Global Milling Advances is a magazine for agriculture professionals worldwide
Issue 15 / May 2016 Auscan Online
Roller Mill Advances
Near Infrared Reflectance
Quadrumat ® Junior from Brabender
Wet Gluten Analysis
Feedstuff Grinding
An update from Bastak
Rotor Beater SR300
Feed quality irreversibly affected by mycotoxins
Expo list
The world’s top events related to milling from around the world, listed on p. 29
SR 300 RETSCH PAGE 10
Poultry affected by subclinical effects of mycotoxins Read more on p.20
BREAKFAST CEREAL MILL
Re-engineered for animal feed Read more on page 13
Published by Nisa Media Ltd www.globalmillingadvances.com www.facebook.com/nisamedia www.twitter.com/nisamedia
Value Added Training
p.23
Bolt ’n’ Go
p.26
Editorial
Issue 15 / May 2016 Auscan Online Near Infrared Reflectance
Welcome to the May 2016 issue of Global Milling Advances. This month we take a look at developments in NIR, Wet Gluten Analysis, Feedstuff Grinding, Roller Mills and much more. As always we strive to provide relevant and useful information to our professional readership; as such contributor submissions, press releases and feedback on our publications are always welcome. Keep up to date with events happening in your industry by visiting our website or checking the events section in this issue (p.28).
Wet Gluten Analysis An update from Bastak
Feedstuff Grinding Rotor Beater SR300
Roller Mill Advances Quadrumat ÂŽ Junior from Brabender
Events
The world’s top events related to milling from around the world, listed on p. 29
www.globalmilling.com
>> Published by:
Keeping in touch with Global Milling follow us on:
NISA Media Ltd 14 Clarke Way Cheltenham GL50 4AX United Kingdom
Twitter: www.twitter.com/globalmilling Linkedin: www.linkedin.com/company/nisa-media-ltd Scoop it: www.scoop.it/t/global-milling Paper.li: www.paper.li/GlobalMilling/1334242597 Pinterest: www.pinterest.com/globalmilling/ Facebook: www.facebook.com/pages/Global-Milling/316973328357939
www.globalmilling.com > Editorial Manager Nicky Barnes Tel: +44 117 2306494 Email: nbarnes@globalmilling.com
> International Marketing Manager Sabby Major Tel: +44 117 2306493 Email: smajor@globalmilling.com > News Editor Martin Little Email: mlittle@globalmilling.com
Global Milling Advances / May Issue 2016
Page 1
AusScan Online advances animal nutrition
Dr Charles Rikard-Bell, Pork CRC Manager, Commercialisation and Research Impact, presents at the AusScan NIR workshop at University of Sydney.
AusScan calibrations have been one of the
Using least cost formulations and today’s
providing rapid and accurate information on
most valuable technological advancements
grain prices, he informed the workshop that
product quality measures before acceptance
in animal nutrition in the past 30 years,
1 MJ DE/Kg was worth $25 to $30 per tonne.
into the feed mill. Workshop attendees learnt the steps required to verify accurate
according to leading South Australian animal nutritionist Tony Edwards of ACE
He suggested that the undersupply or
NIR readings, with emphasis on sampling
Consulting.
oversupply of energy in diets had conse-
techniques.
quences which could further increase costs Mr Edwards recently addressed an AusScan
due to reduced performance of livestock.
near infrared reflectance (NIR) workshop for
Samantha Openshaw of FOSS Pacific gave a live demonstration on scanning whole
Australian nutritionists and feed-mill
Joint venture partners Aunir and Coopera-
grains, with insights into sample prepara-
technicians, which aimed to:
tive Research Centre for High Integrity
tion.
Australian Pork (Pork CRC) made AusScan • Improve industry's knowledge and
calibrations available to customers
Interestingly, the FOSS machine will
understanding of NIR technology.
worldwide a year ago via the AusScan
combine five scans of the grain sample in
• Discuss applications of the technology and
Online website
one pass, thereby ensuring coverage of the
improving data management.
(www.aunir.com/products/ausscan-online).
whole sample.
• Discuss the future of NIR.
Agri-Torque’s Ivan Ward, who consults
According to workshop facilitator, Pork CRC
• Outline how to utilise energy values.
throughout the Asia Pacific region on the
Manager, Commercialisation and Research
application of NIR, discussed the use of NIR
Impact, Charles Rikard-Bell, NIR machines
Speaking at the University of Sydney, he
technology in feed mills, including how in
have user friendly software and uploading
stressed that by knowing the digestible
line NIR opportunities provide real-time
and downloading files to the AusScan Online
energy of grains before feeding livestock,
information and capture nutrient variation.
website is a quick and easy process.
formulations and confidently select the
An excellent case study was presented
Chris Piotrowski of Aunir presented the
correct parcels of grains for composite diets.
which demonstrated NIR’s effectiveness in
future of NIR in industry and the workshop
• Demonstrate using AusScan Online.
nutritionists could provide more accurate
Global Milling Advances / May Issue 2016
Page 2
learnt that technological advancements
It was also now possible to summate
would reduce the size of NIR machines.
spectra files of raw materials to produce a spectra output for a complete feed.
More information: Further information: Aunir: Caroline Noonan, email
“This generated much discussion on the progress made in the development of
To create an AusScan Online account, visit
caroline.noonan@aunir.co.uk or Tel +44
hand-held NIR devices and the correspond-
www.aunir.com/products/ausscan-online
1327 810910
ing accuracy of the measurements,” Dr
and follow the links. A full list of available
Rikard-Bell said.
calibrations can be found on the Aunir
Pork CRC: Roger Campbell, email
website www.aunir.com/products/ausscan-
roger.campbell@porkcrc.com.au or Tel + 61
online.
8 8313 7683
“Chris also gave a fascinating insight on other uses of NIR machines to verify ingredient uniformity simply by viewing spectra curves, noting that feed mills could get valuable insights into product variability simply by understanding spectra variations.”
Alapala News updates Canada meets Alapala Technology One of Canada's leading millers, who have more than 34 years of experience in flour industry, preferred Alapala for its turn-key flour mill project in Quebec. The mill with 200T/24 hrs capacity was completed in five
Alapala and Mill Service joint success: Dumee
months and came into operation on the 1st quarter of 2016.
Alapala and Mill Service have completed a successful project with the capacity of 450T/24hrs in Europe. One of France’s long-established milling companies, Dumée trusted Alapala and Mill Service for replacing its existing flour mill installation. Pre-cleaning, cleaning and flour packaging systems of the mill are provided by Mill Service which added its Italian know-how and experience in tailor-made plants. Complete milling section was designed, supplied and installed by Alapala with its experience in over 4000 flour mill installations.
Global Milling Advances / May Issue 2016
Page 3
Our most important additive? Attention.
50 years of producing feed additives has taught us that most solutions are built on conversations. That’s why we are dedicated to listening, understanding, and getting to know our clients’ concerns. You could say we don’t just produce feed additives: we live and breathe additives. Interested? Visit nutriad.com for your local contact.
Some factors affecting the wet gluten analysis by Zeki DemirtaĹ&#x;oÄ&#x;lu
Wheat flour is the most important raw material in the production of bakery products, since its protein content and quality plays a crucial role in the final product structure and quality. Wheat flour contains a complex mixture of proteins that are albumins, globulins, glutelins and prolamins. Among the cereals, wheat is the only one that contains unique storage protein called gluten. Gluten protein consists of glutenin and gliadin proteins that have significant functionality in dough structure through forming viscoelastic dough. After mixing of wheat flour and water, gluten proteins hydrate and some chemical interactions occur among the gluten and other wheat flour constituents during dough mixing/kneading and gluten proteins impart water absorption capacity, cohesiveness, viscosity and elasticity on dough. In the grain industry, the wet gluten content of wheat flour is generally determined by using the automatic gluten washing apparatus. After removing starch and water-soluble constituents, the remainder material is wet gluten. During wet gluten analysis, precautions should be taken to prevent obtaining inaccurate or erroneous results. Therefore, the factors that might cause error in wet gluten analysis should be defined and taken into consideration. Firstly, a skilled cereal scientist or technologist must be employed and he/she must have a fundamental knowledge about wheat and wheat flour.
Global Milling Advances / May Issue 2016
Page 5
Second, the amount of wheat flour to be analyzed is the biggest concern. There are two well-established and standardized methods (ICC Method No: 137/1 and AACC-International Method No: 38-12.02), generally used for determining the wet gluten content. In those methods, the weight of the sample to be analyzed is 10 g (14% moisture content basis). However, in some countries, the weight of flour sample was adjusted according to 14.5% or 15% moisture content instead of 14% moisture content basis. The accurate result cannot be obtained because of incorrect sample weight. Third, the temperature of the laboratory is another critical factor, which affects the test results considerably. The temperature of the diluted sodium chloride solution used for washing the dough is also important and it must be 22¹2°C. Fourth, the repeatability, that is a measure of the ability of gluten washing apparatus to give comparable results for the same sample at different times, is another concern. Fifth, the reproducibility, which is the degree of agreement between results obtained from different laboratories using the same type of gluten washing apparatus on the same set of samples, must also be taken into account in grain quality evaluation laboratories. In conclusion, all of these factors influence the results during wet gluten analysis and the standard test conditions must be followed continuously considering the abovementioned factors. More information: BASTAK Food Machine Medical Marketing Co., Ankara, Turkey export@bastak.com.tr www.bastak.com.tr
Global Milling Advances / May Issue 2016
Page 6
Brabender® Quadrumat® Junior New roller mill for user-friendly lab flour preparation
More information: Marc Gelautz Brabender® GmbH & Co. KG Germany Tel: +49 203 7788-148 Email: marc.gelautz@brabender.com
The Brabender® Quadrumat® Junior is a universal laboratory roller mill for milling wheat, spelt, rye, barley and rice. In one passage, the multi-stage grinding process produces laboratory flours that are almost equivalent to commercially produced flour in terms of ash content, yield and bak-ing quality. Those can be used for subsequent analyses such as standard tests with Farinograph®, Extensograph®, Amylograph®, Alveograph® or Falling Number. The new version of the mill offers enhanced usability. An easily removable round sifter facilitates cleaning. A more robust housing, larger drawers for flour and bran as well as a lower noise level are substantial advantages of the new Quadrumat® Junior.
Global Milling Advances / May Issue 2016
Page 8
Quick and reproducible grinding of feedstuff with the new Rotor Beater Mill SR 300 by Dr Tanja Hanke, Haan, Germany
More information: Retsch GmbH Dr Tanja Hanke Product Management 42781 Haan, Germany Tel: +49 2104 2333-178 Email: t.hanke@retsch.com
Fig. 1: Size reduction of feed pellets of various sizes in the Rotor Beater Mill SR 300 Grain, compound feeds or feed pellets occur in a variety of forms; compound feeds are usually inhomogeneous. Feedstuff is analyzed, for example, to determine the nutritional value, to detect hazardous substances or genetically modified ingredients. To ensure meaningful and reliable analysis results, representative and homogeneous samples are required. Therefore, sample preparation involves homogenization and size reduction of the material to a defined particle size. RETSCH laboratory mills are perfectly suited for this process. Usually only a few grams or milligrams of sample are required for analysis; these, however, have to represent the entire original sample. Depending on the part of the material from which a sample is taken, information on its composition may vary
adapted to both the sample properties and
control involves daily analysis of a number
greatly. To determine the nutritional value
analysis requirements. This means that
of samples which in some cases are
of compound feed, for example, all
grinding parameters and accessories have
extracted from a few kilograms of material
components need to be equally represented
to be selected in a way that the properties
which are first homogenized to ensure
in the sample which can be achieved by
to be analyzed will not be modified in the
representativeness. Easy and intuitive
thorough homogenization.
process. For most digestion and extraction
operation, effective size reduction and quick
methods a particle size of 0.5 mm is ideal.
cleaning of the mills help to increase
To obtain a correct and meaningful analysis
Feedstuff varies greatly with regards to
efficiency in the lab. Medium-hard and
result, the preparation process needs to be
hardness, moisture or fat content. Quality
grainy feed material is best ground with a
Global Milling Advances / May Issue 2016
Page 10
combination of impact and shearing forces. Impact lets the grains or pellets disrupt and the particles are then further reduced in size by shearing.
Homogenization of large feed pellets without preliminary size reduction Thanks to its robust design and the possibility to process large sample volumes up to 30 l in one working run, RETSCH’s Rotor Beater Mill SR 300 – which is now available in a completely updated and revised version – is perfectly suitable for use in the laboratory and for small scale production. The large free surface of the 360° sieves ensures rapid processing. A selection of accessories makes the mill adjustable to a wide range of applications. The new SR 300 features variable speed from 3000 to 10,000 rpm and a powerful 2.2 kW
Fig. 2: Size reduction of feed pellets (left) and a poultry grain mix (right) in the ZM 200
drive; it accommodates feed sizes of up to 25 x 25 mm resp. 35 x 15 mm. The application example of two different samples of horse feed (500 g each) illustrates the performance of the new SR 300. The soft, round pellets (25
Homogenization of compound feed and corn in the Ultra Centrifugal Mill ZM 200
x 25 mm - Fig. 1, left) are ground at 10,000
outwards. The particles hit the rotating teeth of the rotor and are crushed in the process. Further size reduction is achieved when the particles are ground between
rpm, using a 0.5 mm 360° sieve, to a particle
The high-speed rotor mill ZM 200 is
rotor and sieve through shearing forces. The
size of 90% < 0.5 mm within 2.5 minutes. The
particularly suitable for grinding slightly
sample remains in the grinding chamber for
hard, longish pellets (15 x 35 mm - Fig. 1,
fatty grain or compound feed as well as
only a very short time so that its properties
right) are homogenized to a particle size
small feed pellets. The sample passes
are not altered during the grinding process.
< 0.5 mm after 3 minutes, using a 0.5 mm
through a hopper and hits a horizontal
100 g of feed pellets (10 x 3 mm - Fig. 2, left)
360° sieve and maximum speed.
rotor, where centrifugal forces throw it
is processed in the ZM 200 at 18,000 rpm,
For grinding soft, temperature-sensitive or slightly fat or oily samples an optional distance rotor is available. The larger gap between rotor and sieve serves to reduce frictional heat during grinding so that smudged sieves and rotor blockings are successfully avoided. The use of a cyclone helps to improve sample discharge and provides additional cooling. Thanks to a ring filter and collecting receptacle with convenient bayonet locking mechanism the grinding process is virtually dust-free. Cleaning the mill can be done very quickly due to the removable grinding cassette, push-fit rotor and removable hopper.
Global Milling Advances / May Issue 2016
Fig. 3: Size reduction of rye in the Cyclone Mill TWISTER
Page 11
using a 0.5 mm ring sieve, to a particle size
adaption to a wide range of samples. A 160
below 0.5 mm (d90 value) in less than 30
g sample of rye was milled at 14,000 rpm to
seconds. The ground sample is collected in a
a fineness <1.5 mm within 60 seconds, using
cassette. The patented system ensures that
a 2 mm sieve (Fig. 3).
ring sieve and cassette are removed together thus allowing for full sample
Conclusion
recovery and avoidance of cross contaminations.
RETSCH mills are suitable for grinding and homogenizing all types of grain and
A mini cassette with matching sieves and
feedstuff quickly, reproducibly and
rotor is available for sample volumes below
neutral-to-analysis. Rotor mills have become
20 ml. It can be used, for example, to grind
the standard in the industry thanks to their
10 g of a poultry grain mix with a 0.25 mm
great flexibility and wide selection of
sieve and an 8-tooth rotor at 18,000 rpm to
accessories. Efficiency in the lab can be
a fineness of <200 microns within 20
greatly improved by using RETSCH mills.
seconds (Fig. 2, right). The ZM 200 is also suitable for milling slightly fatty and grainy seeds. For this type of sample the use of a distance sieve is recommendable. A small gap to the rotor ensures that the sieve apertures are not smudged by fatty sample particles. In addition, less frictional heat is generated so that this sieve is also suitable for grinding temperature-sensitive samples. By using a cyclone, the sample is not only discharged more quickly but is also cooled; with a cyclone up to 5 l can be processed in one working run.
Cyclone Mill TWISTER for non-fatty grain samples RETSCHâ&#x20AC;&#x2122;s cyclone mill TWISTER is the perfect choice for grinding feedstuff or grain such
Fig. 4: The latest generation of the rotor Beater Mill SR 300
as wheat or rye. It is mainly used for sample preparation to subsequent NIR analysis. The mill quickly grinds fibrous and soft samples by impact and friction to analytical fineness. The high speed and the optimized shape of the rotor and the grinding chamber generate an air stream which transports the sample through the integrated cyclone into the 250 ml sample bottle while the sample is cooled. Additionally, most of the sample residues are removed thanks to the air stream. Three speeds and sieves with different aperture sizes allow for optimum
Global Milling Advances / May Issue 2016
Page 12
Leading breakfast cereal mill re-engineered for animal feed market E R & F Turner's latest 600 Flaking Mill - re-engineered specifically for the animal feed market A consolidation of highly respected British
Chris Jones, managing director of Christy
"It was very important for us to create a
brands E R & F Turner, Christy & Norris and
Turner Ltd said: â&#x20AC;&#x153;The redevelopment of our
machine, which retains all the necessary
Miracle Mills, Christy Turner Ltd is renowned
600 flaking mill provides real benefits to
features of our proven breakfast cereal
for quality British engineering and innova-
animal feed producers seeking a high
design, but which is simplified, where
tion in the milling industry. With over 650
capacity machine. Many manufacturers
possible, in order to meet the target price
E R & F Turner Flaking Mills operational
know and trust the E R & F Turner brand and
range and specific requirements of the
across the globe, here the leading UK
the after care that comes with it and are
animal feed industry. Our latest mill offers
engineering firm talks us through its latest
attracted to the benefits of our high capacity
just that, together with a more hygienic
innovation launched at VICTAM in 2015.
600 flaking mill, but animal feed producers
flaking process and a newly restructured
simply do not require breakfast cereal style
pricing tariff, enabling the purchase of a
Machines of choice in the breakfast cereal
flakes for animal feed, or the prices that
premium brand at various price breaks,
market - over 90% of the machines used by
come with machines designed to deliver this
dependent on the manufacturer's needs.
UK cereal giant Weetabix at Burton Latimer
level of uniformity."
& Corby sites are E R & F Turner's flaking mills.
E R & F Turner is renowned for its 600, 550 Chris explained: "Breakfast cereal capacity is
and 460 model flaking mills, which are built
limited by flake quality, as the human
upon over a century and a half of engineer-
While the breakfast cereal market is,
consumer does not want compound flakes
ing expertise and innovation. Its 460 and
naturally, dominated by the need to create
(doubles) or excessive fines in their cereal
550 mills are already widely used across the
tasty and aesthetic flakes that meet both the
packet. Flakes also need to be similar in
animal feed sector.
discerning human palate and eye, the
thickness to ensure, when they are toasted,
animal feed market has very different
the colours are uniform. However, in the
Its latest 600 flaking mill - re-engineered for
requirements. It is this key difference which
animal feed market, the demands are very
the animal feed market and launched at
inspired E R & F Turner's latest 600 Flaking
different. A higher capacity can be achieved,
Victam 2015 - is designed to handle steam
Mill - re-engineered specifically for the
with fluted rolls to assist feed rates, as the
flaked, micronized and extruded grains,
animal feed market. The simplified design
eye of the consumer is not as discerning. A
maize, wheat, barley, beans, peas and soya.
enables animal feed producers to install a
thicker flake is also desirable and helps
It takes the proven chassis, bearing
premium, high capacity flaking mill at a
satiation in the animals.
housings and roll design of its 600 mill,
highly competitive price.
Global Milling Advances / May Issue 2016
already used extensively across the
Page 13
already used extensively across the
The following upgrade options are also
ceuticals industries around the world.
breakfast cereal industry, but incorporates
available:
Building upon manufacturing skills and
some key benefits exclusively for the animal feed market, including:
expertise since E R & F Turner started • Fully automated plc control of roll gap via
production in 1837, while making the most
servo valves fitted to the hydraulic pressure
of modern technological advances, Christy
assembly
Turner continue to produce machines of
• Integrated variable speed feed roll unit or
choice for manufacturers around the globe.
standalone vibratory feeder
Businesses looking for high quality flaking
• Water cooled rolls
equipment for breakfast cereal and animal
• Heavy duty construction
• Choice of motor powers
feed production, hammer mills with a
• Hydraulic or spring pressure system
• Conveyor discharge in place of hopper
reputation for reliability and longevity or
provides 60 Ton roll pressure
boards
excellent spares and servicing can comfort-
Key Features of E R & F Turner 600 Flaking Mill, re-engineered for animal feed market
• In process parallel gap adjustment
ably place their trust in a Great British brand
• High precision, rigid bearing arrangement
Chris Jones said: “We are proud to count
with a rich heritage of the finest UK
enabling the production of very fine flakes,
many of the world’s leading animal feed
engineering.
if required
producers as clients, and our new 600
• Chilled iron rolls, manufactured from high
flaking mill further reinforces the reliability
For more information please contact Christy
quality spun cast chilled iron, allowing for a
and quality craftsmanship for which E R & F
Turner on 01473 742325.
long life and considerable number of
Turner is renowned and our commitment to
regrinds
produce equipment tailored to the
During the re-design Christy Turner
• Pneumatically operated scrapers as
industry's very specific needs.”
undertook a zero based design exercise to
standard
question every component, to ensure the
• Vibration isolation as standard. Common
Production has already started, following
resulting machine was as lean as possible.
chassis supporting mill and motors, isolated
last year's launch, and the first 600 mill,
Here Chris Jones explains some of the key
from the surrounding structure on
re-engineered for the animal feed market,
technical differences.
anti-vibration mounts
will be in service later this year.
• Fully guarded rolls at all times, including
Simplification of the drive system
when the covers are open
In 2012, Christy Turner, celebrated 175
• Facility to insert sampling tray during flake
years of supplying high quality robust and
production
reliable Flaking Mills, Hammer Mills,
E R & F Turner's 600 Mill was originally
• Hopper boards discharge product below
Pulverizers, and associated plant for the
designed with breakfast cereal in mind and,
mill
human foods, animal feed, biomass, waste
as such, is fitted with a shaft mounted speed
recycling, minerals, chemicals and pharma-
reducer, as it is desirable for breakfast mills
Global Milling Advances / May Issue 2016
Page 14
to run at a slower surface speed. As an
been completely reviewed in the latest
prevent the mill operating if they fail. So we
animal feed mill generally runs with a higher
model. Complex covers that fully enclosed
looked to offer a simpler proven solution of
roll surface speed the shaft mounted speed
the ends of the machine have gone as, while
an eccentric pin within the pressure
reducer, that formed part of the drive
providing guarding from the drive system,
assembly linked via a cross shaft that is
system, has been eliminated for this model,
they also made cleaning and maintenance
outside the processing area and driven via a
which in turn removes the cost of an
more difficult. These have been replaced by
geared motor with limit switches to prevent
expensive component and takes out a stage
localised guarding around the moving parts
the rolls being moved beyond preset limits.
from the drive system, increasing the drive
of the mill. Around the processing area the
system efficiency.
end panels, at either end of the rolls, have
Hygienic flaking process
been redesigned to facilitate removal,
Strengthened and stiffened scraper carriers
making it easier to remove these panels for
Working within the guidelines of EHEDGE
a roll change or cleaning purposes. The roll
(The European Hygienic Engineering &
nip guarding remains very similar, however,
Design Group) - an organisation dedicated
The existing scraper design uses a bespoke
adjustments have been made to the
to the promotion of safe food by improving
carrier to retain a thin quick change scraper
guarding of the scraper blades. As part of
hygienic engineering and design in all
blade. This blade works well on smooth rolls
the revised guarding the ability to insert a
aspects of food manufacture - adjustments
and can be easily exchanged in less than
sampling tray is possible without opening
were also made to eliminate product traps
one minute, however, it is not suitable for
any doors or covers.
and improve access for cleaning the mill.
use on a fluted roll. We have replaced this system with a heavy duty cast scraper carrier similar to that used on our 550
Roll gap adjustment during flaking
flaking mills. This helps ensure constant contact with the rolls across the full roll
Customer feedback suggests those who
width and enables thicker, longer lasting
operate our mills like the ability to move the
blades to be fitted. The scraper control
rolls in parallel to adjust the gap whilst
remains pneumatic so the blade pressure
flaking. For the breakfast cereal market we
can be easily adjusted to the minimum level
offer this mill with a hydraulic pressure
to keep the rolls clean and turned on and
system which uses a combination of servo
off via a simple rotary switch.
valves and linear transducers to maintain a roll gap to a high level of precision. This
Review of guarding systems to assist cleaning and maintenance
closed loop control system, however, has a significant cost attached in terms of hardware and software and has compo-
The machine covers and guarding have
Global Milling Advances / May Issue 2016
nents such as the servo valve that can
Page 15
XXII 2017
2017
SPECIAL SUPPORT:
31-st of JANUARY - 2-nd of FEBRUARY RUSSIA, MOSCOW, VDNH, PAVILION № 75
EUROPEAN FEED
‘
‘
Pavilion «Khleboprodukty» (№ 40), VDNH, Р. О. Вох, 34, Moscow, 129223, Russia TEL.: +7 (495) 755-5035, +7 (495) 755-5038. FAX: +7 (495) 755-6769 E-MAIL: INFO@EXPOKHLEB.COM. INTERNET: WWW.BREADBUSINESS.RU.
2017 INFORMATION SUPPORT:
Mycotoxin Screening: Detecting the Invisible Enemy in Feed
Figure 2
They infiltrate our food supply through
Mycotoxins can cause different toxic effects
aware that if one toxin is identified in a
staple crops and lay waste to unsuspecting
depending on the type of toxin and the
sample, the chance that other toxins are
consumers. Dubbed the ‘invisible enemies’,
dosage. High doses of mycotoxins can cause
present is highly likely. Therefore, the need
mycotoxins represent a major issue which is
acute illness or, in extreme cases, death.
to test for multiple mycotoxins simultane-
steadily growing worldwide. Despite
However, the greatest concern is thought to
ously is key in ensuring that all prevalent
extensive preventative methods that may be
be frequent low level toxin ingestion, which
toxins are detected quickly.
taken during crop growth, harvesting and
may cause an array of metabolic
storage, it is not possible to completely
disturbances in animals resulting in poor
A growing awareness around the issue of
avoid contaminations in feed. Therefore, the
productivity. In recent studies with pigs and
mycotoxins has resulted in an increase of
use of efficient screening methods has
poultry, it was been shown that low level
available screening technologies, used to
become an increasingly important factor in
mycotoxin ingestion can result in reduced
ensure that levels are adequately
food safety, vital in preventing any potential
feed intake, poor growth rate, reproductive
monitored. Randox Food Diagnostics offers
contamination to the feed and food chains.
disorders, changes in carcass quality,
a range of market-leading screening tools
reduced fertility and hatchability of eggs and
for the quantitative analysis of mycotoxins,
Around 50% of the world’s grain is
suppression of the immune system. Human
using both the unique patented Biochip
contaminated with one or more mycotoxin
exposure to mycotoxins may also result
Array Technology (BAT) and high quality
and it is estimated that they are responsible
from the residues and their metabolites in
ELISAs.
for losses of up to 5-10% of crop production
animal production such as meat and eggs,
globally.1 The toxin itself is invisible to the
or consumption of plant derived foods that
naked eye; however, the fungus that
are contaminated.
produces mycotoxins can be seen.
Biochip Array Technology Biochip Array Technology is an industry
Aspergillus flavus, the fungus responsible
Mycotoxins can affect a range of food
renowned mycotoxin screening solution
for the production of aflatoxin, the most
products including cereals, grains, nuts,
from Randox Food Diagnostics which allows
well-known mycotoxin, appears
spices, dried fruits, apple juice and coffee.
for simultaneous, sensitive and fast
yellow-green in colour. As the fungus ages,
There are said to be between 300 and 400 in
screening of up to 10 of the world’s most
the spores turn a darker green.2 The most
existence, however the toxins that are of
prevalent mycotoxins. Arrays are available
significant factors in determining how
most concern are those that have been
in 10, 7, 5 or 3 assays as follows: See table
rapidly this fungus will grow in feed are high
proven to be carcinogenic and or toxic, such
overleaf (figure 1).
moisture content, relative humidity and
as aflatoxins (B1, B2, G1, G2 and M1),
temperature. Harvest and post-harvest
deoxynivalenol, zearalenone, fumonisin, T-2
Biochips are supplied in carriers, with 9
techniques and pests can also produce
toxin and T-2-like toxins. A number of
reaction wells per carrier, where samples
physical damage on the kernel, predisposing
studies have demonstrated that mycotoxins
and reagents are added. Using a single 50µl
it for mould invasion and toxin production.
occur simultaneously in field situations,
sample of feed, the user will obtain highly
which can profoundly affect the toxicity of
accurate quantitative results for multiple
the mycotoxins present. Producers must be
mycotoxins in under 2 hours, thus
1 http://cordis.europa.eu/programme/rcn/664744_en.html 2 http://springerplus.springeropen.com/articles/10.1186/s40064-015-0947-1
Global Milling Advances / May Issue 2016
Page 17
Myco 10
Myco 7
Myco 5
Myco 3
Aflatoxin B1/B2
Aflatoxin B1/B2
Aflatoxin B1/B2
Aflatoxin B1
Aflatoxin G1/G2
Aflatoxin G1/G2
Aflatoxin G1/G2
Zearalenone
Ochratoxin A
Ochratoxin A
Ochratoxin A
Deoxynivalenol
Fumonisins
Fumonisins
Fumonisins
Deoxynivalenol
Deoxynivalenol
Deoxynivalenol
T2 toxin
T2 toxin
Zearalenone
Zearalenone
Figure 3
Ergot Alkaloids Paxilline Figure 1
increasing the output of tests. Sample
in-house by Randox Food, will then translate
Randox ELISAs are produced to the highest
preparation is straightforward: solvent is
data into a quantifiable result per toxin
standard, offering excellent reliability and
added and vortexed for 60 seconds, then
(figure 3).
limits of detection in line with regulatory requirements.
rolled for 10 minutes, centrifuged for ten minutes and diluted; meaning the sample is
Using Randox Biochip Array Technology
ready for testing within 20 minutes, with no
eliminates the need for costly single tests by
Mycotoxins may be invisible, but their
need for Immunoaffinity Columns. This saves
lowering the cost per sample, saving food
impact on the feed and food industries is
time when compared to alternative methods
testing laboratories time and money. This
not and presents an on-going risk. With
which require separate sample preparations
technology ensures screening food for drug
global controls on food safety and
for each toxin (figure 2).
residues is accurate and efficient and in
contaminants becoming ever more complex,
external and internal studies, Randox
having the right technology to ensure that
For those who wish to customize their
Biochip technology has proven to deliver
mycotoxin levels are adequately monitored
mycotoxin screening according to the most
results which show close correlation to
is key to meeting those challenges now and
prevalent in their particular geographical
confirmatory methods.
in the future. Randox Food Diagnostics screening solutions provide excellent tools
region, MycoFlex is also available. This allows the user to select any combination of
ELISA Technology
for the quantitative analysis of mycotoxins using both the unique patented Biochip
toxins from the 10 toxins available (minimum of 3), and the test menu will be spotted onto
For laboratories that screen for mycotoxins
Array Technology and a high quality range of
a biochip, offering a customised resolution
using ELISA technology, Randox offers an
ELISAs.
for individual laboratory requirements.
extensive range of cross reactants (figure 4):
Biochip Array Technology is used in conjunction with the well-established
Ergot Alkaloids
Alfatoxin B1
Evidence Investigator; the multi-analyte residue screening analyser used worldwide
-Ergotamine
-Ergotaminine
-Alfatoxin B1
to provide simultaneous, rapid testing
-Ergosine
-Ergovaline
-Alfatoxin B2
without compromising quality. The biochip
-Ergosinine
-Ergometrine
-Alfatoxin G1
carrier is inserted in the light-tight
-Ergocristine
-Ergometrinine
-Alfatoxin G2
compartment in the image station of the
-Ergocristinine
-Agroclavine
-Alfatoxin M1
analyser, where the chemiluminescent signal
-Dihydroergochrisine -Lysergic Acid
from each Discrete Test Region (DTR) on the
-Ergocryptine
-LSD
surface of the nine biochips, contained in a
-Ergocryptinine
-iso-LSD
carrier, are simultaneously detected using a
-Ergocornine
-Lysergol
Charge-Coupled Device
-Ergocorninine
-Aflatoxin M2
(CCD) camera. Specialist software, designed Figure 4
Global Milling Advances / May Issue 2016
Page 18
Mycotoxins are highly toxic secondary metabolic products of moulds. The
Author: Radka Borutova, Business development manager, NutriAd Belgium
mycotoxin producing moulds damage crops and can cause great economic losses at all stages of food and feed production. Many of the mycotoxins also impair health, cause diseases, and can cause death in humans and animals that consume contaminated food or feed products. This year's excessive rains close to the time of harvesting in South American corn-exporting countries have hit the quality of local grains. Corn and soybeans from Argentina and Brazil are exported to many countries in South America, Africa, Russia, Asia, and the Middle East. A lot of problems with the grain quality are expected in countries which import corn in 2016 as a result of the weather conditions last year. Grain producers in South America reported that they were not able to harvest some of their grain after it germinated in the cob because it was too wet. In addition to this, the average temperature of around 24-32 째C in the region caused the Fusarium mould species to flourish (Figures 1-2). Currently, there are more than 400 known mycotoxins. The ones of most concern can be divided into six major categories: aflatoxins, trichothecenes, fumonisins, zearalenone (ZEN), ochratoxins, and ergot alkaloids. Nearly 25% of all crops worldwide
Feed quality irreversibly affected by mycotoxins
are affected by mycotoxins and the annual economic costs of mycotoxins to the U.S. agricultural economy are estimated to average $1.4 billion. This clearly illustrates the impact of mycotoxins on food and feed
China, Japan, and Australia. Symptoms
in food, feed, or food contact materials that
production and livestock farming.
include nausea, vomiting, and diarrhea.
are placed on the market in the notifying country or detained at an EU point of entry
Mycotoxins in human food chain
Fumonisin B1 was associated with an illness
at the border with an EU neighboring
outbreak in India with symptoms of acute
country. In the annual report, the identified
The associated health risk for human health
abdominal pain and diarrhea. Fumonisins
risks, the product and its traceability, and
is obvious. Aflatoxicosis in humans leads to
also have been implicated in esophageal
the measures RASFF has taken are
toxic hepatitis with jaundice, and in severe
cancer in China.
published.
extensively linked to human primary liver
In 2015, a total of 3049 original notifications
The most notifications in 2014 were in the
cancer in which it acts synergistically with
were transmitted through the Rapid Alert
hazard categories pathogenic
HBV (hepatitis B) infection and was
System for Food and Feed (RASFF). This is
micro-organisms (745) and mycotoxins
classified by the International Agency for
3.4% less than the 3097 notifications in 2014
(495). Mycotoxins (mainly aflatoxins) were
Research on Cancer (IARC) as a human
but with a 14.6% increase in follow-up
primarily detected in nuts, nut products,
carcinogen (Group 1 carcinogen). Both
notifications.
and seeds coming from China, Iran, Turkey,
cases death. Aflatoxin B1 (AfB1) has been
deoxynivalenol (DON) and ZEN have been linked to scabby grain toxicoses in the USA,
Global Milling Advances / May Issue 2016
US, Netherlands, Germany, Italy, Belgium RASFF notifications report on risks identified
Spain, and the UK.
Page 20
T-2 toxin are the most important for the pig industry. T-2 toxin inhibits feed intake. DON
Figures 1-2. Photos of corn at a field in Argentina taken by NutriAd colleague in March 2016
also reduces feed intake, and in addition decreases growth of the pigs and causes vomiting. Ochratoxins are hepatotoxic and nephrotoxic causing other chronic toxicities. The effects of ochratoxin intoxication are reduced growth, decreased weight gain, and renal lesions. ZEN mainly causes estrogenic effects in pigs. In pregnant sows, it increases the occurrence of abortions and stillbirths. In others, zearalenone contaminated feed induces swelling and reddening of vulva, false heats, and false pregnancy. Fumonisins target the liver, lungs, and pancreas and causes pulmonary edema in pigs.
Poultry affected by subclinical effects of mycotoxins Poultry are sensitive to mycotoxins resulting in several toxic effects. Broiler chickens are less affected by aflatoxins than other poultry
Factors influencing mycotoxin production
mycotoxins are not detectable with
like ducks, geese, or turkeys. Predominantly,
conventional analytical methods. However,
aflatoxins are the most immunosuppressive
these attached molecules may be removed
toxins. Type A trichothecenes (T- toxin, HT-2
Stress factors such as drought, poor
during digestion, thereby releasing the
toxin, diacetoxyscripenol) are of major
fertilization, high crop densities, weed
mycotoxin and affecting the animal.
concern to poultry industries and cause
competition, insect, or mechanical damage (in the field or during harvest, storage, and distribution) can weaken the natural defense
economic losses in productivity. They are
Negative effects of mycotoxins in livestock
highly toxic for poultry, especially for chickens due to their very low LD50. In particular, T-2 toxin reduces feed intake, body
of the plant. This promotes colonization by mycotoxin-producing fungi as well as
Various sources provide information about
weight, quality of breeding eggs, and causes
mycotoxin-formation. Mycotoxins can be
the effects and symptoms of mycotoxins in
oral lesions. Young chicks and turkey poults
found in all grain and forage varieties that are
animals. It should be noted that the effects of
are highly sensitive to ochratoxins. These
used to produce food or feed. They
mycotoxins are very complex and it is
nephrotoxins can suppress feed intake,
accumulate in the food and feed crops whilst
possible that symptoms different to those
growth, egg production, and causes poor egg
in the field, during transportation, or
presented in this paper may occur.
shell quality. Fumonisins are associated with
improper storage. Although analytical test
Generally, younger animals are more
spiking mortality in poultry. Signs of dietary
results maybe negative for mycotoxins in the
susceptible than older animals with some
fumonisin contamination are immune
feed, it is known that they may still be
exceptions.
suppression, decreased body weight and
present. It is well known that mycotoxins are not homogenously distributed in feedstuff but usually occur as â&#x20AC;&#x153;hot-spotsâ&#x20AC;? within the
average daily weight gain as well as increased
Pigs: extremely sensitive to mycotoxins
gizzard weights. Poultry appear to be less affected by zearalenone in comparison to other species like pigs while combinations of
feed. This makes sampling difficult and analysis may not detect the mycotoxins even
Generally, pigs are the most sensitive farm
mycotoxins might cause significant losses in
with correct sampling procedures. Therefore,
animals to mycotoxins. Aflatoxins suppress
fertility and hatchability.
a negative mycotoxin result should not be
the immune system and the first sign of
too conclusive in many situations. Mycotoxins
aflatoxin contamination in the diet is
may also be masked from analytical
decreased feed intake. Clinical signs,
detection by small molecules (glycosides)
depending on the contamination level can
attached to the toxin resulting in a false
range from reduced growth, hepatosis, to
Aflatoxins, trichothecenes and ZEN are as
negative result. Consequently, these masked
death. Among the trichothecenes, DON and
important in ruminants as they are in
Global Milling Advances / May Issue 2016
Mycotoxins: underestimated threat in ruminants
Page 21
monogastric animals. However, mature
mycotoxin levels are known, every feed mill
production in the field pre-harvest.
ruminants are generally more resistant to
can estimate the quality of its raw
However, a mould inhibition program in line
the effects of mycotoxins than monogastric
ingredients in terms of mycotoxin
with the storage conditions and the nutrient
animals. This is due to the mycotoxin
contamination and can effectively and more
availability is key to minimizing post-harvest
detoxification ability of some rumen
precisely (by dosage adjustment) apply
mould growth and mycotoxin production.
microbes. In general, calves are more
mycotoxin deactivator during production of
Storage mycotoxin contamination
sensitive to aflatoxins than adult cattle.
feeds.
(ochratoxins, aflatoxins) can be prevented
Among the most common mycotoxins, aflatoxins, trichothecenes, and ZEN are of
by keeping temperature and moisture
Test the finished feed
importance to cows. Clinical signs of
content in silos low while grain is regularly aerated. In case optimal storage conditions
ingestion of feed contaminated with
Another strategy of mycotoxin risk
cannot be guaranteed, the use of mould
aflatoxin include reduced feed consumption
management is to test mycotoxins presence
inhibitors is highly recommended.
and milk production, diarrhea, acute
in finished feeds. This method has some
mastitis, weight loss, respiratory disorders,
advantages and disadvantages. The most
hair loss, liver damage, and immune
important advantage is that by testing the
suppression. The aflatoxin metabolite AFM1
final mixture, the mycotoxins from the
is carried over into the milk from around 1
individual raw ingredients are more likely to
The fact that feed is the most important
to 6% of the aflatoxin consumed. Numerous
be identified unlike the in rapid test kits
source of mycotoxins cannot be changed.
studies have shown that ruminants are less
where some important raw ingredients
However, assurance can be given that the
affected by DON because it is metabolized
whose inclusion is not high (5-10%) can be
feed provided to the animals despite the
into its less toxic de-epoxyde in the rumen.
missed. These missed mycotoxins can still
mycotoxin contamination can be safe and
However, DON is associated with reduced
cause significant contamination of finished
not affect the health and performance of
feed intake and lower milk production in
feed. The key disadvantage of analyzing
livestock.
dairy cattle. T-2 toxin results in loss of
finished feed is that it usually takes quite a
appetite and weight, slower growth,
long time and by the time the results are
The final possible step in mycotoxin
gastroenteritis, lowered milk production,
known, the feed will have been consumed
management is the application of a
and reduced immune response in calves. In
already.
mycotoxin deactivator. These products work
addition, T-2 toxin has been implicated in
Apply effective mycotoxin deactivator
strictly in vivo and will not counteract or
hemorrhagic bowel syndrome by impairing
Since the 1960â&#x20AC;&#x2122;s, many analytical methods
mask mycotoxin in stored feed or raw
immune function. ZEN causes among other
have been developed for the testing of
ingredients. These products deactivate the
things abnormal reproductive processes in
mycotoxins in human food and animal feeds
toxins directly in the gastrointestinal tract of
cattle, sheep, and other ruminants resulting
due to the concern of toxicity in human
animals, based either on adsorption of
in false heats, anoestrus, premature
health. Among them,
those mycotoxins with suitably located polar
mammary development, and abortions.
thin-layer-chromatography (TLC),
functional groups, or biological degradation
enzyme-linked immunosorbent assay
(bio-inactivation). UnikeÂŽ and ToxynilÂŽ
(ELISA), and immunosensor-based methods
product lines from NutriAd represent
have been widely used for rapid screening,
specially developed feed additives that
The most important role of feed mills is to
while high-performance liquid
protect animals from mycotoxicoses by
keep the levels of mycotoxins as low as
chromatography (HPLC) with fluorescence
adsorption, bio-inactivation, organ, immune,
possible while avoiding multi-mycotoxin
detection (FD) and mass spectrometry
and antioxidant system support and
contamination. Most of the mycotoxins
detection (MS) have been used as
represent an optimal solution for mycotoxin
co-exist resulting in any single commodity
confirmatory and reference tests.
management for farm animals. It is highly
containing numerous mycotoxins at the
Accredited laboratory service is required for
recommended to apply an effective
same time. The best practical way to test
this step.
mycotoxin deactivator which offers an
Test the raw ingredients
opportunity to significantly improve animal
and control mycotoxin levels in raw materials that are not yet stored in silos is to
Use mould inhibitors
health, performance, productivity, and profit that can be impaired by mycotoxins.
use rapid test kit systems. A number of tests are carried out using different rapid test kit
The quality of feed and feed material is
Depending on the target performance,
systems which are validated for different
determined by its composition and its
different mycotoxins will have different
mycotoxins and commodities. These rapid
microbiological load. The number of mould
effects on the productivity. Therefore, using
test kit systems offer a very quick and
spores is especially an important factor.
different products for different animal
effective way of screening raw material
There is not much that can be done about
groups become a rational trend.
before it enters the feed mill. Once the
mould contamination and subsequent toxin
Global Milling Advances / May Issue 2016
Page 22
Value Added Training The Kansas State University IGP Institute offers an array of professional development courses to bring value to the employee and company.
Employers today recognize the need for
practical experience. This four-day intensive
theoretical milling background. This could
quality training to improve employee skills.
course covers the principles of wheat
include individuals with practical work
There is supporting research that links
cleaning, conditioning and milling; under-
experience, or milling or university training.
professional development with employee
standing the importance of wheat quality
motivation and increased morale. There are
and preparation to the milling process; and
Both courses are taught using a blend of
also external factors that support the
the advantages of wheat and flour blending.
classroom lecture and discussion as well as
importance of professional development
hands-on training in Kansas State
and include increased productivity and
Milling Practice to Improve Flour Quality
Universityâ&#x20AC;&#x2122;s state-of-the-art Hal Ross Flour
outputs.
expands on topics from another course
Mill as well as pilot mill facilities located on
offered at the IGP Institute, Basic Milling
Kansas State University campus. Participants
The IGP Institute at Kansas State University
Principles. The course covers topics on
spend time learning fundamental principles
has two courses that will do just that.
quantitative techniques to analyze and
in a classroom format and then apply the
Recently highlighted in Global Milling,
improve the process flow, variables that
learning to real-world equipment and
Managing Mill Balance and Control and
impact production efficiencies, and
situations. This technique has proven to be
Milling Practice to Improve Flour Quality are
troubleshooting skills of mill personnel.
quite successful in allowing participants to
both being offered on-site in Manhattan,
Participants will leave with a more thorough
apply to their work environment in
Kansas.
understanding of how to analyze mill flow
real-time. Participants can then take and
sheets and design; how to analyze mill
apply the experience and knowledge gained
balance and product distribution; how to
to their facilities.
Upcoming Milling Trainings
adjust roll stands; sifting and sifter design; Managing Mill Balance and Control is
purification systems; and process control.
Each day, participants spend approximately
targeted to milling engineers, operation
This course is also ideal for milling
half the day in discussion and lecture and
managers, production managers and shift
engineers, operation managers, production
the other half in laboratories designed to
managers who possess at least one year of
managers and shift managers who have a
further enhance the educational experience
Global Milling Advances / May Issue 2016
Page 23
of the participants. In Milling Practices to Improve Flour Quality, participants complete a baking laboratory understanding the relationship to quality and end products. This particular component of the course offers participants a unique perspective, as flour millers don’t always get to see the application of their products in a production setting. In addition to lecture and laboratory time, participants work through real-world, application based assignments. In Managing Mill Balance and Control, participants focus on optimization, specifically optimizing break release using different classes of wheat. Milling Practices to Improve Flour Quality focuses more on different quality testing, how to read and understand attribute curves and the impact of quality testing on milling and later end products.
Applying Practical Training All courses taught at the IGP Institute are instructed by Kansas State University faculty. The faculty members who teach both milling courses are former industry professionals who have moved into teaching positions. This interesting combination provides participants with a blend of both academic quality lecture with true experience-based application and knowledge. Upon successful conclusion of each course, participants leave the IGP Institute with a completion certificate from Kansas State University, which many participants proudly display on their office walls. In addition, they will leave with knowledge that they can easily apply to their own facilities and a new
Prospective participants who have an
other targeted trainings as they become
network of technical contacts.
interest in attending these offerings can
available as the IGP Institute. More
learn more by going to our IGP Institute
information on this program can be found
Former course participant Jason Wahl, a
website and selecting the on-site training
at GEAPS’ website, www.geaps.com.
miller at Birkett Mills who participated in
tab. There you will find information on Flour
both courses in 2015, wanted to learn more
Milling and Grain processing.
Laying the Foundation
years of experience, I have an idea of what
Participants can further enhance their
These offerings and partnerships are the
I’m doing but I wanted to get more of the
professional development through online
result of over 35 years of work by grain
science behind it and understand a little
distance education courses taught in
science professionals on behalf of Kansas
better what I was doing and what I was
conjunction with the Grain Elevator and
and United States producers. Established
looking for.”
Processing Society (GEAPS) as well through
under the name of The International Grains
about the science behind flour milling. “With
Global Milling Advances / May Issue 2016
Page 24
The IGP Institute has continued to grow over the last 35 years, with enrollment in both distance education and face-to-face courses climbing. This growth is contributed to both the inclusion of distance education into the curriculum as well as the efforts of committed faculty and staff to continue to support the mission of IGP. As an internationally recognized provider in technical education programs related to flour milling and grain processing, feed manufacturing and grain quality management, grain marketing and risk management focused on corn, grain sorghum, soybeans and wheat, the IGP Institute served 1,494 participants in 2015. Those participants attended courses both on-site in Manhattan, Kansas, on-location across the globe or via distance through 61 different course offerings. The IGP Institute continues to be committed to producing quality teaching and technical support to the industry in the forms of on-site training and distance education. As we look to the future, we anticipate more on-location delivered trainings as well as blended courses with components delivered via distance to allow for more hands-on
Laying the Foundation
with four state of Kansas commodity
laboratory time during courses.
groups â&#x20AC;&#x201C; wheat, sorghum, corn and These offerings and partnerships are the
soybeans. In addition, Foreign Agricultural
For more information on the IGP Institute,
result of over 35 years of work by grain
Service of the United States Department of
please visit www.grains.ksu.edu/igp.
science professionals on behalf of Kansas
Agriculture supported the development of
and United States producers. Established
an institute with technical education as the
under the name of The International Grains
primary mission. The Kansas legislature
Institute in 1978, the institute was the
approved use of funds in the spring of 1978
brain-child of former department head of
and the program has been providing
grain science and industry, Charles Deyoe.
technical support and training ever since. In
The mission of the IGP Institute still reflects
the summer of 1978, the first course was
the early work of Deyoe: To provide
offered through the institute by grain
innovative and relevant education and
science and industry professors. The course
technical programs to enhance the market
was on flour milling and was offered
preference, consumption and utilization of
on-location in India.
U.S. cereal grains, oilseeds and their value-added products for the global grain
Later that year, the Institute changed the
industry.
name to International Grains Program to avoid confusion with another institute at
Deyoe saw a need to develop the foreign
Kansas State University.
agricultural market as it related to commodities, specifically United States
Evolving to Today
grains and soybeans. He worked in tandem
Global Milling Advances / May Issue 2016
Page 25
The True Cost of En-Masse Chain Conveyors – How “Bolt ‘n’ Go” Chains keep the running costs down Chain Conveyors are an essential part of
en-masse chain conveyor, we’ll find that a
transported in the chain conveyor. The
many bulk handling systems, where they are
big part of this is the maintenance: the cost
material is fed into the conveyor from the
used to convey bulk materials such as
of replacement chains and links, the cost of
top and falls through the moving chain to
powders, grains, flakes, pellets …etc. Many
the labour and finally the cost of the
the bottom of the box. Because the particles
of these conveyors use drop forged chains
downtime.
interlock, the material moves as a single
with flights as a means of conveying the
stream at the same speed as the chain. This
material being handled. This “en-masse”
For each and every user of chain conveyors,
highly efficient conveying process allows
conveying system is very popular as it is a
it is of vital importance to have the conveyor
nearly the entire conveyor cross section to
simple but highly efficient system of moving
running to full capacity for as long as the
move as bulk.
material.
equipment can allow it. Maintenance and repair can cost a lot of money and time,
Traditionally, the flights are made of steel
When it comes to purchasing a chain
usually requiring the services of a team of
and welded onto the links. The links with
conveyor, it is easy to look just at the
engineers and considerable amount of
flights are then assembled in many different
one-time purchasing cost and the quality of
resources.
arrangements using pins and circlips,
the components. The problem with conveyors is that they are exposed to a lot of wear and tear, and even the best chains can fail after a certain period of time. But
headed pins and circlips or headed pins
So how does the en-masse conveying system work, and where does the chain failure occur?
this can be many years depending on the
assembly is very robust and works well until general wear, operational errors, material build up and many other reasons can cause
conveyor use and maintenance.
In En-Masse conveying, the flight height can
If we look at the lifetime cost of an
be as low as 12.5% of the material being
Global Milling Advances / May Issue 2016
with collars and a roll pins. The whole
maintenance shut down.
Page 26
4B’s Bolt ‘N’ Go system is a new flight assembly system that gets rid of the need for welded flights and pins and circlips assemblies which are quite costly and time consuming in terms of manufacturing. This new system includes: • A set of Nylon flights that can be cut to accurate lengths depending on the desired overall width. These nylon flights are very strong and wear resistant but remain lightweight, therefore reducing the amount of power required to drive the chain. • A hollow pin made of alloy steel (the same In the case of a minor incident, such as the
With 125 years experience and providing
material as the link) and case hardened to
flights breaking, although the chain does not
solutions, worldwide, to customers within
C57 - C62. This pin will take the load in the
require to be changed, it is still necessary to
the bulk material handling industry, the
assembly. It is very strong and can be
order new chain links with flights welded or
engineers at 4B have come up with a
supplied in stainless steel for applications in
grind the sides of the failing links and weld
revolutionary simple solution that
a corrosive environment.
new flights onsite. In both cases, a lot of
minimises conveyor maintenance
resources and time are needed to complete
downtimes and overcomes a lot of the
• Bolts, nuts and washers are used to hold
the maintenance procedure. Having new
problems encountered when using drag
the flights onto the link and assemble the
links with flights welded is only the first step
chain conveyors.
links together. Lock nuts are used to secure
of the maintenance process: the chain
the whole system.
needs to be slackened, the circlips must be broken in order to take out the links where the flights have failed, new links with welded flights need to be put in, and finally the chain has to be tensioned again before the conveyor is at last operational or the whole chain removed from the conveyor. One of the other major causes for concern with this traditional assembly is the fact that the circlips can sometimes come loose due to poor installation, not only causing the chain to collapse therefore again stopping the conveyor, but also contaminating the product that was being conveyed and risking pollution and obstructions in the plant process. Engineers have been working hard at suppressing and minimising the different problems encountered within a chain conveyor as much as possible with solutions such as more frequent maintenance checks, metal detectors…etc. - Whilst this has helped to reduce the number of unexpected break-downs, it hasn’t removed the need for conveyor shut downs when the chains or flights need to be replaced.
Global Milling Advances / May Issue 2016
Page 27
• At no point does the bolt take the load or
The Bolt ‘N’ Go assembly system is an
Bolt ‘n’ Go is currently available for
is in contact with the pin. It merely holds
excellent and robust solution that will not
4B102NA, 4B142NA and 4B142HA links with
and secures the flights.
only improve the overall capacity of the
flights up to 750mm wide.
conveyor to perform at its optimal ability for • The system uses 4B drop forged chain links
longer. But also help to minimise the offline
4B’s drop forged chain is backed by an
that have special lugs on the sides onto
maintenance periods thus improving the
international network of companies with
which the flights are fastened, giving the
yearly capacity and profits made using the
over 125 years of bulk handling experience.
assembly extra stability.
chain conveyor.
4B engineers are specialised in the drop
The Bolt ‘N’ Go system is extremely easy to
The Bolt ‘n’ Go system has been used
engineering design service and advice for
install, yet very robust and has a long
successfully in many facilities across the
any drag or en-masse chain conveyor
lifespan. It has many advantages in
world, in a wide range of applications
application.
comparison to the traditional pins and
including agricultural, wood chips, sugar,
circlips assembly.
animal feeds, etc. All these products have
forged chain industry and can provide
been used in conveyors of various length, This system will undoubtedly save a
For more information please contact:
angles and high capacity applications.
precious amount of time and money when
4B Braime Components
conducting maintenance work. With the Bolt
The system has been such a success that
Hunslet Road Leeds LS10 1JZ, UK
‘n’ Go system, it is no longer required to take
many suppliers of en-masse chain
www.go4b.com
the tension out of the chain and take the
conveyors now offer the Bolt ‘n’ Go chain
Email: 4b-uk@go4b.com
chain out of the conveyor before changing
and flight system as an option.
the flights; the old flights can be taken out and new ones fitted while the chain is still tensioned inside the conveyor. Since a shorter amount of time is required to assemble the Nylon flights rather than welding steel flights onto links, all the flights can be delivered very quickly thus eliminating the need to stock a lot of spare parts; or they can be kept in stock on site at low cost, since they are not welded to the chain. The Bolt ‘N’ Go system will also enable the full use of the links since it is not necessary to change the links every time new flights are needed. Once again this represents a major saving for facilities using this system. 4B's Bolt ‘n’ Go chain links are made of special heat treated alloy steel case hardened to Rockwell C57 - C62 with a ductile core hardness of Rockwell C40. 4B’s superior heat treatment technique and material provides the optimum chain link with a more resilient ductile core for shock resistance, and an extremely hard exterior surface for superior wear and corrosion resistance. This results in reduced downtime and maintenance with an increase in the working life for the chain conveyor.
Global Milling Advances / May Issue 2016
Page 28
Events in detail January MVC: Cereals-Mixed Feed Veterinary â&#x20AC;&#x201C; 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. Victam Asia 29-31st March Thailand www.Victam.com April 120th IAOM Annual Conference & Expo 4-8th April USA www.iaom.info 15th ICC Cereal and Bread Congress 17-21st April Turkey www.icc.or.at
Global Milling Advances / May Issue 2016
http://aquaculturedirectory.co.http://globalmilling.com/wp Click this link to download our events planner today and -content/plugins/download-monitor/download.php?id=13. keep up to date with the latest industry meetings php?id=21 2016 year planner
5th Global Feed & Food Congress 2016 18-20th April Turkey www.gffc2016.com
67th JTIC International 9-10th November France www.jtic.eu
9th International Feed Regulators Meeting (IFRM) 21 April 2016 Turkey www.ifif.org
Eurotier 2016 15-18th November Germany www.eurotier.com
XXVII The European Feed Manufacturers Federation FEFAC Congress 21-22nd April Turkey www.fefac.eu May Food Ingredients Istanbul 2016 4-6th May Turkey http://www.figlobal.com/istanbul/home PIX / AMC 2016 - Australian Milling Conference 29- 31st May Australia www.sfmca.com.au/events/516/ June Cereals 2016 15-16th June UK www.cerealsevent.co.uk August GrainTech India 2016 26-28th August India www.graintechindia.com/ November CICFO Grain 2016, CIFCO Feed 2016, CGOF 2016 4-6 November China www.cicfo.com
Page 29