Global Milling Advances is a magazine for agriculture professionals worldwide
Issue 12 / August 2015 India industry report
By Raghavan Sampathkumar
Industry news
Buhler: Analysis and response
Mixing technology
Expo list
The world’s top events related to milling from around the world, listed on p. 25
Qualities and principles
Extrusion Innovation
Practical product development
All in one mixing concept
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New mixing concept saves costs, eliminates contamination, and lifts, tilts, empties, mixes, and fills containers from one location
Ten important qualities and principles of mixing technology in feed production. PAGE 10
Read more on p.12
CHOPIN TECHNOLOGIES
A CENTURY OF INNOVATION Read more on page 13 Published by Nisa Media Ltd www.globalmillingadvances.com www.facebook.com/nisamedia www.twitter.com/nisamedia
Mixing technology
P.10
India’s pulses puzzle
P.5
Editorial
Issue 12 / August 2015 India industry report Raghavan Sampathkumar
Welcome to the August 2015 issue of Global Milling Advances. This month we hear from Buhler, Chopin, Dinnissen and Brabender, on the latest devbelopments in milling technology, including mixing technology, extrusion and quality control. We also have an extended industry report on the Indian market from Raghavan Sampathkumar. As always we strive to provide relevant and useful information to our professional readership, contributor submissions, press releases and feedback on our publications is always welcome.
Industry news
Buhler: Analysis and response
Extrusion Innovation
Practical product development
Mixing technology Qualities and principles
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Expo list
The world’s top events related to milling from around the world, listed on p. 25
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News Editor
Martin Little Email: mlittle@globalmilling.com
Global Milling Advances / August Issue 2015
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Accurate analysis and prompt response Seasoned millers fear color deviations and a high number of specks in the end product. The new online color and speck analyzer MYHB from Bühler enables real-time analysis of color and specks in flour as well as semolina. The data allows direct corrective measures in the continuous production process without waiting for laboratory results. Flour is not just flour. Color and the number of specks, among other things, distinguish different qualities of flour. The lightness or color of the flour is influenced by three factors: Contamination of the endosperm through bran particles, the natural pigment content that colors flour/semolina yellow and the granulation. Specks can be visible all the way through to the end product, for example as dark spots in pasta. For consumers, these dark spots create a feeling of 'low quality goods'. Therefore, for certain applications the following rule applies: The 'whiter' the flour and the fewer specks it has, the higher its quality.
Color: An eye and experience The accurate determination of color and the exact analysis of the number of specks is of central importance in fine-tuning mills and defining the quality of the flour. For hundreds of years, millers have depended on their eyes and experience for color and speck control. However, with all due respect for the abilities of the miller, "eye-balling" is a subjective judgment and dependent on soft factors such as the type of lighting and the observer's current condition. To compensate, millers have also recently been using hand measurement and laboratory devices with which the color of a flour sample can be determined by its position in the so-called tristimulus color spectrum (L*a*b*).
Global Milling Advances / August Issue 2015
Specks: Counting Brown specks are small bits of the grain hull while black specks come from impurities, which end up in the milling product through suboptimal settings in the cleaning. The volume of brown and black specks contained in the flour allows inferences to be made about errors in various process steps. Determining the number of specks, however, is painstaking work. One possibility is to count the number of specks on an exactly defined surface. The accuracy of this depends on the judgment and physical condition of the person counting on that day and the lighting. Counting can also be done by laboratory equipment.
Continuous analysis Whether the color analysis and number of specks is determined by visual inspection or using measurement devices – in both cases the results are a snapshot based on sampling. With the new online color and speck analyzer MYHB, Bühler has revolutionized color and speck control. The system allows continuous monitoring of speck count and product color in the on-going production of flour and semolina (soft wheat/durum). The core of it is a high-resolution special camera, which is directly integrated into the gravity spouting. The camera delivers reproducible color values in the CIE color spectrum (L*a*b*) and continuous images of the product as it passes by. The constant analysis enables averaging the color and speck values for a large measuring surface. Color deviations from ΔE = 0.2 can be identified. In comparison, the human eye can only identify color deviations of ΔE = 0.5. The analyzer MYHB also recognizes brown
and black specks starting from a minimum of 80µm and can classify them according to their size. The MYHB software reports unacceptable deviations according to individually defined alarm thresholds with no time lapse. The images and the speck reports enable the miller to more accurately limit the causes of the color deviation and specks and to introduce corrective measures.
Combination with NIR The MYHB system for color and speck analysis is excellently suited for combination with the NIR multi online analyzer MYRG. This system is based on the near infrared (NIR) generation with diode array technology and is used for continuous monitoring of ingredients such as protein, ash, moisture or starch damage in raw, intermediate and end products in the grain processing industry. Both systems can be used for multiple measuring spots in the most varied combinations, and are operated with a common software. The software provides a clearly structured user interface with current measurement values and trend charts. Finally, integrating it with the process management system, WinCos, ensures seamless documentation and traceability. For more information Visit: www.buhlergroup.com
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India’s Great ‘Pulses’ Puzzle: Searching for Solutions Raghavan Sampathkumar What is unique about India’s pulses sector? The fact that India is the largest producer, consumer and also importer of pulses in the world is not known to many including those who are working in the food and agriculture industry in the country. At least for me, it was a big surprise to learn more than a third of the pulses consumed is imported. As a vegetarian by religious and family tradition whose diet primarily depends only on pulses for protein, like millions of my fellow Indians, I always wonder why the country has to import pulses.
How important are pulses in Indian diets? India is not monolithic in the context of culture and every 100 kilometers, everything from food, language, accents, culture and customs change dramatically. So, the enormous diversity and uniqueness in cuisines and ingredients used need to be considered in order to understand the importance of pulses in Indian diets.
But, it should not be confused with the popular myth that most Indians are vegetarians and they depend only on plant protein. If one looks carefully at the ethnic, religious and cultural aspects, it is evident that most Indians can and do consume animal protein. However, there are some religious restrictions for some who do not consume pork and/or beef. Only a minority (about 7%) is strictly vegetarians and no matter how much their incomes or purchasing power increases, they will never consume meat. This is contrary to the Western economic models on food consumption that usually project increase in meat consumption as a result of economic growth and per capita incomes. However, as incomes in India continue to grow particularly among the middle-class, growth in consumption of animal protein is, in fact, limited by availability and affordability. This is also true in case of plant protein sources – pulses.
Why the country cannot produce enough and why it has become greatly reliant on imports? There is no simple answer to this question but I can list some direct and also less obvious causal factors including lack of appropriate policy measures to support pulses, lack of marketing opportunities, archaic and outdated produce marketing laws and also fertilizer pricing policies to some extent. Reports claim India’s demand for pulses is nearly 20 to 22 million tonnes and production is usually around 16-18 million tonnes. So the gap needs to be filled with imports. According to NCAER, per capita availability of pulses is about 35 - 40 gms currently, which has fallen from nearly 60 gms in 1950s. However, I would take these numbers with a pinch of salt. Firstly, one of the foremost challenges for Indian
Pulses are one of the most basic staple food items and irrespective of the direction – North or South – of the great hills of Vindhya, every household consumes pulses almost every day. However, the types of pulses vary with the tastes, diet and culinary preferences. In South India, people make sambar and rasam using pulses using toor dal (pigeon pea) to eat with rice while the North Indians prefer red lentils (masoor dal) boiled with spices as the perfect accompaniment with roti. Mung is used as whole or split while chana (chick peas) are essential ingredients in snacks, crispies and sweets across the country and used as both flour and as whole peas in curries.
Global Milling Advances / August Issue 2015
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agriculture is lack of reliable statistical data on production, acreage and/or consumption. Estimates from different sources tend to vary greatly and it is not just the question of pulses but all the crops in general. Insiders will always know how reliable are the acreage estimates given by different sources including the Government, traders and academics. It is obvious what will happen when policies are made without reliable data on these parameters. For example, the poorest section of the society may not consume even half of the official per capita consumption figure. There are no ways to cross check the official data on acreage and the official production figures will be arrived at simply by extrapolation or multiplying historical average yields with ‘guestimates’ of acreage of each crop in each state that are aggregated at the national level.
Why pulses are in news recently? How important are pulses in the food basket particularly in the context of food inflation? Pulses are an important category in the food basket. Recently the term “protein inflation” has become a hot topic of discussion that particularly, prices of pulses and meat are driving overall food inflation up. However, the impact of rise in prices of pulses usually varies quite frequently with monsoon situation in India. Seasonally, the prices rise and fall according to the arrivals. Obviously, when monsoon fails, the whole world will look at India to purchase the lentils, pigeon peas and chick peas to satisfy its enormous demand. But at the same time, interestingly, even during good monsoon years imports of pulses may not come down. This is because of the strong rural demand due to good harvest and increase in incomes of the farmers and rural community. However, one must understand that no efforts to mitigate protein inflation will pay off unless the “plant protein” or pulses are given due attention holistically.
Global Milling Advances / August Issue 2015
How does this affect consumers at the household level, particularly the poorer sections of the society? To start with, I would say the demand can grow more than the claimed 22 million tonnes if the prices of pulses come down significantly. To put in the perspective of a poor household, several states in India sell rice and wheat at Rs. 1 and Rs. 2 respectively mainly through the PDS (Public Distribution System). But toor dal (pigeon pea), which is the main ingredient to make sambar and rasam by South Indians is sold at the PDS shops for Rs. 40. Further, prices of rice and toor dal in the open market is around Rs. 30 and Rs. 70 respectively. For the middle class, salaried households particularly in Urban India, this is a budgeting nightmare if the balanced nutrition is to be maintained as even smaller increase in prices will cause greater fall in consumption. Hence, if the prices of pulses come down, it is a no-brainer to expect a resulting increase in consumption. At some stage, this will translate into stronger price signals and will encourage farmers to grow more
pulses replacing rice & wheat also in some areas.
What are the implications from nutrition and well-being perspective? From nutrition & well-being perspective, I would simply call it “calorie catastrophe”. One can sense what is happening with the calorie intake among larger sections of population. As rice is available cheaply and it is much stomach-filling, households have no option but to cut consumption of pulses when their prices go through the roof. More and more intake of cheaper carbohydrates in place of more expensive protein may lead to imbalanced nutrition and may make people even more prone to health issues like diabetes and cardio-vascular diseases. Already, India is competing with China for the notorious crown of “the diabetic capital of the world” with nearly 66 million diagnosed diabetics plus 77 million more likely to be having pre-diabetes conditions. It is evident that there are huge policy implications if these issues are not addressed appropriately. It would turn
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out to be a public health disaster in future affecting the health & productivity of the workforce in India and will in turn significantly affect the country’s future economic growth.
How other agricultural policies in India may have contributed to pulses getting neglected? In India, in general, food means only two crops – rice & wheat. And it is always “Politics” winning over “Economics”. This is evident from entrenched policies such as minimum support prices and procurement systems seem to favor only these two crops - rice & wheat. By their nature, these policies encouraged more and more production of rice & wheat beyond what the country can actually store and let food grains waste and rot in open spaces. These two crops are possibly the biggest “Votebanks” and any policy amendment or move that might seem to affect the status quo, will be fought down vociferously by various stakeholders with diverse interests. Contrastingly, the country imports huge quantities of pulses and edible oil from global markets, which could well be produced domestically if appropriate policy measures are put in place. This not only affect the options available for a farmer to choose between crops he can grow, it also comes with a huge import bill, skewed trade balance, affects the fiscal health of the economy and also food we consume every day. But, it is highly unlikely that the support measures given to rice and wheat may be revisited holistically in order to promote production of pulses and oilseeds as edible oil is one among India's largest import items.
What are the other issues across pulses value chain that impact domestic production? To start with, primary production? There are significant issues to be addressed at each stage of the value chain for pulses. From input (seed) supply, production, marketing, processing and final consumption.
Global Milling Advances / August Issue 2015
In the primary production front, given the situation currently and in the near future, it is unlikely to increase domestic production of pulses unless some drastic changes in policies supported by much needed investments in marketing, processing and crop R & D bear fruition. Unless vast share rice & wheat cropped areas, new cultivable land and/or marginal lands are brought under pulses cultivation, which is highly unlikely, self-sufficiency can only remain a distant dream. Even now, pulses are regarded as marginal crops in India and do not enjoy the main crop status equal to rice, wheat or soybean. Only about a sixth of the total cultivated land under pulses has irrigation facilities and the Kharif pulse crop is mostly rainfed. Further, average yields of many pulses including lentils in India are only half of the most popular producing regions like Canada or Australia. Even if a farmer gets irrigation facilities, he will naturally choose a crop that he can be sure of disposing (selling to procurement agencies) because on-farm storage is virtually non-existing for the majority of smallholders in India. They
cannot store their produce and sell when prices rise. This perhaps partly answers the question why despite consistent higher market prices, domestic production of pulses has not improved greatly over the years.
How about the input supply side for pulses crops? Since most pulses are essentially self-pollinated crops except pigeon pea with limited scope for hybridization and opportunities for trait differentiation and protection, research is mostly in the purview of public sector and there is virtually no presence of the private sector in either genetic or agronomic research. However, given the slow adoption of the research output, one cannot but wonder whether public investment in R&D is making any real impact on-ground despite having several initiatives such as National Food Security Mission and Pulses Villages etc. It is important to ensure research priorities are aligned with the realities on the ground and what farmers can practically adopt to
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increase yields. Also, the output of the research efforts should ensure demonstrable value to the consumers in terms of improved nutritional content. Availability of quality seeds at the right time ahead of the season for the farmers to cultivate pulses always remain a big issue.
Research on creating novel innovative products using pulses as ingredients is still in its nascent stages and nothing has yet become commercially successful. I would say pulses are rather neglected by the food processing sector despite their richness in terms of fiber and protein content.
Utilization of genetic engineering in pulses still has a long way to go (except soybean) as public acceptance and perception is not so conducive when it comes to staple foods. Commercial crops have more likelihood of being accepted than staple crops.
In countries like Canada, research is already being undertaken to advanced levels to explore opportunities in blending pulses protein with other flour such as wheat flour. Research on novel and innovative food products including granola bars and breakfast cereals are being pursued studiously. Some companies are already selling niche products that cater to, for example, athletes and body-builders, who need more protein in their diets.
What are the issues in the marketing of pulses domestically? Evidently, there are no reliable marketing opportunities for the farmers to sell the crop to. So, if I were a farmer, unless I have no options at all, I won't grow something that I cannot sell. There is no proper marketing channel or procurement system like rice and wheat. Further, archaic laws such as the APMC (Agricultural Produce Marketing Committee) regulations prevent a farmer from entering into direct supply contracts with a processor and/or a retailer. So for an average farmer, the safest crops to grow would be rice or wheat which have minimum support prices that are increased every year and also have established procurement systems. In order to make markets work for the pulse farmers, the above mentioned factors need to be addressed with a long term vision along with investments in promoting R & D, processing and value addition. Essentially, a greater share of the increase in prices must flow back to the farmers.
What about the situation in processing and value addition of pulses? Looking further at the food chain, it is clear that there is very little value addition done for pulses. Mostly, pulses are consumed whole or split. Only desi chick pea is consumed in the flour form and there is growing demand for gram flour.
Global Milling Advances / August Issue 2015
But in India, R & D, at the moment, in public or private sector is not sufficient at all to explore these opportunities and others such as fortification and/or blending pulses with other ingredients that may ignite consumer demand which may in turn be matched by increased production.
How does the fertilizer pricing policy affect the pulses sector in India? This is an interesting but less obvious causal factor. Nitrogen fertilizer is the cheapest available nutrient for the crops while all other essential nutrients have become relatively expensive. Hence, an average farmer does not care about soil health, skewed NPK ratio and organic content etc., but used to simply dump more Urea expecting a good harvest. This is evident in states like Punjab and Haryana. So, as long as Nitrogenous fertilizer is available cheaply as it is subsidized to the extent of two-thirds of its selling price, there won’t be any motivation for a farmer to consider pulses as a stand-alone or even include in crop rotation or as intercrop. However, if the pricing policy is revisited and rationalized, farmers may tend to think of using pulse crops as an important means to save on fertilizer costs while at the same time realize high profits
if marketing opportunities are suitably matched. Farmers in the US and Canada realize huge savings in fertilizer costs for any crop that follows pulses. This has many advantages at both ends of the food chain as farmers will save input costs, enhance their soil health and get good profits, consumers are benefited due to increased availability which may bring down prices of pulses.
What are the implications for other countries outside India? The situation has huge implications not only for India but elsewhere in the world. Huge parcels of land in many African countries like Ethiopia, Malawi, Mozambique and Tanzania are being bought mainly by Indian businessmen with the main aim to grow pulses and import into India since pulses continue to have zero import duty. There are logistical advantages in exporting from these countries as their landing prices are lower than the traditional pulses exporters such as Canada or Australia.
So, what is the way forward? As mentioned above, the situation calls for a holistic understanding of the issues affecting the pulses value chain and major reforms in certain policy measures are critical needs of the hour. Also there is an ever increasing need for more R&D particularly in the public sector in the input side and also on food processing innovations where the goals are aligned with the on-ground realities. Some may suggest allowing export of pulses from India can be one of the options subject to sufficient safe guards that must be put in place to prevent domestic prices from rising beyond affordable levels. This may not only promote production but also create jobs in terms of encouraging the food processing sector to utilize more pulses in India as well as elsewhere.
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Mixing technology
An important step in the feed production process The primary steps in feed pelleting processing are: • Dosing/weighing • Grinding • Mixing • Conditioning • Expansion • Pelleting • Cooling • Sifting • Coating
A good mixer should provide booth fast and efficient mixing. Furthermore, it should be easy to clean and maintain.
Mixer qualities and important principles • Mixing is of enormous impotency and it is very important it mixes all particle sizes equally precise • Many feed formulas contain different enzymes opening phosphors or in some cases to cover the phosphors
Prior to the mixing process, the feed ingredients have been weighed and grinded and the vitamins and minerals have been added to the feed compound. The next step is then for all the ingredients to be mixed together.
• Failed mixing can result in slow grow of the animal
Mixing technology
• A one-day old chicken consumes only 10g per day, but it still needs all planed
• Too many or too few minerals or medicines can result in ill animals or even worse
ingredients to be in the feed for it to grow as planned • Even a full-grown pig consumes 6000g per day and it is equally as important that the formula is mixed properly, so the pig gets exactly the ingredients planned for it to grow • Mixing both formulas demands for high accuracy, as the chicken formula contains as many ingredients as the formula for the grown pigs • Good mixing ensures planed growth of your animals • It is very important that no and absolute no products are carried (cross contamination) from one formula to the next • A mixer needs cleaning as a routine
Basically mixing (or homogenizing) means to transport the individual particles to an exact position in relation to other particles and thereby avoid segregation. It is very important to have all the ingredient mixed together properly to achieve a good feed pellet quality.
Optimum mixing Optimum mixing of the feed ingredients will ensure uniform distribution of nutrients, vitamins and minerals, which will result in a homogeneous nutrient content in each feed pellet. Further, it will ensure optimum growth of the animals.
What is a good mixer? There are many demands to the capabilities of a good mixer. Especially, speed and quality are two qualities customers prioritize.
Global Milling Advances / August Issue 2015
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ANDRITZ proudly introduces the new OptiMix paddle mixer ANDRITZ is proud to introduce the new OptiMix paddle mixer to the market. The new mixer has shorter mixing time and the new patentable design features are unique for the market. The OptiMix has a new improved design to improve its performance. It is three times faster than the old ANDRITZ mixer. Further, cables and other installations are hidden, making it easier to clean.
Key features: • Self cleaning: preventing cross contamination between batches • Ensures fast and efficient mixing • Has a unique design: easy to clean and maintain • Easy installation • Easy access to liquid systems
and MTSE (Micro Tracer Services Europe) by using the toughest test method described. We achieved a mixing probability of (p) > 25% within 75 seconds (Equivalent to CV < 5%).
• Double sealing of bottom damper • Has a mixing quality with a Probability (p) > 25% equivalent to a CV < 5% The ANDRITZ OptiMix is tested and verified by TI (Technological Institute)
Global Milling Advances / August Issue 2015
Focus on research and development The new OptiMix paddle mixer is the result of dedication and hard work from
our skilled R&D team. It is a key factor of our vision to keep providing the best quality machines to our customers that ensure easy production, cost efficiency and high-quality results. ANDRITZ is committed to a substantial R&D efforts in order to lead the industry in technological innovation. We are consistent in offering advanced products, so our customers will continue to see the benefits of buying our products.
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All-in-One Mixing concept New mixing concept saves costs, eliminates contamination, and lifts, tilts, empties, mixes, and fills containers from one location Dinnissen’s new compact and advanced All-in-One Mixing concept lifts, tilts, empties, mixes, and fills containers from one location. In order to design a new mixing concept that is as lean as possible, Dinnissen focused on reducing and simplifying the number of steps as much as possible and optimizing the end product. The All-in-One Mixing concept is especially suited for situations in which it is important to prevent contamination and to quickly and easily switch between recipes.
Complete mixing concept includes functionality for emptying and filling containers The All-in-One Mixing concept is a completely integrated solution for mixing powders, particles, and granulates, including the ability to empty and fill drums and other containers. The concept eliminates the need for transport systems and intermediate storage and focuses on simplicity, labour
savings, and the elimination of contamination. In this new concept, the process operator places a drum or other container with all the necessary ingredients in a special lift. The lift raises the drum and is then hermetically linked to the overall system within a particle-free environment. The drum then tilts automatically and is connected to the mixer, after which a special clean-air system completely empties it into the double-shaft Dinnissen Pegasus® Mixer, without leaving any residues behind. There, the ingredients are gently suspended and mixed extremely quickly and thoroughly. The unique fluidized zone that is created during the suspension process makes the multifunctional processing unit suitable for mixing a wide variety of ingredients very homogeneously, carefully, quickly, and energy-efficiently. After the mixing process, the container that was originally fed into the system and has been emptied, without leaving any residue behind, is automatically filled with the end product. To make this
possible, Dinnissen designed a lift that can tilt as well as lift objects and that can automatically change its location in a linear fashion. As the Pegasus mixer itself can also be lifted, it becomes possible to fill the container that was originally fed into the system and has in the meantime been emptied with the end product at the end of the production process. This new concept makes it possible to simplify and reduce the number of activities to which the input ingredients are subjected and eliminates the need for interim storage between processing steps. This innovative and sophisticated solution minimizes the cost of cleaning, handling and storage and eliminates the risk of contamination.
Optimum end product quality The All-in-One Mixing solution can also be fitted with a mechanism that lowers the Pegasus® Mixer while the input drum is lifted upwards. This makes it possible to resolve any potential height issues. The new mixing concept can also be combined with atmospheric mixing in order to eliminate the risk of dust explosions. Finally, the new concept is also compatible with the Slide Pegasus® Mixer, which makes it possible to easily and quickly slide the mixer sidewise over guide rails so that the input and output components of the mixer can easily be accessed for optimum hygienic cleaning. Dinnissen’s All-in-One Mixing concept has a very compact design, which means that it takes up very little space and can be integrated much more easily into new as well as existing production processes. The input of ingredients into the system in drums also minimizes any potential breakage or damage to powders, particles and granulates, thereby further optimizing the quality of the end product. For more information about All-in-One Mixing, go to www.dinnissen.nl
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Chopin Technologies Almost a century of innovation
For almost a century, CHOPIN Technologies has developed methods and equipment for the quality control of cereals, flours and their by-products. The solutions are designed and manufactured in France and sold around the world. More than 75% are exported via a network of over 60 distributors. Meeting customers needs through product innovation are the very core of CHOPIN Technologies. The Applications laboratory, approved by the French Education and Research Ministry, offers tailor-made training for developing calibrations or predictive methods, adapting protocols or simply improving users skills and knowledge of the instruments. CHOPIN Technologies solutions are recognized by many international standards such as ISO, CEN, Afnor, AACCi, ICCC, etc. In the pursuit of constant improvement and innovation, CHOPIN Technologies has recently launched three new devices: the AlveoLab, the Mixolab 2 and the SRC-CHOPIN.
and precisely regulated. Consequently, the results are independent of environmental conditions, and therefore more accurate. With the AlveoLab, it is now possible to increase by 40% the number of tests carried out daily, thus optimizing the return on investment. First improved step is dough hydration. With the AlveoLab, water is added automatically and very precisely, based on the information given by the operator. In addition, the temperature of the water tank is regulated. Second improved step of the test is extrusion and cutting of dough pieces. Although, this step is not automated, new accessories have been developed to greatly help users in the preparation of dough pieces. A new semi-automatic dough cutter and new resting plates with a high-resistance anti-adhesive coating
have been designed. Final improved step of the test is the inflation of the dough pieces. The positioning and the inflation of the dough pieces are fully automated and carried out in a temperature and humidity controlled compartment. This ensures results are the same whatever the laboratory ambient conditions are. Control is assured by an integrated system (Peltier effect). Therefore, there is no need to connect the equipment to a cooling water system. Moreover, the bubble is inverted and as a consequence more spherical and closer to the ideal conditions of the test. The AlveoLab is associated with PC software where test data is displayed live, test after test. At the end of the test, a standard analysis certificate is automatically generated where company name and logo can easily be added. All data is backed up to assure perfect
AlveoLab: Milestone in CHOPIN Technologies History From the very first model (in the 1920â&#x20AC;&#x2122;s) up until today, the Alveograph has continued to evolve. The recent introduction of the AlveoLab marked a new milestone in the history of CHOPIN Technologies. This new version benefits from very important innovations, making the test easier to run and the results more accurate. It also offers new possibilities for analysis of flour characteristics. The main stages of the test are now automated to minimize the operator impact on the results. The test conditions, temperature, and humidity are controlled
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traceability. The AlveoLab software also offers several features for tests to be more comprehensively analyzed. First, a new feature for optimizing wheat and flour blends has been introduced. Users can select up to 5 products and the software automatically finds the most affordable blend that corresponds to the target Alveograph values. Then, an Improvers Guide helps the user to choose the most suitable additive to reach specific target Alveograph values. Also, it is possible to monitor over time the quality of a specific product in relation to a given supplier or customer. In addition, the software provides the potential to draw a built-in accuracy control chart in just a few minutes in order to check the instrument is functioning properly at all times. Currently there are more than 7,000 Alveographs in operation in 90 countries over the world. The global recognition of
Global Milling Advances / August Issue 2015
the device is indisputable today and has been established over almost 90 years, forged by its quality and performance.
Mixolab 2: Measuring Dough Rheological Performance In order to ensure the smooth running of the manufacturing process and the quality of finished products, the evaluation of dough rheological performance is an essential element of flour quality control. The Mixolab 2 measures the dough rheological characteristics during mixing (water absorption, development time, stability, etc) while assessing the quality of protein network, amylase activity and starch gelatinization and retrogradation properties, from 50g of flour. For this, the device applies a heating/cooling cycle to the dough and records the torque produced by the dough between the two blades.
In addition, the Profiler tool converts the curve obtained into 6 qualitative indexes for the user to quickly identify if the flour is in accordance with the specifications. Running a test is very simple. The user weighs and introduces the flour into the mixer. The rest of the test is then fully automated. Results are displayed in real time by comprehensive, simple and intuitive software. It also calculates the results of blends, helps to determine the appropriate dose of additives to reach a target value, and calculates the results of models for predicting the quality of finished products. The Mixolab 2 is adapted to the analysis of flour, ground grain or dough directly taken from a production line. It therefore offers tremendous flexibility and provides relevant information on a variety of applications: soft wheat, durum wheat, barley, rye, rice, corn, quinoa, cassava, etc. The Mixolab 2 is mainly used to control the quality and consistency of flour, assess the impact of
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additives and enzymes, or develop new formulations, such as high fiber or gluten free products.
These solvents are used to predict the functional contribution of each of the polymers to the quality of the flour.
SRC-CHOPIN: Automation of the Manual SRC Method
Conventional rheology tools measure the combined effects of these three polymers. The SRC method is complementary to these tools (the Alveograph for example) for better understanding each polymer’s individual contribution to the final behavior of the dough. In biscuit-making, for example, the industrial producer seeks minimal water absorption from the damaged starch and pentosans. Effectively, the same global absorption rate can have different causes, which subsequently affect the behavior of the dough during the production process in different ways.
Glutenins, damaged starch and pentosans are three functional components affecting the behavior of dough during the production process and during baking. The glutenins affect the extensibility and elasticity of the dough, the damaged starch affects its stickiness, and the pentosans have a significant effect on the dough’s viscosity. The SRC (Solvent Retention Capacity) method is a measure of hydration based on the increased swelling capacity of the flour’s different polymers when brought into contact with certain solvents – distilled water, 5% lactic acid in distilled water (to measure the glutenins), 5% sodium carbonate in distilled water (to measure the damaged starch) and 50% sucrose in distilled water (to measure the pentosans).
Global Milling Advances / August Issue 2015
By analyzing the contribution of each polymer, SRC testing provides additional information, allowing the behavior of flours and doughs to be more fully understood.
the SRC method and could allow users to reduce their operating time by 65%. Moreover, by eliminating all the variations resulting from manual operations, the SRC-CHOPIN provides consistent results. The manual SRC procedure is a standardized method: AACC (56-11), the results from the SRC-CHOPIN comply 100% with this standard. The next step will be to provide our users with the official standardization of the SRC-CHOPIN method. At CHOPIN Technologies not only do we create innovative new devices to improve users everyday laboratory work, we also continue to develop devices and enhance existing devices, ensuring our solutions are on the leading edge of technology. www.chopin.fr/en/
The SRC-CHOPIN is the first device to completely automate the different stages of
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Global Milling Advances / August Issue 2015
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Extrusion as an innovation driver Brabender® extruders for the food lab
Extruder products rank among the pioneering opportunities for product innovation in the food sector with promising opportunities on the market. This is why practically relevant equipping with extrusion equipment is a fixed constituent of the “toolbox” that is required for product developers in the food industry. New developments in snack products, breakfast cereals, flat breads, sweets, pet food and other special products can be prepared on a laboratory scale using this modern key technology. Brabender® provides suitable instruments for experimental trials of potential product lines with extrudates in a wide range of shapes, colours and flavours. They are compact and can be put to versatile use in innovative food laboratories. They make it possible for modern foods to be developed under realistic process conditions. This means that ongoing production is not impacted, which saves money but is still consistently quality oriented.
Laboratory extruder as sensible alternative for practical applications There are few procedures with as much potential for completely redesigning a product matrix. In order to develop innovative food textures and structures, the parameters of pressure, temperature, and shear can be varied during extrusion without changing the final product. Continuous operation in a closed system combines complex production steps into a constant, continuous production process. If product developers have to experiment on extruders during live operations in order to do this, this can lead easily to operational disruptions. This is why laboratory extruders are a sensible alternative for everyone involved in the development and testing of new processes and products – regardless of existing traditional processes, and with potential prospects for creating something completely new.
Global Milling Advances / August Issue 2015
Six arguments speak in favour of practical product development with laboratory extruders rather than experimental interventions in the production process: • You get to know new processes, and are able to test textures and sensory characteristics before trials have to be conducted on a production scale. • You can vary your application ideas in a wide variety of ways: in terms of raw materials, composition, machine or product. • You require significantly less material to carry out your trials, and hardly any product waste occurs. • You don’t have to worry about impacting your current quality management system. • You can establish methods for measuring your quality from raw material to end product in advance, in order to be in a position to react to quality variations in a better way at a later date. • You can easily achieve a return on investment with an appropriate philosophy of innovation within your company. Triple extrusion expertise from Brabender® The corporate group has many years of global experience with extruders and the practical deployment thereof: Thanks to the transfer of technology between plastics processing, the pharmaceutical industry and the food sector, Brabender® can provide extrusion expertise in three essential fields of application.
The use of measuring extruder systems in food laboratories provides reliable results for the fine tuning of optimal production conditions and to providing constantly high product quality. As is to be expected from Brabender®, the extruder technology that is provided is suitable for a wide variety of uses, especially in the field of grain products, and can be networked with other ‘classical’ quality measuring processes. Single-screw and twin-screw extruders or the modular expansion make it possible to adapt the processing conditions to the many different of products and tasks in the best possible way, customised to suit your operations: • Quality control and analysis of raw materials • Product development and recipe optimisation • Testing of the extrusion properties of different materials • Research and optimisation of processing characteristics • Binding of active ingredients and aromatic substances to a carrier material, such as in snacks • Measurement of rheological properties of material combinations • Extrusion of degradable products • Product manufacturing on a laboratory scale At the same time, studies with laboratory extruders have a range of technical process advantages over other procedures such as the practically-oriented measurement of extrusion conditions
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with small sample volumes, rapid changes in trial conditions, and simple operation and cleaning. Three equipment lines that are specially oriented to food laboratory requirements are introduced here as examples of our extensive product range:
Entry-level single-screw extruders The Brabender® KE 19/25 is an “entry level” model for measurement extrusion: a robust, autonomously operating single-screw extruder, also known as a single-shaft extruder, that is ideal for laboratories and technical institutions. Based on a broad selection of screws and tools, this machine is the ideal solution for • Developing new materials and products, including viscosity measurement • Testing processing behaviour during recipe development and product
Global Milling Advances / August Issue 2015
monitoring in the incoming and outgoing goods areas
into local data networks in PC-controlled mode.
• Quality control during production and throughout processes, with production of a company-specific quality profile for the consistent manufacture of products that comply with specifications • Optimisation of production conditions, full machine capacity utilisation, and minimisation of waste A comprehensive range of die heads is also available that makes it possible for a wide range of product ideas to be developed and tested. The performance features of this compact device are rounded off by powerful and user-friendly software packages that work on any version of Windows, the storage of operating and evaluation parameters in a database, and the capability of exporting the data into the usual Office programs. As well as operating standalone, this machine can also be optionally integrated
The Brabender® KE 19 is a sturdy, directly driven stand-alone extruder for laboratory and pilot plant stations.
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Twin-screw extruders for sophisticated applications Twin-screw extruders are the number one choice for sophisticated, complex applications. The Brabender® TSE product range is particularly attractive because of its wide range of applications and maximum flexibility. The screw and cylinder construction kits that are available in different sizes are designed in such a way that all process stages (feeding, conveying, plasticising, dispersing, reacting, degassing) can be carried out in the best possible way. The combination of several work steps into one continuously operating extruder turns these twin-screw extruders into modern inline compounders. The additional equipment that is required such as measurement and control systems, dosing systems and downstream facilities are also available, making it possible to build up entire modular extrusion systems that are tailored exactly to individual user requirements.
The processing unit in the TSE 20/40 and the TSE 12/36 consists of a hinged horizontal cylinder. This allows individual preparation steps to be visually assessed, and easy screw removal and quick cylinder cleaning are also possible. Furthermore, various mechanical material tests can subsequently be conducted on the extrudate. In this respect, online diagrams provide a quick overview of measurement data and evaluation results, even while measurement is in progress. The test data is stored in a database and can be processed using the usual Office programs, and can then be integrated into your own reports. Brabender® and its modular device designs show a practicable way toward practical implementation of extrusion technology in the food industry – one step at a time: The laboratory professionals develop creative innovation expertise, and companies safeguard their future with affordable investments.
With the Lab-Compounder KETSE 20 / 40 D, Brabender® offers a twin screw extruder as miniature scale with application to the food and animal feed industry for material research and process simulation.
As well as the TSE 20/40 and the co-rotating TSE 25/16 - 48 twin-screw extruders that have proven themselves time and time again in practice, the new Lab-Compounder KETSE 12/36 is now available, a miniature-scale twin-screw extruder with engineering that originates from material development and process simulations in the plastics industry. The combination of the scale-down of the production machine, the comprehensive adaptation capability to any processing task and the ease of operation of the system are the reason for its distinction as an outstanding laboratory measuring device.
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Global Milling Advances / August Issue 2015
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Advanced cleaning solutions critical to reduction of mycotoxin levels in cereal grains In the past few years, grain processors from across the world have intensified their efforts to ensure safe food and feed, despite a growing number of emerging threats. Due to these threats product specifications are becoming increasingly complex. Matthias Graeber, mycotoxin expert within Bühler’s Corporate Technology Group, discusses how advanced separation and optical sorting solutions can be used to manage the risk of mycotoxins and other hazardous contaminants. Among the growing number of safety concerns in grains are pathogens such as salmonella, non-declared allergens, such as gluten-containing foreign kernels in gluten-free produce, foreign bodies, and, of increasing importance, the widespread presence of mould fungi and their hazardous metabolites, referred to as mycotoxins. Aflatoxin, deoxynivalenol (DON), Zearalenone (ZEA) and ergot alkaloids are the mycotoxins creating the most concern, as they are common in grains such as wheat, maize, rye, barley and spelt. With some mycotoxins such as the highly-toxic Aflatoxin, the vast majority of grains are not affected, but just a few highly contaminated kernels could make an entire lot unsafe for further use. One example of an unsafe situation caused by aflatoxins, was in 2012/2013, when South-East European countries were facing a crisis. Contaminated maize was consumed by dairy cows, leading to cases of unsafe levels of the highly toxic aflatoxin M1, in milk intended for human consumption. There has also been a re-emergence of ergot alkaloids in rye in Central Europe, causing the relevant authorities to revise safety assessments and, as a result, ultra-low commercial specifications have been imposed by some companies. Such examples highlight the need to support grain processors in their ongoing efforts to ensure safe products. Through its Food Safety Initiative, Bühler continues developing and offering a comprehensive set of market-specific solutions.
Global Milling Advances / August Issue 2015
Early intervention - best practice for preventing and eliminating food hazards In order to control the hazards, grain processors must first follow the guidelines of good agricultural and post-harvest practice, to reduce the risk of hazardous contamination in cereal grains. However, as extreme weather conditions may cause plant stress, making the crop more susceptible to fungal infestations, problems may still occur, despite following best practice guidelines. In light of these ongoing problems, grain processors require solutions that ensure grain lots comply with commercial specifications and legal maximum levels of toxins. Grain processors also need to make sure any initial contamination does not spread further, by removing the small percentages of hazardous grains, as early as possible in the value chain. In the case of maize, for instance, in some regions the crop has been severely hit in successive years by different mycotoxins. In response, processors have implemented advanced grain cleaning processes to target the affected grains, not only in mills but upstream in the chain, at both grain reception facilities/grain elevators and warehouse levels. These advanced grain cleaning methods complement well-established, pre-cleaning processes at grain reception facilities/grain elevators. A good example of this is Bühler’s TAS grain cleaner, which is available for large capacities of up to 250 tonnes per hour.
Consistently reducing mycotoxin levels in the ppb-range, to meet food safety standards
It is well known that modern grain cleaning technologies can significantly reduce the concentrations of mycotoxins in cereal grains. However, one needs to keep in mind that removing affected grains from a lot can also negatively impact the processor’s yield. It is therefore critical to tailor grain cleaning processes in such a way that mycotoxin levels are reduced effectively and consistently, despite the natural variability of the raw product. This process must also be efficient, with minimal loss of good, unaffected product. This is particularly important as there is no technology available that can directly detect mycotoxins, non-destructively, on cereal grains – certainly not at a product flow of many tonnes per hour. The actual measurement of mycotoxins at the relevant levels – ranging from a few parts per billion (ppb) for aflatoxins to parts per million (ppm) for deoxynivalenol – requires processors to remove a representative sample from the product and then analyse it, using commercially available antibody-based test kits or high performance liquid chromatography (HPLC) laboratory analysis. Therefore, instead of actually detecting mycotoxins, modern grain cleaning technologies target the properties that indicate the presence of a fungal contamination and thus the potential of a mycotoxin contamination.
Processing expertise building on engineering excellence makes the difference Following Bühler’s dedication to provide innovations for a better world, they have partnered with grain processors and world leading researchers in mycotoxin management, such as the Institute of Sciences of Food Production (ISPA) in Italy, to develop solutions for the cleaning of mycotoxin from cereal grains and to provide conclusive data as reference case studies. The results from these case studies have enabled Bühler experts to define
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SORTEX A – the cornerstone of Bühler’s advanced cleaning solution for reducing mycotoxin levels.
standard flow diagrams, incorporating elements for mechanical separation and optical sorting of grains. For example, size separation, as performed by Bühler’s Grain Plus, removes broken kernels from the lot, as these tend to have a higher concentration of mycotoxins. It has also been found that very light product and dust from affected lots typically contain higher levels of mycotoxins, which can be removed through integrated or separate air aspiration systems. A further separation of lower-density grains, using
Global Milling Advances / August Issue 2015
Bühler’s concentrator options, further decreases the mycotoxin concentration. Finally, an optical sorter such as Bühler’s SORTEX A MultiVision™ detects even the most subtle of colour defects and, using InGaAs technologies, can distinguish anomalies in the non-visible, infrared reflectance of the cereal grains. This part of the electromagnetic spectrum can access information about chemical changes in the grains and has proven to be highly effective in identifying mycotoxin-contaminated grains.
It is understood that the larger the mycotoxin concentration in the removed product, the more efficient the cleaning process. As a result, the reduction of aflatoxin levels can then be achieved with less good product removed. Figure 1 highlights the results of an actual case study, carried out on an aflatoxin-contaminated lot of maize in an Italian cleaning facility, running at a throughput of 20 tonnes per hour. The results reveal the relative concentration of total aflatoxins in the fractions removed
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by size separation, aspiration channel, density separation and optical sorting, respectively. The product rejected by the SORTEX A optical sorter, for instance, contained an aflatoxin level of more than 1100 percent of the levels detected in the input material. Such high levels in the removed fractions are a direct result of utilising expert knowledge on the product properties that indicate fungal contaminations, together with world-class engineered optical sorting equipment. This ensures an optimised high capacity product flow, robust high-speed detection of the defective product and accurate ejection.
Advanced cleaning can also reduce other hazards In addition, SORTEX optical sorters reliably remove foreign kernels and foreign materials, which represent a further food safety concern, as they can cause injury if eaten. It is essential to prevent these serious issues, to avoid putting people’s health in danger, as well as risking costly, commercially damaging product recalls and adverse impact on business relationships. The SORTEX portfolio offers a wide range of customisable product options, including advanced proprietary vision and feed systems, allowing processors to meet their exact sorting requirements. These may include, in addition to controlling mycotoxin levels, the removal of discoloured/diseased kernels or the separation of wheat from oats to ensure a gluten free product, or the separation of GMO soy and maize from wheat.
Ensuring profitability for grain processors Bühler’s cleaning solutions for fungal contaminations are available for a wide range of cereal grains, such as wheat, maize, barley and rye, tackling a variety of hazardous fungal contaminations including aflatoxins, DON, ZEA, and ergot alkaloids. Building on outstanding engineering expertise and extensive experience in the reduction of fungal contaminations, in almost any food or feed material, Bühler experts are well placed to identify the solution that is the best match for grain processors needs, ensuring safe food and feed, while maintaining business-critical profitable yields.
Global Milling Advances / August Issue 2015
Figure 1: Aflatoxin concentration of input and cleaned maize, as well as of the fractions removed by the sequential processing steps. The aflatoxin concentration of the input maize has been set to a value of 100 percent. The reduction performance is case specific and may vary for different types of contamination. The sampling followed EU Comission Regulation No 401/2006. Aflatoxin analysis was carried out using HPLC.
About Bühler: Every day, billions of people come into contact with Bühler technologies to cover their basic needs for foods, mobility, or communication. With our industrial-scale process technologies and solutions, we contribute significantly to feeding the world’s population, setting the focus on food security and food safety. Bühler flour mills process around 65% of the wheat harvested worldwide into flour. Its contribution to processing rice and producing pasta, chocolate, or breakfast cereals is similarly important. Moreover, Bühler is a leading solution provider of die casting, wet grinding, and surface coating technologies, with an emphasis on automotive, optics, electronics, printing & packaging inks, and glass applications. The solutions provided for these industries are distinguished by high energy efficiency and sustainable mobility. As a leading technology group, Bühler invests up to 5% of its sales revenue in research and development. Bühler is proud of its Swiss roots, with 10,600 employees in some 140 countries generating sales of CHF 2.3 billion. The family-owned company Bühler is particularly committed to sustainability. More information: Buhler AG CH-9240 Uzwil, Switzerland Tel: +41 71 9551111 Web: www.buhlergroup.com
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Process NIR sensor using modern diode array technology The DA 7440 is a new type of process NIR sensor for over-belt placement. It uses advanced diode array technology to measure accurately even as recipes, ingredients or process conditions change. Process NIR sensors have been used in food and agricultural processing for many years, mainly for measurement of moisture. Up until now sensors have employed basic NIR filter technology, which is limited in analysis capabilities and needs frequent re-calibrations. Diode array is an established, advanced NIR technology which measures accurately without re-calibrations even as raw materials or process conditions change. The Diode Array instrument collects all wavelengths simultaneously averaging multiple, full spectrum readings every second. By doing so it provides accurate measurement of complex parameters including moisture/oven volatiles, fat, nicotine, sugars, seasonings and many more. This enables processors to optimize moisture content, reduce scrap, improve quality and decrease time for product changeovers - all without laborious sampling and reference method testing. The DA 7440 is designed to be installed in food and industrial production areas and meets the particular demands of these environments. The stainless steel housing has high ingress protection (IP69k in DA 7440 SD version) and the cabling is kept to an absolute minimum, all in order to be easy to clean and maintain. To keep the sensor clean and free from contamination it can be equipped with an air-purge window.
Global Milling Advances / August Issue 2015
DA 7440 On-line NIR Read more at www.perten.com/da7440
The Perten Instruments Group, represented in over 100 countries, provides tools for quality control and process monitoring. These tools include cutting edge Diode Array based technology, near-infrared analyzers, high frequency moisture analyzers, the Rapid Visco Analyser, laboratory mills, single kernel analyzers, Falling Number systems, and instruments that characterize dough, gluten and starch quality for the grain, flour, food and feed industries.
For more information please contact: Magnus Lindgren Process Instrumentation Manager Perten Instruments Country Phone: +46 8 505 809 47 E-mail: mlindgren@perten.com Or visit: www.perten.com
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Both sides of the story Milling News from around the world
www.globalmilling.com
Events in detail September #FutureFortified Global Summit on Food Fortification 9-11th September Tanzania www.gainhealth.org/events/future-fortified U.S. SOY Global Trade Exchange and Midwest Specialty Grains Conference 9-11th September USA www.grainconference.org IBA 2015 International Trade Fair: World Market for Baking 12-17th September Germany www.iba.de Global Grain South America 2015 15-17th September Brazil www.globalgrainevents.com Space 2015 15-18th September France http://uk.space.fr/ GSA 2015 65th Australian Cereal Chemistry Conference 16-18th September Australia www.conference.ausgrainscience.org.au/
http://aquaculturedirectory.co.http://globalmilling.com/wp-con Click this link to download our events planner today tent/plugins/download-monitor/download.php?id=13.php?id=2 and keep up to date with the latest industry meetings 1 2015 year planner
Shaping the Future of Food Safety, Together 14-16th October Italy www.efsaexpo2015.eu/
December 100th AACC International Annual Meeting 18-21st October USA www.aaccnet.org/Pages/default.aspx 9th International Wheat Conference 20-25th September Australia www.iwc2015sydney.com/ North American Millers’ Association 2015 Annual Meeting 22-24th October USA www.namamillers.org Animal Farming Ukraine 27-29th October Ukraine http://en.animalfarming.com.ua 26th Annual IAOM MEA Conference and Expo 2015 31st October -3rd November Dubai http://iaom-mea.com/IAOM-DUBAI/ November
Extrutec’2015 17-18th September Ukraine www.extrutec.org/en/
66th JTIC 2015 4-5th November France www.jtic.eu
Livestock Asia 2015 21-23rd September Malaysia www.livestockasia.com
Global Grain Geneva 2015 10-12th November Switzerland www.globalgrainevents.com
October ILDEX Indonesia 2015 8-10th October Indonesia www.vnuexhibitionsap.com
Global Milling Advances / August Issue 2015
Agro Innovate Nigeria 24-26th November Nigeria www.agra-innovate.com
Building a Global Network for Semiarid Cereal Systems 13-14th November USA www.aridcereals.org/
Fats & Oils Istanbul/Feeds & Grains Istanbul 3-4th December Turkey www.agripro.com.tr/?cat=18 Agro Innovate Kenya 8-10th December Kenya www.agra-innovate.com January MVC: Cereals-Mixed Feed Veterinary – 2016 26-28th January Russia www.mvc-expohleb.ru 2016 International Production and Processing Expo 26-28th January USA www.ippexpo.com/ February VIV MEA 2016 15-17th February UAE www.vivmea.nl/en/Bezoeker.aspx GEAPS Exchange 2016 27th February -1st March USA www.geaps.com/exchange/ March AFMA Forum 2016 " Feeding the Future" 1-3rd March South Africa www.afmaforum.co.za.
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Global Milling Directory Company A-Z Events Products & Services
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