International Miller

MIDEAST/AFRICA DISTRICT CONFERENCE RECAP

MILLER INTERNATIONAL

A MAGAZINE FOR THE INTERNATIONAL GRAIN MILLING COMMUNITY

Pearl GULF of the

NFM Rises to Become Industry Leader

4th Quarter 2005

To reach our endowment goal, we need the support of the entire milling industry.

Please consider joining our effort to develop educational opportunities. To make a donation please contact the IAOM office.

contents 17

imdepartments section title 2

PRESIDENT’S MESSAGE

3

CALENDAR

4

DISTRICT UPDATE

5

IAOM UPDATE

17

QUALITY CONTROL

20

COVER STORY

25

TECHNICAL OPERATIONS

25

29

FACILITY MANAGEMENT

How to Work a Section of Sieves in a Sifter Prior to opening up the door of a sifter, it’s important to diagnose the problem. Four common problems help to make the diagnosis: leaks or overs in the thrus, thrus in overs, frequent choking up, and capacity issues.

39

INNOVATIONS

46

CONTRIBUTORS

47

CLASSIFIEDS

47

ADVERTISER INDEX

48

MILLING OVER THE YEARS

QUALITY CONTROL Economics of Heat Treatment for Insect Pest Management

Heat treatment for insect pest management is becoming increasingly accepted as a safe and effective alternative to methyl bromide.

20

COVER STORY Pearl of the Gulf

Al Ghurair Foods has grown from a small flour mill in 1976 to a technologically advanced world-scale multi-product manufacturing enterprise.

TECHNICAL OPERATIONS

29

FACILITY MANAGEMENT

Selecting a Blower The differences between two lobe and three lobe rotary blowers is explained, followed by considerations of package design and protection.

32

FACILITY MANAGEMENT Making Room

A look at the planning, construction, and ultimate integration of the new 50,000 cwt. bulk flour storage and blending plant facility into the existing infrastructure of Mennel Milling’s Fostoria Flour Mill.

35

FACILITY MANAGEMENT

Renewable Energy from Agra-Industry Wastes creative uses of anaerobic biological digestion to economically produce renewable energy.

on the cover

The Al Ghurair Foods Group developed from the depths of the Arabian Gulf with the family’s pearl business. Since then, the family has moved into diversified businesses and is among the top three business groups in the UAE. Essa Al Ghurair heads up the family milling business and true to his family heritage, is an avid scuba diver.

IAOM UPDATE

president’smessage

I

’ve recently returned from my first trip to Africa, during which I attended the annual Middle East and Africa District Conference in Marrakech, Morocco. Based on accounts of previous district meetings, I knew that I was in for a special treat and that IAOM is thriving in this important region of the world. I wasn’t disappointed, as the district had an amazing turnout for their annual meeting.

Of course, there was a great deal of preparation involved in putting on such a terrific event, and I would like to take this opportunity to thank the conference host committee for its organizational efforts and congratulate it on this successful meeting. In particular, I would like to

thank Moroccan National Federation of Milling Industry (FNM) President Ahmed Bouaida, FNM Director Abdellatif Izem, IFIM Milling School Director Mahjoub Sahaba and their teams for all of their hard work and preparation.

As I learned more about the conference host country, it became apparent to me that Morocco is a symbolic location for such a meeting – for centuries it has been a trading center linking Europe, the Middle East and Africa. The fact that more than 1,000 grain and milling professionals arrived in Morocco to exchange ideas and provide a trading opportunity for suppliers seems only a modern extension of this history. In addition to the conference itself, Morocco offered a very interesting and historic culture to absorb.

T h e Middle East and Africa District Conference felt just like many other

district meetings I’d been to over the years – millers and other grain-related professionals enjoyed three days of informative presentations, interaction with industry suppliers, and the unique opportunity to network with their milling colleagues from nearly 60 countries… especially during the sponsored lunches and evening activities. Even with all of the different nationalities represented, there was rarely a language barrier – evidence that our world is getting smaller and communication is no longer a hurdle to overcome.

I found the special blend of education, business and camaraderie is a formula that works for IAOM throughout the world, inspiring millers and suppliers to gather at district meetings. I also found attending a district IAOM meeting as a very exciting, yet comfortable way to explore a new region and experience a new culture – the group is familiar, even though the faces might be new. I would encourage all IAOM members to step beyond the comforts of their own districts when given the chance – there is a whole worldwide network of people with whom we can share our insights, experiences and passion for milling.

James Doyle King Milling Company

The MEA Conference was held in the Palais Des Congres – the venue where the first General Agreement on Tariff and Trades (GATT) was signed in April 1994.

2

INTERNATIONAL MILLER

4th Quarter 2005

IAOM UPDATE

upcomingevents April 7 – Flour City District Spring Meeting Bloomington, MN, USA May 19 – Board of Directors Meeting The Hilton Hotel and Austin Convention Center, Austin, TX, USA May 20-24 – 110th Annual IAOM Conference & Expo The Hilton Hotel and Austin Convention Center, Austin, TX, USA May 20 – Latin America District Meeting The Hilton Hotel and Austin Convention Center, Austin, TX, USA May 20 – Allied Trades/Education/Employee Relations/Environmental, Health and Safety/Food Protection/Global Strategies/Technical Committee Meetings The Hilton Hotel and Austin Convention Center, Austin, TX, USA June 5-9 – Introduction to Flour Milling Short Course Kansas State University, Manhattan, KS, USA June 17 – Flour City District Spring Golf Tournament Mississippi National, Redwing, MN, USA June 19-23 – Advanced Flour Milling Short Course Kansas State University, Manhattan, KS, USA

MILLER INTERNATIONAL

EDITORIAL STAFF Executive Editor Gary Anderson ganderson@iaom.info

Editor Melinda Farris melinda.farris@iaom.info Circulations Manager Carole Smith csmith@iaom.,info Art Direction Q&A Marketing IAOM OFFICERS President James Doyle, King Milling Company Vice President Steve Curran, General Mills, Inc. Treasurer Keith Horton, Grain Millers, Inc. Immediate Past President William Dutton, Deseret Mills & Elevators Executive Vice President Gary Anderson

4th Quarter 2005

IAOM DIRECTORS Jeff Hole, Horizon Milling LLC Central District Anthony Wasinger, Bay State Milling Co. Flour City District Bart Hahlweg, ConAgra Foods Inc. Golden West District Timothy Carroll, Pendleton Flour Mills, LLC Intermountain District Ivo Klaric, Molinos del Ecuador Latin America District Merzad Jamshidi, KFF Mills Middle East and Africa District Aaron Black, Spanglers Flour Mill Niagara District Mark Miller, The Mennel Milling Co. of Illinois Ohio Valley District Gerald Church, Hopkinsville Milling Co. Southeastern District Brad Hover, 21st Century Grain Processing Texoma District Barry McConnell, Ellison Milling Co. Western Canadian District Joseph Woodard, ADM Milling Co. Wheat State District James Hargett, Mennel Milling Co. Wolverine District

International Miller is published quarterly by the International Association of Operative Millers, 5001 College Blvd., Suite 104, Leawood, KS 66211-1618.

Telephone: 913-338-3377; Fax: 913-338-3553.

E-mail address: info@iaom.info. Periodicals postage paid at Topeka, Kansas, and additional mailing offices. International Miller is the official magazine of the International Association of Operative Millers, an international nonprofit organization of milling-industry professionals. Members receive International Miller as a membership benefit, paid by membership dues. Statements of fact and opinion are the responsibility of the authors alone and do not imply an opinion on the part of the officers or the members of IAOM. Advertisements of products and services appearing in IM do not constitute an endorsement

by IAOM. © 2005 by the International Association of Operative Millers. All rights reserved. Materials may not be reproduced or translated without written permission. Direct requests for reprint permission to the IAOM office.

POSTMASTER: Send address changes to IAOM, International Miller, 5001 College Blvd., Suite 104, Leawood, KS 66211-1618.

We invite you to share your expertise and perspective and to comment on articles or ideas covered in recent issues of International Miller.

INTERNATIONAL MILLER

3

I

IAOM UPDATE

Giving BACK

IAOM Members Step Forward to Lead Districts

AOM districts were busy this fall with their traditional conferences, meetings and officer elections. In addition to the large turnout for the Middle East & Africa District conference in Marrakech, Morocco, hundreds of members across North America took advantage of their local district conferences to acquire some additional training and advance their knowledge of new mill technologies and equipment upgrades.

With the last district meeting in Myrtle Beach, SC, all districts have elected their officers for the 2005-06 IAOM year.

The following list identifies each of the district’s officers. More information about district activities can be found on the IAOM website at www.iaom.info/ individualdistrictname (see right).

IAOM President Jim Doyle, King Milling Company, installs the 2005-06 officers of the Niagara, Ohio Valley and Wolverine Districts during the joint district meeting in September.

4

INTERNATIONAL MILLER

4th Quarter 2005

Central District Director Jeff Hole Cereal Food Processors Secretary Jim Schroeder Great Western Mfg. Chairman Joe Reitz Horizon Milling, LLC Vice Chairman Kurt Sulzman American Italian Pasta Co. 1st Exe. Committeeperson Pete Moberg General Mills, Inc. 2nd Exe. Committeeperson Bill Harp General Mill, Inc. Allied Trades Rep. Bill Olson American Ingredients

Flour City District Chairperson Michael Schuele

General Mills, Inc. Director Tony Wasinger Bay State Milling Co. Vice Chairperson Jeff Skiba ADM Milling Co. Secretary Greg Vander Vorste Premier Tech Chronos 1st Exe. Committeeperson Darin Elliott Horizon Milling, LLC 2nd Exe. Committeeperson Charlie Hatch ADM Milling Co. 3rd Exe. Committeeperson Steve Matson Horizon Milling, LLC 4th Exe. Committeeperson Bruce Carlson Horizon Milling, LLC Allied Trades Representative Ron Purvis Bratney Companies

Golden West District Director Bart Hahlweg ConAgra Food Ingredients Co. Chairperson Cody Meyer Horizon Milling, LLC Vice Chairperson Bill Day ConAgra Food Ingredients Co. Secretary Gary Geist Kings Valley Industries 1st Exe. Committeeperson Gary Evelo Horizon Milling, LLC 2nd Exe. Committeeperson Damon Sidles Miller Milling Company 3rd Exe. Committeeperson Nelson Selmers Horizon Milling, LLC

Intermountain District Director Tim Carroll Pendleton Flour Mills Chairperson Fred Weston Central Milling Co., Inc. Vice Chairperson Steve Schortzmann Cereal Food Processors, Inc. Secretary Bob Chamblee American Ingredients 1st Exe. Committeeperson Cory Lare Cereal Food Processors, Inc. 2nd Exe. Committeeperson Greg Skaggs Horizon Milling LLC 3rd Exe. Committeeperson Jeff Daniels Central Milling Co., Inc. Allied Trades Chairman Jeff Chretien Utah Machine & Mill Supply Co., Inc. Recreation Chairman George Majors Halverson Co.

Latin America District Director Ivo Klaric Molinos del Ecuador Chairman David Tullo INAGRAIN, S.A. Vice Chairman Jose Luis Gutierrez Servicios Altex S.A. de C.V. Secretary Marco Fava Grainmade Ltda.

4th Quarter 2005

Middle East and Africa District Leadership Council Director Merzad Jamshidi KFF Mills Essa Abdulla Al Ghurair National Flour Mills Co. (L.L.C.) Andre Bega Les Moulins de La Concorde Ltee Ahmed Bouaida FNM, Moroccan Milling Federation Bachar Boubess Modern Mills of Lebanon John Bunn AWB Ltm. Mustammhil Eissa Eltalib Makin The Flour Mills Co (s) Ltd. Dr. Irfan Hashmi Al-Ghurair Foods/National Flour Mills Co. Chrysostomos Mitsides CHR & C Mitsides Ltd. Mohamad Mortazavi Star Flour Mill Tunde Odunayo Honeywell Flour Mills Limited Richard Prior U.S. Wheat Associates, Inc. Walid Ali Mohd Saeed Al Saeed Trading Co Ltd Martin Schlauri Buhler AG/Switzerland Ilker Tanik USD Turkish Millers Association Nicolas Tsikhlakis The Modern Flour Mills and Macaroni Factories Co. Graham Worden Canadian Wheat Board Secretary/Treasurer Gary A. Anderson International Association of Operative Millers Ex-Oficio Tim Burleigh Colorado Global Resources

Niagara District Director Aaron Black Spanglers Flour Mill Chairperson Drew Stewart ADM Milling Co. Vice Chairperson Anthony Pracek Kraft Canada Inc. Co-Secretary Darryl Tateishi Jaymark Div., B.D.I. (Canada), Inc. Co-Secretary Evan Grabell Smucker Foods of Canada Co. 1st Exe. Committeeperson Gerald Snavely Snavely’s Mill, Inc. 2nd Exe. Committeeperson Joe Farias ADM Milling Co. 3rd Exe. Committeeperson David Park New Life Mills, Ltd. Allied Trades Committeeperson Patrick Nelstrop Satake (Canada) Inc.

Ohio Valley District Director Mark Miller The Mennel Milling Co. of Illinois Chairperson Bob Schmidt Siemer Milling Co. Vice Chairperson Andrew Soukup ADM Milling Co. Secretary Charles Harrington American Ingredients, Co. 2nd Exe. Committeeperson Dave Jansen Siemer Milling Co. 3rd Exe. Committeeperson Kevin Mohr The Mennel Milling Co.

Pacific District Director Jeff Shapiro General Mills, Inc. Chairperson Larry Hinkle Pendleton Flour Mills Vice Chairperson Paul Steinlage General Mills, Inc.

IAOM UPDATE

Secretary Steve Klett Bemis Paper Bag 1st Exe. Committeeperson Nate Neufeld Pendleton Flour Mills 2nd Exe. Committeeperson Jeff Schanz Cereal Food Processors 3rd Exe. Committeeperson Kevin Payne ADM Milling Co.

Southeastern District Director Gerald Church Hopkinsville Milling Co. Chairperson Doug Stucky Milner Milling, Inc. Vice Chairperson Jim Koons, Jr. ADM Milling Co. Secretary Harry Myers American Ingredients, Co. 1st Exe. Committeeperson Larry Yarbro C.H. Guenther White Lily Company 2nd Exe. Committeeperson Gary LeGore Wilkins-Rogers Washington Quality Foods Allied Trades Representative Art Creason Creason Corrugating Co. LLC

Texoma District Director Brad Hover 21st Century Grain Processing Chairperson Joe Hill Panhandle Milling Co. Vice Chairperson Frederick Boeckman Okeene Milling Co. Secretary Cary Efurd American Ingredients 1st Exe. Committeeperson Ryan Platt C.H. Guenther & Son, Inc.

Western Canadian District Director Barry McConnell Ellison Milling Company Chairperson Dan Bouvier Can-Oat Milling Secretary Allan Doherty Hood Packaging Corp.

1st Exe. Committeeperson Kelly O’Brien Rogers Foods, Ltd. 2nd Exe. Committeeperson Dave Thiessen Can-Oat Milling

Wheat State District Director Joe Woodard ADM Milling Co. Chairperson Paul Campbell ADM Milling Co. Vice Chairperson Joe Malone US Energy Partners LLC Secretary Sid Sadowske Sid’s Corrugating & Machinery, Inc. 1st Executive Committeeperson Kendall Allison Cereal Food Processors, Inc. 2nd Executive Committeeperson Troy Anderson Horizon Milling, LLC Allied Trades Representative Dick Zimmerman Creason Corrugating & Machinery

Wolverine District Director Jim Hargett Mennel Milling Chairperson Greg Ball King Milling Co. Vice Chairperson Ken Tilton Star of the West Milling Co. Co-Secretary Tom Carpenter American Ingredients Co. Co-Secretary Wes Lentz Chelsea Milling Co. 1st Exe. Committeeperson Gary Chappell Knappen Milling Co.

INTERNATIONAL MILLER

5

IAOM UPDATE

Districts Honor Veteran Members

P

Nelstrop joined Henry Simon Ltd, T he Nelst rop fa m i ly cont rols atrick Nelstrop, Satake Corp.

Canada, a long-standing member William Nelstrop & Company Limited, milling engineers, based at Cheadle of IAOM’s Niagara District, was founded in 1830, and operates a 4000 Heath, Stockport, Cheshire, after recognized in an awards ceremony for cwt wheat f lour mill in Stockport leaving school and completing two his continuous support and invaluable Cheshire, England – the “Mill on the years of compulsory British National contribution to the district during Hill” as it is affectionately known Service. Following three years practical the joint Niagara, Ohio Valley and locally. and theoretical training Wol ve r i ne D i st r ic t s’ at Henry Simon Ltd., he meeting in Niagara Falls, transferred to Simon Day, Ontario, Canada.

Minn., in 1960 as a mill “ M a ny of you w i l l starter, ga i n i ng expert re me mb e r h i m f rom on-site experience under your visits to the annual Donald Deane, his much conferences & expos, respected mentor. where he could always I n 19 6 2 , N e l s t r o p be found, year after year, moved to Si mon Day, extol l i ng t he v i r t ues Toronto, as Canadian sales of t he var ious pieces representative, and spent of m i l l i ng equ ipment the next 12 years in sales, and associated systems plant engineering and plant that he has represented, commission ing in “the sold and ser viced for golden era” of new mills most of h i s c a ree r,” and expansions. In 1975, st ated A DM M i l l i n g he was promoted to vice Company’s Mike Jarrett, president, and following past IAOM president, as t he buy out by Sat a ke he introduced Nelstrop.

Corporation of Japan in “That his working career 1989, he was promoted to was spent entirely in the Above: IAOM Past President Mike Jarrett, ADM Milling Co., presents a gift of appreciation to Patrick Nelstrop, Satake (Canada) Inc.(left) general manager, Canadian milling industry should come as no surprise,” operations.

Below: IAOM Past President Gary Pickelmann, Star of the West Milling Co., presents a district award to Hans Amme, Buhler Inc. (left) Jarrett continued.

During the joint Nelstrop joined AOM d ist r ict meet i ng, Hans in 1962 and has been a Amme, Buhler Inc., was steadfast supporter of also singled out for his the organization and, in individual contributions particular, the Niagara to the Wolverine District, District. For the past and IAOM in general. The 12 years, he served as district recognition will chairman of the Niagara be added to his already District Allied Trades extensive col lect ion of Committee.

I AOM a w a r d s , w h i c h Although he retired in i ncludes t he T haddeus December 2004, Nelstrop B. Bownik Award, which continues his work in he received at the 2005 the milling industry as a Conference in Nashville; consultant for Satake. He as well as the Allied Trades is still actively involved in Tech nolog y Awa rd for flour milling projects for Support and Dedication Satake in both the United i n 1997; a nd t he Ker r States and Canada, Jarrett Memorial Award in 1978.  explained.

6

INTERNATIONAL MILLER

4th Quarter 2005

IAOM UPDATE

T

he IAOM Middle East

Held in Marrakech, Morocco, this

and Africa (MEA)

was the first time the three-day

District Conference set an

district meeting was held in North

attendance record for the

Africa. The event featured over 25

third consecutive year with more than

technical session presentations and

1,000 participants from almost 60

a trade show with a record-setting

countries at the Sept. 25-28 event.

101 exhibitors.

Mideast/Africa Conference continues to

GROW

4th Quarter 2005

INTERNATIONAL MILLER

7

IAOM UPDATE According to District Director Merzad Jamshidi, KFF Mills, Iran, “the conference is a great opportunity for wheat sellers, machine manufacturers, and any allied trades companies working in the region to meet and showcase their products.

It is where millers are introduced to new products and trends in milling and grain processing through the conference presentations.”

The Moroccan National Federation of Milling Industry served as the conference host and organized the forum. “The organizers did a great job with this year’s conference,” stated

IAOM Executive Vice President Gary Anderson. “The event’s overwhelming success is a direct reflection of the hard work and commitment of the local host committee. Federation President Ahmed Bouaida and his team should be very proud of their efforts.”

The fact that the market is opening for ingredients suppliers in the MEA region was one of the main reasons why Research Products Company’s Monte White chose to exhibit at the MEA Conference for the first time in Marrakech. White said that he thought the turnout was very good

Conference attendees feast on local favorites at the evening banquet sponsored by the Australian Wheat Board.

US Wheat Associates were hosts of the final conference banquet. They organized an evening banquet at the Borj Bladi Restaurant with traditional Moroccan entertainment.

8

INTERNATIONAL MILLER

– with many more people than he had expected. “They seemed to be genuinely looking for product,” he said. He advised those interested in exhibiting at future conferences to bring more brochures and business cards than what are typically taken to the North American conference.

Bill Gambel, American Ingredients Company, was also surprised by the size of the conference, “We were astounded by the number of decision makers present at the conference. It was an excellent venue for suppliers.

We are planning to attend the conference for the foreseeable future.”

Adjoining the Convention Center, the Kempinski Mansour Eddahbi served as one of the official conference hotels.

Conference organizers Dr. Kacem Raji (far left), FNM President Ahmed Bouaida (second from left), and FNM Director Abdellatif Izem (second from right) enjoy the evening’s activities with their colleagues.

4th Quarter 2005

IAOM UPDATE A group of 35 millers from Azerbaijan, Kazakhstan, Kyrgyzstan, Tajikistan, Turkmenistan and Uzbekistan, and the president of the Romanian national milling association met with IAOM members during the MEA Conference to discuss the opportunities and challenges associated with forming a district of IAOM for their region. The contingent from Central Asia passed a resolution to further explore the possibility of holding a regional IAOM meeting in 2006.

The MEA conference, which is hosted annually by one of the

district’s member countries and typically alternates between African and Middle Eastern venues, will return to Beirut, Lebanon, in 2006.

“Beirut served as host in 1994, and we are excited about all Beirut has to offer attendees. We are looking forward to returning to the beautiful capital of Lebanon,” stated Anderson.

“I was very impressed by the conference, not only in the sheer size and number of registrants, but in the ability for so many people from different countries and cultures in that region to work together to further the science and art of flour

Attendees take advantage of the opportunity to visit with the more than 100 exhibitors

milling,” stated IAOM Vice President Steve Curran, General Mills, Inc. “The level of hospitality exhibited toward us was tremendous, not only from the host country but from all of the countries represented in the District. “ Jamshidi emphasized the district leadership’s focus will be on maintaining the very high quality of the conference program as the annual event continues to grow.

“Our most important task is to make sure the conference continues to meet the needs of the local industry professionals,” he said. 

FNM President Ahmed Bouaida, Moroccan Energy and Mining Minister Mohammed Boutaleb, host an official tea ceremony for IAOM President Jim Doyle and IAOM Executive Vice President Gary Anderson after the grand opening of the Expo.

The evening activities feature local entertainment, organized by US Wheat Associates.

FNM President Ahmed Bouaida and IAOM President Jim Doyle are interviewed by local Moroccan and Al-Jazeera television stations during the conference.

4th Quarter 2005

INTERNATIONAL MILLER

9

IAOM UPDATE

From left: 2006 MEA District Host Committee Chairman Bouchar Boubess, IAOM Mideast and Africa District Director Merzad Jamshidi, FNM President Ahmed Bouaida, and FNM Director Abdellatif Izem announce that Beirut, Lebanon will host the 2006 conference.

Evening entertainment awes the crowd at Pacha Marrakech, sponsored by the Australian Wheat Board.

Conference attendees model their newly acquired Fez hats which were a gift from the host committee to all attendees.

A group of Central Asian millers attending the conference, adopt resolutions to form a regional IAOM district and to support our fortiďŹ cation in their respective countries.

IAOM Mideast/Africa Director Merzad Jamshidi (second from right) delivers an opening address for the conference.

Alisher Ishmetov, Uzdonmahsulot presents IAOM Executive Vice President Gary Anderson with a traditional Uzbek robe and hat, as a gesture of appreciation and goodwill.

10

INTERNATIONAL MILLER

A refreshment break allows time for conference attendees to network with their colleagues around the region.

4th Quarter 2005

IAOM UPDATE

The Mideast/Africa Leadership Council Formed First meeting held at Marrakech conference

A

ttendance at IAOM’s Mideast/ Africa District Conference has soared–jumping from around 350 attendees to more than 1,000 in a three-year span under the leadership of former Director Essa Al Ghurair, National Flour Mills, LLC, and current Director Merzad Jamshidi, KFF Mills.

This type of growth spurt is definitely a positive development, however it has also brought to light some challenges for the district and its leadership.

As Al Ghurair left his post of district director, he encouraged incoming Director Jamshidi to form a Leadership Council comprised of district members who have been instrumental in the district’s development, and who represent the membership across the region. The newly-formed Council is responsible for oversight of the district’s goals, programs, operations and development.

It will also review proposals and select venues for future annual meetings, as well as overview the work of district committees.

At the Council’s first meeting in Marrakech, it outlined its work for the year, noting that one of its imminent priorities was to select the location and date of the 2006 Conference. After discussing the advantages of a number 4th Quarter 2005

of locations, the Council selected Beirut, Lebanon as the site of the 2006 Conference. Having served as hosts in 1994, representatives of the Lebanese milling industry are excited to once again invite the district to their capital city.

In order to facilitate future venue selections, the Council discussed the implementation of a transparent review process, which would allow prospective host committees the opportunity to “sell” their location to the MEA Council.

The Council also approved a new conference organizational chart that is designed to provide more support and guidance to the host committee as it undertakes the demanding task of putting together a conference and trade show for such a large group.

In its second meeting of the conference, the Council discussed the formation of a District Education Committee, which would help to adapt the revised IAOM Correspondence Course for local use. The Education Committee will also be responsible for developing the program for the annual conference along with the conference host committee. The Council identified a group of IAOM members to sit on the committee, which will begin its work in the first quarter of 2006. 

IAOM Mideast/Africa District Leadership Council Merzad Jamshidi, District Director KFF Mills, Iran Ahmed Bouaida, 2005 Conference Chairman National Flour Milling Federation of Morocco Bachar Boubess, 2006 Conference Chairman Modern Mills of Lebanon Essa Al Ghurair National Flour Mills Company, UAE Andre Bega Les Moulins de la Concorde, Mauritius John Bunn Australian Wheat Board, Australia Chrystostomos Mitsides CHR & C Mitsides, Ltd. Eltalib Eissa Mustamhil The Flour Mills Company, Sudan Mohammad Mortazavi Star Flour Mill, Iran Tunde Odunayo Honeywell Flour Mills Limited, Nigeria Richard Prior US Wheat Associates, Egypt Martin Schlauri Buhler AG, Switzerland Ilker Tanik Federation of Turkish Flour Millers Associations Nicolas Tsikhlakis Modern Flour Mills and Macaroni, Jordan Graham Worden Canadian Wheat Board, Canada Gary Anderson, District Secretary/Treasurer IAOM, USA Tim Burleigh Colorado Global Resources, USA IAOM Mideast/Africa District Education Committee Andre Bega, Les Moulins de la Concorde, Mauritius Dr. Hikmet Boyacioglu, Istanbul Tech University, Turkey John Bunn, Australian Wheat Board, Australia Dr. Irfan Hashmi, National Flour Mills Company, UAE Richard Prior, US Wheat Associates, Egypt Mahjoub Sahaba, IFIM, Morocco Ilker Tanik, Turkish Flour Millers Association Nicolas Tsikhlakis, Modern Flour Mills & Macaroni Factories Co.

INTERNATIONAL MILLER

11

IAOM UPDATE



Preparations are under way as IAOM plans to convene its 110th annual conference and expo in the Live Music Capital of the World™ – Austin, Texas, in 2006.

AUSTIN: America’s M

“It” City

ovieMaker magazine touts it as one of the country’s “Best Filmmaking Cities.”

Men’s Journal declares Austin has the “Best Nightlife.” According to Money, it’s the “Best Place to Start a Business.” Travel + Leisure lauds it for having the “Best-Looking People,” being the “Prettiest in Spring” and “Friendliest.” And National Geographer Traveler taps it among “Places of a Lifetime.”

All in all, Austin stacks up as the newest “It” city – the place to see and be seen.

It’s a 24-hour city where celebrities enjoy just hanging out alongside the locals— Sheryl Crowe, Lance Armstrong, Sandra Bullock, Billy Bob Thornton, Dennis Quaid, Gwyneth Paltrow, Owen and Luke Wilson—to name a few.

Known for being down-home and sophisticated, laid-back yet bustling with high energy, traditional and avant-garde at the same time, Austin defines coolness.

Yet, Austinites remain individualistic and embrace traditions that brand the city’s unique, often quirky, identity.

12

INTERNATIONAL MILLER

For instance, thousands flock downtown to Congress Avenue Bridge nightly, April through October, to watch more than 1.5 million Mexican free-tailed bats take flight at dusk. As home to the University of Texas and 50,000 college students, the city is awash in burnt orange and white in the fall when the University of Texas Longhorns take to the football field. Aside from politics, nothing strikes up a heated discussion more quickly than trying to name the best barbecue around.

Over the past two decades, the small university town where Willie Nelson sought respite in the 1970s to brand his own unique musical style grew into a big city with a glittery skyline and more than 1.2 million people in the metropolitan area. An incubator for creativity, the capital city of Texas is alternately dubbed “Live Music Capital of the World,” “City of Ideas,” and “Silicon Hills” in tribute to a high-tech industry that includes the headquarters of Dell Computer.

Long revered as the playground of Texas, Austin stands as the gateway to the scenic 4th Quarter 2005

IAOM UPDATE dollar restoration leaves guests awestruck as they stand in the lobby and bathed in a kaleidoscope of light from the stained glass dome.

Before former Governor-turnedPresident George W. Bush, another man also left Austin for the White House.

Lyndon Baines Johnson’s life and legacy are on exhibit at the LBJ Presidential Library and Museum, the most visited of all presidential libraries.

The city’s love affair with all things natural comes into full view at the Lady Bird Johnson Wildflower Center, a 178-acre botanical center honoring the former First Lady’s dedication to the environment.

Few people disagree that Austin is just a bit out of the ordinary. Recent mayoral elections drew serious competition from a bearded, cross-dresser who often holds courts on Congress Avenue dressed in little more than a tiara, thong and stiletto heels. The only thing more plentiful than Tex-Mex diners are tattoo parlors.

And one of the most popular events is Spamarama, a festival celebrating Spam, the canned meat product.

An unending play list of live music echoes from more than 150 venues on any given evening. The sound of blues, country, rock and roll, jazz and folk fuses into a unique genre known as the Austin sound. It’s the music of Willie Nelson, Lyle Lovett, The Dixie Chicks, Joe Ely and thousands of other musicians who make their livings playing and singing in the clubs, restaurants and outdoor stages that flourish here. The largest concentration of music venues is found downtown in the Warehouse District and along Sixth Street, a six-block stretch of bars and restaurants.

Austin celebrates its musical heritage with South by Southwest Music, Film & Interactive Festival each March and the Austin City Limits Music Festival in September. While SXSW is primarily promoted as an industry event, ACL Festival showcases pure American roots music for fans of all ages and musical tastes to enjoy for three days in Zilker Park. 

Austin Facts Austin’s Mean-Eyed Cat bar makes Condé Nast Traveler magazine’s annual “Hot Nights” list. The bar is one of only 35 bars or clubs from around the world named in the publication, including nine from the US. Oslo nightclub made the list in 2004. (May 2005) Sports Illustrated recognized the Longhorn hangout of Scholz Beer Garten as 18 of the “25 Best Sports Bars in America,” noting the bar as being the oldest continuously operated business in Texas.

For the first time, Lake Austin Spa Resort ranks 10th on Travel & Leisure magazine’s list of the world’s best spas, as voted by readers. (August 2005)



Texas Hill Country – a vast region of rolling hills, sparkling lakes and fields of wildflowers. Blessed with a temperate yearround climate and 300 days of sunshine a year, the city lives for the outdoors. A diverse mix of nature trails, parks and greenbelts create a verdant oasis in the heart of the Lone Star State.

The Highland Lakes, a series of seven manmade reservoirs along the Lower Colorado River, cut through Central Texas.

Austin lies 300 miles from the ocean, but it is surrounded by water. Town Lake bisects downtown to provide a verdant oasis with 10.1 miles of hike-and-bike trails.

At the heart of a network of nearly 200 parks lies 360-acre Zilker Park. Along with being a favorite venue for outdoor music events, the park is also home to Barton Springs Pool. Artesian springs feed the natural pool, which remains a constant 68 degrees year round. Zilker Botanical Gardens harbor 22 acres of lush formal, native, Oriental and prehistoric gardens.

Adjacent to the park, Umlauf Sculpture Gardens remains one of the city’s best-kept secrets. This peaceful sanctuary displays the works of the late Charles Umlauf, a world-renowned sculptor who taught at the University of Texas. Bronzes of children, animals, religious figures, and Madonna images are scattered amid the wooded setting.

In this seat of Texas government a visible electricity fills the politically charged air, particularly every two years when the Texas Legislature convenes. At the north end of Congress Avenue sits the imposing Texas State Capitol, a pink granite structure that towers 302 feet high (actually 14 feet taller than the nation’s capitol). At the nearby Bob Bullock Texas State History Museum, the “Story of Texas” comes together under one roof. Interactive exhibits, rare artifacts and multi-media, special effects shows chronicle the development of the Lone Star State and its citizens.

Much of old Austin’s charm lingers at the historic Driskill Hotel, built in 1886 by cattle baron Jesse Driskill. A longtime gathering spot for politicians, the hotel’s most recent multi-million 4th Quarter 2005

The annual study of “Travelers’ Top Tourist Attractions” lists the State Capitol as one of the Top 10 Texas Attractions for non-Texans and Texans. (2005)

Austin’s Oslo nightclub is touted as a “bastion of cool, sophistication and Nordic beauty,” in Conde Nast Traveler magazine’s 2004 “Hot Nights List.” Oslo is one of only 30 clubs from around the world named in the publication.

INTERNATIONAL MILLER

13

IAOM UPDATE

WHAT’S

ONLINE AT

www.iaom.info Join IAOM

Renew your membership online; Learn about membership benefits; Sign up for membership

Start Here with IAOM Membership

B

e sure to visit the Join IAOM section of the website to learn more about membership benefits and how to tap into a worldwide network of milling professionals. For current and potential members, this public section of the website is the place to start.

As the industry continues to evolve and change, IAOM will be there. IAOM is dedicated to providing its members with the resources they need to expand their knowledge and advance their careers. Over the past several years,

14

INTERNATIONAL MILLER

IAOM has made several changes which reflect its continuing efforts to provide added value to its members. Two of the most recent upgrades include a redesigned website – giving IAOM members instant access to archives of conference presentations and past issues of IAOM publications, as well as a community bulletin board where members can discuss current industry trends and issues; and a new quarterly journal, International Miller – offering an editorial mix designed to provide milling professionals with strategic

information on how to effectively manage their plant operations.

IAOM members around the world have long ago discovered that they can count on IAOM to deliver the on-target resources, technology updates and industry news needed to enhance their knowledge and grow their company’s profits. In a world where technology changes every day, redefining the milling industry and your job, it is important to have a partner that helps you to stay ahead of new developments and in touch with the technical community. 

4th Quarter 2005

IAOM UPDATE

IAOM WELCOMES NEW MEMBERS Asia Evgeny Gan Kazakhstan Union of Grain Processors and Bakers Astana, Kazakhstan Erwin Que Philippine Foremost Milling Corporation Manila, Philippines Khurram Shahzad Maqsood Flour & General Mills Gujranwala, Punjab, Pakistan Aleksandr Shefner OAO Independent Bread Inspection Bishkek, Kyrgyzstan Central District Dave Anderson NeuVision Group LLC Overland Park, KS, USA

Intermountain District Jeremy Ferguson Pendleton Flour Mills LLC Blackfoot, ID, USA

Ohio Valley District Kathie Whitley Archer Daniels Midland Decatur, IL, USA

Latin America District Otto Schott Cia Harinera Industrial Cartagena, Bolivar, Colombia

Pacific District Blake Sibley General Mills, Inc. Great Falls, MT, USA

Middle East and Africa Filiz Aybakar Aybakar Co. Ankara, Turkey

Southeastern District Mark Kessler Laidig Systems, Inc. Huntersville, NC, USA

Hamad Elgamar Elmaki Atbara Flour Mill Atbara, Sudan

Wheat State District Quenten Allen Kansas State University Student Manhattan, KS, USA

Michael Gbetanu Dangote Flour Mills PLC Kano, Nigeria

Chad M. Lindow Voyager Ethanol LLC Emmetsburg, IA, USA

Ali Habaj Oman Flour Mills Co. (SAOG) Ruwi, Muscat, OMAN

James Paul Stokes Interstates Companies Sioux Center, IA, USA

Tarek Ibrahim National Flour Mills Dubai, U.A.E.

Europe Max Blum DSM Nutritional Products Europe ltd.

Basel, Switzerland

Mustapha Khalouani Grands Moulins de Guelmim Guelmim, Morocco

Patrick Flot Argenteuil, France

Ahmed Khalouf Khalouf Milling Co. Aleppo, Syria

Viorel Marin The National Association of Flour Milling & Baking Industries Bucuresti, Romania

Mohamed Labana Chemitech Cario, Egypt

Jacques Schil Compagnie Francaise des Ingredients et Adjuvants Paris, France Paulus Schweitzer Commodity Inspection Services BV Rotterdam, The Netherlands Frank Spalek MMW Systems GmbH Wittenberg, Germany Flour City District Jennifer Gabrielson Horizon Milling LLC Lake City, MN, USA Glenn Higgins T.E. Ibberson Company Hopkins, MN, USA

4th Quarter 2005

Richard Prior US Wheat Associates, Inc. Cairo, Egypt Anju Shah McNeel Millers Ltd. Thika, Kenya Hiten Ratilal Shah Bakex Millers Ltd. Thika, Kenya

Dustin Geiger Kansas State University Student Manhattan, KS, USA Harold Mauck The Essmueller Company Hutchinson, KS, USA Wolverine District Donald Mennel Mennel Milling Co. Dowagiac, MI, USA

iaomgrads The following individuals recently completed all five units of the IAOM Correspondence Course in Flour Milling and were awarded diplomas in recognition of their achievement.

Moses K. Samuels ConAgra Tampa, FL, USA Anthony Norton ADM Milling Mount Vernon, IN, USA

Mohamad Syrees Watania Mill Halab, Syria

Chad Lindow Voyager Ethanol LLC Emmetsburg, IA, USA

Niagara District Clark J. Blanchard CBMC Engineering Ltd. Shelburne, Nova Scotia, Canada

Maurice Liwin Sabah Flour & Feed Mills Sdn. Bhd. Labuan, Malaysia

INTERNATIONAL MILLER

15

IMEF UPDATE

InMemoriam

E

Join us in Supporting the

International Milling Education Foundation

To reach our

CORPORATE DONOR LEVELS

INDIVIDUAL DONOR LEVELS

endowment goal,

Benefactor $100,000+

Benefactor $10,000+

we need the support

Patron $50,000+

Patron $5,000+

of the entire milling

Supporter $25,000+

Supporter $2,500+

industry. Please

Donor $10,000+

Donor $1,000+

consider joining our

Bay State Milling King Milling Company

effort to develop

Contributor $5,000+

Contributor $500+

enhanced educational

Central District Ohio Valley District

William Dutton Dr. Dale Eustace

opportunities for the

Friends of IMEF $1,000+

Friends of IMEF $100+

milling industry. To

Intermountain District Western Canadian District Wolverine District

Ernst Auer Mark Avery Melton Battle Thaddeus Bownik Don Buness John Erker Hans Erling Richard Ferrell James R. Giguere Keith Horton Jack Keltz William Kent, Sr. David Mattson

make a donation contact the IMEF office today.

James McCormick Terry Maholland David Neff Roberto Perez-Avila Gary Pickelmann Richard Sheldon Damon Sidles Charles Sosland Henry Stevens Uwe Storjohann David Tullo Walter Wirth

Sowing the Seeds of a Stronger Industry

dmund Dinan, 57, passed away peacefully after a stubborn battle with cancer on June 1, with his wife Barb at his side. Ed had been a member of IAOM since 1974. He served as Western Canadian District chairperson in 1997, and was a long-time member of the Education Committee.

On June 14, Jim Duesenberg lost his brave battle to cancer and died peacefully at home with his family by his side in Green Valley, Arizona.

He had been an IAOM member since 1975, having worked in the milling and baking industry most of his life.

He was the recipient of an American Association of Cereal Chemists’ Outstanding Services award.

James Quinn, vice president of employee labor relations for ADM Milling Co., passed away on June 21. Quinn joined ADM in 2001 and was responsible for employee relations for all non-corporate union and non-union employees in North America. He was also responsible for the negotiations of the labor ag reements. He also ser ved on the IAOM Employee Relations Committee. He will be missed by ADM and the industry.

Joseph Tkac passed away after a lengthy illness on July 1. He had been a member of IAOM since 1970.

Albert Bourassa passed away in October. He was the maintenance supervisor with Ellison Milling upon his retirement in 1995.

IAOM has also recently learned of other members who have passed away. IAOM extends its condolences to the families and loved ones of the following long-time members.

Harold Godsey Jim Jackson Neil Sautter Klaus Seidenstucker

5001 College Boulevard, Suite 104, Leawood, Kansas 66211-1618 USA Phone: 913.338.3377 FAX: 913.338.3553 Email: imef@iaom.info Web: www.iaom.info/imef

16

INTERNATIONAL MILLER

4th Quarter 2005

Bay State Makes IMEF Donation in Memory of Bernard J. Rothwell II

A

ccording to his sons, Bernard J. Rothwell II, former chairman and president of Bay State Milling Company, felt that education is the greatest gift one could bestow upon a person. “As long as you had one, you would never go hungry.”

And in their father’s memory, a $10,000 donation has been made by Trinitas Foundation to the International Milling Education Foundation to support continuing education and training for milling industry professionals. Trinitas Foundation is the charitable arm of the ownership of Bay State Milling Co., which was established by Rothwell II, who was an active philanthropist.

His son, Brian Rothwell, president of Bay State Milling Company, said that his dad

4th Quarter 2005

loved the milling industry and loved helping people achieve their potential.

“He was a true leader, teacher, athlete and church leader,” Brian said. “His whole life was focused on the ‘big picture’ and the future. The future of milling— regardless of technology —rests with the skill the miller possesses.”

That is one of the main reasons why the ownership of Bay State Milling Company decided to support the work of the IMEF. “By keeping the craft of milling, as well as baking, alive it will keep his memory alive as well,” Brian stated.

He also noted that he sees IMEF’s main priority as training future millers and managers. IMEF can have the greatest impact on the profession “by instilling pride in their craft (the millers) and insuring that

IMEF UPDATE

their skills will not be lost – now and in the future.”

Brian said that some of the fondest memories he has of his father are sitting around the dinner table talking family and business – the two great loves of his father’s life.

A 1955 Harvard Business School graduate, Rothwell II joined Bay State in 1946, a company established by his grandfather Bernard J. Rothwell, in 1899.

He worked under his grandfather and father, before being named president in 1959, a position he held until 1974 when he became chairman.

The two sons of Rothwell II currently manage Bay State Milling Co. – Bernard (Buck) Rothwell III is chairman; and Brian. 

17

QUALITY CONTROL

Economics of Heat Treatment for Insect Pest Management

By Brian Kimbrough Armstrong International, Inc

B

18

INTERNATIONAL MILLER

y now, it is common knowledge that methyl bromide will be eliminated as a fumigant for insect pest management.

Methyl bromide fumigation was a proven, effective method to control outbreaks and recurring infestations within milling and grain processing facilities. With the elimination deadline close at hand (January 2006), it is time to focus on alternatives that will continue to provide effective pest management.

Heat treatment for insect pest management is becoming increasingly accepted as a safe and effective alternative and has been successfully performed by major food and grain processing

companies for decades. The process involves a controlled “ramp up” of temperature (usually 10°F per hour to avoid potential structural expansion problems). Once the temperature reaches 125°F to 140°F, the area is held steady to “cook” for an additional 12 to 24 hours depending on the structure construction. Insects have an external (exo)skeleton and are greatly affected by moisture and temperature. Extensive research has shown that insects (adults, larvae, and eggs) will die if exposed to low humidity and temperatures in excess of 120°F. After the “cook,” the structure is allowed to “ramp down” to the original ambient conditions.

4th Quarter 2005

Heat Alternatives Several heat generating options are available including electric resistance, direct-fired natural gas or propane, and steam.

Electric resistance heat is a viable alternative for smaller, target heating. An extensive system would require prohibitive wiring and power requirements. There is also a concern for fires or explosions due to the high element temperatures.

The flashpoint for most flour products is around 850°F, less than the electric element surface temperature.

Natural gas and propane direct-fired heaters introduce some of the same concerns as electric resistance units. Along with the potential for fires or explosions, products of combustion, such as carbon monoxide and moisture, are introduced into the heated space. Recall that elevated temperature along with low humidity is a key factor affecting the mortality rate of insects.

Of the heat equipment options available, steam heaters are becoming increasingly popular to provide a safe, reliable, and cost-effective source of heat. Of course, one must consider whether an existing steam generating and distributions system is available in the areas to be heat treated.

The heaters, controls, piping, and electrical wiring required for a steam heat treatment system can be a significant investment. The budgetar y cost comparisons, in Table 1, are based on a 5story concrete and masonry construction building. The costs are in dollars per 1000 cubic feet of heat treated space.

Year 2005 costs reflect equipment only, a complete installed system, and a portable rental package. Years 2006 through 2009 reflect the average fuel (natural gas) and electric costs per hour per 1000 cubic feet of heat space over a single 24-hour heat treatment per year.

The thermal requirements for selecting the heater requirements in Table 1 are based on the data presented in Table 2, 50°F outside ambient column. Note, as the outside ambient temperature increases the average btu/cubic foot requirement decreases. The first floor will always be the most difficult to heat because of the massive earth heat sink 4th Quarter 2005

QUALITY CONTROL Table 1: Cost Comparison between Heat Treatment Systems

Table 2 Three Year Total Cost Comparison

Table 3 Three Year Total Cost Comparison

and heat will naturally rise to the top floors. Different building designs and construction materials could also affect the average thermal requirements.

A heat treatment system consisting of permanently mounted or portable steam heaters is an investment that will provide a safe, efficient, and cost-effective program for pest management. After the initial capital expenditure, the only recurring cost is maintenance, and the fuel and electricity to power the heaters.

With individual temperature control at each heater and a remote temperature acquisition and monitoring system for the heated areas, the manpower requirements can potentially be reduced.

Not requiring personnel in the heated space for extended periods is also an added safety benefit.

Table 3 details a three year total cost comparison for the three options. Costs

are in dollars per 100,000 cubic feet of heat treated space and based on one heat treatment per year. Year 2005 includes the initial capital expenditure or rental plus the average cost of fuel (natural gas) and electricity during a 24-hour heat treatment. Years 2006 and 2007 only reflect the utility costs associated with a 24-hour heat treatment.

Comparing the costs for permanently installed heaters to portable rental heaters is similar to comparing permanently installed heaters with fumigations. The initial expenditure for heat treatment equipment is more expensive, yet quickly has a cost advantage after a few years of operation.

Now is the time to begin evaluating the economics and feasibility of alternatives for insect pest management. Heat treatment should be investigated as a viable option.  INTERNATIONAL MILLER

19

COVER STORY

“ This profession— feeding people— requires honesty. It is easy to take shortcuts, but this is a product that affects every person, and we have to be responsible and honest with what we do.”

—Essa Al Ghurair

20

INTERNATIONAL MILLER

4th Quarter 2005

COVER STORY

Honesty and integrity guide Al Ghurair family business.

PEARL of the

GULF

W

hen he is not in the office, Essa

from the depths of the Arabian Gulf. According

Abdulla Al Ghurair, chairman of

to Essa, the profits made from the trade in pearls

the family-owned Al Ghurair Foods

and other goods with the Subcontinent, Iran and

Group, would prefer to be in the ocean– scuba

Iraq, made his family look at other opportunities

diving. Maybe it is in his genes…after all, his

on the land – initially acquiring property in the

grandfather started the family’s pearl business in the

United Arab Emirates that made the family one

1930s with divers bringing out the precious pearls

of the largest landowners in the region.

4th Quarter 2005

INTERNATIONAL MILLER

21

COVER STORY

In 1997, the Group built another milling complex at Jebel Ali – a large, man-made port about 30 miles southwest of Dubai.

Since then, the family has moved into diversified businesses and is among the top three business groups in the UAE with an asset base of over $3 billion.

Staying true to the family’s philosophy of building strong foundations by establishing businesses that would foster the economy of UAE, the Al Ghurair Group’s first enterprises in the 1960s included a cement factory, a flour mill, bank and an aluminum fabrication plant.

Al Ghurair Group’s first enterprises included a cement factory, flour mill, sugar refinery and aluminum smelter.

Today, Al Ghurair Investments (AGI), under the dynamic leadership of Abdullah A. Al Ghurair (Essa’s father), is a diversified consortium of businesses in the fields of banking, insurance, shipping, education, power, retail, trading, foods, construction, cement, aluminum, and marble amongst others. It is one of the largest conglomerates operating in and around the region, with a presence in more than 20 countries and approximately 40,000 employees.

22

INTERNATIONAL MILLER

Al Ghurair Foods, one of the largest divisions of AGI, has made tremendous progress over the years – growing from a small flour mill in 1976 to a technologically advanced world-scale multi-product manufacturing enterprise.

With a turnover of over a billion dollars, plants operating in a number of countries, and a market presence in over 50 countries, it is one of the largest foods manufacturing and marketing business in the Gulf.

National Flour Mills is the flagship unit of Al Ghurair Foods engaged in the manufacture and marketing of quality flour and other grain based products.

With two manufacturing sites in the UAE and four sites overseas, it has established itself as a market leader and the largest flour supplier in the region. The Dubai Mill, which was established in 1976, had a milling capacity of 100 tons per day at the time of its commissioning. Over the years, this has been increased by over seven times through modernization and process modifications, to produce the finest quality flour for local consumption as well as for export.

To meet the increasing demand for quality flour, especially from overseas markets, the Jebel Ali Mill with a milling

capacity of 1,300 metric tons per day was commissioned in 1997. The mill produces over 50 different types of flour and caters to the export markets in the Middle East, Africa, the Subcontinent and the Far East.

Today, the two mills in the UAE, together with flour mills in Algeria, Sudan and Lebanon, have an average daily milling capacity of over 4,000 MT. The mills use only the finest quality wheat imported from Australia, Canada, Argentina and the US, providing customers with a large variety of products with uncompromising quality. The group is committed to meeting the highest standards of product quality, food safety and environmental compliance.

The Beginning “The first flour mill was founded in 1976 in the UAE,” Essa said. “Before that, all flour was imported into the UAE. “We started with a 100-MT-per-day mill near Port Rashid in Dubai.”

In 1997, the Group built another milling complex at Jebel Ali – a large, man-made port about 30 miles southwest of Dubai.

The Jebel Ali complex includes a 1,300MT -per-day flour mill – comprised of two 650 MT lines, a 300-ton durum mill, a premix plant, a feed mill, a pulses and legumes plant, a 300- MT maize mill, and a 400- MT edible oil refinery. The total daily milling capacity of all its mills is over 6,000 MT. “The beauty of the new mill we have in Dubai is that we do not blend the wheat,” Essa explained. “We mill different types of wheat separately, and then blend the flour.

While previously we used to mill only two types of flour, now, the number has risen to over 50 as we can supply to so many different market segments and countries, according to their dietary needs and requirements.”

4th Quarter 2005

COVER STORY About 70 percent of the flour produced

by National Flour Mills is exported to other countries in the Middle East, Asia, Africa and the Commonwealth of Independent States. In UAE, there is a thriving local market, with about 400 bakeries comprising the majority of its customers.

“Either we sell directly to the bakery in bags or bulk or to traders in other countries who supply to the bakeries,” Essa explained.

The company had to adjust to changes in local eating habits as well. In recent years, pasta has gradually emerged as a staple diet in the Middle East. Thus, in 2003 the company built a brand new, state-of-the-art pasta plant, which uses the flour from the durum mill at the Jebel Ali complex.

“Our pasta plant is one of the largest in the region, Essa said. “We use durum wheat from the US, Canada and Australia.”

According to Essa, almost 95 percent of the flour produced at the original mill is sold on the local market.

“We have around 75 to 80 percent of the market share for high-extraction flour that is used for raghag, cahpati and Tandoori breads. Its results are very good because we are very selective in procuring the wheat,” he said. “Quality is very important to us. All of our flour for the local market is fortified, although it is not yet mandatory by law.”

Quality Control “As a matter of fact” Essa said, “even before the government made certifications mandatory, National Flour Mills was HAACP-certified, a quality control certification program, and also received ISO 9001 and ISO 14001 certifications. It was the first mill to achieve this status in the Arabian Gulf region.

“We have built quality consciousness into our daily work routine,” he continued.

“It is our way of life. This is reflected in our quality policy statement, which, in 4th Quarter 2005

turn, is our guiding spirit. We take pride in being customer-focused, socially responsible, environmentally friendly, and in the fact that we support initiatives that enhance and enrich the quality of life for the people around us.

“Business integrity and honesty are the main principles of our family business,” he continued. “This profession – feeding people – requires honesty. It is easy to take shortcuts, but this is a product that affects every person, and we have to be responsible and honest with what we do.”

Essa said that he used to check the weight of each and every bag to make sure the customer was getting what he needed and had paid for.

“I would never shortchange anyone,” he said. “You don’t make money from that – your reputation is more important.

Honesty and dedication in this industry is essential.”

Citing the introduction of advanced technologies and efforts to streamline p r o d u c t i o n f l ow s a n d r e m ove inefficiencies, Essa noted that the company has been able to reduce the price of a bag of flour for the consumer – selling it for a lower price today than when National Flour Mills started operations in 1976.

The Group built a trans-shipment facility at the Jebel Ali Port, which is the largest in the Middle East. The state-ofthe-art facility is able to accommodate panamax vessels, and more effectively process cargo. Recognizing the need for flour storage silos –(– since few customers have their own storage facilities) –, Al Ghurair Group instituted a project to construct flour silos in the UAE, and then later in Algeria.

“The first silos were built in 1989,” Essa said. “We started with 150,000-MT capacity, but increased this to 300,000 MT – the largest in the region.”

TOP: A look into one of the JFM Labs. MIDDLE: JFM first floor mill. BOTTOM: Al Ghurair Foods Group Chairman Essa Al Ghurair, former IAOM Mideast/Africa District chairman (left), and IAOM Executive Vice President Gary Anderson open the 15th Annual MEA District Conference in Dubai, UAE, in 2003.

Human Resources Essa attributes much of the company’s success to its high-caliber employees.

INTERNATIONAL MILLER

23

COVER STORY

“We do not hire operators to run the mill,” he explained. “All our millers are either engineers or cereal chemistry graduates and we send them to different milling schools for additional training.

They work in the mill with passion, rather than just being there to spend the eight hours. Instead of hiring high school graduates – we recruit a combination of electrical and mechanical engineers so they can do the maintenance work, as well as oversee the mill operations.”

While labor issues tend to be a major problem in mills elsewhere, Essa said that there are not any issues in his company.

Employees at the flour mills are not only trained locally, but the company sponsors their participation in advanced milling and other grain-related courses offered by such organizations as the American Institute of Baking, the Australian Wheat Board, the Canadian Wheat Board and IAOM. “Once they receive a diploma, based on their experience and performance, they are promoted,” Essa said. “Most of our employees have been working with the company for many years and are an asset to our company. They’ve really grown with the flour mill,” he said. “They stay because they are treated well, and have a chance for career advancement.”

Using the British HAY evaluation system, Essa said perfor mance reviews are straightforward as every person is responsible for what he/she has accomplished.

Essa said that the most challenging issue they face is pricing the flour – as wheat prices fluctuate in the same manner as other commodities like oil.

“We can not just increase the cost of our flour, so we 24

INTERNATIONAL MILLER

work hard to create better blends,” he explained.

The company develops the different blends in its Technical Center at Jebel Ali, which is one of the few cereal labs accredited by the US Wheat Association located outside the continental United States. Staffed by food technologists and scientists at the Technical Center, experienced professionals are continuously striving to develop, through

research and innovation, quality systems and processes that enhance the nutritional value of products for the benefit of the customer.

“For the last decade we’ve done a lot of collaborative work to develop new varieties of wheat with AWB, CWB, and US Wheat,” stated Dr. Irfan Hashmi, vice president for product innovation and quality, who has worked for Al Ghurair Group for over 20 years himself.

“The Technical Center provides product analyses for the company’s mills and conducts milling and other tests besides research and development of new formulations and products.”

E ve n w i t h a l l o f h i s responsibilities as chairman and overseeing the Group’s operations, Essa still manages to take time out of his busy schedule to pursue his favorite pastime – scuba diving.

A CLOSER LOOK As vice chairman of the Essa Al Ghurair Emirates Diving Association, Essa is able to employ his Birth Place: Dubai (UAE) family’s philosophy in his personal endeavors.

Year of Birth: 1956 The EDA’s mission is to conserve, protect and restore Education: BBA, San Diego marine resources through State University (USA) understanding and promoting the marine environment and Family: Five sons and a promoting environmental loving wife diving. As such, the Association is building a strong foundation that safeguards and preserves IAOM: Founding member of the delicate underwater Mideast/Africa District, ecosystem off the coast of longtime District Director the UAE. and twice Host Conference “We do a lot of environmental Committee Chair work in order to help sustain the marine life in the shelf Employment: Started his area,” Essa explained. career with the familyAnd the fact that he works owned business in 1986 to help preserve the waters of and is now the Chairman the Arabian Gulf should not of Al-Ghurair Foods, come as a surprise, since the Al-Ghurair Giga Gold ocean represents the historical Refinery and Trans Asia embodiment of Al Ghurair Gas/Oil Company Group’s heritage and culture. 

Hobbies: Scuba diving, helping others

4th Quarter 2005

HOW to

WORK

a Section of Sieves in a Sifter

W

hen Alice met the Cheshire Cat in Wonderland, she found him perched in a tree at a crossroads. She asked the cat “Which road should I take?” The cat replied, “Where do you want to get to?” Alice said, “I don’t know.”

“Then,” advised the cat, “any road will take you there.”

This story applies to working your section of sieves. Prior to opening up the door, you should play doctor and diagnose the problem first. Ask yourself what problems you are having and then look for the cause.

Because if you don’t know where you are going, no road will take you to your destination.

For this paper, we will use four different problems to help with the diagnosis, and then explain what might be causing each problem. The problems are categorized as leaks or overs in the thrus, thrus in overs, frequent choking up, and capacity issues.

4th Quarter 2005

First, it is important to remember that safety and sanitation should always be considered first before any sifter is opened. Therefore you need to: 1) Lock out the sifter.

2) Make sure that the bottom stockings are removed or sealed as required in your normal operating procedures.

3) Perform your other normal operating procedures.

Now, let’s examine each of the four diagnoses listed above to see how to resolve each problem.

Leaks or Overs in the Thrus As you examine your sieves and flow, the most important thing is to use your eyes and look for signs of leakage. Check your actual flow versus your flow sheet as you go through the sieves.

1) Incorrect Clothing. Do you have the correct clothing on the sieve? Is there a 30-mesh on a sieve that requires a 54-mesh screen? Check

By Allan Hale The Norvell Company

your sieves against your flow sheet and replace any that are incorrect.

2) Clothing Leaks. This is one of the simplest things to look for. Do you have a hole in a screen? On stapledon screens, is the clothing secured correctly? If the staples are too far apart, is a heavy load pushing the screen down and causing leakage? Also check that the stapled edges are not bowed up causing product to leak under the screen. If you find any of these problems, either replace the old screen or properly secure the existing screen.

3) Incorrect Sieve. Do you have the correct sieve in the stack? Has a twochannel sieve been used where a singlechannel is specified? Is a no-hand sieve in the place of a left-hand or right-hand sieve? If you find an incorrect sieve replace it.

4) Improperly Stacked Sieves.

Do you have a sieve that is not stacked correctly? Check to see that none of the sieves are turned 90 or 180-degrees. After you have correctly stacked the sieves, we recommend that you paint a diagonal INTERNATIONAL MILLER

25

TECHNICAL OPERATIONS stripe on the door side of your sieves.

This way your mill personnel can quickly tell if a sieve is installed incorrectly.

5) Tray Leakage. Does the tray (insert) seal tightly into the sieve or does the tray allow product to leak around it? All trays need to have a mechanical seal completely around them. Make sure that the tray is not warped, bowed, or worn to allow leakage. Replace any trays and/or sieves that are not properly sealing.

6) Plush Leakage. Does the plush need to be replaced on the sieves? This can be found by checking the “dead” sifter channels. A plush leak will back up to the point of the leak. Check the insides of the door and sifter.

If the stainless steel is “shiny” instead of “dusty” in places were product does not flow over it then you have a leak that is causing product to polish the stainless steel.

Check the sieves in this area for leakage and replace the plush or sieves as necessary.

7) Sieve Pans. Check the sieve pans. If you have had a choke up, have you blown out one of the sieve pans? If a sieve pan is damaged either staple or screw it back into place or replace the sieve.

8) Open Thrus Channels.

Do you have a “thrus” channel that is not blocked? If you have a full-cloth or single-channel sieve above a single-channel or two-channel sieve then the “thrus” channel on the bottom sieve will need to be blocked to prevent “overs” from falling into this channel.

Examine your flow sheet and then check your sieves to verify that the channels are properly sealed off.

9) Sifter Channel Blocks. Check the sifter channel blocks. Are the sifter channel blocks flush with the side of the sifter? Does the channel block seal tightly against the sieves? Is the channel block bowed? Is the cutout on the sieve at the 26

INTERNATIONAL MILLER

correct height of the channel block? If the channel block is the problem either move the channel block or if worn, replace it.

Example of improper stacking.

Example of proper stacking.

10) Press Top Leakage. Does the press top seal around the top sieve?

Is your sieve stack height too low thus causing the press top to extend down too far and cause product to leak around the press top insert? Has the press top been notched for a double-throated sieve that is not being used now? If the stack height is too low, increase the height with a taller sieve or spacer. If you have the wrong press top for the sieve beneath it, repair or replace it.

11) Plush on Press Top. On conventional wooden sieves with staple-

on clothing the plush is on the top of the sieve. Therefore there is no plush on the bottom of the press top. However if you are using sieves with an aluminum tray insert and glue-on clothing the plush for these sieves is on the bottom of the sieve. Therefore with these sieves the bottom of the press top will need to have plush attached for a good seal.

12) Distributor Bottom Leakage. Does the bottom sealed properly over the outlets? Are there holes in the distributor bottom from wear? Is it turned wrong?

Check to see that the bottom of the sifter is not bowed. If you observe this turn the distributor bottom, repair it, or replace it.

13) Sifter Boxes Out of Square.

On old sifters check that the sifter sections are tight enough that the sieves seal into them correctly.

Make sure that all the bolts are torqued properly and that the boxes are square.

14) Plush Strips. Worn plush strips will allow the sieves to move and thus wear out the sieve plush causing leakage. If you are wearing out the plush consistently on your sieves check your plush strips. If they are worn, replace them.

15) Too Much Clothing Area.

Do you have too much clothing area for the product that you are sifting? If you have too much clothing area your product can “dry bolt.” Dry bolting is when long thin particles stand up and fall thru the mesh.

To visualize this think of a manhole cover.

Manhole covers are round because if they were square the covers would drop through the hole if stood up and dropped diagonally. If dry bolting is your problem you can reduce the area by turning a sieve or two to line up the throats.

16) Sieve Corners Rounded. Examine your sieves to see that the sieve corners are not rounded. Rounded corners would not allow for a proper seal of the sieves into the plush strips. If the corners are 4th Quarter 2005

TECHNICAL OPERATIONS not sealed the sieve can move or turn and cause leakage. If a sieve is this worn it needs to be replaced.

17) Sieve Compression System.

Examine the sifter press top compression system. While in operation does the press top stay down securely and uniformly on top of the sieves? If the press tops are loose, the sieves will move during operation. Check to see that your operators have the tops down instead of up during operation. Make sure that the press tops are not binding as they are being lowered. It is recommended that a pneumatic sieve compression system with indicator lights be used if you have a clean, dry air supply in your mill. This is safer, will speed up maintenance time, and will operate better.

properly? If the cloth cleaners fail the cloths will blind over and you will not sift the product thru the screens. Failure of the cloth cleaners can be caused by product building up on the pans, an inadequate amount of balls or cubes,

worn out cleaners, or the sieve pan bowing up and stopping the cleaner from moving (on no back wire sieves).

To resolve this either add sieves with more pan fall, change out the cleaners, or add spacers beneath the sieve.

Thrus in Overs Once again the most important thing is to use your eyes and observe as you examine the sieves. Examine your ow sheet as you go through the sieves.

1) Thrus Channel Leakage. This is caused by leakage from a sieve thrus channel into the overs. Check the sieve plush and blocking of the sieve.

Make changes to the plush or sieve as necessary.

2) Thrus Backing Up. This would be caused by the thrus backing up into the overs because of a choke up in the section. Resolve the choke up and this problem will disappear.

3) Not Enough Pan Fall. Your product is sifting thru the clothing faster than the pan and pan cleaners can remove it. With this problem the product will build up on the pan and carry over on top of the clothing. To resolve this change these sieves out with sieves that have more pan fall.

4) Mill Balance. If your mill balance is off this can cause additional thrus being sent into the sifter. You will have more product feeding into the sifter than it can handle. Check your rolls and resolve the problem before it gets to the sifter.

5) Failure of Cloth Cleaners.

Are your sieve cloth cleaners working 4th Quarter 2005

INTERNATIONAL MILLER

27

TECHNICAL OPERATIONS 6) Back Wire Blinded Over. Is the back wire clean or blinded over? While this is rare, this too will cause product to back up. Clean the back wire with a brush and examine the cloth cleaners for wear.

7) Not Enough Clothing Area. Your sieves are working properly however you do not have enough clothing area to handle the load you are sending to the sifter. Examine your flow to see if you can either add sieves or change to single-channel or full-cloth sieves to increase clothing area. More on this is addressed under the Capacity Issues section.

Frequent Choking Up When possible stop the sifter when it is under a load. Pull the sieves out and examine where the problem disappears– this is where the problem begins.

1) Improperly Stacked Sieves. Are the sieves stacked correctly in the sifter as per the flow sheet? Examine the actual flow to see if one of the sieves is turned 90 or 180-degrees. (We have even found a sieve upside down.) Correct the stack and as discussed above, paint a diagonal stripe on the door side of your sieves after you have correctly stacked the sieves. This way your mill personnel can quickly make a visual inspection to determine if a sieve is installed wrong.

2) Sieves Are Too Short and/ or Throats Are Not Big Enough.

Sometimes using more sieves in a section is not the answer to a problem but the cause of the problem. If you are having problems pushing a bowling ball thru a garden hose, getting a longer hose will not help. In high capacity/high volume situations using taller sieves with bigger throats is better than using short sieves with standard size throats. To determine if you need taller sieves, examine the bottom of the sieve pans. If they are “shiny” then you have product building up. To resolve this problem, add a spacer or a taller sieve with a larger throat.

3) Not Enough Pan Fall. As discussed above, in high capacity thrus you need to have pitch on the pans to get the product off the pan quickly as your product sifts 28

INTERNATIONAL MILLER

thru. Otherwise it will build up and choke up the section. Once a product has sifted thru a screen you need to get it off the pan and out of the sifter as quickly as possible.

Change the sieves with an inadequate pan fall out with sieves that have the correct pan fall.

4) Sifter Outlets or Spouting Undersized. If the choke up is at the bottom outlet discharge the problem may not be in the sifter but beneath the sifter. Examine your sifter outlet and/or the spouting below to verify that it is large enough to adequately handle the volume passing thru it. If necessary change to a larger outlet or diameter of spouting.

5) Spouting Angle of Repose. If the choke up is at the bottom outlet discharge and the outlets and spouting are the correct size, check the angle of repose on your spouting beneath the sifter. If the angle is too “flat,” product will not flow through the spouting properly. If necessary change your spouting.

6) Circle Size. Examine your sifter, is it running at the correct rpm? Typically if the circle is correct but the speed is slow your drive sheave is worn and needs to be replaced. If the speed is correct and the circle is too small then the sifter is too heavy. This can be caused by either choked up sifter sections or if the weight buckets are not fully extending out. If your sifter section is not choked, examine the weight bucket to see that the buckets are fully extending properly during operation.

7) Sifter Press Top. Examine your sifter press top. Do you have a press top for two-channel sieves improperly blocking over a full-cloth sieve? Does the press top come down far enough to give the product enough clearance to get around the press top insert? If the press top is incorrect modify or replace it. If the press top does not come down far enough shorten the sieve stack beneath it.

Capacity Issues Asking a miller if he has enough capacity is like asking a young single man if his girlfriend is pretty enough. The answer generally is that you can do better. Below

are some of the possible solutions if you are having capacity issues – you’ll have to handle your own girlfriend issues.

1) Inadequate Clothing Area. Do you have enough clothing area? Check to see if you can change to full-cloth sieves or single-channel sieves to maximize clothing area. For example, on 24-11/16” square sieves with 1.5” throats, if you change from a two-channel sieve to a fullcloth sieve this will add 23 percent more capacity to the same amount of sieves.

2) Utilizing Sieve Depths. Are you utilizing the sieve depths that are available?

Earlier we spoke about using taller sieves.

One question we have been asked is how do you determine the proper sieve depth. One of two ways to examine this is to check the bottom inside of the sieves to see how the product is flowing across it by observing the shiny versus the dusty areas. If the sides are all shiny and the bottom of the pan is shiny this indicates that either you do not have enough sieve height, or the product is not getting away. A second way to check for correct sieve height is to stop the sifter under a load. Carefully lift each sieve and observe the amount of product on the screen of the sieve beneath. Measure the product and this will help you to determine the necessary sieve height needed. If tall sieves are not needed, shorten the sieve depths and add one or two more sieves to increase your capacity. Take into account that you do not want to dry bolt with too much clothing area.

3) Loose Screens. If your screens are loose you will typically observe sluggish bolting, where product builds up on the loose screen and the poorly sifted stock floods over the screen in intermittent surges. If your screens are not properly tensioned, remove them and reapply them correctly.

4) Mechanically Stretched Screens.

Are you using staple-on or glue-on screens? Screens mechanically stretched and glued onto the trays will give you greater sifting efficiency. When replacing sieves it is recommended that you switch to glue-on sieve trays that have been mechanically stretched.  4th Quarter 2005

FACILITY MANAGEMENT A closer look at two- and three-lobe blowers

Which

is the better

BLOWER? M

by Connie Rimes Kaeser Compressors-Omega

any times, users of rotary-lobe type positivedisplacement blowers are confused by the impeller styles. Most blower manufacturers have standardized on one design and promote their design regardless of the application.

However, there are advantages and disadvantages to both designs. The twolobe design was the original rotary-lobe blower design and is the standard for most US manufacturers. However, the frequencies from this type of blower can generate standing waves (or, resonance) in piping systems. Most European manufacturers have standardized on the three-lobe (or tri-lobe) type, which was designed to combat the resonance problem.

The three-lobe blowers operate at higher frequencies and produce far less pulsation. A two-lobe blower has two impellers and each impeller has two sides. This means four discharge pulses per revolution. A three-lobe blower has two impellers and each impeller has three sides. This means six discharge pulses per revolution and each pulse is smaller. The two-lobe impeller design has impeller tips that are 180° apart from each other. The three-lobe impeller design has impeller tips that are 120° apart from each other.

In a blower with two-lobe impellers, an impeller is simultaneously closed to the 4th Quarter 2005

2 vs.

3

inlet and the outlet ports of the blower for only a fraction of a second.

In a blower with three-lobe impellers, an impeller is simultaneously closed to the inlet and outlet ports every 60° of rotation. Because the impellers in a three-lobe blower are closed to the inlet

and outlet ports for a longer period of time, the discharge ports can be modified to minimize the difference between the internal pressure and the discharge pressure (further reducing pulsation and noise) without losing too much efficiency.

INTERNATIONAL MILLER

29

FACILITY MANAGEMENT

Which is best?

The blower selection depends on the application.

• If efficiency is the primary concern, then a two-lobe blower is the choice.

Essentially, the third lobe on a three-lobe blower replaces what would be displaced gas in a two-lobe blower

• If the process is sensitive to pulsation, or noise is the primary concern, then a three-lobe blower is a good choice.

► ► Two-lobe vs. three-lobe pulsation

• If there is the possibility of a carryover of contaminants from the process, then the two-lobe, 180° design is a little more likely to sweep the contaminants through the waist of the impeller than the three-lobe, 120° design.

►

►

• If the process is expected to have large pressure surges, a three-lobe blower may be a better choice because the triangular, three-lobe impeller design is less likely to deflect under load.

30

INTERNATIONAL MILLER

In summary, in the milling industry, for example, it would make sense to use two-lobe blowers for vacuum unloading (due to the potential for carry-over to the blower) and tri-lobe blowers for their delivery systems (to minimize noise and pulsation damage to downstream equipment as well as cope with pressure surges due to clogs).

Some manufacturers offer both designs. In some designs the head plates, cylinders, gears, etc., are the same – the only difference is the impeller style. In units of this design, the user does not have to stock both styles because the units are interchangeable. A three-lobe blower could be used in lieu of a twolobe blower and vice versa. This reduces inventory cost while still allowing the user to take advantage of the different impeller styles in their applications.  4th Quarter 2005

BOOTHS ARE GOING FAST! TECHNICAL SESSIONS

Showcase your knowledge, products and services at the 110th IAOM Conference & Expo Each year thousands of general managers, plant managers, technical millers, operations managers, purchasing officers, maintenance professionals and production specialists attend the Annual IAOM Conference & Expo seeking the latest information on new trends and technology in the industry.

As an IAOM exhibitor, you will be part of a tradition of excellence that is unparalleled – reaching an international audience of key industry leaders. Together this group spends millions of dollars annually on products and services.

Don’t miss this once-a-year opportunity!

ENTRANCE

Exhibitor Benefits

 Hyperlink from IAOM website listing to company website or e-mail

 Recognition in milling industry magazines promoting the conference

 Unequaled visibility with key decision makers

 Special discounted advertising rates in IAOM publications

 Opportunity to present an Instructional Briefing on the exhibit floor

 Company name and 50-word profile in official conference program

 Customary breaks and lunch service for attendees held in the Exhibit Hall

 Opportunity to introduce new product/service during What’s New session

 Company name listed on IAOM website in the Equipment and Service Reference Guide

 Access to educational sessions, instr uctional b r i e f i n g s, a n d p a n e l presentations

 A ck n ow l e d g e m e n t o f conference exhibitors in pre-conference promotional materials

 Over 7 hours of unopposed exhibit time

4th Quarter 2005

Exhibit Booth Rental Fees $1,700 for the first booth $1,000 for the second booth $850 for the third booth $750 for each additional booth To reserve your booth contact Melinda Farris, IAOM 5001 College Blvd., Suite 104 Leawood, KS 66211 USA T: 913.338.3377 F: 913.338.3553 E: Melinda.Farris@iaom.info INTERNATIONAL MILLER

31

FACILITY MANAGEMENT

Making Room

I

How Mennel Milling expanded its bulk flour storage capacity

n the late 1990s, due to the Mennel Milling Company’s growth in capacity, diversity of products and needs of its customer base, it became apparent that our bulk flour storage capacity needed to expand. A project on this scale was going to challenge us in several areas: Structurally – The plant is landlocked without much available space. Obstacles such as underground drainage lines, overhead electrical lines, railroad tracks and the ground loop for the sprinkler system were all potentially in the way.

Logistically – Rail tracks on both sides and truck load out bay would be difficult to operate during construction.

Operationally – The plant runs seven days a week and does not present much opportunity for conversion to or integration of a new system.

32

By Joel Hoffa The Mennel Milling Company

INTERNATIONAL MILLER

To deal with all these issues a “Bulk Storage Team” was formed. The team members were: Bob Reid, vice president of operations; Don Mennel, president; Lyle Lahman, vice president of special projects; Joel Hoffa, plant manager; Jan Levenhagen, direction quality assurance; Jeff Work, P&L superintendent; Dean Metzger, production controller; and Gary Strausbaugh, vice president of transportation. Once the team members were determined, our first step was to draw up a mission statement.

to enable Mennel to be the industry leader in flour quality and service, and enhance our profitability through improvements in mill efficiency.

The team then defined the input needs that would drive the design of the finished product:

Team Mission Statement

2. The diversity of products were being made by three separate milling units simultaneously: spring wheat flours, hard wheat flours, soft wheat flours, whole wheat flours, human consumption bran

To determine the storage and blending needs for human consumption products at the Fostoria Mill; then develop, justify and implement a plan to meet these needs

1. The plant may run seven days/week but only delivers five days/week. There needs to be enough storage space to cover this difference. If the plant expands capacity then this difference is exacerbated. This drove the defined storage capacity.

4th Quarter 2005

FACILITY MANAGEMENT products, dried flours off of two driers, pinmilled flours, heattreated flours, and clear flours.

This determined the size and configuration of the bins.

3. A need to maximize milling efficiency by minimizing mill changes due to changes in ash, ingredients, or grist, making temper time more uniform and reducing downtime due to lack of bin space.

4. A desire to maximize customer satisfaction by:

The expansion project brought forth logistical problems– rail tracks on both sides and truck load out bay would be difficult to operate during construction.

a. Improved flour blending capabilities. This drove the system specifications such as batch blending and “loss in weight” ingredient feeders.

Putting it All Together

Ten separate semi trucks were required to deliver the enormous crane necessary to begin construction.

In order to begin construction a new layout for the drainage, sprinkler and 4160 volt electrical service was designed. Also a new traffic flow pattern was created for the wheat cars.

Excavation began in July 2003.

After fill and compaction, to the proper specifications, were complete the forms and rebar were installed for the foundation matte slab. The matte slab was poured in August 2003. Forms were then made for the slip over the course of the next four weeks.

A very large crane was delivered and assembled. Ten separate semi trucks were required to deliver the enormous crane.

In mid-September the slipform began. It took 6 days to reach the final height of 110 feet. A great amount of activity was coordinated during this period of time:

The matte slab was poured in August 2003. Forms were then made for the slip over the course of the next four weeks.

1. Cement trucks, crane, and carts were used to move the concrete to the forms.

2. The crane was also used to stage all of the other supplies such as insulation and rebar.

b. Increasing the storage time of the flour – allows for aging and for more reaction time for dry bleaches. c. Delivering f lour on extremely short order. Often the flour is at the customer’s door just three hours after the order is placed.

5. Operational cost reduction ( i m p r ove d p r o d u c t iv i t y ) .

This would drive the level of automation required by the system.

Selecting a Building Site

Once the above needs were factored into the building design, the next decision was where to build the plant.

The team determined the two possible options: The first option was a site located to the south and east of the existing storage. The second possible site was north of the existing storage. The south side 4th Quarter 2005

would interfere with some of our loadout capabilities and the sewer line; and it was very close to the NS Railroad’s mainline.

The north side location would interfere with rail wheat unloading, sprinkler line, storm drainage, and a 4160 volt electrical service. In addition, this site would require that Mennel purchase a parcel of land from the railroad in order to keep the addition on plant property.

After factoring in power costs, ease of system integration, logistics, and land availability, it was decided to pursue the north side location.

INTERNATIONAL MILLER

33

FACILITY MANAGEMENT 3. The workers had to ensure that the concrete was filling the forms properly, and that the rebar and insulation were in the correct position. In this design, the insulation was actually sandwiched between the inner and outer poured concrete walls.

Then, materials and equipment were staged for installation. The process was facilitated by the fact that everyone knew what was on site and where it was located.

In the next step, the mixer was installed, followed by the screw feeders to the mixer scale, and then the bin hoppers with vibrating dischargers and AC drive screw feeders.

The existing systems then were connected with the new. We had to extend the screw conveyors. The blowing lines and pumps had to be moved, and the magnets relocated. The west side of the building sported ladders, landings and doors. A new loading dock was also built.

The slipform began in mid-September and took six days to reach the final height of

The layout of the building included pick-up hoppers with dust collectors, conveyors and blowing lines on the first floor. The second floor has a batch mixer and conveyors for continuous mix systems. The third floor has bin bottoms

with vibra dischargers and sanitary coving between the floor and pilaster.

The bin top has aspiration and delivery lines, and a bin top dust collector with and AC drive on the fan motor.

Loss-in-weight ingredient feeders and K-Tron weigh belt scales precisely control the addition of ingredients to the flour stream.

There are three transfer systems. Each is rated at 50,000 pounds per hour. Two of the systems are continuous blend and can pull from any of 32 bins. The third system is a batch blend system that can pull from eight bins. These eight bins can be filled by any of the three mills or via one of the continuous blend transfer systems.

The transfer systems can go to 16 flood style loadout bins or 7 flour packer bins.

The total storage capacity is now 90,000 cwts. or 5 days of mill run time. 

PVSE PBOM POM SOS SOM and more ...

34

INTERNATIONAL MILLER

4th Quarter 2005

RENEWABLE ENERGY PRODUCTION FROM

AGRI-INDUSTRY

T

WASTES

he impact of rising fuel prices is being felt around the globe. The soaring prices receive the most attention in regard to transportation, but in reality, virtually nothing is left untouched. It has had a deep

impact on the cost of doing business. Manufacturers in particular, are feeling the impact. However, while much is made of the negative consequences of rising fuel

BY DR. PATRICK HIRL Stanley Consultants, Inc

prices, there is an upside. It is spawning an increase in renewable energy, such as the use of biomass, for energy production.

4th Quarter 2005

INTERNATIONAL MILLER

35

FACILITY MANAGEMENT In today’s economy, manufacturers are struggling with the rising cost of energy to run their processes. As the price of crude oil continues to climb beyond $55 per barrel, the cost of fuel oil follows in its wake. Since 2002, natural gas futures have increased from approximately $2 per million BTU to over $6 per million BTU, with no slowdown on the horizon. The increase in natural gas prices has affected both the direct user of natural gas, as well as electricity prices due to the use of natural gas fired turbine electrical power plants. The price for electrical power also continues to increase with prices ranging from as low as 1-2 cents per kWh to as high as 15-20 cents per kWh. The price to produce electricity or steam from coal is also increasing due to the increasing

It is through anaerobic microbial conversion to methane that many agricultural and agri-industry byproducts can be converted to fuel...

36

INTERNATIONAL MILLER

regulatory pressure to treat the waste gas from coal boilers for constituents such as mercury. Therefore, reducing energy costs can have a marked impact on the manufacturers’ bottom line.

In parallel with the increasing cost of energy is the concern about the reliance of the United States on fossil fuels, particularly foreign fossil fuels. These concerns have prompted the federal government and states to promote the development of locally available renewable energy sources, including wind power and biomass. From 1998 to 2003, the United States generating capacity from wind power increased from approximately 1,800 MW to over 6,000 MW. It continues to increase.

However, over this same time period, the production of electricity from biomass remained relatively constant.

Only now are tax credits, low interest loans, and production incentives for renewable energy sparking an increase in the development and use of biomass for energy production.

The purpose of this paper is to present an evaluation of the use of wheat mill feed (biomass) as a substrate for an anaerobic digester (methane production) in order to produce electricity (renewable energy) for the wheat mill.

Biomass can be converted to energy several ways. Burning plant material, such as sawdust, is one method for conversion of biomass to energy.

Collection and combustion of landfill gas is another. Many plant and animal tissues can also be converted to methane by anaerobic microbial activity and the biogas produced (i.e., a mixture of methane and carbon dioxide) can be used as a fuel. It is through anaerobic microbial conversion to methane that many agricultural and agri-industry byproducts can be converted to fuel while leaving odorless organic matter and nutrients (i.e., ammonia nitrogen and phosphate) available for amendments to cropland.

Many agri-industries produce a waste product that is used as part of

a livestock ration. These include such industries as sugar beet processing, alcohol production (fuel and human consumption), and dry grain milling.

These waste products contain varying amounts of hydrocarbons, fats, and protein, as well as dietary fiber. The hydrocarbons, fats, and protein are all easily converted to methane by anaerobic microorganisms. Therefore, these waste products are potential sources of biomass energy.

Anaerobic Microbial Conversion Anaerobic microbes are capable of generating energy from the oxidation of organic molecules without the use of oxygen. These organisms can reduce nitrate, sulfate, and carbon dioxide while oxidizing the complex organic molecules.

The products of anaerobic microbial metabolism are nitrogen gas, hydrogen sulfide, and, in the largest quantity, methane.

Anaerobic conversion of organic matter to methane occurs in a series of steps that are accomplished by different groups of organisms. The first step in the anaerobic process is hydrolysis. In this step complex organic polymers (i.e., starch, triglycerides, and proteins) are reduced to their monomers (i.e., glucose, fatty acids, and amino acids). The second step oxidizes these monomers to 3-5 carbon organic acids (i.e., propionic, butyric, and valeric acid). The third step converts these acids to acetic acid.

The final step takes acetic acid, as well as carbon dioxide produced in earlier reactions, and converts them to methane and carbon dioxide. It should be noted that amino acids contain nitrogen.

Through the anaerobic conversion of amino acids to methane, the nitrogen from the amino acids is released from the molecule as ammonia. Therefore, the anaerobic microbial activity also releases ammonia nitrogen from its organically bound state in the amino acid, making it more available for plant uptake.

The methane production from protein, starch, and fat can be approximated 4th Quarter 2005

FACILITY MANAGEMENT using microbial stoichiometry developed

by McCarty (1972). Based on the overall chemical reactions for methane production from these complex organic molecules, the methane generation capacities for each general group of molecules have been calculated (Table 1). The potential electricity that could be generated from the methane produced through anaerobic conversion was also calculated assuming a 25 percent efficient generator.

Table 1. Theoretical Methane Production and Electrical Power Generation from Complex Organic Molecules

water and solids provide the anaerobic bacteria for the conversion. The slurry is then pumped into a heated concrete plug flow anaerobic biological reactor. The reactor is mixed, perpendicular to the axis of flow to prevent vertical stratification within the reactor Figure 1. Wheat Mill Feed Anaerobic Digester while maintaining System with Energy and Fertilizer Recovery the plug f low.

The biogas is collected in the reactor headspace. After 15 to 20 days in the reactor the effluent slurry is mechanically dewatered. The solids would be available for an organic soil oxygen. The rate of conversion will amendment and the liquid will be used be proportional to the temperature of for recycle and liquid fertilizer. Thus the the environment and the number of WMF would be converted to fuel (i.e., microbes in the system. A system capable methane gas), fertilizer (i.e., ammonia in of converting wheat mill feed (WMF) to Table 2. Breakdown of WMF by Protein, Starch and Fat methane gas would require creating a 10 to 15 percent slurry of mill feed and anaerobic bacteria and then maintaining it at approximately 100oF for 15 to 20 days.

A p r o c e s s f l ow diagram for this type of system is the separated liquid), and topsoil (i.e., the presented in Figure 1. The WMF would digested solids will have the properties be added to a slurry tank along with of topsoil). The reactor is heated using a recycled water and solids. The recycled portion of methane gas generated either Anaerobic Digester System The conversion of organic molecules to methane by anaerobic microbes must occur in an environment void of

4th Quarter 2005

through a boiler or from the waste heat produced by an electrical generator.

10,000 cwt Wheat Mill Example As an illustration, consider a 10,000 cwt wheat mill which processes approximately 1,370,000 pounds of wheat and generates 370,000 pounds of WMF per day. Table 2 shows the breakdown of the WMF by protein, starch, and fat. Based on the information presented above, the methane generated from each component is calculated.

Therefore, the anaerobic digestion of 370,000 lbs/day of WMF could produce 1,155,000 ft3/day of methane gas. This would equate to 1,155 mmBTU/day of natural gas or 85,000 kWh/day of electrical power (25 percent generation efficiency). Waste heat recovery from electrical power generation could also provide 347 mmBTU/day.

The conversion of protein to methane will also produce ammonia.

Approximately 0.17 pounds of anhydrous ammonia is produced for every pound of protein degraded.

The anaerobic degradation of 70,300 lbs/day of protein could produce as much as 5.8 tons/day of anhydrous ammonia.

INTERNATIONAL MILLER

37

FACILITY MANAGEMENT Figure 2. Theoretical Daily Revenue from Wheat Mill Feed Sales Based on Historical Data

Financial Analysis Over the past five years, t h e ave r a g e price of WMF was $62/ton.

Over this time period WMF has had a maximum price of $96/ton and a minimum price of $38/ ton. The 10,000 cwt wheat mill facility produces 185 tons/day of WMF. Figure 2 shows the daily revenue from WMF sales over the past five years for this example facility.

Anaerobic digestion of the WMF would produce methane gas and ammonia. The methane gas would be used to produce electricity for use at the facility. The analysis above shows that the digestion of the WMF would produce more electricity than the 45,404 kWh/day required for operation of the 10,000 cwt facility. The price of this electricity varies significantly across the country. Assuming a price of $0.075/ kWh, the electricity generated from the anaerobic digestion of WMF would be valued at $6,400/day. The waste heat recovery from the generator (347 mmBTU/day) has an equivalent value of $2,100/day based on displacement of natural gas at $6.00/mmBTU. Ammonia has an average price of $375/ton giving the ammonia produced a value of $2,200/day. This gives the digestion of the WMF a value of $10,700/day or $57.83/ton. Figure 2 shows that 40 percent of the time, the revenue from the sales of WMF for cattle rations would be less than revenue generated from anaerobic digestion.

38

INTERNATIONAL MILLER

Currently, 18 states provide incentives for renewable energy production. For example, Minnesota provides a $0.015/ kWh production incentive for electricity generated from a renewable energy source. This incentive would generate $1,300/day. With this incentive, the digestion of the WMF would generate $12,000/day. Figure 2 shows that 54 percent of the time digestion of the WMF would generate more revenue than sales of the WMF for cattle rations.

In addition, $12,000/day represents a $64.80/ton for WMF, which is greater than the 5-year average price of $62.02/ ton.

The anaerobic digester system capable of converting 370,000 lbs/day of WMF to methane gas would likely cost in the range of $10 million. Assuming a requirement for a return on investment (ROI) of 12 percent, the daily revenue from anaerobic digestion would have to increase to approximately $14,500/day.

Therefore, this project would not meet the required hurdle rate of 12 percent ROI under the given set of assumptions.

It should be noted that an increase in the cost of electricity from $0.075/kWh to

$0.105/kWh would meet a 12 percent ROI. Conclusions Based on available information, anaerobic digestion of WMF could provide 80 percent more electrical power than is consumed by a 10,000 cwt flour milling facility on a daily basis.

Production of energy and fertilizer from the anaerobic digestion of WMF could generate an average revenue greater than that realized over the past five years from sale of the WMF as a cattle ration.

The revenue from generating electricity and ammonia fertilizer is not sufficient to justify the expected capital cost of approximately $10 million. To meet a 12 percent ROI, price for electricity must increase from between $0.10/kWh and $0.15/kWh and/or the value of government incentives for renewable energy must increase. It should be noted that areas of the United States are already paying electricity prices in this range and more of the country could be expected to enter this price range for electricity as the cost of fossil fuels and energy production continues to increase.  4th Quarter 2005

GET On Target

IAOM’s newest publication, International Miller, is an expanded, quarterly version of the Technical Bulletin.

with advertising in the

International Miller’s editorial mix of technical articles,

MILLER INTERNATIONAL

features and departments is designed to provide milling professionals with strategic information on how to

IM FOUR-COLOR RATES

1-2X

3-4X

Back Cover

$950

$810

Inside Front Cover

$850

$725

Inside Back Cover

$850

$725

operations. Feature articles

Two-page Spread

$900

$765

Full Page

$600

$510

highlight the individual miller

½ Page Island

$450

$380

½ Page

$400

$340

1/3 Page

$330

$285

effectively manage their plant

within the larger picture of the industry. Departments cover

IM BLACK & WHITE RATES

1-2X

3-4X

Two-page Spread

$600

$510

Full Page

$450

$380

½ Page Island

$290

$250

½ Page

$250

$200

technology, management,

1/3 Page

$160

$135

safety, sanitation, quality

Price Per Block

the milling professional’s informational needs in

control, maintenance and plant operations.

CLASSIFIEDS

1-2X $50

3-4X $45

Display Classified Rates: A display classified is measured by column inches. One inch equals one block. Display classifieds may be as many as four blocks. Two or more blocks may include a photo, logo, or illustration. One block holds an average of 20 words; two blocks hold 40 words, or 20 words plus one image, etc.

By-the-Word Classified Rates: $50 minimum, $2.75 per word; per insertion. Count each word of the address separately.

Telephone numbers count as one word. E-mails count as three.

IAOM Exhibitor Discounts

15% discount on a reservation for 3 ads 10% discount on a reservation for 3 ads 5% discount on a reservation for 2 ads

PLEASE SEND AD MATERIALS TO: IAOM, 5001 College Blvd. Suite 104 Leawood, KS 66211 Fax: 913.338.3553, email: melinda.farris@iaom.info