Global Milling Advances is a magazine for agriculture professionals worldwide
Issue 10 / February 2015 Hybrid-cloud technology
Deep cleaning your silo
Feed formula management
Keeping them clean and pest fre
Industry news
Innovation and Ideas
Story: Alapala Mill handover in Turkey
Expo list
The world’s top events related to milling from around the world, listed on p. 26
Mixed integer programming
Fortified Rice Kernels
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Choosing the right supplier Six countries currently have mandates to require rice fortification, this is expected to increase. See P.22
Three scenarios of modern software usage in feed formula management PAGE 06
FORMAT INTERNATIONAL ON
INNOVATIONS AND IDEAS Read more on page 10 Published by Nisa Media Ltd www.globalmillingadvances.com www.facebook.com/nisamedia www.twitter.com/nisamedia
Alapala: Semolina Mill in Turkey
Azeus Machinery Co. Ltd
Editorial Welcome to the February issue of Global Milling Advances. In this issue we take a look at hybrid-cloud technology, innovations and ideas including mixed integer programming, pellet conditioning, keeping your silo clean and more.
Issue 10 / February 2015 Hybrid-cloud technology Feed formula management
Keep up to date with events happening in your industry! Download your copy of our 2015 wall planner today at www.globalmilling.com
Industry news
Story: Semolina
Mill handover in Turkey
Innovation and ideas Mixed integer programming
Conditioning
An important
process of Pelleting
Expo list The world’s top events related to milling from around the world, listed on p. 26
Published by: NISA Media Ltd 14 Clarke Way Cheltenham GL50 4AX United Kingdom
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Global Milling Advances / February Issue 2015
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A successful handover of a semolina mill in Turkey Alapala built the new Semolina Mill with a capacity of 400-tonne per day, for Oba Macaroni in Gaziantep, Turkey. The Mill incorporates the latest state of the art Milling Technology as adjacent to the existing mill. Oba Macaroni, which was established in Gaziantep in the year 1966, has always been a pioneer company in macaroni sector. The trademark and the plant, which was purchased by Özgüçlü Family in 2005, makes worlds class production with high production capacity in its modern facilities.
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More information: Ralph Wagner Product Manager Grain Milling Bühler AG in Uzwil / Switzerland +41 71 955 38 91 +41 79 504 42 31 ralph.wagner@buhlergroup.com
Polaris - a big star in milling heaven The MQRG Polaris purifier from Bühler has already sold 800 times First presented to the public at the IPACKIMA in Milan in the spring of 2009, the Polaris purifier from Bühler is now successfully positioned on the market. As a stand-alone machine or as part of the Bühler triumvirate Antares-Sirius-Polaris, the completely revised purifier from Bühler has earned a fixed spot in milling heaven. Since its market entry in 2010, Bühler's state-of-the-art purifier Polaris has already sold 800 times worldwide. The Polaris, listed as article MQRG at Bühler, is primarily used in durum mills for manufacturing high quality semolina for the production of premium pasta. With its high throughput capacity and increased yield for low-ash flours the Polaris purifier can also be used in milling where particularly light and thus low-ash content flours are being produced. Bühler's customers appreciate the 20% increased throughput rate of the Polaris, the maximum purification capacity with its extremely high yield of speck-free semolina, the user-friendly operation and monitoring as well as the maintenancefree operation.
Global Milling Advances / February Issue 2015
Supplier News – Polaris MQRG - 01
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For more information: Zivomir Selakov Managing director SBK Engineering Agriculture software group Brace Grulovic 17, Novi Sad, Serbia Email: zivomir.selakov@animalfeedsoftware.com Web: www.animalfeedsoftware.com
Hybrid-cloud technology in Feed formulation software systems Feed formulas management and optimization is a challenge facing many feed production companies as customer number and requirements increase, as variability and availability of ingredients reaches highest level and as competitive market pushes profit driven operations to the pedestal. Details in the formula, number of formulas, number of ingredients, variable ingredient prices, variability and availability of ingredients, complex constraints, decision making buy/not buy, production plans etc. all of those are services which must be provided by modern Feed formulation system. Cloud computing comes into focus in recent years as it brings a new way of software systems organization, deployment and support. Basically, cloud based software gives the opportunity for the company to outsource software and hardware that will allow maintenance efforts to decrease and focus on core production. No software, no hardware – no worries, is the motto of new age cloud based software. This is why it is usually provided as software-as-a-service, with monthly or yearly support. In the nutshell, the software provider is responsible for hardware and software maintenance because the software is actually run and the data is actually stored in the software provider’s datacenter. User only has client software (thin client or shell client), which is installed to access data and run
calculations. Main benefits of cloud computing are: • Increase volume output or productivity with fewer people – there is no maintenance of software or hardware • Reduce spending on technology infrastructure – it is a responsibility of software provider • Globalization – data can be access from anywhere with Internet access • Speed up business – there is no need for manual data sharing or slow communication – there is one datacenter which is used by all personnel • Reduce capital cost – no need for expensive hardware or software licensing. Pay-as-you-go. • Less training needed – train only for core software purpose • Improve flexibility • Improve fault tolerance – there is no possibility of hardware failure which can stop production • Improve scalability – add more licenses or service as you go There are some cases when traditional systems are better. Cloud based systems are dependent on Internet connection, so
Global Milling Advances / February Issue 2015
for rural areas and for areas with unreliable Internet connection traditional systems where software is installed on single computer (or computers) are more suitable. Although cloud based systems are very safe and that any data sensitivity can be arranged with confidentiality agreement, there are companies that find their data extremely confidential or have own datacenters so they want to have whole system on their premise. To create one solution to suit all needs and allow companies to experience systems which will best suit their business process AFOS has created hybrid-cloud technology for feed formulation software systems.
Hybrid – cloud technology Hybrid-cloud technology is AFOS software implementation of traditional and cloud software architecture in one suite. This technology allows AFOS to be run in the cloud, in the company datacenter and on single workstation in the same time or completely separately. This technology covers three main scenarios of modern software usage: 1. Single, standalone software – both software and database are installed on single workstation. Software is not dependent on communication infrastructure and data is only stored in local
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database. Data can be exchanged with other users manually. Individuals and rural users mostly use this. 2. Cloud software – calculation service and database are installed on cloud infrastructure while thin client for accessing system is installed on client workstations. Software is dependent on an Internet communication infrastructure and data is stored in cloud database. This type of software is targeted for large and geographically diverse companies where multiple users are working on same database in the same time. 3. Private Datacenter software - calculation service and database are installed on company datacenter and client for accessing system is installed on all client workstations. Software is dependent on company communication infrastructure
and data is stored in company datacenter database. This type of software is aimed for companies who have strong IT/OT infrastructure and department and want to take control of system hardware, software and maintenance. Additionally, AFOS hybrid technology allows combination of proposed scenarios. For example, single user might be part of cloud software team but also, in the same time, can have local database. This is very suitable for traveling consultants who are part of bigger teams because they can work in the cloud, while connected to the Internet, and when Internet connection is not available, they can use local database that can be synchronized with cloud later. Schematically, system showed on next figure.
Global Milling Advances / February Issue 2015
architecture
is
Figure 1 - Cloud system schematic architecture In the center of the system is cloud database. Around database is Calculation and data access layer, which determines access rights (who can see what, and who can run which action) and is used as primary point of communication with client applications. Client application can be run on various devices, workstation PCs, laptops, tablets or smartphones. Additionally, workstations and laptops have possibility to instant local database that can be synchronized with cloud database and used in offline mode. Some of the devices can be used only in read-only regime while other can be used for full database management and for running calculation. This is can be configured in the CDAL (calculation and data access layer) and is the responsibility of system administrator.
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Figure 2 – main AFOS screen CDAL can define comprehensive set of rules inside organization. Rules can be organized in geographical and/or technological sense and can be grouped in so called Areas of responsibility. For example rules can be “User A can use tablet in order to only see in read only mode poultry formulas in North America based plants” or “User B will use PC to
manage ruminant formulas and ingredients in Europe based plants”. Hybrid cloud is bringing scalability to the whole new level. Without any investment in hardware, any system downtime and without any data loss user can grow from single, standalone user to multinational user group disperse over the globe.
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Figure 3 – Advanced batch optimization
AFOS is next generation feed formulation system developed on new age cloud infrastructure using latest software technologies and database. This creates unique user-friendly environment, reliable and fast calculation engine and scalability that can be easily adapted to specific customer business process. More information: www.animalfeedsoftware.com or afos@animalfeedsoftware.com
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For more information: Format International Poole Road, Woking, Surrey GU21 6DY UK Web: www.formatinternational.com
Innovations and Ideas Introduction Format’s recent research activities have focused on areas which affect feed manufacturing but which are not adequately managed by traditional least cost formulation systems and the underlying Linear Programming (LP) technique. Those areas include the production parameters of weighing accuracy and silo availability, pelleting energy efficiency and carbon footprint, and on solving with constraints which are non-linear in nature. These considerations have particular relevance in today’s animal feed, aquaculture and petfood industries. Most manufacturing plants have practical constraints which determine how ingredients may be used, whilst a wide range of nutritional research continues to uncover the non-linear interactions between different characteristics of a diet and ingredients used within those diets. Climate levies and the drive to reduce CO2 emissions can influence the choice of ingredients used. Adding these additional dimensions and concerns to the formulation activity has benefits and solving them appropriately brings several benefits. • Products which more accurately meet the required nutritional parameters. • Improved selection of ingredients and their quantity.
• Energy efficiency and managed compliance with Climate Change agreements • A competitive edge to those who use such techniques appropriately.
The innovations Energy Formulation Resulting from a research project initiated by the Carbon Trust, Format has developed a protocol for measuring, predicting and controlling the energy required for pelleting of formulas. The resulting formulation system takes into account not only ingredient cost but also the kWh per tonne required to produce pelleted feeds. It allows formulators to assess the value of ingredients in feeds and the impact of their formulations more holistically than by ingredient cost and nutritional parameters alone.
Mixed Integer Programming Formulations produced by linear programming usually require adjustment before they are able to be used by the production plant. Reasons may include:•
The number of available silos
- For example, 11 bulk materials are available, but, due to plant design, only 9 can be used at once.
Global Milling Advances / February Issue 2015
• Use of ingredients which come in fixed quantities. - For example, certain ingredients are stocked in 25kg bags or other fixed units and must be included in the formula in those whole units. • Ingredient weighing accuracy, including the smallest amount that can be weighed. - For example, Wheat appears in the solution at a level of 22.365984%. With a weighing accuracy of 20kg in a batch of 2000kg, the inclusion will be rounded to 22.0% • Shelf life or expiry date for example particular batches or lots of ingredients must be used first, or used entirely. Using Mixed Integer Programming Format’s system is now able to take these aspects into consideration during the optimisation, giving users huge gains in productivity compared with iterative and manual methods of addressing these production issues. The following graph illustrates the difference between traditional LP and Mixed Integer Programming (MI). A routine exercise was carried out to see the effect on usage of the increasing cost of a particular bulk ingredient in a single product, firstly using standard Linear Programming, and secondly using Mixed Integer Programming. In this example, all
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bulk ingredients were subject to a weighing accuracy of 15 kg in a 2000 kg batch. Note that whilst one ingredient is investigated here, the MI solution is considering the weighing accuracy of all bulk ingredients at the same time.
tonnage. When an ingredient has weighing issues and is in limited quantity it’s even more important that it is used in the formulas where it can be of highest value and weighed up properly. It’s wasteful to include valuable and scarce materials in formulas at levels which are impractical. These will get “rounded out” or “rounded up” in a post-optimisation
adjustment leading to non-optimal costs of the affected formulas and a missed opportunity to use the scarce resource to best effect.
The effect on resource optimisation It is fundamental that the use of optimisation software should assist with
The inclusion levels in the MI solutions are optimised to meet the weighing accuracy of that ingredient. The graph shows that the LP solution chooses the optimal level appropriate to the ingredient’s value as the cost increases, but without regard to the practicalities of what can be weighed – resulting in fact in LP solutions which cannot be implemented in production. Without the MI tool, formulators take an LP solution and apply rounding rules to get it fit for production. This often introduces cost as well as nutritional deviation from specification. Helpfully, the MI solutions satisfy the full nutritional requirements, satisfy the production plant constraints and importantly are often more cost effective than the manually rounded versions. When a full production period is considered, the benefit of the new approach becomes even more significant. The potential difference in the actual usage of an ingredient when the MI constraints are considered can translate into a significant
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the process of evaluation of ingredients and lead to the best selection of ingredients in the right quantities. The efficient management of surplus and scarce materials is critical. An inappropriate selection of ingredients, or an inappropriate distribution of scarce or surplus ingredients leads to unnecessary extra cost and is wasteful of resources. It is imperative that strategic and tactical optimisation models consider the whole manufacturing plant using an algorithm that considers both the production forecast and ingredient availability constraints as inputs. In the context of resource optimisation the new tools enable more practical and cost effective outcomes.
Non-Linear constraints Non-linear equations may be ascribed to nutrients and solved alongside conventional linear nutrients, using Format’s non-linear solver. Typically users are employing the new tools to include –
• Calculation of non-linear nutrients, such as digestible energy. • Calculation of the contribution to nutrients due to the inclusion of enzymes. • Taking account of anti-nutritive effects of the use of certain ingredients (where the effect is non-linear). The new approach is superior to an “approximation” using a linear model and it is able to handle complex relationships which are multi-dimensional. The ability to optimise with non-linear constraints also gives the nutritionist options in specification design. The actual values achieved by current diets can now be calculated and compared with the required specification, and constraints set to this value, or the desired requirement can be maintained and achieved more accurately. There are numerous examples and one is given below.
Global Milling Advances / February Issue 2015
A model for correcting the energy contribution of added dietary fat to a broiler feed. (Data from Leeson and Summers, 2005 and van der Klis, 2010)
Summary The new methods are superior to traditional alternatives since the business constraints are achieved as part of an overall and full solution, and they avoid the need for time-consuming and expensive manual manipulation. They permit a broader analysis than hitherto by including production parameters and more complex nutritional relationships. Format International has brought innovations in optimisation techniques which are practical, relevant, time-saving and cost saving
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For more information: Elva Ren Azeus Machinery Co. Ltd Email: info@feedpelletizer.com Web: www.feedpelletizer.com
Conditioning - An Important Process of Pelleting The Necessity of Conditioning Mash entering the conditioner may be comprised of a wide variety of ingredients that make up the diet formulation. The nutritional, as well as physical properties of this mash have an effect on conditioning and eventual pellet quality. According a survey, pellet quality is proportionally dependent on the following factors: 40% diet formulation, 20% particle size, 20% conditioning, 15% die specifications, and 5% cooling and dry. So, 60% of pellet quality is determined before the mash enters the
conditioner. This increases to 80% after conditioning, but before mash has even entered the die chamber of a pellet mill. (Figure 1: Factors influencing pellet quality) Once the ingredients are mixed and transferred to the bin, the feed flows into a feeder, which moves the feed at the desired rate into the conditioning chamber. This is where steam and molasses are added. Molasses is added according to the level specified by the feed formula. Steam conditioning is the most important element in achieving high
quality pellets at high production rates at a low cost
Reasons for conditioning The importance of steam conditioning was showed by an experiment comparing dry pelleting with pelleting using steam conditioning. The results indicated that steam conditioning improved pellet durability and production rates and decreased the amount of fines generated and energy consumption. From this, it was concluded that steam acted as a lubricant to reduce friction during pelleting. (Figure 2: Advantages of conditioning)
Increased production When we started a pellet mill (30HP) with no steam, the capacity is about 1,200 lb./hour. By simply opening up the flow control valve and increasing the feed rate, it finally got the unit to a rate of 5,000 lb./hour. This is an illustration of where a pellet mill operator was running the pellet mill at 160째F. We can see that the production increased greatly by conditioning.
Increased die life Frictional heat plays an important role in die life. You can increase die life by reducing the frictional heat. Frictional heat can be determined by measuring the feed temperature as it leaves the conditionerand again after it leaves the die.
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The difference between the temperatures measures the friction of the feed through the die. High temperature difference (high friction) reduces die life and increases energy cost. Therefore, a thermometer within the conditioner is necessary.
Desalinize starch for nutritional value Gelatinization is defined as “ the complete rupture of the starch granule, brought about by a combination of moisture, heat and pressure and (in some instances) a mechanical shear”. The gelatinization of starch has two results important to digestion: for one hand, it enhances the ability of starches to absorb large quantities of water and this leads to improved digestibility in almost all cases and improved feed conversion in many cases. For another, gelatinization increases the speed at which enzymes (amylases) can break down the linkages of starch, thus converting starch into simpler and more soluble carbohydrate.
The Structure of Conditioner The conditioner is a blending mechanism for steam or liquid additives to the feed. Its function is comparable to the carburetor in your automobile. The conventional conditioner consists of a chamber with a rotating agitator to blend additives into the feed. Attention must be given paddle adjustments so there is a proper level of feed in the conditioner, giving adequate time and action for blending and absorption. Agitator tip speed is adjusted to the products being pelleted and the retention time required for proper absorption. Generally when one is pelleting light fluffy materials (less than 20 pounds per cubic foot), agitator tip speeds will run between 600 and 900 feet per minute. On higher density feeds, agitator speeds can reach between 900 and 1200 feet per minute for best results. The function of the agitator is to blend, not beat the additives into the feed. Agitator speeds should be kept as low as possible to minimize abrasion. (Figure 3: Typical conditioning)
Steam addition An adequate, well-regulated supply of steam is essential to any efficient pelleting operation. In planning a steam supply system, there are three major considerations: steam quantity, steam pressure, and steam quality.
Steam quantity The steam quantity that can be added at the pellet mill is dependent upon the bound moisture content and the dry meal temperature. Bound moisture is that moisture in the ingredients before the meal arrives at the pellet mill. Added moisture is the moisture added at the pellet mill in the form of steam and molasses. Total moisture of the meal is the sum of the bound and added moisture. The choke point of a pellet mill is approximately 18% total meal moisture. Great quantities of steam can be added when the meal bound moisture is low. As the bound moisture level increases, the amount of added moisture (steam) must be reduced. There is a rule of thumb: for each 1% of moisture added in the form of steam, the meal temperature is increased 20°F.
Steam pressure High-pressure boilers (60 PSI to 150 PSI) are considered more desirable than low-pressure units operating between 10 and 15 PSI. Use of high pressure allows smaller pipes and smaller control valves and keeps down costs. On the newer,
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larger capacity pellet mills, it can be very difficult to find flow control valves of adequate size for low-pressure conditioning. Thus, most customers now utilize the higher-pressure systems.
Steam quality Steam must be delivered at constant pressure and free of condensate. A properly designed steam system is essential and must be included in any welldesigned pelleting system. Condensation in a steam system can cause many problems. It is best to remove as much condensate as possible before it gets to the steam addition system.
Conditioning for different feeds Different ingredients require different treatment in the pelleting process. The amount of steam that can be added will vary for each run, because of formulation, moisture, temperature, etc. It can be classified into six broad categories. The categories should be well understood because each requires a different steam application.
Heat sensitive feeds Feeds in this group contain high percentages of dried milk, whey and sugar. These materials will start to caramelize at about 140°F. Thin dies and fat added to the formula can aid in reducing choke-ups. Normally low-pressure steam will be used.
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Urea feeds Little or no steam should be added to this group of feeds. Urea becomes more soluble as the temperature rises. Steam supplies the heat and moisture to dissolve the urea. The hot pellet temperature should be no higher than 150째F. Too much steam causes choke-ups as well as severe bin hang-up problems. Normally highpressure steam will be used.
Molasses feeds The amount of steam than can be added to this group is directly proportional to the percent of molasses in the formula. Since molasses is approximately 26% water, the quantity of steam that can be added must be reduced or the meal will become too wet. Adding live steam into the molasses line will raise the molasses temperature to 200째F. Under these conditions, higher meal temperature can be achieved without exceeding the maximum moisture level. Normally high-pressure steam is used.
High natural protein feeds This group includes supplements, concentrates and some steer and dairy feeds. Heat is more important than moisture to plasticize the protein. These feeds require more steam than the urea and heat sensitive feeds but less than high starch formulas. Normally high-pressure steam is used.
High grain feeds (high starch)
Complete dairy feeds
Poultry, broiler, hog and turkey feeds are in this group. High temperatures and high moisture are necessary to gelatinize the starches in the grain. The desalinize material acts as a binder to produce tough pellets. To partially gelatinize the starches, the meal moisture must approach 17-18% moisture and the temperature must be at least 180째F. The hotter the meal, the greater the degree of gelatin. This kind of feeds need low pressure steam.
This group is usually between 12-16% in protein. Another characteristic of this group is that they contain large amounts of fluffy, roughage-type ingredients and are also low in grain content. These ingredients have a low ability to accept moisture. Steam addition should be low to keep the meal temperature below 140째F and the maximum moisture level at 12-13%. If above levels are exceeded pellets expand and crack after leaving die.
Download our 2015 Year Planner www.globalmilling.com
Global Milling Advances / February Issue 2015
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For more information Rentokil http://www.rentokil-hygiene.co.uk/specialist-cleaning/silo-cleaning -services/
Deep cleaning your silo: keep them clean and pest-free Luke Rutterford, technical manager at Rentokil Specialist Hygiene, and David Cross, head of technical training at Rentokil Pest Control, discuss why regular deep cleans of silos are crucial
cleaning the silo premises should help to reduce workforce downtime as a result of these issues as well as ensuring the environment is a much more pleasant place to work in.
Silos play a crucial role in the agricultural, grain storage and food manufacturing industries, providing storage for a variety of different commodities such as flour, sugar, maize, grain and animal feed. They keep foodstuffs in a stable environment and should prevent product spoilage from microbial growth, pest infestation or contamination. Protecting commodities and revenue streams in this way makes good business sense and is also a moral duty, as the growing global demand for food places strain on producers and manufacturers, to reduce waste and protect valuable resources.
Cleaning the silo safely
Whilst this is reason enough for agricultural managers to preserve high levels of silo hygiene, cleanliness also directly impacts on the health and safety of the workforce. Agricultural workers are often time-short and operate alone, exposing them to health and safety risks, but ensuring silos are properly and regularly cleaned could help to reduce these. Accumulations of dust and mould in the silo facility can leave workers vulnerable to respiratory problems, coughs, headaches and flu-like symptoms. Deep
minimum to protect anyone undertaking a silo clean.
The cleaning of these enormous structures can be a daunting and challenging task and it is recommended that silos are fully serviced with the help of a specialist hygiene team, who can clean with minimal disruption to the operation of the plant. It is also essential that the cleaning team is fully trained in confined space entry, emergency rescue, and the use of the correct access and safety equipment, such as gas monitors, escape kits and various protective clothing. Using the correctly rated, intrinsically safe equipment is paramount, especially when working with dusty foodstuffs such as flour. There’s dangerous potential for a spark from poor electrical equipment to ignite dust and cause an explosion, and sadly there are instances of this eventuality occurring most years. It is also recommended that specialist cleaners have some respiratory protection devices to hand. The cleaning process itself can produce a huge quantity of dust, and exposure to this can increase the cleaners’ risk of lung conditions. P3 particle masks are therefore an absolute
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Although automated equipment can be used to negate the need for manual entry, by far the most effective method for cleaning silos is to actually have someone inside. A team of three is standard, with the entry technician being winched into the main chamber and supported by a winch man or ‘top man’. A second person should also be on hand to record gas readings and assist in case of emergency.
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The cleaning process for a silo is fundamentally the same as cleaning any large storage area and involves dry brushing, scraping and the removal of waste. The only real difference is in the difficulties posed by the commodity. Sugar can set like concrete, and flour is prone to clinging onto the sides of the silo, or forming a hard crust on the top that remains in position, when the flour beneath it is emptied it creates a thick layer of flour suspended in mid-air, which can then become an ideal area for microbial growth and insect infestation. Grain can present a similar hazard. If grain is left to spoil or absorbs too much condensation it can harden into large clumps. This prevents grain flowing freely in the structure, and enables a pile to accumulate on one side. If this clump is accidentally dislodged whilst someone is inspecting inside the base of the silo, then they can suffer serious injury as a result of large amounts of grain falling on them.
Four top tips to prevent serious injury in silos The below tips apply equally to everyday employees at the facility and specialist hygiene technicians. 1. Never enter a silo from the bottom to try and dislodge blockages. This is very dangerous and immediately jeopardises your safety, as it raises the possibility of the rest of the stored commodity falling
on top of you.
foodstuff from clustering together.
2. Always wear a harness, and never enter a silo unless you have a top man who can assist in case of an emergency.
4. Always use a specialist cleaning service when cleaning these large facilities. They will ensure that your facility is kept as hygienic as possible, whilst also following the correct safety procedures.
3. Always test the air (top middle and bottom) using a gas detector before entering a silo, it may be oxygen deficient at any point and opening the vents won’t always eliminate the risk. Ventilation in your silo is key, and can make all the difference when reducing the amount of grain that can get stuck to the sides of the structure. Try to keep moisture levels to a minimum as this will prevent particles of
It is the job of the quality assurance officer/ production manager to liaise with the specialist cleaner to make sure that regular cleaning is scheduled at realistic and sensible intervals. This consistent approach makes business sense as costs are minimised, silo downtime is reduced and the risk to employees is kept as low as possible.
Stored Product Insects (SPIs) The regular cleaning of silos is essential in preventing the build-up of product residues on the internal surfaces. If this is allowed to occur, they can create the perfect conditions for microbial growth and the breeding of Stored Product Insects (SPIs). Stored Product Insect (SPIs) pests are responsible for the spoilage of stored commodities worldwide, the disposal and replacement of which can be extremely costly. The most common SPIs are grain weevils, rice weevils, saw toothed grain beetles, flat grain beetles and flour beetles.
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STORAGE SYSTEMS WORLDWIDE
Big things have small beginnings...
Dragonby Vale Enterprise Park, Mannaberg Way, Scunthorpe, North Lincolnshire, DN15 8XF, UK T: +44 (0)1724 282 828 E: info@bentallrowlands.co.uk W: www.bentallrowlands.com
Global Milling Advances / February Issue 2015
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All of these insects can cause serious problems for farmers or food manufacturers that store grain, or grain based products in bulk, as the insects can eat large amounts of food while developing from egg to adult. This in turn can cause a considerable reduction in the weight of the product, resulting in a major loss of revenue. In addition, SPI-infested grain, which is destined for human consumption, can be downgraded due to physical damage and reduced nutritional value of the commodity. There are four ways to look out for SPI infestations:
1. The presence of live insects on the surface of the commodity or on the grain walls is sometimes an indicator of a more serious problem below the bulk. Use cone traps, probe traps and floor traps around the store to receive early warning signs. 2. Adult insects will leave tracks in the dust. 3.
Emerging adult weevils and grain borers will leave visible exit holes in the grains.
4. Webbing is produced by the larvae of stored product moths as they feed. The most effective way of controlling an infestation is to fumigate the product with phosphine gas, widely used to fumigate stored cereal and cereal products. The gas will not taint the product, is cost-effective and treatment can be carried out in one go. However, the use of phosphine gas is heavily regulated, so if you’re dealing with an SPI infestation, it’s important that you know who to contact before using these substances.
Rodents Farms are at greater risk of rodent infestation due to the abundance of food and shelter they offer. Grain mills, storage facilities and silos provide a perfect environment and are therefore especially vulnerable.
Rodents, in particular rats, are known to spread infections such as Salmonella, Hantavirus and Weil's disease. If they enter the silo they can contaminate food with their urine, faeces and hair, and can also cause significant damage to electrical cables, insulation and aeration systems by gnawing. With such high risks involved, it makes sense to ensure you proactively prevent and quickly deal with any signs of infestation. There are a number of ways that you can tell if your facility has become a home to these small mammals:
1.
Smell and sound: Rats and mice have a very strong ammonia stench and are often very noisy, making scrabbling noises in the premises.
2.
Droppings: Rats excrete dark, pellet shaped droppings up to 14mm. Mice droppings are typically 5mm and spindle shaped.
3. Smears: You may notice grease marks where rodents brush up against your walls and surfaces. 4. Damaged: Perhaps one of the most obvious pointers, but also the most difficult to spot – gnawing marks, shred
Global Milling Advances / February Issue 2015
ded paper and damage to feed sacks and hay bales are all common signs of rodent activity. One way to control the spread of rodents is to go back to basics by modifying the habitat around the farm to make it less acceptable to rodents. Whilst the silo itself should be well sealed, surrounding farm buildings can be a big draw for rodents if poorly maintained. Sealing any obvious holes in the exterior of buildings with wire wool, metal kick plates and cement will discourage entry. Vegetation should also be kept from growing too high next to buildings and items such as old pallets and corrugated sheeting should be removed, as they provide rodents with ideal harbourage and nesting sites. Whether you’re dealing with a rodent problem or an SPI infestation, it’s important that you know who to contact. An integral part of any external contractor is to be fully up-to-speed on the latest legislation changes in their area of expertise. Pest controllers are no different, so if you’re in any doubt as to what methods you can and can’t use, or how to use them, then it’s always best to check with the experts.
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For more information Food Fortification Initiative 1599 Clifton Road, NE Atlanta, GA 30322 USA Email: info@ffinetwork.org Web: www.ffinetwork.org
Choosing from a growing number of fortified rice kernel suppliers Adding vitamins and minerals to rice during milling – a process called fortification – is becoming more common as public health advocates see the potential for this staple food to deliver extra nutrition to consumers. This post-harvest process typically involves blending fortified kernels with unfortified rice. To meet the demand, more manufacturers are getting into the business of providing fortified rice kernels. For example, Abdul Monem Group in Bangladesh has recently opened a hot extrusion facility. The demand is driven in part by governments and organizations like the United Nations World Food Programme with the objectives of improving public health. Six countries currently have mandates to require rice fortification. This is expected to increase, just as 81 countries now require fortification of wheat flour. Rice fortification legislation typically requires certain levels of specific vitamins and minerals in the final product but does not specify which provider or technology rice millers must use. “Securing a good source of fortified rice kernels is a critical step,” said Scott J. Montgomery, Director of the Food Fortification Initiative (FFI). “Getting it right is a great opportunity for rice millers to be involved in improving the health of their employees and their customers.”
In 59 countries, an average of more than 75 grams of rice per person per day is available for human consumption, according to the Food and Agriculture Organization of the United Nations. The highest average is in Bangladesh with 475 grams. The total population of these 59 countries is 4.1 billion. If fortification of industrially milled rice reached even half of that population, 2 billion people would have more nutritious rice in their daily diets. Generally the rice miller’s choice for fortified rice kernels is between those made by extrusion or coating. In extrusion, rice flour is blended with a mix of vitamins and minerals; this mixture is then extruded to look like a rice kernel. It can be made to match the color and shape of unfortified rice kernels of any variety. With coating, a layer of vitamins and minerals is added to unfortified rice to make fortified kernels.
have multiple choices for their supply. Following are four considerations to help rice millers decide on the best source for their needs. These are based on the United States Department of Agriculture commodity requirements for fortified milled rice in international food assistance programs: 1. Ensure that fortified kernels closely resemble non-fortified rice in size, shape, color, and density in both dry and cooked state. Regardless of the type of fortified rice kernels used, the average consumer must
Extrusion equipment produces fortified rice kernels, made from a blend of rice flour and a mix of vitamins and minerals. Photo courtesy of Buhler.
With either technology, fortified kernels are blended with unfortified rice via continuous or batch mixing. The ratio of fortified rice kernels to unfortified rice varies based on the final nutritional outcome required, but the ratio is usually between 1:200 and 1:50. The blended product is then packaged and sold to consumers as fortified rice. As more fortified rice kernel producers come into the market, rice millers will
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be unable to distinguish between unfortified rice and fortified rice kernels. In Asia, people commonly pick through rice before it is cooked. If consumers there can identify the fortified rice kernels, they are likely to pick them out and not eat them. This means they are not getting the nutritional benefits, and the fortification efforts are wasted. As a result, riboflavin (vitamin B2) is usually not included in rice fortification because it can give fortified rice kernels a yellow or orange color. 2. Require no change in traditional rice preparation or cooking. One reason that fortification successfully improves nutrition is that it does not require consumers to change behaviors. They simply keep eating foods they enjoy. Expecting consumers to change their habits to benefit from fortification would make it less effective. In the United States for example, rice is fortified by dusting rice with a mix of vitamins and minerals. This is easily washed off, but most consumers in the United States do not wash rice before cooking it. Consequently, dusting is approved for rice fortification there, though dusting would not be effective in countries where rice is washed before cooking or where rice is cooked in excess water. As another example, fortified rice kernels made through coating are usually rinse resistant, but the coating breaks down in cooking, and the nutrients are dispersed in the water. This is acceptable in countries where all the water used in cooking rice is absorbed and eaten. But in places where rice is cooked in excess water that is later discarded, fortified rice kernels made via coating would be less effective. 3.
kernels is becoming less of a cost consideration as more suppliers enter the market. In Costa Rica, where both extruded and coated rice kernels are used, the costs are very similar - about US$ 2 per kilogram of fortified kernels. When fortified kernels are blended with unfortified kernels at a ratio of 1:100, the cost to fortify one metric ton of rice will be about US$ 20. Montgomery noted that as the demand is created for more fortified rice kernels, the technology will improve and costs will come down. 4. Seek scientific evidence of nutritional effectiveness. This step involves being sure that the nutrients added to fortified rice kernels are available for humans to absorb after the rice is cooked. It also involves ensuring that enough nutrients are included to meet the needs of the population. For example, the parboiling process drives vitamins and minerals from the outside layer of the kernels into the starchy endosperm, thus naturally increasing the rice’s nutrient levels. Parboiling eliminates the need to fortify with vitamins B3 and B6, however parboiled rice is not a rich source of other essential nutrients such as iron, zinc, vitamin B12, and folic acid (vitamin B9). Thus parboiling typically does not meet this fourth requirement.
Nutritional deficiencies, most notably iron deficiency, are a common cause of anemia. Regardless of the cause, anemia reduces productivity, hinders children’s physical and mental development, and contributes to maternal deaths. In 2011 an estimated 801 million people worldwide had anemia, according to a study published in the July 2013 issue of The Lancet Global Health. The total is more than the combined population of the United States, Indonesia, Brazil, and South Africa. Folic acid, a form of vitamin B9, is commonly added to wheat flour and is recommended for rice fortification as well. Vitamin B9 deficiency can also cause anemia, and insufficient folic acid increases the risk of pregnancies being affected by a neural tube birth defect such as spina bifida. Even if excellent healthcare is available, spina bifida is permanently disabling. Another type of neural tube defect is anencephaly which is always fatal. Researchers estimate that 246,297 such birth defects could be prevented every year if women consumed at least 400 micrograms of folic acid daily before conception and in the early weeks of their pregnancy. Fortification provides this nutrient through regularly consumed foods.
Choose a cost-effective option.
If a country has a large demand for fortified rice, a miller could make a strong business case for investing in a facility to make fortified rice kernels. A fortified rice kernel production line close to the mill will lower the total costs of fortification. In the initial stages of fortification, fortified kernels are often imported which means shipping costs are relatively high. However the costs of fortified rice
Global Milling Advances / February Issue 2015
This is an example of fortified rice kernels made to look exactly like unfortified rice. Photo courtesy of Buhler.
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Information for this article is based on presentations during a “Scaling Up Rice Fortification� conference held in Thailand in September 2014. This conference hosted discussions about the latest evidence on the effectiveness of rice fortification, best practices from countries where rice is already being fortified, and the latest developments in technologies and policies. Nearly 200 representatives attended from countries which are planning or already working to introduce the distribution of fortified rice. Countries
represented included Bangladesh, Cambodia, Indonesia, India, Laos, Myanmar, Nepal, the Philippines and Sri Lanka.
For presentations from the meeting, see: http://www.ffinetwork.org/about/calen dar/2014/RiceMtg_Bangkok.html
Participants included government and private sector representatives, as well as experts in nutrition, public health, food technology and development issues, donors to development and humanitarian activities, and representatives from the private sector, such as rice traders and millers, to provide information about the commercial viability of rice fortification.
The Food Fortification Initiative is a partnership of public, private, and civic sector representatives helping country leaders plan, implement, and monitor grain fortification programs. For information, contact info@ffinetwork.org.
FFI
at
This girl at a market in Jakarta, Indonesia, is an example of consumers who will likely improve their nutrition when rice is fortified. Photo by Dani Bradford for the International Food Policy Research Institute (IFPRI).
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