Global Milling Advances is a magazine for agriculture professionals worldwide
Issue 11 / May 2015 Solutions through stewardship Managing Chemical Residues
Buhler at IDMA 2015
The latest technology on show
Mill pest control
Expo list
Stored Product Insect Control
Power to the people
Knowledge, understanding and skill
The world’s top events related to milling from around the world, listed on p. 26
Experts for African Mills
04 Four methods of making puffed rice. Rice grains expanded through heating in the presence of steam. PAGE 23
Read more on p.18
KANSAS STATE’S IGP INSTITUTE
EDUCATING THE INDUSTRY Read more on page 20 Published by Nisa Media Ltd www.globalmillingadvances.com www.facebook.com/nisamedia www.twitter.com/nisamedia
Heat: The perfect fumigant
P.9
Power to the people
P.15
Editorial
Issue 11 / May 2015 Solutions through stewardship Managing Chemical Residues
Welcome to the May 2015 issue of Global Milling Advances. This month we hear from experts in pest control, education, training and more. As always we strive to provide relevant and useful information to our professional readership, contributor submissions, press releases and feedback on our publications is always welcome.
Industry news
Buhler: The latest technology on show
Power to the people
Knowledge, understanding and skill
Keep up to date with events happening in your industry! Download your copy of our 2015 wall planner today at
www.globalmilling.com
Mill pest control
Stored Product Insect Control
Expo list
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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 www.globalmillingadvances.com
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News Editor
Martin Little Email: mlittle@globalmilling.com
Global Milling Advances / May Issue 2015
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IDMA 2015 Bühler demonstrated processing expertise The Bühler Group was prominently on display at the IDMA technology trade show in Istanbul / Turkey from April 23 until 26, 2015. The Business Area Grain Milling showcased the entire breadth of its processing expertise on its approximately 600 m2 booth. Under the motto, "One step ahead in processing grains to food", Bühler presented various new or improved machinery and plants to the technical public. Besides the two roller mills, Dolomit and Antares, Bühler demonstrated the innovative plansifter Seginus. With a seamless synchronous processing set-up that is unique worldwide, this plansifter uses a minimum amount of space while maintaining top sanitation and enables flexible sifting and sorting of flour and semolina at a throughput capacity of up to 20% more.
To round up, the new impact machine Matador for reliably destroying insect eggs in flour and semolina as well as three measuring systems for continuous particle size measurement (Online PSM MYTA), the NIR Multi-Online Analyzer for determining moisture, protein, ash and starch damage (MYRG) and the sensor MYHB for color and speck analysis were also display at the Bühler trade show booth at the IDMA 2015.
For more information: Markus Baffy Head of Marketing & Communication Grain Milling Bühler AG 9240 Uzwil, Switzerland Phone +41 71 955 30 79 Mobile +41 79 723 59 41 Email markus.baffy@buhlergroup.com
Bühler also showcased its sorting skills with the color sorter from the Sortex A series that has sophisticated and multifaceted sorting functions. In addition, Bühler also displayed the newly developed destoner, Combistoner, the latest generation of the moisture control unit MYFE and the water proportioning unit MOZH as well as the flexibly usable, automatic Bühler bagging line for free flowing and non-free flowing products.
Global Milling Advances / May Issue 2015
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Solutions through Stewardship: Managing Chemical Residues in Farm Produce By Raghavan Sampathkumar, Stewardship Director, CropLife Asia, Singapore. E-mail: raghavan.s@croplifeasia.org
The Food Security Challenge Globally, agriculture is facing enormous pressure to produce more food for growing population while it is increasingly getting affected by shrinking cultivable land area, water availability and climate change. With impressive economic growth, homogeneity of diets across countries has increased in the last 50 years and is pushing more and more countries become heavily reliant on a shorter list of major crops - wheat, maize and soybean. Any shortfalls in one crop in one major country create seismic ripple effects in the global trade and push millions deep into hunger and poverty particularly in Asia and Africa. Further, crops need to be protected from pests and diseases and crop protection chemicals globally play a vital role in protecting crops on the field and in storage, assuring production of adequate quantities of safe and quality food and play an important role in achieving food security.
Global Milling Advances / May Issue 2015
In India, according to a recent study by ASSOCHAM (Associated Chambers of Commerce and Industry), crop losses due to pests and diseases amount to a whopping Rs.50,000 crores (US$8.6 billion), which is quite significant particularly in a country where 300 million Indians live below the poverty line for whom getting two square meals a day is a challenge. Importantly, this is avoidable to a great extent by using appropriate control methods which can broadly be classified as IPM – Integrated Pest Management. It includes judicious and responsible use of crop protection chemicals as one of the several tools within IPM to maximize crop yield and food quality; minimize risks to health and environment and ultimately manage residues in the final produce. Several media reports in India have emerged recently on excessive levels of chemical residues found in commonly consumed vegetables and key export crops including tea. These reports evoked mixed reactions from different groups having diverse interests.
While some groups concerned about consumer food safety and quality, called for stricter regulatory regimes and better surveillance while some proposed stricter measures to regulate availability and importantly, control pesticides that are banned elsewhere in the world on health concerns. Those who oppose usage of pesticides in crops and paint a scary picture to the poorly-informed, have gone to the other extreme of proposing blanket bans.
Pest and disease infestation amounts to crop losses worth a whopping Rs. 50,000 Crore (about US$ 8.6 billion) each year in India. ASSOCHAM
While it is important to have the necessary regulations in place and implement them effectively on-ground, in the long-term perspective, it is more important to invest in capability building, training, educating and promoting awareness among farmers on good agricultural practices combined
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with appropriate stewardship activities particularly, judicious and responsible use of crop protection chemicals. It is a shared responsibility of every entity involved in the food value chain to equip the farmers to do their job better and ensure food that reaches the consumers is safe.
Ensuring that the food reaching consumers is safe is indeed a shared responsibility of every entity in the food chain.
Initiatives by CropLife International Network In crop protection products, stewardship is a holistic product life-cycle approach whereby the benefits are maximized through responsible and judicious use while risks are minimized through educating the users against indiscriminate and unscrupulous usage. Spearheading the stewardship responsibility of the industry, CropLife International-sponsored initiatives in India and worldwide successfully demonstrated enormous benefits - both tangible and intangible - to the farmers, Governments, rural societies, entire food value chain and consumers. In Guntur, Andhra Pradesh, when Chilli farmers were educated about stewardship and responsible use principles, they realized higher net returns (about 52% higher) with significant real savings in input costs as their produce were conforming to the MRLs for exports. In Adoni, Kurnool district of Andhra Pradesh, CropLife is engaged in hands-on training of farmers on responsible use and IPM practices and about 1,01,000 were trained since 2009. Farmers were able to better identify beneficial insects, understand pesticide labels while purchasing and also wear personal protective equipments while spraying.
Global Milling Advances / May Issue 2015
In Burdwan taluk, West Bengal, under the GRES (Green Revolution in Eastern States) initiative, rice farmers were trained on productivity improving technologies with key focus on IPM and responsible use of chemicals and preliminary results show that the farmers achieved at least 22% higher yields. Other benefits for the farmers and the rural community were reduced usage and expenditure on pesticides, improved personal health and overall reduction in environmental pollution and public health hazards due to indiscriminate use of crop protection chemicals. These initiatives and other resources developed by CropLife International and its regional networks including CropLife Asia are aimed at promoting farmers’ awareness and encourage adoption of good agricultural practices including responsible use of crop protection chemicals, use of personal protective equipments and following necessary intervals between pesticide applications particularly, prior to harvest. Several Governments across Asia adopted the materials for training their extension staff who in turn provide training to the farmers.
Way Forward For addressing the issue of residues holistically in the long-term, it is important to have a balanced perspective considering the contribution of the crop protection industry to the agricultural GDP and overall economic growth. Short-terms measures such as improved surveillance, stringent implementation of existing regulations related to food safety and quality and holistic adoption of the International Code of Conduct on Pesticides Management are needs of the hour. In the long term, it requires revitalization of agricultural industry through promoting investments on R&D and infrastructure as well as forging partnerships with the private sector for capacity building, technology transfer and educating the farmers on the benefits of adopting better farming practices particularly, in using crop protection chemicals responsibly.
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Initiatives like the abovementioned go a long way in equipping farmers with necessary knowledge and technological tools to support their pursuit of feeding the billion-plus population that is growing faster than the productivity growth in key food crops.
Global Milling Advances / May Issue 2015
It requires a strong will, commitment and long-term vision to promote stewardship to the top of national priorities for the agricultural sector which will eventually pay off ensuring healthy, prosperous farmers helping the country achieve its food security goals.
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“Heat Treatment: The Future in Pest Control, Available Now” Does the perfect fumigant exist? Our choice of existing fumigants in most countries is limited to the following list: • Methyl bromide is phased out as it is depleting the ozone layer. It is used only under Critical Use Exemptions. • Sulfuril fluoride is a fumigant registered in many countries and its label covers buildings and grain. It has some limitations such as high cost and need for high temperatures to be effective, but is a drastic alternative providing successful results. • Phosphine is a popular fumigant registered in most countries but it has its limitations too: it corrodes copper thus damaging electronics and cannot be used for structural fumigation. If we could synthesize the perfect fumigant we would make it effective, fast, safe for humans, difficult to develop resistance, easy to register and amenable to precise fumigation!
The perfect fumigant exists! It is called HEAT.
Global Milling Advances / May Issue 2015
Insects die at temperatures above 45oC because their cell membranes melt, their body enzymes get damaged, the salt equilibrium in their bodies changes and their proteins coagulate.
Vasilis Sotiroudas, Agriculturist – Food Scientist AgroSpeCom Ltd v.sotiroudas@agrospecom.gr
Heat is fast, as the largest flour mill is treated in less than a day. Heat is safe for humans, as fumigators enter the premises regularly during a heat treatment to inspect the process. No insect resistance to heat has been monitored yet. There are insects that are more or less susceptive to heat, but no specific mutations have been recorded to withstand killing temperatures. Heat needs no registration and it can offer the most precise fumigation available!
So do we have the perfect weapon? Yes and no. We are in the age of precise treatments and if we regard heat treatment as such, we will reap its benefits. However, only a decade has passed since the day that fumigators used to open a bottle of MeBr and run out of the building. Even today, we still encounter fumigators and millers who believe that phosphine works well in a mill! They seldom measure the concentrations
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though. People can easily misuse an insecticide, especially when it has no label. Heat has no label. Research and training is available around the world for someone who wants to seek it, but I constantly encounter many professionals who want to buy or construct (!) a heater and leave training for later. This attitude could easily lead to failures and damages.
The principles The relation between temperature and time is key. Increasing the temperature very fast or reaching temperatures above 65oC may cause damages to structures or machinery. The rule of thumb for a heat treatment is: 50oC for 24 hours, or 55oC for 16 hours. Electricity, gas, petrol and steam may be used to create heat. We have found that each type of heater has its plusses and minuses. For example, electrical heaters are easy to use, easy to handle, but cannot treat an empty concrete silo. You need a gas heater for that, with a long duct. Gas heaters need to be placed out of the building, so for tall buildings you need to lift heaters by crane to the top floor. The petrol heaters that we have used proved to be not so effective and we have often faced malfunctions. In comparing the recycling of air (heaters placed inside the buildings) with introduction of new air (gas heaters placed outside), we found out that the increase of air pressure helps hot air enter cracks and crevices. An important principle is to empty a building completely before a heat treatment. So pallets with raw material, additives and packing material should be taken out of the building and be fumigated or thoroughly cleaned before re-entering. Silos should be emptied and cleaned prior to heat treatment. A bit of dust on the floor or on a line may not jeopardize the treatment, but some kilos of flour in a packing machine may act as an insulator offering insects shelter from heat (see photo 1).
Preparing for a heat treatment
Photo 1: Proper cleaning of a silo is important; dried cakes of flour dropped from a silo after a heat treatment.
We use a gas heater to treat the top floor
We use a gas heater to treat the ground floor below the silos
Photo 2: A gas heater placed on top of concrete silos to treat the empty silos from top to bottom and two more heaters treating the lower levels.
It all starts with proper planning. The correct type of heater should be selected, enough heating capacity should be available and energy supply lines should be verified.
Global Milling Advances / May Issue 2015
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Proper placement of heaters should be effected (see photos 2-6) and the tricky corners of the facility (notorious for infestations) should be identified. A checklist of preparation works should be provided by the therminator team (new term used instead of fumigator). The facility should be cleaned and inspected prior to turning the heaters on. Any unclean area may become a mistreated area. No sealing is needed. We only close doors, windows and ducts.
We place the gas heater gas on the roof and reach the top floor with the ductwork through a window Line bringing propane to the heater
Inside of top floor with ductwork getting inside of each one of 14 silos
Photo 3: A gas heater on the roof of a silo building.
Photo 4: Ductwork entering a silo.
Photo 5: Gas heaters outside a flour mill.
Photo 6: Electrical heaters treating a rice mill.
The most difficult areas to heat in a flour mill are concrete silos (see photo 4) and the basement. Additionally, we may have insects crawling out of windows, doors, panels and cracks to the outside area, to return when the heat is off. To avoid this liability, we spray with contact insecticides on door thresholds and window panes. Spraying must be done before heat treatment and may be repeated afterwards as an optional measure.
Technology for monitoring We use the Therminate™ solution (www.therminate.com) to monitor temperatures, control and verify accurate heat treatment (see photo 7). It employs wireless sensors connecting to the cloud, which provide excellent coverage even in multi-story, concrete structures. The software enables remote monitoring of the heat treatment progress, and even reports kill rates based on statistical models in the literature. An adequate number of sensors should be used to ensure heat transfer is correctly monitored and no ‘cold spots’ (e.g. areas where temperature remains below 50oC) are left out during the heat treatment process. Consider contacting the therminate.com team for a recommended configuration for the facility you intend to treat.
Photo 7: Remotely monitoring heat treatment progress on a smartphone, using the therminate.com solution. with people working next door. Heat provides the treatment of the future, but it has started happening today!
Conclusion
Sources:
Heat treatment does not pose health or safety hazards. It can lead to a precise treatment with excellent results. Heat is teaching us where the insects hide, it gives us a clear picture of the severity of the existing infestation and it can take place
AgroSpeCom photo archives, 2008-2015. Hofmeir P., ThermoNox Heat Treatments, Germany, 2009. Hulassare R., Temp-Air Heat Treatments, USA, 2012.
Global Milling Advances / May Issue 2015
Mueller D., Stored Product Protection, USA 1998. Subramanyam B., Department of Grain Science and Industry Kansas State University.
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appropriate full genuine documentation.
Flour Mill Insect Control By David Hammond, Thermokil Ltd All photos copyright David Hammond
Stored Product Insect (SPI) Control in flour and other related mills is an important yet complex process. It requires, not only a specialist understanding of the biology and habits of the likely pest insects, but of the unique features of the complex flour milling process and production requirements of an often high volume, low margin industry. Insect control post methyl bromide is therefore complex and expensive, but still very necessary. Such conflicting interests can often lead to millers being acutely aware of the cost/return
relationship for cleaning and pest control. This can be a difficult balance but it is essential to get it right. Flour and other millers can be divided into different groups depending on the key markets they have chosen to attempt to supply. Suppliers to the Marks & Spencer / top end of the market will be able to command a degree of premium on their product, however in return M&S and the like demand and expect zero detectable infestation levels, meticulous hygiene and cleaning standards supported by
The middle, larger section of the market is devoted to production and a pragmatic cost effective approach to insect control, realistically sticking to the letter of their customers’ requirements and legal requirements of food safety, but working together with their customers to achieve “acceptable” levels of insect control and food hygiene at “the right price”. At the budget end of the market and in many feed mills and some pet food providers, we still see significant insect infestations that are not controlled properly, not picked up by EHOs and with customers purely fixated on price. There is no concern about, or understanding of the potential perils of shipping out infested products. I would qualify this by saying there are some pet food and feed manufacturers whose insect control and hygiene practices put many food manufacturers to shame! Insect control can be divided into two stages – “Assessment” and “Control”
Assessment stage: 1) Where exactly the infestation is located, not in terms of visible dead adult beetles or moth on the floor, but where are the eggs, larvae and pupae – the core of the infestation, and in what numbers? 2) How the location of the infestation and numbers of insects relate to risk to the product? - A moderate sized Rust Red Flour beetle infestation in 2nd BK rolls is of less immediate threat than a small infestation of Broad Horned Flour beetle in a finished product bin, or a few mill moth on a flour packer.
Inspection of milling machinery needs to be carried out when mill stopped.
Global Milling Advances / May Issue 2015
3) Where the infestation has come from and where is it likely to spread to? – Rust Red Flour beetle are quite capable of coming from grain – check grain monitoring systems, likewise some mix back and sweepings can be put back into the system at 2nd BK roll stage, so this may be the source. However they could theoretically go all the way if conditions are right to infest the whole mill. However in many mills, they tend not to like pure flour and Confused Flour beetle or Broad Horned Flour beetle become dominant in the UK.
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4) What deficiencies in the mill process management have allowed the infestation to develop? – e.g. a) Lack of proper checking of raw materials, wheat, returns, pallets, bags, tankers etc. b) Poor dust control or exhaust leading to external dust problems or internal humidity problems c) Inaccessible dead spaces inside machinery or in fabric of building d) Poor cleaning of accessible dead spaces due to inadequate training or supervision of cleaners.
Control Stage: Control options are; 1) Physical cleaning and removal of harbourages and insects, particularly moth webbing. 2) Heat treatment – Spot treatment of machinery, rooms or silos or space treatment of whole buildings.
Thermokil treatment of French flour mill
3) Cold contact (Cryonite).
Integrated Pest Management in Mills
4) Direct insecticidal contact e.g. aerosol, mists, fogs, “organic” sprays and substances. 5) “Novel” insecticidal treatments such as desiccant dusts, pheromone disruption programmes, Insect growth regulators etc. 6) Regular residual insecticidal dusts and sprays. 7) Fumigants such as sulphuryl fluoride, phosphine or CO2. 8) Modified conditions to inhibit breeding and population development e.g. too dry, too hot, too cold, too physically hostile.
In the real world of flour production, downtime for treatments is often limited, therefore systems of prevention and inhibition of population development are important, and where treatments are carried out it is important to make them as effective as possible at targeting not just adult SPI, but importantly eggs, larvae and pupal stages which are the core of any SPI infestation with adults just being the visible symptoms. In the milling situation in the UK, only HEAT, PHYSICAL CLEANING or FUMIGATION kill eggs, larvae and pupae, other control
measures play their role in disrupting or inhibiting population development by maybe killing adults before they can mate and lay eggs, and it is the role of the pest control biologist or manager in charge of over -seeing a flour mill IPM system to work closely with the mill management to target and balance the finite physical and financial resources to maximum effect. A single annual Sulfuryl Fluoride fumigation may achieve a good kill rate of adult insects for a short period of time, but unlike methyl bromide, it is not as good a fumigant for killing eggs and a very high concentration x time product is required to have any long term effect. Sulfuryl Fluoride is a very penetrating
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Global Milling Advances / May Issue 2015
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gas, and at high concentrations it leaks very quickly from buildings even in still conditions, any form of wind enhances the leaking process massively and threatens the success of the fumigation unless the gas is topped up regularly throughout the job to maintain the required concentration inside – which can be incredibly expensive. Heat treatments of whole buildings can be very effective, however, it should be noted that thick walls and floors will not heat up sufficiently unless very long treatment times are used, and even then, a deep crack in a concrete ground level floor will never heat up, as essentially the energy is always being conducted away to earth. Typically whole mill treatments will last 24 to 48 hours, however the preparation required in terms of sealing compared to fumigation is minimal. Mill moth adult - one of the most important mill pests Three space treatment techniques are mainly used, dry convected air, hydronic radiator heating systems or electrical systems. Each have their advocates but prices will vary considerably and success rates depend as much on the equipment as on the heat treatment technicians. Heat treatment is a highly specialist form of pest control, unfortunately a number of “cowboy� operators have entered the market place promising the earth and delivering disappointing results and damaged property. In the wrong hands heat will cause damage, which is why at Thermokil we only ever sell food factory treatment kits with at least 5 days training and supervision. Thermokil advocates a combination of targeted heat combined with other treatment techniques as appropriate depending on the situation. Every single mill is different, and even if the mills and infestations were identical, the approach and abilities of the mill managers will vary between sites making some systems workable with some managers, impracticable with others. The linchpin of any treatment programme is the pest control biologist over-seeing the treatment programme and his team, their knowledge of the milling process and insects concerned, his specialist knowledge
Global Milling Advances / May Issue 2015
Mill moth larvae - insect larvae need to be the main target of the treatment options and his/her ability to work with the site managers and their staff. For more information contact David Hammond, Managing Director of Thermokil Ltd on 07870 562874 or at dave@thermokil.co.uk . David has had 30 years of insect control experience working in over 100 mills around the world and in 25 different countries.
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Power to the People To be successful, either as an individual or as an organisation, you need to acquire knowledge, understanding and skill. These attainments give improvement and power. They are vital to the success of millers and milling companies.
programme remains up-to-date and relevant. Most of this work is down to the team of tutors and examiners retained by nabim who respectively teach and assess the students. Each of the fourteen men and women currently engaged in this work have many years experience in the milling industry; most are still in full-time employment with milling companies. Without doubt, it is fair to say that the tutors and examiners give so much of their own time to the development of others because they have a love for the milling industry; their primary motive is that they wish to give something back to an industry that has given them so much. Not everyone who comes into the milling industry falls in love with it ... but many do ... and they stay in it for a lifetime, often showing a real concern for those around them and those who come after them. Perhaps this is the way that the soul of the craft miller, grown by centuries of graft at the millstone, has survived and flourished within the highly mechanised and automated environment of today. Enrolment in the seven modules (Safety, Health and Hygiene; Wheat and the Screenroom; Mill Processes and Performance; Product Handling, Storage and Distribution; Flour; Power and Automation; Flour Milling Management) will open in June for the 2015-16 course session.
Diploma awards For over a century, nabim, the trade association for the UK flour milling industry, has been concerned for the training and development of the people who work in the industry. Today, nabim still seeks to assist its member companies produce the skilled workforce necessary within a capital intensive environment, to play their vital role in the food supply chain. Where possible, this assistance is also offered to the milling industry around the world. Two very different examples of nabim’s training provision and learning opportunities are outlined below
Global Milling Advances / May Issue 2015
1) nabim continues to run a distance learning programme (“the correspondence courses”, originating in the first half of the 20th century) studied each year by hundreds of mill employees around the world. Developed and delivered by millers, the programme’s seven modules provide an essential overview of all aspects of the flour milling process and industry, appreciated by those in all disciplines within milling, from millers to technicians to accountants.
2) Developed in the early years of the 21st century, in response to member companies’ wish that nabim provide a practical and technical training programme significantly beyond the level of nabim’s other qualifications (such as those to which its distance learning programme lead), nabim runs an Advanced Milling Diploma programme in partnership with Campden BRI, in the UK, and the Buhler Training Centre in Switzerland. Run every three years, the Diploma programme aims to: develop millers of the highest potential; improve the industry’s skills base, meeting its changing training needs; provide a means by which millers may gain a greater understanding of flour functionality; and apply advanced theoretical knowledge in practical skills training.
Study material is reviewed regularly and textbooks revised to ensure that the
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The testimony of successful candidates (and their employers) from the first three Diploma programmes confirms that these aims have been fulfilled in terms of knowledge and understanding of milling and flour functionality but the candidates have also gained interpersonal and other skills through the opportunities provided by the programme. Furthermore, the sponsoring companies have seen immediate returns on their investment in the work that their candidates have undertaken during the ‘research project’ section of the programme. The fourth running of the Diploma programme commences in autumn 2015. The Advanced Milling Diploma has fulfilled its objectives – and more besides and will continue to do so for years to come, equipping a new generation of millers with the practical competence and understanding to enable and inspire them to lead the maintenance of a profitable, sustainable and adaptable flour milling industry. Recently, nabim conducted a review of its’ member companies’ training priorities. It was clear that the industry now wishes nabim to concentrate on producing new training resources, rather than new programmes or qualifications, which they can use within their own training provision, tailoring training to their own needs and those of their employees. Milling companies continue to recognise that investment in their workforce is vital to the companies’ future prosperity. This finding fitted in well with work in which nabim was already engaged. One of the problems with training people in milling is that it is largely a closed process. This makes it very difficult for people to see what is happening within the machinery. Stopping the process and opening up the equipment is costly and even then the trainee does not see what is happening when the process is running. So nabim has made four videos which use animation, coupled with demonstration and commentary, to get inside the process: wheat cleaning and conditioning; first break rollermill and plansifter; purification and reduction; and mill performance.
Global Milling Advances / May Issue 2015
All four videos are now available on one DVD (price £150 + vat as appropriate: orders to info@nabim.org.uk). Building on this project, nabim has now begun work on an interactive training tool. This is still at an early stage but a simple prototype, developed using skills learned and used in the oil and automobile industries, will be ready soon. The vision is to have a resource through which students can learn more effectively the dynamics within the milling process; how making a change at one point in order to have one effect can actually have a multitude of implications downstream. It will also aid trainees in fault diagnosis and problem solving. Thus, the resource will play its part in creating the skilled millers of the future. nabim and its member companies believe this continuous development is essential if the ever-increasing automation within the milling process is not to generate a workforce of machine minders who need outside help when things go wrong.
It is often said that in this fast-moving world, to stand still is to go backwards. This is most certainly true in flour milling. Wherever a company’s customer base is concentrated, whatever products it specialises in, it needs to use all the resources available to optimise its performance. The people who work in the milling industry are a valuable commodity and companies wish to invest in them so that they develop for the benefit of both the company and the individual. So nabim will continue to look to the future. It will continue to provide the training resources that millers need to develop a workforce fit for the challenges ahead, to the benefit of company, employees, others in the cereals supply chain, and the final consumer. Learning gives power. Power to the people! Nigel Bennett Employment Affairs Manager nabim
Silver medal FMN
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Global Milling Advances / May Issue 2015
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Experts for African Mills Bühler takes care of young professionals and successors to the African milling industry. As the demand for flour increases and new mills are subsequently set up, the need for qualified personnel rises as well. Bühler AG, the Swiss processing technology company, has decided to address this issue by establishing the African Milling School (AMS) in Nairobi, Kenya. The first AMS class started in February 2015. Bühler launched its African Milling School in the Kenyan capitol city of Nairobi in February 2015.
"Africa is a market with strong growth," says Martin Schlauri, explaining the significance of the African continent for the Bühler Technology Group. Along with enormous population growth, metropolitanization is also taking place. The result is a rapidly increasing demand for basic foods which in turn allows the food processing sector to grow. Companies, particularly those that process grain, are ready to invest in new capacity. However, the lack of trained personnel for operation and maintenance is frequently a limitation.
Vocational school for millers The African business metropolis of Nairobi, Kenya was selected as the location for the AMS. Just 25 minutes from Nairobi's International Airport, it is an ideal place in terms of transportation. The AMS offers young employees from industrial mills a comprehensive and intensive education with a focus on theoretical and practical training. The goal of this training is to enable millers to manage a milling plant with the best yield, highest quality of flour and optimized cost effectiveness. Bühler's African Milling School is designed to be a classic vocational school.
Global Milling Advances / May Issue 2015
Following the dual training principle for apprenticeships, it trains apprentices to become certified millers. The core training lasts two years and ends with the miller certification examination. Young millers then have an option to continue their training, after completing at least one year of work experience, with a one-year course to become a head miller. For training as a plant manager, an international school must be attended.
Launch in February 2015 The first basic course started in February 2015. Participants must be at least 20 years old, speak English and have a certificate of graduation from a secondary school (grade C). The first class was advertised throughout English-speaking Africa and was very well received. For Buhler, the opening of the African Milling School is a link in the chain of our long tradition of passing on knowledge – for our customers and for our staff. The best technologies need the best qualified people in order to maximize their advantages. Buhler operates a worldwide network of skills and training centers such as in North Amerika, South Amerika, South Africa, India and China. But more to that, Dr. René Bühler was the founder of the Swiss School of Milling (SMS) in St. Gallen, a highly reputed school for Milling Technologists.
Training course for millers Core training to become a miller lasts two years. Apprentices are present at the school for four-week periods three times a year. The first year's program covers the areas of grain, grain intake and storage, cleaning and the first part of wheat milling. The second year completes the
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continuation of wheat milling as well as the topics of maize milling, end products, quality control and preventive maintenance. Participants take a mid-term examination after the first year. Successfully completing the apprenticeship earns the apprentice a professional diploma of miller. Beside the apprenticeship program for young millers Buhler also introduces a number of short courses to meet the needs of the milling sector. In this regard this year Buhler offers four short courses in mechanical maintenance, electrical maintenance, advanced milling, baking and grain analytics. These courses are targeted towards experienced staff in the industry.
Teaching staff Martin Schlauri, Principal of the African Milling School, acts as well as teacher in the subjects technology and quality control. Martin Schlauri is a milling engineer with over 35 years’ experience with Buhler, having joined the company after having graduated at the Swiss School of Milling. With Martin Schlauri, Stefan Lutz, Food Technologist and Milling Engineer teaches the subjects machine design and functionality as well as cereal science. Stefan Lutz has over 14 years’ experience in in the grain industry. Depending on need and progress of the course, they are assisted by experts from the Bühler employee pool. This ensures that graduates of the African Milling School can learn from highly qualified and experienced professionals.
First class of apprenticeship program at African Milling School.
More information at: www.africanmillingschool.com
Quality test in the laboratory.
School mill for wheat and maize grinding.
Global Milling Advances / May Issue 2015
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IGP Institute Educates the World’s Grain Industry Kansas State University’s IGP Institute offers credentialed courses on a variety of topics that enhance industry knowledge for participants by Kelly Hannigan
Mark Fowler explains the flour milling process as part of the U.S. Wheat Associates Nigerian Flour Milling course. Whether it’s learning the latest milling techniques or gaining a better understanding of animal nutrition, Kansas State University’s IGP Institute serves as a multi-facetted platform for industry professionals looking to advance their knowledge. The IGP Institute, previously known as the International Grains Program, provides world-class education and facilities to individuals focused on the safety and quality of the world’s food supply. The mission of the IGP Institute is to provide innovative and relevant education and technical programs to enhance the market preference, consumption and utilization of U.S. cereal grains, oilseeds and their value-added products for the global grain industry.
Global Milling Advances / May Issue 2015
Jay O’Neil leads a Q&A session during the IGP-KSU Risk Management course.
“The IGP Institute continues to actively pursue new ways to reach and interact with our customers to be of better service,” says Jay O’Neil, senior agricultural economist and grain marketing and risk management curriculum manager. “We strive to be innovative and up-to-date in our programs, and our efforts to be a world-recognized provider of knowledge, training and education.” Established in 1978, the IGP Institute has a reputation for being one of the leading educational institutions of its kind in the world. Housed in K-State’s Department of Grain Science and Industry, the IGP Institute was built upon international training programs the department started conducting in 1961.
Core Curricula The IGP Institute is divided into three core curricula featuring flour milling and grain processing, grain marketing and risk management, and feed manufacturing and grain quality management. The courses are designed to provide continuing education to grain industry professionals and educate foreign business leaders and government officials about U.S. grains and oilseeds. The vast array of milling courses cover all aspects of managing the flour milling process, including technical milling, management practices, maintenance, quality control and food safety, and HACCP training.
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“We wanted to develop a training program that would benefit new millers, mill owners and others involved in the industry,” says Mark Fowler, IGP Institute associate director and flour milling and grain processing curriculum manager. “It is beneficial for young professionals whether they are graduating from high school, technical school or with a bachelor of science from a university to receive milling-specific training as they are entering the workforce.” The grain marketing and risk management portion of the program offers courses for international commodity buyers and merchandisers that will take them to the next level in their contracting strategies and their price risk management. “Our industry operates in a high value, high risk and low margin environment,” O’Neil says. “Therefore, it is critically important for buyers, sellers, processors and traders of grain and oilseed commodities to understand how to establish proper cash contracts and to develop sensible risk management strategies to protect their interest in these challenging times.”
Fran Churchill teaches IGP-KSU Introduction to Flour Milling course participants about flour.
The final pillar of the program is the feed manufacturing and grain quality management sector of the IGP Institute platform. A series of courses explore the major elements of modern feed manufacturing and examine advances in new technology. “Participants come to the IGP Institute to learn the new trends in feed manufacturing and to strengthen their knowledge on the important concepts that make the feed production process more efficient,” says Carlos Campabadal, IGP Institute’s feed manufacturing and grain quality specialist.
Blended Learning In a world filled with increased technology capabilities and individuals with limited time and attention spans for learning, the IGP Institute has become a pioneer in education utilizing a blended learning model.
Global Milling Advances / May Issue 2015
During the lab portion of the course, participants Chukwudi Elechukwu and Lily Haidome from Dangote and BUA Flour Milling, respectively, experiment with various types of flour used in baking.
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“A blended learning model is a way to balance the theory and the application in education,” says Brandi Miller, IGP Institute assistant director and online education and professional development coordinator; and GEAPS/K-State continuing education and credentials program associate director. “By providing theoretical information first in a distance format, the gap in knowledge can be closed prior to the on-site training.” Miller says that supporting off-site employee training has become increasingly difficult in the industry because of both direct and indirect costs to the participants. Along with the direct costs associated with training, such as travel and accommodation costs, the indirect costs are those sustained to cover employee’s absences during the training period. “With a one- or two-week course there is only so much you can learn,” Fowler says. “By extending out the time for learning the material and then giving participants an interesting hands-on experience, they have a greater opportunity to retain the information long term and apply it to their work more effectively.” The online portion of the course generally lasts six- to eight-weeks and involves quizzes and lecture notes to ensure participants understand the content. After the completion of the online course material, participants arrive at the IGP Institute for the hands-on learning experience and to work with the top professionals in the field. “Having an online introduction to the course material put us all on the same basic level so it was easier to follow the presentations when we were here,” says Arlette Soria, course participant and animal production specialist with Trouw Nutrition in Mexico. According to Miller, other participants echoed Soria’s positive feedback on the educational delivery methods. “Giving participants time to digest the materials at their own pace and also revisit the information allows them time to better understand the content,” Miller says. “It also proves to be a great tool for course presenters, as they are given access to the data to see where the gaps are based on the online quiz questions and email discussions prior to the course.”
Global Milling Advances / May Issue 2015
Members from the USDA Cochran Grain Purchasing group from Vietnam observe soybeans on a field trip while learning about Kansas agriculture.
Course Participation by the Numbers In 2014, the IGP Institute experienced tremendous growth in delivering professional education with a total of 1,687 total course participants from 45 countries in 62 trainings. The faculty and staff are working diligently to reach the goals set for 2015 including expanding course reach and access and increasing effort to establish a preference for U.S. grains and oilseeds. Gordon Smith, IGP Institute director, says that the IGP Institute is
uniquely suited to provide meaningful training through innovative approaches across an expanding range of critical offerings. Smith says, “As technology evolves, traditional boundaries of distance, culture, economics and accessibility soften allowing our education and outreach missions to have an even greater impact.” He adds, “Knowledge and self-improvement are becoming key enablers that allow individuals and businesses to reach their optimum potential.”
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Puffed Rice & Nutrition Facts Introduction to Puffed Rice Rice is a staple food in many parts of the world, especially in Asia. It can be consumed steamed or boiled. Raw rice may be ground into flour. It may also be made into various types of noodles. Like other cereal grains, rice can also be puffed. Puffed rice is also called murmura or muri, or pori in India. As the name suggests, puffed rice is nothing but rice grains, which is usually expanded through high-pressure heating in the presence of steam. Puffed rice is commonly used in ready-to-eat breakfast cereals and snack foods. Large in volume and light in weight, puffed rice is both delicious and healthy to add to your diet.
Usage of Puffed Rice Puffed Rice Balls
Contact: Sophia Ren Email: info@food-machines.org Web: www.food-machines.org
Global Milling Advances / May Issue 2015
Puffed rice is used in various breakfast cereal and snack foods. In the United States and Europe, puffed rice is served with milk as a breakfast cereal, such as the brand Rice Krispies. Some chocolate bars include puffed rice, and puffed rice cake is eaten as a healthy snack. Puffed rice is used as an ingredient of Bhel Puri-a popular Indian chaat, prepared by incorporating puffed rice, vegetables and a tangy tamarind sauce. Puffed rice is combined with jaggery to make the delicious chikkis along with the addition of nuts. Puffed rice is also used as an offering to Hindu gods and goddesses.
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Puffed Rice Nutrition Facts
History of Puffed Rice
Adding puffed rice to your diet can benefit your health for the nutrients it contains. One cup of puffed rice supplies many minerals, including 16 mg potassium, 4.4 mg iron, 14 mg phosphorus and 1 mg calcium. Puffed rice contains 56 calories per cup, consisting just 1 percent fat, but with 93 carbohydrate percent by volume and 12.57 g per cup, which is 4 percent daily value based on a 2,000-calorie diet, puffed rice may not be ideal for some weight-loss programs. Puffed rice contains only 0.98g of protein per cup, making it an insignificant source of protein. Understanding the full nutritional profile of the cereal can help you determine how to make it part of your diet plan.
Modern “Puffed Rice” is attributed to Alexander Pierce Anderson, an American botanist. In an experiment with starch crystals in December 1901, Anderson heated corn starch granules that were sealed in a glass tube. When they change color, Anderson hit the tube with a hammer. The still-hot tubes, which became pressurized as the temperature rose, exploded, and the corn starch ballooned into a “porous puffed mass”. Anderson was granted a patent for the process in 1902, and was backed by the Quaker Oat Company. At the 1904 St. Louis World’s Fair, Anderson débuted puffed rice, shot out of eight bronze “cannons”. In
Methods of Making Puffed Rice A. Gun Puffing By gun puffing method, rice grain is first conditioned to the optimum moisture content, and then pressurized to something like 200PSI. When the pressure is released suddenly, the pressure stored inside the grain causes it to puff out, creating a puffed rice which is spongy in texture.
Serving Size 100 g
Serving Size 1 cup Calories 54 kcal
1905, Quaker Oats sold Anderson’s new product as a breakfast cereal called Puffed Rice. Two years later Quaker took over production advertising puffed cereal as "Prof. Anderson's Gift". Later, the puffed grain was advertised as "Food Shot From Guns".
Calories from Fat 1
Calories 383
% Daily Values*
Calories from Fat 8 % Daily Values*
Total Fat: 0.13 g
0%
Total Fat: 0.9 g
1%
Saturated Fat: 0.045 g
0%
Saturated Fat: 0.32 g
2%
Polyunsaturated Fat: 0.048 g
Polyunsaturated Fat: 0.34 g
Monounsaturated Fat: 0.025 g
Monounsaturated Fat: 0.18 g
Cholesterol: 0 mg
0%
Cholesterol: 0 mg
0%
Sodium: 1 mg
0%
Sodium: 5 mg
0%
Potassium: 16 mg Total Carbohydrate: 12.29 g
Potassium: 116 mg 4%
Sugar: 0 g Fiber: 0.2 g
Total Carbohydrate: 87.77 g
29%
Sugar: 0 g 1%
Fiber: 1.4 g
6%
Protein: 7 g
Protein: 0.98 g Vitamin A 0%
Vitamin C 0%
Vitamin A 0%
Vitamin C 0%
Calcium 0%
Iron 2%
Calcium 1%
Iron 16%
* Percent Daily Values are based on a 2000 calorie diet. Your daily values may be higher or lower depending on your calorie needs. Nutrition Values are based on USDA Nutrient Database SR18
Global Milling Advances / May Issue 2015
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The following image shows a popular grain puffing machine, which is the largest capacity puffing machine at present. The puffing machine uses liquefied petroleum gas or electricity as heating source. Temperature and pressure can be measured by thermometer and pressure gauge equipped. Besides rice, the machine is also suitable for puffing and expanding corn, wheat, barley, sorghum, millet, and other grains. The machine increases the quantum of production, and is utilized for commercial production by many businesses. B. Roasting Puffed rice can be made by heating rice in a sand-filled oven. In this way, the puffed rice is generally prepared from soaking in hot water, partially drying and milling. The milled rice are treated with salt water to the an optimum content, and then subjected to puffing by sand roasting method. Rice puffed in this way is crisp, and known as "crisped rice". This is a slow heating process of the grains. The process is tedious and laborious comparing with the pressure heating method. C. Extruding Rather than whole grains, puffed rice can also be made from a rice dough, which is extruded into small pellets under heat and pressure. After the moisture reaches the proper content, a sudden release of pressure gun-puffs and dries the shaped dough again. Most puffed snacks today are made with an extruder.
Puffing Machine
Conclusion Puffed rice is used in various breakfast cereals and snack foods. Puffed rice supplies many minerals. Although low in fat, the high carbohydrate content makes it not suitable for some weight-loss programs. Several ways can be used to make puffed rice, including gun puffing and extruding.
D. Making Puffed Rice at Home Puffed rice can be prepared at home using a few other techniques with simple kitchen items. For example, you can use a wok to puff the rice. First heat your cooking oil in the wok to about 375 degrees Fahrenheit. Then drop the hulled rice into the wok a few at a time, thus your rice will be puffed. Then you can drain the puffed rice and allow it to cool. This way is more suitable for home as you don’t need commercial machine and it’s more safe as there is no great pressure.
Global Milling Advances / May Issue 2015
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Events in detail May 119th IAOM International Association of Operative Millers Annual Conference & Expo 4-8th May USA www.iaom.info/annualmeeting Ipack-Ima 2015 19-23rd May Italy www.ipackima.it Global Grain North America 2015 19-20th May USA www.globalgrainevents.com The 6th edition of Milling Industry Expo & Conference (IFIM) 27-28th May Morocco www.fnm.org.ma/ 5th International Grain Tech Expo 2015 28-30th May Bangladesh www.limraexpo.com/events/graintech/ June Grain & Feed Asia – Indonesia 2-4th June Indonesia www.grainandfeedasia.com IGC Grains Conference 2015 9th June UK www.igc.int Victam International 2015 9-11th June Germany www.victam.com Cereals 10-11th June UK www.cerealsevent.co.uk
Global Milling Advances / May Issue 2015
http://aquaculturedirectory.co.http://globalmilling.com/wp-con Click this link to download our events planner today tent/plugins/download-monitor/download.php?id=13.php?id=2 and keep up to date with the latest industry meetings 1 2015 year planner
VIV TURKEY 2015 11-13th June Turkey www.vivturkey.com
Global Grain South America 2015 15-17th September Brazil www.globalgrainevents.com
Livestock Philippines 2015 24-26th June Philippines www.livestockphilippines.com
Space 2015 15-18th September France http://uk.space.fr/
Whole Grains Summit 2015 24-26th June USA www.wholegrainsummit2015.com/
Livestock Asia 2015 21-23rd September Malaysia www.livestockasia.com
July
October
Grains for Feeding the World 1-3rd July Italy https://expo2015.icc.or.at/
ILDEX Indonesia 2015 8-10th October Indonesia www.vnuexhibitionsap.com
Institute of Food Technologists Annual Meeting and Food Expo 11-14th July USA www.ift.org
100th AACC International Annual Meeting 18-21st October USA www.aaccnet.org/Pages/default.aspx
Indo Livestock 2015 Expo & Forum 29-31st July Indonesia www.indolivestock.com/
26th Annual IAOM MEA Conference and Expo 2015 31st October -3rd November Dubai http://iaom-mea.com/IAOM-DUBAI/
August November The third International Grain Quality and Food Security conference 3-6th August USA www.ksre.ksu.edu/news/story/food_sym posium042514.aspx September IBA 2015 International Trade Fair: World Market for Baking 12-17th September Germany www.iba.de
66th JTIC 2015 4-5th November France www.jtic.eu Global Grain Geneva 2015 10-12th November Switzerland www.globalgrainevents.com
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