OCT 2021 | Milling and Grain magazine

October 2021

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In this issue:

- So you want to be a Miller?... So much to learn – you never stop growing

R E CENT P O LL , MIL

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LLE ER S OF U K F L OU R MI

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A I N WA S V O T E D # 1 M

- Oat drinks: The environmentally sustainable alternative to cows milk

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RUS

TED M

ILLIN G MAG A

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- The fibre revolution

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Milling and Grain . Volume 132 . Issue 10 . October 2021

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AN

- BACK TO THE FUTURE: Steeped in milling history yet remaining highly competitive

Volume 132 Issue 10

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VOLUME 132 ISSUE 10

October 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 Clarissa Garza de Yta Tel: +52 669 120 0140 clarissag@perendale.com Nigeria Marketing Team Nathan Nwosu Tel: +234 8132 478092 nathann@perendale.com Egyptian Marketing Team Mohamed Baromh Tel: +20 100 358 3839 mohamedb@perendale.com Turkey, Eurasia and Middle East Marketing Team Mehmet Ugur Gürkaynak Tel: +90 537 3646457 mehmetg@perendale.com Editorial Manager Peter Parker peterp@perendale.co.uk

48 - Steeped in milling history yet remaining highly competitive

Sub-editor Andrew Wilkinson andreww@perendale.co.uk Editorial Assistant Levana Hall levanah@perendale.co.uk

ISSUE HIGHLIGHTS

Caitlin Gittins caitling@perendale.co.uk

NEWS

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

FEATURES

42 So you want to be a Miller?... So much to learn – you never stop growing

48 BACK TO THE FUTURE: Steeped in milling history yet remaining highly competitive

FACES

8 10-31

58 Trends in the Korean rice industry

62 Algae in broiler, swine & ruminant diets 64 Oat drinks: The environmentally sustainable alternative to cows milk

114 People news from the global milling industry

PRODUCT FOCUS

36

CASE STUDY

98

66 Escalating UK flour prices: A sign of a broken post Brexit Britain or yet another Covid caused crisis?

74 Processed Animal Proteins: A relaxation of European feed ban in Europe looks set to open new markets

70 How insects & grain mills are improving sustainability 72 The fibre revolution

EVENTS

100 Event listings, reviews and previews

78 Waffle Flours STORAGE

88 South American shipping crisis

TRAINING

32 Industry training news

COLUMNS millingandgrain.com ISSN No: 2058-5101 ©Copyright 2019 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. More information can be found at www.perendale.com Perendale Publishers Ltd also publish ‘The International Milling Directory’ and ‘The Global Miller’ news service Grain & Feed Milling Technology magazine was rebranded to Milling and Grain in 2015

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

8 PUBLISHER Roger Gilbert

86 MARKETS Andrew Wilkinson

112 INTERVIEW David Wright

COVER IMAGE: BACK TO THE FUTURE: Steeped in milling history yet remaining highly competitive - see more on page 48

Dedication to food supply There is continuous demand for the construction of grain storage, flour and feed mills globally that the pandemic may have slowed but has not stopped. With a greater understanding of the Covid19’s mode of operation and the precautions we are adopting country-by-country and state-by-state, businesses are returning to some resemblance of normality. Events are being planned with more confidence and some are even being held and attracting a localised attendance.

Roger Gilbert

company with its 155-year family history in milling in the area has been built for the future, adopting the latest technologies, to protect the past and to carry the company forward in an extremely competitive marketplace.

With a concern that the average age profile of a worker within the milling industry is too high, our correspondent James Cooper looks at what it means to work in the milling and how younger people might enter and the job satisfactory they can achieve.

Training staff is essential to the success of each, and every milling operation and I’m pleased to report that both the Online Milling School for Feed Milling and Aqua Feed Production have started their autumn courses. It’s never too late to sign up so look for details in this edition.

An industry achievement

I’m thinking of the trouble Australians and New Zealanders are having in not being able to return home from each other’s countries and UK passport holders who have been banned from travelling from the UK to the USA - although I’m pleased to learn that this ban will be lifted next month after a year or more in place.

As I write this editorial, in late September, I can’t help but believe our industry has a strong collective voice that is being listened to. In our review of flour fortification earlier this year we highlighted the fact that the UK was one country resistant to the adoption of Folic Acid as a regulatory requirement. When our correspondent delved deeper in to the subject it was revealed that economics were playing a part in the decision to withhold Folic Acid fortification. Others have worked tirelessly over time to reverse this decision not to adopt and we believe our focus on this important issue earlier this year gave weight to an ongoing review being conducted into its important to the UK population.

But this time we are highlighting the delayed commissioning of the new 450-tonne-per-day flourmill commissioned by GR Wrights and Sons Limited in Harlow, north of London. This

We present a wide range of topics for millers and grain handlers in this edition. There is something for everyone and it’s always worth learning about what’s new and happening in the various milling-related sectors of our industries. Enjoy this edition!

However, international travel is still time consuming to organise, involves additional expenses and may even end in isolation if things turn around whilst we are away.

Despite these constraints, building work in our industry has continued and factories and facilities commissioned.

Congratulations to all those who are taking charge of new production and storage operations, in this issue we have been fortunate enough to visit one of the most advanced flour milling plants in the UK yet built (although this might be superseded with the commissioning this year of the Bühler E3 mill which we will feature in our pages next month).

I’m pleased, on behalf of all those who have supported the call for Folic Acid inclusion and have been involved in gaining approval for its inclusion in UK-produced flour to congratulate the industry and government for not only supporting the health of the unborn, but demonstrating to other countries - who have not yet adopted this form of fortification - to consider doing so at the earliest opportunity.

OAT DRINKS

BACK TO THE FUTURE

The environmentally sustainable alternative to cows milk.

Steeped in milling history yet remaining highly competitive

Oat drinks are now stronger within the category of plant-based milk alternatives than soy and almond drinks combined.

PAGE 64 SPECIAL FOCUS

Milling everywhere has history. But no more so than in the UK where family owned-companies can trace their lineages back over generations.

PAGE 48

FOOD

PROCESS

FEED

STORAGE

GUT HEALTH

South American shipping crisis

Assessing the effect of critically low river levels on trade in Argentina.

ALGAE IN BROILER, SWINE & RUMINANT DIETS

Using seaweed extracts to reduce antibiotic consumption in animals.

PAGE 88

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Milling

News

Welcome to the October edition of Milling and Grain magazine and to this, its respective Global Miller column.

Ms Valerie Schuster, the managing director of Livalta (which is part of the AB Agri company) in the UK, talks to Roger Gilbert of Milling and Grain magazine in the Rongorongo Live video studio about the production of ‘responsible proteins’ produced from locally sourced raw materials for the feed industry.

The company was set up by AB Agri Ltd just over a year ago with the goal of repurposing and adding value to protein sources that provide feed manufactures with functional protein-rich ingredients from more locally-sourced raw materials.

The company is aiming to produce a range of new proteinrich products that have better environmental footprints than some of the more traditional proteins being used. The goal is to produce products based on raw materials, such as algae and yeast, that improve animal health and allow livestock to reach their genetic potential.

The goal is to develop a range of products in areas best suited to adopting them in diets before turning to economiesof-scale and the transference of production processes to regions best suited to produce them and which are more able to supply a localised or regional demand, says Ms Schuster.

Controlling the whole process from raw material input through to the delivery of the finished product allows Livalta to support the claim of manufacturing protein ingredients in a responsible manner, in other words support its goal of supplying the industry with ‘responsible proteins.’ Visit our MAGTv page on our website to view the Rongorong Live video interview and learn more about this company’s ambitions for the feed sector globally.

See www.millingandgrain.com/rrl/ 10 | October 2021 - Milling and Grain

With harvesting either under way or as good as finished in the northern hemisphere, farmers throughout the world are beginning to count up their yields and beginning to establish whether all of their hard work has been worth it.

Whilst the farmers of the world have their noses buried deep in their accounting books, it seems that the Covid-19 virus's tentacles are still clenching and constricting themselves around industry events across the globe. In certain regions at least, organisers are once again finding themselves losing money, whilst their feelings that things will one day be better again are probably following suit.

If you are detecting a feeling of melancholy whilst you are reading this then your instincts are not failing you, as this column is being written shortly after the announcement - and quite rightly so - of the announcement that VICTAM Asia has been cancelled, which was of course the venue for the GRAPAS Award ceremony.

So, with all of our plans for returning to the drawing board be sure you keep an eye on our online and print publications for the latest news on this.

Staying on the subject of industry events, this time focussing on an event that has taken place, SPACE in France was a roaring success by all accounts - offering some semblance of hope that our lives may one day return to the pre 2020 kind of normality that we all remember, if only in the most vague of senses.

You know, back in the good old days when seeing a picture of more than 10 people in the same room didn’t make us all wince with panic, when an unmasked fellow shopper didn’t make us react like they were pointing a loaded gun at us.

Yes, those good old days.

As well as in Europe there have been a selection of successful shows in both North and South America that have also been successful – with IAOM and GEAPS both reporting successful levels of attendance. With that in mind, maybe one day we are all going to one day return to the smiles, hugs and handshakes world of exhibitions.

That said, it does seem that with this pandemic, like with so many other aspects of modern life, any big sudden changes all too often do not have the desired effect and are soon reversed.

Setting the success of vaccination campaigns aside, one begins to wonder if all of these measures have in fact been worthwhile, if the virus is going to get us all through physical, financial and psychological ruin in the end anyway.

Still, recent history - especially in the UK, has shown that patience will beat being brave every time, so let us all just sit tight, and hope that hope returns one day very soon. gfmt.blogspot.com

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Milling News

IAOM Best of Show Award goes to Swiss milling start-up

S

wiss milling and technology start-up swisca ag wins the coveted and prestigious Best of Show Award at the IAOM (International Association of Operative Millers) international milling trade fair in the United States.

With a world first and impressive levels of energy efficiency, the industry newcomer from Appenzell in Switzerland succeeds in convincing the experts at the 125th anniversary conference.

The jury of experts was especially convinced by the unique ‘Dampe’ dampening system from the Swiss think tank. This system uses nozzles to spray the grain with clouds of water at the very beginning of the processing chain in the mill.

This enables higher efficiency in flour production later on. At the same time, the innovation also scores highly with energy efficiency, whilst it also provides a high level of food safety.

Ensuring uniform grinding & high yields

An important production process in a flourmill is moistening to ensure uniform grinding and high yield. The grain is thus prepared for an optimal milling condition.

By adding water to the grain and tempering it in the silos, the bran layers become tough and elastic and the endosperm inside the grain is softened. This is the optimal condition for separating the hull and the endosperm as efficiently as possible during milling.

With swisca's invention, the moisture and density can be measured precisely during weighing, with the necessary addition of water then calculated exactly. Described by swisca as being a completely new process with minimal energy requirements, the system applies the moisture to the surface of the grains with a fog of water.

The innovative machine, which was developed together with the St.Gallen-based company Trinox Engineering AG, it is automatically cleaned using clean-in-place technology for optimal food safety.

Swisca is aiming to produce high quality machines and processes with a focus on food-safe and energy saving solutions, which it hopes will ultimately result in sustainable solutions.

Manufactured in Appenzell, Switzerland for food-processing companies, its machines are exported to over 40 countries and are characterised by energy efficiency and food safety.

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Light at the end of the tunnel

by Mehmet Ugur Gurkaynak, Milling and Grain

Dear friends, Distributed this year, Issue 29 of our International Milling Directory is the result of a period of great dedication and teamwork. It was published a few months ago, shortly before it was sent to the addresses of our readers. Our guide, for which we have received positive feedback on both its producer and potential customer information, was also met with great interest this year.

As we have all witnessed for ourselves, we are going through difficult times. Years ago, the predictions of scientists about climate change and global warming, such as floods, droughts and extreme heat, have now become a part of our daily lives today. In addition to the changing climate, we have also faced the Covid-19 pandemic too.

Since 2019, when the virus first spread across the world, many changes have occurred in our lives. Just as we have given up some old habits, we have made new ones. So much so that many of us even made our own bread at home.

As well as the rise of home baking, our trade has also been greatly affected by the cessation of domestic and international travel, with all events either cancelled or postponed. Conferences, seminars, and even fairs have now become online fixtures.

Throughout this process, we have tried to support our friends operating in the sector as much as we can by promoting them with our printed and digital publications, and we will continue doing so.

The light at the end of the tunnel

Thanks to us learning how to fight Covid-19 and through mass vaccination, domestic and international customer visits, even fairs, have started to be held gradually, although some of them are

still postponed. With this news in mind we can now truly say that there is light at the end of the tunnel.

With 12 offices around the world, our friends at Perendale Publishers Ltd have started to attend fairs and conferences in the countries they are in and in the surrounding countries.

GEAPS Exchange in the USA, Norway - AquaNor, USA Aquaculture 2021 are just some of them. The IAOM Fair, which is planned to be held in Dubai, United Arab Emirates between October 10-12, 2021, is amongst the list of long-awaited events.

As are MillTech Istanbul Fair, which is planned to be held this year between October 20 – 23 in Turkey, and IDMA Russia fair that takes place in Russia between September 22 – 24, 2021.

Our online trainings

In cooperation with Progressus Agrischools, our sister publications Milling and Grain and International Aquafeed magazines have been organising online trainings on feed milling and aquaculture for a long time.

Our training programs, which bring together industry stakeholders from different continents and countries of the world at the same time, also help the participants to start working on commercial issues.

The school will open its doors again for the Online Aquafeed School on September 14 and the Online Milling School – Livestock Feed courses on October 6, 2021.

For information on sponsorship and for opportunities to promote your company and its products, you can access the details and contact information on the school's website www.onlinemillingschool.com.

I hope to be able to see all of our friends in person again very soon but for now, please stay well.

Milling and Grain - October 2021 | 15

Milling News

UK to begin adding folic acid to flour to help prevent birth defects

T

he UK government has announced that folic acid is to be added to UK flour to help prevent spinal birth defects in babies, reports the BBC. Taking Vitamin B before and during pregnancy can help guard against spina bifida in unborn babies, although many women don’t take it despite being advised to.

Adding folic acid to flour has to potential to prevent up to 200 birth defects a year. Only non-wholemeal wheat flour will be affected, with gluten-free foods and wholemeal flour exempt, says the BBC report which was published on its website on September 21, 2021 Mandatory fortification - which the government ran a public consultation on in 2019 - will see everybody who eats foods, such as bread getting more folic acid in their diets.

Neural tube defects, such as spina bifida (abnormal development of the spine) and anencephaly, a life-limiting condition that affects the brain, affect about 1000 pregnancies per year in the UK. Many babies diagnosed with spina bifida survive into adulthood but will experience life-long impairment.

“Women are advised to take 400mg of folic acid a day for at least a month before conception and up to the twelfth week of pregnancy.

But about half of pregnancies are unplanned and women are not always aware they should take the supplement - or forget to,” says the BBC report.

Folic acid is added to flour in more than 80 countries - and when it was added to bread in Australia, neural tube defects fell by 14 percent. Previous concerns have been raised in that mandatory fortification could have unintended health effects, such as masking a vitamin B12 deficiency or increasing the risk of colon cancer.

16 | October 2021 - Milling and Grain

The government's independent advisory body - the Scientific Advisory Committee on Nutrition - has been satisfied that these concerns are not supported by the evidence. Since World War Two, the UK's non-wholemeal flour has been fortified with iron, calcium and two other B vitamins - thiamin and niacin.

It's taken years of debating to reach this decision, as the gains need to be carefully weighed against any potential harms. Adding folic acid to flour used in common foods, such as bread, will mean dosing the masses.

Getting enough folic acid around conception and during pregnancy is important for cutting the risk of women having babies with spina bifida or other neural tube defects. Most other people however, already get their required amount of folate – the natural form of the vitamin – from a normal diet.

Prime Minister Boris Johnson says folic acid-fortified flour would be “a quick, simple win” to enhance a baby’s development, as well as helping to boost the health of UK adults, adds the BBC report.

Health and Social Care Secretary Sajid Javid says preventing life-threatening health problems like spina bifida would mean fewer people needing hospital treatment.

Kate Steele, chief executive of Shine, a charity providing specialist support for people affected by spina bifida and hydrocephalus and which has campaigned for mandatory fortification of flour for more than 30 years, says she is “delighted” by the decision.

"In its simplest terms, the step will reduce the numbers of families who face the devastating news that their baby has anencephaly and will not survive,” she says.

“It will also prevent some babies being affected by spina bifida, which can result in complex physical impairments and poor health.

This is truly a momentous day.”

The B vitamin will be listed on the labelling of all foods made with flour.

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Hamlet Protein launches new fibre product for piglets

H

amlet Protein, a multinational producer of specialty nutrition ingredients for young animals, announces the launch of HP FiberBoost©.

Marketed as a pure fibre product containing functional fibres produced specifically for dietetic use in piglets, it completes the company’s fibre range and offers producers an additional option when formulating diets without Zinc Oxide (ZnO).

Therapeutic use of ZnO has been a very effective tool for preventing post-weaning diarrhoea in piglets. Without pharmacological levels of ZnO, and with the well-known restrictions on the use of antibiotics already in place, European producers are forced to look for alternative strategies to maintain animal performance and health.

“We do not think one single product can replace the current use of Zinc Oxide. comments Erik Visser, Hamlet Protein CEO. “A ZnO- free pig production requires improvements in many fields that include farm management, biosecurity, genetics, and nutrition.

“The introduction of fibre as a functional ingredient, to stimulate the gut and ease the transition at weaning, forms part of Hamlet Protein’s strategy to help pig producers to transition to Zinc Oxide- free diets,” he adds.

Milling News

Where HP FiberStart combines enzymatically coprocessed protein and fibre raw materials, HP FiberBoost is a pure fibre product containing functional fibres produced specifically for dietetic use in piglets. The product addresses a market demand from producers that are interested in pure fibre without the inclusion of protein.

“HP FiberBoost allows flexibility apart from the protein for optimising the fibre content in pig starter and/or sow diets. Having this option and flexibility for feed formulations is important to many of our customers,” concludes Mr Visser.

Addressing market demand HP FiberBoost was developed to address a market demand from customers interested in combining fibre with a vegetable protein source of their choice.

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Milling and Grain - October 2021 | 19

Milling News

Insect proteins now available for use in pig & poultry feed

I

n what has been described as an important step for circular agriculture, insect proteins are now approved in poultry and pig in Europe.

A natural food for these animals, insects bring nutritional, health, welfare and sustainability benefits. The approval of using insect protein meal for feed helps reduce the dependency on protein sources that are connected to deforestation and overfishing.

As of September 7, 2021, the European Union authorises the use of insect proteins in poultry and pig feed, with this authorisation widely hailed as an important step and a key milestone in

animal feed production.

This is because insects are a valuable source of highly digestible proteins and may contribute to reducing the reliance of the EU livestock feeding system on proteins from third countries while simultaneously advancing the circular agriculture.

The European Commission Farm-toFork strategy is just one example of the EU promoting a circular feed system with the use of sustainable and local ingredients.

“Insects can play a major role in moving towards a circular food system, since they are able to transform waste streams into high-quality animal feed,”

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SIEVE CLEANERS

says Jan Huitema Member of the European Parliament.

“This way, Europe will become less dependent on feed imports, and the environmental impact of livestock production will be lowered.”

Insect-based ingredients on an industrial scale

Protix is the first company worldwide that is able to produce insect-based ingredients on an industrial scale. The new legislation is a result of targeted work that Protix initiated in 2013 with the founding of IPIFF (International Platform of Insects for Food and Feed).

Strong partnerships with innovative companies like Coppens Diervoeding and Agrifirm have accelerated these developments.

“With Agrifirm we have also laid down fundamental work in large applications in poultry,” says Kees Aarts, CEO of Protix.

“Insect protein is a high quality, nutritious and sustainable protein and provides a true benefit to our animal feed. It is a key part of our solution to contribute to a more sustainable livestock production,” says Hendrik de Vor, CEO of Coppens Diervoeding.

“Insect-based ingredients are an important enabler for sustainable production of poultry and will help us source more locally with a lower footprint,” adds Dick Hordijk, CEO of Royal Agrifirm.

In 2012 Protix founded IPIFF (International Platform of Insects for Food and Feed) to promote the use of insects as a source of nutrients for human consumption and animal feed to policy makers in Brussels. The IPIFF is now the world’s leading insect association to promote the use of insects for feed and food.

Since then, the insect industry has developed strongly with the key milestone of the approval of using insects in sustainable feeds for fish in 2017. Today’s approval of using insect meal for poultry and pig feed is another, even bigger milestone.

Line of centrifugals

JW Aizlewood’s Crown Mills Sheffield Part 2

by Mildred Cookson, The Mills Archive, UK

Milling journals of the past at The Mills Archive

T

his article follows on from last month by describing changes at Crown Mills since 1906. The Miller in June 1928 described a visit to the mill following Henry Simon’s reconstruction of the mill and its wheat cleaning department.

The firm, by 1928 named John Aizlewood Ltd, was founded at Masborough, a town near Rotherham in 1857, and was transferred to Sheffield in 1861 to the Albion Crown Mills.

As business developed and larger premises were required, the founder, the late Mr John Aizlewood, purchased a site in Nursery Street and erected the current buildings, known as the Crown Flour Mills in 1878. By the time The Miller’s visit occurred, the mill was marking its jubilee in the same year as that of the National Association of British and Irish Millers.

John Aizlewood died in 1907 and two years later the mill had become a private limited company, two of the sons being the directors and shareholders. George, one of his sons, owing to ill health, appointed James Gillespie as Director and Secretary of the firm.

Mr Gillespie had worked for 20 years at the Battersea Flour mills, run by Colonel Mark Mayhew. It is also notable that Mr. Gillespie became the Technical Editor of Milling for some time, whilst Mr Walter Peacock became the inside mill manager and was a man who had much experience in milling engineering and milling in general, having apprenticed under Mr Thornton of Retford.

Crown Flour Mills when first opened used millstones. There were fourteen pairs with the necessary accessories, such as sieves and bolters. This plant remained in use until 1884 when a roller system was installed and put into operation the following year. In 1905 a

22 | October 2021 - Milling and Grain

thorough remodeling was undertaken under the guidance of the Mr GH Aizlewood, a son of the founder, who had been apprenticed to the trade and was a thoroughly practical miller.

Meeting the demands of modern competitive milling

The firm continued to make steady progress, and from time to time the mill was reconstructed in order to meet the demands of modern competitive milling. The question of power had to be considered and in 1912 a new horizontal compound condensing engine was put in by Pollitt & Wigzell, Ltd, of Sowerby Bridge.

A new Green’s Economiser was also installed and the steam raising plant completely overhauled.

Towards the end of 1926, Aizlewood’s decided to carry out a major reconstruction in order to bring the plant right up to date.

They placed the order with Henry Simon Ltd, Manchester. The contract included a complete overhaul of the wheat cleaning and flour milling plants and the installation of a number of Simon’s latest type machines.

After the completion of the work, the screen room had been rearranged, with almost entirely new machines. A large-size Simon self-balancing separator with ‘Juby’ drive was added.

A new Reform combined washer, stoner and whizzer (Mumford patent) and the latest type of ‘Reform’ conditioner was also installed together with six new conditioning bins.

This gave ample facilities for thorough washing and conditioning of the wheat. The screen room was now exhausted by means of a central system that made it a healthy department for the mill operatives to work in.

In the mill proper, a Germinal brush had been installed after the mill bins and immediately preceding the first break rolls. The wheat was then fed into a new Simon 60" x 10" four roller mill by means of an ‘Exact’ measurer following an Avery weighing.

The main roller floor

JW Aizlewood (top), James Gillespie and Walter T Schofield

Aizlewood’s Crown Mills Sheffield 1928

The mill is still standing

The Alphega system had been adopted and this worked well, allowing the middlings to pass to their respective graders free from flour particles and bees wing. An elaborate system of grading had been adopted and the new Simon fanless purifiers dealt with coarse and medium semolina.

The reduction system included a B2 run and was extended down to N. The flour dressing was done on centrifugals, eight new three sheet Simon machines having been installed to give a clear dressing of flour and a thorough separation of dunst stocks.

Four brands of flour were produced by the firm including Five Crowns, a top patent; Four Crowns, a second patent; Corona, straight run; and Three Crowns, a baker’s grade. At the Sheffield Master Baker’s Exhibition, held in the Cutlers Hall, Sheffield, on December 17, 1927, the gold medal and silver challenge cup of the Association were won by a user of Aizlewood’s Five Crowns.

All trade of the mill was done within a radius of twentyfive miles and delivery of the products was done by means of the firm’s own fleet of transport vehicles, which included a 5 ton Karrier, a three and a half ton Commer, and two Morris Commercial vehicles, with the mill running continuously, having a three-tier system in force.

I am grateful to Philip Aizlewood for enabling me to bring the story up to date. He is the last surviving family member who worked at Aizlewood's Mill before its closure as a flour mill in 1969.

“George Henry Aizlewood died in 1927, and his brother John William in 1929, his son, my father, Philip John took over in 1930 and ran the business until 1962 when ABF (Westons) bought the mill,” he writes.

“I worked at the mill as Mill Manager until 1966 when I emigrated to Canada. The good news is the mill is still standing, looking as good as it was when opened in 1861, and is now a business centre.” www.aizlewoodsmill.co.uk

www.millsarchive.org

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The Rex Wailes Collection With the windmillwrights in fen and marsh

by Nathanael Hodge, The Mills Archive Trust Another interesting find in the Rex Wailes collection at the Mills Archive is a typescript entitled ‘With the windmillwrights in fen and marsh’. It is an account of the adventures of Douglas Reid in the marshes and fenlands of Lincolnshire, England, accompanying millwrights as they went to work.

In November 1931, Mr Reid accompanied Hunt Brothers of Soham to Cattell’s corn mill, Willingham. He describes the scene: “I arrive to find that Tom and Jack Hunt have been given sole charge of the undertaking. Tom, who has been disconnecting and removing the long iron ‘striking’ rod that tunnels the wind-shaft and automatically operates the sail shutters, is now aloft enjoying a few minutes rest. His position seems decidedly precarious.

“Mind you don't fall Tom’ calls Mrs Cattell. But Tom only smiles.

He is standing on the sail buck which has been rotated into the horizontal position. True, he steadies himself with one hand, but later will be holding on to nothing save the heavy hammer with which he strikes, using both hands, on the great bolts uniting the 'clamps' to the back. For in this mill there are additional timbers or clamps on each side of the back which besides strengthening it help to prevent slipping in the eye. “… On the following day the back is removed. And now it is that the miller assembles his friends. And as it is a great occasion his daughter must hurry and fetch the cat and the kitten! The miller is

The Hunt Brothers’ Waterside Works, Soham

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Lowering the ‘back’ of the sail

very proud of his cat and its mousing exploits at the mill.

“We make a merry party as we pull on the ‘anti bump’ rope attached to the lower end of the back. We resemble a tug of war tea heaving then giving way for a moment so that the back swings backwards and forwards. This seesawing has the effect of snaking the beam downwards through the eye.”

A keen photographer and lover of the Fenland area

Douglas Reid was born in 1881. He was a keen photographer and a lover of the Fenland area and its traditions, and would have known Rex Wailes from the involvement of both in the Cambridge Antiquarian Society Photographic Survey. Reid worked at the Cambridge University School of Anatomy, but his life came to a sad end when, after losing his job, he committed suicide in 1934.

The typescript appears to have been sent to Rex Wailes for possible publication. Sadly after 31 pages the text breaks off and the remainder is missing.

We are fortunate however that this fascinating account was preserved among Rex Wailes’ papers Tom Hunt on the sails of Cattell’s mill and has now come to light.

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

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

26 | October 2021 - Milling and Grain

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Milling News

BIOMIN publishes mycotoxin related reproductive issues research compendium

A

Dr Paula Kovalsky

Dr Christiane Gruber-Dorninger

nimal nutrition and feed additive firm Biomin has recently published a book detailing the latest scientific knowledge about zearalenone, a mycotoxin that is commonly found in feed materials and associated with reproductive challenges in animals.

The Zearalenone Compendium, edited

by Dr Paula Kovalsky and Dr Christiane Gruber-Dorninger, compiles the literature on zearalenone in a practical manner. It provides an overview of the symptoms caused by zearalenone in different animals and the strategies available to counteract them. Every chapter of the compendium starts with a short summary of the most important findings.

Due to its structural similarity to oestrogen, fungi-produced zearalenone latches onto the estrogen receptor, which can induce hyperestrogenism and lead to lower reproductive performance in animals.

“New tools have allowed us to form a considerable amount of knowledge about the occurrence of zearalenone and its negative impacts on animal production,” commented Dr Paula Kovalsky, Product Manager at BIOMIN. “Our aim with this book is to ensure that the industry and academia have the most up-to-date understanding of zearalenone in order to be better able to confront it head on,” added Dr Kovalsky.

Occurs in all kinds of commodities Results of the Biomin Mycotoxin Survey, which comprises the most comprehensive data set on mycotoxin occurrence in feed crops, reveal that zearalenone occurs in all kinds of commodities worldwide, especially in corn (maize), wheat and soy.

“Increased awareness of the risks that zearalenone presents to human and animal health have led to adoption of maximum guidance levels in animal feedstuffs and regulations in food in places such as the European Union over the last fifteen years,” noted Dr Christiane Gruber-Dorninger, Scientist at BIOMIN. The electronic version of the Zearalenone Compendium is available via most major e-book platforms and 5m Publishing’s website. Select chapters on the effects of zearalenone in poultry, pigs and ruminants are available on biomin.net.

US Wheat Associates welcomes suspension of Vietnam wheat import tariff

I

n a recent press release the US Wheat Associates (USW) has announced that it is grateful to the Biden Administration and USDA’s Foreign Agricultural Service (FAS) for their work alongside Vietnam’s Ministry of Finance to reduce the cost of wheat for Vietnam’s millers and consumers.

As part of a bilateral package announced during Vice President Kamala Harris’ Indo-Pacific trip, Vietnam will reduce or eliminate import tariffs on several US commodities including wheat. The tariff suspensions are expected to be implemented soon and will help reduce food costs for the Vietnamese people. It will also help make US wheat more competitive in Vietnam’s growing wheat market.

Vietnam, like many countries this year, has seen significant food and feed price inflation due to the rise in global commodity prices and COVID impacts on supply chains.

Vietnam’s government should be commended for taking this proactive step to assist their domestic millers and consumers.

A particularly noteworthy announcement The newly announced reduction follows one from July 2020, when Vietnam reduced its tariff on imported US wheat (excluding durum) from five percent to three percent in a revision of its Most Favoured Nation (MFN) tariff rates.

28 | October 2021 - Milling and Grain

Vietnam is the last remaining Comprehensive and Progressive Trans-Pacific Partnership (CPTPP) country applying a tariff against US wheat imports but not against Canadian and Australian wheat, making this announcement particularly noteworthy for US wheat growers.

Despite the tariffs, Vietnam’s imports of US hard red winter (HRW), soft white (SW) and hard red winter (HRW) wheat exceeded 500,000 metric tons in marketing year 2020/21, second in volume only to Australia. Vietnam currently imports an average of more than three million metric tons of wheat per year.

The suspension was granted because of the dedicated work between USDA/FAS, co-operator organisations and the Vietnamese importers who petitioned their government to reduce or eliminate certain MFN tariffs to help hold down rising food and feed prices.

The mission of the US Wheat Associates' (USW) is to develop, maintain, and expand international markets to enhance wheat’s profitability for US wheat producers and its value for their customers in more than 100 countries.

Its activities are made possible through producer checkoff dollars managed by 17 state wheat commissions and cost-share funding provided by USDA’s Foreign Agricultural Service.

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Milling News

Sixth Annual Aqua Feed Extrusion Conference will be held on January 2022

D

ue to the ongoing worldwide pandemic, the management teams of VICTAM Corporation and VIV worldwide have decided to postpone VICTAM Asia and Health & Nutrition Asia in Bangkok to the third quarter of 2022.

The current situation is still not as optimal as it was estimated. Above all, the health of exhibitors and visitors and the successful outcome of the event are most important to the organisers.

In light of the recent increase in Covid-19 cases, which has forced the Royal Thai Government to implement new strict measures to control the spread of the pandemic, and the delays of the vaccination programs in several Asian countries, VICTAM and VIV do not see the opportunity to realise a large-scale event in the short term.

Looking at the ongoing travel restrictions from and to Asia, the organisers also believe that it is not possible to guarantee the event quality they are known for. The postponement to the third quarter of 2022 is in the interest of the whole industry.

It is a very unfortunate time that with Covid restrictions, lots of people cannot travel to other countries and attend conferences, seminars, or short courses face to face.

That said, the Aqua feed industry is booming at present and the pandemic is not stopping the growth of business as everyone must secure their food supply and eat healthy food.

The management team for the Aqua feed Conference decided to hold their sixth annual Aqua feed Extrusion conference virtually like the last conference, on January 11-12, in order not to postpone it.

Major extruder companies (Andrtiz, Clextal, ExtruTech, Wenger) are already committed to give talks at this conference, as well as other equipment and ingredients suppliers, (Reynolds Engineering, Kemin, and Texas A&M University).

Very soon they will be adding more speakers to their program. If any equipment or ingredients company is interested in giving a talk at this conference, they can contact Dr Mian N Riaz, from Texas A&M University via his email (mnriaz@tamu.edu). The program will be finalised soon and emailed out.

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Naturally ahead

Milling and Grain - October 2021 | 31

Mill

TRAINING There are still places available on the Milling for Executives course run by Bühler, located at the Milling Academy in Uzwil, Switzerland. The course runs from November 22 – 26 as well as November 29 – December 3, and is available in English and Spanish.

Milling for executives No technological knowledge is required to take part, although this course is well suited for managers in leading positions and mill owners.

You will learn how to make a flourmill efficient - about basic milling processes, machine design and plant operation. But this isn’t just theoretical training.

You will spend an entire day at Bühler’s fully operational school mill learning to understand how a mill works, followed by another full day at the Bakery Innovation Centre to understand the art of bread making. Discussions will also take place, regarding the key drivers of investing in the latest milling technology and how to maintain business profitability.

Michael Albers, who joined the Milling Academy team in 2017, runs the course, as well as conducting mill assessments. He completed his apprenticeship in 2007 and graduated from the German Milling School in Braunschweig in 2010, working in the milling industry for seven years before joining Bühler.

The classroom is situated right next door to the milling floor, where you can explore many of Bühler’s latest milling machines, gaining practical experience and learning how the machines operate in a normal industrial environment.

mymag.info/e/1204

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CONFERENCE

One full day Aqua feed extrusion conference.

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mymag.info/e/1158

The Feed Innovation Awards, as well as the GRAPAS Innovations Awards for 2021, have both been postponed and will now take place in mid-2022 in Europe.

Feed Innovation and GRAPAS Award postponement Human capital is the key to success in changing markets.

The next courses at our Milling Academy: Wheat milling for operators Level 3: 15.11. - 19.11.2021 Milling for executives 29.11. - 03.12.2021 Maintenance Mechanical: 08.11. - 12.11.2021 Electrical: 15.11. - 19.11.2021 Durum processing 13.12. - 17.12.2021

Register now: buhlergroup.com/academy

Innovations for a better world.

32 | October 2021 - Milling and Grain

The Awards were to have taken place during Victam Asia 2021 and then on its delayed date of January 12-14, 2022.

Both Awards host a respective seminar and conference which will now be included in the Victam event programme being planned for Europe and which will take place from May 31–June 2, 2022.

The seminar/conference will be held simultaneously on the second floor at the Jaarbeurs, Utrecht, The Netherlands on the first day of the show.

The GRAPAS Conference is hosted by Milling and Grain magazine and is co-located with VICTAM International 2022.

The full GRAPAS program will be available shortly once companies have had time to re-consider the dates and others wishing to enter have had an opportunity to do so. To date, over 10 companies have entered the GRAPAS Innovation Award for 2021 and more are expected.

All GRAPAS Innovation Award recipients will be published in an edition of Milling and Grain magazine leading up to the event followed by a review of the event itself in a subsequent edition.

These issues will not only reach Milling and Grain print readers, but will be promoted widely through the magazine's social media and through the magazine’s individual language apps to ensure maximum awareness of the Award winners within throughout the milling industry globally.

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Mill

TRAINING With the feed milling employment market an increasingly competitive arena these days, potential employers are always looking for the applicant with a skill set that places them above all others, that truly gives them that winning edge.

Online Milling School - Autumn editions Aquafeed and Livestock feed production school sessions return The next time that you find “that job” and you apply for it, the best way of ensuring that you have the right qualifications on your CV is to enrol on one or both of the upcoming Autumn editions of the Online Milling School from Progressus Agrischools.

With courses available in both aquafeed and livestock feed production, you can boost the power of your CV without even having to leave the comfort of your own home.

Introduced by long time industry publisher and journalist Roger Gilbert and Yiannis Christodoulou, founder and owner of Progressus Agrischools Asia, a warm welcome is always extended to the 600 or so attendees who log-in from wherever they are all over the world.

The course provides an excellent learning platform or refresher training for those involved in feed production of livestock and aquaculture feeds at their place of work.

The 48 available Online Milling School sessions feature a proud total of 20 facilitators, with the most experienced individuals within their respective industries counted amongst this number.

The schedule of each session is dominated by two hours of live training, with an important aspect of feed mill operation and management selected as its focus.

At the end of the two hours of learning, delegates then have the opportunity to interact with the facilitators/speakers in a live Q&A session, whilst all of the documents used in the presentations are also made available as fully downloadable handouts.

Online Milling School - Aquafeed

The Autumn series of the Online Milling School – Aquafeed is made up of 12 sessions that cover a broad range of topics relating to aquafeed production including ingredients, equipment used, how it is operated, and the desired final product specifications.

As well as thoroughly examining these four crucial areas, the course also goes into meticulous detail on how they interact with one another, as each affects the other during the aquafeed production process.

The sessions cover all areas of the process, running right from when the nutritionist makes the formula, through to when the sales or the customers define the desired end product; with the production process in between needing to perform accurately and efficiently.

The breakdown of the weekly sessions is typically two or three seminars written, prepared and presented by carefully chosen industry experts. This proud list includes Joe Kearns, whose 44 year career at Wenger saw him hold the positions of Vice President Aqua-Feed Division and Aquaculture Process Engineering Manager for a combined total of over 10 years.

Keeping to a fairly regular but at times flexible routine, the live training is then followed by a virtual question and answer session with a panel made up of the speakers from that particular day.

The weekly sessions are also broadcast on consecutive days in order to accommodate two different time zones, with each session broadcast twice for convenience of European and Asian audiences.

The first of the two transmissions is scheduled for the convenience of audiences in Europe and Asia, with candidates able to join the Tuesday session at 14:00 Bangkok Time/09:00 CET Time. For the Friday session, candidates from the US and Latin America, can join at 10:00 Chicago Time/13:00 Buenos Aires Time.

Online Milling School - Livestock Feed

Like its aquafeed counterpart, the Autumn series of the livestock edition also consists of a series of 12 two hour sessions that are broadcast twice weekly in order to cater for the two different time zones.

Although the course begins on October 6, 2021, applicants are more than welcome to enrol past this date, with all sessions that they may have missed available to watch on demand for two weeks following the conclusion of the course on December 22, 2021.

The livestock feed edition is also organised and delivered

by Progressus Agrischools and Perendale Publishers, the organisation responsible for such publications as Milling and Grain magazine, which is our industry’s longest running print publication.

Each session is scheduled to be broadcast twice for the convenience of audiences in Europe and Asia, with the he first of the two transmissions is scheduled specifically for the audience in Europe and Asia, with candidates able to join the Wednesday session at 14:00 Bangkok Time/09:00 CET Time. The Thursday session, which is timed specifically for candidates from the US and Latin America, can be joined at 10:00 Chicago Time/13:00 Buenos Aires Time.

Designed with current and prospective owners, managers and plant operators of feed mill plants, quality assurance and maintenance staff, nutritionist and feed formulators, feed additive and animal health suppliers, and industry advisors in mind, once you have watched all 12 sessions, either live or on demand, you will be awarded an industry accredited certificate, and a new gold stripe to add to your CV.

Certificates & group applications

Following the conclusion of all editions of the Online Milling School, the teams from Progressus and Perendale Publishers Limited issue all participants that complete the 12 sessions with a certificate.

You can also purchase all 12 sessions for your group of 10 people. Once you have provided a name list of your group, you will receive one log-in account which will allow you all to watch together. Upon course completion, everyone in your group will receive their own certificates.

You can join each session for US$40, or you can enrol on the full 12-week course for just US$360 - meaning you only pay for nine sessions, a saving of 25 percent!

For more information about group registration, or for answers to any other questions that you might have, please contact the team at Progressus Agri-Schools, who will be more than happy to assist you.

For more information visit: For the livestock edition:

mymag.info/e/1202 For the aquafeed edition:

mymag.info/e/1203

www.onlinemillingschool.com YOUR GLOBAL PARTNER

Milling and Grain - October 2021 | 35

PRODUCT FOCUS October 2021

In every edition of Milling and Grain magazine, we dedicate this page to taking a look at the products that will save you both time and money in the milling process.

Should you have a new product or service that you would like to feature on this page in a future edition of our magazine over the coming months, then be sure to contact us at editorial@perendale.co.uk The myMAG link will take you directly to the company's product information page

The MaxSignal® Mycotoxin Automation Bundle from PerkinElmer PerkinElmer, Inc announces the launch of its new MaxSignal® Mycotoxin Automation Bundle. Using the new assays and automation of this bundle, users such as food safety QA managers and lab teams at feed mills can now accurately and efficiently process up to 180 samples in less than 90 minutes.

Mycotoxins are naturally occurring toxic compounds that can grow on a variety of common foodstuffs.

This offering includes complete workflows from screening to analytical confirmation, integration software and application support to develop new methods and improve existing method performance.

In addition to significant improvement in sample throughput, these automated solutions are designed to handle complex matrices with high sensitivity and accuracy.

The workflow is intended to be “set it and forget it” to minimise the need for human intervention, reduce the risk of manual error and help customers meet regulatory standards.

www.perkinelmer.com

Mold-Nil® from Adisseo One of the leading quality parameters of raw materials and feed is its microbiological load. Before harvest, little can be done about mould contamination and subsequent mycotoxin production.

However, post-harvest there are several strategies that can be adopted to reduce destruction of valuable nutrients and a reduction of animal health and performance.

Mold-Nil®, is an effective mould inhibitor available in both liquid and dry form and uniquely formulated with a synergistic buffered blend of propionic acid and other organic acids.

The use of this particular is well-established in preventing mould contamination in raw materials and feed, thereby stabilising the nutritive value - as well as allowing safe-handling throughout longterm storage.

In addition to keeping feed materials palatable and of a high nutritional value, further benefits of Mold-Nil include that it prevents the production of storage mycotoxins whilst it also supports animal health and performance.

Analysette 22 NeXT laser particle sizers by Fritsch Depending on your needs, you can select either the Analysette 22 NeXT Micro for all typical measurement tasks from 0.5-1500 μm or the high-end instrument Analysette 22 NeXT Nano with an extra wide measuring range from 0.01-3800 μm.

With this piece of equipment, the whole measuring process is flexible and easy to program via SOPs with a total measuring time of less than one minute. The results are easily replicable, and you can also record additional parameters such as temperature and Ph value during wet dispersion A particle size analyser can only be as good as its dispersion capabilities. Due to the Analysette 22 NeXT‘s cleverly reduced design and robust engineering, the dispersion unit is particularly durable and practically maintenance-free.

To measure samples tending to agglomerate, simply add the optionally available high-performance ultrasonic box to the sample circuit.

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Almex AL300 Expander

Mastercube by Anpario

Almex offers a range of expanders which not only improve the quality of finished feed, they also do the same for mono-components too. These expanders are unique because of their ability to condition and hygienise feed at temperatures than other optiuons currently available on the market, typically ranging from 110 to 130°C with mechanical friction and pressure.

The Almex expanders have a robust design and are equipped with a unique Active Disk system (AD-system) in order to control output and quality of the product. The AD-system is simple to control and it is easy to exchange wear parts.

The features and benefits of using this system include that it eliminates heat sensitive bacteria (salmonella), higher fats and liquids inclusions, the gelatinisation of available starches, improved end product durability and strength, ease of cleaning and less downtime for maintenance.

Mastercube is a free-flowing, low inclusion, ureafree pellet binder produced by Anpario that is formulated from a blend of polysaccharide gums on a specialist mineral carrier.

Polysaccharide gums that are natural plant extracts that rapidly bind feed mix into a flexible matrix, helping to reduce die friction and improve flowability.

Mastercube helps to improve pellet durability to ensure pellets are capable of withstanding the high pressures exerted in feed delivery and auger systems. In addition, the product also helps to reduce fines, preventing nutrient losses throughout the production process and optimising mill hygiene.

This latest product from Anpario has also been shown to be as effective as synthetic gums in terms of improving energy usage, reducing fines and increasing pellet durability.

It is a cost effective, multi-purpose, low inclusion pellet improver and provides flexibility in feed formulation by releasing nutrition space.

www.almex.nl mymag.info/e/1200 36 | October 2021 - Milling and Grain

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mymag.info/e/1201

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FOCUS

SPECIAL FOCUS Italian based milling machinery manufacturers Ocrim are creating a Fluting Hub for managing the grinding of rolls, which will also include provision for grinding and balancing stations, along with a system for coating the rolls in titanium.

In addition to completing the production phase of their roller mills, the hub will also extend the shelf-life of the company’s capacity to deliver service to customers, with standards maintained right through to the management of their grinding rolls.

Founded in 1945, Ocrim specialises in the supply of milling plants, feed mills and grain processing systems in general, also and above all, with the ‘turnkey’ formula. The company is also focused on and invests in training, customer satisfaction and communication.

The Fluting Hub allows Ocrim’s customers to directly make use of a new specific area for management of the grinding rollers that will accommodate a new roller fluting detachment system.

The newest feature consists in the supply of stations for fluting, grinding, balancing and an innovative system for coating the outer surface of the rollers in titanium to enhance their efficiency, wear-resistance and to lengthen their service life.

Ocrim’s CEO, Alberto Antolini, gave the go-ahead for the creation of the new department for managing the grinding rolls earlier this year, which will include fluting, grinding and balancing stations, as well as the introduction of an innovative system for coating the rolls in titanium.

The company describes this new service as being a useful process which will allow Ocrim to have the certified quality of the products intended for our customers under the company’s own control and responsibility.

Ocrim – Fluting Hub

In addition to dedicating itself to other on-going works, the Research and Development Department has worked on the engineering fulfilment of this project in order to make it a functional and highly operational service.

This feat has been achieved by the conduction of an indepth study which focused on the processes used during roll’s manufacturing stage, as well as investigations into how to improve their performance over time.

In order to both achieve and maintain this idea, Ocrim decided to design an entire department dedicated to its management. This activity, which, in addition to completing the production phase of the roller mills, will also provide a fully comprehensive level of service to the company’s many thousands of customers, throughout the entire life-cycle of their roller mills.

“This is a new addition to Ocrim’s values scale,” says Alberto Antolini, when presenting the Fluting Hub project. “We are optimistic that this important investment will increase our core business, strengthen our customers’ businesses and will make us stronger and more established in the milling industry.”

According to a company spokesperson, this additional choice reflects Ocrim's desire to increase the strategic production chain, further confirming their bond with the Italian Made point of view - of quality and great customer service.

So, in this instance, they have chosen a prevention rather than cure philosophy, one that the company hopes will lead to fewer machine stops and maintenance call outs, saving their customers money in both the long and short terms.

The company is one of the largest and best-known companies in the milling industry and is active on all continents, thanks to its significant technical expertise and a thorough knowledge of the cultures and needs of the various countries and markets.

www.ocrim.com Milling and Grain - October 2021 | 39

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So you want to be a Miller?

So much to learn – you never stop growing

James Cooper, Milling and Grain’s contributing correspondent, examines an industry which brings together the best of craft, science and technology through its commitment to training. It’s an industry focused on its future, where employment opportunities are changing and a younger generation is being called upon to join

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by James Cooper, MAG Correspondent

here’s more to being a miller than a love of bread.

There are many different careers within the flour milling industry and many benefits of working in it. In one way or another nearly everyone in the UK purchases flour; it is a significant source of a range of vitamins and minerals and protein. That’s quite some super-hero status – that both feeds and nourishes a nation.

Also, vital to the smooth running of mills are engineers, food scientists, nutritionists, laboratory workers, marketeers, accountants and hauliers among others. A potential big lure to new recruits is that salaries within the flour milling industry are above the average for food manufacturing and on a par with advanced engineering sectors such as aerospace.

According to industry figures the average salary for a Miller in the UK is UK£35,652 (US$50,000).

It's a sophisticated, technical industry, but one that offers plenty of job opportunities both here in the UK and overseas.

I’ve taken the opportunity to talk with three representative from different walks of life within the industry to offer their views on milling as a career and the importance they place on training.

A word of warning though; working in a mill all day may arouse a passion for artisan baking!

42 | October 2021 - Milling and Grain

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An educator says ...

Nigel Bennett, Training Manager at UK Flour Millers (formerly NABIM) Nigel Bennett coordinates the development and delivery of training resources for the flour milling industry.

While his prime responsibility is to the UK milling industry, he also finds that overseas students, and their companies, benefit from the programmes as well, such is the international reputation of the training UK Flour Millers provide.

“Our programme has stood the test of 100 years or more.

“It's constantly being developed, and it's been found to work for those companies. Many people will know it as our correspondence course, but I prefer to call it a distance learning programme,” Mr Bennett explains.

Up until about 20 years ago the courses led to UK’s City and Guilds examinations but around that time NABIM took over the examining role from City and Guilds.

Each year the scheme enrols 500-600 students from around the world, between a third and a half are from the UK. Each student receives by mail a textbook and a workbook.

They submit coursework, and then there's a written examination in May each year. While the qualifications aren't formally recognised by UK government because, incredibly, flour milling is too small an industry in this country to fit into any of the existing categories.

However, it is an industry-recognised qualification, not only here but around the world, he adds.

“We train all age groups and we've always tried, through the programme, to cater for people of all academic abilities; from people who come with no academic qualifications to graduates,” Mr Bennett says.

“Students must have a reasonable understanding of English, so that can be a challenge.

“Our best overseas customer is Australia and we work with the

44 | October 2021 - Milling and Grain

Australian Technical Millers Association in the delivery of the programme, but we also have many students from Africa and Southeast Asia.

“In fact, I think, usually we have students from every continent bar, maybe South America and Antarctica. We haven't found any flour mills in Antarctica yet’, he adds with a wry smile.”

Mr Bennett explains that several times over the years, UK Flour Millers have considered introducing a flour milling apprenticeship.

However, in terms of getting recognition from government for an apprenticeship programme, they simply don't have the numbers of people. But what they have identified, and their members have been identified, is that there are apprenticeships out there which can contribute greatly to training in milling.

They might be in food production, but they might be in engineering or any related subject, he adds.

The industry engineering behemoths are also heavily behind the training scheme. Both Bühler and Satake are associate members of UK Flour Millers and are fully engaged with their training.

“We have an advanced milling diploma programme which is run every three or so years, for about five to 10 candidates each time, and from UK millers. These are people who have progressed beyond our distance learning programme and are perceived as being key employees for companies in the future,” Mr Bennett explains.

Both the Bühler Training Centre in Switzerland and Campden BRI (which is the UK’s food and drink research body), are partners in the delivery of the programme and in the development of key training resources.

“We've also had, for example, dealings with Satake and Bühler in the development of our virtual flour mill, which is the most recent training resource we have developed,” he says.

Much like a ship’s bridge simulator for naval cadets; milling students get to operate a mill safely without breaking machinery or ruining the product. But it really points to the high level of sophistication coming into the industry.

Mr Bennett also observes a shifting demographic, “We've recognised that we've got an ageing workforce, but certainly over the last five or 10 years I think companies have been more active in recruiting from a younger age group, and therefore there's been a renewed emphasis on training.”

The job opportunities don't come around too often, and it's always been the case that labour turnover has been low in this industry. It's not for everybody, but people who get into milling really love it and often stay in the industry for life.

“Despite its huge importance, milling is a niche industry with few opportunities, but it’s very rewarding and a great career path, if it's a good fit for you.”

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A Miller says …

Richard Phipps, 38, Mill Manager, GR Wright & Sons Ltd, UK “With all the technology in the world, there is still a requirement for a well-trained, technical Miller,” explains Richard Phipps.

“There’s a hands-on [approach], being able to touch the flour and the flour streams and work out what's going on.

You can have all the NIR systems in the world (Near Infrared Spectroscopy – the systems that connect the plant to the laboratory), to tell you what your colour is, what your moisture and protein is, but there's nothing like a guy going out there, opening a roll, checking the flour for himself.

“I am not a blue-chip titled guy, and I like the fact that I don't get siloed into a specific thing that you're supposed to do, where you're not allowed to look at anything else. So I like small to medium sized businesses, and we're probably the top end of that.

“One of the expectations when you work here, is that just because you are mill manager does not mean that if there's a choke in an elevator downstairs and you're the closest guy to it, you're the guy dealing with it,” Mr Phipps says.

Having previously held successful roles in other food production environments, Mr Phipps saw the job of Mill Manager advertised and thought it would be a great opportunity to further his experience and career prospects towards becoming a Head Miller. He’s now responsible for the milling of 450 tonnes of wheat per 24-hour shifts, every week.

“Wrights have just put me through my MBA, so yeah, we focus heavily on people and training and we don't necessarily expect people to come in with degrees.

“We've got a lot of success stories of people who've just come through agencies that have progressed through the business just based purely on merit.

“Essentially, if you have the right attitude, no matter what your background is, we will invest in you and we will spend time training you and the only thing that we expect back is a willingness to continue to learn,” Mr Phipps adds.

And his job is rapidly evolving, “Access to technology is a definite perk for me because I like on-day, online data capture and we’re going through a bit of a transition now.

“Quite a lot of the old mills are being decommissioned and you've got companies like Bühler putting technology into mills, which is making the older, more traditional-style of mill look at technology in a different way.

“We're working at a time where the industry is really changing and it's exciting, considering that milling is a traditional process that really hasn't changed over many millennia,” he explains.

Milling and Grain - October 2021 | 45

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An employer says …

David Wright, Managing Director, GR Wright & Sons Ltd, UK David Wright is a 5th generation miller, running a family business that has been milling flour for over 155 years. So, where’s the appeal for somebody looking to start a career in milling, when they don't have the luck of having a family business to step into?

I asked him about getting a foot in the door: What would it take to achieve the exalted position of Miller?

“Milling is a very practical job mixed with a high degree of technical knowledge required in the background, and so it brings together science, practical skills and data analysis today’s flour mill is highly sophisticated, running on specialised software. But as the sophistication grows in milling, a degree would be useful, but certainly not essential” he explains.

Conclusion

Culturally this is an industry people want to stay in, but one of the biggest problems Wright’s may face in the next five years is its ageing workforce.

But that’s the same across the industry, and presently there is no dedicated milling apprenticeship framework at all, so entering as a milling apprentice is difficult.

Flour mills, although they’re getting bigger, don't necessarily employ more as a result.

It’s a fairly niche market in terms of job opportunities. The whole industry in the UK probably employs around 2500 people.

Perhaps around a quarter are involved in production, but there’s a lot of opportunity in distribution, the technical side, business administration and so on. The business of milling is evolving for the better, with more training and incredible technological improvements being adopted and this is creating different and often more rewarding jobs.

From my own personal experience of speaking to people in 46 | October 2021 - Milling and Grain

But what’s also apparent is that many enter a career in milling, by working their way up from the shop floor.

Promotion can rapidly come to capable people from the shop floor, wearhouse or laboratory, even through forklift or truck driving.

A career in milling can start at trainee or production manager level, but certainly the lack of a degree is not a barrier to entry as this is an industry with an embedded ethos of continuing professional development.

Rather like the orchestra conductor or head chef, Mr Wright does emphasise that running a shift as a first Miller is really considered in the process to be the peak job, “Lots of other people in the business do their milling examinations, so I think it's a job that is very well respected within the organisation. It is as much a craft as a science. You're taking a raw ingredient, which is wheat, grown in a field and getting control of it by blending and cleaning and mixing,” he says.

Mr Wright is keen to note the steadfast industry ethos that, “Mills have got bigger, and fewer in number, but the principles of milling are the same as they were 100 years ago.”

“It's just the level of technology that’s now bolted on to flour milling. But it’s still a hands-on, ‘miller's thumb’ type operation, that means they have that craft, that skill, that human feel for the product.

“To be able to produce a product, which people buy and make something from, I think is particularly rewarding.

“In our company people come to work for us, and by and large, the vast majority don't leave which shows something.

“I think you'll probably find across the industry people enjoy working in flour milling partly because there is so much to this job that you never stop.”

the wider milling industry, it’s also a very positive group of people involved. They are totally committed, dedicated people, motivated in the same direction in terms of producing quality products that people want to consume every day.

There’s a great amount of pride being invested in quality milling.

But crucially, unlike many industries, this is one with no barriers to entry or glass ceilings. It really is a life choice as much as a job. Literally anyone with an ambition and drive can set out on a career path in milling.

To work in milling is to join a dedicated and passionate team, with a diverse platform of opportunities and where lateral moves can lead to fantastic career progression.

Milling certainly hasn’t put Richard Phipps off baking with flour; the fruit of his labour.

“Actually, I love sourdough. Though I wouldn't say I'm particularly good at it, I do like baking sourdough on the weekends. My wife laughs at me horrifically, because I make a terrible hash of it, but I do enjoy it.”

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James Wright, Production Director and 6th generation family member on the production floor in the company’s new Harlow mill in Essex, England

BACK TO THE FUTURE

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Steeped in milling history yet remaining highly competitive

by Roger Gilbert, Milling and Grain magazine

illing everywhere has history. But no more so than in the UK where family owned-companies can trace their lineages back over generations - and no more so than the flour milling company of GR Wrights and Sons Limited, which is in its 155th year, and is in the hands of its sixth generation of family members and producing flour in North London at its Ponders Mill Site in Enfield.

In April this year the company moved into its new manufacturing facilities in Harlow, while retaining its historical mill site with limited production at Ponders End, outside London just inside the M25 motorway which circumnavigates the city.

Let’s not feel that the move from Ponders End draws to a close to millers working on the Lea at Ponders End, which they have done so for nearly 1000 years The old mill has a vital short-run production obligation for specialist flour to continue to fill.

However, GR Wrights and Sons’ new milling facility, built just 10 miles away in Harlow which is almost directly north of the historic mill but on the other side of the M25, is anything but historic.

In fact, quite the opposite – it’s as modern as the old site is historic.

Arriving at the new Harlow mill is very much like arriving at an inner-city corporate company address. A well-established office block - which has been repurposed - dominates a corner position near downtown Harlow and is fronted by trees and a parking area 48 | October 2021 - Milling and Grain

that separates it from surrounding roadways of this ‘new town’ which was one of eight new towns established outside London this one being in the west of Essex - in the wake of World War II in an effort to decentralise the capital.

You enter a wide expanse of an open lobby with ceramic floors and large picture windows to be greeted and then whisked to the second floor and into the modern offices of this very modern flourmill.

Not a vibration nor sound can be heard yet you know you are in a space occupied by an 18-tonne-an-hour – which processes close to 450 tonnes of wheat per day at full capacity - brand new production plant, as we meet father and son, owner/Managing Director and Production Director respectively, David and James Wright across a board room table in a classical glass-partitioned room.

The factory came online in January this year after a four-year development program which cost UK£47 million (which included the purchase of the land) and will be handling over 160,000 tonnes of wheat per year.

“We haven’t been long in our offices,” explains David Wright, who is affable, welcoming and willing to talk about his family’s major undertaking and investment and its future in milling.

A quick look back

The Ponders End site as a milling site on the river Lea can be traced back to the Great and Little Doomsday Book first published in 1085 and which was given a ’Sunday best’ refurbishment in 1869, just two years after the formation of GR Wright and Sons Limited in 1867.

Looking down at Wrights and Sons delivery lorries and its reception and laboratory area (top centre), from on top of the mill

Today’s company was formed by George Reynolds Wright in 1867. He had three sons all of whom worked in the business – they were George William, Walter James and Leonard. It was Leonard’s son George William who followed his father and in turn passed on to the fourth generation in Kenneth Reynolds before Kenneth’s son David took over control in 1982. David Wright, sitting across from us today and still in his working prime, is currently passing the running of the company to James, one of his three children.

Both David and James are graduates of the Swiss Milling School. David’s training included working at Simon Engineering, just at the end of its hay-day at Cheadle Heath near Manchester, in the UK. It was a good time to have been there and to have witnessed this company before its demise, he says.

James on the other hand did his early work in milling, starting at age 11, by completing school projects before working in the mill itself and then following in his father’s footstep to graduate from the Swiss Milling School in St Gallen in 2013. He became the company’s mill manager in 2016 and has had a hands-on involvement in the planning and construction of the new Harlow flour mill since its inception.

Why build new?

“If you sit down and only look at the numbers you might never do anything,” says David, when asked the question of why build a new mill and why in Harlow, just 10 miles from the historic Ponders End mill site.

“The principle is that we love flour milling and we want the business to be successful not in five years or 25 years’ time, but beyond that. We wanted to future-proof the business and our production processes.”

The first thought was to build the new mill on the old site.

“But then we asked ourselves where were we going to locate and put all of the equipment needed? We have got Listed Buildings there - the original mill building and the barn are all protected and you can’t knock them down.

“Old buildings, the process flow and the cost of the new equipment and the limitations of the old mill site said to us that

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F it was a compromised location. We felt that we should start again on a completely brownfield site and have it how we want it. It won’t have the compromises and we’ll have it exactly as we want. It costs a bit more but we felt if we were going to spend quite a lot of money at Ponders End then let’s spend a bit more and get it absolutely right.”

The new mill is fully equipped with Bühler equipment except for the silos and the packaging machines - the silos being designed and installed by Bartons of Bristol, the UK’s market leader in silo design, manufacture and installation and Arodo and Fawema packaging systems. Even the new 7.5-tonne-an-hour pellet press for bran processing is Bühler’s.

The company has left space for a colour sorter but not yet decided upon one.

“It’s a fabulous bit of equipment. But if you are doing a lot of brown flours and whole meals there might be more of a need, but our wheat comes in very clean and I don’t think there is a pressing need for us to have one, but that said we have got the space there should that decision change,” says David.

He turned and asked his James what he thought!

“Brown flours and whole meals, that’s where they have their value. I’m all for them. I’d like someday to be putting one in,” he replied.

“But James would have every piece of new equipment if he could!” retorted his father, who said the company had the option but was yet to evaluate its benefit.

“We’ve got the space and we’ll keep a watching brief.”

The selection of mill equipment supplier and mill contractor, after considering several, was based on a decision “to go with what we know.”

The build took two years and the commissioning started in December 2020 with the mill running in January.

“After that we had four months of settling in with everyone coming across from Ponders End in April - the office, the transport, etc.”

Clockwise – The stairwell; James Wright and Tuti Tan discussing new automation in the mill; mill performance indicators from Mercury (MES); technical team members Leona Poon, Michael Browne and Rebecca Borley in the fully-equipped on-site testing laboratory.

50 | October 2021 - Milling and Grain

Ten miles was close enough for our staff to come with us or commute, added David.

“April was the time we really got going, with everyone coming along and it was the beginning of May when the mill went into full 24-hour production.

“It’s only the last month or so that we have become completely happy with the way everything is working.”

Generational change

It was clear to the visitor that a generational chance is occurring for this milling family.

David, of the older, more experienced generation, has successfully steered his family’s business, as its managing director, for almost 40 years up to the point of commissioning a brand-new flour mill in an extremely competitive environment.

He is passing operational control across to the next generation, his son James who is clearly focused on new processes, new sensor technology, big data and the possibility of running a mill at consistently high outputs and a product quality second-to-none for the next 30-plus years.

He recognises that the ability to gather and interpret data may well provide the information needed to allow the management of a production line running 24/7 at the great efficiency, while maintaining flour standards demanded by discerning customers.

When I provoked David by suggesting that developing the business to where it is now - having commissioned a new 450-tonne-per-day factory in recent months – was only half the job and that it would be the future use of technology and data that would take the company forward and determine its success, he wasn’t fully convinced.

He admitted that the focus on the utilisation of the data concerned him.

“To me it’s great provided that data is used and we get benefit from it, rather than spending money on lots of reports that are just very interesting. If we can use that to improve output then

F “In terms of automation our equipment is the best you can get for a flour mill with all the sensors that you would expect to have today.

“The Mercury (MES) software system runs everything.

“We were the first mill in the country to have that. It was software that was still being developed and written as we were commissioning the mill. We were very much a test mill where that system is concerned. I don’t particularly like the test aspect of new technologies because as a business you have to minimise risk to protect yourself. You don’t want anything to go wrong.”

Operations

Asked if the company was employing more staff with the new mill, David says, “We didn’t increase staffing levels at all.

“In fact, on the new site there are less people. There are 120 staff in the company with about 40 at Delta Park, Enfield where the company has a mixing and packing plant.

“That’s where we make all our retail packs, mixes and blends and there’s a skeleton staff of six still at Ponders End. We have 20 drivers out on the road each day.”

The company operates a four-shift system in the mill and works 24/7; working four days on and four days off on 12-hours shifts rotations with one miller per shift.

The mills output is approximately 50 percent bulk and 50 percent bags and a lot of ‘Skus’ (which is an abbreviation referring to the sale of units and their different sized bags for different products).

Intake it’s brilliant. But you’ve got to watch these collection systems because all these add-ons cost money to install and operate.”

However, he readily acknowledged that data gathering is proving itself.

“We installed a system called Blackbird on our Arodo packing line, which is relatively inexpensive and comes with a monthly subscription. It’s counting the bags that go through. It’s webbased so you can see it from anywhere, at any time, what is being packed and every time it stops.

“In the past we relied on operators to report stoppages. But there are micro-stops throughout the day that are not recorded, and these can add up to possibly three hours of downtime a day which might not sound a lot but across the month it is.

“We’ve been trying for years to improve our efficiencies, which was all done with men-in-place systems. Sensors can be the way to drive improvements,” he admitted.

That brought James into the conversation. He’s an early convert to Bühler InSights, a subscription-based model which in his view “has been fantastic” so far.

“You can see everything, all the data of all the machines which is fed to the cloud, and we can use that data to drive efficiencies in the plant. Bühler InSights offer a free trial before you decide what modules you want to continue with. For example, we received a report today, which is 40 pages long, but goes through the complete performance of the mill; what’s gone through the mill, the extraction rate, power consumptions, the storages, what’s in each bin and a complete picture of how the plant is being run and what we could do to make that better.

“So in terms of that, data it’s pretty fantastic. Normally, you would have to put it all on a spreadsheet and look at limited information you might have in a historic way.”

James adds that this is not the SmartMill nor the new E3 Mill (which Milling and Grain will highlight in its November edition), but a new mill with Bühler’s top line equipment run through its Mercury SCADA system.

“Another great benefit here is wheat intake. There’s an automated process where 200 tonnes an hour can be received, and it takes just eight minutes to tip a 29 tonne load of wheat. And that was one thing which we are particularly keen on - making sure that we were a good home for farmers to bring their wheat. And the drivers and the hauliers love it here too as they are rarely delayed,” he says.

“We never tip without testing.,” says James.

Right at the factory gate is the mill’s laboratory.

Sampling, weighing and testing, is not included in the eight minutes tipping time, is done using Samplex spear sampling equipment that takes a number of representative samples for the laboratory team to test. This process might add a further eight minutes to a delivery.

Everything is operated automatically using bar codes which open doors and start delivery routes to the raw wheat silos. A system called ‘Safe’ books in all incoming wheat and interfaces with Mercury (MES) to automatically route wheat to the correct bin so there’s no human intervention. The intake system utilises Bühler drum sieves and intake separators which take out a lot of the of the screenings before the wheat gets into the raw wheat bins.

If a delivery is out of spec it’s rejected. Otherwise, the delivery driver waits for a signage board to identify his vehicle number and OK him to proceed to the tipping point.

Good relationships with suppliers mean that they know their contractual obligations so anything out of specification will usually be picked up before the delivery even begins. As a final safeguard all wheat supplies come through known merchants and are variety specific.

“We are boring buyers of wheat. We will stick with a variety of wheat we like until it is no longer available before moving to the next one. We buy only Crusoe and Skyfall which are our main varieties. As Crusoe is now on the way out, we will be looking around for the next one to replace it. The business is small enough to be able to find the varieties we want and not have to rely simply on what’s available to keep the mill running,” says David.

Milling and Grain - October 2021 | 53

F Incoming wheat is routed to bins based on their quality, such as protein content, etc.

The mill has 6000 tonnes of storage capacity and approximately 1200 tonnes of final flour storage.

“We have future-proofed the site so have space and foundations in place for the next set of wheat and flour silos, and another mill.

So we feel we are ready should we want to expand in the future.

In the plant

Donning laboratory coats, hard hats, shoe coverings, earplugs and face masks we walk to the end of the corridor that opens into a walkway and through into the factory proper which has been purpose built behind the office block.

We entered the mill on the first level and proceeded to the control room on the roller mill floor.

James, shows us around the roll floor and in into the control room where the Mercury (MES) control system runs and monitors all the plant.

Top-Bottom - Bühler Bran Finishers MKLA, Sirius Sifters MPAK and filters.

“Both the products and the mill settings are recipe driven so everything comes across here,” pointing to the first screen. The recipe attached to each product will allow for automatic roll adjustment and other settings in the mill, all controlled by the Mercury (MES) software.

Set grist and product specifications set out the requirements needed for products and the plant setup.

Included in the spec is the protein content with the option for gluten addition to top up the protein level if required.

Once cleaned and conditioned wheat goes forward for processing. The Harlow mill is a hybrid, meaning is not dedicated to either soft or hard wheat but has the ability to process both.

“If we want a higher protein flour we will tend to blend in higher protein wheats, such as Canadian.”

What we want is a consistent product for the recipes we run and the best way to achieve that is to blend, blend and blend some more. The more wheat you can blend the better. This irons out any small inconsistences that may occur and the scope for wheat blending here is very good because of the bin set up we have. We can blend from up to 26 different raw wheat bins.

“From the raw wheat bins the wheat is cleaned again in the screen room which is also incorporated into the mill building for optimum plant supervision. Cleaning is carried out on the Bühler Vitaris Combicleaner – almost a whole screen room in one machine and the first of its kind in the country. Water is added using Bühler MOZL intensive dampening equipment which ensures moisture levels called for by the recipe are achieved accurately.”

Conditioning times vary depending on the wheat type with consistency ensured using first-in-first-out bin dischargers.

“From this point it’s brought into the mill with the opportunity to blend once again before second cleaning. Bühler Scourers and Aspirators remove the dust from the crease before entering a holding bin where it is weighed before going onto the first break.”

We have the option to pass the wheat through Bühler Wheat Peelers which have a more intense scouring process prior to milling taking off a much higher percentage of the bran layer before going onto first break, adds James.

“What we find with peeling and scouring, is that stocks perform better in the mill, there is less fragmented bran to deal with and it also reduces the potential for microbial activity.”

We use double roller mills on first break and when asked the purpose James says it’s a practical benefit is it gets more space for roller mills on the floor. We only use them here on first break and not on any of the reduction passages.

Building new has allowed the company to ‘engineer out’ issues that posed safety risks to millers and staff, particularly with regard to the roll guards on the high rollers, where wheat flakes can gather between the separate rolls to pose a safety or fire risk.

The roller mill allows for automatic roll gap adjustment as part of the Mercury-based recipes. Tighter roll gaps mean a harder grind.

Another feature is the automatic diverters and adjustable tube screw feeders that allows for the diversion of stocks around the mill as it exits the sifters with the ability to automatically vary the feed of these stocks into the flour streams depending on recipe.

“This allows us to fine-tune the flour and achieve a more accurate distribution of different bran stocks when making specialist brown flours.

“We’ve built this whole milling facility based on our experiences gathered at Ponders End,” he adds.

Steps in the process

The mill uses all top-of-the-line Bühler equipment - Antares roller mills MDDR, Polaris purifiers MQRG and Sirius sifters 54 | October 2021 - Milling and Grain

AAT21_Adv(LV)-W90xH132mm_Oct.pdf 1 2021/9/8 上午 09:30:34

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MPAK sifters that together process the wheat into high quality consistent flour.

Flour extractions based on the scales at the beginning and the end of the mill process and on our visit showed flour yield at 78.7 - where the company wants to be “There is no wastage in this mill,” says James.

In fact, it’s the downtime for maintenance, that impact the bottom line of a modern mill.

“We use the Ultimo maintenance package to monitor preventative maintenance work that is required to help ensure good plant reliability.

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Replay

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To gain greater insight into what is happening and what has previously happened within the mill, the control screen can go to ‘replay’ mode and operators can go through the process from start-up of any run to check where and why a problem might have occurred.

When the mill is running within the predefined parameters the system shows up green but as soon as a falls outside those tolerances it provides red indicators to alarm and inform the controller.

“In replay mode you can see where things might have gone wrong and how they might have been corrected,” says James.

“I can go back three weeks and see what the production runs were looking like which has been especially useful at correcting issues during commissioning You can really find out what happened and what it was that caused shutdowns or other interruptions during the shift. This makes it easier to find permanent fixes on those issues.

“Having 24-hour visibility of the mill is fantastic.”

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Milling and Grain - October 2021 | 55

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Once milled

The company uses Bühler loss in weight feeders for accurate dosing of minor ingredients added to the flour stream. Following processing the flour moves past an online Bühler NIR Multi Online Analyzer MYRG which monitors in real time during milling, continuously evaluating protein, moisture, water absorption and bran specks.

What is fantastic about Bühler InSights, he says, is that this quality data is totally tied into the production data so you can go back to any point-in-time and see what you were making and the product’s test results at that time. And there is also a traceability option built into Mercury (MES).

Comparing with the E3 Mill

“In our view this mill’s control system and equipment compares very favourably with the E3 Mill that Bühler has developed,” adds James.

In fact, Mercury (MES) is the latest control system from Bühler and GR Wrights and Sons has been the first company in the UK to have installed and use it.

Final checks

Quality assurance at the mill tests the flour produced every hour with a sample going to the laboratory.

“We are using both the on-line NIR and the tests from physical sampling in the laboratory at present which are comparing very well.

Food safety is paramount and so a robust sieving and redressing system is in place to ensure product integrity throughout the

56 | October 2021 - Milling and Grain

process. There is also an option once again to blend flours to meet final specification before going to the warehouse for packing in a range of bags from 500g upward via the two packers - Arodo for big bags and Fawema for retail bags - through to bulk out-loading when flour is dropped from three 80-tonne out-loading bins into tanks of 29 tonnes.

Finally, everything is weighed off at this mill, from the cleaning and screening section through to the flour and bran produced.

There is no unexplained waste occurring in the process. The bran, by the way, goes to animal feed trade.

“We pelletise the bran - which is a new experience for us but that returns a premium as a pelleted feed material, creates very little dust and the increased density means more can be transported on a lorry.”

Bran first goes into one of three 35-tonne holding bins which automatically start and feed the pellet press as they fill.

Key components

From the latest roller mills from Bühler, with recipe-driven automatic roll gap adjustment, automatic roll temperature monitoring to a control centre using the latest generation of the Mercury SCADA software along with Bühler’s MYRG technology for continuous online measurement of finished products (including protein, moisture, water absorption and bran specks) to Bühler InSights that analyses all aspects of production, yield efficiency and downtime, this mill ranks high on the list of the most advanced ever built.

In addition, the mill has Bühler’s up-to-date air makeup system which monitors temperature and pressure within the building and

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utilises heat recovery to control and filter all process air.

In addition to the Blackbird monitoring software installed on the company’s packing equipment, there is also a Mettler Toledo Freeway software system for data recording of check weights, metal detection and check quality data and operator checks.

Departure

Leaving such a dynamic, ultra-clean and positive atmosphere of this new mill through the walkway back to the office block was difficult.

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David accompanied us down the stairs to the foyer. The elevator trip up in the morning had bypassed the stairwell which, on walking down to ground level, is lined with historic pictures in chronological order and information pertaining to each of the six generation Wright family members, and others, that in my mind reinforced the concept that this new, ultra-advanced and wholly modern mill was built to protect the hard work of the past by future-proofing the business for the next 155 years of family ownership and operation.

Please see our interview with David Wright on Pages 112-113 in this issue

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Trends in

THE KOREAN RICE INDUSTRY

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By Yang Longguang, Deputy Head, International Management Division, Satake Corporation

he consumption of rice in the Republic of Korea (South Korea) is thought to have started around 3000 years ago. Rice is the staple food of Korea to the point that people commonly say that the power of Korea comes from rice, with 30-40 percent of their daily energy believed to come from eating it.

Although rice has been Korea’s staple food for a long time, Table 1 shows that the consumption per capita has been continuously decreasing. According to a survey by Statistics Korea, rice consumption per capita in 2020 was 57.7 kg, a decrease of 2.5 percent compared to the previous year. The decrease in consumption is due to several factors. The Korean diet has become increasingly westernised, and fewer people are eating breakfast.

It is also believed that the diversification of food along with the increase in the national income has resulted in shifting food choices. More people are choosing to eat grain products like bread and noodles for variety and their perceived health benefits.

Meeting the challenges of a changing economy

In order to meet the challenges of a changing economy, the Korean government has reviewed farmhouse protection policies and instituted measures to expand rice exports and enhance international competitiveness.

In the 1994 Uruguay Round Agricultural Agreement, Korea removed non-tariff barriers on all agricultural products and opened up the market instead of reducing the impact of market opening by gradually lowering tariffs. Rather than continuing to extend the deferral of rice tariffs, in 2004, Tariff Rate Quotas (TRQ) were established.

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Since 2015, the Korean government has been negotiating with the WTO to instate tariffs on rice, and in 2019, allocated quotas by country based on the recent performance of the five major exporting countries (US, China, Vietnam, Thailand, Australia) in relation to TRQ operation.

In 2020, processed rice exports amounted to US$137.56 million, an increase of 26.9 percent from the previous year and the highest ever recorded. The reason for the increase in exports is the five-year plan for the promotion of the rice processing industry carried out by the government. After the enactment of the Rice Processing Industry Act in 2011, the first “Five-Year Basic Plan” was established and promoted in 2014. In June 2019 the second plan was established and is currently being implemented.

In addition, in 328 facilities between 1991 and 2001, rice milling facilities or Rice Processing Complexes (RPC) have been scaled up and modernized in order to maintain industrial competitiveness. The goal between 2007 and 2019 was to foster 100 representative rice brands.

The second generation of the RPC has been continuously disseminated in response to the declining trend in rice consumption from 5.81 million tons in 2010 down to 3.50 million tons in 2020. Despite the general decline in rice consumption, the demand for processed rice products is increasing.

According to the 2020 report of the Ministry of Agriculture, Food, and Rural Affairs (MAFRA), the retail market of major processed rice products, including processed rice, rice cakes, porridge, rice crackers, rice noodles, brown rice milk, and rice bread amounted to 884 billion (KRW) Korean Won (US$752 million) in 2019, an increase of about 10.9 percent from the previous year.

In response to the societal changes triggered by the outbreak of the coronavirus, rice producers and processing and distribution industries are also promoting new marketing activities that meet the needs of changing consumer behaviour.

Diversity of rice-based processed foods

Another notable change in the rice market is the diversity of rice-based processed foods and the addition of value-added rice. In the past these foods have mainly consisted of rice cakes, alcoholic beverages, and other processed rice foods. As the demand for home-cooked meals has increased substantially as a result of the social distancing implemented after the coronavirus, large corporations are moving to target the growing home-cooked meal market.

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Whilst consumption of new types of rice, such as home meal replacement and instant rice, is increasing, large food companies are expanding investment in aseptic rice facilities to secure market share. The domestic convenience food market is KRW4 trillion (US$3.4 trillion) in 2019 and is expected to exceed five trillion KRW (US$4.25 trillion) in 2022.

The primary reason for the growth besides the current social distancing policies is believed to be an increasing proportion of single-person and dual-income households.

In line with the times, home convenience food is evolving into a product which can replace frozen foods and home-cooked foods while considering health, taste, and nutrition.

More opportunities to eat at home

As there are now more opportunities to eat at home than eat out, the tendency to value quality over quantity is increasing. For example, functional GABA rice is gaining popularity because it contains a large amount of ingredients which help to prevent dementia, lower diabetes levels, lower blood pressure, and also improve cerebral blood flow and promote brain cell metabolism.

In 2021, the Korean government decided to expand technological development and human resource training and investment in order to develop into a value-added economy. One of their hopes is to create new market demands for home meal replacement and value-added rice in order to revitalise rice consumption.

Loan support (50 billion KRW) for facilities/renovation, operation/purchasing funds for rice processing companies, and an increased limit for the facility support funds from 7 billion KRW to 10 billion KRW have also been created. Although the production and consumption of functional rice are still insignificant, Korea is transforming its staple food into one which better appeals to consumers’ growing interests in health.

New challenges and opportunities

Changes in rice consumption patterns have presented new challenges and opportunities for the Korean rice industry. To stay competitive, rice producers will need to enhance their facilties in order to suit consumer palettes for high quality rice products.

With the help of government support policies, contract cultivation, and improvements to storage and processing facilities, producers must make an effort to develop products which are responsive to changing consumer demands.

Table 1. Annual rice consumption per capita in Korea

1990

1999

2008

2011

2020

119.6kg

96.9kg

75.7kg

71.2kg

57.7kg

(Source: Statistics Korea)

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ALGAE IN BROILER,

SWINE & RUMINANT DIETS

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Using seaweed extracts to reduce antibiotic consumption in animals

by Bygora, Bavaria, Germany

lgae is now being used as a tool to reduce antibiotic consumption, with certain macroalgal polysaccharides being selected for this reason. Thanks to their ability to support immune function and the intestinal epithelium, they can reduce an animal’s reliance on antibiotics.

With the current modern production of antibiotics, gut health can easily be disrupted. This is a huge challenge in the industry and is something that scientific research is looking to eliminate with algae moving forward.

When animals take antibiotics, the gut barrier and immune system can often be weakened, which leads to further digestive issues. Both local and systemic inflammation are often experienced, which goes on to impact the growth and health of the animal.

The industry is working to find solutions for this issue. Which offer the ability to protect the health status of the animals without relying on antibiotics as much. Adding in-feed macroalgal polysaccharides is a reliable alternative to assist with immune function and the intestinal barrier function, offering animals more resistance against external aggressors.

The types of algae used

Seaweed is one of the top options that’s being investigated for this purpose. The structural complexity of this type of algae offers high reactivity, as well as many other benefits to animals.

Seaweed polysaccharides are derived from sugar units, such as xylose, uronic acids, and rhamnose. This results in their branched structure and sulfate groups. They are very 62 | October 2021 - Milling and Grain

F soluble, which helps to increase reactivity and makes host cell recognition easier.

Macroalgae contain sulphated polysaccharides, which aren’t found in freshwater microalgae or terrestrial plants.

These marine biotechnologies have been studied for over 20 years by the Olmix Group in France, which resulted in them developing Algimun. This in-feed product contains two biologically active macroalgal extracts. They are a red algae extract, which works to improve the gut barrier function, and a green algae extract, which targets the immune responses.

A research project that was conducted alongside INRA (National Research Institute for Agriculture, Food and Environment) in France showcased the benefits of green algae extract when tested in an in vitro model. The extract is believed to influence gene transcription, and improves the recruitment of antigen-presenting cells, and also offers anti-inflammatory properties.

Testing with broiler chickens & pigs

Further scientific studies also concluded that green algae extract offers immunomodulating properties and works to improve the monocytes and heterophils protection activities when tested on broiler chickens and pigs. The Olmix Group conducted multiple experiments alongside the Intestinal Biotech Development in 2017.

They could study the red algae extract to see how it impacts the intestinal barrier function. Research showed that it upregulates both scaffolding proteins and gene expression of transmembrane, which help to offer the optimal function of multiprotein junctional complexes. It also helps to establish the mucus layer, regulates epithelial cell differentiation, and prevents pathogen colonisation.

Another study featuring the red algae extract was given to mice by INSERM (National Institute of Health and Medical Research, France) in 2018. These results show the reduction of gut permeability to the blood. When tested on stressed animals, it is shown to reinforce the intestine’s barrier function while defending the animal from toxins and pathogens.

The benefits of using combined algae extracts

Algimun, which features a combination of red and green algae, offers improved growth performance and reduces the mortality rate in animals by 4.5 percent. These figures are compared to control animals, and they showed a net benefit of €0.03 (US$0.04) per broiler for the integrator.

When tested in sows, the product was shown to increase colostrum quality by 25 percent when compared to the control animals. Fewer treatments from vets were needed, and higher body weight when weaning was indicated. It was shown there was a 10 percent net benefits increase of €7.75 (US$9.16) per sow.

When tested in piglets, the results showed that the inflammatory status lowered by 16 percent, and 57 percent fewer animals were required to have veterinary treatment following the tests. By the end of the trial, growth had increased by an average of 300g per animal.

Therefore, the trials have successfully shown that the product with green and red algae extract offers a wide range of benefits to many animals. Algae is a good option for a natural alternative to antibiotics. It works to improve overall health and growth performance, allowing farmers to reduce their reliance on antibiotics in the future.

Adding in-feed macroalgal polysaccharides is a reliable alternative to assist with immune and intestinal barrier function.

Milling and Grain - October 2021 | 63

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Oat drinks

The environmentally sustainable alternative to cows milk

by Tietjen, Germany

Oat drinks are now stronger within the category of plant- based milk alternatives than soy and almond drinks combined, reports the Frankfurter Rundschau. The increase in awareness of health and related nutrition, makes dairy alternatives so successful.

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at drinks are now stronger within the category of plant- based milk alternatives than soy and almond drinks combined, reports the Frankfurter Rundschau. The increase in awareness of health and related nutrition, makes dairy alternatives so successful.

Right now, the oat drink is way up there on the popularity scale. This is because plant-based alternatives offer benefits such as cholesterol reduction and diabetes control and are therefore becoming increasingly popular and in demand.

However, the journey from the field to the oat drink is a long one. Without fine milling of the raw materials such as oat kernels or oat flakes, there is no oat flour, which is the basis for the production of the drink.

Oats are not a simple product for fine milling in terms of their properties. Important for successful milling is always the equipment of the hammer mill, as well as the "know-how" in the project planning and design of the entire milling plant.

Preservation of valuable nutrients

Oats naturally contain a lot of dietary fibre such as beta-glucan, minerals and essential amino acids. Especially the fibre here is higher than in animal milk and has been shown to have a positive effect on cholesterol and blood sugar levels.

But that's not all: a diet rich in fibre can prevent cardiovascular diseases and positively influence intestinal health and digestion. The oat drink is also a good alternative for allergy sufferers. The drink contains no lactose or gluten, nor soy or nuts.

64 | October 2021 - Milling and Grain

In order not to reduce or even destroy the valuable components of the oats during flour production, gentle milling is required.

In particular, very fat-containing products must be milled to a fine flour in this way.

Most Tietjen milling plants are designed by means of milling tests with customer-specific raw materials on the Tietjen test stand. The designed plants are always delivered with individually adjustable grinding parameters in order to be able to react to product variations or end customer specifications in the future.

From oat grain to oat drink

Oat drinks consist largely of water and, as the name suggests, oats. The starting material is oat grains. These are cleaned and hulled ("dehulled") before further processing. Next up they are processed into oat flakes and then ground, preferably, using a Tietjen hammer mill. Then the oatmeal is mixed with water. An enzyme is added to this emulsion, which starts a fermentation.

After a few days, the emulsion is dehydrated to a syrup. At the bottler, the oat drink is topped up with water to the desired concentration of 10-11% oats. If necessary, flavourings such as vanilla, chocolate or almond are added. In industrial processing, additives such as calcium or stabilizers are then added, and the product is made more durable by ultra-high temperature heating.

Qualitative production is crucial for a high-quality end product.

This includes the milling step, and that's where Tietjen comes in. The Tietjen high-speed mills VL3, VDK 5 and VDK 7 are recommended for the grinding of oats.

These high-speed mills are available in the stainless steel version and are all easy to clean and are also equipped with wear plates. As a result, the mills enjoy particularly good protection against wear and thus a long service life.

The VDKs also come up trumps with beaters that can be turned and changed quickly and easily with a special changing device.

F Efficiency is also the focus here. Since the high-speed hammer mills are designed for industrial use, oatmeal can be produced 24 hours a day, seven days a week.

The VL is a universal mill for coarse grinding

Sustainability dominates the market

As well as tasting great, the production of oat drinks is also environmentally friendly. Compared with semi-skimmed cow's milk, they consume only 40 percent of the energy needed to produce them and at the same time require 80 percent less floor space – two benefits that are not only well received by society, but also impress in production.

In the EU, oats are also grown without the use of genetic engineering. In addition, oat drinks are produced almost exclusively from organically grown oat grains, which also benefits the environment. So those who choose oat drinks do so with a clearer conscience.

Sustainable consumption is becoming increasingly important to consumers, which means that the market for oat drinks will also continue to grow over the next five years. In the EU and the UK alone, sales are expected to increase from EUR€3.4 billion (~US$4 billion) to EUR€5.0 billion (US$5.9 billion) from 2020 to 2025, according to an ING study. The Boston Consulting Group even forecasts a fivefold increase in global sales of vegan dairy products to 54 million tons by 2035.

The VDK is the classic mill for medium throughputs

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Escalating UK flour prices

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A sign of a broken post Brexit Britain or yet another Covid caused crisis?

by Levana Hall, Milling & Grain magazine lour is a staple food throughout the world.

In the UK this is no different - with about 11 million loaves of bread, two million pizzas and 10 million cakes and biscuits made every day, a feat that could only be achieved with the daily production of approximately 14,000 tonnes of flour, which is present in roughly one third of all supermarket food products.

The price of flour has been on the rise since the 1970s, starting off at just UK$0.12 (US$0.17) per 1.5kg, reaching almost UK£0.70 (US$0.97) by 2004. In 2011 there was a huge spike in flour prices, reaching a peak of UK£1.34 (US$1.85) per 1.5kg of flour, although this spike was due to a series of adverse weather events, such as droughts and high temperatures, as well as flooding in other parts of the world reducing the majority of crop to just feed grade. Plantings were delayed due to unforeseen weather changes, rare freezes, and spring rain, all destroyed potential crops, causing the stock-to-use ratio to fall close to a 40 year low.

Supplies ran low again in 2014, causing another price hike, but dropped down to around UK£0.90 (US$1.24) per 1.5kg in 2015. Flour prices had been on a slow decline since then, reaching as low as UK£0.68 (US$0.94) per 1.5kg, but rose quickly during the pandemic to UK£0.74 (US$1.02), so the effects were not as bad as the 2011 price hike but still bad enough that it affected those across the UK. As the pandemic slowly ends, the price also lowers, staying around UK£0.59 (US$0.82) for

66 | October 2021 - Milling and Grain

now. There is still a potential for price spikes, although this would be due to weather conditions now that we have the pandemic under better control (See Figure 1).

The Brexit effect

With the UK leaving the EU in January 2020, many supply chains have had to adapt to new rules, some even ceasing trade with the UK altogether. It has been difficult to judge how much it has affected us, with Covid-19 hitting around the same time and causing more damage to the economy it leads to some tangled data.

With additional customs and safety checks being introduced in January 2020, trade fell sharply, exports from the UK to the EU

were five percent lower in April 2021 than in December 2020 according to some companies, but elsewhere the figures were closer to 24 percent (see Figure 2).

The baking industry took one of the bigger hits when dealing with the Brexit fallout - as demands for flour and grains rose, so did the prices. Flour trade has had more problems all over the country, where a lot of flour that we export contains a high proportion of Canadian or American wheat.

The Republic of Ireland has a heavy reliance on flour imported from the UK, but with tariff imports increasing their costs, consumers could see a nine percent rise in the price of bread, causing a potential knock-on effect between the nations.

Most millers will already be aware of this, including director of the UK Flour Millers, Alex Waugh. “We have certainly noted the impact of this issue, and indeed the concerns of the flour milling sector were raised directly with the [European] Commission and UK government on more than one occasion before the TCA was signed,” he says. “We particularly highlighted the potential impact of the now-agreed rules of origin on Irish bakers and consumers.”

There are a few solutions to this problem, however. “The most obvious would be a slight adjustment to the productspecific rules of origin applying to wheat flour, so that it would be acceptable to make flour from third country grain where the originating grain would itself have been subject to the same tariff in both jurisdictions.

“It so happens that both the UK and EU apply a tariff of zero to the high-quality Canadian and US wheat used to make the flour in question. This is because grain of the required quality and with the correct technical characteristics is not available within either the EU or the UK.” A steady supply of wheat to mills and flour to bakeries is needed to keep supply chains running smoothly, disruptions in this could cause effects across the whole industry, and a shortage could lead to increased prices. Throughout the pandemic, the Government has recognised millers and their situation by helping with the necessary flexibility needed to deal with risks in staff absences and growing demand.

Global shortage of logistical resources

Despite the pandemic drawing to an end, issues still continue to arise that have the ability to affect supply continuity.

There have been major HGV driver shortages across the UK, there was already a decline before the pandemic, but it has worsened in the past year.

There are many reasons for a shortage of drivers, such as HGV training capacity being restricted due to lockdowns, retirement of HGV drivers, as well as EU drivers leaving the UK – another potential Brexit side effect.

If there are no HGV drivers, it is a lot harder to get produce to where it needs to be. There is also a lack of short-term visas being given out, which means fewer drivers are able to go to and from where they are needed.

Not only is there a shortage in HGV drivers, there is also a global shortage of shipping containers. Many countries implemented national lockdowns at the start of the pandemic, meaning shipping companies began to reduce the number of cargo ships they were sending out. This stopped the flow of imported and exported goods, and meant the empty containers weren’t being collected.

As consumers spend more time in lockdown, they would turn to online goods more, which were often imported. This has bumped up cost and demand, resulting in companies

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F struggling to keep up. Even in the UK, importers are facing additional delays and charges, so goods are taking even longer to get to consumers and costing even more.

Not being able to import goods at the right times means delays in the milling industry, wheat is used by millers in the UK to blend with lower quality domestic milling wheat, without the imported wheat millers will have to use more of their own produce. This results in millers using up their supply faster, meaning higher costs for everyone else.

Brexit breakdown or Covid catastrophe?

Some believe the ‘pingdemic’, referring to when you are pinged by the NHS Covid track and trace app, is causing shortages in production, as when you are pinged you have to self-isolate even if you have only been in the general vicinity.

This means more employees will get called out of work, slowing down production. Another potential cause in shortages could be due to the stockpiling that took place at the start of the pandemic, pushing stock to its limits very early on.

Others believe it is purely due to Brexit that food shortages are rising. Many aisles in supermarkets will be full one week and empty the next, as many deliveries were made via EU companies and even small business owners, who now can’t afford to pay the

admin costs of the paperwork since Brexit.

Now, deliveries go through London, which can cause further delays due to border checks. Some of the food imported has quite a short shelf life, so by the time it gets through all these delays there isn’t enough time to get it to the stores and sell all the stock, causing lower quality food to be sold and potentially losing customers.

This will affect smaller businesses more than the larger supermarkets, but it will still have a lasting effect for anyone involved in the importation of goods.

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How insects & grain mills are improving sustainability Starch production plants produce a range of intermediate products for human and animal consumption, as well as for industrial processing.

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by Dirk-Michael Fleck, Bühler, Switzerland

rain mills produce the flour we need to make bread, pasta and animal feed – but that’s not all. Starch mills also produce intermediate products used is various applications including recyclable packaging.

In this article, Dirk-Michael Fleck, Senior Advisor Biorefinery at Bühler’s Milling Solutions Business Area explains how new grain processing solutions can be connected in a sustainable and intelligent way.

As a general rule, grain is used to make flour but by using specifically adapted grinding and separation processes, other products such as starch, protein, fibre and germs can also be obtained from different types of grain. These semi-finished products form the basis for a number of end products including modified starch, glucose, alcohol, gluten and organic fibres.

The Milling Solutions Biorefinery Segment of Bühler is specialised in designing and building the plants for manufacturing intermediate products such as these. Other business units offer solutions for the downstream value chain.

We are all familiar with flour mills, but Dirk-Michael Fleck is mainly involved in engineering and building starch mills and he begins by discussing what differentiates one type of mill from the other.

Comparing a flour mill with a starch mill is like comparing a road system of a large city with an intercity highway, both are roads, but whereas one is used for local transport services, the

70 | October 2021 - Milling and Grain

other is a high-speed link between two cities.

In the same way, while a flour mill needs to be able to produce different qualities and quantities of flour, a starch mill must be as simple and robust as possible in order to produce consistently a specific quality of flour at high capacity.

A starch mill has to be designed to fit perfectly into the operating environment of a highly modern biorefinery. Upstream and downstream processes must be seamlessly interlinked, and when it is in fully automated 24/7 operation, the mill must continuously supply a constant product quality for the downstream process.

This is particularly important because starting and stopping wet separation and biotechnological processes cause great expenses and losses. The mill has to be fully automated and operate safely at high capacity in order to achieve economic efficiency. A medium-sized starch mill, therefore, has a capacity of 800 t/24 h.

What a starch mill produces

Starch mills usually produce one main flour and several secondary products such as bran from grain. The flour has to meet specific requirements so that, in the wet separation process that follows, starch, protein and other high-quality products can be obtained as efficiently as possible, with high yields and high levels of purity.

In the next step, semi-finished products such as starch, protein, fibre or germs are obtained from the flour through specifically adapted grinding and separation processes.

At Bühler, by “biorefinery” they mean a deep-processing plant that separates cereals into their pure natural components and then processes these intermediate products into high-quality end products. A modern biorefinery has major advantages – it not only creates a sustainable circular flow economy but also recovers energy in a synergetic way.

Yes, it is very multifaceted and complex, but it also an extremely interesting and challenging area in an industrial sector that has great potential. It’s amazing to see the huge variety of high-quality, sustainable products that can be produced from grain: not only starch and its derivatives – which include alcohol, sweeteners and acids – but also protein, fibre products, fats and oils from germs, wheat and corn gluten, dried distillers' grains with solubles (DDGS) and organic fibre.

F Without a doubt, protein is the most valuable fraction. Whether it is obtained from wheat, corn or pulses. Even though this protein fraction accounts for only five to 30 percent of total production, depending on the raw material and process, the demand for them is highest, and therefore the profit, too. These proteins are mainly used in the food industry for meat replacing products but also in the fish feed and petfood industry.

grain processing. But the finished products that are produced in a biorefinery are probably of even greater importance.

Here, Bühler offers an exceptional platform for producers and investors: with solutions for animal nutrition, aqua feed, pet food, bakery and confectionery, extrusion of meat analogues and, more recently, our innovative insects business, Bühler provides holistic solutions for these promising products and markets.

How this starch is used

The bakeries & insects biorefinery connection

Most of it goes into food, especially if you include sweeteners for soft drinks and confectionery. Often the starchy fraction is being converted in a fermentation and distillation process into alcohol. It can be portable alcohol or biofuels to ensure more environmentally friendly combustion.

In times of Covid-19 hand disinfectant also has to be mentioned. It contains around 80 percent alcohol, which is derived from starch and thus from grain. However, the greatest potential for growth in the recent past has come from the rapid increase in e-commerce and the booming online trade.

Packaging has to be of a certain strength to protect transported goods. It is starch that provides this strength. The huge advantage over plastic packaging, for example, is cardboard’s high level of recyclability and environmental compatibility. Recycled cardboard contains around 10 percent starch, which acts as an adhesive holding the cellulose fibres together and providing stability.

Bühler’s contribution to this growing sector

Biorefinery is in the center of Bühler’s main focus areas. A significant amount of grain is processed in biorefineries and Bühler is one of the world's leading technology companies in

Specialist in the design and build of installations for the grain-processing and compound feed industry

Take sponge cake or tasty bread - the glucose used for sweetening cake and the wheat gluten used to improve the baking properties of bread flour are both products that come from a starch plant.

With insects, we have great upcycling opportunity in the value chain of a Biorefinery plant.

In future, a significant amount of our animal protein requirements will be met through protein production at large insect facilities. This because of insect’s high sustainable and low ecological footprint on protein production. Recently, Bühler commissioned one of the first large-scale industrial plants for insect protein production.

The feed for these insects can be produced from by-products of a cereal-based biorefinery. The protein obtained from the insect plant can then be processed into a high-quality aqua feed, with extrusion technology from Bühler.

Biorefinery is becoming increasingly important and the key to success in a growing market for biorefinery plants is to combine each solution to a high sustainable and profitable value chain.

The example of insects shows how a sustainable and intelligent combination of a wheat starch mill and insects can play an important role in tackling the major challenges that our planet faces with its growing population.

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F

F

by Diego Navarro, PhD, Swine Nutritionist, Hamlet Protein, Denmark

ibre has traditionally been viewed as a negative component of the diet, particularly in early nursery. This perception stems from uncertainty surrounding its role in nutrition and health.

This uncertainty is a consequence of an incomplete understanding of what fibre is, how it should be measured, and what happens to it in the body. Advancements in fibre analysis has enabled nutritionist to effectively incorporate high-fibre ingredients into monogastric diets to improve or maintain production performance.

Dietary fibre is ubiquitous and practically unavoidable in animal feed but some ingredients are more fibrous than others. Cereal grains, oilseed meals, and ethanol byproducts contain varying concentrations of fibre. Not only do their fibre contents vary, the types of it are also different.

For example, the structure of arabinoxylans in wheat are more branched than the structure of arabinoxylans present in corn.

Fibre is defined as indigestible carbohydrates or lignin from plant material that have physiological effects on humans and animals.

It is considered indigestible because it cannot be broken down by enzymes produced by the body.

However, digestibility trials indicate that some fibre fractions do in fact disappear from the digestive tract, this is because they may be fermented by the gut microbiota.

How dietary fibre works

Fibre reduces the available energy in the feed because fermentation is a less efficient source of energy for the animal.

In addition, high levels of dietary fibre has been shown to reduce digestibility of energy, protein, and minerals in monogastric animals.

72 | October 2021 - Milling and Grain

These must be considered when formulating high-fibre byproducts (distillers dried grains, wheat middlings, sugar beet pulp, soy hulls, rice bran, etc.) into the diet. However, these ingredients may also contain factors that reduce performance, such as mycotoxins in distillers dried grains or β-conglycinin in soy hulls, that can easily be overlooked.

We can use high-fibre ingredients to effectively limit feed intake in gestation, improve laxation in lactation, or simply to reduce the cost of the diet. Fibre supplementation in the nursery is used to address health challenges and improve stool consistency, but it is not a “plug and play” solution.

There are a multitude of factors that contribute to post-weaning diarrhea and accurate diagnosis should be the first step in solving the problem before any intervention. Fibre should be viewed as an essential tool in a toolbox, not a cure. Does that mean that fibre should only be used in health challenged scenarios? No, insoluble fibres stimulate movement of digesta through the intestinal tract to prevent stasis and proliferation of pathogenic bacteria.

Prebiotic carbohydrates may improve performance by aiding the maturation of the gut. The key is to know what fibres you are working with because not all will give you the same result.

How do we measure the effectiveness of fibre supplementation?

Similar to evaluating other feed technologies, first we define our metrics for success using variables that are easy to measure.

If the objective is to reduce post-weaning diarrhea and improve health status, does it make sense to conduct fecal scoring or monitor the number of falloffs and mortality? If we are feeding sows, is it simpler to measure feed intake or sow condition scores? The challenge is effectively measuring these metrics that are practical on the barn level.

If evaluating return on investment, it is important to consider the other components of the diet. If a fibre solution contains prebiotic carbohydrates and increases production of butyric acid, it may be possible to remove feed additives with similar modes of action.

F Fibre’s role in the sustainability of animal agriculture

Constantly changing regulations in animal agriculture closes the door for many feed technologies while opening it for others.

The use of pharmacological levels of zinc oxide has been proven successful in addressing post-weaning diarrhea, which led to its worldwide adoption after strict regulations were put in place to limit the use of antibiotics.

However, the use of pharmacological levels of zinc oxide is now starting to be phased out in many regions which prompted the search for alternatives. Many are lowering crude protein in early nursery diets and investigating other feed technologies. We must be proactive, rather than reactive, when it comes to nutrition by improving gut health to produce a robust herd.

Fibre will play an increasingly important role in animal nutrition and a sustainable animal production system. There are many potential synergies to be explored with fibre, such as its use with enzymes and probiotics. The goal is not to completely break fibre down into simple carbohydrates using various enzymes, but rather to hydrolyze specific linkages in its structure to make certain substrates more accessible to both the animal and its microbiota.

These substrates may serve as smaller links of prebiotic carbohydrates that are cleaved from larger carbohydrate structures or even certain nutrients that were encapsulated within the fibre matrix.

Fibre application may also have potential implications on the environmental impact of swine production. High levels of dietary fibre may shift nitrogen excretion from urea in the urine to ammonium in the faeces. Ammonium in the faeces is a more stable form of nitrogen, reducing the amount of nitrogen released

“Prebiotic carbohydrates may improve performance by aiding the maturation of the gut. The key is to know what fibres you are working with because not all will give you the same result" into the atmosphere as ammonia and improving the value of manure as fertiliser.

High concentrations of ammonia in the barn will negatively affect animal performance and can cause health issues in humans.

Trapping the nitrogen in the manure will result in healthier animals and a safer working environment.

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HP FiberBoost is an enzyme-treated functional fibre solution from Biomin that combines the physiological benefits of insoluble fibre and the stimulating effect of prebiotic carbohydrates on gut health. Specific enzymes hydrolyze sections of the carbohydrate structure to reduce viscosity while maintaining the desired physical characteristics of fibre.

This targeted cleaving enhances the concentration of prebiotic carbohydrate fractions that stimulate beneficial bacteria in the hindgut to produce significant amounts of butyric acid.

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Milling and Grain - October 2021 | 73

F

Processed Animal Proteins A relaxation of European feed ban in Europe looks set to open new markets

P

by EFPRA, Belgium

rocessed Animal Proteins (PAPs) are now available for use in pig and poultry feed after many years as an important ingredient for pet food and aquafeed.

PAPs are produced from animal byproducts from healthy animals that are fit for human consumption. In every animal reared for food, a significant quantity of material is inedible or not eaten for cultural reasons. These by-products contain a range of valuable fat, protein and minerals, the rendering industry recovers these materials and makes them into raw materials for use in feed and other applications.

Recovering material and putting it to a high value use such as animal feed represents a useful step towards a more sustainable food system. The composition of PAPs also offers potential animal welfare benefits by providing a nutrient rich diet to pigs and poultry thereby improving health and welfare.

74 | October 2021 - Milling and Grain

Opening up new markets

In Europe, using Processed Animal Proteins (PAPs) in aquaculture was restricted until 2013. Since then, non-ruminant PAPs have been permitted reflecting scientific consensus on the safety of feeding land animal proteins to fish. Rendered animal fat and oil have been available to use in aquafeed for many years without any restrictions.

PAPs are free from any specified risk material and the highest standards of hygiene and traceability mean it is a safe, healthy animal feed. Prior to this announcement, the use of PAPs in the diets of farmed land animals was much more restricted in the EU, with the recent relaxation welcomed by many stakeholders across the continent.

The European Fat Processors and Renderers Association (EFPRA) welcomes the recent relaxation of the so-called feed ban that relates to the reuse of animal proteins, with the move widely considered to be a signal of commitment to building a more sustainable circular economy in Europe.

F Annex IV of Regulation (EC) No 999/2001 has now been amended to allow Processed Animal Proteins (PAPs) to be used in the diets of non-ruminant animals. Specifically, protein derived from pigs may be used in poultry diets while, protein derived from poultry is allowed in pig diets.

“Our members are understandably pleased with the changes in the regulations which opens up new markets for their products,” says EFPRA General Secretary Dirk Dobbelaere.

“It is testament to the hard work member companies have done to ensure the industry operates at a very high technical and scientific level. It means we can produce safe, healthy single species animal proteins that are highly valued as feed ingredients.

“Today is really the first stage in the process, the next step is for EFPRA members to work closely with other parts of the food supply chain to find beneficial ways to increase use of animal by-products in animal feed.”

A Europe-wide move towards more sustainable practices

The decision marks a Europe-wide move to more sustainable circular business

practices. This includes initiatives such as the Green Deal, Farm-to-Fork Strategy and UN Sustainable Development Goals.

Rendering, with its history of reprocessing by-products back into useful raw materials is a longstanding example of the circular economy in action.

“The member companies of EFPRA facilitate the operation of the whole animal-based food chain,” says EFPRA Technical Director, Dr Martin Alm. “Safety is always our first priority; we take the by-products from animal production and make them safe. This protects the health of humans and animals by preventing disease.

“And we do more, we take these byproducts and transform them into a diverse range of raw materials and ingredients which are used in food production and other areas of the economy.”

Dr Alm acknowledges that livestock production can be a hotly debated issue in discussions around sustainability, but he is keen to stress EFPRA’s role in lowering the environmental impact of the whole animalbased food chain.

“By mass, approximately half of every animal produced for meat doesn’t become food. Renderers make sure that everything is used, and nothing is wasted. The materials such as PAPs and fertiliser that

Milling and Grain - October 2021 | 75

F are the recycled back into food production have a low carbon footprint compared to virgin raw materials.”

A lower carbon footprint

EFPRA uses the GFLI accreditation system to assess the sustainability credentials of animal fats and proteins as animal feed.

According to this analysis, PAPs have a lower carbon footprint than soy, particularly when land use change is taken into account.

It is also thought that there are health benefits to pigs and poultry consuming a diet containing PAPs. Research projects are already underway at Wageningen University in the Netherlands to investigate this.

“Restrictions on animal protein use were introduced 20 years ago.

Since then, agricultural practices as well as technology and methodology in the rendering industry has changed but the standard values for animal proteins in feed tables has not,” says Carine van Vuure, member of the EFPRA Technical Committee.

“Research is aiming to fill this critical gap in our knowledge as well as measure if there are any animal health and performance benefits to using PAPs.” At present, there are some early indications of these benefits, but the size and scope of the studies means that there is no conclusive evidence until more research is complete.

Summaries of the research to date into pig and poultry diets containing PAPs, including feed tables for linear programming for compounders are available at the EFPRA website.

EFPRA anticipates that inclusion rates of 2–10 percent will become commonplace to

Sjors Beerendonk

Dr Alm

Understanding more about PAPs Dirk Dobbelaere

Caine Van Vuure

Elevator parts

www.vav.nl contact@vav.nl +31(0)71 40 237 01 76 | October 2021 - Milling and Grain

supply protein and other essential nutrients in the feed ration. “PAPs are one of nearly 2000 ingredients so we need to work in partnership with pig and poultry producers, and feed compounders to understand the optimum usage.”

Compounders and farmers are the immediate customer for PAPs, but EFPRA is also thinking about attitudes further along the value chain.

“Retailers and consumers need to know that PAPs are a safe, healthy and sustainable feed ingredient,” says EFPRA President Sjors Beerendonk.

“Pigs and poultry are omnivorous so would naturally seek out protein rich food, that is why PAPs are such a valuable feed ingredient.

Likewise carnivorous fish such as salmon as well as domestic cats and dogs can all benefit from diets that include PAPs. “Europe has the world’s most effective animal by-product regulation to ensure the safety and quality of the finished product. To make PAPs for pig or poultry feed, every stage of the process is strictly segregated by species, right down to the lorry which delivers compound feed to the farm.”

To help the public understand more about PAPs and the rendering industry in general, EFPRA has prepared a wide range of information available on its website. It includes answers to some of the most common questions they are asked about the topic.

Following Brexit the changes in regulation do not apply to the UK, which still prohibits animal proteins in pig and poultry diets. FABRA, the UK rendering industry trade body and EFPRA member, has published a position statement about whether a similar change in legislation will happen in the UK.

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F

Waffle

flours

Developing a quick and reliable testing method for establishing the characteristics of raw materials prior to production on an industrial scale

W

by Zuleyka Rodriguez Gutierrez, Bühler Food Equipment GmbH, Austria & Markus Löns, Brabender, Germany

affles are flat fine bakery products, which are baked between two hot iron plates using either a waffle iron or within a specifically designed waffle machine. Many different varieties of this baked good exist including flat, soft or cross waffles, which are all different in structure and texture.

Flat waffles consist of a dry pastry with a porous structure, which is mainly caused by evaporating water. Waffles are used for different purposes (rolled or casted ice-cream cones), in layers used in sweets (flat waffle, waffle sticks) or also as waffle sheathing for a chocolate filling (hollow waffle).

Waffle recipes are quite simple and do not need many ingredients beyond water and flour, with the latter being the main component. That said, milk, sugar, salt, baking improver and/ or fat may also be added into the mixture should it be deemed necessary.

Although most waffle-masses are fluid and pumpable, in order to obtain a complete structure of the waffle sheet, the flour used should be weak, with low protein and wet gluten content.

The water absorption rate of waffle flours should also be low, with the addition of just a small amount of water creating a well pumpable dough, which also allows for the wide use of water as a baking agent (water steam proving).

Production on an industrial scale

When producing waffle cones on an industrial scale, the waffle mass is pumped through a tubing system. During this process, 78 | October 2021 - Milling and Grain

mechanical energy is applied onto the mass, which leads to a viscosity change if gluten protein is present.

This so-called “gluten aggregation” can influence the dosing, and thus leads to the waffle forms not filling properly, or that the baked products show other unwanted defects such as cracks. It is also possible that clots are formed, which can lead to a blockage of the dosing dies.

Therefore, establishing a quick and reliable method for identifying most of the main flour parameters (wet gluten, protein content, and water absorption) is of great importance for the producers of waffle products.

Adopting measures such as the evaluation of flours with a Brabender GlutoPeak, and the GlutoPeak evaluation “Rapid Flour Check” (RFC) provides one solution, which implements a quick characterisation of flours by mixing a small quantity of flour and water within a controlled environment.

The purpose of this procedure is to analyse and monitor the gluten development within that dough. As an onward development, the “Low Protein Check” (LPC) method now exists that is specifically designed for properties of low protein flours.

Within the project described within this article, these GlutoPeak methods were tested using 20 different flour samples provided by mills and food manufacturers. The aim of these tests was to check if these methods gave reliable results and offer the same opportunities to obtain information relating to the mixing and baking of waffle products within a short time range, in comparison to standard routine analysis.

The project partners were the companies Bühler AG from Uzwil, Switzerland, as well as the Brabender GmbH & Co. KG, Duisburg, Germany. The baking tests, the planning, realisation, and evaluation where carried out at Bühler Wafer Innovation Centre in Austria (Leobendorf). There was also the GlutoPeak

F

instrument that was used, which was provided by the Brabender company.

Typical waffle or cookie flours

For the project work, 20 different wheat flours were available, which were representative of the flours that are typically used to make waffles or cookies. As a baking test, standard ice cones were also produced and tested.

All flour samples were tested with the GlutoPeak and standard laboratory analyses, in accordance with the International Association for Cereal Science and Technology (ICC) guidelines, prior to the waffle dough preparation and baked to ice cones.

With the exception of one sample, all other samples fulfilled the basic requirements of a waffle dough (See table 1).

The first analysis was carried out with the GlutoPeak (Picture 1) in accordance with the standard RFC method and the available evaluation algorithm.

After defining the moisture content of the flour sample, approximately 9ml water (depending on the water content of the

corresponding sample) was filled into the measuring bowl and inserted into the GlutoPeak.

By using a connected thermostat, the measuring opening in the housing was heated up to 36°C, in order to provide for equal test conditions including homogenous temperature distribution in the measuring bowl.

After two minutes, during which an even temperature distribution within the water filled measuring bowl is achieved, the corresponding flour quantity (depending on the water content of the specific flour) was added.

By pressing down the measuring head, at which at its lower side the measuring paddle is mounted, the GlutoPeak is closed and the test starts automatically. Before the test, the corresponding test parameters were stored into the MetaBridge instrument software.

Then the motor that is built into the measuring head, drives the paddle and thus generates the rotation.

Depending on the flour property, the measurement takes twoto-five minutes at 2750 min-1. Due to the high energy input, a gluten network develops depending on time and corresponding to

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Milling and Grain - October 2021 | 79

F

each gluten quality and quantity, showing a peak (gluten peak) as highest value (torque).

Shortly after this phase the network is destroyed due to the mechanical energy input, the curve declines and the measurement is ended. A typical curve diagram is depicted in Figure 1.

After the test ends, the highest torque is listed as peak (BEM/ max. torque), and the necessary time (PMT/Peak Maximum Time) is evaluated. Additional measuring points are the torque every 15 seconds before and after the maximum (AM/PM).

The Rapid Flour Check analysis also provides for correlations towards other measuring procedures. These are protein content, wet protein content, water absorption, and the W-value (Alveograph process), whereby the latter mentioned was not

considered. After a short cleaning, the next measurement was then taken. Due to the rapid test procedure and easy cleaning, up to eight measurements per hour were possible.

The LPC method, which was developed during the project, was used in a second step. Hereby approximately 12ml water per 11g flour (depending on the water content of each flour) are weighed.

This method is done with reduced speed of 2500 min-1 and a temperature of 35°C. The previously mentioned evaluation is not changed by using this method. All tests were carried out as triple measurements and the results were collected and evaluated with the specified software (MetaBridge).

Most flour samples available were provided with the appropriate specifications. In most cases, these contained an average range within which the corresponding flour parameter should result.

However, in some cases it was not detectable if standard analysis methods were applied for testing.

In order to get reliable information about the available samples, in accordance with the standard ICC methods, all samples were checked by an accredited laboratory in Austria. All results of the flour analysis in accordance with ICC-Methods are specified in Table 2.

The final product properties depend on those of the flour

The recipe used for making the waffle mass is depicted in Table 3. In fixed order, water and sodium bicarbonate were given into an IKA laboratory stirrer equipped with a R1300 blade mixer and mixed with moderate speed until a complete homogenisation was reached.

Following the next process steps, flour was inserted stepwise and the mixer speed was increased. After adding all of the flour, a 80 | October 2021 - Milling and Grain

F Table 1: Analytical Parameter for Waffle Flour Wheat type: Soft wheat Flour aging period: 1 to 2 weeks storage after milling Analytical Parameter

Ideal

Acceptable

Moisture content, %

< 14.5

< 15

Protein (14% moisture), %

ca. 9.5

< 10.3

Protein (relating to dry substance), %

ca. 11

< 12

Wet gluten, %

ca. 25

< 27

Ash content, %

0.4 – 0.6

0.4 – 0.75

< 55

< 56

no

no

Water absorption, % Addition of ascorbic acid

further mixing of the waffle mass is done until again a complete homogenization was reached. Then followed by the next step the pre-prepared 1:1 mixture of sunflower oil and soy-lecithin was added into the mass und mixed for another 60 seconds.

Immediately after mixing, the viscosity was measured using a gravity feed cup of 100 ml and an 8mm die (diameter) (according to ASTM D 333). In case that the measured viscosity showed a deviation towards the defined viscosity of 20 seconds (+/- 1 second) the water amount of the recipe was then adjusted, and a new waffle mass was prepared.

By adjusting the viscosity of each dough to 20 seconds (+/- 1 sec.) the mechanical behaviour during baking can be considered similar for all flours, thus assuming that the product properties can only depend on the properties of the flour itself. The necessary water/flour-relation is an important parameter for developing a specific viscosity and is recorded for all test masses.

The baking of the cones was carried out with an electrical heated laboratory instrument type LB-SWAK_STAK, equipped with an industrial baking pan and a corresponding core plate.

The pan was heated up to 180°C, whereas the cores were heated up to 190°C. Using a spraying device, seven ml of waffle mass was inserted and the baking time was 80 seconds. Prior to closing the carrier for the final baking process, it was closed and opened twice (so called breathing: two seconds open, two seconds closed) in order to let the steam evaporate out of the system.

After baking, the cones were removed from the open baking pan and left for cooling at room temperature for approximately 10 minutes. The cooled cones were packed in PE wrapping, hot sealed, and stored at eight degrees celsius until the texture analysis took place.

The texture analysis was carried out with a TA.XT.plus Texture Analyser (Stable Micro System) using an ice cream cone pan (A/ ICC). This tool measures the force that is necessary to create a break, when a ball like item of a certain diameter and weight is pressed into the cone.

The most important texture parameters are the distance the ball moves, as well as the force which is necessary to break the cone. In order to carry out the texture analysis for every flour, 10 visually inspected cones were tested. The obtained results are summarised and evaluated afterwards.

Showing relatively high deviations

The GlutoPeak method titled “Rapid Flour Check” was developed for flours destined for baked goods, which require medium-to-high gluten level quality behaviours. Although flours for waffle production do not require high standards with regards to protein content, the method should be verified for its applicability.

Comparing the results of this method with the results obtained with the standard analysis, in principle the correlation of all 82 | October 2021 - Milling and Grain

F

relevant parameters (protein content, wet gluten, and water absorption) is good (Figures 2 – 4), however showing relatively high deviations.

Brabender states, that the correlated protein content is varying by +/- 0.8 within a range of 10.5 to 15 percent. Testing the flour samples, similar results are obtained (apart from W700 having a high protein content).

The wet gluten numbers should range within +/- 2.3 in comparison to the standard analysis, which was nearly reached for the flour samples tested.

In both cases the GlutoPeak method underestimated the results of the standard measurements, and was somewhat lower in protein content by around 3.5 percent, and wet gluten content by 11 percent.

The GlutoPeak method, however, overestimated the water absorption by around two percent (see Figure 4). Brabender specifies a deviation in water absorption of +/- 2.8, which the Bühler results confirm nearly. It is clearly recognisable that the deviation is increasing with lower WA values (waffle flour of a WA < 55%). This is a disadvantage of the method, as it is designed for flours with higher protein quantities and water absorption.

In order to maximise the potential of the GlutoPeak results and optimise the significance in regards to waffle flours, Brabender included the newly developed “Low-Protein” method in the course of the test series.

Afterwards, the already obtained data was re-evaluated and compared with the results of the ICC-Method. The results obtained showed a good correlation between both methods, which is commented later in the course of this study.

High water absorption leads to low product density

In order to verify a correlation between required water quantities – the respective product weight on one side, and flour parameters on the other - the data of the standard analysis and GlutoPeak analysis are dealt with separately.

Primarily it presents that a correlation exists towards the standard laboratory data. Following it is tested if the correlation with standard laboratory data is also observed with the GlutoPeak data.

The basic correlation of the amount of water required (for a determined dough viscosity) and the water absorption of the flour, is well known within waffle production and can also be illustrated for similar flours (see Figure 4).

Flours with a higher water absorption need more water for reaching a defined dough viscosity. This can be a disadvantage during waffle baking, as the baked waffle normally has a water content of one-to-two percent.

Thus, all of the water included in the waffle mass has to evaporate during baking to reach that residual.

During the baking process this evaporating water acts as a leavening agent, thus leading to very brittle or even incomplete products (inaccurate distribution of the mass within the baking pan).

Table 3: Recipe for Making a Waffle Dough Water

~ 300

g

2

g

200

g

Sunflour oil

2

g

Soy-Lecithin

2

g

Sodium bicarbonate Flour

84 | October 2021 - Milling and Grain

F Table 2: Measured Flour Parameter according to ICC-Method Moisture [%]

Wet Gluten [%]

Protein [%]

Water absorption [%]

Ash content [%]

13.6

24.6

10.5

57.1

0.59

W700

11.9

35.3

15.0

62.0

0.70

B1

13.2

22.3

10.1

59.1

0.47

B2

13.1

23.8

10.1

58.3

0.61

B3

13.2

23.2

10.1

57.3

0.68

B4

13.2

24.5

10.0

55.9

0.78

B6

12.8

25.0

10.7

56.1

0.66

M-01

14.6

23.8

10.2

56.2

0.54

M-02

13.8

23.7

10.7

56.3

0.61

M-03

11.3

25.7

10.8

56.3

0.64

M-04

13.0

19.4

9.0

57.6

0.62

M-05

15.5

23.6

10.2

51.3

0.45

M-06

14.6

22.9

10.6

55.2

0.64

M-07

14.5

26.0

11.0

56.5

0.56

M-08

14.7

23.9

10.2

55.3

0.55

M-09

13.0

25.6

11.4

57.7

0.62

M-10

11.3

22.9

9.8

54.5

0.60

Juwel B

M-11

14.6

23.6

10.9

54.3

0.58

M-12

14.6

24.2

10.7

55.0

0.64

M-13

11.3

24.4

10.2

56.6

0.60

A water reduction, however, is not always possible when those flours are involved, as the resulting increase in viscosity influences the dough and final product properties negatively, with a decisive factor being the amount of water that the particular type of flour demands for it to reach the desired level.

An easily detectable aspect that relates to the water requirement is the product density, and the specific weight. The higher the water amount, in relation to the water demand, the lower the density of the waffle product (i.e. product weight).

A high level of water absorption leads to products with a low density, as qualitatively depicted in Figure 6. Besides the flour properties, parameters like baking temperature influence (especially the core temperature can strongly vary during batch baking) certain characteristics including the dosing volume and density of waffle products.

Considering these additional influencing factors during baking, implies that the correlation of the product weight with the water absorption is less significant than the correlation with the water demand in dough preparation.

Perhaps more importantly, this applies to the batch baking of waffle sheets on laboratory scale, where significant differences in waffle density may occur.

The correlation of the water absorption obtained with the GlutoPeak method “Rapid Flour Check” and the water demand result in less significant values in comparison with standard analysis (see Figure 7).

Sample W700 (very high protein- and wet gluten content) is clearly identifiable within the sample points. If only the waffle flours are considered, there is no clear trend visible, with the same also applying to the product density (Figure 8). Therefore, the GlutoPeak parameter WA is less significant compared to the water absorption, measured by standard analysis.

A better correlation is achieved, when the parameter G (wet gluten content) is selected instead of the parameter WA (Figures 9 and 10).

Predicting waffle properties from flour data is difficult, as not only is the dough influencing the product, but the temperature/ temperature deviations in the oven, and dosing (quantity,

speed) are too. The data acquired from the texture analysis of the waffle product is already exhibiting a significant static variance and does not correlate well 258 with the flour properties.

452 Considering the test set-up (see Picture 3) the 385 essential properties relating to the product stability, 316 are the distance the ball is pressed into the cone (until the first crack appears), as well as the 350 corresponding force maximum for that crack.

279 Both parameters are severely influenced by the waffle 457 structure near the steam vent of the baking pan. Flours 381 of low water absorption show generally also at that 449 point homogenous, dense structures (see Picture 4).

414 Stronger doughs tend to withstand the steam flow, 373 if they have higher water absorption properties, and 457 present streamline structures close to the steam vents 433 (See Picture 5). The stronger the flour, the more 377 intensive these structures are, which lead to areas with less density and corresponding lower stability.

347 As mentioned earlier, the influence of flour is only 424 a partial aspect, which is influencing the stability 240 of the waffle material. Therefore, establishing a 367 direct correlation, even with the data obtained with 412 standard analysis, is difficult (see Figure 11).

385 Flours with visibly higher water absorption tend to form products with lower stability. As an example, the sample W700 with its high water absorption of > 60 percent results in less stable products, compared to the other flours.

However, flours with lower water absorption can also result in less stable products. This principle process is also exhibited, if correlated between the designated primary peak value Fmax with the GlutoPeak parameter G (see Figure 12).

Falling Number [s]

The newly developed Low Protein Check method

As the test results of the Rapid Flour Check (RFC) method did not produce optimum information, the test evaluation was carried out with the newly developed Low Protein Check (LPC) method.

By using this modified method, flour data of weak flours can be assessed with a rapid method (see Figures 13 – 18) with satisfactory accuracy compared to ICC methods. Contrary to the RFC method the LPC method is verified to flours with low protein (<11%) and wet gluten content (< 25%).

Therefore, the correlation of dough- or baking relevant parameters obtained with the modified GlutoPeak method (see Figures 16 and 17), are nearly as reliable as those flour parameters of ICC methods, The basic predictions regarding product properties (stability, for example) will lead to similar conclusions (see Figure 18) as this is already possible with data obtained relating to ICC-Methods.

This leads to the conclusion that the “Low-Protein”-Method of the GlutoPeak is a valuable alternative to the ICC-Methods.

As already mentioned, the prediction of product properties with regards to weight, or perhaps even more evident, the mechanical properties, obtained only from flour data is rather inconsistent.

These properties are not only defined by the water absorption of the flour used, but by far more other values.

During the GlutoPeak tests there were two flour samples which showed the phenomenon, that no peak developed. The necessary aggregation of gluten forming proteins obviously did not take place, and lead to the fact that no relevant change in torque is measured (see Figures 19/20). This test series was carried out as triple tests in order to rule out any application mistakes. Due to the curve progression and the resulting missing values, it was not possible to include these flours into the evaluation.

Milling and Grain - October 2021 | 85

F As a reason for the missing peak, it is assumed that the gluten building flour protein contained, was too low to aggregate for influencing the torque. There could also be the reason of a protein damage due to a denaturisation caused by too high temperatures during the milling process.

Predicting quality trends of baked waffles is very difficult

Every prediction could be reproduced in principle. This is valid for the standard laboratory analysis as well as for the results obtained with the GlutoPeak measurements.

However, the results of the Rapid Flour Check (RFC) method showed only a good correlation to a certain degree with the ICC laboratory data.

Especially the water absorption – a crucial factor for characterisation of waffle flours – was insufficiently displayed.

From 20 tested flours, 19 samples were defined as suitable raw material for waffle production. Only one flour sample was outside the specification shown in Table 1. The selected random sample is considered as homogenous.

Predicting quality trends of baked waffles is independently of the flour analysis used, very difficult, as a number of further influencing factors are affecting the product properties.

This is particularly valid, when not only the raw material flour, but also the baking parameter have a significant influence on the measuring data (such as waffle cone texture). Laboratory data of the baking does give better correlated results, when acquired via ICC-Methods in comparison with the RFC-GlutoPeak evaluation statistical wise. This could be due to the fact that the RFC-Method was developed more specifically for gluten strong flours.

Because of that, the flours were also tested and evaluated with the newly developed Low Protein Check method, which at the beginning of the project, however, was not yet available. The corresponding optimised LPCGlutoPeak method was modified by including the evaluation algorithm towards the ICC-standard methods, and adapting the necessary parameter.

Thereby equivalent results were generated in comparison with the ICClaboratory data.

With the exception of these two flours, which did not show any peak when applying the LPC method and therefore showing no results, the tests carried out with the GlutoPeak are suitable to describe the flour quality.

Due to its flexibility, easy handling, small sample quantities, and short measuring times a quick characterisation of waffle flours is provided. The stored correlations, like wet gluten content, showed a good reference value with the obtained results, by applying the usual ICC Methods.

Based on the flour characterisation provided with the LPC – Method, a quick test of much smaller flour samples for its standard suitability as waffle flour is as well possible, as a quick comparison of different flour batches.

Furthermore, the measuring results may be used to make a quick estimations relating to the necessary water demand, leading to a possible change of recipe or energy consumption. Predicting the product properties based solely on flour analysis, independently from the measuring method, is not possible.

86 | October 2021 - Milling and Grain

F

STORAGE

South American shipping crisis

A

Assessing the effect of critically low river levels on trade in Argentina

by Andrew Wilkinson, Milling & Grain magazine

t almost 5000 kilometres long, the Paraná is one of the longest lowland rivers in the world, whilst its extensive basin covers 2.6 million square kilometres, which is equal to the entire surface area of continental Argentina.

With a current depth of less than half of its historical average, the river’s unusually low flow is having a catastrophic effect on Argentina’s exports, as without sufficient depth of water, navigating the vital waterway has become all but impossible.

The low water level, considered to be the lowest for nearly eight decades, cost exporters as much as US$244 million in 2020, with incoming and outgoing vessels unable to operate or load normally. This situation also reduces the potential loading capacity of large ships, whilst leading to higher costs and potentially uncompetitive prices. This has in turn lead to Argentinian exporters failing to capitalise on high global prices for agricultural commodities, as a large share of the grain crop harvests from Argentina, southern Brazil and Paraguay are exported via the ports of Santa Fe, which is linked to the Paraná via a 60 metre wide, six kilometre long access channel.

In addition to the depth situation, establishing its cause is also creating a sense of uncertainty amongst experts as they seek to find a long term solution. One possible contributing factor is

88 | October 2021 - Milling and Grain

believed to be lower rainfall in the region, with further possible causes including deforestation, damming in southern Brazil and climate change also being considered.

A vast river system

The Paraná is much more than its main channel, it is also a river system with a vast network of secondary channels, valleys and floodplains that are served by the ebb and flow of floods and low flows that are typical of this type of ecosystem throughout the world.

Far from being a typical waterway, an impressive 17,000 cubic metres of water flow per second along the Paraná, mainly via the upper reaches of the basin located in Brazil, and also the Paraguay River. Its characteristic brown colour is due to the sediment it carries from the rivers of north western Argentina, such as the Bermejo. It was the flow of rainwater from the upper Paraná and the Paraguay that ceased in the southern hemisphere’s spring of 2019 due to unusually low rainfall.

Low water means low trade

In this instance the level of the water appears to be directly correlated with the levels of trade as the lower flow of water in the Paraná. This is because once the water level drops below a certain depth, the maximum size and weight of the ships that can still navigate the waters without becoming beached is significantly reduced, which translates into higher transportation costs in terms of both money and time.

F Gustavo Idígoras, president of the Argentine Oilseed Industry Chamber (CIARA), says that he is “very concerned” about the low water level, adding, “it has negative effect on navigability, which causes delays, ships get stuck and there are stoppages.”

According to Mr Idígoras, some 4500 large ships enter and leave the Paraná every year, taking out most of Argentina's agricultural production, with the low flow putting the flow of exports at risk.

“We see that there are cycles of drought returning with great force in South America. This is going to affect the region and works have to meet these needs while protecting environmental aspects... we stress the need for more in-depth and detailed studies,” states Mr Idígoras.

The low flowing river also makes it necessary to take more care when loading, generating logistical cost overruns. The low flows also affect land-locked South American countries Paraguay and Bolivia, for whom the Paraná is the main channel for commercial river transit.

Commercial navigation is at its most intense during the harvest peaks of the southern hemisphere’s Autumn months, as this is when ships and barges require the greatest depths possible, as well as a generous channel width for safe navigation.

Hope for the future

"With a current depth of less than half of its historical average, the Paraná river’s unusually low flow is having a catastrophic effect on Argentina’s exports"

Amidst these challenges, Argentina is discussing a new tender for the management and dredging of the waterway. Of its total length from the source in Brazil to its mouth in the Rio de la Plata, 3500 kilometres of the Paraná’s river are managed waterways, with the concession covering a vast 1300-kilometre stretch.

AZ_GRANIFRIGOR_EN_190x132_RZ.indd 1

11.02.21 14:56

Milling and Grain - October 2021 | 89

F This section of the river system contains a port hub made up of some 25 terminals owned by large multinationals that moved some 82 million tonnes of grain crops, flour and oils in 2019, making it “the most important agro-exporting port node in the world,” according to estimates by the Rosario Stock Exchange (BCR).

Since 80 percent of grain crops, by-products and oil shipments travel along the waters of the Paraná the waterway plays a fundamental role in Argentina's grain trade. Argentina’s landlocked neighbours Paraguay and Bolivia also bring their production down to the major ports on barges.

Covid-19, the death of Argentina's transport minister Mario Meoni and political disagreements over whether the waterway should be operated by a public or private company have led to

90 | October 2021 - Milling and Grain

Argentina extending the current concession until the end of July.

The hope is that the new investments will lead to a deepening of some sections, which will allow larger vessels to enter and leave with fuller loads.

However, there is no certainty over when and how the new tender will be launched with some reports suggesting that it may not happen until April 2022.

In Argentina there appears to be a broad agreement that any end to the drought and low water is not yet in sight. It is likely that the La Niña climate pattern will return at some point soon, which does not favour the production of near-normal rainfall in the region, let alone rainfall that will be significant enough to produce a noticeable recovery in the river’s water level.

Barley: Imports by China

• Despite ongoi barley originat In 2020/21, shipments to China experienced an 2020/21 im unexpected rebound, rising to a record level, even increased sign though dispatches from Australia remain

Resilience is in flexibility

I

n conjunction with the recent International Grains Council’s Market Conditions Committee meeting, its Secretariat recently held a press briefing to present its latest estimates for the grains, rice oilseeds and pulses

by Andrew Wilkinson trade, as well as highlighting current developments which may also be having an impact on trade – such as The latest droughts in Canada and the ongoing grains, rice and global Covid-19 pandemic. oilseeds and The discussion, which consisted of a 15-minute Secretariat pulses forecasts presentation followed by a lengthy from the IGC and thorough Q&A, was held on Friday 10 September via video Secretariat conference platform Zoom.

Featuring a panel of speakers which included the International Grain Council’s Executive Director Arnaud Petit and Senior Economic Analyst Miriam Morath, most of the presenting duties were patiently and ably undertaken by Nathan Kemp, who is a Senior Economist with the organisation.

Providing forecasts for barley, maise, soybeans, rapeseed and canola, this report seeks to provide an insight into the information that the organisation provided during this meeting, as well as providing you with a quick fire summary of the reported predictions.

Grains & Oilseeds With forecasts for world grain and oilseed production in 2021/22 mostly revised lower in recent months, global supply is at record high, but tightening, particularly for high quality varieties of wheat.

Consumption growth includes record feed use, including a rise in the EU. World stocks look set to fall for the first time in three years, with those in the major exporters currently at a nine year low. The IGC predicts that high import costs could contain trade, although recent indications do suggest that buying interest has been robust.

In recent seasons world durum crops have also underperformed, whilst supply has been outstripped by demand. As a result, stocks have progressively tightened, but this year’s poor world harvest could see a particularly steep drop, to a 14-year low at the end of 21/22. Inventories in Canada and the USA are especially tight, whilst quoted export prices have soared sharply higher in recent weeks.

Barley: Imports by China In 2020/21, shipments to China experienced an unexpected rebound, rising to a record level, even though dispatches from Australia remain interrupted, successfully securing supplies from elsewhere, whilst a small decline is anticipated for 2021/22, as shown in Figure 1.

92 | October 2021 - Milling and Grain

interrupted, successfully securing supplies from elsewhere. A small decline is anticipated for • 2021/22.

Increase in de strong uptake industry.

Jul/Jun imports by origin 14

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EU Argentina

Canada Kazahkstan

• China has sw securing supp (mostly Fr Argentina, Kazakhstan.

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• Shipments i expected to re 0 levels, but are 12/13 13/14 14/15 15/16 16/17 17/18 18/19 19/20 20/21 21/22 (est.) (f'cast) to be down Source: China Customs, IGC estimates, 20/21 incldues country-data up to Jun. supplies.

Despite ongoing interruptions to barley originating from Australia, 2020/21 imports by China increased significantly year on year, with this apparent increase in demand largely believed to be driven by strong uptake from the feed industry.

China has also switched origins, with the country now securing supplies from the EU (mostly from France), Canada, Ukraine, Argentina and Kazakhstan. Shipments in 2021/22 are expected to remain at very high levels but are currently projected to be down year on year on tighter supplies.

Due to ongoing trade disruptions with China, Australia has increased shipments to other destinations in Asia, including Saudi Arabia, Japan, Thailand and Vietnam. Before China introduced an 80.5 percent import duty on supplies originating from Australia in May 2020, China accounted roughly for two thirds of exports from Australia.

In fact, the last shipment from Australia to China was recorded in Nov 2020 and since then, no further exports have been recorded - an absence of nearly 12 months.

That said, buoyed by a bumper harvest, barley exports from Australia have rebounded sharply, with the shipments mainly destined to other destinations in Far East and Near East Asia.

2

Maize Discussing the forecast for maize, the question of whether 2021/22 trade will be shaped by China again was asked.

On that subject, the IGC predictions do suggest that global volume may retreat, but ex-China purchases do look set to Maize: 2021/22 trade to be shaped by China again? rebound (see Figure 2).

Global volume may retreat, but ex-China purchases to rebound.

Changes in 2020/21 imports

Changes in 2021/22 imports

mt

mt

Others

Others

Bangladesh

Turkey

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Brazil

Brazil

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Poor barley crop Sharply lower maize supply in the south Some substitution of barley

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Algeria

Colombia

Colombia

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Egypt

Morocco

Rebound in barley availabilities

Turkey

EU

Improved feed grain supplies

EU

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Much larger maize crop

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World ex. China

World ex. China

Large carryover from 20/21

Larger maize crop, elevated feeding of alternatives, moderating feed demand

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© International Grains Council

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F

Moving away from China, Brazil’s maize exports look set to fall to a five-year low, whilst in the US they look set to drop back from the peak, but still remain high. In Argentina and Ukraine the situation in these two great producing nations also looks set to rebound.

US export commitments have received a welcome boost from Chinese purchases, although no fresh sales have been announced to that particular destination since May earlier this year.

Soyabeans & rapeseed/canola The soybean situation also paints a very mixed picture as whilst production is forecast to expand to a new high, major exporters’ stocks are predicted to stay tight. That said, US inventories are seen to be well below average on prospects for high domestic use and exports.

With regards to rapeseed/canola, trade is mostly shaped by demand from Asia - including - China and the EU, with imports expected to drop on reduced supplies. With this in mind, the IGC forecasts do suggest that global supply and demand prospects in 2021/22 could require substantial demand rationing.

With supplies shrinking amid lower outturn, paired with very tight opening stocks, uptake in rapeseed/canola is projected to decline amid demand rationing. Amid these reports of shrinking supplies, consumption is also projected to retreat, mainly on reduced uptake in the EU-27, China and Canada.

To cover this shortfall, the IGC believe that end-users are likely to utilise greater quantities of alternatives, such as soyabeans and its product to meet overall requirements. Although stocks are set to decline further, mainly linked to low Canadian inventories.

Amid tight exportable supplies and high prices leading to likely demand rationing among key buyers in Asia, trade is forecast to contract by nearly one-fifth.

Strong sales from India to sub-Saharan Africa and Far East Asia seen underpinning trade in 2021, whilst increased freight costs Soyabeans: A record outturn in 2021/22 should allow for may also curtail the pace of exports in the coming months, with some stock gains, but exporters’ reserves to remain thin the overall outlook for 2022 remaining uncertain.

As stated by Nathan Kemp, Senior Economist at the IGC, those Major exporter end-season stocks commodities that have shown be resilient throughout the various While production istoforecast to expand to a 35 m t

crises grains major and oilseedsexporters’ industries have endured the newthat the high, stocksoverare past two years, are those that have adopted a more flexible approach. predicted to stay tight: US inventories seen This flexibility extends not only from their chosen supply lines 30 well below average on prospects for high but to chosen markets and end use. So according to Mr Kemp, the domestic use and exports key to resilience lies in flexibility.

18/19

Opening stocks Production Total supply

48 363 411

Total use of which:

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Closing stocks Major exporters

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Trade (Oct/Sep) a)

Argentina, Brazil, USA

19/20 20/21 (est.) (f'cast) 63 340 403

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21/22 y/y (proj.) change 53 380 433

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95 | October 2021 - Milling and Grain

Industry Profile

PLP Systems

S

Continuous coating test plant

pecialising in machinery and systems for food, pet food, aquafeed, animal feed and chemical industries, PLP Systems is a company with over 40 years’ experience in dosing, mixing, spraying, coating and handling of liquids and micro powder additives.

The primary focus of the company is to create customised dosing units suitable for the client’s needs, projecting on each occasion a tailored solution on request. For this reason, PLP Systems invests substantially in research and development (R&D) each year, developing new and exciting concepts whist always trying to improve and push forward existing technology.

An important area for PLP is the coating process that is used in different sectors including: post pellet coating for feed and aquafeed, pet food coating, seeds coating and fertiliser, as well as crisps, chips and snacks in the food sector.

Developing a continuous coating system

Initially, testing for new coating applications were done using internal small-scale laboratory equipment, simulating what could possibly be a true production, but this procedure was limited in many aspects compared to real production conditions.

Key changes occurred once PLP developed a continuous coating test plant system in its workshop which was able to reproduce the full capacity of the demands of the industry and minimise the difference in results between a lab test trial compared to a real production.

After having faced various challenges brought on by following a great variation of projects, we have managed to gain an extensive knowledge, understanding and competence in this field.

96 | October 2021 - Milling and Grain

This in-house continuous coating test plant is used for: Innovating PLP technology and know-how in order to compete in the market with an advanced post pellet coating application.

The focus is not only on the coating machine but also on the development of new types of sprayers, dosing equipment and software managing systems.

Customers that are looking for creative applications are able to test and develop new products for their feed (aqua feed, poultry, pigs, dairy) by coating with powders such as aromas, vitamins, whey and milk powder, flour meat, probiotics, antibiotics and medicines in general.

Another service that the company provides for new customers, is to let them fully test our PLP coating application before purchasing the system, in order to make them comfortable on deciding to choose our technology.

The test plant can be adapted for different products with a production capacity ranging from 300 kg/h up to 40 tons/h, managing different densities. It is equipped with an accurate gravimetric continuous dosing of the main product (pellets or mash) done by either a weighing belt or weighing screw.

Dosing of liquids by pumps and flow meters and dosing of the powders by loss in weight feeders. All are controlled by the automation and proportional dosing adjusted by frequency control drives.

The test plant can be integrated with three different PLP continuous coating technologies including drum coaters, twin paddle continuous coater and mass spin coater.

Specifically recommended for small pellets

The state of the art of the more traditional drum coater is specifically recommended for small pellets extruded or granulated and for a lower capacity of production.

The special corrugated shape of the drum increases the rotation of the product, at the same

time it protects it from damage and reduces the residue dirt inside the machine, making it a perfect machine to be used in the most delicate of applications.

The same Drum Coater, applied with different construction standards is widely used in the food process and seeds coating, where the handling of the product is very important.

It’s our most utilised machine for standard coating applications.

This machine has received the most improvements during the last few years of R&D. There are different models that can cover all production ranges required with high inclusion rates of liquids or fats.

The focus of the machine is the retention time, and this is achieved by independent speed regulations of the shafts, internal damps and automatic hatch valve on the outlet that retains the product. Retention time in standard production can reach up to 200 seconds.

This coater is used in the feed and aquafeed industry for adding a high inclusion of oils, molasses on cattle feed, whey powder on the pellets for piglet feed. Cross contamination is prevented in the feed plant as antibiotics and medicines are added at the end of the production directly on the outside of the pellets. It’s also able to add small inclusion rates such as vitamins, enzymes and probiotics, guaranteeing a perfect homogeneity of distribution.

The machine can be used as a continuous mixer, for mixing pellets with grains and flakes, different types of mash feed or for the preparation of minerals in the premix industry.

Mass Spin Coater

A compact continuous coater is used for adding micro liquids from 0.005 up to one percent, which includes enzymes, probiotics, vitamins, acidifiers, aromas, sweeteners etc and powder additions from 0.005 up to 0.25 percent for items including aromas, medicines, nutritional additives, vitamins, probiotics.

The MSC integrates a continuous and precise weigher technology, based on Coriolis forces, able to detect the flow of the main product (pellets, mash, grains) from a minimum of four ton/h up to 100 tons/h.

Thanks to a special 360° nozzle and the configuration of the spraying chamber, it is able to obtain a perfect homogeneity even when the inclusion rates are very low.

The same technology is also used to add medicines and other additives on the mash feed just before entering the conditioner and pelleting machine, in order to bypass the batch mixer and transportations, avoiding the cross-contamination through all the lines, by dedicating one pelleting machine for the addition of these products.

QUAT2RO® Monitoring With QUAT²RO® Monitoring you can easily observe your machine in real time and get daily reports of your system´s performance on any digital device you want.

Contact: Phone: +49 251 9796 252 E-mail: sales@behnbates.com www.behnbates.com

Powder coating additives

Powders are often used to coat the products, if you look at the food sectors a wide range of powders (salts, pepper, garlic, paprika and many other spices) are added on the surface of the crisps and snacks. In pet food a lot of appetising powders are used to coat the kibbles.

PLP applies this science to the feed and aqua feed industry for the use of coating powder additives and medicines. The powders can be injected in a dry form, in a suspension or a solution of powder and liquid more or less concentrated, creating a slurry that is then sprayed on the pellets.

The company has developed different types of sprayers, motorised or statics, that are able to distribute and inject the liquid solution or the dry powder in a even way, avoiding the risk of blocking of the nozzles.

A HAVER & BOECKER Company

Milling and Grain - October 2021 | 97

CS

Case Study FEED MILL

Dabaco’s new feed mill

V

Building a more responsible and high-quality aquaculture industry in Vietnam

ietnam is a top player in global aquaculture, with the country currently the largest producer and exporter of pangasius, whilst it also ranks in the top five in the world for shrimp exports too.

As well as this, the country also has a huge potential for mariculture thanks to its long coastline and diverse water bodies embracing lagoons and bays, with more than 1.6 million people currently employed full time in aquaculture in Vietnam.

The fast growth of the sector in Vietnam has raised sustainability concerns among several stakeholders, including Dabaco Group – one of the very few local enterprises operating in the entire closed Feed-Farm-Food Value chain in Vietnam.

Committed to providing users and the markets with good quality, safe and efficient products and services, whilst also responding to the call of local government to promote international sustainability standards in order to accelerate green growth in Vietnam’s aquaculture, Dabaco Group has conducted a number of activities.

These operations range from the research and development of innovative products, to the investment of high-tech production systems and the development of better farming practices to promote responsible aquaculture development in the country.

Bringing wealth to farmers and prosperity to the country

Founded in 1996, Dabaco Group is a Vietnam-based multifaceted group that specialises in feed, food and pig and poultry breeding. Its aim is to create a more controllable, sustainable and closed feed-farm-food supply chain in Vietnam.

The newly opened aquafeed mill in Bac Ninh Province 98 | October 2021 - Milling and Grain

is its seventh feed mill. At its 25th anniversary celebration held on April 29, 2021, it was awarded with the National First-Class Labor Medal for its contributions to bringing “wealth to farmers and prosperity to the country.”

The company officially announced the opening of a stateof-the-art aquafeed mill in Bac Ninh Province on April 27, 2021. With two successfully running, efficient extrusion lines and premium, sustainable feed products, the new plant for sure will help Vietnam aquaculture sector feel more confident in the international market. And the success of the new plant is also a gift from Famsun and its local partner to Dabaco Group for its 25th anniversary.

An inspiring project

Thanks to its highly skilled and dedicated local team and by closely collaborating with Dabaco’s feed nutrition experts and an experienced engineering team from local industry, Famsun had successfully delivered the project on schedule despite the challenges posted by Covid-19.

The state-of-the-art aquafeed mill is located next to its existing animal feed mill in Bac Ninh Province. The two plants will share some public facilities such as the office building, part of the receiving area and in- plant logistic infrastructure to reduce the idle time of these facilities, improve operation efficiency and cut cost of construction and investment.

In addition, Bac Ninh Province is where Dabaco Group headquartered, the company hopes its investment can improve the sustainability, productivity and quality of local aquaculture production, create a value-added, sustainable feed-farm-food chain, and bring more environmental, economic and social benefits to local communities. These requirements were also the principles that Famsun followed to deliver the project.

As efficient and hygienic as possible

With reasonable layout and sophisticated engineering design, the feed mill was constructed to be as efficient

and hygienic as possible, taking account of future requirements and the continuous production of the existing feed mill.

It accommodates two state-of-the-art extrusion lines from Famsun with its latest SJPS 120x2 Aquafeed Extruder and SJPS 156x2 Large-Scale Aquafeed Extruder. By equipping 170 Ultra-fine Pulveriser, intelligent dryer, vacuum coater, as well as a bulk density control system into the extrusion lines, Dabaco can innovate and produce a broad range of aquafeeds with improved flexibility, quality and production performance.

Dabaco’s products seek to cover the needs of various aquatic species in different growing stages, from fry to adult, and from shrimp to marine fish, and with good water stability to promote growth and prevent pollution.

The project is the culmination of long-term thoughtful design, deep expertise, and best teamwork across the agri-

food value chain ever. Installation was started on November 18, 2020 and completed on January 30, 2021. After completing the Integrated Solution Provider commissioning phase, it moved into normal production before Dabaco’s anniversary in March.

“It is incredible to bring this amazing project into being under extraordinary circumstances of Covid-19 pandemic in such a tight schedule but at Dabaco project construction site we made it,” says Chris Liu, the member of the Famsun Vietnam team who is responsible for this project.

“Every day, work starts from stringent biosecurity measures, we care about each other and make sure every team member is safe and healthy,” he adds.

All people, no matter from Famsun, or Dabaco personnel, or local engineers, worked with a clear list of daily tasks whilst also strictly following the guidance of Famsun FPD system to improve working efficiency while ensuring project quality.

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Milling and Grain - October 2021 | 99

31

INDUSTRY EVENTS 2021

October

23-25 VIV MEA 2021 Abu Dhabi, UAE www.vivmea.nl

AUTUMN COURSE Learn more – Learn onsite Enroll in the 12-week Course

www.onlinemillingschool.com 13-15 Vietstock 2021 Ho Chi Minh, Vietnam www.vietstock.org 14-16 IAOM MEA Virtual Technical Milling Forum Online www.iaom-mea.com 10-12 31st Annual IAOM MEA Conferences and Expo Dubai, UAE www.iaom-mea.com 20-23 Mill Tech Istanbul 2021 Istanbul, Turkey www.milltechistanbul.com POSTPONED - NEW DATE TBC In order to protect exhibitors and visitors from the Covid-19 epidemic, the effects of which are still ongoing, MillTech Istanbul Fair, which was planned to be held October 20 – 23, 2021, has been postponed to a later date. This decision was also made due to the desire of the organisers to realise their vision of the fair more comprehensively.

The fair, which will be organised by Pozitif Fair Company, one of the CNR Holding companies, and the Milling Machinery Manufacturers Association (DESMÜD), will now be held in 2022 and the exact date will be announced in due course.

MillTech Istanbul remains one of the world's largest and most comprehensive fairs with machines such as mill, feed, bulgur, legumes, rice, starch, oil, coffee, automation, transportation, filling, storage and quality control, with manufacturing companies from many countries showing a great deal of interest in the event.

Thousands of professional buyers from Europe, Africa, Turkic Countries, Middle, and Far East countries will attend MillTech Istanbul, where new technologies and applications of the world milling machinery industry will be exhibited.

All of the B2B bilateral business meetings that will take place between exhibitors and visitors at the fair will result in long-term trade agreements.

2021

November 3-5 AFIA Equipment Manufacturers Conference 2021 New Orleans, Lousiana, USA www.afia.org/events/emc-2021/ 11-13 Livestock Philippines 2020 Manila, Philippines www.livestockphilippines.com

☑ = Meet the Milling and Grain team at this event 100 | October 2021 - Milling and Grain

17-18 JTIC 2021 Dijon, France en.jtic.eu POSTPONED UNTIL 23-24 November, 2021

24-26 Ildex Indonesia 2021 Jakarta, Indonesia www.ildex-indonesia.com 2021

December 10-12 Agri Livestock 2021 Yangon, Myanmar www.agrilivestock.net 2-4 Taiwan Smart Agriweek 2021 Taipei, Taiwan www.taiwanagriweek.com

2022

January 12-14 VIV Asia 2021 Bangkok, Thailand www.vivasia.nl POSTPONED UNTIL MARCH 8-10, 2023

VIV Asia postponed to March 2023 & Meat Pro Asia also delayed Although vaccination programs are speeding up in Thailand, Vietnam, Indonesia, and other ASEAN countries, travel restrictions continue and the timeline to reopen the countries looks longer than expected.

The control of the pandemic has also met extra challenges in the recent months with further delays in the overall Asian region recovery plan.

For this reason, the organisers VNU Asia Pacific and VNU Europe have announced that VIV Asia is taking place on March 8-10, 2023, instead of January 2022.

The Impact Challenger 1-3 Halls, in Bangkok, Thailand is the confirmed venue for the coming edition of this leading event. The co-location of VIV Asia with the first edition of Meat Pro Asia is also confirmed on March 8-10, 2023 by Meat Pro Asia organisers Messe Frankfurt (HK) Ltd and VNU Asia Pacific.

“Looking at the recent official statistics regarding the overall vaccination program in Thailand and surrounding countries, we foresee that the Covid situation will not improve fast enough to clear travel restrictions and allow such an international show as VIV Asia, with more than 65 percent of visitors coming from outside Thailand, to welcome the expected high number of Feed to Food professionals in the beginning of 2022,” says Heiko M Stutzinger, Director VIV worldwide and Managing Director VNU Asia Pacific and VNU Europe.

VIV Asia is thus officially returning to the traditional March cycle in the odd number years, after the Covid-19 pandemic disruption.

The organisers trust that this decision will bring a clear and final direction for all stakeholders’ future business planning.

VIV Asia is coming back as the #1 leading international event for the livestock, animal proteins, feed to food industry with global and regional players and industry professionals finally gathering in 2023 in the exciting city of Bangkok from the entire Asian continent.

Exhibitors and visitors will also enjoy by then the complete BTS Skytrain extension from city centre directly to the venue.

In addition, Health & Nutrition Asia in co-location with VICTAM Asia are also rescheduled to new dates on September 7-9, 2022, instead of January 2022. The new venue is IMPACT Halls 9-10, in Bangkok, Thailand.

18-20 VICTAM and Animal Health and Nutrition Asia 2022 Bangkok, Thailand www.victamasia.com POSTPONED UNTILSEPTEMBER 7-9, 2022 Due to the ongoing worldwide pandemic, the management teams of VICTAM Corporation and VIV worldwide have decided to postpone VICTAM Asia and Health & Nutrition Asia in Bangkok to September 7-9, 2022.

The current situation is still not as optimal as it was estimated.

Above all, the health of exhibitors and visitors and the successful outcome of the event are most important to the organisers.

In light of the recent increase in Covid-19 cases, which has forced the Royal Thai Government to implement new strict measures to control the spread of the pandemic, and the delays of the vaccination programs in several Asian countries, VICTAM and VIV do not see the opportunity to realise a large-scale event on the short term.

Looking at the ongoing travel restrictions from and to Asia, the organisers also believe that it is not possible to guarantee the event quality as we know them for. The postponement to the third quarter of 2022 is in the interest of the whole industry.

VICTAM Asia in co-location with Health & Nutrition Asia are thus rescheduled to September 7-9, 2022. The new venue selected is IMPACT Halls 9-10, in Bangkok, Thailand. The objective remains the same: to realise the Total Animal Feed and Health event.

The dates secured in September 2022 will give all stakeholders room to breathe and pay attention to other vital issues. The organisers’ mission is to present a strong, value-adding event to the industry with high benefits for all parties.

VICTAM Corporation and VIV worldwide will also continue their partnership in Europe in 2022 by co-locating VICTAM International and VIV Europe at the Jaarbeurs venue in Utrecht, the Netherlands, from May 31 – June 2, 2022.

22-27 IPPE Atlanta, USA www.ippexpo.org 2022

February 16-17 SOLIDS Dortmund 2022 Dortmund, Germany www.solids-dortmund.de

2022

March 21-23 Ildex Vietnam 2020 Ho Chi Minh City, Vietnam https://www.ildex-vietnam.com

☑

26-29 GEAPS Exchange 2022 Kansas City, Missouri, USA https://geapsexchange.com/ 2022

May 1-3 PIX AMC 2022 Gold Coast, Australia www.pixamc.com.au 2-6 126th Annual IAOM Conference & Expo Richmond, Virginia, USA https://www.iaom.org/event/126th-annualiaom-conference-expo/

2022

July 6-8 16th Indo Livestock Jakarta, Indonesia https://indolivestock.com

Jan. 25 – 27, 2022 Atlanta, GA USA

RECONNECTING YOU WITH THE ENTIRE INDUSTRY

{

SERVICES BUYERS NETWORKING TRENDS INNOVATION NEW PRODUCTS SOLUTIONS TECHNOLOGY AND MORE

Join us for the in-person 2022 IPPE where you can evaluate products, new technology and services that meet your needs while reconnecting with your colleagues.

Register at www.ippexpo.org #IPPE

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INDUSTRY EVENTS AFIA’s annual PISC brings industry colleagues together Postponed from March, The American Feed Industry Association (AFIA) welcomed over 275 feed ingredient buyers and sellers from across the country to Orlando, Florida, for its annual Purchasing and Ingredient Suppliers Conference (PISC).

The three-day program offered attendees the ability to reconnect with industry colleagues, make new connections, conduct business and engage in professional development.

“Since March 2020, our members have been solely focused on safely manufacturing animal food to keep the U.S. food and pet food supply chain stable amid many pandemic-induced challenges,” says AFIA’s President and CEO Constance Cullman.

“Although our industry has adapted well to the new business environment, it thrives on personal relationships and we knew our members longed to reconnect with their industry colleagues in a professional forum.

“While we certainly missed those who could not be with us in-person this week, we heard from PISC attendees that they relished the time spent learning about the current market forces that could impact their businesses and networking with their industry colleagues.”

A diverse line-up of speakers

The event included two days’ worth of educational programming, with a diverse lineup of speakers, including: • Temple Grandin, PhD, of Colorado State University, who challenged the industry to leverage the expertise and innovation

from small players in agriculture to help the US achieve its sustainability goals and address consumers’ demands for locally produced products • Eric Mittenthal, of the North American Meat Institute, who spoke on changing consumer attitudes toward animal protein and plant-based foods • Lt Colonel Dan Rooney, a fighter pilot and PGA professional, who spoke on how individuals can find purpose by following their dreams despite their fears of failure.

For the first time, the AFIA conducted a blood drive to assist in the nationwide blood shortage, collecting over a dozen units of blood with the potential to save 30 American lives.

A recording of the educational program will be made available for purchase in the AFIA Online Store starting in September and photos from the event are available on AFIA’s social media channels.

The AFIA thanks its sponsors: diamond sponsor Arm & Hammer Animal and Food Production; platinum sponsors Barchart and The FL Emmert Company; gold sponsors Adisseo USA, Ardent Mills, CJ Bio America, Nutrien and Watt/Feed Strategies.

The silver sponsors Alfagreen Supreme, Animal Agriculture Alliance, Baymag, Central Life Sciences, Diamond V, DSM Nutritional Products, Huvepharma, International Flavors and Fragrances, Inc, International Nutrition, Micronutrients, Mosaic, Phileo by Lasaffre, Premier Magnesia and Zinpro Performance Minerals.

Next year’s edition of PISC will be held in San Francisco, California, March 8-10, 2022. For further information, visit the PISC website: https://www.afia.org/events/pisc-2021/

Milling and Grain - October 2021 | 103

INDUSTRY EVENTS

EuroTier 2022 aims to transform animal farming The next edition of EuroTier, a leading trade fair for animal farming and livestock management, will take place in 2022 and be held in Hanover, Germany alongside decentralised energy supply trade fair EnergyDecentral.

Taking place November 15-18, 2022, the organiser DLG (German Agricultural Society) has selected the guiding theme “transforming animal farming” to underpin the technical program.

“Production and value chains, as well as social and environmental demands on livestock farming are constantly evolving,” emphasises EuroTier project manager Ines Rathke.

“Together farmers, farm managers and agricultural companies are actively shaping the future, in management, purchasing and marketing.

As an international platform, EuroTier presents innovations and solution strategies – not just for the current hot-button topics,” adds Ms Rathke.

New and improved for 2022

New at EuroTier 2022 is the dedicated start-up area “DLGAgrifutureLab” for newly-founded innovative companies. This prime location within the trade fair allows both national and international company founders to launch their presence prominently, attracting plenty of footfall. The German Ministry of Food and Agriculture (BMEL) supports the participation of German start-ups at the trade fair.

For the first time at EuroTier 2022, DLG will be adding a new award category “Agrifuture Concept Winner” to its EuroTier innovation award scheme. The new award will recognise innovative and pioneering concepts for the animal husbandry of tomorrow.

This award category allows exhibitors to submit concepts and future visions that are not yet market-ready and still in the development phase but already demonstrate strong potential for improved professional practice or process optimisation.

DLG-Connect, DLG’s online platform, is an online professional venue that accompanies DLG’s trade fairs and events in the agricultural, agrifood and food industries, presenting topical and current content relevant to the industry as well as networking and a comprehensive market overview along the value chain.

SPACE 2021 The 35th edition of SPACE, inaugurating its new format, was held from September 14th to 16th, in person, at the Parc-Expo in Rennes, and continued on September 17th in a digital version. This return of SPACE symbolises the resumption of activity in the events sector, which has been severely impacted by the health crisis. SPACE 2021 was the first and only worldwide trade show this year for all animal sectors. Look out for the full report coming in the November edition of Milling and Grain!

104 | October 2021 - Milling and Grain

IPPE launches 10th Annual Young Leaders Program The International Production & Processing Expo (IPPE) has celebrated the 10th year of the annual IPPE Young Leaders Under 30 Program with the launch of the 2022 program.

The IPPE Young Leaders Under 30 Program targets young professionals who work for companies directly involved in the production and processing of poultry and meat or in the production of animal food and pet food who normally would not have the opportunity to attend IPPE. The goal of the program is to engage and invest in the next generation of young professionals, between the ages of 21 and 29, while celebrating their status as up and coming leaders in their companies.

Recognising professional leadership qualities

The program is designed to recognise professional leadership qualities and allow recipients to reconnect with other industry professionals at the world’s largest annual trade show involving the production and processing of meat and poultry products and the manufacture of animal food and pet food products.

The program provides education to further each person’s knowledge in their respective industry and will expose the recipients to the latest technology used in the industry.

In addition to receiving free access to the Expo, selected recipients will receive IPPE-assigned complimentary hotel accommodations for two nights and admittance to all complimentary education programs.

They will also be recognised at a special breakfast held on their behalf and gain leadership insights from a keynote speaker.

Dates for Latin American Poultry Summit The International Poultry Expo (IPE), part of the International Production & Processing Expo (IPPE), and the Latin American Poultry Association (ALA) have announced the date for the 2022 Latin American Poultry Summit, to be held in-person on January 24, 2022.

In response to attendee feedback, several upgrades are being made to the program. This includes the development of a one-day agenda to allow all attendees to have as much time as possible to reconnect and engage with exhibitors on the trade show floor.

The theme for the 2022 Latin American Poultry Summit is, “A Look at Today's and Tomorrow's Poultry Farming: Challenges and Answers,” and will be presented in a new format. The Summit program will include two keynote speakers, a panel discussion, an overview of two research projects funded by USPOULTRY and ALA that were centred on issues relevant to the Latin American poultry industry, as well as additional education sessions throughout the day.

The education sessions will focus on topics around economic changes, technological inputs, disease, animal welfare and environmental sustainability. The Latin American Poultry Summit will provide several networking opportunities including a luncheon, coffee breaks and a reception.

Special recognition will be given to students and advisors participating in the USPOULTRY Foundation International Student Program during the event.

The 2022 IPPE event will be held at the Georgia World Congress Centre in the famous American city of Atlanta from January 2527, 2022.

EXPERIENCE THE DIFFERENCE

aggrowth.com

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

Van Aarsen International +31 475 579 444 www.aarsen.com

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

Siwertell AB +46 4285880 www.bruks-siwertell.com

Yemmak +90 266 7338363 www.yemmak.com

Air products

Symaga +34 926640475 www.symaga.com

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

Kaeser Kompressoren +49 9561 6400 www.kaeser.com

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

Bagging systems Bühler AG +41 71 955 11 11 www.buhlergroup.com FAWEMA +49 2263 716-0 www.fawema.com Maxtex Trading Group Co. Ltd. +66 29488281 www.maxtex.net Statec Binder +43 3112 38 5800 www.statec-binder.com TMI +34 973 25 70 98 www.tmipal.com Golden Grain Group +86 371 68631308 www.g-grain.com

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

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

Bulk storage AGI www.aggrowth.com Behlen +1 402 564 3111 www.behlengrainsystems.com Behn + Bates +49 251 9796 252 www.behnbates.com Brock +1 866 658 4191 www.brockgrain.com Bühler AG +41 71 955 11 11 www.buhlergroup.com Lambton Conveyor +1 519 627 8228 www.lambtonconveyor.com Ozpolat Makina Gida +90 342 337 1217 www.ozpolatmakina.com.tr Port Tarragona +34 977 259 400 www.porttarragona.cat Silo Construction & Engineering +32 51723128 www.sce.be

Sukup +1 641 892 4222 www.sukup.com

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

The Essmueller +1 800 325 7175 www.essmueller.com TSC Silos +31 543 473979 www.tsc-silos.com

Van Aarsen International +31 475 579 444 www.aarsen.com

Elevator buckets 4B Braime +44 113 246 1800 www.go4b.com

Van Aarsen International +31 475 579 444 www.aarsen.com

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

Cereal and pulse conditioning Bühler AG +41 71 955 11 11 www.buhlergroup.com Vibrafloor +33 3 85 44 06 78 www.vibrafloor.com

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

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

vibronet-Gräf GmbH & Co.KG +49 6441 62031 www.vibronet.com

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

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

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

Cimbria Srl +39 0542 361423 www.cimbria.com

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

Maxtex Trading Group Co. Ltd. +66 29488281 www.maxtex.net

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

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

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

Computer software Inteqnion +31 543 49 44 66 www.inteqnion.com Van Aarsen International +31 475 579 444 www.aarsen.com

Van Aarsen International +31 475 579 444 www.aarsen.com

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

Coolers & driers Bühler AG +41 71 955 11 11 www.buhlergroup.com

Mühlenchemie GmbH & Co KG +49 4102 202 001 www.muehlenchemie.com

Consergra s.l +34 938 772207 www.consergra.com FrigorTec GmbH +49 7520 91482-0 www.frigortec.com FAMSUN +86 85828888 www.famsungroup.com Sukup +1 641 892 4222 www.sukup.com ThermoNox GmbH +49 8442 8823 www.thermonox.de Wenger Manufacturing +1 785-284-2133 www.wenger.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

Wenger Manufacturing +1 785-284-2133 www.wenger.com

Van Aarsen International +31 475 579 444 www.aarsen.com

The Essmueller +1 800 325 7175 www.essmueller.com

Yemmak +90 266 7338363 www.yemmak.com

VAV Conveyor Components & Solutions +31 7140 23701 www.vav-nl.com

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

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

Feed nutrition Adisseo + 33 1 46 74 70 00 www.adisseo.com Anpario +44 1909 537 380 www.anpario.com Biomin +43 2782 8030 www.biomin.net Evonik Nutrition & Care GmbH +49 618 1596785 www.evonik.com/animal-nutrition Hamlet Protein A/S + 45 75 63 10 20 www.hamletprotein.com PHIBRO +1 201 329 7300 www.pahc.com R-Biopharm Rhône Ltd +44 141 945 2924 www.r-biopharm.com Romer Labs Division Holding GmbH +43 2782 803 0 www.romerlabs.com The Anderson Inc +1 419-897-6758 www.andersonsgrain.com

Feed milling Bühler AG +41 71 955 11 11 www.buhlergroup.com Christy Turner +44 1473 742325 www.christy-turner.com Dinnissen BV +31 77 467 3555 www.dinnissen.nl FAMSUN +86 85828888 www.famsungroup.com Friedrich electronic +49 6406 1509 www.friedrich-electronic.de Milltech Tel: +90 332 502 13 00 www.milltech.com.tr Myande +86-514-87849111 www.myandegroup.com Ottevanger Milling Engineers +31 79 593 22 21 www.ottevanger.com PLP +39 05 23 89 16 29 www.plp-systems.com Sangati Berga +55 11 2663 9990 www.sangatiberga.com.br Wynveen +31 26 47 90 699 www.wynveen.com

vibronet-Gräf GmbH & Co.KG +49 6441 62031 www.vibronet.com Viteral +90 332 2390 141 www.viteral.com.tr Yemmak +90 266 7338363 www.yemmak.com Zheng Chang +86 2164184200 www.zhengchang.com Golden Grain Group +86 371 68631308 www.g-grain.com

Feed Mill Automation Bühler AG +41 71 955 11 11 www.buhlergroup.com Van Aarsen International +31 475 579 444 www.aarsen.com

Flour Improvers Mühlenchemie GmbH & Co KG +49 4102 202 001 www.muehlenchemie.com

Grain handling systems Behlen +1 402 564 3111 www.behlengrainsystems.com Brock +1 866 658 4191 www.brockgrain.com Bühler AG +41 71 955 11 11 www.buhlergroup.com Cimbria A/S +45 96 17 90 00 www.cimbria.com Lambton Conveyor +1 519 627 8228 www.lambtonconveyor.com Ozpolat Makina Gida +90 342 337 1217 www.ozpolatmakina.com.tr Port Tarragona +34 977 259 400 www.porttarragona.cat Sangati Berga +55 11 2663 9990 www.sangatiberga.com.br

Zaccaria +55 19 3404 5700 www.zaccaria.com.br Golden Grain Group +86 371 68631308 www.g-grain.com

Hammermills Alapala +90 212 465 60 40 www.alapala.com Aybakar AS +90 312 398 0247 www.aybakar.com.tr Bühler AG +41 71 955 11 11 www.buhlergroup.com Christy Turner +44 1473 742325 www.christy-turner.com Dinnissen BV +31 77 467 3555 www.dinnissen.nl Ottevanger Milling Engineers +31 79 593 22 21 www.ottevanger.com Selis +90 222 236 12 33 www.selis.com.tr Viteral +90 332 2390 141 www.viteral.com.tr Van Aarsen International +31 475 579 444 www.aarsen.com Wynveen +31 26 47 90 699 www.wynveen.com Yemmak +90 266 7338363 www.yemmak.com Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com Zheng Chang +86 2164184200 www.zhengchang.com/eng

Laboratory equipment

Siwertell AB +46 4285880 www.bruks-siwertell.com

Bastak +90 312 395 67 87 www.bastak.com.tr

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

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

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

Christy Turner +44 1473 742325 www.christy-turner.com

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

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

107 | October 2021 - Milling and Grain

Tekpro +44 1692 403403 www.tekpro.com

Hydronix +44 1483 468900 www.hydronix.com

Zaccaria +55 19 3404 5700 www.zaccaria.com.br

Zaccaria +55 19 3404 5700 www.zaccaria.com.br

Loading/un-loading equipment Bühler AG +41 71 955 11 11 www.buhlergroup.com

MSC +44 1473 277 777 msc.com/sugar

Hydronix +44 1483 468900 www.hydronix.com

Neuero Industrietechnik +49 5422 95030 www.neuero.de

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

Van Aarsen International +31 475 579 444 www.aarsen.com

vibronet-Gräf GmbH & Co.KG +49 6441 62031 www.vibronet.com

Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com Yemmak +90 266 7338363 www.yemmak.com

Plant Bühler AG +41 71 955 11 11 www.buhlergroup.com Sangati Berga +55 11 2663 9990 www.sangatiberga.com.br

Mycotoxin management

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

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

Mill design & installation

Biomin +43 2782 8030 www.biomin.net

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

Packaging

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

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

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

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

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

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

Christy Turner +44 1473 742325 www.christy-turner.com

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

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

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

Van Aarsen International +31 475 579 444 www.aarsen.com

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

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

Maxtex Trading Group Co. Ltd. +66 29488281 www.maxtex.net

IMAS - Milleral +90 332 2390141 www.milleral.com

Yemmak +90 266 7338363 www.yemmak.com

Rolls

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

Ocrim +39 0372 4011 www.ocrim.com

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

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

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

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

Yemmak +90 266 7338363 www.yemmak.com

Sangati Berga +55 11 2663 9990 www.sangatiberga.com.br Satake +81 82 420 8560 www.satake-group.com

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

Moisture measurement

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

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

Van Aarsen International +31 475 579 444 www.aarsen.com

Golden Grain Group +86 371 68631308 www.g-grain.com

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

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

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

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

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

Palletisers

Yenar Dˆk¸m A.S. +90 332 2391073 www.yenar.com.tr

Roller mills

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

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

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

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

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

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

Van Aarsen International +31 475 579 444 www.aarsen.com

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

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

Wynveen +31 26 47 90 699 www.wynveen.com

Golden Grain Group +86 371 68631308 www.g-grain.com

Christy Turner +44 1473 742325 www.christy-turner.com

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

108 | October 2021 - Milling and Grain

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

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

IMAS - Milleral +90 332 2390141 www.milleral.com

Koyuncu Sanayi +91 224 723 92 92 www.koyuncufirca.com

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

Sefar AG +41 898 57 00 www.sefar.com

Milltech Tel: +90 332 502 13 00 www.milltech.com.tr

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

Ocrim +39 0372 4011 www.ocrim.com

Zaccaria +1 5519 34045715 www.zaccaria.com.br

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

Golden Grain Group +86 371 68631308 www.g-grain.com

Pingle +86 311 88268111 www.plflourmill.com Sangati Berga +55 11 2663 9990 www.sangatiberga.com.br Selis +90 222 236 12 33 www.selis.com.tr Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com Golden Grain Group +86 371 68631308 www.g-grain.com

Roll fluting Bühler AG +41 71 955 11 11 www.buhlergroup.com Christy Turner +44 1473 742325 www.christy-turner.com Fundiciones Balaguer, S.A. +34 965564075 www.balaguer-rolls.com Yenar Dˆk¸m A.S. +90 332 2391073 www.yenar.com.tr

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

Scalling Bühler AG +41 71 955 11 11 www.buhlergroup.com NorthWind +1 785 284 0080 www.northwindts.com

Sifters ASG Group (Degirmen Makine) +90 342 357 01 50 www.degirmen.com Brock +1 866 658 4191 www.brockgrain.com Bühler AG +41 71 955 11 11 www.buhlergroup.com Dinnissen BV +31 77 467 3555 www.dinnissen.nl Filip GmbH +49 5241 29330 www.filip-gmbh.com Gazel +90 364 2549630 www.gazelmakina.com

Inteqnion +31 543 49 44 66 www.inteqnion.com vibronet-Gräf GmbH & Co.KG +49 6441 62031 www.vibronet.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

Silos

Kansas State University +1 785 532 6161 www.grains.k-state.edu

AGI www.aggrowth.com

OMS +441242 267700 www.onlinemillingschool.com

Altinbiliek +90 222 236 13 99 www.abms.com.tr

Ocrim +39 0372 4011 www.ocrim.com

Behlen +1 402 564 3111 www.behlengrainsystems.com Bühler AG +41 71 955 11 11 www.buhlergroup.com A/S Cimbria +45 9617 9000 www.cimbria.com CSI +90 322 428 3350 www.cukurovasilo.com The Essmueller +1 800 325 7175 www.essmueller.com Lambton Conveyor +1 519 627 8228 www.lambtonconveyor.com Obial +90 382 2662120 www.obial.com.tr Ozpolat Makina Gida +90 342 337 1217 www.ozpolatmakina.com.tr Port Tarragona +34 977 259 400 www.porttarragona.cat Silo Construction & Engineering +32 51723128 www.sce.be Silos Cordoba +34 957 325 165 www.siloscordoba.com

UK Flour Millers +44 2074 932521 www.ukflourmillers.org

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

Weighing equipment Bühler AG +41 71 955 11 11 www.buhlergroup.com PLP +39 05 23 89 16 29 www.plp-systems.com TMI +34 973 25 70 98 www.tmipal.com Van Aarsen International +31 475 579 444 www.aarsen.com Vibrafloor +33 3 85 44 06 78 www.vibrafloor.com vibronet-Gräf GmbH & Co.KG +49 6441 62031 www.vibronet.com

Yeast products Leiber GmbH +49 5461 93030 www.leibergmbh.de

Siwertell AB +46 4285880 www.bruks-siwertell.com Sukup +1 641 892 4222 www.sukup.com Symaga +34 91 726 43 04 www.symaga.com Top Silo Constructions (TSC) +31 543 473 979 www.tsc-silos.com Van Aarsen International +31 475 579 444 www.aarsen.com

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

29TH PRINT EDITION

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Mühlenchemie. German Quality Worldwide.

Made in Germany by Mühlenchemie

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We’re very international about service.”

Sven Mattutat, Head of Global Baking Applications, Mühlenchemie

Quality. We can assure it, because we monitor the development and production processes from start to finish. It starts in the test processing of grain lots in our own milling machines as a basis for precision flour analysis – and that’s just the beginning.

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myMAG PRODUCTS AND SERVICES FEATURED IN THIS ISSUE

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Milling and Grain - October 2021 | 111

the interview

David Wright, GR Wrights and Sons Limited

David Wright, at 59, came into the family flour milling business, GR Wrights and Sons Limited, in 1981 representing the fifth generation milling on the company's River Lea site at Ponder’s End. Nine years later, in 1990, he took over as Managing Director at 29-years of age. He is a graduate from the Swiss Milling School, which he had attended in 1983. He had also trained as a miller at UK mills - namely the Timms Mill and at Heygates Mill in North Hampton. Mr Wright is the great, great grandson of George Reynolds Wright and under his direction the family business expanded in an extremely competitive marketplace through his attentions to staff support and adopting the latest technology. The company gained BS5750 Certification in 1994 – one of the first milling companies in the UK to achieve this accreditation. He also saw his company gain recognition for its support for employees by again being one of the first in the milling sector to lift the ‘Investors in People Award’ in 1998. He also secured a ‘London’s Manufacturer of the Year Award’ in 2004 followed by a ‘Passport to Exports Award’ in 2005.

This latter award was for finding new markets for bread mixes abroad. After developing bread mixes in consumer packs he introduced cake mixes, which were more recently rebranded in 2015, but had already penetrated markets overseas, such as France and The Netherlands.

Mr Wright focuses on his people, new technologies and has an uncanny eye for market opportunities in the flour milling sector. Here he talks to Milling and Grain about the latest company development – the building and commissioning of his new 18-tonne-per-hour flour mill at Harlow north of London Do you see continuity critical to the business itself given the company’s historic past? Is that continuity projecting into the future and your decision to build a new mill at Harlow Essex in the UK? Yes, we are very proud of our heritage.

You walk around here, including this new office, and everything is about our history on the walls. It’s our heritage which is great and something to be proud of, but it doesn’t get us new business and we have got to look forward to the future with modern plant that’s going to see us through for the next 25-30 years plus.

A lot of big corporate businesses never look far ahead. They are looking to five years of achievements and that they have to make their mark on behalf of shareholders in that time. It’s always short-term.

In terms of the investment can you give readers an idea of how much has been invested in this new mill?

A lot! At the moment it stands at UK£47 million and I don’t anticipate that going up any more now, but we’ve had to go through quite a difficult time with Covid-19 which impacted us during the build.

If you want to include the purchase of the land, then it’s probably a five-year project - three years to secure the land and two years to build and commission the factory.

Is the original milling plant at Ponder’s End in Enfield, North London, still in production. Or has it been replaced completely? If it’s running, what is the future for it. Will it continue to be a production centre for the company?

Yes, I hope so. It is the intention. We have two plants at Ponder’s End. One is a small five-tonne-an-hour mill and the other is a bigger 10-tonne-an-hour mill. We have closed the bigger plant and the little plant runs making speciality flours.

The new build here is an 18-tonne-per-hour plant, so it’s quite nice having that smaller plant to play around the more specialist-type flours.

How important is location in the decision-making for a business of this nature? Had the old Ponder’s End site become restricted due to its location today?

At one point we had 150 contractors on site building the mill.

Then the next day it was down to about six. They had all left.

Contractors by their nature live away from home so they all went home. But after a couple of weeks they gradually came back. Overall, we were delay on the project and this cost us a fair bit and that delay was around four or five months. We were planning to open in August last year 2020, but we didn’t really get started until December and really from January this year its taken a few months to get everything bedded down.

It’s only just starting now to feel right.

The first thought was to build the new mill on that site. But where were we going to locate and put all the plant and equipment needed? We have Listed Buildings up there - the warehouse and the barn are all protected and you can’t knock them down. Old buildings, the process flow and the cost of the new equipment plus the limitations of the old mill site said to us that it was a compromised site to work with.

Whereas we felt that we could start again on a completely brownfield site and have the mill how we wanted it and we won’t have to compromise; and we’ll have exactly what we want. It cost a bit more, but we felt if we were going to spend the money at Ponder’s End then let’s spend a bit more and get it absolutely right.

Did the contractors - Clegg Food Projects, who were the principle contractor and the installers Salford Engineering - achieve a good oucome for such an advanced and modern construction?

Does Harlow give you a better location for distribution?

We look back now and say ‘wow’. They did an excellent job overall. Was the whole project flawless, no it wasn’t. There were always going to be things that needed picking up and there are lesions to be learnt from that, but essentially, it’s been really good. From breaking ground, the whole build took just two years.

112 | October 2021 - Milling and Grain

Yes and no. We are only 10 miles away from the other site.

It’s not a big deal. We didn’t want to be too far away so that everyone could come from Ponder’s End to here or readily relocate. Anything more 10 miles than people might say they do not want to move. More or less everybody came across and we’re happy that they have done so as we are a very close family business.

What about your raw material flow, the incoming wheat for example? It that better here?

All raw material is coming into the factory by lorrie. Look out the window and you’ll see we are now in Essex and not in London and so there’s two benefits - we are nearer to the wheat fields, which is good but further from the Port of Tilbury which is not quite so good, but it’s still not enough to incur any further costs and we do a lot of flour trade north of here as well. By and large I would say there is a slight benefit to moving here in terms of raw material flow and moving finished flour.

Also Ponder’s End was is a low-emission zone so some of the older wheat lorries couldn’t get in there.

What is the balance between local wheat supply and imported wheat in annual throughput here at Harlow? Are imported hard wheats used for in your flour products?

We process mostly all local wheat but we do buy Canadian wheats. Local wheat makes up between 70 and 80 percent of he wheat we process. We only really make bread flours here in this company. We do a bit of plain and raising flours but 90 percent is bread flour. We provide all major UK retailers, big bakeries and wholesalers, some with their own labelled bags.

What’s your USP or unique selling point as a company in a very competitive market? What separates you from the rest of the UK major millers?

We have always provided quality rather than gone the cost reduction route. Premium production with a strong focus on service and being on time is a big thing. When you walk around you’ll see that we are quite a complicated business.

For example, you’ll see one scale producing for one customer and it’s all going out in bulk which is very straightforward, but we also have hundreds of customers and hundreds of ’Skus’ (small units) and there are lots of complications that comes with that.

When I first came into the business we looked at things that would give us an edge and allow us to compete in a very competitive market dominated by very big flour producers. We went for the specialist and difficult things to produce that nobody else typically wanted to do. That’s how we grew.

Milling and Grain - October 2021 | 113

PEOPLE THE INDUSTRY FACES Duo with valuable levels of experience join Alltech Ireland’s pig & poultry teams

A

lltech Ireland has announced the appointments of Dr Hazel Rooney as technical pig coordinator and Paula Mc Cooey as poultry manager. They join Alltech with valuable education and experience in their respective species.

Dr Rooney will be responsible for coordinating and developing technical solutions for pigs for the Irish and European marketplace, working closely with the Alltech Ireland sales and gut health management teams.

As the Alltech Ireland poultry manager, Ms Mc Cooey is responsible for managing the poultry accounts across the island of Ireland and she will work closely with customers at all levels.

“We are pleased to have Hazel and Paula join the Alltech Ireland team as they are well-accomplished in the pig and poultry industries,” says Cathal McCormack, country manager at Alltech Ireland. “They will be key assets to our team and customers.”

Mike Gauss to join AFIA as chair-elect in 2022

T

he American Feed Industry Association’s (AFIA) Board of Directors has voted in a special election to accept the nomination of Mike Gauss, president of Kent Nutrition Group, Inc, to become the Board chair-elect of the organisation.

Mr Gauss currently serves on the AFIA Board of Directors and Executive Committee and has been an active member in the AFIA Production Compliance Committee for many years.

“We are thrilled that Mike Gauss has committed to leading the AFIA Board of Directors next spring, bringing with him years of technical knowledge and industry experience that will challenge us to keep moving the industry forward in innovative ways,” says AFIA President and CEO Constance Cullman.

“Mike understands what animal food manufacturers need in order to bring solutions to a competitive global marketplace and will help us shape our advocacy program.”

GMP+ International appoints new Commercial Director

B

ram Schuit joins GMP+ International in the new role of Commercial Director. He joins Roland van der Post to complete the new management team.

Mr Schuit joins GMP+ International from Kiwa where he served as International Business Development Manager. He primarily garnered his experience in agricommodities and in the food & feed business.

“By staying in close contact with current and future stakeholders in the entire global feed supply chain, we continue to strengthen the position of ourselves and partners in order to achieve our main ‘Feed Safety Worldwide’ goal,” says Mr Schuit.

“Bram’s experience, drive and people-oriented approach will be a great addition to GMP+ Internationa,” says Roland van der Post, GMP+ International’s Managing Director.

“As we continue to strengthen our worldwide position, Bram’s expertise will be invaluable. I’m looking forward to having him on the team.”

New appointment sees Perendale Publishers expand its editorial team

T

he producers of International Aquafeed and Milling & Grain magazines, Perendale Publishers Ltd are proud to announce the appointment of Caitlin Gittins to the position of Editorial Assistant.

Following the achievement of an English degree at Birmingham University in the UK, Ms Gittins then completed a social media marketing intern placement with Reynaers, who specialise in the development of aluminium solutions.

“This internship proved to be a relevant and invaluable experience in terms of the insight I gained,” says Ms Gittins, speaking shortly after her recent appointment.

“I was given a better understanding of how companies marketed to their customers and the programmes they used. I am hoping to bring this insight with me alongside skills from my English degree.

“I am very excited to gain a more rounded understanding of the aquaculture sector working for Perendale,” she concludes.

114 | October 2021 - Milling and Grain

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