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Packaging for the future

In this issue: •

Cultura Technologies’ MillMaster

Greater gains from phytase through improved formulation

Need to explain complicated software? It’s a piece of cake

Cooking cereals with extrusion

Taking the first step: How to help yourself and others develop the love and understanding of flour milling

A subscription magazine for the global flour & feed milling industries - first published in 1891





Herbold Meckesheim: new pulverizing concept with vertical pulverizer Grain grinding in the Glen Creston Cross Beater Mill Cal-BMS-KSL to be renamed Cultura Technologies Merger of ESM (UK) Ltd and Satake Europe Ltd More exact bulk materials dosing with innovative Batch Controller New version of moisture sensor from IntelScan Novus commemorates the expansion of its LEED Silver Certified Manufacturing Facility


Features: August

Choosing the right Hazard Monitoring System Synthesis of animal feed formulation techniques: Linear and Non-Linear model Pellet production to save energy, improve feed efficiency and safety Conditioning as part of the pelleting process Energy-efficient and cost-saving innovations for cereal processing Vibronet ® - The Revolution for all tempering processes Victam 2011: A review from Cologne, Germany Pelleting: The link between practice and engineering EDME Limited - A producer of natural cereal based ingredients


Publisher Perendale Publishers Ltd 7 St George’s Terrace, St James’ Square Cheltenham, Glos, GL50 3PT United Kingdom Tel: +44 1242 267700 Fax: +44 1242 267701 Editorial Manager Nicky Barnes Tel: +44 1242 267707 Design and Page Layout James Taylor Tel: +44 1242 267707

4 4 5 5 6 6 7

8 10 10 14 18 22 22 26 30 34

Commodities: Raw material outlook, by John Buckley


Book Review

Enzymes in Farm Animal Nutrition MillionsFed-Proven Successes in Agricultural Development Remote Sensing of Global Croplands for Food Security

Circulation & Subscriptions Manager

44 44 45

Tuti Tan Tel: +44 1242 267707 International Marketing Team

What is this? This is a QR (Quick Reference) graphic that is unique and scannable using a free application on any smartphone or tablet. QRs - although around for some years - have come of age as portable hand-held devices have become increasingly popular. We are adding QRs to major features and will be supplying QRs to our advertisers to place in their advertisements if they wish. They can be pointed to any url or digital destination - and can be changed at any time in the future meaning related information can be kept up-to-date. Perendale generates and manages QRs for all it customers and authors free-of-charge!

Caroline Wearn Tel: +44 1242 267707 Sabby Major Direct: +44 1242 267707 Lee Bastin Tel: +44 1242 267707 Annual Subscription Rates Inside UK: UK£70 Outside: US$140/ Euros110 More information

Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. Copyright 2011 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form


or by any means without prior permission of the copyright owner.

volume: 122 number 4

issn No: 1466-3872


Guest editor - Roger Gilbert


t Victam 2011 in Köln, Germany last May, GFMT had the honour of sponsoring the first ‘ GRAPAS Award for Milling’ – and on the day presenting the winners with their trophies. GRAPAS – which stands for Grain and Pasta – had been introduced by the organizers Victam International to recognize the broad nature of milling of which feed manufacturing is a significant but just one of its many milling disciplines. The objective of the GRAPAS Award is to recognize the contribution to milling – in this case anything involving grain, rice and pasta - made by suppliers and manufactures of milling equipment and services alike. As GFMT is the industries oldest magazine still in print – we are 120 years old this year – we immediately accepted the request to sponsor an award that reflects the importance of all suppliers to our industry in a way the recognizes their contribution to the improvement in

Recognizing the contribution to milling – involving grain, rice and pasta - made by suppliers and manufactures of milling equipment and services alike our industries’ efficiency, safety and production processes while encouraging more companies to consider innovation as a central ingredient of their research and development programs.

The GRAPAS Conference

Getting involved As the host, GFMT is inviting exhibitors to apply for the GRAPAS Award – Asia 2012 by downloading the application form from our website. You can also email us requesting a copy. We are also inviting speakers to join the program. If you or your company is interested in participating in the conference program, please contact Roger Gilbert (

A new venue Victam Asia and its conferences will no longer be held at the Queen Sirikit National Convention Centre in Bangkok, which has been the traditional venue for the show. For 2012 the show will be moving to the impressive purposebuilt exhibition venue of the Bangkok International Trade & Exhibition Centre (BITEC). BITEC is just a few minutes

Allen Willoughby General Manager of CPM Europe (left) and Ing Paul Alderliefste pose with Victam ‘Award for Milling - GRAPAS 2011

from downtown Bangkok. As we go to print we are informed that BITEC is now connected directly by Skytrain to the heart of the city! As you would expect the Skytrain is fully air-conditioned and is a low-cost and comfortable way of getting to-and-from the exhibition and around town.

With Victam Asia set down for February 15-17, 2012 in Bangkok, Thailand, GFMT is again honoured to be invited to host the GRAPAS Conference. This will be a one-and-a-half-day program held in Winners of the first GRAPAS Award three equal sessions that will have a separate focus for The winner of Victam’s inaugural ‘Award for Milling each. Attending the conference will be free-of-charge to GRAPAS 2011’ was CPM’s ‘Roll Speed Measurement’ delegates – the conference supported by the exhibition because of “the absolute relevance to the milling industry.” organizers itself – while program speakers will comprise Golfetto Sangati Spa of Italy received a ‘Highly experts from exhibiting companies talking on specific Commended’ from the judges who explained that the aspects of grain and pasta milling identified by the confer- “unique innovative features of the Golfetto rollermill ence planners. ‘Synthesis SY09’ proves to be very relevant to the industry.” Seating will be limited and delegates will be requested to register their intention to attend ahead of time. The conference program will be published on the GFMT website shortly along with a delegate registration form.

2 | July - August 2011

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“Sticky extruded pellets and kibble slide right out of Tapco urethane buckets. We clean less often now and worry a lot less about


Jeff Bowman Extrusion Plant Manager


Andy Gingrich Owner/Millwright


How Tapco Helped Spectrum Feed Services Overcome a Sticky Situation

Topical liquids used in the extrusion process of pet food manufacturing are sticky and particularly hard to clean, especially when they congeal in colder weather. “Before changing to Tapco urethane buckets, we’d sometimes have to stop production and clean twice a day,” Jeff Bowman, Extrusion Plant Manager, Spectrum Feed Services, STYLE CC-HD Ltd. says. “That meant allocating Severe Duty Urethane Elevator Bucket 2-3 hours for two staff members to hand scrape every bucket on our 60-foot-tall legs, each time. Trust me, nobody liked THAT job.” Cross-contamination was also a constant concern and led to more rework to maintain product quality.

After consulting with Tapco, Spectrum had Proactive Industrial Maintenance replace the existing buckets with FDA-compliant urethane resin CC-HD buckets. Tapco urethane buckets resist product adhesion and flex to release caked-on build-up. “Now sticky extruded pellets and kibble slide right out of Tapco urethane buckets,” Bowman says. “We went from scraping buckets twice a day, to cleaning on a weekly schedule, without concerns of cross-contamination,” Bowman says. “The cleaning process is faster and easier, too, which is important when you’re processing 140 tons a week.”

Need help out of a sticky situation? Talk to Tapco and find out why 75% of design engineers, contractors and bucket elevator manufacturers* trust Tapco FANGED HEAD buckets to keep business moving. Elevator Bolt


St. Louis, Missouri USA Tel.: +1 314 739 9191 • +1 800 AT TAPCO (+1 800 288 2726) • Fax: +1 314 739 5880 • Email: *Grain Journal, Country Journal Publishing Co., Inc., Decatur, Illinois, U.S.A.

© 2011 Tapco Inc.® All rights reserved.

July - August 2011


Alapala completes flour mill in Indonesia


lapala Machine Industry Trade Inc, a leading manufacturing company of flour mill turn-key projects in Turkey and worldwide, attended the May 21, 2011 opening ceremony of a 150-tonne-perday-capacity flour mill in Medan City, Indonesia.

The green-field facility has 7600 tonnes of grain storage and room for further expansion. Alapala said the facility was the first commercial size mill in the

The mill, Pt Halim Sarigandum Prima, was fully supplied and installed by Alapala at the beginning of 2011.

province of North Sumatra, Indonesia. In terms of equipment flow, the plant was designed from the pre-cleaning to the packing section including electrical works and supervision. Alapala noted that this successful achievement in Indone si a would serve as a significant reference in the Asian region for the company.



Suzan SERT Area Sales Specialist Alapala Machine Industry Trade Inc Istanbul World, Trade Center A1 Block, No: 453, Yesilkoy 34149 Istanbul Turkey Tel: +90 212 4656040 Fax: +90 212 4656042 Website:

Novus International celebrates 20th Anniversary focusing on ‘Innovation with Integrity’


ovus Intern ation al hosted more t h an 50 0 people from more than 30 countries at its global headquarters facility in Missouri Research Park for the celebration of its 20th Anniversary. Customers, partners and friends of Novus joine d t oge t he r t o e njoy a Ce l e b r at i o n C e re m o ny featuring leaders from government and the agriculture industry. Speakers at the Novus 20th Anniversar y Ceremony included: • Honorable Jeremiah ‘Jay’ Nixon, Governor of the State of Missouri • Susuma Katagiri, Mitsui and Company, Ltd (representing Novus’ Board of Directors) • Thad Simons, President and CEO, Novus International 4 | July - August 2011

• Dr Joe Privott , President of Pr ivot t s , LLC and Former President of Novus International • Dr Jon Hagler, Director o f A g r ic u l t u re S t at e o f Missouri • Roberto Kaefer, President, Globoaves • Thanomvong Taephaisithphongse, Executive Vice President , Betagro Group • Dr William H. Danfor th, D a n fo r t h P l a n t S c i e n ce Center • Dr M arcos F av a N eve s , Professor University Sao Paulo, Br a zil and author of ‘ The Future of Food Business’ “’Innovation with Integrity’ has been a central attribute of Novus’ culture from the beginning, and our heritage has been built on developing i n n ov at i ve , sc i e n ce - b a se d

health through nutrition products for livestock, pets and people,” said Thad Simons, president and chief executive of f icer of Novus. “We are very proud of our global network of employees, customers and partnerships and excited to celebrate with the many people who support our continued grow th and success.” N ov u s 2 0 t h A n n i ve r s a r y Celebrations were initiated e a r l i e r t h i s y e a r, w i t h back-to-back events at the A si an - P acif ic Aqu aculture i n Ko c h i , I n d i a a n d t h e International Poultr y Expo in At l ant a . The inte ntion of these celebrations is to demonstrate appreciation for the customers and partners who have supported Novus through the years and still do today. Novus will continue to host

a p pre ci at ion ce le br at ion s for customers and partners at its facilities throughout the world, including China, Belgium, Brazil, Spain, Thailand and Australia. Novus was founded in 1991 a nd t od ay h a s e m p l oye e s working in more than 10 0 countries, serving more than 3000 customers worldwide. Novus has facilities including corporate offices, research and development laboratories and m a nu f ac t ur ing o pe r at io n s in more than 50 countries. More


Novus, International 20 Research Park Drive St Charles, MO 63304 USA Tel: + 1 314 576 8886 Fax: +1 314 576 2148 Website:

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UNORMAK DEG. MAK. IML. SAN. ve TIC. LTD. Sti Konya Organize Sanayi Bรถlgesi 7. Sokak No: 5/1 Konya / TรœRKIYE Tel: +90 332 2391016 Fax: +90 332 2391348 e-mail: WEB:

July - August 2011



range of automatic on-stream and bagging scales by Bryan McGee, a milling industry consultant and contributing feature writer


echmach Technology, of Krugersdorp in South Africa , now offers a comprehensive range of fully electronic precision scales which are designed and manufactured in-house to robust standards to meet the requirements of most process industries handling powdered and gr anular materials in continuous and demanding duties. Scale on test.

scales on-build

The scales are available in durable powder coated mild steel or in stainless steel to suit the application. The range comprises machines for on-stream process weighing 6 | July - August 2011

and also for bagging purposes. The on-stream scales are available for loss-in-weight or in-process batching applications at up to 250 tonnes per hour. The bagging scales are available for net or gross weighing from 500g to 1500kg and to suit a variety of feeders and with various bag clamping configurations The use of the latest CAD design and CNC manufacturing equipment in Techmach’s plant has enabled new standards of component and build accuracy to be maintained, thus ensuring dust tight and extremely reliable operation. Each scale incorporates top qualit y specialist pneumatic and load ce l l c o m p o n e n t s and state of the art electronic control. The dust tight doors are easily removed for c le aning and maintenance and the pneumatic cylinders are all of standard sizes and re adily accessible. The weigh hopper of each scale i s s u p p o r t e d by three Model 355 stainless steel load cells, which obviate the need for any stay-bars with their potential for weighment interference. TMS scales are controlled

by a Beckhoff PC plc and pneumatic controls running Windows CE to provide comprehensive information and a versatile user-friendly operator interface. The PC can be dedicated to a single scale or provide the interface to multiple scales and its displays are on an easy to use and understand touch screen, the size of which weigh hopper inverted can be chosen to suit the application. The PC is fully password protected and also offers RS232, RS 485 or ethernet serial interface facilities for linking to a plant PLC, SCADA system or sequence server. The on-stream process scales will fill and empty on a systems can display extraction semi-random basis. and log shifts to a memory stick Some of the features which can in Excel format. be provided include: totalising of The Pioneer Group of southern material throughput, hourly rate Africa are currently the leading display, monitoring and control users of TMS scales which they of material flow rate, upstream operate in their Sasko maize and downstream interlocks, non- and wheat mills and also in their erasable totals, USB downloads Nova feed mills. directly from the unit and on-screen real time status display. More information: Some of the useful applications Techmach Technology of these scales include the ability (PTY) Ltd to operate a multiple scale 10 Nicholls St system and to calibrate and Chamdor control one or more additive 1754 Krugersdorp feeders for accurately adding South Africa a small proportion of, say, Tel: +27 11 7621091 vitamins to a finished product. Fax: +27 11 7627325 Another application is to use Email: Website: the scale feeding first break in a flour or maize mill to control Bryan McGee, a milling industry consultant, may be contacted the final water addition. For at milling applications these

&feed milling technology




July - August 2011

STIF set up in

Grain&feed m techno11





China F


r e n c h c o m p a n y S T I F, manufacturer for handling bulk products sets up in China.

With a wealth of dominant position behind it in Europe, company STIF increase its international growth of business by the creation of a subsidiary of production, located in the city of Suzhou (West of Shanghai). The strategy of STIF is not to produce in China and then to export to Europe but, on the contrary, to produce in China while developing sales in all Asian countries. Pursuing a commercial policy, STIF will be participating in several shows, in particular in China, Indonesia, Malaysia and the Filipinas as well as in Australia. The main products proposed by this structure are components for buckets elevators JET (elevator buckets, elevators belts, devices of detection), compression couplings Eurac (pneumatics conveying tubes) as well as the explosion vents panels Vigilex. More



Charles Le GOFF STIF ZA de la Lande 49170 St Georges / Loire France Tel: + 33 2 41721682 Fax: +33 2 41393212 Email: Web:


Have you got news that you would like to share with the industry Send your press releases to

Z.A. de la Lande 49170 ST-GEORGES-SUR-LOIRE - FRANCE Tél. : 33 2 41 72 16 82 - Fax : 33 2 41 39 32 12 E-mail : - Web :

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July - August 2011 | 7


July - August 2011


Mühlenchemie opens production plant and laboratory in China There is growing demand within China for greater flour standardization and flour fortification. Addressing that need is the new Mühlenchemie production plant and baking laboratory in Suzhou which will enable the development of faster and more individual solutions for Chinese millers seeking greater knowledge.


This will enable the flour improvement specialist to meet the needs of Chinese millers on the spot, with tailor-made solutions.

The Chinese are the world’s biggest producers and consumers of wheat. In this huge country there are hundreds of genetically different wheat varieties. This diversity results in extreme fluctuations in the baking properties of flour, so there is a growing demand for standardization in the production process in order to achieve uniform quality in the end products. Mühlenchemie has now

plant that permits the flexible production of batches in volumes between 10kg and 50 0 k g. By using dif ferent containers and separate production lines it is possible to meet the highest safety standards and exclude the risk of contamination. In a second stage of expansion the plant will also manufacture vitamins and minerals for the Chinese food industry. One-third of the initial 15

Besides facilities for manufacturing functional systems for flour standardization and improvement, the company has established a modern baking laborator y at the Suzhou site. The affiliate in Suzhou is a 100 percent subsidiary of t he G er m an com p any Mühlenchemie.

established a production and research facility of its own in Suzhou in eastern China, 120km from Shanghai, in order to meet the needs of Chinese millers faster and with more individual products. In cooperation with Matcom IBC (UK), Mühlenchemie has designed a container blending

employees at the site are e ng aged in re se arch and development. In order to help the Chinese millers on the spot, the company has set up a baking and rheological laboratory in Suzhou where training courses for employees of the mills will take place regularly. At the test facility equipped in

t a ceremony attended by over 10 0 guests from local political and academic circles and partner firms, Mühlenchemie GmbH & Co KG of Germany officially opened a production plant in China.

8 | July - August 2011

cooperation with the partner enterprises Brabender and Perten, it will be possible to analyze different wheat lots and simulate the effects of additives. In this way Mühlenchemie will enable its customers to find the right flour treatment agent for the end product they wish to make. “We feel it’s very important to involve our customer s in the process of analysis and development . B esides achieving optimum results, we are also able to offer a high degree of transparency in the manufacture of the products – something the Chinese population is demanding more and more”, s ays H e ndr ik M öge nb urg , General Manager of Mühlenchemie in Asia. In doing so the company draws on the comprehensive knowhow it has acquired as the world’s leading enterprise in the field of flour treatment. Every year Mühlenchemie standardizes over 70 million tonnes of wheat. The company was established in 1923. It has been a member of the Stern-Wywiol Gruppe since 1990 and acts as a partner to over 1000 flour mills in more than 120 countries. More


Nicole Schulze (Marketing) Mühlenchemie GmbH & Co. KG Kurt-Fischer-Strasse 55 22926 Ahrensburg Germany Email: nschulze@

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July - August 2011


Novus International and Verenium announce strategic partnership An expanding product portfolio is being driven by Novus’ commitment to enzyme and fermentation solutions to feed cost optimization


he enzyme solutions available to nutritionists, producers and others looking to optimize nutrition in poultry, pork, beef, dairy, aquaculture and companion animals will be expanding as the result of a strategic collaboration announced today between Novus International, Inc and Verenium Corporation (NASDAQ: VRNM). The partnership is the result of the focus Novus has on generating enzyme solutions to optimize nutrition—and the resulting feed costs—in a number of production livestock species, as well as companion anim als wit h t he highe st performing quality solutions. “Our partnership with Verenium will allow us to work together to develop and commercialise a suite of new enzyme products for the global animal nutrition and health market,” notes Thad Simons,

&feed milling technology


president and chief executive officer of Novus International. “These new enzyme products will give us the ability to offer new solutions to the performance challenges our customers face.” Novus International, a company with more than 20 years experience in the animal nutrition market, is deeply committed to the enzyme and fermentation business. “The enz yme business is perfectly aligned with Novus’ mission to m ake a cle ar d i f fe re n ce i n su s t ai n a b l y meeting the growing global demand for animal nutrition,” says Gary Hayen, Novus global business director, Fermentation Products Business. “ T hi s p ar t ne r s hi p br ing s together the synergy of both the biotechnology and animal nutrition fields. We really believe we’ve only started to scratch the surface of the industry’s demand for enzymes

and are excited to provide innovative solutions, powered by Verenium, to meet the market’s needs.” “ Vere nium’s approach to product development is very innovative and based on the highest standards of science,” adds Simons. “This partnership is a natural alignment and we expect to deliver great results to our industry by working together.” Combining the strengths of two industry leaders builds on Novus' existing enzyme offering and knowledge of animal nutrition by offering the strength of Verenium’s world class enzyme biotechnology. The continued expansion of Novus’s enzyme product offering in collaboration with Verenium will add to the track record of success that enzymes have in providing critical solutions in the poultry and livestock sectors. “We are extremely enthusiastic

about our partnership with Novus, the potential opportunity it represents for the continued development of our pipeline and for Verenium to become a more active participant in the animal health and nutrition marketplace with our suite of high-performance enzyme products,” said James Levine, President and Chief Executive Officer at Verenium. “Novus brings world-class leadership and experience launching products in this market , and with our com bined sk ills , we look forward to working closely as partners to commercialize a series of market-leading products over the coming years.” More


Novus International USA Tel: + 1 314 576 8886 Fax: +1 314 576 2148 Website:

July - August 2011 | 9

July - August 2011


New feed analyser offers next logical step in high performance near infrared analysis


he NIRS™ DS2500 feed analyser allows users to migrate to the new high-performance platform while re-using existing valuable calibration data. Foss announces the NIRS™ DS2500 feed analyser, a robust, pur p ose - b uil t in s t r u me nt combining high performance near infrared (NIR) analysis with full compatibility to Foss NIR solutions.

Unique, high-per formance across a broad wavelength range of 400nm to 2500nm gives accurate analysis results for a range of parameters such as protein, moisture, fat, ash,

amino acids, fibre and starch in under a minute and empowers feed millers in handling intake, improving production and ensuring final product quality. Compatibility to other NIR analysis solutions ensures that feed millers can migrate to the new high-performance platform while re-using existing valuable calibration data. Robust and simple to use, the instrument can be used in the laboratory or in the feed mill. Foss feed industry manager, Christian Tolleback says, “Like all great concepts, near infrared analysis ju s t ke e ps on get ting bet ter and the NIRS DS2500 marks a new exciting milestone in its evolution. “ Now you can get all the latest technology developments in one go and without worrying about losing your hard earned calibration data.” 100% compatibility avoids loss of valuable data Instrument calibration based

on reli able me asure ment data is an important aspect of NIR analysis, especially in the feed industry where a wide variety of raw material is used. Backwards compatible to existing Foss solutions such as XDS, and NIR System II solutions, the NIRS DS2500 allows users to take the best from any existing calibration data and transfer it quickly and easily to the advanced DS2500 instrument offering the best-inclass performance. Ef fective oper ations with standardised instruments It’s easy to get started using the NIRS DS2500 as every instrument that le aves t h e f ac t or y i s h ard w are standardized. Light intensity, bandwidth and wavelength precision are t horoughly controlled in production to ensure complete consistency between instruments. Built-in measurement standards help to control i n s t r u m e n t p e r fo r m a n ce , ensuring that no deviations occur over time. This helps to maintain consistency between instruments and makes it e asy to inst all additional

instrument units. Likewise, multiple instruments can use the same calibrations without any modifications.

Unmatched optical performance The DS2500 is a monochromator based NIR reflectance and transflectance analyser with a scanning range of 400–2500nm. The measuring chain is highly optimised with regard to linearity and S/N ratio delivering unique analytical performance. The wide spectral range makes the system ideally suited for analysis of demanding parameters such as amino acids. The NIRS DS 2500 has been designed for high performance in the hardest production environments. It is IP65 certified to withstand humidity, vibration and temperature fluctuations. More


Christian Tolleback Feed Industry Manager FOSS Slangerupgade 69 Postbox 260 Hillerd, DK-3400 Denmark Email:

EU Commission vote on GM will lead to more secure feed ingredient supply


he Agricultural Industries Confederation (AIC) has welcomed the European Commission’s adoption of a long aw aited ‘technical solution’ that introduces a 0.1 percent threshold for the low level presence (LLP) of EU non-authorised GM material in imported feed materials. AIC ’s Feed Sec tor He ad, George Perrott, described the move as a significant step in securing trade in imported feed materials in coming seasons. It is the culmination of years of 10 | July - August 2011

intensive lobbying by the feed industry and is the outcome of three months scrutiny by the European Parliament. “As production of GM crops has increased across the world, the European Union’s zero tolerance of GM traits that it has not authorised has put great uncertainty over imported feed supplies,” explains Mr Perrott. “Until now, a single soybean could result in a 20,000 tonne cargo being turned away from European por ts. That was totally impractical for those shipping the feed ingredients

which Europe depends on.” The new Regulation will permit up to 0.1 percent traces of genetically modified traits, not yet approved by the Commission. This decision also regulates analytical and sampling procedures used to evaluate such traces. However, Mr Perrott points out that the ‘threshold’ only covers GM material authorised for commercialisation in a third country (for example the US, Canada, Brazil and Argentina) and for which the EU authorisation procedure

has been pending for more than three months and for which a validated detection method is available. More


George Perrott Head of Feed Sector Agricultural Industries Confederation (AIC) East of England Showground Peterborough, PE2 6XE United Kingdom Tel: +44 1733 385252 Email: george.perrott@ Website:

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July - August 2011


Bag compactor from Flexicon gives safer operational performance


lexicon Europe, a world leader in the supply of bulk handling systems for processing powders, flakes and granular materials, has developed a bag compactor as an integral part of its range of Bag Dump Stations, enabling operators to easily and safely discard and compress up to 80 used bags into a compact neat bundle for subsequent disposal. The Flexicon Bag Dump Station provides a simple yet highly effective method of manually introducing bagged materials for hopper replenishment or direct feed into a processing line via flexible screw or pneumatic conveyors. As each bag is split and manually emptied into the bag dump station high velocity vacuum fans automatically draw dust

&feed milling technology


away from the operator onto two cartridge filters, protecting workers and preventing plant contamination. Addition of the bag compactor b r i n g s ad d e d s a fe t y a nd improvements to the work area as emptied bags can now be contained within the confines of the machine rather than being discarded into adjacent wire cages. Since the compactor becomes an integral part of the bag dump station any residual dust is also contained within the machine structure preventing escape during the compaction process. The new bag compactor can be mounted to either the left or right of the bag dump station and is accessed via a small horizont al let terbox-st yle flapper in the side panel of the dump station.

A pneumatically powered ram compresses the used bags and depending on size and thickness, it is estimated that between 50 and 80 bags can be compacted into a removable polybag lined bin. A full indicator light signals time to remove the bin from the Flexicon Bag Compactor, tie the polybag ready for collection, reline and replace the bin, the final bale size is no larger than 440x440x600mm high. The Flexicon bag compactor is fabricated in stainless steel as is the Bag Dump Station and are suitable for application in industries such as food, dairy or pharmaceutical. Units are also available in other materials such as Carbon steel with a tough durable finish for more general industrial applications. There are a number of safety features to prevent potential

risk including interlocks on the flapper to prevent manual bag induction or opening of the main door during the compaction process. The combined bag compactor and Bag Dump Station are just two parts of a comprehensive range of bulk handling systems and equipment available from Flexicon Europe, all designed t o incre a se produc t ivi t y, improve plant efficiency and create a better, safer working environment. More


Mr Alan Walton General Sales Manager Flexicon (Europe) Ltd 89 Lower Herne Road, Herne, Herne Bay, Kent, CT6 7PH United Kingdom Tel: +44 1227 374710 Website:

July - August 2011 | 11

July - August 2011


Feed manufacturer sees annual savings of UK£17,000 after installing inverter technology from RJW


hen a major animal feed manufacturer, employing 200 people across the UK and producing over 34,000 tonnes of product every year from its Merseyside plant, explored energy saving opportunities, the first company contacted was Rewinds & J Windsor, an ‘Official Drives Partner’ for Control Techniques’ inverters.

department and installed by the company’s site installation team. The drives varied in size from 5.5kW to 37kW with an average size of 15kW. By using inverter drives instead of other methods of controlling airflow, it was possible to reduce the speed of the motors running the fans and therefore save the energy used in powering the motors. The

payback calculations made by RJW during the planning phase of the project. This relatively small investment has had a noticeable effect on the electricity usage for the plant as a whole, reducing consumption to UK£77,000 and lowering the cost per tonne of end product by 18 percent.

A reputation for ship repairs

Electricity consumption at the Merseyside plant was close to UK£94,000 per year and as prices are to rise even further, the company tasked RJW with a sitewide energy reduction survey. Following the survey, 12 motors and motor/fan units were identified as offering potentially the greatest payback, this according to the cost analysis software specially written by Control Techniques. Once the go-ahead was given, 12 drive panels containing ‘Commander SK’ inverters were built at RJW’s panel building

saving made is equivalent to the square of the speed reduction, meaning that a speed reduction of only 20 percent (which is usually possible) creates close to a 50 percent energy reduction!

Additional benefits have been reported by the site’s engineers with greater plant reliability attributed to the introduction of the drives, which in turn has created maintenance savings with reduced downtime. The local environment has also benef it ted with machines running a lot quieter. With a boost in production planned for this year, plant energy efficiency gains per unit of product are expected to be even greater than before, whilst modifying the inevitable rise in electricity costs.

which now includes a growing business in wind turbine motor servicing. The company uniquely in the UK holds the DNV accreditation for welding processes as well as the ASME qualification for spiral welding.

Short payback period Significant results have been shown following a suitable period for analysis. The initial saving from the UK£14,000 investment was a UK£17,0 0 0 reduction in electricity costs, within a payback period of less than one year! This matched the

Established over 64 years ago and with organic growth through acquisition Rewinds and J Windsor (RJW) now employs over 130 personnel at its three sites. The company originally built its reputation on ship repairs then moved into heavy electrical engineering,



Lee Windsor RJW Ltd 81 Regent Road Liverpool L5 9SY United Kingdom Tel: +44 151 2072074 Website:

THE GLOBAL MILLER Covering all aspects of the grain feed and milling technology, with industry news stories, company press releases, book reviews, company profiles and much more.

You can catch my daily blogs at 12 | July - August 2011

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July - August 2011


Carl Swisher joins 4B as Sales Manager


B Components Ltd, a worldwide manufacturer of material handling and electronic components for bucket elevators and conveyors, announced on July 11, 2011 that Carl Swisher has been hired as sales manager for material handling products. “Carl will help to strengthen our position as a global leader and manufacturer of material handling products. He comes with a strong knowledge of the elevator bucket business and will be a great asset to the 4B team,” says Johnny Wheat, Senior-vice President and Director of 4B Components.

Mr Swisher has over 20 years of experience in industrial sales and international business. Proficient in Spanish, he is a graduate of Washington University in St Louis and holds an MBA from New York University’s Stern School of Business in marketing and international business. Prior to joining 4B, Swisher was the sales manager for Tapco Inc. More

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Norbert Dentressangle feeds Duffield’s supply chain


.L. Duffield & Sons, manufacturers of animal feeds, has appointed Norbert Dentressangle to support the distribution of palletised products through its flexible and cost-effective nationwide network. Based in Saxlingham Thorpe, Norwich in the UK, with another site in Wingham, Kent, the family-owned company has been supplying farmers in East Anglia and the South East with animal feeds in the ruminant, pig and poultry sectors for over 100 years. Over the last year the company expanded its thriving business with the addition of bespoke concentrates and packaged products, taking its combined factory and traded goods production to over 250,000 tonnes of feed per year. To manage this growth, Duffields required a specialist pallet transport solution to ensure it meets customer demand. To support the continued expansion, Norbert Dentressangle makes daily collections of palletised products from Duffield’s mill in Saxlingham and a storage depot in Bury St Edmunds before consolidating loads

at its nearby site in Ipswich. Next day deliveries are made to various customer locations including game, dairy, poultry, pig and stud farms via its shared-user network. Duffields also owns Pen Mill Feeds based in Yeovil and through the Norbert Dentressangle transport network supplies feeds across the South and South West regions to cater for the high number of livestock reared in the areas. To improve operational efficiency, Duffields is utilising Norbert Dentressangle’s bespoke SHARP (Shipment Handling and Reporting Program) technology. The integrated online system enables the company to place orders electronically, which are scanned and tracked in real time, and access proof of delivery information. More


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July - August 2011 | 13


Revised Buckets C2 half page 2.indd 1

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Packaging L

ike so many areas of today’s animal feed sector, packaging has evolved enormously.

Thanks to the development of new technology and the efforts of the industry’s forward thinking suppliers, users now have access to a whole range of next generation solutions that can deliver new and innovative benefits. One business in particular that has been a leading name in the evolution of animal feed packaging is British-based bpi.visqueen. As Jerry O’Brien, sales director at the company, explains: “The demands faced by the modern packaging producer are now more diverse and challenging than ever before. “In addition to the growing concern of rising material and energy costs, the desire for more sustainable packaging solutions means users are increasingly looking for packaging that can help to reduce their environmental impact. “As one of Europe’s leading manufacturers of polythene films and sacks, bpi.visqueen is committed to keeping pace with these demands and providing ever more capable answers to the sector’s packaging needs. As such, we continue to invest heavily into new technology, product research and development and enhanced manufacturing facilities.”

New packaging possibilities The manufacturer’s Ardeer factory in Scotland is a prime example of this commitment. 14 | July - August 2011

Having recently undergone a UK£7million upgrade, the site is perfectly placed to provide advanced packaging solutions that meet the needs of today’s animal feed producer. Among the state of the art technology now at bpi.visqueen’s disposal is a five layer wide width film line – capable of producing films measuring up to 22 metres across. Believed to be one of the largest wide width blown film extruders in Europe, the new line means that the business is now able to reach new levels in terms of overall production volumes and new product development. The enhanced Ardeer site has already been pivotal in the development of new animal feed packaging solutions through the further advancement of tubular filmand sheet film-on-the-reel formats. These formats allow users to employ higher speed packaging lines and require less manual input, helping to improve productivity and output while reducing costs. There are also other benefits to using filmon-the-reel, including improved pack consistency, reliability and overall performance.

Going green by going thinner The enhanced manufacturing facility at Ardeer will also be central in enabling bpi. visqueen to help users tackle the challenges that come with rising material costs and the increasing demand for greener packaging solutions. “With the rising costs of materials an ever present concern in the packaging industry, it’s now more important than ever that animal

feed producers pursue every opportunity to reduce outgoings and increase profit,” explains Mr O’Brien. “It’s for this reason that bpi.visqueen has introduced the latest downgauging technology, which essentially entails the creation of packaging that offers more performance from less material. “A simple and effective way to cut costs without any compromise on product performance, these downgauged films allow users to boost both their efficiency and their green credentials in one fell swoop.” Using advanced polymers and the latest extrusion technology, this downgauging technology results in products that offer all the strength of conventional tubular film and film sheets – but from a considerably thinner film profile. For instance, bpi.visqueen’s downgauged films now enable customers to create sacks which perform like they’re made from 150 micron (mμ) film but using a film that’s actually just 110mμ thick. The net result of this downgauging - which can deliver film savings of 20-25 percent - is a significant reduction in packaging costs. In addition, users are able to minimise their environmental impact, as the ability to produce packaging with less film by weight leads to less packaging waste. Plus, in the case of bpi.visqueen, this downgauged packaging is also100 percent recyclable. Best of all, the green benefits don’t stop there. As downgauged films are thinner, more

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July - August 2011 | 15


ties at Ardeer are equipped with lines that can detect any potential issue with seal integrity before sounding alarms and automatically cutting out. The same cutting edge technology also gives the manufacturer finger-tip control of factors such as film consistency enabling it to offer sacks that give smoother running and fewer machine stoppages. Plus, it can even tailor characteristics such as film slip differential to suit the individual machines of customers.

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Ardeer extruder products can be accommodated on a standard reel. This greater length of film per reel reduces delivery requirements and as a result, associated vehicle emissions.

Increasing efficiency Aside from their improved environmental credentials, there are other major attractions to bpi.visqueen’s next generation downgauged packaging solutions. Most notably, they also have the ability to deliver genuine commercial advantages. “Downgauged packaging’s capacity to deliver more from less is as beneficial from a commercial point of view as it is for the environment”, explains Mr O’Brien. “For instance, the greater yield of film offered by reels of downgauged packaging allows users to create more sacks with fewer stoppages for reel changes. Not only does this maximise machine and operator time, but the improved efficiency also tends to lower per unit packaging costs. “On top of this, the need for fewer film deliveries reduces associated administrative demands such as the need to order film, to deal with deliveries at goods inwards and to process related paperwork. This frees up time and resources which can then be spent on other higher value or more profitable activities.” Further benefits stem from the fact that the packaging process itself becomes faster and less labour intensive, offering users additional opportunities to save on both energy and labour costs. To maximise the impressive benefits offered by downgauged films, bpi.visqueen has taken steps to introduce the latest sack manufacturing technology. For instance, its sack production facili-

16 | July - August 2011

Not content to stop there, bpi. visqueen has looked for opportunities to add value to its customers in the animal feed industry. This includes offering them greater scope to utilise packaging as a means of brand awareness. “In today’s brand conscious market, manufacturers and merchants have to take advantage of every opportunity to raise their company profile,” says Mr O’Brien. “This means that packaging now has the dual purpose of protecting and containing a given product while also acting as a promotional tool for a business. “Advances in printing technology can play a vital role in helping to build brand awareness. For instance, at bpi.visqueen we now offer our customers the benefit of eight colour flexographic printing. This not only maximises opportunities for better brand representation, but can also help to increase the visual impact of a product. “These improved aesthetic qualities can prove invaluable in helping products to achieve greater ‘stand out’ at the point of purchase, encouraging brand loyalty and increasing repeat business.”

Adding value In line with its commitment to meeting the evolving demands placed on animal feed packaging producers, bpi.visqueen has also invested considerable time, effort and resources into product research and development. The result is packaging that offers new solutions to established problems. A case in point is bpi.visqueen’s Ventisack product. Originally developed for the cement industry but just as suited for use with any dusty product, Ventisack is a high-strength, tear resistant, co-extruded FFS film, which is able to offer new levels of performance by enabling the creation of sacks with an innovative back seam. This seam allows air to vent from the formed sacks quickly – an important requirement of modern high speed packing lines. It also allows the sacks to ‘breathe’’ whilst still

remaining waterproof. This makes Ventisack a perfect choice for water sensitive goods like supplements and minerals - which are frequently stored outside. The venting characteristics can also be tailored according to specific customer needs whilst added value features like embossing can be included to provide anti-slip properties if desired. In the cement industry, Ventisack has shown itself capable of significantly reducing spoilage rates and of extending product shelf life. bpi. visqueen is confident it can now deliver the same benefits in the animal feed sector. Plus, aside from its exceptional technical innovation, Ventisack can be printed in up to four colours with 360o coverage around the entire film tube. This means no wasted areas of plain white space along the sidewalls of the resultant sacks and no lost opportunity to promote a marketing message.

Focused on the future And it seems that further breakthroughs are already on the way. bpi.visqueen’s Ardeer facility has not only improved its ability to produce its existing technically enhanced range, it will also play a crucial role in helping the manufacturer to pioneer new possibilities in animal feed packaging. In particular, bpi.visqueen is currently working to set new standards in animal feed packaging, with a focus on powders, minerals and supplements, such as food ingredients, dried milk powder and calf milk replacer. As Jerry O’Brien from bpi.visqueen sums up: “The needs of today’s animal feed sector are rapidly changing, and it’s no longer enough that packaging merely fulfils a functional role. “It can now actually add value and contribute to a feed producer’s success in much the same way as certain feed ingredients or certain types of manufacturing technology. “As a business, bpi.visqueen is committed to meeting the challenges and demands of modern packaging environments. That’s why we continue to provide high quality solutions that are not only greener and more cost efficient, but that also deliver in terms of product performance, productivity and presentation.”

Jerry O’Brien

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Wear protection underwrites continuity of production & supply, delivering optimum ROI in demanding animal feed market by John Connolly, MD, Kingfisher Industrial, West Midlands, United Kingdom


he global demand for animal feeds has never been higher, fuelled by increasing heavy consumption of meat in China and wealthy countries in the ASEAN block. This demand means that continuity of supply is all important, placing stress all along the supply chain from processing and transferring of raw materials and finished product in animal feed plants, to handling, conveying and storing the product at ports for onward shipping. Handling solid and liquid ingredients together with binding agents makes the whole process of producing animal feed 18 | July - August 2011

an activity where success depends on the equipment remaining reliable, 24-hours a day. However, militating against this is the nature of animal feeds themselves. The operations of processing, mixing, blending, conveying and transferring bring large volumes of semi-aggressive media into contact with a variety of plant surfaces. This media has the capability to wear out hoppers, feeders, chutes and mixing equipment very quickly, resulting in lost production and excessive maintenance costs. Whether the feed is conveyed as dried, mixed or packaged, the process creates wear problems.

Depending on the volumes and the operational regime, these will significantly reduce the value of the processing company’s capital equipment if the plant is not wear protected for continual operation. Constant wear, leading to frequent repairs and maintenance can be avoided if the correct wear protection is applied. The result is drastically reduced cost of repairs on worn-out chutes, ruptured pipelines, crumbling silos and conveyors. Eliminating these on-going wear and repair concerns enables the process to operate as designed, maximising its efficiency and the operational team’s resource capability allowing production efficiency improve-

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ment and improved ROI in the animal feed processing business.

Operational factors In common with other bulk materials handling industries, the equipment for processing and conveying animal feeds needs to cater for many operational factors. If considered from the onset, these factors can be catered for and a design element introduced to compensate for potential wear problems. Factors such as volumes, loadings, particle size and shape, viscosity and moisture content are typical criteria that must be addressed in order to eliminate potential problem wear areas. Selecting the right liner materials, hopper design and pipe installation can prevent the need for replacement and maintenance for up to 20 years. “No maintenance requirements over the lifetime of an installation means reduced risk, reduced cost and more production uptime over longer periods – all of which are critically important to improve the efficiencies of companies that operate 24/7,” said John Connolly, managing director of the UK wear protection specialist, Kingfisher Industrial.

symaga_quarter page_IAFD2011


Complex and multi-layered In quantitative terms the benefits to the plant user are huge, because maintenance of process plant and equipment is a complex and multi-layered operation. Avoided are the ongoing cost problems of interruptions to production as a result of breaking down pipework; the requirement for specialist labour, and the safety risks involved with personnel working at height, performing hot work and lifting operations. In addition, the tasks of organising access platforms and plant hire, with their attendant costs – and risks – are no longer necessary; nor are procedures devised for the cleaningup of spillages that may occur when process pipework is perforated, thus creating an environmental issue or potential breach of legislation. As a result, the system user benefits from continuous operational gains, which defray the cost of the protection system, guaranteeing a prompt return on investment. Using a combination of ceramic, metallic and polymer lining systems, Kingfisher has had overwhelming success in protecting equipment and extending the service life of bulk materials handling plant. In many instances, the benefits of protect-


ing plant are threefold: in addition to protecting against wear, the low friction nature of the lining material reduces energy usage and increases production by allowing a greater volume of material to be throughput. “A major benefit of wear protection is that it can be employed at any time in the life of a process system, so users do not have to throw away their existing plant and start again,” says John Connolly. “In addition, because high conveying speeds and abrasive materials cause wear of varying intensity at different points in process plant systems, it is often the case that protection need only be applied to areas that are most vulnerable to wear, further reducing upfront costs and improving ROI for the system user.”

Protection from inception If a process system is designed with wear protection from its inception, then overall equipment costs can often be reduced because the system chosen to protect the equipment can often remove the requirement to manufacture components using heavier grades of material.

Page 1

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July - August 2011 | 19


In addition, involving a wear specialist such as Kingfisher at the design stage of process conveying equipment can streamline the design, optimising process efficiency through reduced turbulence and improved material flow, at the same time ultimately delivering improved service life. Kingfisher has produced a graphic to highlight the benefits of its whole life cost argument (see Table 1). The graphic compares the ongoing costs associated with Table 1

equipment and installations that do not benefit from wear protection, with the one-off (i.e. purchase) costs of enhanced protection, highlighting the continuous operational gains of the latter investment strategy. The thrust of the argument is clear when considering the typical example of an enclosed pipework system for conveying bulk materials. The system is wear protected, and so is able to provide up to 20-years of life. With this one-off approach, the system user has little or no maintenance requirements over the lifetime of the installation. He does not have the ongoing cost problem – say every 4-years - of breaking the pipework system down - and of interrupting production in the process. The long term benefits of wear protection as a safeguard for animal feed processing 20 | July - August 2011

equipment against unplanned maintenance and costly downtime are evidenced by a 2003 application of the technology at a major animal feed supplier in Shropshire. The company was experiencing constant problems of perforation in pipes, along which abrasive animal feedstuffs were conveyed pneumatically at high speed. A number of solutions were tried, but the frequency of replacements and downtime resulting from these led to an approach to Kingfisher Industrial, which advised another approach, based upon the company’s ceramic K-Bas Cast Basalt Lining System. With a hardness rating of approximately eight on the MOHS hardness scale, K-BAS offers key benefits, such as resistance to frictioninduced abrasion and erosion in plant where bulk solids are conveyed, stored and processed by mechanical, pneumatic or hydraulic means. In addition, K-BAS is a relatively inexpensive form of wear protection, which is corrosion resistance, and offers the additional advantage of promoting material flow. “K-BAS is one of the many liners we offer,” said John Connolly. “There is no one-size-fits-all philosophy in respect of wear protection, that’s why we always carefully analyse all aspects of the equipment, site and surrounding environment before we put a firm solution proposal before our customer. What we are aiming to achieve is the longest possible operating life from an installation, to payback the initial investment many times over. Our success is evidenced by installations such as the one in Shropshire, which is now in its eighth year of operation, with no problems to report.” In the case of the Shropshire installation,

the pipework for the Kingfisher solution was manufactured and lined with K-BAS at Kingfisher’s purpose- built factory in the West Midlands, and then delivered to site for final assembly. Assembly of the pipework was carried out, in this instance, because of timing, by the feed supplier’s own maintenance personnel. However, Kingfisher generally takes full turnkey responsibility in the wear protection projects that the company handles. “We provide a full turnkey service with our wear protection systems, including complete installation and commissioning,” said John Connolly. “Our customers generally like this approach, as it ‘keeps everything under one roof’, giving them the security of a single source supply from a partner company they can trust.”

About Kingfisher Industrial Kingfisher Industrial provides wear solutions for process plant used to convey, process or store bulk solid materials, in either dry or hydraulic states. With its range of ceramic, metallic and polymer protection systems, Kingfisher can overcome wear problems; engineering suitable protection systems that can add many years’ of life to a plant, and in some cases outlast the design life of a process completely. These solutions cater for the operating criteria, budget and life cycle of either new equipment - particularly when initially installed - or existing equipment, which can be retrofitted with a protection system to add to its current asset value.



John Connolly Managing Director Kingfisher Industrial Cradley Business Park Overend Road Cradley Heath West Midlands B64 7DW United Kingdom Tel: +44 1384 410777 Email:

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adv material for 2011 for April, August and December 2011

July - August 2011 | 21


Figure 1: Thermal twin-screw extruder

Cooking cereals with extrusion by Mian N Riaz1 and Brian Plattner2 , Food Protein Research and Development Center1 Texas A&M University, College Station, Texas 77843-2476, USA Email: 2 Wenger Manufacturing Company, 714 Main Street; Sabetha, Kansas 66534, USA Email:


ost cereals contain a large amount of starch. In its natural form, the starch is insoluble, tasteless and unsuited for human consumption. To make it digestible and acceptable, it must be cooked. Cooking or gelatinization of starch in the traditional cereal process is controlled by time, temperature and availability or presence of water. In the extrusion cooking

Figure 2: Steam injectors

process, shear is a fourth dimension that impacts product quality. Almost any cereal can be cooked using an extruder, but if expansion is a major objective, the numbers of functional cereals 22 | July - August 2011

are limited to de-germed corn/grits and rice. they have been subjected to the process of Cereals that have high amounts of lipids are toasting, this means is used extensively for more difficult to expand due to dough slippage preserving grains and cereal foods. within the extruder barrel. This type of cereal usually requires high moisture and high tem- Cooking factors perature before significant puffing will occur. How long a cereal needs to be cooked In general, starches with 5-20 percent will depend upon several factors. amylase content will significantly improve The length of time to cook cereals also expansion as well as texture of the break- varies with their kind and form, the coarse fast cereals and snack foods. An old method of cooking cereals or starchy foods is called browning or toasting and it involves cooking them by dry heat. A thin layer of grain is spread in a shallow pan and this is placed in a slow oven. After the grains have browned Figure 3: RVA comparison between slightly, they are stirred whole corn flour and extruded material and then they are permitted to brown until an even color is obtained. By this method the flavor of the ones requiring more time than the fine ones. cereals is developed and their digestibility Because of this fact, it is difficult to say just increased. how much time is required to cook the Since grains keep much better after numerous varieties thoroughly.

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or oven whereas for human uses the method of cooking cereal may be more sophisticated and detailed. Some of the most common methods used for cereal cooking are listed here: Batch cooking Conventional extrusion Twin screw Single screw In extrusion cooking several steps are combined in a single continuous unit, which offers several advanHowever, little difficulty will be experi- tages to cereal manufacturers, resulting in enced if it is remembered that cereals should making it a more economical method than always be allowed to cook until they can be traditional cereal cooking processes. readily crushed between the fingers, but not Recently, a new twin-screw extruder until they are mushy in consistency. called ‘Thermal Twin Extruder’ has been There are different cooking methods, introduced in the market, which can cook which the industry can use to cook cereal cereals better and more efficiently. grains. Some of the main differences between traditional twin screw and thermal twin screw are: Increased extruder barrel volume allows increased levels of thermal energy addition Increased thermal energy reduces the level of mechanical shear required for cooking Reduced mechanical shear results in less breakdown of the starch chains Less mechanical starch Figure 4 Shows samples that have been cooked damage gives a product using thermal twin-screw extruder with reduced ‘stickiness’ The new thermal twinThe method of cooking depends on the screw (see Figure 1) extruder offers a unique finished product and the objectives of the screw profile with single flight and variable cereal cooking. pitch. It also has a large volume steam injecFor animal feeding, cooking can be done tor with 45 degree angle and screw speeds simply by heating the cereals using a toaster up to 700rpm (see Figure 2). Traditional extrusion cooking of cereal grains results in mechanical damage to the starch granules giving varying levels of cold water soluble starch and depressed final viscosities. Figure 3 shows the RVA comparison between whole corn flour and extruded material that has been highly sheared. The extruded sample shown in the RVA data had thermal to mechanical energy Figure 6: Light microscopy of extruded samples ratios of 0.25:1. Figure 5 Shows the results after hydrating extruded samples

24 | July - August 2011

Energy inputs lowered With the new thermal twin-screw cooking system the specific mechanical energy inputs can be lowered dramatically when extrusion cooking cereal grains. The cereal grains can still be completely cooked, but since the primary energy source is thermal energy the amount of starch damage is significantly reduced. Figure 4 shows samples that have been cooked using this system in which the thermal energy to mechanical energy ratio is at least 4:1 and as high as 25:1. The starch gelatinization levels of the thermally extruded and cooked samples can be controlled from 50 to 95 percent by varying the level of direct steam injection. Even with the high levels of gelatinization there is limited coldwater viscosity for the samples. Figure 5 shows the results after hydrating these samples. The beakers in the photo contain samples 1, 2, and 3 (shown in order from left to right). These samples were allowed to sit for one hour then gently stirred before taking the photo. The lowest cook sample gave the cloudiest water and fell apart. The highest cook sample had relatively clear water and good particle integrity. After hydration this sample was spongy and had a texture that could be pulled apart. It is important to note that the sample held together and did not fall apart even with the addition of the mechanical agitation. This would indicate that the starch in sample three was well cooked. Even though sample three is highly cooked, it does not become sticky upon hydration. High levels of thermal energy do not disrupt the starch granules to the same extent as mechanical shear and therefore the product remains non-sticky even after hydration.

Light microscope These samples were also examined under a light microscope (see Figure 6). The first micrograph is from the highly sheared corn flour. As you can see there is no ordered structure in the sample, which is what one would typically expect in a highly sheared extruded sample. Figure 6 is of sample one. The sample still has some intact and uncooked starch granules. As the amount of thermal energy to the extruder was increased for sample two, the individual granules disappeared. There is still some ordered structure, which most likely indicates intact cell walls. The final sample, sample three, has a more disrupted structure than the previous samples, but there is still an ordered appearance to the cereal grain structure.

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Twin screw extrusion technology to produce breakfast cereal a flexible & sustainable solution

by Anne-Sophie Le Corre, Process manager at Clextral Inc R&D center, Tampa, Florida, USA


lextral pioneered twin-screw extrusion technology for breakfast cereals in the early 1970s, introducing a process that was faster, simpler and more economical than the traditional batch processes. The advantages of the twin-screw extrusion technology compared to the traditional processes are many and include: faster manufacturing time (15 to 30 minutes for extrusion cooking versus six to 10 hours for traditional process) with less energy consumed; reduced space requirements; continuous and automated production system allowing easier traceability; quick start up, shut down and cleaning procedures; possibility to switch easily from one product to another; simplified maintenance; very large range of processed raw ingredients; and consistency of product quality. Analyses like Rapid Visco Analyser (RVA) and texture and acoustical emission have been useful in the characterisation of commercial corn flakes produced by traditional process versus twin-screw extrusion technology. Thanks to these techniques, it has been demonstrated that commercial corn flakes produced by traditional process and twin-screw extrusion technology present similar profiles and sensory analyses.

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Twin-screw extrusion Twin-screw extruders (TSE) are processing machines consisting of two identical co-rotation, intermeshing, self-wiping screw profiles operating within a closed barrel. During extrusion the materials is forced to flow under controlled conditions along the length of the extruder barrel and through a

thermomechanical cooking factors, including technology design (screw profile, L/D of the machine) and operating conditions (screw speed, temperature profile, water content, dry mix rate); and die texturisation factors (die design, insert shape, opening section). Using a complex combination of all these variables allows the production of a wide vari-

shaped opening (also called die assembly) at a defined throughput. TSE can perform various functions including feeding, conveying, mixing, forming, compression, hydration, heat transfer, shaping and cooking. Variables that influence extrusion process can be separated into three main components: raw materials composition and formulation;

ety of products in a range of shapes, sizes, bulk densities and textures. Because of its operating mechanism, TSE offers many more advantages compared to single screw extruders. The TSE is a continuous mixer/cooker/former, which performs a positive pump action; it can operate at high pressures and high moisture levels and does

July - August 2011 | 25

FEATURE not rely on internal friction between screws and barrel to convey the cooked mass towards the die. It can process a variety of particle sizes and variety of raw materials composition while maintaining uniform product shear and production flow. In addition to the basic features the TSE can offer, some extruders manufacturers offer many advantages to enhance flexibility including

hydraulic opening of the barrel, quick access to the screw profile, quick and automated change of die assembly, and quick adjustment of ancillary equipments. Due to the versatility of the twin screw extruders, flaked or expanded products made from various grains are easily produced in the same plant, using the same extruder and barrel configuration and ancillary equipment upstream (feeder, preconditioner, liquid injection) and downstream (flaker, toaster, coating unit). The major steps in the breakfast cereal complete line process include:

Raw materials handling and premix station Raw materials handling presents a range of options from sack tip to fully automatic bulk systems. Typical mixers for dry mixes are ribbon mixers, also called horizontal batch mixers. The blender delivers the mix to a surge hopper. Then, it passes through a metal detector, and is fed continuously and uniformly to the extruder platform through a loss-inweight feeder or a volumetric feeder.

Preconditioning a modular barrel design, accurate temperature and shear devices, automatic barrel opening for easy access to screw profile, and computerized operation and control.

Direct expanded and indirect expanded The products obtained with twin-screw extrusion technology can be divided into two sections: the direct expanded products and the indirect expanded products. The direct expanded product is an extruded product that expands just after the die, due to moisture flash-off. Configuration of direct expanded implies high shear level screw profile, high temperature and low water content. The indirect expanded product does not expand after the die, but later during post operations. Extruder configuration for indirect expanded product usually includes a first step that allows a perfect cooking of the starch components and then a cooling section that controls the expansion at the end of the machine. The change of configuration between direct expanded and indirect expanded products can be done very easily and quickly while performing other maintenance requirements on the line. It usually requires a slight change to the screw profile, the die and a few ancillary devices. These set-up changes are made very easily thanks to equipment features such as the

26 | July - August 2011

Preconditioning essentially involves heating and prehumidifying the raw materials to start the gelatinization of the starch. The preconditioner has two shafts fitted with variable pitch blades that stir the material and move it towards the outlet. The shafts are usually contra-rotating. The configuration of the blades and the speed of rotation play an important role in the quality of the mixture dispersion. During preconditioning, the mix is humidified by spraying water into the preconditioner via nozzles. Other types of liquids (colors or malt syrup, for example) can be added via different injection ports, at different steps into the preconditioner. The mix is preheated at the same time by steam injection via multiple injectors.

tion, which combined with the screw speed variable (200-450 rpm), allows the right level of thermomechanical cooking on starch component. The time-temperature-shear history in the screw-barrel assembly determines the expansion ratio at the die as well as the textural quality of the products. If desired, liquids may be simultaneously added through a metering pump to add specific characteristics to the final product. For example, in the case of crisp rice or corn flakes, sugar-based malt syrup is added along the barrel to reinforce the toasted taste of the end product. The temperature is accurately controlled in each section of the modular barrel by internal cooling channels and external heating elements. The dough coming out of the die presents different levels of expansion depending on the targeted product and the process conditions. It can be die face cut (usually, but not exclusively, for direct expanded products) or indirect cut thanks to post cutting system (usually, but not exclusively, for indirect expanded products).

Tempering and flaking (for flakes only) In the case of the flake process, a tempering zone may be added between the extrusion process and the flaking unit. This stage may be essential to separate the pellets that would otherwise stick together and to allow control of the dwell time before flaking. After the tempering unit, the pellets are flaked between two chilled steel rollers. Adjusting the roll pressure on the product controls product specifications such as stickiness, thickness and surface characteristics.

Toasting/drying The direct expanded products coming from the extruder or the flakes from the flaking rolls are fed into the dryer/toaster to reduce the

Extruding, forming and shaping After preconditioning, the mix continuously enters the twin screw extruder. Twin screw extrusion cooks the ingredients with a combination of heat, mechanical shear and added moisture. Water is added to reach the appropriate moisture content (15-25 percent depending of the product). The extruder is equipped with a high shear screw configura-

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FEATURE moisture to three percent and to give toasted taste to specific products. With toasted products an air-impingement dryer is usually chosen, which aims to fluidizing the product, and optimises the contact between hot air and cereal. Temperature and residence time can be adjusted for each product. During this heat

added simultaneously to sugar coating to finetune product characteristics. Coating of product is usually associated with additional drying of the product (and particularly drying of the thin surface of sugarsyrup applied on the product). This drying can take place at the same time of the coating (Coater-Dryer) or continuously in an additional belt dryer, just after the coating.

“We wanted a very flexible and multi purpose line as we provide high quality direct expanded cereals, flakes cereals and co-extruded products” treatment, the flakes develop their specific blistering, crisp texture, flavor and color. Direct expanded products are traditionally dried in belt drying technology, but can be also dried with an air-impingement drying technique. For some specific products, such as the crisp rice, this technique allows a quick Maillard reaction to develop and give the right quality profile to the final product in terms of texture, taste and surface color. Then, dried cereals are conveyed to a sifter to eliminate fines, and to the coating/cooling unit when necessary.

to approximately room temperature by convective heat transfer. They are then packed in the desire package, thanks to multi-weighing units linked to vertical baggers and vertical cartooning machines.


According to a breakfast cereal manufacturer using twin-screw extruders, “We wanted a very flexible and multi purpose line as we provide high quality direct expanded cereals, flakes cereals and co-extruded products.”

The dried or tasted products may be fed to a coating unit where a sugar-syrup preparation is applied in the required proportion (10-35 percent of final product, depending on the country and type of products). The spraying system of the coating equipment is designed to ensure optimum contact between product and sugar syrup. The temperature and Brix degree are adjusted to control the surface aspect of the coating (from shiny to glassy surface appearance, according to market requirements). Dry additives can be

Twin Screw Extrusion and Drying Technologies

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Before entering the packing units, the products are cooled down

Save money and improve quality


Food & Feed Processing Lines



Due to the versatility of the twin-screw extruders, flaked or expanded products made from various grains are easily produced in the same plant, using the same complete line from the mixer of raw materials to the packaging units. Simple clip-on modules can be easily and quickly added to this unique line, allowing the launch of innovative products such as multi-colors, multiple shapes, co-extruded, or multigrain products. Complete lines using twin-screw extrusion bring reactivity and flexibility to cereal manufacturers and thus open the door to short term and reactive innovation.

Use superior analyzers • Immediate analysis at raw material intake • Grain and flour functional testing • Verify finished product quality Used by leading companies all around the world. Read more at

IM 9500 Whole Grain analyzer

Meet us at 2-5 oct 2011 Dead Sea, Jordan - Stand 32

(+33) 04 77 40 31 31 July - August 2011 | 27


Cultura Technologies’ MillMaster Cultura Technologies’ MillMaster provides unrivalled and comprehensive process control links to systems supplied by companies such as Datastor, DSL, Promtek and others, enabling the operator to eliminate costly errors encountered with manual and basic interfaces whilst at the same time providing a detailed analysis of production performance.


he communication process is two-way: MillMaster being the master source for data such as raw materials, product and additive formulations, production plans, product labelling details, cross-contamination rules and intakes. The process control system returns details on: • Production plan status • Target and actual raw material usage (including raw material batch numbers where applicable) • Finished product batch detail • Press data including liquids • Moisture • Batch stocks and plant downtime As data is only entered once, operators can be certain that information is consistent across all systems. For example, if all formulations can only be amended via the Formula Storage Module, and then downloaded to process control, there is proper control of the nutritional analysis, labels and costs. However, if formulations are changed ‘in flight’ on process control, no such controls exist.

Raw material MillMaster transfers details of any new raw materials directly to process control systems, ensuring both databases are kept in line. Once the arrival of a raw material intake is recorded within MillMaster, details of the expected weights are transmitted to process 28 | July - August 2011

control. Assuming the intake is accepted, once the load has been tipped and the tare weights entered into MillMaster, the final net weight of the load is submitted to process control in order to keep the stock balances in line. For batch tracked materials, batch numbers and expiry dates can be transmitted to process control.

Product and additive formulations

on forward sales order and stock requirements. During the plan creation process operators are able to verify the manufacturing sequence against the same set of sophisticated cross-contamination rules used within MillMaster and process control. Once a production plan has been submitted to process control, an online dialogue between the two systems captures and transmits any changes to the plan and also updates the current plan status.

Approved mill-ready formulations held within the MillMaster Formula Storage Production batches Module can be automatically transferred to During the production process, the procprocess control, eliminating potential errors ess control system collates and transfers during manual entry and reducing delays in ‘real-time’ batch and press data to MillMaster waiting for formulae to be added. for analysis. Along with details of the finPlant-specific production data such as ished product batch weights, raw material micro-ingredients, tip point, grinder screen usage and raw material batch numbers any and target moisture can be maintained and operator changes made on process control downloaded with each new formula version. Each formula can have an We have activation date the missing and time, allowpiece ing formulations to be prepared With over 30 years of experience in the Feed Industry in advance.

Production planning Production plans can be created based

Complete Mill Control • Legacy System Upgrades • Trending, Historic & Real Time Data • In-line/On-line Moisture Monitoring and Control • Integration with Nutritional and Business Systems • Micro Ingredient Hand Weighing Solutions • Energy Monitoring and Control • Labeling & Bar code Systems Please visit our website @ or telephone +44 (0) 01260 277025

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Cultura Technologies Tel: +44 1473 744000 Email: Website:

to the base formulation transferred by MillMaster (such as raw material substitutions), will be transmitted back, against which, a sub-version of the formula will be created. Details of target and actual moisture inclusion can also be transferred back into MillMaster.

Press runs Actual fat and molasses usages are captured for the whole run and once complete are apportioned back into the individual production batches, thus allowing accurate costing of liquid raw materials.


Control systems for Animal Feed, Flour, Pet Food, and Premix Plants

Downtime and events Downtime details and any other events recorded within process control are captured and transmitted to MillMaster, which together with any additional details you enter manually, provide the total picture of the shift via the production diary module.

Bulk outloading Details of sales orders are automatically downloaded from MillMaster, ready for despatch by the bulk outloading system. Any subsequent order amendments are updated to process control, to ensure that both systems are kept in line. Once an order line has been physically loaded, MillMaster immediately receives the bulk outloading details from process control. When all order line details have been received, MillMaster will automatically despatch the order and produce a delivery note, incorporating the weighbridge details and statutory declaration.

Stock balances and adjustments Physical stock counts can be recorded within MillMaster and where applicable can be by batch number. The raw material stock balances can be requested from the process control system and any adjustments applied as a result of the manual count will be applied to both systems. Details of raw materials despatched through MillMaster are transmitted to process control, in order that the stock records are decremented accordingly.

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“DSL were selected based on the fact they used the latest technology and were regarded as the best available”

William McAusland – Production Director, Fane Valley Feeds

“Changing to DSL’s AutoPilot4Feed was the best thing we ever did.” Tom Rylands - Managing Director, M. E. Waterhouse

DSL Systems, Adbolton Lane, West Bridgford, Nottingham NG2 5AS, England T: +44 (0) 115 981 3700 | |

July - August 2011 | 29

PRODUCT SHOWCASE - 2011 GranifrigorTM Cooling Units

AutoPilot4Feed process control and information system

For 50 years, FrigorTec GmbH - formerly part of Sulzer-Escher Wyss GmbH and later on Axima Refrigeration - produces and distributes cooling units worldwide for industrial and food applications.

AutoPilot4Feed is an advanced process control and information system designed specifically for Animal Feed Mills, Premix Plants, Pet Food Plants, Flour Mills, Biomass Plants and Liquid Tank Farms. Specific benefits of installing an AutoPilot4Feed control system include: • Reliable systems with built-in redundancy • Optimise production and increase throughput • Responsive 24 hour 7 day support • Simple and intuitive operation • Fully configurable, flexible and modern systems • Reduce energy consumption • Low maintenance - modern software and off the shelf hardware • Comprehensive long term recording of all information • Improve regulatory compliance • Reduce operator workload • Cost effective upgrades from older systems with minimal downtime • Seamless integration with commercial and finance systems

The GRANIFRIGORTM cooling units are designed specifically for ecological grain preservation. For the various climatic zones the GRANIFRIGORTM Tropic Series and the Desert Type are making the different unit types perfectly complete. All units are manufactured by our skilled workers in our factory in Amtzell/ Germany.

Nivobob 4000 The most cost effective content measurement available. Designed to withstand material properties such as conductivity, dust, di-electricity Engineered for direct mounting on pitched silo roofs. Easy installation and maintenance-free operation. Simple and reliable measuring principle. Suitable in hazardous locations (dust explosion). ATEX certified. Multi-language software menu. Nivobob 4000 has been developed to perform in demanding conditions. It is particularly suitable for the building, animal feed and grain industry

30 | July - August 2011 | T: +44 115 981 3700

Universal Voltage UWT UK Ltd rotating paddle switches Rotonivo RN3000, RN6000 and RN4000 are now available with universal voltage electronics. These level switches can now be used throughout in the world regardless of the country’s input voltage system, without the need for manual alteration to the switch. The instrument detects the input voltage and makes the necessary adjustments automatically. Manufacturers and suppliers can now order one switch, under one part number, for all applications in all countries. Automatic Dampening System Accurate moisture control of free flowing grain including, wheat, barley, oats, maize and malt. Sold to over 700 mills worldwide this automatic system delivers an effective and reliable method of moisture control. This product is just one of a series of inline control products from Suffolk Automation which include NIR analysis, continuous weighing and batching and moisture control technology. For full product details visit our website: products

Econase XT Econase XT is the first and only intrinsically thermostable xylanase enzyme on the market. It is a successful example of an enzyme which has been specifically developed for use in pig and poultry diets based on corn or wheat. In trials, the product has been quantitatively analysed in feeds conditioned up to 95°C (203°F) for 30 seconds followed by pelleting. It also shows outstanding efficacy in animal trials.

The AB Vista team work together to achieve outstanding results. As a leading international supplier of new generation micro-ingredients for the animal feed industry, AB Vista realise the importance of individual performance alongside strong teamwork, both within your business and with your suppliers. Visit our website and contact us to find out just how being part of a team with AB Vista could benefit your business.

Tel: 01473 829188

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Finase EC

Quantum XT

Silo 42 m.diameter

Finase EC is our second generation 6-phytase from E.coli, meaning that it is highly active under the conditions found in the intestine in the short time that it stays in the gut. Finase EC results in:

Quantum XT is a third generation phytase which:

Overcoming highest feed global demand ever, is Symaga’s first commitment and to reach this goal our production has tripled in the last 3 years.

• Works across the pH range found in the upper GI tract

• Improvements in feed conversion ratios

Quantum XT has superior gastric stability, a highly targeted mode of action and intrinsic thermo-tolerance. It goes beyond increased phosphorus uptake to release the full nutritional value of your diets.

It is our Reliability which has lead us to become one of the top silos manufacturer company worldwide, but it is our aim to keep creating more and more value to our customers, and for this reason we have always incorporated the most modern machinery in the market to our production lines, implementing new quality control systems as well as developing new products, such as our silo 42 m.diameter, which is currently under development.

CONSERFRÍO® grain chiller

Smart storage

STIF bulk material handling

Consergra, S.L. is a specialist in grain conservation, and manufactures the CONSERFRÍO® grain chiller. It’s a modern, highly energy-efficiency cooler which helps to conserve a wide variety of grains, seeds, oily and granulated perishable items stored in silos and warehouses. Its use, independently of climatic conditions, prevents shrinkages of weight, rotting, insects damage and toxin build up. The conservation with the CONSERFRÍO® is natural and highly cost-effective, the pay-back on the investment is extremely fast. Our units, installed all over the world preserve millions of tons of grain every season. Our product range covers from 40 up to 500 ton per day, per machine. Consergra, S.L. puts their 50 years experience at your service!

SCE, Silo Construction and Engineering, of Belgium earned its merits in the human food and animal feed industry all over the world with its money saving dosing, storage and bulk silos.

STIF is a leading manufacturer of components for the bulk material handling industry.

• Is intrinsically thermo-tolerant so begins working faster than coated phytases

• Improved phosphate availability • Improved further phytate-bound nutrient availability

• Delivers significantly improved nutrient utilisation The AB Vista team work together to achieve outstanding results. As a leading international supplier of new generation micro-ingredients for the animal feed industry, AB Vista realise the importance of individual performance alongside strong teamwork, both within your business and with your suppliers. Visit our website and contact us to find out just how being part of a team with AB Vista could benefit your business.

• Reduced environmental impact from phosphate excreted by poultry

• Consistently improves performance for a greater ROI

The AB Vista team work together to achieve outstanding results. As a leading international supplier of new generation micro-ingredients for the animal feed industry, AB Vista realise the importance of individual performance alongside strong teamwork, both within your business and with your suppliers. Visit our website and contact us to find out just how being part of a team with AB Vista could benefit your business.

• Improvements in live weight gain

Turnkey engineering solutions Expert in twin-screw extrusion and drying, Clextral supplies turnkey engineering solutions and services for the food & feed industries. The applications include breakfast cereals, savoury & sweet snacks & pellets, co-extruded products, flat crispy bread, croutons, baby food, functional ingredients, pasta products, couscous semolina, pet food & aquaculture feeds,... Extrusion & drying complete lines for the food industry

Clextral international skilled teams assist food manufacturers in meeting new markets requirements continuously striving to improve the processes and seeking sustainable solutions.

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The easy to install modular bins have smooth walls and are rectangular, consequently are far less wasteful of space. Functional design and practical advice in the field of silo construction are of crucial importance. Every project is therefore custom made.

6 sec compositional analysis DA 7200 NIR analyzer makes it possible. Using our complete Calibration Packages for grain, flour and feed accurate results are available without hassle. It is very easy to use and could be placed At-line. The DA 7300 complements the bench top system using the same technology platform for On-line analysis and with the same calibrations.

Our main products are pressed steel and plastic elevator buckets, rubber elevator belts, compression coupling (for pneumatic handling), slide-valve and diverter valve (grain handling), safety valve and manholes, and our new product range: the Explosion Vent Panel VIGILEX ( Our new products are: • Atex approved plastic elevator buckets • White rubber FDA + Atex ISO340 approved elevator belt - The bucket elevator dedicated range of Monitoring System. Under speed monitor and belt alignment devices • EC certified curved explosion vent panel VM-R.

Flat bottom silos Diameter Ø4,58m. Up to 32,08m. Max capacity 19.000 tonnes/22.000m3

Commercial hopper silos Diameter Ø4,58m. Up to 11,00m. Max capacity 1.500 tonnes/2.800m3

Economic hopper silos Diameter Ø3,66m. Up to 6,41m. Max capacity 180 tonnes/216m3

Feed Silos Diameter Ø1,83-2,14-2,83m. from 2 tonne up to 22.5 tonne

July - August 2011 | 31

Brabender® FarinographAT und Kernelyzer

Satake’s AlphaScan optical sorter

The new Brabender® Farinograph-AT with tempered, automatic water dosing optimizes the quality control, research and development. Infinitely adjustable speeds and various kneading and mixing systems offer a wide range of applications venues, such as the simulation of one mixing profile of a production mixer. The standards of the AACC, ICC and ISO will continue to be met.

Satake’s AlphaScan optical sorter is a dedicated grain & seed sorter that matches each individual’s requirements to remove discoloured contaminants. This affordable sorter will enable you to produce the cleanest product in a compact, small footprint, with high capacities whilst using high speed digital signal processing technology.

The Brabender® Kernelyzer-F based on NIR offers fast, accurate results. Simple operation, sample preparation and administration of their own calibrations make him an indispensable part of quality control.

It is ideally suited for cereals, rice, seeds (mustard, rape etc) at capacities up to 35 tonnes/hour. Grains are cleaned to remove contaminants such as ergot, foreign seeds, broken seeds, wild oats and many other impurities.

The Double Rollermill

Working Flour Mill for Sale

It is an inevitable machine in grinding sections of flourmills. In these rollermills with eight balls, the ball mechanisms having two power contacts are mounted directly one on the other. Its usage easier and efficient than the other roller mills by the help of special air circulation and its being real pneumatic so it prevents to leakage of product outside and provides to cooling of milling rollers during operation.

Intake Plant with 3 off 20 ton feed hoppers and intermediate process hoppers with interconnecting conveyors to suit the whole plant.

• • • • •

• Damas Feed Cereal Cleaner - Conditioner • 3 off Skiold Horizontal Stone Mills • Rotary Sifter • 4 off Break Rolls plus Cyclones • 4 off Finishing Roller Mills plus Cyclones • Rectangular Sifter • 1.2 ton Skiold Unimix Mixer • Flour Sack Packer • Associated Control Equipment to suit process

Atlas AM Elevator bucket 4B’s new heavy duty Atlas AM Nyrim elevator bucket has excellent surface resistivity dissipating properties, thanks to its antistatic material, making it ideal for ATEX applications. The bucket’s non-stick properties are enhanced by its smooth surface finish and open design. The Atlas AM is a very tough, long life elevator bucket with ultra heavy duty design and construction; the material makes this bucket up to 6 times stronger than other industrial elevator buckets. A very versatile elevator bucket, the Atlas AM is suitable for heavy industrial applications as well as grain and sticky materials.

Milleral Multimilla Multimilla offers new trends in roller mill design. Multimilla is introduced for effective results in grain milling. Roll Change in 20 minutes Maintenance and roll change time is minimized with new design roll pack. Easy Operation and Maintenance Dismantling and maintenance is very easy with our front cover that can be opened completely and new modular system feeding roll packs. The central lubrication system enables lubrication of roll housings from a single point even while the roller mill is operating. High Sanitation and Product Safety Stainless steel is used for surfaces in contact with food to provide the best possible hygienic working environment.

Including an all new useful information section Thousands of industry related products and services listed Over 1000 companies with full up-to-date information International Organisations Our improved equipment comparison section Now including: - Coolers & Dryers - Elevator Buckets - Extruders & Expanders - Hammermills - Mixers & Grinders - Pellet Presses

2011/12 OUT NOW

32 | July - August 2011

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Taking the first step

How to help yourself and others develop the love and understanding of flour milling by Nigel Bennett, Secretary, NABIM, United Kingdom



e regularly advertise nabim’s distance learning programme in flour milling ‘seven steps to success’.

Not that clever (there are seven modules, and most people like an alliterative headline) but it is intended to do more than just attract the eye. We do regard the courses as being stepping stones to an understanding of milling - and for many people, the more they understand it, the more they love it. That is why, in an age when the majority of people in the UK are expected to switch careers several times during their working life, many flour millers still don’t leave until the day they retire - and some have been known to stick around even longer than that! Though designed, developed and delivered in the UK, British students are by no means the only beneficiaries. These courses continue to be used around the world. By the time you read this, the pass lists for the May 2011 examinations will have been published; they will feature the names of successful students from over 20 different countries, spread across five continents. We believe that the distance learning programme can, amongst other things: teach the basics of working in a mill environment, including an appreciation of the safety of both product and people; introduce the concepts and machines used in the milling process; address the means by which wheat, mill stocks and flour may be conveyed and stored; develop an understanding of flour 34 | July - August 2011

quality and its control; provide an introduction to breadmaking and other uses of flour; and encourage the student to think about the management of the whole operation of a flour mill.

Tutor & mentor For each module, the student is allocated one tutor, a miller himself, who provides guidance and advice on the coursework. However, we believe that an important complement to the tutor’s help is that the student’s sponsor, normally a milling company, appoints someone within the company to act as their mentor. The mentor should be someone close at hand, who encourages the student to participate fully in the course and maximise the value both of the employer’s financial investment and the student’s investment of time. The mentor should also take responsibility for ensuring access for the student to relevant areas of the site, even if they do not feature in the student’s regular responsibilities at work. The role of the mentor is akin to the parent helping the child to read; schoolteachers may provide expert tuition, but without the encouragement and support of the parent at home, providing opportunities for the child to practise their reading, success will be limited. Provided with the right learning environment, however, the child will learn to read more quickly and develop an appetite for reading, keen for exposure to more and more stories. Anyone involved in training has to remember - and it is a difficult skill to master - what it was like when one didn’t know (or

couldn’t do) something. If we switch the analogy from reading to walking, taking one step is not much of a challenge for an adult; but, for a child, their first step is a significant achievement (which also brings a surprising degree of delight to their parent/mentor!). So nabim’s distance learning programme is designed to take the student through the whole syllabus, one step at a time. Each of the seven modules is taught in four separate lessons, working their way through the textbook. By allocating one tutor to each student for the whole module, the tutor is better able to gauge the level of understanding of the student; by building a relationship, the student is encouraged to produce work for the tutor and to ask for guidance when understanding proves difficult.

Milling in bite-size chuncks Readers of a certain age may recall that the student of the 1980s was faced with learning from two formidable textbooks (‘The Practice of Flour Milling’) covering a similar amount of knowledge as is found within the seven modules. I can imagine students sitting down to their first piece of coursework, feeling somewhat discouraged as they opened the tome of over 600 pages of small type. Small steps (or bite-size chunks to change the activity again) are better, encouraging the student to love learning. I have heard it said that ‘life isn’t fair’, because students of today have it easier than past millers. I have heard it said more recently that the online complementary materials we are developing are similarly unfair because

&feed milling technology



Laurie (in pre-House days). A mentor is supposedly training a new employee but is really just standing by, letting them learn by trial and error, and criticising when they get it wrong. “Why don’t you show them the correct way?” the mentor is asked. “No-one ever showed me” comes the reply, “why should they have life any easier?” “But” replies Mr Laurie, “wouldn’t they learn more quickly if you did? And wouldn’t that make your life easier too?”. The penny drops Our working lives are generally easier, less frustrating and more rewarding, when those who work with us and for us know what they are doing. (Hopefully, your boss feels the same way, having experienced the ‘penny drop’ described above.) If the people reporting to you are developing a love and understanding of milling, nurtured by yourself and others, supported hopefully by the nabim distance learning programme, then you are going to find a lot more enjoyment from your work than you otherwise would. they make topics easier to understand. This is a strange argument! I recall a training video about mentoring, produced by Video Arts and starring Hugh

Three steps

people in our courses; volunteer to be their mentor; don’t waste the opportunity you and they have signed up for. As you help to develop someone’s love and understanding of milling, it is very likely that you will strengthen, perhaps even rekindle, your own love; who knows, you may even learn (or re-learn) something yourself. Details of the 2011-12 course programme can be downloaded from the nabim website, at: correspondence-courses.html. Alternatively, send an email with any questions to: info@



NABIM 21 Arlington Street London, SW1A 1RN UK Tel: +44 20 74932521 Email: Web:

So, here are three steps for you to take over the coming weeks: enrol one or more

Flour Milling Training Seven Steps to Success

 Internationally recognised distance learning programme  Developed for millers by industry professionals

Hygiene, Health and Safety

 Studied every year by hundreds of millers worldwide

Wheat and the Screenroom

An indispensable tool for developing the knowledge and

Mill Processes and Performance Product Handling, Storage and Distribution

competence of flour millers and their colleagues. A clear presentation of the industry and process, in 7 modules. Dedicated tutor support given to every student, providing professional guidance throughout the course year.

Flour Course Fees 2011-12

Power and Automation

The cost per module is: £310 (+ VAT at 20% where applicable) includes postage, textbook and exam registration nabim Members: £210 per module (a discount of £100)

Flour Milling Management

Non-UK Companies: £260 per module (a discount of £50)

To enrol or find out more, contact:

nabim 21 Arlington Street London SW1A 1RN UK Tel: +44 (0)20 7493 2521 Fax: +44 (0)20 7493 6785 email:

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July - August 2011 | 35



here’s more to come from the use of phytase in pig and poultry diets. Much more.

That was the message received loud and clear by delegates at the 1st International Phytase Symposium held in Washington DC at the end of September 2010, with AB Vista managing director Richard Cooper suggesting that another US$2bn of benefit could still be available to the feed and animal production industries. “The phytase enzyme market is one of the massive success stories of the last two decades – it’s a US$350m market generating a benefit to the animal feed industry worth US$2bn globally,” he stated. “But I believe we’re now at a point of change, and the destruction of phytate in monogastric diets could be worth another US$2bn to the industry.” The IPS was jointly hosted by AB Vista, Massey University, the University of Maryland and the University of Sydney, and brought together scientists from all aspects of phytase research, development and application. A wide range of topics were presented and discussed, but it was the opportunity to make better use of the current commercially available phytase enzymes that took centre stage on the second day of the symposium. 36 | July - August 2011

As Mr Cooper outlined, the industry has produce more food, more sustainably, from previously concentrated primarily on the less land.” Highlighting the value of just one of the potential to release phosphorus bound to extra-phosphoric effects of phytase enzymes phytates in plant-derived feedstuffs. However, he claimed that the future (that is in addition to the release of phosphorus held increased use of phytase enzymes for from plant phytates), Associate Professor Aaron phytate destruction through ‘superdosing’ Cowieson of the University of Sydney, discussed (>1500 FTU phytase/kg diet as meas- the impact on amino acid digestibility. It is a ured at pH3.0), environmental protection (for example reduced mineral excretion), animal welfare (e.g. improved bone strength) and feed processing improvements (for example increased pelleting throughput). “As for the future, we can’t stand still,” he stated. “The animal food industry Figure 1 – Matrix values for improved amino acid digestibility is under a lot from phytase use (Quantum®) of pressure to

&feed milling technology



Figure 2 – Impact of phytase addition on cation digestibility in pigs a) Phosphorus, calcium, sodium, potassium, magnesium b) Copper, zinc

benefit now recognised as being extremely important nutritionally, with the potential to add further economic value to phytase use even at standard (non-superdosing) levels of inclusion if accounted for during diet formulation. To demonstrate the extent of the effect, he presented an initial set of matrix values for amino acids for AB Vista’s phytase enzyme, Quantum® (at 500ftu/kg diet, as measured at pH 5.5), shown in Figure 1.

Strongest for cysteine, glycine, serine, threonine and proline, the effect varied considerably between individual amino acids. Associate Professor Cowieson noted in particular the lower responses for methionine and lysine, which are typically well digested even in the absence of phytase. It was clear that the incorporation of these additional effects of phytase enzymes – generally the result of improved diges-

Grain cooling

GRANIFRIGOR™ The most natural way of grain preservation:

• Protection against insects and microbes • Without chemical treatment

tive efficiency due to phytate destruction – would be of value to the majority of pig and poultry producers. However, incorporation into commercial diet formulations would not be straightforward. In addition to the effects on amino acid digestibility presented by Associate Professor Cowieson, the potential for improved availability of a wide range of mineral cations was high-

GFM04 Mog65th#3 Spread 132x90:GFMT 132x90 01/02/2011 13:35 Page 1

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Figure 3 – Impact of dietary calcium level on mineral cation digestibility response to phytase Figure 4 – Value of superdosing with phytase (Quantum®) in pig starter diets

lighted by Dr Age Jongbloed of Wageningen UR, in The Netherlands. Plant phytates bind with a wide range of cations, he explained, with mineral digestibility improved differentially as phytase dose is raised (see Figure 2).

Digestibility responses vary Dr Jongbloed also discussed the extensive interactions that take place between the 38 | July - August 2011

different minerals. Using data from trials feeding diets containing different levels of dietary calcium, he demonstrated that not only did digestibility response to phytase vary for each of the minerals examined, but that the nature of the trend differed also. However, it was AB Vista technical manager Dr Rob ten Doeschate who best summarised the extent of the challenges facing nutritionists wanting to fully incorporate the benefits of phytase enzymes into commercial diets. Reminding delegates that current diet formulation techniques rely on the nutrient levels within feed ingredients being both linear and additive, he stated: “This is a really big assumption.” In fact, the effect of phytase addition on nutrient release was not linear (as demonstrated by Figure 2), and probably not additive, he claimed, with a number of key interactions (for example the dietary calcium level effect shown in Figure 3) also having a substantial impact on the level of response. It was also highly probable that the combined effects when phytase is used alongside other feed enzymes (for example xylanase) is also not additive. Dr ten Doeschate went on to explain a number of techniques currently used to help overcome these limitations, although it was generally accepted that ongoing research would, in time, illuminate the finer details of many of

these interactions. At present, the non-linear nature of many of the responses meant relying heavily on the nutritionist’s expertise in adapting formulations in order to realise the full advantages of phytase use. When carrying out least-cost formulations for commercial pig diets, for example, the incorporation of phytase affected the

inclusion of more feed ingredients than would perhaps be expected. Even using the only matrix values for improved phosphorus digestibility, the extra ‘space’ in the ration – created by not having to add as much inorganic phosphorus – allowed inclusion of a greater proportion of lower-specification, and hence lower-cost, energy feeds. The result was a value, in terms of cost savings, that came from substantially more than just phosphorus. Typical changes included a reduction in oil and fat content, with a corresponding increase in cereal inclusion, and initial investigations had shown that savings available from using a full phytase matrix (incorporating values for improved amino acid and energy digestibility) could be two or three times higher than those achieved with the current mineral-only matrix. “So is phytase a mineral enzyme or something else?” questioned Dr ten Doeschate.

Superdosing The emergence of superdosing was the other big step towards increased economic benefit from phytase use, and IPS delegates were shown data confirming the extra value available. There were typically three options, Dr ten Doeschate explained, the first of which was to maximise the growth promoting benefits of phytate destruction, using the extra nutrient digestibility to boost performance (see Figure 4a). An alternative was to minimise ration cost for the same performance, using the improved digestibility to match existing diet specifications (see Figure 4b). The third option was to take the middle ground between these two extremes. Already being used commercially, superdosing in starter diets allowed the use of cheaper plant-derived protein sources such as soyabean meal to replace more expensive animal-derived feed ingredients. The inclusion of plasma, whey, milk and fishmeal naturally lowers the phytate level in young pig diets (animal tissues contain only small traces of phytate), but it is an effect that can now be more cost-effectively achieved by using high doses of phytase to destroy the phytate in plant-derived feed materials. “It is not as easy as it sounds,” concluded Dr ten Doeschate when summing up the challenges being faced in formulating diets to make better use of phytase. But the economic benefits to be gained from improved performance or reduced diet costs appear to be substantial, and improved matrix values and superdosing are already a reality. For the delegates at the IPS, it was clear that phytase enzymes have a very bright future. Further research and collaboration would inevitably shed light on those areas needing clarification in due course, opening up a whole range of new opportunities for commercial pig and poultry producers through the elimination of dietary phytate.

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Need to explain complicated software?

It’s a piece of cake

by David Evans, Head of Marketing, Format International, United Kingdom



hen it comes to formulation software, things can get complicatespecially on the inside.

Let’s face it; anything that can take a specification and calculate the least cost recipe from hundreds, sometimes thousands of ingredients requires some serious number crunching ability. But now Woking based software company Format International Ltd have launched something special. They call it Format iNDIGOTM and we’ve taken a quick look. The main thing you notice, whether you’re an end user or IT specialist is that iNDIGO looks like ‘normal software’. You feel instantly at home with the user interface, which is clean, crisp and inviting. Beta testers have reported taking to it like a duck to water. But with iNDIGO, beauty is far more than skin deep. The software has been developed using the very latest technologies available today for the .NET4 platform with C# being the primary underlying technology used throughout its architecture. The permanent data store is a SQL Server 2008 database and critically, the Windows Presentation Foundation (WPF) is used for the Graphical User Interface (GUI) definition (the windows and controls that the user sees on the screen).

40 | July - August 2011

WPF is one of Microsoft’s latest offerings for the development of a rich Window Forms type application. The networking and communication management is based on the Windows Communication Foundation (WCF), which consolidates and brings up to date the principal previous Microsoft networking protocols.

Layers of a cake Format iNDIGOTM has been developed as a multi layered architecture. Think of it as layers of a cake. Each layer has its specific purpose and is abstracted from the other layers. Each layer comprises several components each with their specific tasks and can be described from the bottom up as follows: ∙ SQL Server 2008 database: This is the permanent data store for iNDIGO and contains a series of database tables that relate to each other. These tables store the data seen within the application and also store ssmeta data; data that describes the nature of objects used in the system ∙ Data Access Layer (DAL): The DAL is responsible for all direct communication with the database and uses the Entity Framework model with an Object Relational Mapped (ORM) architecture. The essence of the ORM is the mapping of business objects directly to the

database tables. This results in many fewer lines of code in comparison to older, conventional methods for database communication. Importantly, the DAL ‘guards’ the database and maintains data integrity. It contains the data validation logic ∙ Business Logic (BL) layer: This layer contains the business rules of the system, and should not be confused with data validation logic. It is the collection of business processes, which make up the applications functionality ∙ Communications layer: This manages all communication between the business layer and the client. It may operate across an internal Intranet or the internet. One of several networking protocols may be used which include HTTP and TCP ∙ Client Layer: Contains the presentation logic and the graphical user interface (GUI) definition. Data is displayed according to the presentation logic and shown on the screen via ‘data binding’. The data binding binds the data to the controls and involves fewer lines of more efficient code compared to previous methods used to display data. The user interface is described by XAML files, which are read when the application is run. This allows the user interface to be changed dynamically

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is that they may be replaced by alternative layers in the future. For example the SQL database may be replaced by an Oracle database with a compatible DAL layer. Future developments of iNDIGO should see the client layer changing from WPF to Silverlight. This will allow for a rich internet application (RIA) that may be run from various devices including mobile phones for example. The user interface presents a rich application with high quality controls to improve the user experience. Subtle colouring and shadings are used which are pleasing to the eye. ‘Frills’ which have only recently come onto the software scene, such as gradient colouring and bevelled edges, are used throughout the interface. Dockable windows allow the user to arrange the windows as they desire to make optimum usage of their screen area. For the icing on the cake as far as the user experience goes, features such as task management, calendars and favourites; whilst a common occurrence within everyday office software and smart phones, have not traditionally been seen in formulation software. This introduction further aids workflow and boosts the overall efficiency of the user.


and supports user definability. The presentation logic defines how data is to be displayed and governs the windows shown.

May be replaced in future In addition to the layers above there is a module, which contains the definition of the business objects, which form the data model of the system. Instances of the business

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objects are passed from one layer to another and provide the vehicle for transporting data from the database to the user interface and vice versa. Each of the layers may communicate only with the layer above or below it. With the exception of the database layer, each has an interface, which the layer above uses to exchange data and pass requests. The advantage of the abstraction of the layers

The hardcoded functionality of iNDIGO is known as the core functionality and is delivered to all recipients. In addition to the core functionality, custom functionality may be implemented by altering the UI XAML files to provide custom interface controls. These controls are ‘powered’ by calling a VBScript file, which contains the custom operations. Custom functionality is provided on a consultancy basis and will usually be implemented by Format International for a client. However, clients may implement their own user definable functionality, in addition to the custom functionality, to achieve the desired behaviour for the application. Finally, there are many third party facilities on the market today for use with the .NET 4 platform. Powerful charting facilities are available for the most effective representation of data such as 3D contour charts for example. There are also many reporting facilities compatible with Microsoft SQL server and other third party facilities for viewing and editing XML files. Some of these will be procured and utilised where it is effective to do so, after all there is no point in ‘re-inventing the wheel’ and clients are able to use their own internal standard choice of these tools where they have one. So there you have it. A cake; beautiful on the outside and with each layer lovingly crafted. It meets the needs of management, IT personnel and users and for once, this cake is calorie free.

July - August 2011 | 41


Every issue GFMT’s market analyst John Buckley reviews world trading conditions which are impacting the full range of commodities used in food and feed production. His observations will influence your decision-making.

Light at the end of the tunnel for raw material costs?

Amid the rebound in Russian/other CIS supplies, the world market should easily cope with less EU exports and Europe itself will also avail itself of a lot of this cheap Black Sea wheat to keep upward pressure off its own feedgrain prices (Black Sea milling wheat was offered for export $25/35 cheaper than French in early July).

42 | July - August 2011


mproving supply outlooks, a retreat of speculative support and worries about the global economy recently drove wheat prices to their cheapest level for a year. Maize also fell in a switchback ride from all time record peaks to seven-month lows in one remarkable fortnight. Does this mean the bull market is over and that consumers can look forward to further declines in grain and feed input costs? The answer is a mixed one – encouraging for some market sectors but less certain for others – and with plenty of caveats yet – both from weather and the demand side of the market. Wheat has long been – and remains - a tale of two markets divided by quality. The worldwide shortage of high grade breadwheats this past year was real enough and merited a significant price response. The jury is still out on this year’s crops after wet weather delayed and downsized planting of spring wheat in North America but a repeat of last year’s pre-harvest weather disasters in so many countries for a second year running seems unlikely. For ordinary bread/feed wheats the supply situation - even with the loss of 30m tonnes to drought in the former Soviet Union last year - never really justified ordinary milling/feed wheat costs returning to the highs of 2008 as they did earlier this year. Markets are increasingly recognizing this anomaly and coming, as we forecast last year, about

halfway back to where they were before last year’s supply upsets. The fall in these ‘run of the mill’ bread/feed wheats might have been even steeper if not for record high maize prices and short barley crops, raising the intrinsic value of all grains as feed. Even after the recent price drop, coarse grains are still relatively expensive (maize is at highly unusual premiums to wheat on the US market). This may continue to prop up wheat to some extent, at least until we know more about the coming maize crop in the USA, the world’s largest supplier. The key development for wheat in July has been the return of the Russians, ending their export ban and already aggressively selling a barely harvested – but clearly recovered - crop on the world market, undercutting all rivals as they attempt to restore their role as reliable top suppliers. Better weather across the region means Ukraine and Kazakhstan also have more wheat to sell abroad and Ukraine has also relaxed export restrictions. Big crops are also coming onto the world market from past net importers, Pakistan and India. Against that, Western Europe has suffered a muted version of the droughts and heatwaves we saw in the Black Sea region last year and currently expects to see only a marginal gain rather than the originally hoped significant recovery in wheat production. Stocks have also been whittled down to supplement last year’s disappointing harvest as exporters cashed in on Russia’s absence as a competitor. Still, this year could have been far worse for the EU which at one time, was looking at possible 20% to 30% crop losses. Also, the EU’s principal source of high grade milling wheat, Germany, will hopefully get much better quality than it saw from last year’s rain-spoiled harvest - assuming recent untimely rain doesn’t set in the for too long. Given the lack of rain over much of its hard red winter wheat belt

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since planting time, the US also seems to be emerging with a better than expected crop of this principal export grade, well down in terms of yields and tonnage but with some good quality. However, both the US and Canada have had major problems with wet

weather holding up and downsizing their spring wheat plantings from earlier targets. With crops still developing late in both countries, a needed rebound in quality milling wheat supplies from this region may already have been compromised – although it should not be written off just yet. If Canada gets enough sunshine from now through to harvest’s end, it may yet end up with a higher proportion of milling quality wheat from a smaller than expected total crop, rather than the excess supplies of feed wheat that resulted from last year’s wet weather. If the North American spring wheat crops do fall short, the onus will fall more heavily on the other big quality supplier Australia. Planting here has so far been going reasonably well. Some dryness issues linger in the West but if the eastern states avoid last year’s highly unusual harvest washouts, we could see a complete reversal of that result (when Australia saw its worst milling crop for many years).

Feed consumers praying for an end to the past season’s endless litany of crop weather problems must have wrung their hands during May and much of June when incessant rains threatened to stop US farmers planting enough maize to keep up with demand (let alone to start making up for last year’s deficits and stock draw-downs). They needn’t have worried, it seems, as the USDA’s latest survey shows the second highest acreage since 1944. This came as quite a shock for the US maize

44 | July - August 2011

market, which had risen to record highs in June after the USDA estimated lower plantings. With good weather recently, maize yield potential is rising and some analysts think the crop could be large enough to start loosening up carryover stocks (recently projected at their tightest level for many years). The USDA also ‘found’ an extra 7.6m tonnes from last year’s crop in its June 1 quarterly stocks survey - which may mean the crop was under-rated or that feed/ethanol demand has been over-rated. This combination of higher than expected acreage and stocks caused a massive slide in Chicago maize prices in the first week of July- but it wasn’t only ‘fundamentals’ that drove prices down. Much of the decline was down to a hemorrhage of support for futures from speculative funds across commodities, especially ‘overbought’ markets like maize, as investors become increasingly spooked by ideas that the global economic recovery was stalling. There has also been a lot of discussion in the grain trade and in the broader financial community about record high commodity prices – for grains, oil and metals - starting to destroy demand. It is too early to judge how this phenomenon will pan out. So called macro-economic markets are notoriously fickle, rarely behaving with consistency these days as fund managers and currency dealers and their offshoots try to second guess the way ahead in uncharted waters. There is also a school of thought that some funds may actually be dumping their commodity assets to help drive prices down, so they can buy them back at much cheaper prices and so own both the good and the profit (from the earlier price rises). No-one knows how this story will end because financial markets are being driven by ‘sentiment’ – perceptions, scare stories and hopes rather than facts. As we go to press, fears of another meltdown in confidence like the Lehman bank collapse of 2008 – focus on a potential Eurozone or US debt defaults or a Chinese industrial slowdown. Any of these could be a mega-restraint on cereal prices although the potentially seismic effects of more macro-economic instability would hardly be welcomed by any industry, including the milling, feed and livestock sectors. Macro-economic meltdowns aside, speculative funds need fundamentals to go their way before jumping on, or off, a market bandwagon. In this respect all eyes in coming weeks will be on the weather in the USA. High maize yields could pitch this market into modest surplus, preventing prices from returning to the highs and maybe allowing them (depending on European and S American

maize crops) to return to much cheaper levels. Good pre-harvest weather in Canada, Europe and, later in the new season, Australia, could also reduce the big quality premiums currently being asked on milling wheat. Traders will also be keeping a keen eye the US soyabean crop, sown on a much smaller than expected acreage as farmers either planted more maize for the high prices or found themselves thwarted by the weather at planting time. Any supply problems for the world’s largest oilseed producer could set a firmer tone across the oilmeal complex, especially at a time of disappointing European rapeseed production (see below). Fortunately, Latin America is continuing to reduce US dominance of this market with its own larger crops – a trend that should continue into 2012 if soyabean prices stay anywhere near present levels.

Main commodity highlights since our last review Wheat – a welcome drop in prices Better than expected supplies, an early return of exports from the former Soviet Union and a crash in maize prices helped wheat prices to drop on both sides of the Atlantic to some of their lowest levels since July 2010, almost 37% below the February (2½-year) peaks. Strong maize prices had been a key support to wheat through the feed link between the two grains. Without that help, wheat has had to acknowledge its own more bearish news. This included the Intrenational Grains Council raising its world crop estimate from 663m to 666m tonnes after upward revisions for China, India, Pakistan Turkey and North African countries, more than offsetting an expected cut in the EU estimate. The IGC also raised consumption, so world ending stocks will still decline slightly in 2011/12 – though at 185m tonnes, the projected figure is hardly tight in relation to consumption needs. The adequacy or otherwise of quality supplies remains a key question for the wheat market going forward after last year’s wet weather downgraded so much milling to feed in North America, Australia and parts of Europe. At this stage, it is too early to make an assessment of any likely rebound – North American spring crops are hardly sown, Australia has just began planting and European harvests are still some weeks away. Weather in the next few weeks and months will gradually clarify this picture. In the meantime, the omens are mixed Good quality – and a bit more tonnage than the pessimists feared – from the US hard red winter crop has seen this important breadwheat taking a larger role, both in the US – where it has been replacing some of the market share held by tighter and more expensive hard spring wheats – and on

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July - August 2011 | 45

overseas markets, where it has dominated US export sales. Along with an early, fast harvest, the better crop news saw HRW fob export prices come down to about $470/fob

recently, about 23% under the May peaks, which were the highest in two years. Dark Northern spring wheat (14% protein) for export has dropped by a similar amount as US millers switched to HRW. A lot of uncertainty persists over the size of the US and Canadian spring planted crops due to wet weather holding up fieldwork. The USDA’s June survey put US sown area at 13.6m acres compared with 14.4m expected in March but many private observers still think this optimistic. The same applies to Canada, where about 6m acres of cropland in total is thought likely to be abandoned to the weather this year. Still, it is not out of the question that some better late summer weather will give Canada a higher milling component than from last year’s weatherplagued crop. Canadian western red spring wheat prices have also come down on fob markets with US wheat. Attention is also turning to Australia, where planting has recently star ted in western states. Some dr yness problems have been repor ted

there but the main issue will be whether the east avoids last year’s untimely soaking and produces its usual, mainly high quality harvest. Despite some downward revisions from drought and heatwaves, Europe’s crop has been nowhere near as bad as some feared back in May. The wheat total seems to settling around 134/138m tonnes versus last year’s 136m and the recent peak (2008) of

46 | July - August 2011

156.1m. Within the total, soft wheat could be as high as 130m tonnes, higher than last year. EU expor ts to Third countries, which star ted so strongly last year, have finished with a relatively small gain and will clearly be lower in 2011/12, due to the smaller crop and carryover stocks. The EU is also availing itself of cheaper foreign wheat, dropping import restrictions and in the early weeks of the new season (starting July 1) actually importing far more than exorting. Amid the rebound in Russian/other CIS supplies, the world market should easily cope with less EU exports and Europe itself will also avail itself of a lot of this cheap Black Sea wheat to keep upward pressure off its own feedgrain prices (Black Sea milling wheat was offered for expor t $25/35 cheaper than French in early July). Millers will also be hoping that Germany – which has suffered some yield loss from drought - escapes last year’s wet harvest problems and reasserts its role as the EU’s quality wheat provider, reducing dependence on expensive high protein North American wheats. The French already seem to be getting some good quality from early cuts, if more variable yields – a classic result of a too hot/dry summer. Latest IGC estimates suggest the CIS region as a whole will harvest 103.5m tonnes of wheat compared with last year’s dismal 82.3, and the average 115m of the previous two years. The USDA, which forecasts similar crop figures for the CIS, has exports for the region rebounding to 26m from 12.7m tonnes with some analysts even two or thee million tonnes higher still. These crops are not yet all home and dry – in the EU or in the Black Sea region – but the picture should be clearer by the time of our next issue. The EU market has responded to this loosening outlook with much che a pe r pr ices recently. On the Paris futures market, milling wheat recently fell as low as €185/tonne from a high of €251 in May - a far cry from markets targeting €300 earlier this year. London feed wheat futures are also sharply down, with added pressure from larger than expected stocks and the UK’s giant Ensus ethanol plant announcing a halt to operations due to this year’s high raw material costs. A mild bounce in prices has been seen on both markets as we go to press but further declines in European wheat costs can’t be ruled out if harvests continue to turn out better than expected in coming weeks and/ or the US futures markets have another shakeout.


• Quality and quantity of North American, German and, late in the year, Australian high grade wheats • US/EU planting intentions/weather this autumn – it’s not so far away and, in the US there will again be hot competition for land from corn • Russian and other CIS export sales strategy. Will they continue to market aggressively – or will they (Russia especially) put more into stocks after last year’s crop scares? • Import demand for wheat – will it increase as the market gets cheaper? • Will the US maize crop be big enough to lower prices, slowing diversion of feed demand to low grade wheat? Coarse grains – more maize than thought Maize supplies may be less tight than they looked a few months ago. In Europe itself, the earlier droughts and heatwaves appear to have left this crop largely unscathed and production is expected to rtise from last year’s 55.6m to 59/60m, possibly a few hundred thousand tonnes higher still after recent favourable weather. However, the main driver in this market is the USA where the government shocked the trade at the close of last month when it not only ‘found’ an extra 7.6m tonnes of old crop stocks but estimated planted acreage far higher than expected after this year’s weather-delayed star t. On ‘trend’ yields of 158.7 bushels/acre, the new US harvest area estimate of 84.9m acres implies a 342m tonne crop – just ahead of domestic and export demand forecast at 337m – allowing some replenishment of thin stocks, rather than another drawdown as expected in the previous month. If yields dropped to last year’s levels, output would fall to 330m. But if it repeated the 2009 yield (also a late crop), output could advance to 355m tonnes, accruing a comfor table increment to carryover stocks. Until recently, all the early moisture and some good weather since suggested higher rather than lower yields. However, the crop needs to get through the key pollination period when some predicted heatwaves could lower potential so this crop is by no means on the home run yet. Elsewhere in the maize supplying world, the CIS countries are expected by the IGC to raise production to 21.5m from last year’s 17.6m tonnes. Some of this increase will likely go to export, mainly from Ukraine which has emerged as the world’s number four maize supplier in recent year’s, supplyling about 8% of trade. Argentine maize output is also expected to increase from 21 to 24m tonnes, raising export supplies to about 17m. However, frost may have trimmed the Brazilian crop and with feed demand rising internally, its contribution to export could drop from 11m to 8m, or less.

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July - August 2011 | 47

Upward pressure on maize prices has been relieved by the past season’s abundance of feedwheat on world markets at cheaper prices, dampening buying interest for the coarse grain from compounders in the big Asian importing countries. Demand also seems to be levelling off in other sectors, including evidence of consumer resistance in the USA when corn approached $8/bushel ($315/tonne) on futures markets. Although higher meat prices have helped livestock producer margins, some sectors are struggling and US total feed demand will either stagnate or grow only slowly next season and then, not even back to the 2009/10 level from which it fell over the past season. US ethanol use of maize is seen increasing by a mere 2% compared with 9% in 2010/11 and 23% in 2009/10. The US Congress is currently battling over whether to extend subsidies on blending and import protection for the ethanol industry at the end of this year amid a clamour to end them from food, feed and other traditional users. Some experts believe that, while world energy (i.e. crude oil) prices stay up, the US 15% blending mandate will continue to draw maize into this sector, subsidies or not. Time will tell. The maize market also needs to keep one eye on China, where the gap between local crops and growing domestic consumption, mainly in feeds, is continuing to widen. China has recently been an active buyer of US maize, this season being the first in many years that it has required significant imports. Some traders see that demand expanding to as much as 5m or 8m tonnes ahead – certainly enough to put a more bullish tone back into

US and world maize prices if it all transpires. Fortunately for other users, world maize trade in total is not expected to grow much in 2011/12 at around 93.7m tonnes, partly due to ongoing competition from feedwheat, partly to smaller EU import needs amid this year’s larger domestic crop. However, feed grain supplies get no extra help from barley this year, despite a forecast increase in world production of 7.5m tonnes, courtesy of larger CIS crops. World carry-in stocks of this grain have been drawn down even more, by 13m tonnes, so another deficit year is expected to reduce consumption and stocks further in 2011/12. The EU’s own

48 | July - August 2011

disappointing arley crop looks like ending up about 1.5m tonnes below last year’s, 10m below the 2009 result and 13m under 2008.

KEY FACTORS IN THE MONTHS AHEAD The size of the US maize crop – will it mean some stock accumulation or further depletion? China’s deficit and its attempts to fill that with imports – markets get jittery when China moves Global economic problems – not good for consumer confidence, so no friends to meat and feed demand but potentially bearish for grain & raw material prices Speculators’ interest in commodities – is the party over? Probably not quite yet. Ethanol competition for maize supplies – getting amber signals for endless government subsidies? Demand growth seems to be slowing but shortages of sugar-based ethanol from Brazil are tightening the world market for this gree fuel, supporting its price structure. That could turn out more bullish for maize going forward

Oilmeals Soya ‘sentiment’ is caught in a play-off between conflicting factors. The US is running to a tight finish with old crop supplies and, after disappointingly low plantings, is officially expected to see its harvest contract by 3m tonnes this summer. Weather there is also a bit too hot for comfort, so there could be a yield penalty too. This is making users uneasy and has been pushing up prices on the US and European markets recently. However, acreage recounts in August might find the US crop area is under-rated. Also, for a crop only recently planted many pundits it is too early to start writing down yield prospects on the basis of one, possible hot week. Less bullishly, Latin America’s larger than expected 2011 crops are still feeding into the market, later than usual in the year, offsetting tight US supplies. Many analysts think this region will again try to raise production in the autumn (for harvest spring 2012) if soyabean prices stay anywhere near current levels. That could mean enough soya for the rest of the new season whether or not the US crop has been under-rated. Another restraint on this market is slower demand growth from the top soya customer, where imports grew 22.5% in 2009/10 but only by 3% this past season. Chinese imports are expected to accelerate somewhat in 2011/12, largely because it has sown a smaller domestic

crop. However, even this anticipated growth has been trimmed from 11.5% to 8.5% in the past month to reflect a slower pace of buying amid high port stocks and weak crush margins. China has been responsible for two thirds of all the growth in world soya meal demand in recent years. Soya in turn accounts for twothirds of all oilmeal production, so China’s influence on this sector remains vast. In fact this is the biggest factor in a slowdown in the growth of world demand for oilmeal products from 6.2% in 2010/11 to an expected 3.8% in the coming season. In a still recessionary world environment, that implies some restraint on prices although it could obviously be over-ruled if something went seriously wrong with the North or South American soya crops in coming months, Among the other oilseeds, USDA expects world rapeseed production to dip for a second year running to 58.75m tonnes with a 2m tonne drop in the EU only partly offset by a larger Canadian crop. Estimates for both remain negotiable. The EU’s currently looks slightly better than the USDA figure after late rains followed the summer drought. Canada’s, on the other hand could be anywhere between 12.6m and 13.4m tonnes after rain delayed sowings and brought forth an array of estimates for abandoned plans. As usual rapeseed meal prices will tend to track market leader soya. Sunflower prospects are currently better than last year’s, thanks largely to recovery in the former Soviet countries hit by drought and heatwaves last year. Russia’s crop is seen rising to 8.3m from 5.35m tonnes, Ukraine’s to 7.5m from 6.8m. Even the EU crop is currently expected to improve a bit, from 6.8m to 7.1. Although one-time leading supplier Argentina expects a fall from 3.6m to 2.8m tonnes (drought) world output should advance from 31.1m to 34.6m tonnes. Along with larger crops of cottonseed and palm kernels, these changes suggest a total world oilseed crop of 455.5m tonnes – plus 4.3m. Crush will grow faster (13.3m) but there is plenty of slack in the food use/stocks numbers to cope with that so carryout at the end of the season will be ample.

KEY FACTORS IN THE MONTHS AHEAD • Final US soya planting estimates and weather in the next two months • Is China, the engine of world crush growth, slowing down? • How much soya will the Latin Americans sow this autumn? • Did Canada complete its rapeseed planting plans? • EU winter rapeseed plantings- up or down for 2012?

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THE GLOBAL MILLER Hi I am the Global Miller Welcome to The Global Miller page in GFMT. This page highlights what is happening in the world of milling, covering stories that appear daily on our blog. I will be blogging the latest news from around the world that relates to the movement, storage, milling and use of all types of grains and cereals for the food and feed industries. To receive my reports regularly why not sign up to this blog directly or follow us on Twitter and Facebook?! - The Global Miller by Martin Little, Blog Editor In this months round up of world news on the Global Miller we see how Kenyan farmers are turning a poisonous weed into animal feed (July 11 2011) and we see the Roxarsone has been withdrawn from the Canadian market (12 July 2011) and on the July 19 we see that a fire destroyed the ABN mill at Cupar in Fife Scotland. A sample of stories from this month is available below. Feed additive marks poultry meat contamination Aberystwyth University scientist are developing a system to detect minuscule traces of fecal contamination on chicken carcasses in abattoirs. The Improved Food Safety initiative - a Collaborative Industrial Research Project undertaken by the University’s Institute of Biological, Environmental and Rural Sciences (IBERS). Read more at: FOSS announces new few analyser The new NIRS DS2500 feed analyser from FOSS, this new machine is the next logical step in high performance infrared analysis. It can give an accurate analysis in under a minute for a range of parameters. This new machine empowers the feed miller in handling intake and product quality. Read more at: US$30 billion cut from agriculture The President and the Lawmakers are looking to cut some US30 (€21.151 ) billion or more in agricultural spending as part of a deficit reduction deal. The farmers know it has to be done, but they fear too many cuts could cause a sharp decrease in crop prices, sending them back to the days of the 1980’s farm crisis. Read more at:

50 | July - August 2011

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Arabic simultaneous translation provided during the conference!     



Register now to secure your participation in the biggest event this year!

Largest gathering of commodity traders and millers in the Middle East and Africa Region. Participation of over 500 industry elites from all over the world. New educational program with management topic and presentations. Grand exhibition displaying the latest innovations and trends in product development in the milling industry. Largest exhibition specialized in the milling technology and production, with participation of more than 80 companies.

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July - August 2011 | 51

Prioritizing Agricultural Research for Development - Experiences and Lessons


rioritizing Agricultural Research for Development: Experiences and Lessons (2009) was edited by David A Raitzer from the Center for International Forestry Research and George W Norton from Virginia Polytechnic Institute and State University.

This book looks at the need to guide limited public resources to the area of research in agriculture that has the greatest potential to benefit the poor along with the environment. It is a compilation of valuable experiences that intend to return the focus back to how decisions are made regarding the use of research resources. The intention is to offer a unique menu of options and lessons for future research planning efforts by NARS institutes and their international partners. This publication is split into four parts; it presents both experiences and innovations with priority assessment methods in Consultative Group on International Agricultural Research (CGIAR) and its partners at various levels. Each chapter presents and appraises one or more methods that have been used in priority assessments and shares the strength and weaknesses that each method encountered. Chapter one: Introduction to Prioritizing Agricultural Research for Development
- David A. Raitzer and George W. Norton Section One. Background Tools Chapter two: Participatory Impact Pathways Analysis (PIPA) and Research Priority Assessment Section two. Institute Level Approaches Chapter three: Research Priority Assessment at the International Potato Center (CIP)
 Chapter four: The International Institute of Tropical Agriculture’s (IITA) Experience in Priority Assessment of Agricultural Research
 Chapter five: Priority Assessment at the Center for International

Book review

Forestry Research (CIFOR): Confronting the Challenges of a Policy Oriented Natural Resources Management Research Portfolio Chapter six: Research Evaluation and Priority Assessment at the International Crop Research Institute for the Semi-Arid Tropics (ICRISAT): Continuing Cycles of Learning to Improve Impacts
 Chapter seven: Using Multiple Objectives in Participatory Assessment of International Livestock Research: Lessons Learned
 Chapter eight: Priority Assessment for Rice Research in SubSaharan Africa
 Chapter nine: Highlights of the Evolution of Priority Assessment and Targeting at the International Center for Maize and Wheat Improvement (CIMMYT) Section Three. System and Regional Approaches Chapter 10: The International Center for Agricultural Research in the Dry Areas’ (ICARDA) Experience in Agricultural Research Priority Assessment Chapter 11: Strategic Priorities for Agricultural Development in Eastern and Central Africa: A Review of the Institutional Context and Methodological Approach for Undertaking a Quantitative, Sub-Regional Assessment Chapter 12: Methods and Approach to Identify the Consultative Group on International Agricultural Research (CGIAR) System Priorities for Research Section Four. Synthesis and Ways Forward Chapter 13: Synthesis and Options for Enhanced Priority Assessment for Agricultural and Natural Resources Research
 This book was compiled with the aid of many individual authors that have experience in this field from around the world. The book is a must for anyone studying funding in agricultural research and development, in the international market and government agencies that deal with funding issues as well as economic students, one for the bookshelf.

ISBN 978-1-84593-566-5

Are you a Perendale bookworm? Perendale Publishers Ltd, the publishers of Grain & Feed MiIling Technology, has set up an online Amazon-based ‘Book Shop’ that lets you browse a wide range of recently-published reports and books on Grain & Feed relaed topics. You will soon be able to read an extended review before making your selection and purchasing directly from Amazon. We will undertake to put forward for your consideration the most recent publications and as a result become a reference point for your reading and research.

Of course you will be charged for any books purchased, but you will be dealing directly with Amazon, which has a world-class ordering/payment gateway, packaging and mailing service. Consult Perendale Publishers online Book Store at:

52 | July - August 2011

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Book review Encyclopedia of dairy sciences - Second edition


n 2011 the second edition of the encyclopaedia was published this publication was edited by John W Fuquay, Professor emeritus of dairy science at Mississippi State University, Professor Patrick F Fox, Head of the Department of Food Chemistry at University College, Cork and Paul L H McSweeney Professor of Food Chemistry in the School of Food and Nutritional Sciences, University College, Cork, Ireland. This edition of the encyclopaedia was published in four volumes; each volume is laid out as a series of entries in alphabetical order. Some entries are single articles well others are multiple articles laid out in a logical sequence within an entry. The aim of this encyclopaedia is to provide a complete resource on the subject of dairy science. The key subjects relate to milk production and dairy technology and also provided is information on nutrition, public health and dairy industry economics including aspects of trade in milk and dairy products The encyclopedia is divided in to four volumes. Volume one: has an introduction covering the history of dairy science and technology along with the history of dairy farming, dairy products and processes, dairy chemistry and dairy bacteriology. The core subject mate-

rial is laid out in alphabetical order from A to C and covers subjects as diverse as additives, analytical methods, animals that produce dairy foods. As well as beneficial bacteria, biofilm formation bull management. Volume two: covers D to I and deals with subject like dairy education, as well as dairy farm layout and design. It covers feed ingredients, feed prediction of energy and proteins and ration formulation. Also covered is gamete and embryo technology, genetics, hormones in milk and husbandry of dairy animals. Volume three: covers L to N and deals with labeling of dairy products, lactic and bacteria, lactose and oligosaccharides. Also mammals, mammary gland milk biosynthesis and secretion with milk proteins and protein products. Finally in this volume subjects covered are from nutrients, digestion and absorption to nutrition and health. Volume four: covers O to X and deals with subjects such as the Office of International Epizooties, packaging, and replacement management in cattle through to utilities and effluent treatment. Vitamins, water in dairy products and yeast and molds. This publication is a complete reference source to all that is dairy production covering many subject areas in depth. As well as the science it looks at the technology of dairy farming and production. I believe this is the only source reference material anyone in the industry would need. A great book for researchers, students, and practitioners involved in all aspects of the dairy sciences as well as those involved with economic and nutritional policy.

ISBN: 978-0-12-374402-9

Good Agricultural Practice New Delhi I Mexico City I Cape Town I Sao Paulo I Cairo I Warsaw I Atlanta I Bangkok

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Everything you need to know about Good Agricultural Practice Certification at a place near you! Register now on

Meet us in one of the following cities:  New Delhi – India, 1/2 March 2011  Mexico City – Mexico, 11/12 April 2011  Cape Town – South Africa, 11/12 May 2011  Sao Paulo – Brazil, 6/7 June 2011  Cairo – Egypt, 12/13 July 2011  Warsaw – Poland, 14/15 September 2011  Atlanta – USA, 17/18 October 2011  Bangkok – Thailand, 22/23 November 2011

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Would you like to know more about the GLOBALG.A.P TOUR 2011? Then please see or contact Nina Kretschmer: Follow us on Twitter@GLOBALGAP!

July - August 2011 | 53

Classified section Analysis • Automation Products, Inc. • Brabender® GmbH & Co KG • CHOPIN Technologies • Diversified Laboratories, Inc. • Evergreen Analytical Services, Inc. • Foss Analytical AS • FOSS UK • Lancaster Laboratories • NDC Infrared Engineering Ltd • Neogen Corporation • Pfeuffer GmbH

Silo Construction & Engineering

SCE Maximum bulk storage

• • • • • • • • •

Blo-Tech Ltd Cargotec Sweden AB Christianson Systems Inc Clyde Materials Handling Ltd Cyclonaire Corp Dunbar Kapple/Vac-U-Vator Dynamic Air Inc Dynamic Air Ltd. Geroldinger GmbH & Co KG

AquafeedClassified40_2x40mFINALrevsd Elevator Buckets


12:35 AM

Feed processing +32(0)51 723128


• Schmidt-Seeger GmbH • Silos Cordoba S.L

Block 10 Todd Campus West of Scotland Science Park Acre Road, Glasgow Scotland G20 0XA


Polyethylene Elevator Bucket


Tel: +44 141 945 2924

St. Louis, Missouri USA

T:+1 314 739 9191• F:+1 314 739 5880

R-Biopharm Rhône Ltd, Unit 3.06 Kelvin Campus, West of Scotland Science Park, Maryhill Road, Glasgow, G20 0SP Scotland Tel: +44 (0) 141 9452924 Fax: +44 (0) 141 9452925,

Competence in Food and Feed Analysis



Ctra. Arenas de San Juan, Km 2.300 13210 Villarta de San Juan - Spain Tel: +34 926 64 05 40 BiopharmRhoneClass.indd 1 31/03/2010 15:36 Fax: +34 926 64 02 94 Animal Health & Nutrition Email:

Elevator & Conveyor Components

• Systech Instruments Ltd

• Alicorp SA

CENZONE TECH INC. 2110 Low Chaparral Drive San Marcos CA92069 USA Tel: 760 736 9901 Fax: 760 736 9958 Web:


• Teta Engineering Inc.

Material Handling & Electronic Components for all Applications • Hazard Monitors

03/11/2010 10:37 • Level Controls

Symaga_class.indd 1

• Elevator Buckets & Bolts • Belts & Fasteners • Forged Chains & Sprockets



• Danisco Animal Nutrition • Noack - Group of Companies • Papillon Agricultural Products, Inc

Bulk Storage

Flour improver


Bulk Handling • Croston Engineering Ltd


• Alicorp SA • Dr Eckel GmbH


Almex b.v., Verlengde Ooyerhoekseweg 29 7207 BJ Zutphen, Netherlands, tel.: +31 (0)575 572666 e-mail:, internet:

• Anderson International Corp • Amandus Kahl

Croston Engineering Ltd Tarvin Mill Barrow Lane, Tarvin Chester CH3 8JF Tel: 01829 741119 Fax: 01829 741169 E-mail: Website: BULK STORAGE, HANDLING, AND PROCESS ENGINEERS FOR THE ANIMAL FEED, GRAIN, FLOUR, BAKERY, HUMAN AND PET FOODS INDUSTRIES

54 | July - August 2011

• • • • • • • •

Anderson International Corp Amandus Kahl Andritz Feed & Biofuel Brabender Clextral Dinnissen BV Extru-Tech Inc Jiangsu Muyang Group Co Ltd.

• • • •

Flour improvers Enzymes Baking premixes Advice on applications

Kurt-Fischer-Strasse 55, D-22926 Ahrensburg Tel.: + 49 (0) 4102 / 202 001, Fax: -010 A member of the Stern-Wywiol Gruppe

Ein Unternehmen der Stern-Wywiol Gruppe

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Classified section Grinder hammers John Staniar & Co.



• Arodo BVBA


• Andritz Feed & Biofuel BV • Kay Jay Chill Rolls Pvt Ltd

Grinder Screens A Clondalkin Company


John Staniar & Co.

Level measurement CB Packaging is a market leader of multi-walled paper sacks. With over 50 years of experience, we offer solutions for a wide range of industries, including animal feeds, pet food, seeds, milk powder, flour and root crops.

• Millson Engineering Limited • Muench-Edelstahl GmbH


For more information, please call Tim Stallard: +44 (0) 7805 092067

Yingchun Group

Process control • • • •

Grain Silo Manufacturing

Converteam UK Ltd Datastor Systems Ltd KSE Protech BV RED-BERG s.r.l.

Buhler AG CH – 9240 Uzwil, Switzerland T: +41 71 955 11 11 F: +41 71 955 66 11 E:

Tel: +86 546 8313068 Email:

Analysis & Control

Equipment for sale

Intake and Inline measurement of moisture, protein, temperature, structure, ash, fat, fibre, starch and colour. Recipe management and traceability records.

Shangdong_class.indd 1

Condex (UK) Ltd

29/03/2011 11:20 ®

For maximum control and efficiency call:

Buhler Class ad_GFMT10.indd 1

11/12/2009 09:07

01473 829188

Recruitment • AGRI-Associates • Agribusiness Recruiters

• TekPro Ltd • Wallace & Associates Inc. • Younglove Construction LLC

Milling Industry Recruitment Specialist +44(0)161 427 2402

&feed milling technology


For more company information, visit: market


Mill Design & Installation

OUT NOW July - August 2011 | 55

Events 2011 AUGUST 8th - 12th August 11


Buhler-KSU Executive Milling Course, Kansas State University, Manhattan, KS, USA Contact: IAOM Course Administrator, 10100 W 87th Street, Suite 306, Overland Park, KS 66212, USA Tel: +1 913 338 3377 Fax: +1 913 338 3553 Email: Web: & workshops/ residentcourses.htm

SEptember 8th - 8th September 11


XVIIth Annual International Conference Black Sea Grain and Oilseeds 2011/12 «Year After: searching for successful equilibrium between domestic and export grain markets development», Moscow City, Russia Contact: Ms. Anna Gerasimova, The Russian Grain Union, Orlikov lane 1/11, Zip code 107139, Moscow, Russia Tel: +7 495 607 82 85 ext. 124 Fax: +7 495 607 83 79 Email: Web: php?SECTION_ID=198&ID=1328

62nd JTIC International Milling & Cereal Industries Meeting, Reims, France Contact: AEMIC, 268 rue du Faubourg St Antoine, 75012 Paris - France Tel: +33 1 47 07 20 69 Fax: +33 1 44 24 56 25 Email: Web:

10th - 14th September 11

* 6Th Annual Eurasia District Conference &

28th - 30th September 11

* Animal Farming Ukraine 2011, International

Expo of the International Association of Operative Millers IAOM, , Hotel Sheraton, Via Giovanni Agnelli 33, 50126 Florence - Italy Contact: Via Riva Reno 61, 40122 Bologna - Italy Tel: +39 051 6564300 Fax: +39 051 6564334 Email: Web:

Exhibition Center (IEC), Brovarskiy Prospect 15, Kiev, Ukraine Contact: Mr. Kuno Jacobs (Project Manager), BTO Exhibitions BV, Europaweg 187, 7336 AL Apeldoorn, The Netherlands Tel: +31 55 534 11 40 Fax: +31 55 534 01 68 Email: Web:

GLOBALG.A.P TOUR 2011 – Atlanta, The Westin Peachtree Plaza, Atlanta, USA Contact: Nina Kretschmer, c/o GLOBALGAP Foodplus GmbH, Spichernstr.55, D-50672 Cologne, Germany Tel: +49 221 57993 693 Fax: +49 221 57993 89 Email: Web:

15th - 15th September 11


Globalg.A.P Tour 2011 – Warsaw (Poland), , Le Royal Méridien Bristol, Poland Contact: Nina Kretschmer, c/o GLOBALGAP Foodplus GmbH, Spichernstr.55, D-50672 Cologne, Germany, Tel: +49 221 57993 693 Fax: +49 221 57993 89 Email: Web:

13th - 14th October 11

18th - 18th October 11

18th - 20th October 11

Protein Technology innovation 2011 Conference, Amsterdam, The Netherlands Contact: Marjolijn Cohen, Jan van Eijcklaan 2, 3723 BC Bilthoven, The Netherlands Tel: +31 30 2252060 Email: Web:

october 22nd Annual IAOM Mideast & Africa District Conference & Expo, Dead Sea, Jordan Contact: Eva Mulyana, PO Box 566, P.C. 112, Ruwi, Muscat, Sultanate of Oman Tel: +968 2471 2338 Fax: +968 2471 1340 Email: Web:


20th - 22nd October 11

1st - 2nd November 11

* 6th Livestock Asia 2011 Expo & Forum 4th - 6th October 11

Bangalore, India

7th - 11th November 11

06-07-11 13:03


Buhler-KSU Executive Milling Course, Kansas State University, Manhattan, KS, USA Contact: IAOM Course Administrator, 10100 W 87th Street, Suite 306, Overland Park, KS 66212, USA Tel: +1 913 338 3377 Fax: +1 913 338 3553 Email: Web: & workshops/ residentcourses.htm

our magazine at this * See show

• More information available adv-ildex-india-2012-90x132-V2.indd 56 | July - August 20111


Overview of Particulate Handling Technology, Kent, UK Contact: Caroline Chapman, The Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich, Central Avenue, Chatham Maritime, Kent, ME4 4TB, UK Tel: +44 20 8331 8646 Fax: +44 20 8331 8647 Email: Web:

Feedtech Croptech

The dedicated event for the Indian Milling industries



Special themes



Aviana Africa 2011, Accra, Ghana Contact: Dr. Inderjit Singh, 13/29 Subhash Nagar, Delhi - 27, India Tel: +91 9582709491 Email: Web:

Asia’s International Feed, Livestock & Meat Industry Show, Kuala Lumpur Convention Centre, Kuala Lumpur, Malaysia Contact: Ms. Ery Tan/ Ms. Michelle Ha, Suite 1701, 17th Floor, Plaza Permata, 6 Jalan Kampar, Off Jalan Tun Razak, 50400 Kuala Lumpur, Malaysia, Tel: +603 40454993 Fax: +603 40454989 Email: Web:

Visit our website n for more informatio


VIth International Grain Trading Conference Global and Middle East grain outlook 2011, Sharm El Sheikh, Egypt Contact: Ms. Anna Gerasimova, Russian Grain Union, Orlikov lane 1/11, Zip code 107139, Moscow, Russia Tel: +7 495 607 82 85 ext. 124 Fax: +7 495 607 83 79 Email: Web: php?SECTION_ID=196&ID=1325


28th - 29th September 11

2nd - 5th October 11

February 22 - 24, 2012

Your portal to India’s Feed to Meat trade


The 3rd International Conference “Oilseeds & Oils 2011”, Marriott Asia 5*, Istanbul, Turkey Contact: Irina Ozip, Chicherina str. 21, Dnepropetrovsk, Ukraine, Tel: +380562320795 Fax: +380562320795 Email: Web: oo2011/index.php

VIV/ ILDEX India 2012



22nd - 24th September 11

GrainTech India 2011, Gayathri Vihar, Palace Ground, Bangalore, India Contact: M. B. Naqvi, Media Today Pvt Ltd, T-30, 1st Floor, Khirki Extension, Malviya Nagar, New Delhi 110017, India Tel: +91 11 65656554 Fax: +91 11 26681671 Email: Web:

9th - 11th September 11

&feed milling technology




The 2012 International Poultry Expo and International Feed Expo will be held January 24 – 26, 2012, and the week of the Expo has been officially designated as “IPE Week” with an emphasis on educational programs rounding out the week-long event. The Expo is shifting to a TUESDAY, WEDNESDAY, THURSDAY format to increase the education programs available to attendees.

• • • •

The World’s Largest Poultry and Feed Technology Exposition Over 20,000 Industry Leaders from Over 100 Countries Over 14 Acres of Exhibits Exceptional Educational Programs Planned for IPE Week - International Poultry Scientific Forum - Hatchery-Breeder Clinic - Pet Food Conference - Animal Agriculture Sustainability Summit - Workshops on Safety and Environmental Issues - Symposium on Egg Production - Pre-Harvest and Food Safety Conference - Executive Poultry Outlook


Events 9th - 11th November 11


Vietstock 2011 Expo & Forum – Vietnam’s No. 1 International Feed, Livestock & Meat Industry Show, Saigon Exhibition & Convention Centre, Ho Chi Minh, Vietnam Contact: Ms. Michelle Ha, Suite 1701, 17th Floor, Plaza Permata, 6 Jalan Kampar, Off Jalan Tun Razak, 50400 Kuala Lumpur, Malaysia Tel: +603 40454993 Fax: +603 40454989 Email: Web:

23rd - 23rd November 11


GlobalG.A.P TOUR 2011 – Bangkok Contact: Nina Kretschmer, c/o GlobalGAP Foodplus GmbH, Spichernstr.55, D-50672 Cologne, Germany Tel: +49 221 57993 693 Fax: +49 221 57993 89 Email: Web:

december 1st - 3rd December 11


IAI Expo, NDRI, Karnal, India Contact: Ms. Shweta Baweja, 923, Sector-9, Urban estate, Karnal, India Tel: +91 9991705009 Fax: +91 1842231050 Email: Web:

8th - 10th December 11


Livestock Philippines 2011 Expo & Forum – 1st International Feed, Livestock & Meat Industry Show, SMX Convention Centre, Manila, Philippines Contact: Ms. Michelle Ha/ Ms.Miza, Suite 1701, 17th Floor, Plaza Permata, 6 Jalan Kampar, Off Jalan Tun Razak, 50400 Kuala Lumpur, Malaysia Tel: +603 40454993 Fax: +603 40454989 Email: Web:

our magazine at this * See show

• More information available

Your events If you have an event that you would like to see featured in our pages, please send your information to Tuti Tan Email:

58 | July - August 2011

2012 january


24th - 26th January 12

2012 International Poultry Expo and International Feed Expo, Atlanta, GA, USA Contact: Pennie Stathes, 1530 Cooledge Road, Tucker, GA 30084, USA Tel: +1 678 5141977 Email: Web:



7th - 9th February 12

EuroKarma 2012, MTPolska Center Ul. Marsa 56, 04-242 Warszawa, Poland Contact: Agnieszka Niemczewska, PO Box, 73, 32-332 Bukowno, Poland Tel: +48 514 544 048 Email: Web:


9th - 11th February 12

ISRMAX India 2012, Chandigarh, India Contact: Geetika Malhotra Asudani, Pixie Consulting Solutions Ltd, #923/9, Urban Estate, Karnal, Haryana, India Tel: +91 9991705003 Fax: +91 1842231050 Email: Web:

15th - 17th February 12


FIAAP, Victam & GRAPAS Asia 2012, BITEC, Bangkok, Thailand Contact: Andy West, Victam International, Po Box 411, Redhill, Rh1 6We, Uk Tel: + 44 1737 763501 Email: Web:

22nd - 24th February 12 VIV/ILDEX India 2012, BIEC centre, Bangalore, India Contact: Guus van Ham, P.O. Box 8800, 3503 RV Utrecht, The Netherland Tel: +31 30 295 2302 Fax: +31 30 295 2809 Email: Web:


GEAPS EXCHANGE 2012 Exchange 2011, held in Portland, Ore., Feb. 27 through March 1, was a huge success for everyone involved. As predicted, Exchange 2011 welcomed a large number of attendees: over the Expo’s three days, 2,065 delegates, exhibitors and guests came to Portland for Exchange 2011, and 368 booth spaces were occupied by 264 companies. Attendees enjoyed countless hours of networking and the largest-ever student day program, as well as 30+ hours of educational programming. Looking ahead to Exchange 2012 in Minneapolis, Minn., booth sales are already breaking records. During Exchange 2011, all 383 booths in the main hall were sold to 212 companies. An annex with an additional 62 booths will be opening later this summer and there are already many companies on the waiting list to select their booth location for 2012 once the annex becomes available.

FIAAP, Victam & GRAPAS Asia 2012 Over 50% of exhibition area sold at new venue BITEC, Bangkok. The event has a similar format to the successful 2010 show which attracted 6000 industry executives from throughout Asia/Pacific. There will again be a FIAAP exhibition (feed ingredients, additives & formulation), a Victam exhibition (feed processing & biomass technology) & a GRAPAS exhibition (rice milling & grain processing). All three trade shows will be co-located within one hall which will enable visitors to view the products and technology they require in order to formulate and operate safe and economic animal feed production and grain processing facilities.

AgroFarm AgroFarm has continued its dynamic growth in 2011. 230 exhibitors from 19 countries presented an extensive range of products and services linked to animal husbandry, breeding, feeding and health as well as primary processing on 10,100 m² from 12 to 14 April 2011. With 8,930 livestock farmers and experts, the event was again able to increase visitor attendance by 6 percent. The wide-ranging technical programme with more than 50 events generated considerable interest amongst professionals.

AUGUST 29th - 31st August 12


ISRMAX Asia 2012, Bangkok, Thailand Contact: Geetika Malhotra Asudani, Pixie Consulting Solutions Ltd., #923/9, Urban Estate, Karnal, Haryana, India Tel: +91-9991705003 Fax: +91-184-2231050 Email: Web:

November 13th - 16th November 12 EuroTier 2012, Hannover / Germany Contact: Dr. Karl Schlösser, DLG, Eschborner Landstrasse 122, 60489 Frankfurt/Main, Germany Tel: +49 69 24788259 Fax: +49 69 24788113 Email: Web:


Oilseeds & Oils 2011 APК-Inform Agency announces about holding of the third international conference “Oilseeds & Oils 2011”, devoted to the market of oilseeds, vegetable oils and by-products, which will be organized in Turkey (September 22-24, 2010, Istanbul). Thematic sections of the forthcoming conference: World market of oilseeds and vegetable oils: new challenges and prospects, the portraits of main countries-players. The Government regulation of markets of oilseeds in Turkey, and the Black Sea region. Crude oil positions correlation on the base of the tendencies of vegetable oils market. The market of sunflower with high content of olein as the most fast developing segment of fat-and-oil market. It is the time to resume the current season and plan your workfor the future marketing year.

&feed milling technology




1 5 – 1 7 F e b r u a r y 2 0 1 2 . B a n g k o k I n t e r n a t i o n a l Tr a d e a n d E x h i b i t i o n C e n t r e , B a n g k o k , T h a i l a n d

For everything you need for producing and packaging safe and cost-effective aquafeed No new hw in ome B


The conferences Aquafeed Horizons Asia 2012, The FIAAP Conference 2012, Petfood Forum Asia 2012, The Thai Feed Conference 2012

Supported by Thailand Convention & Exhibition Bureau

Co-located with GRAPAS Asia 2012 The show for rice & flour milling, grain & noodle processing, breakfast cereal & extruded snack production

Further information For additional information and free visitor registration visit: or

a partnership with synergy...your key to success


2011 related links AB Vista =

In every issue of GFMT, we will be providing a list of companies and web links related to key stories and topics within each specific issue. If you would like information on how your company can get involved, please contact our Marketing Manager, Caroline Wearn. Email: Tel: +44 1242 267707

Mogensen Raw Materials Handling =

Ad Farm = Agricultural Industries Confederation (AIC) =

Mondi Industrial Bags GmbH =

Alapala Machine Industry and Trade Inc. =

Muyang Group =

Almex b.v. =


Muhlenchemie GmbH & Co KG = MYSILO DIS TICARET LTD. STI = Norbert Dentressangle =

Bastak Gida Makine Medikal =

nv SCE = Obial =

Brabender GmbH & Co KG =

Ottevanger Milling Engineers B.V. = Perten Instruments AB =

Braime Elevator Components Ltd =

R-Biopharm Rhone Ltd = RJW Ltd =

Buhler AG =

Satake Corporation = Satake Europe Ltd =

Clextral =

Shanghai ZhengChang International Machinery and Engineering Co., Ltd =

Consergra s.l =

Silos Cordoba = Skov AS =

Cultura Technologies Limited =


Datastor Systems Ltd =

Suffolk Automation Ltd =

DSL Systems Ltd =

Suncue Company Ltd =

Extru-Tech =

Symaga SA =

Flexicon (Europe) Ltd =

Tapco Inc =

Food Protein R&D Center =

Techmach Technology (PTY) Ltd =

Format International =

TSC B.V. =

Foss = FrigorTec GmbH =


InVivo NSA =

UWT (UK) Ltd =

JCB Consulting Ltd =

VEGA Controls Ltd =

Jiangsu Hualiang Machinery =

Vigan Engineering S.A. =

John Staniar & Co. =

Wenger Manufacturing Inc. =

JSConwell Ltd =

Wynveen International B.V. =

Kingfisher Industrial = Leonhard Breitenbach GmbH =

Get the best out of your grain. That means maximum throughput capacity with maximum yield in processing raw materials such as wheat, barley, rye, oat, and rice. The SORTEX A is distinguished by its exceptional accuracy and separating efficiency. Its sturdy design and intuitive user interface make the SORTEX A the ideal optical sorter for the grain milling industry. For more information, please visit

Bühler AG, Grain Milling, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 66 11,

SORTEX A – for premium end products Excellent performance – Unchallenged throughput capacity – Outstanding separating efficiency High profitability – Maximum yield on raw material – Profitable investment, short payback Maximum reliability – Top availability, maximum operating time – Consistently high sorting performance for maximum process and product safety Unrivaled flexibility – High throughput capacity with minimum footprint and low space requirement – Intuitive, multilingual user interface

Innovations for a better world.

Jul | Aug 11 - Grain & feed Milling Technology  

The July | August edition of Grain & feed Milling Technology magazine