. After building numerous projects across the globe for over 140 years, the company today continues to develop new technologies for the milling industry, such as those for its flour and rice milling customers which we are very familiar with.

‘The mill was built following the decision to close the original Henry Simon-built Colman’s Mustard mill in Norwich and invest in a new site.

The new mill produces mustard flour and other specialty products that are packed on site or processed in other facilities to produce mustard paste 116 | January 2021 - Milling and Grain

and a tin packing facility for its very popular dry mustard flour, frequently seen on UK supermarket shelves and for export around the world,” says Condimentum’s Managing Director David Martin.

“The decision to use Henry Simon, to provide milling expertise and equipment, continues a tradition of partnership with the Colman`s brand dating back many years.”

HSRM Roller Mills

The solution from Henry Simon provides a turnkey package for the design and installation of the mustard mill; from seed cleaning and preparation, milling and blending, right through to small and large bag packing.

Also included is the provision of all seed and flour storage bins, mechanical installation, electrical installation and control system with Supervisory Control and Data Acquisition (SCADA) capability.

Henry Simon milling equipment includes the HSREZS Colour Sorter, the HSRM - one of the most modern roller mills in the world, the HSQP Plansifter and the HSPU Purifier.

Collectively the equipment provides the means of production of high-quality finished products in a state of the art manufacturing environment.

The UK-based Satake Europe Manchester is responsible for the entire Henry Simon milling project’s design and project management. www.henrysimonmilling.com www.satake-europe.com

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F CASE STUDY

CASE STUDY

W Yihai Kerry

A grain facility with the largest paddy silos in Asia

ith its ideal location in the capital of Jiangxi Province - the third largest ‘rice-bowl’ in China with over 3.5 million hectares occupied by paddy fields Yihai Kerry (Nanchang) Oils, Grains Foodstuffs Co Ltd, is operating an integrated rice business that encompasses the entire rice value chain - from cultivation, processing, merchandising, right through to the manufacturing of consumer food.

By taking full advantage of their location, the company has easy access to the quality paddy produced by the rice farmers from around the province.

This enables the company to support its rice milling and further processing business in its large-scale industrial production base, that opened in Nachang at the end of 2009. The base, designed with an annual capacity of 200,000 tonnes of milled rice, needs to source and handle about 350,000 tonnes of paddy every year.

In order to make the most out of its scale, that is to fully integrate and maximise the logistical advantages of is own business model, as well as extracting profit margins at every step of the value chain, Yihai Kerry (Nanchang) is always looking to expand its capabilities.

The company is also looking to improve both its operational synergy and cost efficiency, in line with the business strategy of its ultimate parent company, Wilmar International. To this end, the company also added a grain facility with 80,000 tonnes of paddy storage capacity in 2019.

Wilmar and Yihai Kerry

Headquartered in Singapore, Wilmar International Limited (‘Wilmar’ or the ‘Group’) is Asia’s leading agribusiness group and one of the largest listed firms by market capitalisation on the Singapore Exchange (SGX).

Wilmar’s vast business portfolio includes oil palm cultivation, oilseed crushing, edible oils refining, sugar milling and refining, manufacturing of consumer products, specialty fats, oleochemicals, biodiesel and fertilisers as well as flour and rice milling.

It has over 500 manufacturing plants and an extensive distribution network covering China, India, Indonesia and some 50 other countries and regions. The Group has a multinational workforce of about 90.000 people.

Yihai Kerry is a subsidiary of Wilmar incorporated in Mainland China, and has about 30,000 employees, more than 70 118 | January 2021 - Milling and Grain

production bases in total in 26 provinces, autonomous regions and municipalities and over 100 production enterprises.

Its core entity, Yihai Kerry Arawana Holdings Co Ltd, reported a growth at about five percent annually in the past three years and contributed to more than half of the Group’s revenue in 2019.

Yihai Kerry today is the largest edible oils refiner and specialty fats and oleochemicals manufacturer, as well as being a leading oilseed crusher, producer of branded consumer pack oils, rice and flour and one of the largest flour and rice millers in China.

Hygienic silos for food safety and security

On the subject of rice, this particular grain is the main staple food for China’s population of 1.4 billion people by some margin.

In fact, rice accounts for about 50 percent of the total cereal food use in Chinese diet.

Though producing about 147 million tons of rice every year, which accounts for about 28 percent of the world’s rice, the country still has to import a considerable amount in order to build a food security system with sufficient stock.

Reducing losses and waste along the rice value chain and using the valuable resources efficiently has therefore become the most pressing concern in China.

As a key agribusiness player in China, Wilmar International is always aiming to improve local food security whilst finding opportunities for development, through its China subsidiary Yihai Kerry.

For example, Wilmar entrusted Famsun to build the largest paddy silo facility with the aim of gaining a competitive edge in terms of quality, cost, service and innovation. The two parties have now collaborated on over 10 silo projects around the world with a total storage capacity of over 700,000 cubic tonnes.

The project has 16 spiral steel silos with storage capacity of 5000 tonnes each. The solution that Famsun delivered also included intake, loading, conveying, pre-cleaning, fumigation and automation solutions. The paddy storage and handling facility was built with a special focus on hygienic designed and food safety.

The silos are all an airtight and spiral shaped design that is modeled specifically for use with paddy. Built to a specification of 22 metres (φ) × 23 metres (height), making this the largest paddy silo in all of Asia. The fully enclosed design also facilitates ease of both fumigation and heat preservation operations.

In Famsun’s airtight spiral silos, the fumigation gas has a halflife longer than 55 seconds when decreasing the air pressure of silos from 500Pa to 250Pa, which is far longer than the industry standard of 40 seconds. This is a very important function as fumigation plays an important role in both pest elimination and sterilisation in stored products. The high-spec airtight design also contributes to a much improved fumigation performance, better product quality, reduced losses and prolonged shelf life.

By insulating with polyurethane, the extent to which the temperature varies inside the silo does not reflect he variation of temperatures outside, thus avoiding the problem of grain condensation due to sharp temperature change. This in turn enhances the quality stability and safety of the grain. Polyurethane boasts a reputation for offering great insulation, as well as being environmentally friendly and easy to install.

CASE STUDY F

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Milling and Grain - January 2021 | 119

2020 IN RETROSPECT

by John Buckley A special report by Milling and Grain’s Commodities Editor John Buckley on the impact COVID-19 and other key factors have exacted on the supply of raw materials for the milling industries over the past 12 months and what we might lie ahead for our industries over the coming months

A year of rising costs Crop shortfalls combined with moderate consumption growth to boost raw material costs for the grain and feed sector in 2020. For many commodities, prices exceeded levels most observers could have expected at the start of the year, especially wheat which, on paper at least, was in another year of record surplus.

That traditional unpredictable, weather, played its part, turning out smaller than expected maize and soya crops in the USA, soya in Argentina and wheat in Europe and Ukraine. But it also gave some compensation - larger than average (for the second year running) Latin American maize and (Brazil at least) soya crops alongside bigger Russian, Canadian and, more recently, Australian wheat output.

On the demand side, covid-19 did no harm to wheat or soya consumption. Consumers needed bread and storable cereal products more than ever while livestock herds, expanding in a number of countries, still had to be fed. However, the pandemic’s drastic curbs on transport did have a big impact on corn, over 40% of which (usually well over 120m tonnes) normally goes to ethanol fuel in the key producer/consumer country, the USA (which has so far shed about 18m of that). But even then, the world still consumed more corn than it produced for a fifth year running, eroding stocks to multi-year lows and, amid a second disappointing US crop in a row, helped fuel a jump in prices to their firmest since mid-2019.

Despite that the late summer/autumn headlines were still grabbed by wheat and soya, prices of which recently reached their highest since 2016 and 2014 respectively.

Wheat’s strength, amid large ‘surplus’ stocks can be partly explained by half of these being held in China - ‘off-market’ and assumed of lower than market quality – for food use at least. Even accounting for that, supplies were hardly tight – why prices have recently receded from their autumn peaks – if leaving the impression that this market might have been undervalued in recent years.

While the US soya crop fell short of target, this commodity’s phenomenal rise in value – from a four-year low in April to a six-year high in November - was more a reflection of demand. Top of the list was the ‘phase 1’ trade accord signed at the turn of the year between the US and China allowed the former to reclaim exports lost during the early Trump years of trade confrontation with the number one soya customer.

As a result, US soybean stocks, earlier expected to finish this season over 11m tones, are now expected to drop well below 5m – a wafer thin security cushion against any weather problems in Latin America over coming months or in the US itself from spring onward. Just two seasons back, the US had been worried about a potential 30 million tonnes surplus causing End 2019 CBOT wheat/bu EU Milling Futures/t CBOT Maize/bu CBOT Soy/bu *Lowest since August 2016

120 | January 2021 - Milling and Grain

2020 High

2020 Low

Latest

Futures

Dec 2021

US$5.59

Oct 6.38¼

Jun 4.68¼

6.19¼

6.04½

€208

Dec 211¼

Sep 158

205¾

188

US$387¼

Nov 430½

Apr 301*

420¼

410¼

US$943

Nov 12.00

Apr 808¼

11.52¼

10.53¼

source, producing record large crops and sitting on its biggesta soya price crash! With rapeseed and sunflower seed crops also ever stockpile. underperforming, soya, as the dominant meal source has lent Currently December 2021 CBOT soft wheat futures suggest strength to prices across the protein sector. prices not far from those seen recently while Paris milling wheat Is the worst over? futures – assuming EU crop recovery, point to an 11 percent Factors developing at the close of 2020 suggest prices may stay decline from current levels. relatively firm into 2021 or are, at least, unlikely to retreat fully.

On the supply side, wheat is pricing in weather risk to the Maize coming year’s winter wheat crops in Russia and the US – the two Maize is also taking support from weather risk, mainly in Latin largest exporters. Some Russian analysts think 20 percent of their America where the La Nina system threatens to renew and/or crop has already been lost to drought at planting time. extend droughts already seen in both Brazil and Argentina. But The US also has drought over a large area as we go to press and if they do get the currently forecast crops, their supply should be continues to sow smaller than normal acreages. Ukraine’s current outlook is not much better. On the plus side are this season’s large Australian and Canadian crops, harvested later than in Europe, the FSU and the US, so still to fully work through the market.

While it produced more than expected in 2020, Russia may soon curb export sales or slap a levy on them, if 2021 output looks like falling very short of target as the government struggles already with food price inflation. Yet the US has a good supply including a still large carryover stock. If the dollar continues to weaken as some expect* it could help fill any Russian gaps in first half 2021. In fact, US export sales are already up by 13% on the year against an USDA prediction of a mere two percent gain.

However, more spring wheat – especially higher quality hard wheat, will need to be sown in the US, Canada and Russia to compensate for the winter crop … because that’s what we do, too. On every single shortcomings. Europe meanwhile FILIP cleaner, we monitor every detail throughout the expects a bigger winter wheat entire manufacturing process. We know that our crop in 2021 on larger planted proven quality will guarantee effective sieve cleaning acreage, assuming weather within your plansifters. And that, in turn, will ensure improves after an unlucky 2020 a high yield from your passages. with too much and too little rain at times.

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adequate through first half 2021.

Attention then turns to US planting weather and acreage plans.

Soya has recently offered better returns than maize and could grab the lion’s share of any extra acres going. But the US needs to expand planting too, to avoid its stocks going even lower, especially if domestic feed and ethanol use re-inflates as forecast.

Ethanol’s outlook depends on how quickly a Covid vaccine can get life back to normal – economic activity and transport fuel consumption. One of the salutary charts of 2020 was the crude oil price - from almost US$69/barrel in January to just over US$19 in April and, despite recently heading back towards US$50, still down by over a quarter on the year.

Import demand for maize could stir the market, particularly China’s, expected to double this season to at least 16.5 million – some say as much as 30 million tonnes after domestic crop shortfalls. Three or four years ago, it imported just 2.5 million tonnes. The US will be a key supplier and into the New Year, Latin America too.

Traders will also be watching crop performance in Ukraine, which could sow more – and the recent top corn importer, Europe (around 20m tones last year) where production is not seen growing much in 2021.

Weighing up these and other factors, forward futures suggest a fairly relaxed market that has factored in the smaller supply at prices no higher than a year hence than they are now.

Soybeans US/global soybean stocks are looking precariously tight at end 2020/21. A record large Brazilian crop – still possible could help but the US is getting well sold, exposing the market to potential price strength in first quarter 2021 unless China cancels some US purchases and switches back to Brazil. Amid tight stocks and strong price signals, US farmers seem certain to sow a far bigger soya area in the coming spring but they’ll need cooperative weather. The size of that crop may be the key factor determining soya meal prices through to 2022. Among other oilseeds, Canada might sow more spring rapeseed but the EU – while possibly on course for minor crop recovery in 2021 (+1 million tonnes?) if weather cooperates. Ukraine’s dry winter sowing may also reduce this major exporter’s contribution, raising the onus on Australian supplies. Spring-sown sunflowerseed crops need to increase in Russia, Ukraine and Europe. It should be emphasized that soya has carried most of the burden of rising global oilmeal consumption in recent years. So whatever happens with other oilseeds, meal costs across will be dominated by soybean crop fortunes.

Markets will also be keeping an eye on the speculative community’s attitude towards food commodity markets as inflation talk smolders in the wake of various countries’ vast Covid rescue spending sprees – a potentially big grey area for future price prediction.

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INDUSTRY EVENTS 2021

January The Online Milling School www.onlinemillingschool.com

Learn more – Learn onsite

Enroll in the 12-week Winter Course 25-29 IPPE 2021 Online only www.ippexpo.org The International Production & Processing Expo (IPPE) has announced that IPPE Marketplace will take place at the end of this month, January 2021. IPPE will continue to support the poultry, egg, meat and feed industries through its new, online IPPE Marketplace that will be available during IPPE’s originally scheduled dates, January 25-29, 2021 - and beyond.

Through the IPPE Marketplace, more than 1000 exhibitors will be connected with IPPE’s worldwide audience of 30,000 invited participants. The participants will be able to search for exhibitors using product categories and keywords and then review the descriptions and links provided by each matching exhibitor.

Through digital personal guides, participants will be able to review all exhibitors and select those matching their individual needs.

The IPPE Marketplace will host live and on-demand, free and paid education programs during the week. These programs will include the International Poultry Scientific Forum, Pet Food Conference, Latin American Poultry Summit, Market Intelligence Forum, International Rendering Symposium, Feed Education Program and more.

Young leadership engagement and student recruitment will also be offered through ‘IPPE’s Linked In With Tomorrow’s Leaders’ program and the USPoultry College Student Career Program, where hundreds of students will have an opportunity to interview for jobs and internships within the poultry and egg industry.

To round out the IPPE Marketplace, on-demand TECHTalks and the opportunity to view innovative products through the Innovation Station / New Product Showcase will be available. Participants will also have access to view the industry trade publications that are typically offered during the Expo through IPPE’s website and the IPPE Marketplace.

“While we are disappointed that we will not be hosting an in-person event in 2021, we heard very clearly from our IPPE community of attendees and exhibitors that they still want to connect.

“More information about the exciting things you can expect during IPPE Marketplace week will be coming soon,” said IPPE show management.

27-28 Paris Grain Day 2021 Online only www.parisgrainday.com 2021

February 9-12 Eurotier 2021 Online www.eurotier.com 23-25 GEAPS Exchange Virtual Conference Online www.geapsexchange.com/online/ 25-3 Interpack 2021 Düsseldorf, Germany www.interpack.com

☑ = Meet the Milling and Grain team at this event 124 | January 2021 - Milling and Grain

2021

March

2021

9-11 AFIA Purchasing and Ingredient Suppliers Conference 2021 Orlando, Florida, USA www.afia.org 10-11 The Aquafeed Extrusion Conference Online mymag.info/e/989

April 11-13 PIX AMC Gold Coast, Australia www.pixamc.com.au

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.

The conference will provide a comprehensive programme with the latest in innovation and information, featuring knowledgeable industry experts from both Australia and overseas. The programme 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.

26-30 Agrishow Brazil Ribeirão Preto, Brazil www.agrishow.com.br 2021

10-13 IAOM Eurasia 2021 İstanbul, Turkey www.iaom-eurasia.info

5-7 FIGAP 2021 Guadalajara, Mexico www.figap.com

10-12 VIV Asia 2021 Bangkok, Thailand www.vivasia.nl POSTPONED UNTIL 22-24 SEPTEMBER 2021

6-7 3rd Agrifood International Congress Online www.agrifoodporttarragona.com

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 all have numerous reasons to meet once more in Bangkok and be part of the premium show in the heart of Asia.

At VIV Asia 2021, 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.

18-20 Ildex Vietnam 2020 Ho Chi Minh City, Vietnam https://www.ildex-vietnam.com

29-31 16th ICC Cereal and Bread Congress Christchurch, New Zealand www.icbc2020.icc.or.at The 16th ICBC Conference will be held in Christchurch, New Zealand on January 6-8, 2021 and is continuing the established ICC event series. The conference will feature plenary sessions and concurrent sessions embracing the challenges and opportunities facing the cereal science community. Themes for the conference include cereal nutrition for health-conscious consumers, food safety and security, sustainable agricultural technology systems, milling and bread making technology and much more.

☑

19-21 Rice Market and Technology Convention 2021 Panama www.ricemtconvention.com 26-28 Livestock Philippines 2021 Pasay City, Philippines www.livestockphilippines.com

10-13 Mill Tech Istanbul 2021 Istanbul, Turkey www.milltechistanbul.com 18-20 IDMA and VICTAM EMEA 2021 Istanbul, Turkey www.idmavictam.com POSTPONED UNTIL 27-29 MAY 2021

May

27-29 Agritechnica Asia 2021 Bangkok, Thailand www.agritechnica-asia.com 2021

June 9-10 Cereals 2021 Lincolnshire, UK www.cerealsevent.co.uk 10-12 VIV Turkey 2021 Istanbul, Turkey www.vivturkey.com 16-17 Solids Dortmund 2020 Dortmund, Germany www.easyfairs.com Postponed from 24-25 June to 17-18 March

TAKE YOUR PLACE IN POWER UNION

YOU

27-29 MAY 2021

Istanbul Expo Center, Hall 5-6-7 Yesilkรถy - Istanbul / Turkey

9th INTERNATIONAL

Flour, Feed, Corn, Semolina, Rice, Bulghur Milling Machinery & Pulses, Pasta, Biscuit Technologies Exhibiion

www.idmavictam.com

9th Internaaonal Flour, Feed, Corn, Semolina, Rice, Bulghur Milling

Machinery and Pulses, Pasta, Biscuit Technologies Exhibiion

THE BUSINESS NETWORK LINKING PROFESSIONALS FROM FEED TO FOOD

MOSCOW UTRECHT QINGDAO ISTANBUL ABU DHABI MUMBAI BANGKOK NAIROBI KIGALI

HO CHI MINH JAKARTA

*NEW DATES MEAT & POULTRY INDUSTRY RUSSIA 2021 MOSCOW | MAY 25-27

VIV ASIA 2021* BANGKOK | SEPTEMBER 22-24

VIV TURKEY 2021 ISTANBUL | JUNE 10-12

VIV MEA 2021 ABU DHABI | NOVEMBER 22-24

ILDEX VIETNAM 2021* VIETNAM | JULY 21-23

ILDEX INDONESIA 2021*

POULTRY AFRICA 2021 KIGALI | SEPTEMBER 1-2 VIV QINGDAO 2021 QINGDAO | SEPTEMBER 15-17 MEAT PRO ASIA 2021* BANGKOK | SEPTEMBER 22-24

JAKARTA | NOVEMBER 24-26 VICTAM AND ANIMAL HEALTH AND NUTRITION ASIA 2022 BANGKOK | JANUARY 18-20 VIV EUROPE 2022 UTRECHT | MAY 31-2 JUNE

Organized by

INDUSTRY EVENTS Agri-Tech Expo 2020 brings together the Asia agricultural community The 4th edition of Asia Agri-Tech Expo & Forum, Taiwan’s ‘theone-and-only’ international agricultural trade event, concluded its three-day ran from November 5-7, 2020 at the Taipei Nangang Exhibition Centre Hall 1, held concurrently with Livestock Taiwan Expo & Forum and Aquaculture Taiwan Expo & Forum.

Once again, the show reaffirmed its role as one of the Asia’s most important gateway to the Asia agricultural market, attracted 155 exhibitors for in-person exhibition and 8,382 professional visitors from over 18 countries and regions.

Due to travel restrictions, Asia Agri-Tech launched its first online exhibition which was held concurrently with the in-person exhibition. The online exhibition hosted 128 exhibitors from nine countries and regions who were presented their innovative products and services online, this attracted 970 professional visitors from 38 countries and regions. The organisers commented, “the online exhibition has proved the success of the ‘online and offline’ formula by offering brand-new updates, avant-garde industrial solutions and innovative contents to revitalise agricultural industry under this tough period.

The event saw 27 professional conferences and seminars featuring smart agriculture, biosecurity, animal health and circular economy, attracting an audience of more than 1,200

people. A joint international forum, The Practice and Benefits of Circular Agriculture in Waste Reducing and Recycling, organised

by The Asia Pacific Food and Fertiliser Technology Center (FFTC) together with Livestock Research Institute (TLRI) and co-organised by Informa Markets Asia Ltd., Taiwan Branch, attracted more than 300 people both online and offline.

Ms Sabine Liu, the General Manager of Informa Markets Taiwan Branch stated, “Asia Agri-Tech Expo is the only one hybrid trade show after pandemic outbreak for the whole Asian agricultural market, quantity and quality of visitor exceeded industry and exhibitors’ expectation. Taiwan was removed from the foot and mouth disease list last year, so the Taiwan government decided to invest US$333 million to revitalise its pig industry, which also attracted industry leading brands, such as Cargill, Skiold, Bühler, Korea Feed Ingredient Association, Taiwan Fertiliser, Tatung, US Soybean Export Council, EVERLIGHT etc. get together to present their innovative products.”

The 5th edition of Asia Agri-Tech Expo & Forum is planned to take place at Taipei Nangang Exhibition Center, Hall 1 from 1113 November, 2021. According to Informa Markets in Taiwan, at the close of the 2020 trade show, more than 1200n square metres were booked by exhibitors for 2021 Edition.

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Scan the QRCode for more information

Henry Simon +44 0161 804 2800 www.henrysimonmilling.com Lambton Conveyor +1 519 627 8228 www.lambtonconveyor.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

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

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

FrigorTec GmbH +49 7520 91482-0 www.frigortec.com

FAMSUN +86 85828888 www.famsungroup.com Soon Strong Machinery +886 3 9901815 www.soonstrong.com.tw

Bentall Rowlands +44 1724 282828 www.bentallrowlands.com

Sukup +1 641 892 4222 www.sukup.com

Chief +1 308 237 3186 agri.chiefind.com

Wenger Manufacturing +1 785-284-2133 www.wenger.com

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

Yemmak +90 266 7338363 www.yemmak.com

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

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

Colour sorters

ERKAYA +90 312 395 2986 www.erkayagida.com.tr JEFO +1 450 799 2000 www.jefo.com Mühlenchemie GmbH & Co KG +49 4102 202 001 www.muehlenchemie.com

Consergra s.l +34 938 772207 www.consergra.com

Grain technik +91 114608 9500 https://graintechnik.com

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

Enzymes

Chief +1 308 237 3186 agri.chiefind.com

Mühlenchemie GmbH & Co KG +49 4102 202 001 www.muehlenchemie.com

Bulk storage

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

Coolers & driers

Geelen Counterflow +31 475 592315 www.geelencounterflow.com

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

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

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

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

Bearings

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

Elevator & conveyor components

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

4B Braime +44 113 246 1800 www.go4b.com

Cimbria Srl +39 0542 361423 www.cimbria.com

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

Flour Improvers Mühlenchemie GmbH & Co KG +49 4102 202 001 www.muehlenchemie.com

Grain handling systems Bühler AG +41 71 955 11 11 www.buhlergroup.com Chief +1 308 237 3186 agri.chiefind.com

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

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

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

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

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

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

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

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

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

IMAS - Milleral +90 332 2390141 www.milleral.com

Viteral +90 332 2390 141 www.viteral.com.tr

Ocrim +39 0372 4011 www.ocrim.com

Van Aarsen International +31 475 579 444 www.aarsen.com

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

Wynveen +31 26 47 90 699 www.wynveen.com

Sangati Berga +85 4008 5000 www.sangatiberga.com.br

Yemmak +90 266 7338363 www.yemmak.com

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

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

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

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

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

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

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

Perten Instruments +46 8 505 80 900 www.perten.com

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

Tekpro +44 1692 403403 www.tekpro.com

Hydronix +44 1483 468900 www.hydronix.com

Loading/un-loading equipment

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

Cimbria A/S +45 96 17 90 00 www.cimbria.com

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

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

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

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

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

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

Biomin +43 2782 8030 www.biomin.net

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

Neuero Industrietechnik +49 5422 95030 www.neuero.de

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

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

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

Hammermills

Mill design & installation

Mycotoxin management

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

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

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

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

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

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

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

131 | January 2021 - Milling and Grain

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

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

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

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

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

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

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

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

Gazel +90 364 2549630 www.gazelmakina.com

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

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

IMAS - Milleral +90 332 2390141 www.milleral.com

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

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

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

Milltech Tel: +90 332 502 13 00 www.milltech.com.tr

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

Ocrim +39 0372 4011 www.ocrim.com

Yemmak +90 266 7338363 www.yemmak.com

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

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

Pingle +86 311 88268111 www.plflourmill.com

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

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

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

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

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

132 | January 2021 - Milling and Grain

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

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

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

Yemmak +90 266 7338363 www.yemmak.com

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

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

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

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

Sifters

Roller mills

Palletisers

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

NorthWind +1 785 284 0080 www.northwindts.com

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

Yemmak +90 266 7338363 www.yemmak.com Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Scalling

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

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

Reclaim system Vibrafloor +33 3 85 44 06 78 www.vibrafloor.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 Lambton Conveyor +1 519 627 8228 www.lambtonconveyor.com MYSILO +90 382 266 2245 www.mysilo.com Obial +90 382 2662120 www.obial.com.tr Silo Construction & Engineering +32 51723128 www.sce.be Silos Cordoba +34 957 325 165 www.siloscordoba.com Soon Strong Machinery +886 3 9901815 www.soonstrong.com.tw 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 Bühler 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 50,000 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:

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

Tuti Tan tutit@internationalmilling.com Mehmet Ugur Gürkaynak mehmetg@perendale.com

Member news Bühler are re-certified with the latest ISO 9001:2015 international quality standard for their optical sorting solutions Evonik launch their own product for enhancing energy metabolism in livestock, called GuanAMINO® Myande recently signed a contract with the Youth Development Foundation to fund the establishment of Myande Hope Primary School, to continue their goal of providing an education, bursaries and scholarships to children throughout China Yenar present at the twelfth and final Online Milling School presentation, concerning Design and Construction

The International Milling Directory is free to join if you are a supplier company.

List your company, products and services today!

If you would like to order a print copy of the Directory, please visit our website at:

internationalmilling.com

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

internationalmilling.com

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 - January 2021 | 133

Donâ&#x20AC;&#x2122;t let COVID-19 keep your company in the dark

Let Milling and Grain shine a light on your business

Donâ&#x20AC;&#x2122;t let travel and exhibition curtailment keep your business in the dark

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

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Milling and Grain - January 2021 | 135

the interview

Prof. Wang Weiguo, Henan University of Technology

Milling and Grain had the opportunity to interview the head of China’s technical committee who is leading its proposal to have all feed manufacturing equipment compliant under a new ISO/TC293 standard.

Professor Weiguo Wang, who graduated in 1977 from Zhengzhou Grain College, Henan Province, majored in grain processing before teaching at Zhengzhou Grain College (now, the Zhengzhou University of Technology). He achieved his Masters’ Degree in Grain, Oil and Plant Protein Engineering in 2001 from Jiangnan University, became associate professor in 1992 and professor in 2000 in feed science and technology. He was also head of the Department of Grain Engineering from 1997-98 and chairman of the Bio-engineering College from 1999-2007.

Today, Prof Wang is the chairman of feed branch of the Chinese Cereal and Oil Association, a member of National Feed Evaluation Committee of China and a member of the Standardisation Technical Committee of Feed Machinery of China and is the convenor of ISO/ TC293/WG1. He has published 160 papers on feed science and technology and has received three first prizes in science and technology on both provincial and ministerial level What brought you into this industry?

Actually, it is the requirement for opening the new course of feed processing technology and equipment in our university that brought me into the feed industry in 1979. 1978 is the first year of China’s reform and opening and also the starting year of Chinese feed industry.

In that year, developing the feed industry became the policy of Chinese government to promote the development of animal feeding and to change the native shortage of meat, egg and milk. So, training talents in feed processing technology for the feed industry became an urgent task. At the beginning of 1980, I was asked to change my teaching course of flour milling to feed processing technology as my English and Japanese were good. I am the ‘witness’ of the development of Chinese feed industry over the past 40 years. China became the top feed producing country in 2011 and has maintained the position of the largest feed producer in the world until now.

What are your proudest achievements during your time at university?

As the leader of feed specialty of our University, I promoted and set up the feed engineering specialty of junior college in 1987, the animal nutrition and feed processing specialty of bachelor’ degree in 1995 and animal nutrition and feed science specialty of masters’ degree in 2003.

All these specialties have engineering basis, that are different from the animal science specialties with pure agricultural basis in most other agricultural universities in China. So our graduated students can be engaged in the job both in feed engineering and feed science. Now our university can educate doctor degree students in feed science and technology.

More than 2500 students of feed specialty graduated from our university, they have played important roles in feedmill design and construction, feed production management, feed product development and feed quality control in native and foreign feed companies, feed machinery companies and some of them work in universities and research institutes. The second proudest achievement is that I have served the Chinese feed industry for 40 years ,especially in feed processing technology.

What major challenges do you foresee for the feed industry over the next five years?

Major challenges are feed safety, feed resource stability of supply, feed efficiency enhancement, energy saving and science and technology innovation ability.

For feed safety there are some new issues that need to be deal with. For example, biosecurity issues, such as ASF, some pathogenic bacteria, new found allergens etc.

136 | January 2021 - Milling and Grain

As the world’s population continues to grow feed production will need to increase to 1.5 billion tonnes by 2050. How to supply enough protein resources and other ingredients to the feed industry will be the greatest challenge. Enhancing the feed utilisation rate can both reduce the feed resources needed and reduce the impact on the environment, but this needs key scientific and technology innovations in developing new protein resources and other feed resources.

The precise nutrition and accurate processing technologies of feed products can also make important contributions to this issue. Energy saving is always the cost effective aim of all feedmillers and the aim of green development to reduce carbon emissions. The science and technology innovation ability is a complex issue related to long-term investment from nations, provinces, enterprises etc long-term focusing on the key basic and application technology, research issues and good talent training and management system.

What are the developing trends of feed industry in China in the future?

Antibiotics used as growth promoter (AGP) were officially banned from July 2020 in China. The AGP replacing technologies become the hottest topics now across China.

Some abstracts and their prescriptions from the Chinese herbs have shown positive results in animal feeding practice, more are in research.

The comprehensive measures including nutrition profile improvement, feed ingredient and product sanitary control, developing and optimised application technologies of potential non-AGP feed additives and novel feed processing technologies are in development.

China is the largest soybean meal consumer and importer for compound feed production now and future, so increasing native soybean production, developing new and quality protein sources to improve protein supply and developing innovative technologies to enhance feed protein utilisation markedly will be a very important developing trend.

Novel feed processing technology trends will mainly focus on the new physical processing technologies and novel bio-processing technologies. The first includes new cleaning, special grinding, thermal conditioning, extruding and drying technologies etc which can improve energy efficiency, nutrient availability, product quality, product safety, reduce processing cost, increase feed profit.

The second refers to the novel specific fermentation technologies for different raw materials and feed products, which can reduce anti-nutritional factors, pre-digest the materials, improve the nutritional profile and flavors, produce some functional components etc.

Quick and on-line testing technologies for feed raw materials, feed additive, product in progress and finished product are very important for instant and precise feed

quality control and decision making. NIR and other new non-destructive testing technologies will play a more important role in the future.

The standard for the pathogenic bacteria in feed materials and feed product will be increased like in human foods.

The biosecurity system for feedmills will be strengthened, such as the prevention measures for ASF and other pathogenic bacteria, virus.

How do you see sustainability evolving in the feed industry?

The sustainability of feed industry is one part of the whole of societyâ&#x20AC;&#x2122;s sustainability globally. So each part should take its responsibility in order to reach the goal for sustainability for the whole society. For the feed industry we should develop ecological feeds. I proposed the concept of ecological feeds in 2001 in my paper â&#x20AC;&#x2DC;Ecological feed and its manufacturing technologyâ&#x20AC;&#x2122; (Feed Industry, 2001,22(3)).

Ecological feed refers to the feed product which has the best nutrient utilisation and animal performance, with the best safety to the feeding animals, operators and the environment, can promote the ecological harmony.

Sustainability involves many sub-issues such as energy saving, feed efficiency enhancing, feed safety, production safety, environment protection, professional health, animal welfare, etc. we can expect big progress on this issue in the future.

Focusing on feed industry, how do you see feed equipment developing over the next decade?

Feed equipment in the past has greatly promoted the progress of feed industry processing technology, product quality and cost, production efficiency and safety, as well as maintaining the competitive advantage of feed mills. I believe that feed equipment technologies will be progressed along the following aspects: higher energy efficiency equipment, safer equipment technologies, intelligent control technologies of feed processing machines and whole production line, unmanned feed production lines, new automatic solid fermenting equipment.

How to cultivate and strengthen skilled employees for the feed industry?

Cultivating talent is one of the most important issues for the feed industry. From universities the feed industry needs mainly graduates from animal science and nutrition specialties, feed technology and engineering specialties and other related specialties such as quality test and control, marketing management etc for ordinary operations and management.

For feed technology research and development or innovation, masters or doctor degree students are needed.

The most sought after talents are those with the knowledge of feed engineering and processing technology, feed science and management.

As I know, only Kansas State University of USA has the specialty-feed science and management course. In China, now only two universities - Henan university of Technology and Wuhan Polytechnic University educate bachelor students with a feed engineering basis in animal science.

Now we are promoting the establishment of a feed engineering specialty in the catalogue of undergraduate major. For feed enterprises, talent training or cultivation also needs to be strengthened. That is the key work to keep an enterprise sustainable, with strong compatibility, confronting fierce market competition.

Milling and Grain - January 2021 | 137

PEOPLE THE INDUSTRY FACES Silo and grain expert joins Bühler Singapore

P

ablo A. Fernandez Moriana joins Bühler Singapore as the Head of Grain Storage for SEA and Oceania Region, a newly-created position that will lead the Grain Storage business.

Mr Fernandez will be responsible for driving business activities in the Grain Storage division including developing business plans and strategically executing cross business units in the SEA and Oceania.

His new role with Bühler Singapore will also see him interfacing and coordinating with the different entities including Bühler Belingries (Germany), Bühler Changzhou (China) and Bühler Uzwil (Switzerland). Mr Fernandez brings with him more than 10 years of experience in the Silo and Grain Storage industry. After taking a Bachelor’s Degree in Business and Administration, he also obtained a Global Executive MBA from EAE Business School in 2019.

His vast experience in the field of Silo and Grain industry combined with his strong technical and business knowledge will help Buhler to further develop its Grain Storage division.

EFFPA elects Valentina Massa as new President

T

he European Former Foodstuff Processors Association (EFFPA) General Assembly have announced the election of Valentina Massa as President of the EFFPA.

Massa is the Managing Director at DALMA Mangimi, the largest former foodstuff processor in Italy as well as a founding member of EFFPA. Ms Massa succeeds Paul Featherstone, who was EFFPA’s president since the foundation of the association in 2014.

Valentina Massa, President of the EFFPA said, “I am honoured with the trust and appreciation from the EFFPA members to lead the association in its ambition to produce safe and sustainable feed from former foodstuffs”.

“The former foodstuff processing sector is determined to show to policy makers and chain partners that we hold the key to compound feed production with lower climate emissions and food manufacturing with reduced food waste in line with the Farm to Fork Strategy. Our role in the circular food economy is essential to come to more sustainable livestock production”. -

Hamlet Protein Announces new additions to its US Commercial Team

H

amlet Protein, a global leader in the production of soy based protein ingredients, has announced a sales team expansion, with Chelcee Hindman joining the Findlay (Ohio) headquartered North American organisation.

In the past months, Hamlet Protein has invested in people and plant capacity as it aims to further grow its leading position in the North American market.

Ms Hindman grew up on a farm in central Iowa and graduated from Iowa State University.

She worked with several of the leading companies in the feed industry.

“Hamlet Protein is a reference in young animal nutrition and I am thankful for the opportunity to work with such a talented and ambitious team,” says Ms Hindman

“We believe that high quality young animal feed is the key to optimising productivity. We also believe that North America will maintain a dominant role in the global animal protein space. We are well positioned to further grow in swine and developing the poultry market,” says Grady Fain, Regional Director NCA.

Hamlet Confirm further commercial team appointment

I

n addition to Chelcee Hindman, Lamar Rider is also joining Hamlet Protein’s American commercial team. Mr Rider graduated from the University of Alabama and has an extensive track record in the animal health and nutrition industry.

“The strong track record in piglet nutrition, coupled with a desire to develop the poultry market makes Hamlet Protein a very attractive company,” says Mr Rider.

“We are excited about strengthening the team through the hiring of Chelcee and Lamar.

Their experience in swine and poultry will help us in realising our growth ambitions and expanding our commercial team will help us spend more time with our customers,” concludes Grady Fain, Regional Director NCA.

138 | January 2021 - Milling and Grain

Arrius®.

A new era in milling.

With Arrius, Bühler has developed the heart of milling from scratch.

Every single component was newly conceived: the roller pack; the drive unit; the feeding module; the switch cabinet; the user interface.

Hence, Arrius is not an incremental improvement of a roller stand, but the first fully integrated plug & play grinding system – a step change towards autonomous flour milling.

Find out more about Arrius: buhlergroup.com/arrius

Innovations for a better world.