Global Milling Advances is a magazine for agriculture professionals worldwide
Issue 09 / November 2014 Oil or Meal?
Feeds & Pet Food Extrusion
Insta-Pro talk about Dry High Shear Extruders
Industry news
Practical short course
Extrusion Innovation
Story: Milling
Extrusion
as an innovation driver
over the years
Expo list
The world’s top events related to milling from around the world, listed on p. 20
Extrusion Innovation
06
Products and perspectives Extruder products rank among the top pioneering opportunities for product innovation in the food sector
Six arguments in favour of practical product development with laboratory extruders PAGE 8
INSTA PRO TALK ABOUT DRY
HIGH SHEAR EXTRUDERS Read more on page 14 Published by Nisa Media Ltd www.globalmillingadvances.com www.facebook.com/pages/GlobalMilling/316973328357939 www.twitter.com/nisamedia
BrabenderÂŽ GmbH & Co. KG
ADER - Milling over the years
www.agra-innovate.com
www.agra-innovate.com/exhibit mailto:sponsorship@agra-innovate.com
Editorial Welcome to the November issue of Global Milling Advances. In this issue we take a look at Extrusion Innovation, Oil vs. Meal, Milling through the years and more. Keep up to date with events happening in your industry! Download your copy of our 2015 wall planner today at www.globalmilling.com
Issue 09 / November 2014 Oil or Meal? Insta-Pro talk about Dry High Shear Extruders Industry news
Story: Milling
over the years
Extrusion Innovation Extrusion as an innovation driver
Feeds & Pet Food Extrusion Practical short course
Expo list The world’s top events related to milling from around the world, listed on p. 20 Keeping in touch with Global Milling follow us on: 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
Published by: NISA Media Ltd 14 Clarke Way Cheltenham GL50 4AX United Kingdom www.globalmillingadvances.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 / November Issue 2014
Page 3
More information: Ernest Badertscher ADER Champ-Bornu 7 1350 ORBE Switzerland Tel: +33 24 4413550 Email: ebacher7@gmail.com Developer of the Mill: ANUTEC Gmbh, arthur.nussbaumer@anutec.ch
Milling over the years Aanutec has perfected a simplified milling system using only 10% of energy in comparison to traditional milling, thus giving it the name F 10. This system was developed in collaboration
with Ader, an apolitical association for the development of renewable energy. In the past, the simple and economical method was to pass grain between two rough stones, one of which was operated manually using hydraulic, animal or electric force. This method produced flour that was whole and a little coarse. Sieving removes some of the bran, but the flour is still "mixed", that is, it still contains enough bran, which is too finely ground to be removed by sieving. Present day. Since 1830, an engineer from Zurich named M端ller, a word that means... "miller" in German, who, while
discussing with his dentist, had the idea of replacing millstones with metal rollers. The roller mill gently and sequentially crushes the grain, while between each pass sieving in a new pair of rollers and thus getting very nice flour without roughness. There are in fact 6 to 18 pairs of rollers, some are fluted and the others smooth, with as many sieves and pressure or bucket based conveying systems. This is very complicated and this method, though automated and in constant evolution, is not the best example of good rationalisation. In addition, losses are substantial and this process, because of its complexity, requires highly skilled workers to manage the whole system. Its weak point is the loss of sensory qualities due to multiple passes in conveyors and sifters, installations that are almost never cleaned. In the future. Most mills will continue this milling technology using rotary rollers, even though other technologies are inching, or rather have inched forward. In fact, a patent filed in 1894, and which has never been applied, was updated at Orbe in 1997. This process was
Global Milling Advances / November Issue 2014
described in ADER's book "Energy in the future." This milling, called "Flour F10", shows that a high quality flour, with higher yields, could be produced by using 10 times less energy. At the Museum of wheat and bread at Echallens, this F10 flour was tested on about thirty kinds of breads and pastries. They described it as excellent and easier to work with than traditional flour. Principle of F10 milling: The special feature of this mill is its simplicity. Just one pass is enough through the mill turning at very high speed, around 10,000 rpm, followed by a single sieving to obtain quality flour, with very high yield, very clean bran and without industrial taste. This mill called "multi-pin" has been used since long for a wide variety of milling, especially to obtain very fine powders, like icing sugar and a wide variety of chemical or food products. It is made up of several rows of gear teeth on a fixed support and a second movable support that is rotating at high speed. Wheat grain enters in the centre, it is not crushed, but is beaten while passing through the various rows of gear teeth. The peripheral speed is around 130 meters per second. The principle of the process is to finely grind the wheat kernel, without breaking its bran too much. Bran has the characteristic that if it is very moist, it becomes very soft and behaves like rubber and does not
Page 4
www.5smak.com.tr
mailto:info@5smak.com.tr
break up when passing between the gear teeth. The trick therefore is to quickly moisten the grain's surface for a few minutes before milling. The inside of the grain is not over-moistened and allows itself to be finely milled. Therefore just one pass through the mill and one sieving to separate the bran is enough. By varying the diameter of the sieve meshes, it is possible to get different types of flour: bran, half-white, white. It is also possible to get whole meal, without sieving, which further simplifies the process. Another advantage, this turbine draws in enormous amount of air, which helps in instantly removing the added water.
Another interesting fact is that this method allows for very small productions, from a few kilograms per hour to several tonnes if necessary. This is possible since the system is easily expandable, which is not the case in a traditional mill.
• For fairly large flow rates, only the multi-pin mill type has to be adjusted by selecting a machine with a different diameter. This is possible since this process is scalable, which is not the case in roller lines.
Advantages
• Guaranteed destruction of insects that may be present in the wheat.
• The same installation can be used to grind durum wheat without any additional installation.
• No mechanical or industrial tastes or
• Using the same mill, the flow rate can be adjusted from 1 to five without any problem.
• Very clean bran, with no kernel pieces.
smells.
• Significant reduction in energy consumption. • Easy to use and does not require trained workers. • Milling of all types of cereals. • Allows small quantities of local productions. • Opportunity for farmers or traditional mills to diversify. • Forming a cooperative simplifies the organisation of work, financing of the line and prevents being absorbed by a third party. • Compact installation and with low total volume
Global Milling Advances / November Issue 2014 Global Milling Advances / August Issue 2014
Page 6 Page 6
Milling line F 10 STORAGE OF WHEAT
HUMIDIFICATION
HOT WATER
PIN MILL
1 SIEVE ONLY
BRAN
Global Milling Advances / November Issue 2014
FLOUR
Page 7
More information: Brabender® GmbH & Co. KG Kulturstr. 51-55 47055 Duisburg · Germany Tel.: +49 (0) 203-7788-0 E-Mail: food-sales@brabender.com Web: www.brabender.com
Products and perspectives: Extrusion as an innovation driver Extruder products rank among the pioneering opportunities for product innovation in the food sector with promising opportunities on the market. This is why practically relevant equipping with extrusion equipment is a fixed constituent of the “toolbox” that is required for product developers in the food industry. New developments in snack products, breakfast cereals, flat breads, sweets, pet food and other special products can be prepared on a laboratory scale using this modern key technology.
combines complex production steps into a constant, continuous production process. If product developers have to experiment on extruders during live operations in order to do this, this can lead easily to operational disruptions. This is why laboratory extruders are a sensible alternative for everyone involved in the development and testing of new processes and products – regardless of existing traditional processes, and with potential prospects for creating something completely new.
5. You can establish methods for measuring your quality from raw material to end product in advance, in order to be in a position to react to quality variations in a better way at a later date.
Brabender® provides suitable instruments for experimental trials of potential product lines with extrudates in a wide range of shapes, colours and flavours. They are compact and can be put to versatile use in innovative food laboratories. They make it possible for modern foods to be developed under realistic process conditions. This means that ongoing production is not impacted, which saves money but is still consistently quality oriented.
Six arguments speak in favour of practical product development with laboratory extruders rather than experimental interventions in the production process:
The corporate group has many years of global experience with extruders and the practical deployment thereof: Thanks to the transfer of technology between plastics processing, the pharmaceutical industry and the food sector, Brabender® can provide extrusion expertise in three essential fields of application.
Laboratory extruder as sensible alternative for practical applications There are few procedures with as much potential for completely redesigning a product matrix. In order to develop innovative food textures and structures, the parameters of pressure, temperature, and shear can be varied during extrusion without changing the final product. Continuous operation in a closed system
1. You get to know new processes, and are able to test textures and sensory characteristics before trials have to be conducted on a production scale. 2. You can vary your application ideas in a wide variety of ways: in terms of raw materials, composition, machine or product. 3. You require significantly less material to carry out your trials, and hardly any product waste occurs. 4. You don’t have to worry about impacting your current quality management system.
Global Milling Advances / November Issue 2014
6. You can easily achieve a return on investment with an appropriate philosophy of innovation within your company.
Triple extrusion expertise from Brabender®
The use of measuring extruder systems in food laboratories provides reliable results for the fine tuning of optimal production conditions and to providing constantly high product quality. As is to be expected from Brabender®, the extruder technology that is provided is suitable for a wide variety of uses, especially in the field of grain products, and can be networked with other ‘classical’ quality measuring processes. Single-screw and twin-screw extruders or the modular expansion make it possible to adapt the processing conditions to the
Page 8
www.ippexpo.org
www.ippexpo.org
many different of products and tasks in the best possible way, customised to suit your operations: • Quality control and analysis of raw materials • Product development and recipe optimisation • Testing of the extrusion properties of different materials • Research and optimisation of processing characteristics • Binding of active ingredients and aromatic substances to a carrier material, such as in snacks • Measurement of rheological properties of material combinations
• Testing processing behaviour during recipe development and product monitoring in the incoming and outgoing goods areas • Quality control during production and throughout processes, with production of a company-specific quality profile for the consistent manufacture of products that comply with specifications • Optimisation of production conditions, full machine capacity utilisation, and minimisation of waste
The performance features of this compact device are rounded off by powerful and user-friendly software packages that work on any version of Windows. As various mechanical material tests can subsequently be conducted on the extrudate, online diagrams provide a quick overview of measurement data and evaluation results, even while measurement is in progress. The test data is stored in a database and can be processed using the usual Office programs, and can then be integrated into your own reports. As well as operating standalone, this machine can also be optionally integrated into local data networks in PC-controlled mode.
A comprehensive range of die heads is also available that makes it possible for a wide range of product ideas to be developed and tested.
• Extrusion of degradable products • Product manufacturing on a laboratory scale At the same time, studies with laboratory extruders have a range of technical process advantages over other procedures such as the practically-oriented measurement of extrusion conditions with small sample volumes, rapid changes in trial conditions, and simple operation and cleaning. Three equipment lines that are specially oriented to food laboratory requirements are introduced here as examples of our extensive product range:
Firstly: Entry-level single-screw extruders The Brabender® KE 19 is an “entry level” model for measurement extrusion: a robust, autonomously operating singlescrew extruder, also known as a singleshaft extruder, that is ideal for laboratories and technical institutions. Based on a broad selection of screws and tools, this machine is the ideal solution for: • Developing new materials and products, including viscosity measurement
Global Milling Advances / November Issue 2014
The Brabender® KE 19: The ‘entry level’ model for measurement extrusion
Page 10
The Brabender速 Lab-Compounder KETSE 20/40, a stand-alone twin-screw extruder for material research and process simulation.
Secondly: Twin-screw extruders for sophisticated applications Twin-screw extruders are the number one choice for sophisticated, complex applications. The Brabender速 TSE product range is particularly attractive because of its wide range of applications and maximum flexibility. The screw and cylinder construction kits that are available in different sizes are designed in such a way that all process stages (feeding, conveying, plasticising, dispersing, reacting, degassing) can be carried out in the best possible way. The combination of several work steps into one continuously operating extruder turns these twin-screw extruders into modern inline compounders. The additional equipment that is required such as measurement and control systems, dosing systems and downstream facilities are also available, making it possible to build up entire modular extrusion systems that are tailored exactly to individual user requirements.
www.innovationsinagriculture.com
Global Milling Advances / November Issue 2014
Page 11
As well as the TSE 20/40 D and the co-rotating TSE 25/16 - 48 D twin-screw extruders that have proven themselves time and time again in practice, the new Lab-Compounder KETSE 12/36 D is now available, a miniature-scale twin-screw extruder with engineering that originates from material development and process simulations in the plastics industry. The combination of the scale-down of the production machine, the comprehensive adaptation capability to any processing task and the ease of operation of the system are the reason for its distinction as an outstanding laboratory measuring device.
Brabender® and its modular device designs show a practicable way toward practical implementation of extrusion technology in the food industry – one step
The processing unit in the TSE 20/40D and the TSE 12/36D consists of a hinged horizontal cylinder. This allows individual preparation steps to be visually assessed, and easy screw removal and quick cylinder cleaning are also possible.
Global Milling Advances / November Issue 2014
at a time: The laboratory professionals develop creative innovation expertise, and companies safeguard their future with affordable investments.
The Lab-Station, Brabender®’s torque rheometer equipped by the TSE 20, a co-rotating twin-screw extruder.
Page 12
www.animaliaistanbul.com
More information: Dr Dave Albin, Applied Nutrition Technologist Insta-Pro International 4043 120th Street Urbandale, IA 50323, USA Email: info@insta-pro.com Web: www.insta-pro.com/
Oil or Meal? Which one is considered to be of higher value? It depends on the applicable use and quality of the final ingredient. Oilseeds, including cottonseed, are typically valued for their oil content over meal. However, cottonseed has 25-30% oil leaving the meal portion of cottonseed more abundant than the oil. With proper extrusion and oil pressing processes, a business is capable of using cottonseed to produce two quality products out of one material. As a global crop, cotton is grown for the cellulosic fiber and seeds. Cottonseed contains oil, protein and carbohydrates; but must be properly processed for those uses. The oil from cottonseed can be used as cooking oil, biofuel production and an energy-rich ingredient in livestock feed. However, cottonseeds contain a potent defense mechanism called gossypol, which are polyphenolic molecules and
toxic to all animals. An effective processing system can separate meal from oil, reducing the amount of gossypol. Ruminant animals can digest and detoxify a limited amount of gossypol due to the abundant microbial fermentation in the rumen of the gastrointestinal tract. By utilizing an effective processing system, a processor can separate meal from the oil reducing gossypol levels, allowing the protein from cottonseed meal to be digestible in animals. A processor can obtain raw cottonseed in various forms, with varying levels of lint (fiber) and with or without the fibrous outer cover (“decorticated� when this covering is removed). To eliminate the variables in processing and insure a high quality product, a processor will need to obtain raw material from a consistent supplier or purchase high quality, durable machinery that can withstand the variation in raw material.
Dry, high-shear extruders from Insta-Pro International have been used for decades to extract oil from various oilseeds. Dry extruders, which generate heat internally through friction, produce high pressure and high temperature conditions that effectively rupture cell walls, liberate internal components and reduce gossypol. The oil is then extracted using mechanical presses, which physically squeeze oil from the meal. Physical extraction differs from other methods, as it does not require the use, storage or disposal of any harsh chemicals, such as hexane. All of this results in a high percentage of oil separation from the other components. The oil cake can then be processed into meal through a mill and used for other purposes, such as protein for ruminant animals. Through the high pressure short cook time process, the amino acids in protein have not been damaged, instead, they have been made more digestible. In addition, extruded, expelled cottonseed meal retains some of the oil which has been freed via extrusion and serves as a high-quality, value-added energy source for livestock. Insta-Pro International recently conducted a research project to evaluate different processing conditions to determine which processes maximize oil extraction and decrease the gossypol content with decorticated cottonseed. Different strategies, involving high-shear, dry extrusion and mechanical oil pressing were evaluated and samples were taken for laboratory analysis. In order to determine oil extraction efficiency, oil cake samples from the press were collected. The amount of residual oil, compared with the initial oil content in the decorti
Global Milling Advances / November Issue 2014
Page 14
www.viv.net www.vivturkey.com
cated cottonseed, is a simple indication of extraction efficiency. It is equally important to know the amount of oil remaining in the meal to properly formulate diets for livestock. When processing raw materials, it is important to use appropriate measurements for testing processed oil content. During the extrusion process (heating) the molecules in oil become chemically bound to other components in the cottonseed, especially carbohydrates. As such, the oil must be acid hydrolyzed to release
it before analysis in the lab. This provides a more accurate picture of what is happening to the oil during the heating process. As mentioned above, when evaluating oil data following heat processing it is important to know the testing method that was used to generate the data. During the research study, Insta-Pro looked at the acid-hydrolyzed oil content in oil cake samples following three different processes:
mailto:info@zhengchang.com
Global Milling Advances / November Issue 2014
www.zhengchang.com
Page 16
1. High-shear, dry extrusion, followed by mechanical oil pressing 2. Mechanical oil pressing, followed by high-shear, dry extrusion, and a second mechanical oil pressing 3. As indicated in #1, but the entire process completed twice
The residual oil contents of the samples ranged from 9.3-11%. The greatest oil extraction efficiency was observed with dry extrusion and mechanical oil pressing (#1 above), which was 66%. So, 66% of the oil content in decorticated cottonseed was physically removed. The other two processes were under 66%. Also studied was the effect of high-shear, dry extrusion on gossypol. It is important
to assess the free, or unbound form of gossypol. This is much more toxic than protein-bound gossypol, which is much less active when consumed. A sample of extruded, decorticated cottonseed was taken immediately out of the extruder barrel. This was done to isolate the hightemperature, high-pressure, short-time effects of dry extrusion which is where all of the heat processing occurs. Mechanical oil pressing by itself is only effective at squeezing oil for isolation and not at heating or cooking. Laboratory analyses on high-shear, dry extruded, decorticated cottonseed samples revealed an 85% reduction of free gossypol levels.
world. It’s equally important to be able to provide service and support such as plant layout, equipment service plans, nutrition services and quality advice. Insta-Pro provides these additional services and solutions for all equipment customers, including cottonseed processors. For example, if cottonseed oil is your focus, nutritionists from Insta-Pro can help you formulate high by-pass protein diets for ruminant livestock and determine potential marketing channels for the meal through on-site educational consultation sessions with potential customers or other nutritionists.
Conducting research studies, like the cottonseed study above, showcases how Insta-Pro International goes beyond selling equipment – it’s important to be able to make high-quality, durable, easyto-use processing equipment that is economical and well-known around the
Please contact Insta-Pro
mailto:sales@stifnet.com
Global Milling Advances / November Issue 2014
info@insta-pro.com or +1.515.252.1260 to speak to a representative about how you can successfully optimize your process and enhance your operation.
www.stifnet.com
Page 17
More information: Mian N. Riaz, Ph.D Director, Food Protein R& D Center Head - Extrusion Technology Program Graduate Faculty, Nutrition and Food Science Dept. 2476 TAMU; Food Protein R&D Center Texas A&M University College Station, TX 77843-2476, USA Tel: +1 979 8452774 Email: mnriaz@tamu.edu
Practical Short Course On Feeds & Pet Food Extrusion February 1-6, 2015 A one-week Practical Short Course on Feeds & Pet Food Extrusion will be presented February 1-6, 2015 at Texas A&M University by staff, industry representatives, and consultants. The program will cover information on designing new feed mills and selecting conveying, drying, grinding, conditioning and feed mixing equipment. Current practices for production of pet foods, preparing full-fat soy meal; recycling fisheries by-products, raw animal products, and secondary resources; extrusion of floating, sinking, and high fat feeds; spraying and coating fats, digests and preservatives; use of encapsulated ingredients and preparation of premixes, and least cost formulation are reviewed. Practical demonstration of pet food, vacuum coating, and several others are demonstrated on four major types of extruders - (dry, interrupted flights, single and twin screw), using various shaping dies. Reservations are accepted on a firstcome basis. For more information, programs and application forms, see contact info above.
Global Milling Advances / November Issue 2014
Page 18
mailto:agro@kmkya.kiev.ua www.grainexpo.com.ua
Events in detail September AFIA Liquid Feed Symposium September 9th – 11th New Orleans Marriott New Orleans USA www.afia.org VIV China 2014 September 23rd – 25th New China International Exhibition Center (NCIEC) Beijing China www.viv.net
Agra Innovate November 18th – 20th The Landmark Centre Lagos Nigeria www.agra-innovate.com
Click this link to download our events planner today http://globalmilling.com/wp-conte and keep up to date with the latest industry meetings nt/plugins/download-monitor/do 2015 year planner wnload.php?id=13d=10
March GFIA 9-19th March Dubai www.innovationsinagricu lture.com
December IAOM MEA 2014 Cape Town December 2nd – 6th Cape Town South Africa www.iaom-mea.com
VIV Asia 11-13th March Thailand www.vivasia.nl
October
January
North American Millers’ Association 2015 Division Meeting 14-17th March USA www.namamillers.org
AACC International Annual Meeting 2014 October 5th – 8th Providence Rhode Island USA www.aaccnet.org
IPPE 2015 27th - 29th January USA www.ippexpo.com
AgraMe 16-18th March Dubai www.agramiddleeast.com
Livestock Myanmar 2015 29th -31st January Myanmar www.livestockmyanmar.c om
3rd ICC Latin American Cereal and Grain Conference and ICC Jubilee Conference - 60 Years of ICC 29th March – 1st April Brazil www.icc.or.at/events
AGROSALON 2014 October 7th – 10th Moscow Russia www.agrosalon.com 9th Annual Oilseeed & Grain Trade Summit October 7th – 9th New Orleans Hyatt Regency New Orleans USA www.cvent.com/events/oi lseed-grain-trade-summit2014/event-summary-8f0c b45631e54c149ffbcb6e7f9 bc45c.aspx November UK Grain November 5th Peterborough Arena Peterborough, UK www.farm-smart.co.uk/u kgrain EuroTier 2014 November 11th – 14th Hanover Germany www.eurotier.com
2015
February Animalia Istanbul 2015 5-8th February Turkey www.animaliaistanbul.co m Rice Milling Expo 2015 6th - 8th February India www.ricemillingexpo.com Oilseed Congress Europe/MENA 2015 9th -10th February Spain www.oilseedcongress.com Grain Tech Expo 2015 11th -13th February Ukraine www.grainexpo.com.ua GEAPS Exchange 2015 21th -24th February USA www.geaps.com
Global Milling Advances / November Issue 2014
April IDMA 2015 FAIR 23-26th April Turkey www.idma.com.tr May 119th IAOM International Association of Operative Millers Annual Conference & Expo 4-8th May USA June IGC Grains Conference 2015 9th June UK www.igc.int
Victam International 2015 9-11th June Germany www.victam.com
Organising an show or event
Cereals 10-11th June UK Web: www.cerealsevent.co.uk
CONTACT US to ma ke su re t h a t you are
VIV TURKEY 2015 11-13th June Turkey www.vivturkey.com
in 2015?
FEATURED
Livestock Philippines 2015 24-26th June Philippines www.livestockphilippines.com
July Institute of Food Technologists Annual Meeting and Food Expo 11-14th July USA www.ift.org September IBA 2015 International Trade Fair: World Market for Baking 12-17th September Germany www.iba.de Livestock Asia 2015 21-23rd September Malaysia www.livestockasia.com October ILDEX Indonesia 2015 8-10th October Indonesia www.vnuexhibitionsap.com 100th AACC International Annual Meeting 18-21st October USA www.aaccnet.org/Pages/d efault.aspx
Page 20
MillingWorld Milling World, a new blog from NISA Media Ltd, bringing together agriculture news stories from around the world.
As well as looking at events and shows we look at companies involved in agriculture, food production and animal production as well as the feed industry and veterinary aspects of farming and agriculture. The blog runs side by side with our online resource Global Milling Annual. Publishing press releases from key companies and key and information from global sources. As well as looking at the ever-changing face of agriculture, through GMO’s, research and other innovative approaches to agriculture. Another aspect of the agriculture world is the everchanging effect of climate change on the industry, and as natural disasters occur, such as droughts,
mailto:mlittle@globalmilling.com Contact Martin (mlittle@globalmilling.com) with your latest news! Global Milling 2013 Annual - Page 4