February 2015 YOUR GLOBAL PARTNER
In this issue:
Grain conveyors • Moisture control in storage • Fortification monitoring • Constructing a rice processing facility • GEAPS product showcase • IPPE Review • History of milling in Northern Europe millingandgrain.com perendale.com
Volume 126
Issue 2
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VOLUME 126
ISSUE 2
FEBRUARY 2015 Perendale Publishers Ltd 7 St George’s Terrace St James’ Square, Cheltenham, Glos, GL50 3PT United Kingdom Publisher Roger Gilbert Tel: +44 1242 267707 rogerg@perendale.co.uk Editorial Olivia Holden Tel: +44 1242 267707 oliviah@perendale.co.uk Design Manager James Taylor Tel: +44 1242 267707 jamest@perendale.co.uk Circulation & Events Manager Tuti Tan Tel: +44 1242 267707 tutit@perendale.co.uk Australia Correspondent Roy Palmer Tel: +61 419 528733 royp@perendale.co.uk
36 Moisture control in storage
International Marketing Team Tel: +44 1242 267707 Darren Parris darrenp@perendale.co.uk Tilly Geoghegan tillyg@perendale.co.uk Tom Blacker tomb@perendale.co.uk North America Office Mark Cornwell Tel: +1 913 6422992 markc@perendale.com Latin America Marketing Team Iván Marquetti Tel: +54 2352 427376 ivanm@perendale.co.uk Pablo Porcel de Peralta Tel: +54 2352 427376 pablop@perendale.co.uk India Marketing Team Assocom-India Pvt Ltd Tel: +91 47 675216 india@perendale.co.uk
Getting the moisture levels right in a silo can be challenging but it is essential that the target level is reached within the shortest possible time.
REGIONAL FOCUS NEWS
24 Milling in Northern Europe
©Copyright 2015 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. More information can be found at www.perendale.com Perendale Publishers Ltd also publish ‘The International Milling Directory’ and ‘The Global Miller’ news service
IN THIS ISSUE
78 People news from the global milling industry
PRODUCT FOCUS
22
CASE STUDY
48
32 Fortification monitoring
26 Fortification - effect of different iron compounds on the colour of dried noodles and pasta
FACES
4 6-19
FEATURES
Nigeria Marketing Team Nathan Nwosu Tel: +234 805 7781077 nathann@perendale.co.uk
Grain & Feed Milling Technology magazine was rebranded to Milling and Grain in 2015
Europe
36 STORAGE: Moisture control in storage
40 STORAGE PROJECT: Grain handling equipment upgrades at Strawson’s Farms
EVENTS
62 Event listings, reviews and previews
42 STORAGE: Grain conveyors examining this important piece of equipment 52 Feed formulation and nutrition focus Ruminants
TRAINING
21 IGP Institute and GEAPS
COLUMNS 8 Mildred Cookson 9 Tom Blacker
2 GUEST EDITOR Jim Jundt
54 MARKETS John Buckley
76 INTERVIEW Joel Newman
Guest
Editor
Combining World-Class Education with Unparallel Industry Access As International President of the Grain Elevator and Processing Society (GEAPS), I am very excited to head to St. Louis Missouri, U.S. Feb. 21-24 for GEAPS 86th annual International Technical Conference and Exposition, also known as GEAPS Exchange. GEAPS is an international organization made up of grain handling and processing operations professionals around the world, and every year we gather to share knowledge and network with new contacts from across industry sectors.
GEAPS Exchange provides an opportunity to learn about emerging trends and technologies through education sessions and workshops, and to visit more than 350 solutions providers in more than 200,000 feet of exposition space. The Exchange is open to all industry professionals and we look forward to welcoming attendees from 23 countries this year. I think it is safe to say that wherever you are in the world, our industry is evolving at an amazing rate as we embrace new technology, and work to improve the safety and efficiency of our grain handling and processing operations. GEAPS Exchange combines industry-specific education designed to advance continual improvement in daily operations with the opportunity to meet with the suppliers that can provide the products,
services and technology for your business.
GEAPS Exchange provides an outstanding opportunity to learn about the trends and issues facing our industry. This year’s education topics include: electrical safety in grain handling and processing facilities, drones and their use in the industry, dust explosion hazard assessment, contractor selection, safety and management and more.
GEAPS educational programs are developed by members and industry leaders to provide industry-wide insight, standards and best practices. As the Exchange continues to grow, GEAPS will be working to expand the education program to offer sessions focused on processing operations. The newlyformed Processing Continuing Education and Credentialing Committee will also be meeting during Exchange to establish core competencies that will define new processing distance education courses.
GEAPS is growing with a global focus, and we are excited by the immense potential of expanding our options for processing professionals. I hope you have an opportunity to join us in St. Louis for GEAPS Exchange. Not only can you make valuable connections across industry sectors that will help your business run more efficiently, but you can also be on the forefront of creating world-class educational offerings that help drive the industry on a global scale. See you in St. Louis! Jim Jundt
Pacific Ethanol Columbia LLC, International President, Grain Elevator and Processing Society (GEAPS)
An industry resource for 2015
Feed statistics – who needs them? For a long time that was the attitude towards the collection of the most basic feed production figures by country and by species globally. Feed International and more recently AllAboutFeed were two publications that attempted the task believing they held the credentials and resources to secure and host a comprehensive database on industry production figures; the former showing the greatest commitment to an annual survey and review over many years. The task is necessary in order to show those of greatest influence – in government and industry – where the greatest need is in terms of animal proteins. MAG (under its former title of GFMT), published in early 2014 a benchmark of feed production per capita that countries need to achieve to address food security – that figure as 133.6kg. Alltech’s latest and most refined figures yet from 2014 (reported in this issue on page 19) support this figure.
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REGIONAL FOCUS
EUROPE Storage project
NEWS
New food crime unit The Scottish-based company, which was at the forefront of food safety in the horsemeat scandal of 2012, has welcomed the UK Government’s plan to set up a food crime unit to combat the trade in fraudulent products. See the full story on page page 16
Grain handling equipment upgrades at Strawson’s Farms In 1998 Strawson’s Farms, Louth, installed a range of 30 tonnes per hour (tph) and 60 tph grain handling equipment from Perry of Oakley Ltd and a 20tph drier. More recently Mr Strawson has found this system had not been able to keep up with the amount of grain he is now producing on the farm, and so made the decision to upgrade his drier and handling equipment. Each year Mr Strawson may need to dry up to 6000 tonnes which will be a combination of wheat, barley, oilseed rape and beans. See the full story on page 40
EUROPE STATS
HISTORY
EU exports 2013-14 512, 859 tonnes –the total amount of exported duram wheat, common wheat, seed and common wheat 716, 607 tonnes – the total amount of Barley exported 234, 227 tonnes – the total amount of wheat flour exported 246, 335 tonnes – the total amount of rapeseed exported 35, 705 tonnes – the total amount of oats exported 512, 859 tonnes – the total amount of tonnes exported of duram wheat, common wheat, seed and common wheat 6, 873 tonnes – the total amount of malt exported Source: HGCA
4 | Milling and Grain
Northern Europe has a unique place in the history of milling. Fortunately there are sufficient remnants of the distant past to stimulate interest. Although much is now consigned to museums and archives such as the Mills Archive (www.millsarchive.org), many European countries feature active groups of professionals and amateurs keeping traditional skills and techniques alive! See the full story on page 24
News
FEB 15
Milling
A blog dedicated to milling industry professionals globally
GLOBALGAP and GMP+ International enter into strategic alliance
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LOBALGAP and GMP+ International have entered into a world-wide strategic partnership. The respective Letter of Intent was signed by the two parties on the 27th of January 2015. GLOBALGAP and GMP+ International are both certification scheme providers who operate on an international level and whose activities ideally complement each other. Both organisations expect their alliance to strengthen their operations to the benefit of the involved certified companies in the feed, livestock farming and aqua culture businesses by providing greater uniformity and transparency as well as ultimately lowering cost. Both organisations, while keeping their independence, are looking to harmonise governance and system rules in order to provide a strong, efficient and transparent tool for the feed industry, which is also in the best interest of downstream livestock and aquaculture farmers. “We aim to achieve optimal results by focusing on our respective core businesses, while at the same time aligning the normative requirements so as to operate according to the same principles in governance, certification and integrity. In due course this will result in us being able to operate at lower cost while providing the same high quality levels”, says Johan den Hartog, Managing Director of GMP+ International. “With a focus on providing safe and wholesome food for consumers, we are joining hands with GMP+
6 | Milling and Grain
International to eliminate any possible certificate duplication and to create synergies in the standards and systems, thus enabling the feed industry and farmers to participate in a controlled chain of custody system”, Dr Kristian Moeller, CEO of GLOBALGAP explains. GLOBALGAP is a leading Good Agricultural Practice certification scheme for the primary production of arable products as well as for livestock farming and aquaculture. Today, approximately 140,000 primary producers are under GLOBALGAP certification in 118 countries, including 5000 livestock farms and 220 aquaculture farms, amounting to two million tons of farmed seafood. GLOBALGAP schemes primarily focus on product safety, environmental impact and the health, safety and welfare of workers and animals. The company is also active in the feed supply chain, where 75 larger compound feed manufacturing companies, with an annual production of approximately ten million tons of feed, have been certified to this day. GMP+ International is a global leader among Feed Certification schemes, addressing feed safety as well as feed responsibility issues, based on well-balanced multistakeholder participation in the feed & food chain. Today, more than 13,400 companies / locations in the entire feed (supply) chain in approximately 70 countries around the world are GMP+ certified.
The Global Miller blog is an online offshoot of Milling and Grain magazine. While the monthly magazine covers milling technology issues in-depth, the Global Miller takes a lighter approach. Our columnists have a keen eye for the most interesting, relevant and (let’s face it) bizarre milling stories from across the world. Each weekday we scour the internet for top-notch news and package it for your perusal in one neat daily digest. Nutriad survey analyzes Polish 2014 maize for mycotoxins bit.ly/1Ihl9hM 4B Braime appoints David Wolstencroft to ‘Operations Director – 4B Chains’ bit.ly/1vw2c5o AFIA/Eurofins Partner for HACCP and Feed Safety Courses bit.ly/1Ky286G Protease enzymes make lower-cost sorghum viable in animal feed bit.ly/1yQuP9h
GF
MT
gfmt.blogspot.com
The IMC Group launches ‘Contor’ – new ‘state-of-the-art condition monitoring to avoid costly breakdowns
C
ondition-based monitoring (CBM) is playing an increasingly important role in supporting preventative maintenance programmes. And it’s easy to see why, when the modest investment required to implement a CBM solution is compared against the potentially huge costs associated with repairing or replacing machinery that has been damaged. Designed and manufactured in the UK, the IMC Group has revolutionised condition based monitoring with the new wireless Contor system. With no need for external consultants Contor can be used for in-house predictive maintenance analysis to enhance internal preventative maintenance (PM) objectives. First customers report that Contor units are very intuitive and simple to use, and capable of accurately measuring and displaying shock impact and vibration data for critical equipment condition monitoring whilst in operation. One recent application is where Contor has introduced vibration and shock monitoring technology to a series of CNC milling machines used to produce aluminium parts for the aerospace industry. The unexpected failure of the machines had left the owners of the facility facing significant costs and loss of customer confidence. Central to the effective running of a machine are its spindles and bearings, which are subjected to massive forces during operation. Yet heavy demands on manufacturing and engineering teams, manual checking procedures are not always a high priority and when they are missed hidden problems can arise. Additionally, not all potential problems are even detectable by a worker, whereas monitoring technology can pick up the smallest inconsistencies. Contor uses tri-axial Piezo accelerometer technology to record precise spindle vibration, assisting the operator to manage preventative maintenance. The real-time condition based monitoring information provided by the IMC
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Key Benefits • Easy-to-use data collection and display • Accurately implement predictive maintenance regimes e.g. bearings by monitoring the RMS vibration • Significantly reduce machine downtime and loss of production • Increase machine life • Provide accurate data for warranty claims • Significantly reduce maintenance costs by reducing the number of unnecessary scheduled preventive maintenance operations • Optimise machine performance e.g. milling machines • Eliminate cost of consultancy Strengthen customer confidence Contor unit prevents damaging outcomes with instant alarm notifications of excessive impact to the spindle, providing customers with vital data that reduces maintenance costs and production downtime. IMC Contor uses sophisticated communication via ZigBee RF to a central Contor interface where data is stored within an SOL database. Data from the central IMC Contor interface can then be interrogated via the comprehensive software, overcoming a traditional problem of CBM systems where huge volumes of data are produced, which take significant time and expertise to analyse. The system developed by The IMC Group incorporates user-friendly software that automatically identifies potentially dangerous data trends and delivers an alert. Contor technology can output to MODBUS to work alongside customers’ existing systems, such as SEIKI, adding an additional layer of performance optimisation. Customers benefit from significantly reduced machine downtime and loss of production. Excessive vibration can be a symptom of problems and monitoring the RMS vibration of the system enables predictive maintenance for the bearings. Spindle damage is significantly reduced thus increasing spindle life. Milling machine performance is optimised, unnecessary maintenance is eliminated and costs are reduced. There’s even accurate data available for any warranty claims!
Milling News
COMPANY UPDATES
Delacon has restructured its research and development, product management and innovation schemes. These previously separated teams are now united within a division called ‘product innovation’. While remaining the species leader for poultry, Dr Jan Dirk van der Klis has become the head of this new division and now directly reports to CEO Markus Dedl. Delacon sets up an office in India and hires country manager. Their holistic benefits are paying off around the world. In order to deliver individual solutions for different markets, Delacon’s network is growing steadily. The company have set up with a permanent base in India and hired Dr Jeetandra Verma who will serve as company manager.
GLOBAL G.A.P. has recently teamed up with LEAF (Linking Environment and Farming), Sustainable Agriculture Network (SAN), launched a joint initiative (The Declaration of Abu Dhabi) together with the Sustainable Agriculture Initiative (SAI) platform and the International Trade Centre (ITC), and entered into partnerships with UNIVEG as well as REWE International AG. These were the first steps undertaken in 2014 to counteract the ever growing number of duplicate audits around the world and to increase the incentives for farmers to adopt safe and sustainable production methods, which will be followed by further new partnership initiatives in the coming years.
Get daily news updates on the Global Miller blog gfmt.blogspot.com February 2015 | 7
Milling Journals of the past at the Mills Archive
T
by Mildred Cookson, The Mills Archive, UK he third of the significant journals from the 19th Century that I am highlighting is The Weekly Northwestern Miller, a publication from the United States published by ‘The Miller Publishing Company’ based in Minneapolis, but with an office in London. It commenced publication in 1872. The paperback magazine varies in format, unlike Milling, which remained consisted for many years. The earlier editions were the same size as Milling, but later on the magazine was reduced in overall size to American Letter size (8.5 x 11 inches). The number of pages varied, sometimes issues were very thin with 40 pages and then increasing to thicker ones containing up to 92 pages. In general the magazines had more advertisements, attracting increasing interest as the years go by. The colours of the cover also varied, from various two tones to full colour, and then back again to twotone in the more recent editions. The front covers for some years had lovely colour illustrations covering many themes, from ancient milling, to a particular wind or watermill, or threshing and even nursery rhymes (see the 1925 cover -“Sing a song of sixpence, a pocket full of rye”). The 1903 cover was typical of many years before the First World War, advertising Nordyke & Marmon of Indianapolis, “America’s Leading Mill Builders”, with different illustrations of their flour milling machines. It was important reading for American Millers, as well as others in the trade worldwide, reading it kept you up to date with information and illustrations on new machinery and technology. The contents included correspondence, news about mills, and a section titled, ‘Local and Personal’. There were updates from each American state on the flour market, showing the week’s flour output, foreign and domestic flour and grain prices, etc., it usually had an article called, Around the World, which featured a mill or mills of a particular country. A weekly review of the help wanted, situations vacant, mills for sale and to lease and even pages on individual leading steamship and transportation lines for bulk freight. There was also a section on representative flour importers of Great Britain and the continent. One unusual column was headed: News by Telegraph (special cables and telegrams from Northwestern Miller correspondents). For example: “Kansas 8 | Milling and Grain
Mill Burned: Kansas City Nov 3rd –Special Telegram- the new 150-bbl mill of Edward Pierson at Lawrence, Kansas, was struck by lightning Saturday and damage done to the amount of $5,000 by the fire which resulted”. Inside the back cover of each edition there was an index of advertisers, which included many mills, many pointing out how good their flour was! One thing in particular caught my eye in the early editions, on each page there was the small illustration of a child stood against a barrel of flour with a full sack leaning on it, in the background is a windmill. Throughout each page of the magazines it shows the child doing something different as seen here in a couple of the drawings. The Mills Archive holdings from the first forty years of publication have recently been boosted by a donation from Satake, of an almost complete set of loose issues of the magazine, dating from the 1920s to the 1950s. We are now applying for a grant for binding them, but also importantly, a very large bookcase to hold them once bound! To find out more contact me on mills@millsarchive.org
Milling News
Mühlenchemie responds to the durum shortage
M
ühlenchemie has enlarged its Technology Centre to include a pilot plant for pasta; this is currently being used to seek economical solutions in response to the shortage of quality wheat for pasta production According to forecasts, the international wheat market will move in two opposite directions in 2015. Whereas an excellent harvest is expected for bread wheat / soft wheat, the durum market faces massive losses. The industry analyst Jim Peterson from the North Dakota Wheat Commission predicts the smallest harvest of Triticum durum in 13 years. The crop will be unsatisfactory in respect of both quantity and quality. This negative trend is to be seen in all the important producing countries. Italy, Greece, Spain and even Canada, the biggest exporter of durum, are expecting for serious losses. Bruce Burnett, the harvest expert of the Canadian Wheat Board, estimates that less than a quarter of the Western Canadian durum will achieve the top two quality categories. Another severely affected area is North Dakota, where about half of all the US durum wheat is grown. Unusually high rainfalls in the spring and autumn have done serious damage to the harvest. This state is expecting a fall in quantity of over four percent. The estimated loss to the US market as a whole is eight percent. In view of such bad news, insiders predict that financial pressure on the processing industry will increase massively in 2015. Many pasta manufacturers will have to make do with weaker durum qualities or resort to mixtures of pasta and bread flour. But such compromises generally result
in loss of quality. Bite, colour, cooking properties – all these factors depend to a large extent on the quality of the flour. Mühlenchemie, one of the world’s best-known enterprises in the field of flour treatment, is familiar with these complex interactions; for years it has developed customized enzyme systems that ensure efficient performance in spite of inferior flour quality. “To complement our years of expertise in raw materials, we have now invested in a pasta laboratory of our own which will enable us to meet our customers’ requirements even more specifically”, says Managing Director Lennart Kutschinski of Mühlenchemie’s latest service offer to pasta manufacturers. “On our Pavan pilot plant we can simulate practically any industrial process. For example, at the customer’s request we can test the effects of different enzyme systems and adjust the recipes accordingly. Is a compound from our Pastazym series the most suitable for treating this particular flour, or one from the EMCEdur series? How do they affect the taste, mouth feel and stability after cooking? On our pilot plant we find answers to all these questions on our customers’ behalf”, Kutschinski explains. Mühlenchemie’s Managing Director is convinced that the new all-round service meets a very real demand. “Our applications technology enables us to find practical solutions for the pasta industry that reconcile quality and economy even in difficult times. In recent projects, for example, we have replaced 75 percent of the durum with bread wheat and achieved the same quality and colour by using Pastazym. Support of this kind will become more and more significant in future.”
Local & Global Tom Blacker International Milling Directory It has been a busy time here at the International Milling Directory (IMD). The team headed over to IPPE in Atlanta USA, taking with us, several hundred copies of the Directory. Copies were distributed to visitors of our stand, and I am pleased to report that we got some very positive feed back about our latest print edition as well as some great ideas from readers, that we hope can be incorporated into our next edition and website over the coming months. It was great to talk to you! It always brings home the global scale of this industry when travelling to events such as IPPE - but something that we consistantly hear from you is, dealing with local companies is just as important in your day to day operations. This is a point that we have addressed in the new version of the IMD website. If you have visited www.internationalmilling. com recently, you will have noticed that we have a world map right there on our home page, complete with icons to show company locations (as well as a search tool). This allows our users to find suppliers in a specific country, and then see exaclty where there business is located. We hope that this will be a great addition to the site, not only for companies trying to find a local supplier, but also for companies that operate on an international basis, and want to find suppliers in a specific country. Later this month (21-24 Feb) we are looking forward to our visit to GEAPS Exchange, where we will taking copies of the IMD to distribute to the industry. If you are planning to attend the event why not come along to our stand and meet the team. On the subject of events - if you are from a company that is attending GEAPS (or any other event) - did you know that you can now enter this information onto the IMD website to let your customers know that you are attending?
Tom Blacker Directory coordinator February 2015 | 9
Milling News
T
EAAP gives the Best Poster Award to INRA and Adisseo’s researchers he scientific committee on animal physiology at the European Association for Animal Production (EAAP) decided to give the best poster award to Rosa Castellano, for its Research achieved in Inra Rennes under the supervision of Florence Gondret, in a collaborative project between INRA (Marie-Hélène Perruchot, Sophie Tesseraud) and Adisseo (Yves Mercier). The authors received the Award during the 65th annual meeting of EAAP in Copenhagen in 2014. Their work aimed to understand the effects of methionine supply on adipogenesis and lipid metabolism of pigs. The rewarded poster was focused on the effect methionine levels on adipocytes differentiation and adipose gene expression in vitro. This program allowed
a better understanding on how dietary methionine supply can modulate lipid deposition by changing nutrient energy usage towards lipid synthesis and hence explain excessive fat deposition when pigs are fed methionine deficient diets. This prize rewards the result of an effective collaboration between Adisseo and INRA centres emphasises Yves Mercier. This work was done in the continuity of a larger program initiated 4 years ago including Alberto Conde-Aguilera and Jaap Van Milgen on the effect of methionine levels on tissues amino acid composition and the effects on protein synthesis. Detailed information about the consequences on oxidative stress and redox status of pigs will be given at the 47th JRP (Paris, France, 3-4 February 2015).
AusScan Online - NIR calibration delivery is now live
offer access to its wide range of in vivo energy calibrations for broilers, pigs and ruminants,” they said. “Results will be delivered to the user via the website, where they can review previous results and trend their data. And the good news is they will only pay for what they need.” Aunir will also maintain and update the calibrations to ensure users enjoy access to the very best information to suit their businesses and operational needs. The expected usual proximate analyses will be offered, plus a range of non-starch polysaccharide and amino acid analyses, including total, reactive and standardised ileal digestible lysine. Users of AusScan Online can analyse their wheat, barley, sorghum, triticale, soya and canola samples via the website.
A
new online platform, known as AusScan Online, is set to revolutionise feed ingredient near infrared reflectance spectroscopy (NIRS) calibrations, thanks to a licensing agreement between the Cooperative Research Centre for High Integrity Australian Pork (Pork CRC) and Aunir. According to Pork CRC CEO, Dr Roger Campbell and Aunir Technical Director Chris Piotrowski, AusScan Online users no longer need to load the calibrations onto their NIR machine and are now able to upload spectra files to the new website, and run the calibrations over the internet. “But the most exciting aspect, is AusScan’s ability to
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10 | Milling and Grain
Milling News
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February 2015 | 11
Milling News
Polaris - a big star in milling heaven
The MQRG Polaris purifier from Bühler has already sold 800 times
F
irst presented to the public at the IPACK-IMA in Milan in the spring of 2009, the Polaris purifier from Bühler is now successfully positioned on the market. As a stand-alone machine or as part of the Bühler triumvirate Antares-Sirius-Polaris, the completely revised purifier from Bühler has earned a fixed spot in milling heaven. Since its market entry in 2010, Bühler’s state-of-the-art purifier Polaris has already sold 800 times worldwide. The Polaris, listed as article MQRG at Bühler, is primarily used in durum mills for manufacturing high quality semolina for the production of premium pasta. With its high throughput capacity and increased yield for lowash flours the Polaris purifier can also be used in milling
where particularly light and thus low-ash content flours are being produced. Bühler’s customers appreciate the 20 percent increased throughput rate of the Polaris, the maximum purification capacity with its extremely high yield of speck-free semolina, the user-friendly operation and monitoring as well as the maintenance-free operation.
Since 1947
www.perryofoakley.co.uk sales@perryofoakley.co.uk +44 (0)1404 890300
IMD in print The 23rd print edition of the IMD is out now! The 23rd edition is bigger and better than ever before!
23 2014/15
IMD on the web Our website has been completely revised for 2015 with new features and a better user experience
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Milling News
New food crime unit
Horsemeat scandal watchdog R-Biopharm Rhône welcomes plan for new food crime unit
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he Scottish-based company, which was at the forefront of food safety in the horsemeat scandal of 2012, has welcomed the Government’s plan to set up a food crime unit to combat the trade in fraudulent products. R-Biopharm Rhône, the manufacturer and one of Scotland’s biggest exporter of diagnostic test kits, hailed the recommendation which is the major plank in a report by food security expert Professor Chris Elliott of Queen’s University Belfast. He has suggested food crime prevention measures including better intelligence gathering, unannounced audits, improved lab testing capacity and a more investigative approach by the food industry to its supply chain. Simon Bevis, Managing Director of R-Biopharm Rhône, said: “This is a welcome move and it is encouraging that ministers have indicated that all the recommendations in Professor Elliott’s report will be accepted. “It is of the utmost importance that consumers in the UK can have confidence in the provenance of their food and be assured that the product is actually what it is labeled as. If it is not, then it is fraud.”
R-Biopharm Rhône was in the front line of the UK’s defences against food contamination during the horsemeat scandal two years ago, when the Food Standards Agency found beefburgers with traces of equine DNA, leading to tens of millions of burgers being taken off the shelves by major retailers. The company is now spearheading investigatory testing as concerns mount about cheap fish being substituted for expensive fish without the consumer knowing. Carol Donnelly, Marketing Manager at R-Biopharm Rhône, said: “We are seeing increasing concerns, particularly in the fish processing industry, about cheap fish, such as pollock or coley, being substituted for premium species such as cod.” The Glasgow-based company sells DNA test kits which can determine the authenticity of fish products and provides a testing service to speedily let companies know if their fish is the species they paid for.
UK industry stalwart Pat Donovan passes away Patrick Donovan CBE passed away peacefully on Monday 2 February, aged 90
P
at was born in the Liverpool area but spent his first few years in Dublin. He came to England in the 1930’s after his father left the family flour milling business (John Donovan & Sons) in Tralee, County Kerry and set up Kings Mills at Knottingley, Yorkshire. He was later educated at Belmont Abbey School, Hereford. He was always keen on sport and became Captain of the school rugby team. In later years he returned to play in the Old Boys rugby matches. One year he captained the Old Boys team and the school captain was his eldest son David as his three sons went to the same school. On leaving school he joined the family flour-milling firm, Kings Mills at Knottingley and served his apprentice there. Having obtained his first class City and Guilds certificate he then went to do his National Service in the Army and got a commission. On leaving the army he re-joined the family business with his brother Denis as his father had had a stroke. He and his brothers continued to expand the business. Then in 1962 the family sold out to Associated British Foods and became part of Allied Mills Ltd. Pat and Denis continued at Kings Mills until Pat was moved to some of the other mills within the group before becoming Managing Director of Allied Mills: later to become Chairman 16 | Milling and Grain
and Managing Director; then a Director of Associated British Foods Ltd under the Chairmanship of Garry Weston. Pat then made sure Allied Mills kept up to date and in the fore front of the milling industry. He started to expand the activities of the group into starch production, grain merchanting, rice milling, grain import and export and maize milling. He was very much involved in the activities of the National Association of British and Irish Millers of which he was President on two occasions for his work for NABIM he was awarded the CBE. On a few occasions he was invited to America to talk to the milling industry there about the improvements in the modern milling industry. His widow, Margaret, survives him. Pat has three sons none of whom came into the milling industry but were successful in their careers. He was always concerned about members of his staff and took an interest in them. Rugby was his main sport playing as regular member of Headingley Rugby Club (Leeds) and for Yorkshire. The other sports he played were tennis and badminton. He liked walking and did so most days. The funeral will be held on Tuesday February 24 with a Requiem mass 11:30 at St Gregory’s Catholic Church, St James Square, Cheltenham GL50 8LE (No flowers please, donations instead to Stroke Association and Age UK). Contributed by Noel Donovan, Pat’s brother.
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The industry’s most authoritative resource on feed production
TWO PERCENT YEAR-ON-YEAR INCREASE
RUMINAN T2
7%
India
29
Japan
24
France
22
Spain
Russia Germany
29 26 24
5
5
3
0
8
14 1 9 6
10
5.3
5
3 2 3
7
3
3
4
0.2 24
55
0.2
4
11
0
0.2 0
0
0.3
0
0.4
6
2
31
0
18
0.4
1
1
2
7
11
0.3 0.2
Horse
Broiler
20
0.3
2
41
0
0.1 0.1 5
Layer
Calf
Dairy
Beef 2
21
Pets
31
6
19
Aqua
66
Mexico
85
24
Turkey
USA 173
Pig
Total mil tonnes
FEED BY COUNTRY
2
The findings based on the data from 2014 reveal an increase of two percent in the feed industry. Global feed tonnage was measured at 980 million metric tons, while last year it was roughly 960 million metric tons. Feed industry trends throughout 2014 were impacted by myriad events, including widespread droughts, high costs of raw feed materials, fluctuating governance over import/export standards, and animal diseases such as avian influenza and the PED virus in pigs, which proved to be disastrous for many farmers.
China 183 Brazil
P
0%
LTRY 45% OU
Increase over 2014
Looking at global livestock species, poultry held its position as industry leader with a 45 percent share of the feed market at 439 million tons. Pet and pigs saw the largest percentage of growth, with 5 percent increase in pet food and 5.3 percent increase in pig feed. Aqua saw a slight 1.8 percent increase and poultry and horse both saw a decline.
PIGS
2
015 marks the fourth consecutive year that Alltech has conducted its global feed survey. It has become the industry’s most authoritative resource on feed production by country and by species and has challenged several leading organisations that represent animal feed output to re-evaluate and bring their figures up-to-date. “This undertaking requires a significant amount of work each year, mainly because the feed industry is measured differently and in varying degrees of thoroughness from country-to-country,” says Aidan Connolly, Alltech’s Chief Innovation Officer. “Yet, each year, better information is discovered and more is learned about how farmers around the world feed their livestock.” Alltech isn’t the only entity interested in these trends. Increasingly, more farmers, supply companies, the Food and Agriculture Organization of the United Nations, Non-Governmental Organizations, food businesses and indeed consumers are interested in what goes into the food humans consume. What foods are truly nutritious? How do farmers raise livestock that are healthy? How can agriculture increase efficiency and therefore, feed more people? Answers to these questions and many others can be found by starting with an examination of the feed animals are eating worldwide, says the company. The report outlines Alltech’s estimate of the world’s feed tonnage and trends to date and is intended to serve as an industry resource for the coming year. Alltech assessed the compound feed production of 130 countries. “Where possible, information was gathered in partnership with local feed associations and, when that wasn’t possible, it was done utilizing information collected by the more than 600 members of Alltech’s global salesforce, who had direct contact with more than 31,000 feedmills. “When reviewing the data, there are two considerations to bear in mind. “First, numbers for less developed countries may be less accurate, but given their size, this had little numerical influence on the overall dataset. Second, the definition of feed, feed mill and species varied from country to country,” adds Mr Connolly.
0
9
6
1
0.5
0
0
1
3
0.4 0.2 0.5 0.2
4
10
0.6
2
4
0
9
6 2
11 4 3
0
1
0
0
1
0
0.5
0
0
0
0.3
0 0
0.3
1.1 0.3
Although China was once again the leading producer of feed with 183 million tons manufactured in the official estimate of more than 9500 feedmills, this is the second year of decline in its production. The country experienced a notable four percent decline from last year’s numbers. Some analysts contribute this downturn to a slow hog market and bird flu that suppressed consumer demand. India, on the other hand, had a considerable increase in feed production, up to 29.4 million tons (a 10 percent increase over 2013), owing mainly to favorable weather conditions and consistently-improving farming methods and technology. The United States and Brazil ranked second and third respectively, with 172 million tons from 6,718 feed mills and 66 million tons from 1,698 feed mills. When grouped into regions, Africa and Latin America saw the greatest growth in 2014. Asia Pacific, Europe, North America and the Middle East all showed a slight incline. Several individual countries can be highlighted as bright spots of growth and development. Among them were Turkey, Indonesia, Romania, Tunisia and Bolivia, all of which experienced their second consecutive year of significant increase in feed production. February 2015 | 19
Mill
Training
As the milling and grain processing industry continues to evolve internationally, it is vital that milling personnel obtain a consistent level of understanding throughout the profession. The Kansas State University IGP Institute has developed a combination program of on-site courses and distance education courses to advance the skills of industry professionals.
through trainings sequenced in a structured program that was developed and peer-reviewed by many of the grain industry’s top specialists. All of the material is based on current industry practices and standards that course participants can relate back to their respective businesses. “We’re confident that grain processing and milling companies will find the courses and credentials very useful,” says Dirk Maier, IGP Institute director. “They help train new employees and improve the job skills of current employees – even up to the veteran levels. They also help build a career path for young people proving them with qualifications at the entry level.”
Helping to Grow Industry Expertise - IGP Institute and GEAPS partner to offer credentials to the rapidly growing processing industry “We wanted to develop a training program that would benefit new millers, mill owners and others involved in the grain industry,” says Mark Fowler, IGP Institute associate director. He adds, “It is beneficial for young professionals whether they are graduating from high school, technical school or with a bachelor of science from a university to receive milling-specific training as they are entering the workforce.” To meet these demands, the IGP Institute is partnering with the Grain Elevator and Processing Society (GEAPS) to offer distance-learning courses that lead to credentials in either grain processing or grain operations management. Through these courses, new employees are able to learn
Training courses February
GEAPS 521: Aeration System Design and Fan Operational Management GEAPS 530: Quality Management Systems for Bulk Materials Handling Operations GEAPS 544: Preventing Grain Dust Explosions
To learn more about the credential program, course content and schedules, please visit the GEAPS website. Following is a brief description of the courses that might be of great interest for milling industry professionals. These are planned for February and March. Registration for the February trainings closes February 3 with the courses being conducted on-line from February 9 to March 13. The March trainings registration closes March 10 with the courses being conducted on-line from March 16-April 17. The cost for the training is $640 for GEAPS members and $815 for non-members. To view a full course description and register, visit the GEAPS website www.geaps.com
March
GEAPS 500: Introduction to Grain Handling Operations GEAPS 540: Safety Management of Grain and Processing Facilities GEAPS 620: Grain Receiving, Cleaning and Conditioning (Processing) To learn more about the IGP Institute, please visit the website at
www.grains.ksu.edu/igp
February 2015 | 21
Wide-Corr® Centurion® bins
PRODUCT FOCUS FEBRUARY 2015 In every edition of Milling and Grain, we take a look at the products that will be saving you time and money in the milling process.
Wide-Corr® Centurion® flat bottom bins and Wide-Corr® Centurion® hopper bottom bins are designed for the rigors of commercial applications including use in grain terminals, feed mills, and biofuel facilities. Designed for faster assembly and improved overall strength, Westeel’s patented commercial series roof features 100% bolting on all roof panels and a tight middle connection. For added insurance against sagging and leaking from heavy snow or ice, Wide-Corr® Centurion® bins include heavy beam roof framing supports with patented continuous ring purlins and tension plates.
www.westeel.com
Kanalsystem™ Grain Cooler Grain is our food! Using a Tornum Grain Cooler we can help you treat it that way. A Tornum Grain Cooler accomplishes what nature cannot always provide – safe storage temperature regardless of ambient conditions. The Kanalsystem™ was originally designed to provide the quality airflow to properly condition grain using the total climate control provided by the TORNUM Grain Cooler. It has accomplishes this goal in all types of silos up to 170 ft (52m) height and is equally at home in flat storage buildings.
With the GEAPS EXCHANGE 2015 coming up on February 21-24 in St Louis Missouri (USA) - we take a look at some of the products on display from more than 350 exhibitors that will be attending this year
www.tornum.com
Titan series TSG Slide Gate The Vortex Titan Series TSG gate is designed to meet the most demanding applications when handling heavy-duty abrasive materials such as sand, gravel, coal, whole grains, metal powders or minerals. The TSG gate handles dry material in gravity flow applications where positive material shut-off and dust tight sealing are required. Vortex slide gates offer a wide variety of actuation choices – including electric, hydraulic, pneumatic, chain wheel, and hand crank. Features include hardened steel cam-adjustable rollers, grease zerks, side mounted switches, carbon steel contact, inlet/outlet transitions, seal access ports, removable seals, and more.
www.vortexvalves.com
22 | Milling and Grain
Bolt ‘N’ Go™ Drop Forged Chain The Bolt ‘N’ Go flight system is a revolutionary assembly method for drop forged conveyor chain designed to reduce downtime and maintenance costs. Link and flight assembly has been made easy by using a standard bolt and nut with a high strength hollow pin. There are no circlips to become loose and no intricate assembly. No welding is required to attach flights, no need to remove chain from the conveyor for installation, and no issues with strength. Just bolt the links and the flights together. It’s easy, simple and reliable! The Bolt ‘N’ Go system is available in 7 chain sizes ranging from 102NA to 200NA.
www.go4b.com
FOCUS
SPECIAL FOCUS
The Roff R70
The Roff R70, launched 17 April 2013 on the farm of Mr Flippie Blignaut, is arguably South Africa’s most costeffective, compact four tonne per hour mill. Roff has already installed two of these mills in Zimbabwe to ensure more affordable food staples for the public by reducing supply chain and distribution costs. Perfect setting for the R70 - As a successful business built through hard work, innovative thinking and the agility to adapt to changes in the marketplace, Mr Blignaut’s farm provided the ideal backdrop for the South African launch of the versatile R70. The farm’s mill, Sardinia Milling, was established 13 years ago to add value to the primary crop, maize. A combined farming model ensures optimised efficiency and an increased profit margin. Maize is produced, stored in silos on site, high
conditioning equipment (with a conditioning bin), degermination, milling, sifting, conveyors, electrical panel, electrical cabling and all steel structures. Clients only need to provide the building, water point and electrical supply to the panel. • Compact to save floor space and reduce installation costs, the Roff R70 has the capacity to produce 100 tonnes of maize per day. This equates to 30,000 tonnes per year, which is a potential annual turnover of R100 million; • The R70 is one of the best value for money maize mills on the market, with the cost of the installed mill in South Africa between R2.5 million and R3.5 million for a 4 tonne per hour plant, with smaller capacity options also available; • To reduce installation time on site, the mills are preassembled in the Roff factory; • Sheet metal parts are laser-cut to ensure excellent quality;
quality endosperm is extracted and marketed as top-notch meal, and maize bran – a by-product of the milling process – is used as base for the animal feed provided to cattle feeding schemes. As such, maize only leaves the farm in the form of meal and livestock. This model shortens the supply chain to ensure maximum profitability. The end-user also benefits, as a large percentage of the product is distributed within in a small radius, which keeps distribution costs to a minimum. Grown across a huge part of Africa, there is a move towards processing and distributing maize in the area in which it has been produced. Entrepreneurs can still supply to other areas if it proves profitable, but by supplying more maize in the vicinity of the farm, transport costs are greatly reduced. The Roff R70 mill can play a significant role in the reduction of supply chain and distribution costs, as it provides a compact, all-in-one solution to farmers like Mr Blignaut. R70’s innovative design optimises productivity The Roff R70 comes standard with a surge bin for maize inlet, cleaning and
• All operational equipment is installed across two levels, so that processes are visible from multiple angles. This enables the miller contact with the process and easy control of the plant; • All components are easily reachable. The top floor is not an operational floor, but mainly used for maintenance purposes; • The R70 is a proudly South African mill. With the exception of a few small parts, it is manufactured in Roff’s Kroonstad factory; and • For the client’s peace of mind, the R70 is covered by an optional maintenance contract. Adding value to a wide client base - Small enterprises can also benefit from the Roff R70 mill, as it can be installed at two tonnes per hour on a similar platform as the R70 on the Blignaut farm. It is easily upgradable to a four tonne per hour configuration without missing more than 48 hours of production time during the upgrade.
www.roff.co.za February 2015 | 23
#
2
F
Researching and Reporting
Milling in Northern Europe A historical overview Northern Europe has a unique place in the history of milling. Fortunately there are sufficient remnants of the distant past to stimulate interest. Although much is now consigned to museums and archives such as the Mills Archive (www.millsarchive.org), many European countries feature active groups of professionals and amateurs keeping traditional skills and techniques alive!
by Mildred Cookson
I
n 1972 a group of volunteers set up Gilde van Vrijwillige Molenaars in the Netherlands. This “guild of volunteer millers” (http://tinyurl.com/ oe6bx69) runs training courses and provides proficiency certificates, which are required by most Dutch mills. In the UK in 1987, I helped to set up the Traditional Cornmillers Guild for professional millers operating traditional wind or water-powered flourmills, and this is still going strong (http://www. tcmg.org.uk/). Before the middle of the 19th century such traditional mills were vital to the rural economies of Europe and the subsequent “roller flour mill revolution” has been well described by Rob Shorland-Ball in previous issues of this magazine. The tide of technology and economic necessity stimulated by the Industrial Revolution ensured the rapid adoption of new more efficient milling techniques across the continent. In the United Kingdom as well as the rest of Northern Europe, these changes took place over several decades. Almost all villages would have had their own wooden post mill supplying the local community with its flour. With growing populations, villages and towns expanded and new canals and railway systems appeared, allowing grain to be brought to the mills instead of relying on local crops. Soon new mills were built next to rivers and canals for easy unloading of imported cereals. With these new mills came the opportunity to install the new roller mills. As early as 1820 several roller mills were invented, in Switzerland, Austria and France but none worked well enough to go into production. An important breakthrough in design came in 1834 when a Swiss engineer, Sulzberger, used three pairs of
24 | Milling and Grain
steel rollers (two smooth, one fluted) with a speed differential. Although these were adjustable, they did not give under pressure and had no feed control. Even so, Müller of Warsaw built several of these mills in Switzerland, Germany, Italy and Hungary. The roller mill was still not accepted yet as ‘The Miller’ journal stated in 1876 – “there is a lack of adaptability and intelligence of the workmen”. The breakthrough came in 1873 when another Swiss, Frederick Wegman, developed a roller mill with porcelain roller, where the pressure was kept constant. Together with Ganz & Mechwart of Budapest the roller mill was improved; now recognisable as the modern roller mill (see Rob’s article in the previous issue of Milling and Grain, page 24), it was soon advertised and used all over Northern Europe. In 1878 there were 9,000 flour and
F provender mills recorded, by 1887 there were 461 roller process mills and Milling magazine suggested that in 1901 there were over 1,000 complete roller mills in the British Isles. Roller milling transformed flour production across Northern Europe, and gradually the likes of Simon, Buhler etc., with their roller systems allowing proper adjustment and requiring less attention, offered higher capacity, and more grades of flour. The roller flour revolution had begun and was here to stay. In my travels across Europe during the 1980’s and again in early 2000 I saw that in many villages in Hungary, Germany, France and Denmark the wooden post mills were still being used, adapted to roller milling to grind local cereals such as wheat, rye and spelt. The Mills Archive is intending to set up an archive devoted to the history of roller flour milling across the world. A heritage spanning almost 200 years has been sadly neglected and we plan
to offer a safe home to documents and images that cover not only the transition from traditional to modern flour milling, but also the stories of the people and firms involved in the drive for more efficient flour production. If you can help in any way or would like to know more please email mills@millsarchive.org
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February 2015 | 25
Figure 2: Different types of iron compounds
F
Fortification
E
effect of different iron compounds on the colour of dried noodles and pasta by Lena Kampehl and Martina Mollenhauer, Mühlenchemie GmbH & Co KG
very year, 600 million tons of wheat and maize flour are produced and consumed in the form of noodles, bread and other flour products. Fortification of industrially produced wheat and maize flour is therefore a simple and effective way of providing the world’s population with vitamins and minerals. Industrially produced flour is defined as products from mills with a capacity of more than 20 t/day. According to the FFI, nutrients are added to about 30 percent of all industrially produced flour worldwide. It estimates that 97 percent of the wheat flour in America, 31 percent in Africa, 44 percent in the Eastern Mediterranean, 21 percent in SouthEast Asia, six percent in Europe and four percent in the Western Pacific regions are fortified. The consumption of flour with added vitamins and minerals is a significant step towards preventing micronutrient deficiencies. The cost of flour fortification is more than made up for by savings in the public health system. In the United States, fortification is credited with preventing 1,000 neural tube defects a year. Annual fortification costs are approximately US$ 3 million, and direct medical costs averted are US$ 145 million per year; consequently US$ 48 is saved for every dollar spent on fortification. One indication of the success of flour fortification is that at least law in 82 states now prescribes the addition of iron or folic acid to flour. Three countries follow the recommendations of
26 | Milling and Grain
the World Health Organisation (WHO) voluntarily, and in 22 countries including Turkey, statutory flour fortification is in the planning phase. In 2004 only 33 states took part. There are very different approaches to regulating fortification. It is important to consider the eating habits and nutrient deficits in the country concerned. Some countries fortify all flour with micronutrients, which means that all the resulting products benefit. Other countries treat flours according to the purpose for which they are used, so there are differences between bread and pasta flour, for example.
“Fortification of industrially produced wheat and maize flour is therefore a simple and effective way of providing the world’s population with vitamins and minerals” There are also different recommendations for the minerals to be added. Whereas some countries only specify the quantity, for example of iron, others state, which iron compound, is to be used, e.g. ferrous sulphate. The following tests were carried out because the use of ferrous sulphate is prescribed compulsorily in one Latin American
F
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28 | Milling and Grain
Revised Buckets C2 half page 2.indd 1
21/09/2010 11:37:09
country. When fortified flour was used in noodle production, the boiled noodles were found to have noticeable grey discolouration, which was not acceptable to consumers. Six different iron compounds were used in the series of tests. The dosage used was 60ppm iron, since this is the highest level in the flour fortification standards. The 60ppm iron were converted for the iron compounds according to molecular weight, added to the flour and mixed with it. The differences in the uptake of iron into the bloodstream (bioavailability) were not taken into account in the tests. In practice, however, it is usual to adjust the dosage of the iron compounds to their bioavailability, so that similar amounts of iron are available in the bloodstream. For production of the spaghetti, a hard wheat with 12 percent protein was used. The water content of the noodle dough was 32 percent. In the laboratory the spaghetti was pressed with a Sela pasta machine, type TR 75 W, and dried for 24 hours at 35 °C and 60 percent relative humidity. 100 g pasta were then placed in 1 litre of boiling water with 5g salt and boiled for 8 minutes. The dried and the boiled noodles and also the water in which they were boiled were compared visually (Table 1). Ferric pyrophosphate, ferric orthophosphate and electrolytic iron had no effect on the colour of the noodles. With ferrous fumarate and ferric sodium EDTA the noodles were lighter in colour and less yellow, and with ferrous sulphate they had a noticeable greyish tinge. The reasons for this presumably lie in the reactivity of the iron. An analysis of the water used for boiling also suggested reasons for the differences in colour. In ferric pyrophosphate and ferric orthophosphate the iron is in a trivalent form and chemically inert. It does not enter a reaction. Since the products are not soluble in water, they are not washed out in the cooking process, and the noodles remain similar in colour to the untreated controls. The divalent iron in the sulphate and fumarate enters redox reactions with the colour-giving substances of the flour, e.g. carotenoids, and this results in colour changes. Ferrous sulphate is more readily soluble in water than the fumarate, and thus more reactive. The colour deviation of the boiled pasta is therefore more noticeable than when fumarate is used. The ferric sodium EDTA forms a complex with the pigments, which are partly washed out when the pasta is boiled. This is further confirmed by the loss of 40% of the iron through cooking. The boiled noodles were the lightest in colour in the comparative test.
F
Hydronix Moisture Sensors
Save You Money
Hydronix digital, microwave moisture sensors are designed and manufactured in the UK and provide accurate and cost effective moisture measurement and control in feed meals and pellets, grain, cereal and pulses.
Hydro-Probe XT
Figure 1: Status of flour fortification in December 2014. 82 states require the fortification of flour with at least iron and/or folic acid (Source: FFI, 2014).
The Hydro-Probe XT has been specifically designed to measure moisture in organic materials, typically being installed in or underneath silos or in the material on a conveyor. The Hydro-Mix VII is a flush mounted sensor that is ideally suited to installation in mixers, augers or the inlet / outlet of grain dryers. Both sensors offer a choice of digital measurement modes enabling the producer to select the best option for the material being measured.
Hydro-Mix VII
Table 1: Changes in the colour of noodles caused by different iron preparations
Following the above results, the use of ferric phosphate for fortifying pasta flour was permitted in the country concerned, and consumer acceptance was restored.
References:
FFInetwork.org - Food Fortification Initiative WHO Recommendations on Wheat and Maize Flour Fortification, Meeting Report: Interim Consensus Statement, 2009 3 Grosse, Scott, et. al., Reevaluating the Benefits of Folic Acid Fortification in the United States: Economic Analysis, Regulation, and Public Health. American Journal of Public Health 95 2005:1917-1922. 1 2
Hydronix sensors include:
• • • • • • •
Digital technology with precise linear output Wide moisture measurement range Suitable for chutes, silos, mixers or conveyors Choice of measurement modes Not affected by dust or colour Different installation options Temperature stable
enquiries@hydronix.com
www.hydronix.com GFMT half page vertical 90 x 270 plus 3mm bleed not left.indd 1
February 2015 | 29
13/01/2014 10:00:18
F FLOUR
FORTIFICATION MONITORING
T
Flour millers in three countries demonstrate ‘rigorous’ fortification monitoring by Sarah Zimmerman, Food Fortification Initiative
hree recently completed case studies have verified that industrial flourmills in Chile, Indonesia, and the Republic of South Africa (RSA) have rigorous internal controls to confirm that their products comply with country standards for fortification. While other types of monitoring varied considerably, the studies show that milling leaders have developed standard operating procedures to maintain and improve internal quality systems. “We are pleased to see that these flour millers are at the forefront of ensuring that their customers receive the health benefits from fortification,” said Helena Pachón, Senior Nutrition Scientist for the Food Fortification Initiative (FFI). The studies are a collaborative effort between UNICEF, FFI, and the U.S. Centers for Disease Control and Prevention. Research for the case studies included interviewing government personnel responsible for monitoring fortification and visiting mills, bakeries, food retail outlets, inspection laboratories, and companies that produce vitamin and mineral premix. The authors found that the industry had instituted regular physical and visual control points. Industry procedures used for internal monitoring in the three countries included: • Check weighing the premix feeder. This is when a miller weighs the amount of premix discharged by the premix feeder over one to two minutes then compares the amount to the weight of premix expected to be discharged over that period. • Ensuring that the feeder is working properly. This involves confirming that the feeder has adequate amounts of premix and that it is delivering the required quantity of premix. • Recording results of fortification checks. This includes keeping accurate records, such as the amount of premix used compared to the amount of flour produced, so if a variation from the norm is noted, it can be resolved. Several resources are available to help plan monitoring programs. For example, the FFI website has a page about internal quality control at http://www.ffinetwork.org/monitor/internal. html. The Flour Millers Toolkit at http://www.ffinetwork.org/
32 | Milling and Grain
implement/toolkit.html, which offers a section on assuring quality control at the mill. The World Health Organisation and the Food and Agriculture Organisation of the United Nations discuss other types of monitoring in detail in the book “Guidelines on Food Fortification with Micronutrients”. See http://www.who.int/ nutrition/publications/micronutrients/9241594012/en/ Yet, the collaborating partners for these case studies determined that very little information was available on how fortification monitoring operates in real-world settings. The case studies consequently looked at the strengths and challenges of actual monitoring systems in three regions. Rigorous internal monitoring was one of the few things the countries had in common. Among the highlights from the other types of monitoring are: • Chile has the most comprehensive external monitoring plan in which government regulators conduct a strategically planned and financed program. The program focuses on the point of production and on-site warehouses with some review of the mill’s internal records of fortification monitoring. Warnings and sanctions are issued if flour samples are non-compliant in two or more micronutrients. Results of Chile’s monitoring activities are published annually on the Ministry of Health website. • Indonesia has the most extensive commercial monitoring program as it concentrates efforts on the retail sector. Commercial monitoring assesses whether flour being sold at retail establishments is properly fortified. • Indonesia is the only country of the three studied with significant amounts of imported flour. All premix shipments require a Certificate of Analysis at Customs, but a lack of laboratory resources and funding restrict regular monitoring of imported flour. • Chile is the only country of the three studied with a household and individual monitoring aspect of the fortification program. This determines whether fortified flour is available and being used by specific population groups. • All three countries have some health impact evaluation component, which determines whether the nutritional goals of the program are being met. Some of the impact evaluations are
F
Ramadan Deliu, Head of Laboratory at M & Sillosi Milling Company in Kosovo, prepares flour for an iron spot test. Photo credit: Kate Wheeler
conducted through non-governmental special projects. This information can be used to improve fortification to achieve the maximum health benefits. For example, the Republic of South Africa is using its impact evaluation to reconsider the levels and type of iron used in fortification. While the case studies reviewed all aspects of monitoring, not
all components are needed for every flour fortification program. Commercial monitoring of packaged flour may not be needed, for example, if most flour is distributed to bakeries rather than sold at retail outlets. And import monitoring may not be needed if most flour is domestically produced. Ideally fortification monitoring programs are created by
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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: info@nabim.org.uk www.nabimtraining.com February 2015 | 33
F
CASE STUDIES A number of case studies that support this article are available online: Chile: www.ffinetwork.org /monitor/Documents/ChileCS.pdf
Indonesia: www.ffinetwork.org /monitor/Documents/IndonesiaCS.pdf
South Africa: www.ffinetwork.org /monitor/Documents/SouthAfricaCS.pdf multiple-sector stakeholders who consider the country’s capacity to measure the program’s performance. The stakeholders can evaluate the human, technical, and financial requirements for
34 | Milling and Grain
effective monitoring then design a fortification program with the resources needed to implement a monitoring program. In most cases, however, it is logical for national fortification programs to include at least internal and external monitoring, Pachón said. Internal monitoring at the production site identifies and resolves issues quickly before problems become widespread. Since flour milling is typically a centralised industry, external monitoring of a smaller number of mills is usually more practical than commercial monitoring of thousands of retail establishments. As the next step, collaborating partners reviewed the case studies to identify key components for successful monitoring programs. This led to several questions that are being asked of all countries that legislate fortification of wheat flour, maize, flour, and/or rice. The questions include: • Is there a national committee that oversees the flour fortification program? • Are rules and operating procedures by national authorities for external monitoring, commercial monitoring and import monitoring of flour fortification stipulated in a document? • Has a national report on the status of wheat flour fortification monitoring and compliance been compiled? • Has an impact evaluation of the wheat flour fortification program been completed? This information will be added to FFI’s database on global fortification progress and become a resource for countries wanting to design or improve fortification monitoring programs. A good example of a well-designed evaluation is an effectiveness evaluation of the food fortification program in Costa Rica. The study, published in the American Journal of Clinical Nutrition in November 2014, indicates that fortification is the plausible cause of improved iron status and reduced anemia there. Costa Rica had been using reduced iron in wheat flour; however, it is not an effective iron compound for fortification. In 2002, the fortification standard for wheat flour was changed to include ferrous fumarate. Also, ferrous bisglycinate was added to maize flour in 1999 and to liquid and powdered milk in 2001. The study used national surveys and sentinel sites before and after those years to gather baseline and follow up data. Authors also gathered monitoring data and found that foods were fortified as mandated. The results showed that anemia declined in women (from 18.4 percent to 10.2 percent) and children (from 19.3 percent to 4.0 percent). Fortification of milk and wheat flour provided about half the estimated average requirement for iron in children. In children, iron deficiency declined from 26.9 percent to 6.8 percent, and iron deficiency anemia, which was 6.2 percent at baseline, could no longer be detected at the follow up assessment. FFI has traditionally tracked the number of countries with legislation to fortify wheat flour. In 2004, 33 countries had documented national regulations for adding essential vitamins and minerals to wheat flour. By 31 December 2014, 81 countries had such legislation, 12 countries included maize, and six countries required rice fortification. While the increase in legislation is progress, fortification must be well implemented and monitored for it to have the desired health impact. The industry’s role in internal monitoring, as documented in these case studies, is a positive step toward that goal.
Celebrating the 90th anniversary of Mühlenchemie
Mühlenchemie – we never sleep. As the international market leader in flour im provement and flour fortification, Mühlenchemie operates in over 100 countries worldwide. Our branches in Germany, Singapore, Brazil, China, India, Mexico, Russia and Poland advise our customers on the spot and collaborate closely with our own laboratories and trial bakeries, of which we have several around the globe. So when the staff of our facility in Wujiang, near Shanghai, make their way home at the end of the day, work has already started in Mexico City – and of course noone turns the light off before an individual solution has been found for each of our customers.
• Flour improvement • Flour standardization • Fortification with vitamins and minerals • Flour analysis • Applications services • Metering equipment for micro-ingredients
German Quality made by Mühlenchemie.
A member of the SternWywiol Gruppe
info@muehlenchemie.de
www.muehlenchemie.de
STORAGE
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MOISTURE CONTROL IN STORAGE
B
entall Rowlands Storage Systems Limited is a leading UK manufacturer in complete storage and processing equipment solutions for the agricultural and industrial markets. We offer a wide range of galvanised steel silos and hoppers, water tanks, catwalks and platforms, material handling equipment, cleaning and grading and weighing and drying systems that are assembled worldwide. With the capabilities to design, manufacture, supply, and install storage systems from an extensive range of products, we provide a comprehensive end-to-end solution, which can be designed to any specific clients’ requirements. We have designed and installed silos worldwide in countries that include the UK, Kenya, Thailand, Holland, France, Germany, Ukraine, Malawi, New Zealand and many more. Kevin Groom, Technical Director says, “Our storage systems are individually designed for all clients. Each project has a bespoke design that is sure to match, if not exceed clients’ expectations. We are extremely proud of the projects that we have undertaken in these geographically challenged areas, proving that whatever the specification, we are sure to provide the most suitable design necessary.”
36 | Milling and Grain
by Louise Smith and Nick Carter, Bentall Rowlands, UK
Moisture levels and consequences
Getting the moisture levels right in a silo can be challenging but it is essential that the target level is reached within the shortest possible time. If this does not occur, the results would be the formation of mycotoxin and quality degradation. The main causes of spoilage in stored grain are fungi, insects and mites.
Fungi is one of the main consequences of a variety of different moisture contents and temperatures stored in grain. In order to control this, a principal method known as drying and cooling needs to be put in place. No storage fungi will grow below a moisture content of 14.5 percent but they do continue to grow
STORAGE
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slowly at near 0°C. This means that cooling alone is not sufficient but the lower the temperature, the slower the rate of growth. Another nuisance is storage mites which breed rapidly under favourable conditions and will cause direct damage to the grain by hollowing out oilseeds or eating the germ. Physical control methods are used for mites. If the grain is dried to 14.5 percent moisture content then the mites are unable to breed. If you cool the grain to 5°C, this can also help to prevent the build up of them. However, if you are storing oilseed rape, this is less susceptible to insect attack than cereals. This will protect the grain bulk, but during winter, the moisture content on the surface of the grain may increase, meaning that mites can become a problem in the surface layer. A final problem relating to moisture control is insect presence and infestation problems. These can occur where bad hygiene is present. Good store hygiene is therefore an important first step in eliminating these pests. Both the building structure and the stored grain should be monitored using traps. Traps within the grain bulk should be positioned approximately 5 – 10cm below the surface to monitor any insect species with different behaviours. Stores should be thoroughly cleaned prior to the intake of product. It is extremely important for eliminating any sources of contamination from storage fungi, insects and mites. Store preparation is a key stage in ensuring the safe storage of grain. Whether the grain is being stored temporarily, or for a longer period of time, this is a necessary step that needs to be followed. Good store preparation needs to work in conjunction with obtaining and maintaining the target temperature and moisture content. This will ensure the safe storage of grain. There are a number of key features of a good grain store, including: • Proofed against rodent and • Clean bird entry • Dry • Watertight roof • Well ventilated • No physical contaminants • Correctly functioning • Secure equipment
How best to store your grain
A steel grain storage silo is a fully bolted vessel and while not being airtight they are water-tight. On all the joints, sidewall and roof, a sealing mastic is used to prevent against the ingress of water. The roof sheets overhang the eaves to ensure snow and rain cannot gain access. At the peak of the silo the roof sheets fit 38 | Milling and Grain
under the collar or petal and are sealed with blanking plates. As a manufacturer of silos we will give advice on how to seal the silo at base level. All of these design features, tried and tested, over many years of product development are in place to stop the external moisture from reaching the grain. The level of moisture and temperature of grain in a storage silo comes from good housekeeping. It is very important that the operators of storage systems, both on-farm and industrial stores understand the levels required to maintain the quality of the grain being stored. There are a number of good technical papers available and it is good working practice to re-view. As the grain comes into the system it is important to know the level of moisture. From this the operator will know if the grain will require drying. There are many forms of grain dryers such as in-bin systems or continues mixed flow. The in-bin systems tend to use gas as a fuel and can be limited on the hourly capacity whereas the mixed flow dryer can run on gas, fuel oil and solid fuels. Different types of fungi live at different moisture contents and temperatures in stored grain; Storage fungi can grow on cereals from about 14.5 percent moisture content upwards and may cause heating and loss of germination. Once the grain enters the storage silo or flat floor storage system it is important that the checking of grain does not stop. Most modern silos are supplied with ventilation systems. The concept of these systems is very simple and has been used for thousands of years. By passing air through grain it is possible to not only reduce the temperature of grain but also to reduce the moisture content. There are two main types of ventilation systems in silos: either a trench system or full floor. These systems allow low volumes of air to be pushed into the silo with a ventilation fan either Axial or Centrifugal. The fans are connected to either the silo base for a trench system or to the silo sidewall for a full floor system. The pressurised air then moves up through the grain and thus lowers the temperature of the grain. This action will also cool air dry the grain and lowers its moisture content. Within the silo it is possible to have a number of temperature monitoring cables. These cables have a series of sensors which will measure the temperature of the grain in a given area. The system will allow the operator to see what is happening within the silo. As the air moves through the grain it will evaporate water from the grain, helping to reduce the moisture content of the grain. The moisture, which has been absorbed by the air, then passes into the open roof area of the silo. It is important with silos to ensure that there is good free air movement around this area. This will allow the moisture-laden air to simply vent to the atmosphere. The design of the roof vent is very important. Not only should it allow good airflow but must stop birds, rodents, snow and rain getting in. As you can see from the photograph this vent is designed for free movement of air but by being triangular it prevents rubbish collecting around its face. This is a common problem with roof vents and you can see areas of rust building up in this area. Another way to ensure good airflow around the internal open area is to use roof exhaust fans. These are used to equalise the temperature of the air within the internal area and atmosphere. By using the design shown in the photograph they can easily be reached for maintenance or to be closed when using a fumigation system. On our range of silos we use a dimpled eave-retaining clip. This clip gives a 2mm gap between the roof sheets and the sidewall sheets. Tucked well under the eaves it is designed not only to help with air movement around the internal area but also to allow any beads of condensation which may have formed on the inside of the roof structure to simply run off. www.bentallrowlands.com
CIMBRIA.COM
GROWING INTO THE FUTURE TAKING CARE ADDING VALUE SOLUTIONS FOR HANDLING AND STORAGE OF GRAIN AND SEED Cimbria develops and manufactures an entire range of equipment and solutions for seed processing. Thorough technical engineering experience and in-depth product knowledge enable us to supply solutions for cleaning, grading and treatment of various seed and grain products. Special focus is kept on effective sorting and cleaning, gentle handling, crop-purity, safe and dust-free operation and low running costs.
CIMBRIA UNIGRAIN A/S Praestejorden 6 | DK-7700 Thisted Phone: +45 96 17 90 00 E-mail: unigrain@cimbria.com
CONVEYING | DRYING | SEED PROCESSING | ELECTRONIC SORTING | STORAGE | TURNKEY
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Storage project Grain handling equipment upgrades at Strawson’s Farms
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by David Perry, Managing Director of Perry of Oakley Ltd, UK
n 1998 Strawson’s Farms, Louth, installed a range of 30 tonnes per hour (tph) and 60 tph grain handling equipment from Perry of Oakley Ltd and a 20tph drier. More recently Mr Strawson has found this system had not been able to keep up with the amount of grain he is now producing on the farm, and so made the decision to upgrade his drier and handling equipment. Each year Mr Strawson may need to dry up to 6000 tonnes which will be a combination of wheat, barley, oilseed rape and beans. It was decided the 20tph drier would be changed to a Perry 50tph M611 drier and the handling equipment was upgraded to the 100tph Perry heavy-duty agricultural range of conveyors and elevators along with re-using one of the existing Perry conveyors. The heavy duty agricultural range (from 60tph to 120tph) is a mid range specification that bridges the gap between the lower capacity agricultural range (from 8tph to 60tph) and the high capacity industrial range of products (from 60tph up to 600tph). All Perry machinery is designed and manufactured in house and has an all bolted and riveted construction with heavy-duty dimple form countersunk joint for high mechanical strength. The heavyduty agricultural range is suitable for a throughput up to 30,000 tonnes per annum. The new handling equipment at Strawson’s Farms incorporates a 100tph curved combination conveyor, two 100tph store filling conveyors, a 100tph flow and return conveyor & two 100tph single lift elevators. Mr Strawson was happy to use Perry handling equipment again as it had performed well on the original installation and found it straightforward to use & maintain. The drying process starts with product being tipped into an existing pit which feeds a 300mm intake screw that was already installed at the farm. The product is then picked up by a 14.45m 100tph elevator which then routes the product to either the drier via a 9.1m flow and return conveyor, or feeds the product to an 8.5m 100tph conveyor which is connected to a 27.5m 100tph 40 | Milling and Grain
15° curve combination conveyor. The system was designed and drawn by Perry’s Area Sales Manager which is a service available to all our customers. We help our customers design a solution for their needs using our over 60 years of grain handling and drying experience. The curve combination conveyor is made up using Perry’s market leading horizontal conveyor and flight elevator designs. Each conveyor that leaves the factory has been tailored to suit the customer’s needs, with a wide range of optional extras and heavy duty construction Perry’s will be able to fill any customer’s requirements. The curve runs along the line of the roof giving more vertical storage height. Coming off of the curved conveyor are two existing Perry conveyors that were uprated to cope with the increased required capacity, these deposit the product to the back of the store, allowing the store to be filled to its maximum potential. If the product has been routed through the Perry drier the shutter discharge deposits the product into another 8.5m 100tph conveyor and is then moved up to the curve combination conveyor via a 10.55m 100tph elevator. Perry’s agricultural and heavy duty agricultural range of elevators are fitted with low stretch, oil resistant EP nitrile rubber belting as standard and have slatted pulleys to help reduce the build-up of material on the pulleys. Along with a durable galvanised steel finish the elevators have been designed to offer a high specification machine at an affordable price. When the drier is operated at 125°C it is capable of a throughput of 48.5tph (based on dry wheat at 750kg/m³), it stands at just over 10m tall by 6m wide. This gives the drier a holding capacity of 51 tonnes. All Perry driers designed and manufactured to BS6399 for wind loading & BS5950 for structural strength, the drier has been designed to be as efficient and long lasting as possible. Perry has a dedicated research and development drier that allows
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them to constantly update their technology and understanding of their driers. All Perry driers have a reliable pneumatic shutter discharge system. Mr Strawson’s new M611 drier is fitted with Perry’s new Light Grain & Chaff Recovery System (LGCRS). The LGCRS is a pneumatically operated system that is installed at the base of the exhaust plenum. It has been designed to help reduce the build up of dust, chaff & light seeds in the exhaust plenum by periodically discharging any product that may have been drawn, by the fans, from the grain column and puts it back with the main grain flow. This is an optional extra that can be fitted to new Perry driers and it can be retrofitted to existing Perry driers that have been fitted with shutter discharges. The whole system is controlled using the Perry’s PLC drier and plant control panel. The 12 inch touchscreen PLC panel has been designed and programmed by Perry engineers and is capable of controlling up to 10 machines as standard along with the drier.
The panel displays a mimic of the complete store as well as having multiple automatic and manual routes available. In the drier control section alone there are over 70 alarms and messages, making drier operation easy to understand. Another impressive feature of the drier panel is its ability to calculate and set the parameters needed for the target moisture content when the crop type and intake moisture content is specified. There is also no need to babysit the drier as the panel can send live status updates via email or text to designated addresses and numbers. It can also be controlled remotely from any computer, allowing Perry staff to offer remote support to any drier. Mr Strawson said: “Having used Perry handling equipment previously I was happy to upgrade to the Perry heavy duty agricultural range of machinery. The drier is performing well and the LGCRS saves me time, as I don’t have to empty the exhaust plenum as often. The PLC Panel is easy to use and overall we are very happy with our installation.”
February 2015 | 41
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Grain conveyors: examining this important piece of equipment by Mike Spillum, Hi Roller, US
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Hi Roller Conveyors, Sioux Falls, South Dakota, specialises in the design and manufacturing of enclosed belt conveyors for grain and grain byproducts.
t is well known that grain dust is very dangerous. Not only is it a health hazard for workers, it is also a serious explosion hazard. Even with this knowledge, tragedies occur yearly resulting in down time, property damage, injuries, and even deaths. Although there are many methods of conveying grain, open belt conveyors had historically been the primary choice for moving large volumes or for conveying long distances. Alternative enclosed methods such as chain conveyors or screw conveyors have limitations in regards to length and capacities due to power consumption and other design constraints. Outweighing the advantages of open belt conveyors are the many negatives. They can be messy. Although the majority of outdoor installations include covers, they are still exposed to wind and the elements resulting in dust clouds and spillage. Indoor installations create a health and safety hazard if dust is not contained. The cost of proper dust collection equipment and associated maintenance can be high. Product spillage results in lost profits and requires additional employees to perform clean up. While cleaning around open belt conveyors, employees are
42 | Milling and Grain
exposed to the hazardous dust and can become injured working around moving parts. As a contractor serving the grain industry in the 1970’s, Hi Roller’s founder felt that there had to be a cleaner, safer, more efficient way to convey grain. Numerous attempts had been made to enclose conventional open belt conveyors. Companies were utilising standard conveyor components and cumbersome reloading designs to address product spillage issues. Enclosures were being built around standard conveyor idlers. Product would build up on idler brackets and other ledges. While containing dust within the enclosure, they were exposing the explosive grain dust to the idler bearings. A failed bearing can create heat or a spark resulting in a fire or an explosion. The return side of the conveyor belt slid on a steel pan rather than rollers. Grain that fell to the bottom of the enclosure was conveyed to the tail end of the conveyor. The reloading of product at the tail section was attempted by utilising “loop conveyors” which incorporated chains, paddles and multiple gearboxes. If any of these items failed, product could build up which again created a maintenance or explosion hazard. The original Hi Roller design was developed nearly 40 years ago and continues to be the standard of the industry for the clean, safe conveying of bulk materials. The Hi Roller was designed with some primary goals in mind. First, it needed to be totally enclosed. Second, there were to be no internal brackets or ledges that would allow product to build up. Third, it needed to be self-cleaning and self-reloading. Fourth and most importantly, there could be no bearings exposed to the internal atmosphere of the conveyor. In order to accomplish all of the above, innovate conveyor components needed to be used.
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The Hi Roller conveyor utilises a spool-shaped idler to support the conveyor belt in a troughed configuration. A heavy pipe runs through the center of the idler providing its support. Inserted in to either end of the pipe is a stub shaft. The stub shafts protrude through the sides of the enclosure and attach to externally mounted bearings. This design keeps the bearings away from the dust and eliminates any internal idler support brackets that would allow dust build-up. The conveyor belt returns on an antistatic UHMW return liner. The return liner has a low coefficient of friction so that power requirements are not increased significantly versus return rollers. A bottom enclosure cannot simply be installed under standard return rollers. Product would build up on the pan and eventually prevent return rollers from rotating. The slide return is a crucial feature for enclosed belt conveyors. 44 | Milling and Grain
Dust and spilled product fall on to the return side of the belt and is conveyed to the infeed or tail section of the conveyor. Dust that clings to the carrying surface of the belt is swept to the same area by a row of wiper cleats that are attached to the carrying surface of the belt. With every belt revolution the wiper cleats continually clean the UHMW return liner, preventing product build-up. Once at the tail section, product is automatically reloaded back on to the carrying surface of the belt. This is accomplished by the use of a reloading tail pulley, developed and patented by Hi Roller. Material is diverted to the outer edges of the tail pulley which has “reloading flippers� attached. As the pulley rotates, material is picked up and thrown against a stationary deflector, which directs material back on to the belt. Today, Hi Roller offers a variety of conveyor styles to handle capacities ranging from 50 to 3800 metric ton per hour of grain.
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The original “Hi Roller” model uses a spool shaped idler design as previously described. The patented “Hi Life” model utilises 3 idlers that rotate independently of each other. While resembling the profile of a conventional open belt conveyor idler, all bearings are isolated from the internal atmosphere of the conveyor. The idler is completely supported by the conveyor sidewalls eliminating any internal support brackets. The Hi Life idler design provides a deeper trough and longer idler and belt life. Hi Roller conveyors are commonly used within tunnels for unloading various types of storage structures. They are also used under truck receiving pits and incorporate multiple opening control gates often referred to as ladder gates. Seldom will you find an open belt conveyor in such applications for the many reasons described previously.
46 | Milling and Grain
Other uses include processing plant feed conveyors due to their 24/7 usage. Storage silos are filled by utilising cascading enclosed belt conveyors with built-in 2-way discharge valves. A single enclosed belt conveyor can accomplish the same utilising stationary intermediate discharge trippers. High capacity enclosed belt conveyors are also used to fill rail cars, barges, and ships. Hi Roller has worked jointly with multiple ship loader suppliers to incorporate enclosed belts into their systems. While many grain operations are similar, they all incorporate various design challenges. Hi Roller prides itself on customising features to meet a specific application. Hi Roller’s design team provides approval drawings with each sale and works jointly with the customer to assure the proper design and installation of the conveyor. Conveyor inlets and discharges are customised as needed to match up to the customer’s other equipment. Complimentary equipment such as control gates, support legs, and safety devices are incorporated as needed. Hi Roller has discovered this communication to be an invaluable source of ideas and information. Improvements on the life and maintenance of the conveyor belts are often considered a joint venture with clients. Changes are made to adapt to the customer’s existing parameters. Other manufacturers often expect the customer to adapt the company’s standards. Hi Roller’s consistent effort to integrate the needs of the customer into the design process has proven beneficial to both parties. This willingness to veer from their standard features is the key to developing a strong following. Hi Roller is amidst construction of a new facility in Sioux Falls, South Dakota. It will house Hi Roller’s headquarters including all office and manufacturing functions. The new facility will include a powder coat paint line, state-of-the-art manufacturing equipment and space for future growth. The anticipated completion date is the summer of 2015. Hi Roller conveyors are in use worldwide. Hi Roller (www. hiroller.com) is owned by Canadian-based Ag Growth International (www.aggrowth.com), which offers a full catalog of storage and handling solutions. AGI has 11 manufacturing facilities in Canada, the US, the United Kingdom and Finland. mikes@hiroller.com
www.symaga.com symaga@symaga.com
Symaga, the first industrial silo manufacturer obtaining CE Certificate
Visit us:
RICE MILLING EXPO
06-08th February, Karnal, India Stand 8
Offices and Factory: Ctra. de Arenas km. 2,300 13210 Villarta de San Juan • Ciudad Real- Spain T: +34 926 640 475 • F: +34 926 640 294 Madrid Office: C/ Azcona, 37 • 28028 Madrid - Spain T: +34 91 726 43 04 • F: +34 91 361 15 94
RICE TECH EXPO
13-15th February, Warrangal, India Stand ASP-51
GRAIN TECH MIDDLE EAST
23-25th February, Cairo, Egypt Hall 19
F CASE STUDY
CASE STUDY
Kennedy Rice constructs rice processing facility Opened in September 2012 with the capacity to process up to 136,000 tonnes of rough rice per year, the Kennedy rice mill took two years to build and cost over £6.2 million.
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ccording to the US Department of Agriculture (USDA), the total 2012 US rice harvest is estimated at 8.9 million tonnes. The vast majority of this crop comes from six states – Arkansas, California, Louisiana, Mississippi, Missouri and Texas – an estimated 2.1 million tonnes, or about 24 percent, from Louisiana alone. Because the Louisiana harvest takes place primarily over two months, it places a huge demand on the area’s processing capacity. Any delay in moving the processed rice to market can result in severe cash flow problems for growers. To deal with this peak demand, Kennedy Rice, one of the largest growers in Louisiana, has constructed a new rice processing facility to convert freshly harvested and dried grain, known as rough rice, into polished white rice ready for sale to customers. Opened in September 2012 with the capacity to process up to 136,000 tonnes of rough rice per year, the facility took about two years to build and cost over UK£6.2 million. The Kennedy rice mill fills orders as they are received rather than stockpiling polished white rice in a warehouse. Ninety-five percent of the finished product is shipped in bulk by rail or barge, but a growing amount of it is packaged in 907kg bulk bags which the company fills using a Twin-Centrepost™ bulk bag filler from Flexicon.
Bulk bags filled in response to orders
“We usually try to complete bulk bag orders two to three days in advance. The bulk bag filler is located in the warehouse, so filled bags do not need to be moved until they are ready to be shipped,” says Marley Oldham, plant manager. 48 | Milling and Grain
“Since we only recently began offering polished white rice in bulk bags, they account for a small percentage of our total production,” explains Mr Oldham. “We expect demand to increase significantly, however, and our bulk bag filler is designed to meet our future requirements.” The polished white rice to be packaged in bulk bags is aspirated to remove dust particles before being fed into a 2m high, 2.3m3 capacity hopper mounted above the bulk bag filler. The rice flows from the hopper through a dome valve and 25.4cm dia flexible downspouting into the bulk bag suspended above the deck of the Model BFL-CFHW-X Twin-Centrepost™ Bulk Bag Filler.
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F CASE STUDY
Bulk bag filler designed for automatic operation
Plant air inflates the 1.3 m high bag for filling while an inflatable collar on the fill head holds and seals the bag spout. A filtered air vent at the fill head assures dust-free delivery of material to the bulk bag while providing a simple way to allow displaced air to exit the bag. Except for manually connecting the bag spout to the inflatable collar, the process is automated by a programmable logic controller (PLC). Load cells beneath the pallet deck send signals to the PLC, which automatically stops the flow of rice by closing the dome valve when the bag reaches its target weight. The operator only needs to pull the bag spout off the inflatable collar and tie it closed. The filled bag and pallet are removed by forklift. “Connecting, filling and disconnecting a bag takes only about three minutes altogether,” says Mr. Oldham. “Flexicon’s representative, Robert K. Wilson & Associates of Houston, Texas, worked with Flexicon’s engineering department to evaluate our needs and determine equipment specifications, and then helped supervise installation and startup,” continues Oldham. “This new facility has created over 20 permanent local jobs,” says Elton Kennedy, who along with his daughter, Meryl, oversaw design and construction of the mill. “It also gives regional producers another outlet for their rice crops with lower transportation costs and a faster return on their investment.”
Inside the Mill: The Rice Polishing Process
Freshly harvested rice, known as paddy rice, is dried and shipped with hulls and bran intact to the Kennedy rice mill. This rough rice is temporarily staged in receiving tanks from which samples are taken and sent to the lab where they are graded for quality and checked for insect infestation and 50 | Milling and Grain
CASE STUDY F
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other contaminants. Once the rice has been catalogued by lab analysis, it is cleaned to remove insect shells, sticks, stones, mud, metals and other debris. Milling removes the husk and bran layers, leaving the edible white rice kernel, free of impurities. “Sheller” machines first remove the hull, leaving “brown rice” in which bran layers still surround the kernel. Then milling machines rub the grains together under pressure, revealing white, or “polished,” rice, which is sorted into three different sizes. Rice comprised of the largest kernels is called Head Rice, while rice containing the second largest kernels is called Second Head. Rice containing the smallest size kernels is called Brewers Rice because, historically, it went into brewing alcoholic beverages. After being sorted by size, the rice is then sorted by colour to remove grains with insect damage, stains and other imperfections. www.flexicon.com
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Leiber brewers’ yeast products Excellent for: Cell regeneration Immune system Fertility/Performance Digestion Prebiotic effect Coat/hooves
Leiber GmbH Hafenstraße 24 49565 Bramsche Germany Tel. +49 (0)5461 9303-0 Fax +49 (0)5461 9303-29 www.leibergmbh.de info@leibergmbh.de
February 2015 | 51
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Feed formulation and nutrition focus by Elena Forbes, Azeus Machinery co ltd, China
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he main feedstuffs fed to cattle include: grass, hay, grain, silage and total mixed ration. There are in fact, many types of feeds that can be fed to cattle, for example, crumbles, meals, coarse mix and pellets made from raw material such as corn, wheat, soybean. In this article, Elena Forbes of Azeus Machinery takes a closer look at the processes involved in creating a good quality pellet. With the global demand for cattle feed ever increasing, the need to produce high quality and nutritionally balanced feed has become an essential issue in the feed market.
What are the advantages of pelleted cattle feed?
Raisers have been using pellets for decades to feed their cattle. Compared with other kinds of feed-stuff, a good quality pellet actually offers a lot of benefits to the raisers such as decreased eating periods, improved palatability, less segregation in the feed and reduced waste. First of all, pelleted feeds take up significantly less storage space, particularly in the case of pelleted hay products. A ton of baled hay can take up 200 to 330 cubic feet of storage space in a barn; a ton of hay pellets or cubes requires only 60 to 70 cubic feet. Secondly, compared to other types of feed, they are very low in dust. “Compete” pelleted feeds can include not only grains, but also vitamins and other supplements. Manufacturers have created many types of pelleted mixes to suit all sorts of cattle, no matter their activities. Almost no commercial feed ration is left untouched by the pelleting process - sift through a prepared sweet feed with your fingers, and you’ll discover a smattering of pellets mixed in with the oats and corn and other grains. That pellet generally contains a vitamin/mineral supplement for the ration, bound up with a fibre source such as dehydrated alfalfa. Moreover, cattle consume feed pellets more readily and rapidly when compared to other forms of cattle food. Furthermore, the pellets produce less waste as mentioned above making it a very economical method to feed dairy animals as well. This is especially important for small raisers for whom every penny counts. Similarly, the waste reduction also helps raisers a lot during the droughts because they will have to spend less amount of money feeding cattle. Pellets also improve the palatability of the cattle feed. Finally, it is always good to feed pelleted concentrates to the cattle. There is nothing wrong in doing so; rather it is a beneficial and fruitful method of feeding cattle.
Demand for cattle feed pellets in the global market place
With the increasing awareness among people towards safety and quality of beef choosing high quality and nutritionally well-balanced feed is essential in order to promote cattle feeding standards. Cattle feed pellets being made from corn, wheat bran, rice, sorghum, and beans, appears to be the obvious choice, as it decreases feed wastage, has high bulk density and better material handling characteristics. Pelleted cattle feed prevents selective feeding on preferable ingredients in a formulation. 52 | Milling and Grain
The cattle feed pelleting Process: a comprehensive overview Stage one: cattle feed grinding
Material is held in the grinding chamber until it is reduced to the size of the openings in the screen. The number and size of hammers on a rotating shaft, arrangement, sharpness, the speed of rotation, wear patterns, and clearance at the tip relative to the screen or striking plate are essential variables relating to grinding capacity and the appearance of the product. Impact grinding is most efficient with dry, low-fat ingredients, although many other materials may be reduced in size by proper screen selection and regulated intake.
Stage two: cattle feed mixing
Feed mixing may include all possible combinations of solids and liquids. Mixing is recognised as an empirical unit operation, which means that it is more of an art than a science and must be learned by experience. Three mechanisms are involved in the feed mixing process: a. The transfer of groups of adjacent particles from one location in the mass to another b. Diffusion distribution of particles over a freshly developed surface c. Shear slipping of particles between others in the mass.
Stage 3: cattle feed pelleting
The goal in any feed pelleting operation is to produce good quality pellets while simultaneously maintaining an acceptable production rate at minimum cost. There are many factors being involved in making a good pellet, such as material density, source of supply, ingredient quality,
Cattle feed formulas - Cattle require adequate
levels of protein, energy, vitamins and minerals in their diet, which will vary according to each animal’s age, size, weight and stage of reproduction. Thus, design of feed formula should be based on the cattle raisers own requirements.
F Formula 1 - dairy cattle feed
Formula 1 - calf feed Ingredients
%
Ingredients
%
Ripe-bean cake
40
Wheat bran
15
Corn
22
Oyster meal
2.0
Sorghum
20
Salt
1.0
Formula 2 - calf feed Ingredients Dosage/g
Ripe-bean cake
19
Wheat bran
29
Corn
48
Oyster meal
2.5
Salt
15
-
%
Ingredients
Bran
17
Corn germ dross
4.0
Corn
10
Dry hay
9.0
Soybean curb residue
15
Sorghum
Tips: the average daily weight gain of 6 months old calves is 549g; 12 months calves have a weight of 286kg; 18 months old calves have a weight of 380kg
Ingredients Dosage/g
Ingredients
-
Tips: the average daily weight gain of 6 months old calves is 607g; 12 months old calves have a weight of 273kg, 18 months old calves have a weight of 360kg
7
Bean cake
4.5
Corn silage
Oyster extract
1.5
-
%
32 -
Tips: averagely daily milk production is 17.52kg, annual production is 6200kg
Formula 2 - dairy cattle feed Ingredients
Dosage/g
Ingredients
Dosage/g
Corn
49.5
Zinc oxide
0.3
Wheat bran
32.9
Cobaltous sulfate
0.043
Bean cake
16.5
Sodium selenite
0.044
1.1
Potassium iodide
0.017
Calcium hydrophosphate
Tips: supply 9kg concentrated feed one day; the expected daily milk yield is 18.12kg and the feed/milk ratio is 0.5:1.
The purpose of cooling is to remove heat and moisture after the pelleting process. A pellet is in its most fragile state as it leaves the die. It has been formed but is a soft plastic, easily deformed product at this time. Every endeavor should be made to handle this product as gently as possible until it is cooled, dried and hardened. From a system standpoint, the pellet should drop directly from the pellet mill into the cooler, since any type of mechanical handling will generate fines.
Stage five: Pellet Crushing
Crushing is an important part in the feed pellet line. By crushing, large feed pellets can be divided into different particle sizes in the certain range. Crushing has a direct impact on both the cost and the nutrition of feed pellets. Cooled pellets may be ground on corrugated rolls and the resulting product sifted into various sizes of granules. The specifications of cattle feed pellets are usually as follows: Diameter: 3-5mm Length:15-20mm
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Stage four: cattle feed pellet cooling
Since all ingredients have been moulded together, cattle must eat a balanced formulation, minimising waste and improving feed conversion. Capitalising on the growth trend in the global cattle feed pellet market, some leading companies are rushing into the development and manufacturing of feed pellets. The increasing demand for cattle feed pellets is prompting the global players to turn their attention to feed pellet products in order to meet growing needs.
Connected events:
protein content, temperature, moisture, die specifications and pellet mill operation. Incoming raw material flows into the feeder and (when conditioning is required) is delivered uniformly into the conditioner for the controlled addition of steam and/or liquids. From the conditioner, the feed is discharged over a permanent magnet and into a feed spout leading to the pellet die. Interelevator flights in the die cover feed the material evenly to each of the 2 rolls. Feed distributor flights distribute the material across the face of the die. Friction drive rolls force the material through holes in the dies as the die revolves. Cut-off knives mounted on the swing cover cut the pellets as they are extruded from the die. The pellets fall through the discharge opening in the swing door.
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February 2015 | 53
MARKETS OUTLOOK Wheat market absorbs Russian export curbs
by John Buckley
“Prior to the export curbs, Russia was expected to supply about 22m tonnes or 14% of the world’s wheat import needs in 2014/15. The lion’s share of this, about 17-18m tonnes, has already been shipped, already more or less matching Russia’s bumper 2013/14 exports - with half the current season still to run”
54 | Milling and Grain
GLOBAL wheat markets have spent most of 2015 to date in retreat from a steep run-up in prices in the final weeks of last year. Many readers may be aware that the main element in that upturn was the decision by fourth largest exporter Russia to curb the too-rapid flow of its once-plentiful milling wheat onto world markets at a time when doubts were rising about the size of its next harvest. As the rouble nosedived with the collapse in value of Russia’s crude oil exports and Western sanctions – keeping Russian exports cheap - there did seem a real risk, as the year turned, that too much of its wheat would be snapped up by foreign buyers, leaving its domestic market short and at risk of escalating costs for that most basic staple, bread. Russia is also thought to need more wheat and other cereals for animal feed this seaso as it tries to boost domestic livestock output to replace embargoed meat imports from Europe and the USA. Mindful that it couldn’t simply embargo exports without reneging on its WTO obligations, Russia initially used various indirect measures to slow them down, led by stricter phytosanitary (plant health and other rd tape. These certainly put the brakes on trade during the late December/ early January timeslot. However, they’ve now been overtaken by the introduction of a more direct instrument in the form of an export duty, recently equal to around E30/$40 per tonne, applying from February 1. This has been effective in cutting off further Russian sales in recent weeks, yet seems to have been absorbed by the markets without less fuss than the earlier indirect measures. Prior to the export curbs, Russia was expected to supply about 22m tonnes or 14% of the world’s wheat import needs in 2014/15. The lion’s share of this, about 17-18m tonnes, has already been shipped, already more or less matching Russia’s bumper 2013/14 exports - with half the current season still to run. That partly explains the muted market reaction, despite the latest news that neighbouring Ukraine’s government had also agreed ‘voluntary’ curbs with its exporters on its Feb/Mar wheat sales. These could be loosened up somewhat if its own winter wheat crop emerges in reasonable condition from what (for both countries) has been a fairly challenging winter to date (dry start, poor crop establishment, some snow cover issues raising greater than usual risk of ‘winterkill’ etc). However, like Russia, Ukraine has already shipped out the bulk of what it intended to export during 2014/15 so this doesn’t leave a huge gap in the market. At worst, the CIS absence means the floor price of wheat on world markets is a bit higher than it would have been, had both continued selling freely (i.e. no longer rock-bottom). Even if Russian sales fall 2m to 4m tonnes short of the target 22m this season, there is no shortage of contenders to take its place. Top of the list has been the EU, which has recently seen some of its best weekly export sales of the season and now seems on course to match, if not exceed last season’s record 30m tonne total. It could sell even more without leaving EU consumers short. Even after consuming an extra 9m tonnes in animal feeds, Europe is still expected to finish with carryover stocks of about 17m tonnes compared with just 10m when the season started, thanks to last year’s massive domestic crop. However, what this good clearance of EU wheat supplies has done, along with the weakest euro/dollar exchange rate for 11-½ years has been to lift internal wheat prices
off the 4½-year floor they tumbled onto last September. As we go to press, the European milling wheat futures market is trading about 30% over those lows, if still about 9% below its 2014 highs. Feed wheat prices had also dropped with this season’s larger low/middling grade soft wheat supplies in countries like France. The UK market has frequently been even weaker than the Continent due to the relative strength of sterling versus the euro. While consumers obviously won’t cheer any cost increases, most will probably recognise that farmers who last autumn faced break-even or loss-making prices have to make a living too, to ensure continuity of supply. Summing up, world markets, where the value of wheat is ultimately ‘made,’ still appear to be amply supplied for the rest of 2014/15 to end June. The USDA’s own global crop estimate has even risen further since our last review, by about 3m to a new record 723m tonnes, or about 8m more than last year. USDA has also edged up its estimate of global wheat consumption although this remains about 10m under production which means end-season carryover stocks rise by the same amount to a comfortable 196m tonnes – about 27.5% of projected consumption or 14 weeks supply.
56 | Milling and Grain
These extra stocks provide a cushion against an expected smaller world wheat crop in 2015. Recent estimates suggest the negative outlook for Russian and Ukrainian crops will knock about 10m tonnes off their combined output this summer. That might be offset somewhat if they plant more spring wheat but that yields less than winter wheat. There is also much concern about how both countries will finance their seed and input needs for these crops (especially the significant imported portion of these) as their currencies continue to tumble – a factor that could take another bite out of yields. The EU’s own 2015 wheat outlook is a bit of a mixed bag with some countries apparently sowing a bit less, others more, some in need of more rain, some at risk of possible frost damage etc. One recent private estimate suggested output could be about 7m tonnes down from last year’s crop based on yields also coming off last year’s highs. However, it shouldn’t be forgotten, that the 2014 crop was a record one at 155.5m tonnes, 12m more than in 2013 and 22m over 2012 – so this would hardly be a disaster. The USA has also had some weather issues affecting winter wheat potential, lingering dryness in some areas, frost threats in others and a general crop rating below this time last year’s. Even so, some analysts expect a slightly larger crop based on area increases. Canada’s crop is a bit of an open book at this stage, the bulk not sown until the spring so much depends on weather then and relative returns from competing crops like rapeseed. Current government thiking there is that overall acreage will increase by almost 800,000 acres but the lion’s share of that gain will be for duruym rather than spring breadwheats. Among the other big suppliers, Australian and Argentine crops (technically 2014/15 harvests but the bulk marketed in 2015) are both adequate. Australia is currently expected to export at least as much as last year’s 18m tonnes while the USDA sees Argentine trade exports soaring from just 1.6m in 2013/14 to as much as 6m tonnes. However, that assumes a less restrictive export policy, which may an be optimistic hope, given that the government has only recently told exporters they won’t get permits unless they pass on a fair share of the world prices to farmers. That said, the above export potential is easily enough to make up for any Russian shortfall - albeit at a higher price than if Russia had continued to sell freely. But the list doesn’t end there. To these regular exporters can
anything the ‘experts’ could have imagined, market chatter has be added other ‘non-traditional’ potential wheat suppliers. India begun to question not only the level of discretionary (voluntary) burdened with huge stocks after three successive large harvests, blending but the longer term viability of the mandate itself. wants to export about 2m tonnes while neighbouring Pakistan, There have even been some moves in Congress to challenge the more frequently an importer, reportedly plans to put about 3m mandate although current opinion suggests these are unlikely to tonnes on world markets. succeed at this stage. Finally we should not rule out both Russia and Ukraine Still, the fundamental question needs to be answered, what returning to the market as exporters sooner than harvest time. happens to ethanol demand in the longer term if the green fuel It has happened before after past embargoes and both will want can’t be produced as cheaply as petrol? No one saw this coming to do all they can to re-portray themselves as reliable suppliers, and opinion is unsurprisingly split on how long it will last. Will once their domestic needs appear to have been safeguarded. crude’s demise contain fracking and reduce less-economical Overall then, there is nothing much in wheat supply/demand fossil fuel production and, if so, over what timeframe? The irony ‘fundamentals’ to justify price rises and, depending how the CIS is that US ethanol production was recently running at record crops shape up, maybe even potential for cheaper wheat. This levels, buoyed up by the collapse of maize feedstock costs over isn’t yet apparent on the US futures markets where the forward the past two years. months carry a small premium. However, European new crop Whether or not ethanol continues to account for about 40% wheat is slightly cheaper than current months. of US corn disposals, supplies of the coarse grain will remain Maize crop estimate trimmed – but still huge in substantial surplus. Even after trimming the US 2014 crop Like wheat, maize has been getting cheaper into the New Year estimate by almost 5m tonnes in January, the USDA still has after an earlier run-up in prices. The latter move reflected a production at an all-time record high of 361m tonnes. That combination of factors including better than expected domestic and export demand for US maize, ideas the latter’s 2014 crop had been over-rated, forecasts that its farmers would sow less in 2015 and some dry weather issues overhanging prospects for the South American harvests coming on stream this spring. Given the way some of these fundamentals have shifted to a more bearish slant in early 2015, it seems mildly surprising that the US market hasn’t come down more (It’s lost about 9% from its GRINDING mid-December DOSING Probably the biggest undermining influence has A TAILOR MADE been the 60% collapse in the FEED PRODUCTION international value of crude oil PROCESS, DESIGNED under the weight of the US shale WITH A CLEAR FOCUS ON: gas boom and OPEC’s (mainly
The optimal solution for your process
Saudi’s) attempts to make up in volume what it’s lost in unit revenue (and by doing so, maybe help drive its new competitors out of business). It’s hard to over-state the impact that ethanol has had on US maize disposal and values and, to a lesser extent total world grain use in the fuel sector in recent years. Ten years ago, US annual maize use in this outlet was a mere 33m tonnes. This season it’s expected to exceed 130m. When crude oil prices began their collapse earlier last year, it was assumed that usage would remain protected by the government’s legally binding minimum blending requirement within the Renewable Fuel Standard. But as crude prices continued to fall far beyond
• Lowest operational costs • Energy efficiency • Feed safety
MIXING
CONDITIONING COATING
PELLETING
w w w. a a r s e n . c o m
February 2015 | 57
compares with US consumption of 301m and exports of 44.5m. The surplus will allow the US to go into 2015/16 season with 48m tonnes of stock versus 31m this season and just 21m the previous year. Global maize output is meanwhile estimated at 988m tonnes – about 17m over consumption, resulting in stocks rising by that amount to 189m. As in the USA, this is the highest stock for some years. It’s moderated somewhat by the fact that over 40% of it is held in China, whose figures are often considered unreliable and whose quality is usually thought questionable in comparison with maize from the other big producers. Nonetheless, the market
must accept that maize – on paper/in fact – is in loose supply. In recent weeks, maize markets have also been watching the weather in South America, which seems to have improved after a dry start in Brazil and some excess rain and flooding in Argentina. Some Brazilian private estimates are running about 5m tonnes over the USDA’s 75m tonne forecast (down about 4m on last year). Argentina is expected to produce about 22m versus last year’s 25m tonnes. Although previously up-and-coming exporter Ukraine’s last crop was also 4m tonnes lower than the previous year’s it is still a big one by historical comparison. Its exports will be down by a similar amount and have so far been a bit slower than expected. However, as we go to press, it seems to be stepping up sales and undercutting the dominant US exporter by about $8 to $10 per tonne. US exports have performed quite well so far this season,
58 | Milling and Grain
underpinning prices on the bellwether Chicago futures market to some extent. However, with Ukrainian, then Lat-Am competition expected to pick up later into first quarter 2015 and beyond, export-based support for US prices will likely diminish. Although US feed demand is thought to be expanding this season (helped by lower maize costs amid higher meat prices) it may not be enough to fend off bearish supply-side pressures if ethanol demand does weaken. Further forward, crop analysts have been expecting the US sow less maize this spring but a predicted shift to soyabeans may be smaller than earlier thought as soya prices are currently dropping faster. As always, though, the weather at planting time will have a huge influence on the mix of crops. Within the EU, maize demand is expected to edge up by about 1m tonnes to a new peak of 77m but with the domestic crop up by almost 10m tonnes, Europea consumers will be able to slash their dependence on imports from 16m to perhaps 6m or 7m tonnes. With demand from other importers expected to be down by a similar amount, maize looks more and more like a buyer’s than a seller’s market. As in the wheat market, then, there is not much in the fundamentals to support higher prices going forward - despite US futures markets quoting new crop up to 10% dearer than current months. Soya supply glut looms If Europe were growing more soyabeans, rather than importing the bulk of its 13.5m tonne crush, meal costs might be falling with the global trend amid the largest surplus on record. However, while dollar-quoted meal prices have dropped by about 25% this season, the euro has tumbled to its lowest in 11 years versus the US currency, keeping prices on the Continent more expensive than in the autumn of 2014. Even UK consumers cushioned by relatively stronger sterling versus the euro, are not doing so well when dollars are turned to pounds, robbing them of much of the benefit of the sliding US price. That said, European meal costs are at least being restrained somewhat by the supply glut and, as the largest ever South American soya harvests crank up, this could yet exert more downward price pressure on both sides of the channel. Most of the increase in this season’s global oilseed and meal production is in soyabeans, for which world output has recently been estimated at 314.5m tonnes – up by about 2m since our last review and a hefty 30m tonnes over last year’s crop. That increase would equal about 24m tonnes more meal if all were crushed. In fact, only about half the extra beans will be used for feed, creating about 11.5m tonne more meal – which roughly equals the expected rise in this season’s global meal demand. The high end-season stocks of soyabeans (a record 91m tonnes versus last year’s 66m and about 55m in the previous two seasons) provide an ample cushion against any supply shortfalls from coming soya crops. Over the past two months, weather has steadily improved for South American oilseed crops, confirming record output to be marketed over coming months. A weak Brazilian currency should help ensure good exports from the major supplier to cash in on the strong dollars in which beans are traded. Estimates have recently been raised for Argentina’s coming crop, which should ensure very large exports from this supplier too. Argentina crushes two thirds of its crop to export as meal, for which it is far and away the world’s largest supplier. In a couple of months’ time, the US will start planting its own soya crop which some analysts think will expand by about 2m acres to cover a new record area. Even if yields dip from last year’s record highs closer to the long-term trend, that would deliver another ‘mega crop,’ currently seen around 104/105m
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tonnes – below last year’s record 108m but far more than the normal 85m/90m tonnes of recent years. Of course, we have yet to see what weather will accompany the US sowing and growing season up to September. But if conditions are normal, it is hard to see how this supply outlook can point to anything but flat to weaker prices. The futures markets currently show only small discounts on forward soya beans and meal. However, some analysts see leeway for bean prices (already down 37% from last summer’s highs) to drop by a further 10-15% under this scenario, As soya is so protein-rich and usually a reliable quality leader, pricing of other oilmeals will, as usual, have to broadly follow the soya price trend. The European feed industry is expected to use about 1m tonnes more soya meal this season. The rest of the increase is spread over China (+5m), the USA (+1m), Brazil (+0.4m) and a number of small/moderate-sized consuming countries.
KEY FACTORS AHEAD
WHEAT • Concern persists over the state of Russian winter sown wheat crops, a larger percentage than normal described as in poor condition. A better picture will be available when plants emerge from dormancy in the spring. The outcome could have considerable influence on wheat prices going forward – at this stage seen more bullish than bearish. • Ukraine has also had some over-wintering problems tha will become clearer in a few weeks’ time. Its massive currency devaluation during February (in addition to an earlier long slide) augurs ill for spring crop finance and yields – although maybe it will get some financial help fro western aid packages. Russia also faces problems of spring crop finance at a time when it needs to boost sowings on failed winter crop lands. • Crop ratings have continued to deteriorate for US winter wheat for harvest 2015 but some timely rains could yet allow some recovery. This has not emerged as a major factor yet because 60 | Milling and Grain
the most affected crop has been soft red wheat, for which export demand remains poor amid hefty foreign competition for this class. European crops have had a generally unchallenging, mild winter but lack of ‘hardening off’ leaves them exposed to frost damage from late cold snaps. World stocks of wheat carried into 2015/16 remain hefty, a cushion against any crop weather problems in the months ahead. The drop in wheat values close to or, for some farmers below, cost of production remains an issue that may affect future sowing plans. Decent quality premiums will continue to merited for milling/ bread wheats as feed wheat prices remain under pressure from large, cheap supplies of coarse grains. Global feed consumption of wheat is still expected to rise by about 10m tonnes this season but remain below the high levels of three years ago. But will ethanol use of wheat hold up at expected levels in Europe under the low oil-price scenario?
COARSE GRAINS • How much maize will the US sow in 2015? Current forecasts suggest a cutback but still enough for another large crop which, with large carryover stocks from this season, will keep this market well-supplied. • Ukrainian and Russia spring sowing of maize may face financing challenges caused by their lack of access to credit, weak currencies pushing up imported input prices. A clearer picrure may be available on this factor within the next couple of months • Ample maize supplies from Latin America and the CIS countries will continue to compete at discounts to US exports in Asia, Europe and other markets, restraining CBOT maize futures prices and global prices. • The EU has been well supplied with its own maize crop this season, enabling it to slash imports – the main factor in a lower global maize trade. Will it sow as much for 2015? • Competition for coarse grain customers continues from larger than usual feed wheat and adequate barley supplies, helping to contain livestock feeders’ costs • Will the US ethanol industry continue to use as much maize if the price of conventional petrol stays down/gets cheaper still? • Declaring its policy to move to a more ‘market-oriented’ plan, China could draw down more of its own massive reserve stocks – rather than imports - to fill its ongoing annual gap between domestic crops and growing consumption. That would removes a potential bullish influence for world maize export markets OILMEALS/PROTEINS • Large US and Lat-Am soyabean crop surpluses continue to offer potential for cheaper global oilmeal costs as 2015 progresses • Lower oilmeal costs and ample supplies may yet spur greater than expected demand in countries developing livestock production systems – China, India, Indonesia etc. Developed consumers like the USA may also use more as high meat prices contribute to profitability. • Rapeseed and sunflower expansions have slowed down or reversed in the past year but as ‘oil-rich’ oilseeds these will have less impact on the meal sector. • One result is that soya will raise its already dominant share of the protein market. As the high-protein, reliable quality and most voluminous product, its price trend will have to be followed across the meal sector.
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Industry events 2015
n 29 March - 01 April
3rd ICC Latin American Cereal and Grain Conference and ICC Jubilee Conference - 60 Years of ICC Expo Unimed Curitiba, Brazil https://www.icc.or.at/news/3rd_icc_lacc_2015
n 19-22 February
Aquaculture America 2015 Marriott’s, New Orleans, USA http://www.was.org
n 05-07 April
Middle East Aquaculture Forum 2015 DWTC, Dubai, UAE http://www.meaf.ae
n 21-24 February
GEAPS Exchange 2015 America’s Center St. Louis, USA http://www.geaps.com
n 23-26 April
Dust Explosions – How to demonstrate DSEAR/ATEX Compliance The Wolfson Centre, Kent, United Kingdom http://www.bulksolids.com
n 03-04 March
IV International Agro-technological Conference Rostov-on-Don, Russia http://www.grun.ru
n 23-26 April
IDMA 2015 FAIR Istanbul Fair Center – CNR Expo Halls http://www.idma.com.tr
n 10-12 March
Storage and Discharge of Powders and Bulk Solids The Wolfson Centre, Kent, United Kingdom http://www.bulksolids.com
n 04-08 May
119th IAOM International Association of Operative Millers Annual Conference & Expo Renaissance Palm Springs Hotel and Palm Springs Convention Center, Palm Springs, USA http://www.iaom.info/
n 10-12 March
Global Grain Asia 2015 Shangri La Hotel, Singapore http://www.globalgrainevents.com
n 11-13 March
n 18-21 May
VIV Russia 2015 Crocus Expo International Exhibition Center Pavilion 2 – Halls 7 & 8 65-66 km Moscow Ring Road, P.O.BOX 92, 143402 Moscow area, Krasnogorsk, Russia http://www.vivrussia.nl/en/Bezoeker.aspx
2015 Purchasing and Ingredient Suppliers Conference Hyatt Regency Grand Cypress 1 Grand Cypress Blvd Orlando, USA http://www.afia.org/afia/home.aspx
n 11-13 March
VIV Asia 2015 BITEC, Bangkok International Trade & Exhibition Centre 88 Bangna-trad Road, Bangna, Prakanong Bangkok 10260 Thailand http://www.viv.net/en/Portal.aspx
Milling and Grain event: CropTech-FeedTech - part of VIV Asia Thursday, March 12, 2015 from 15:30-17:00 http://conta.cc/1zCsKBC
n 16-18 March
n 19-23 May
IPACK IMA 2015 Fieramilano, Rho Milano, Italy http://www.ipack-ima.it/ita/home
n 26-30 May
World Aquaculture 2015 Jeju Island, Korea http://www.was.org
n 28-30 May
5th International Grain Tech Expo 2015 - Egypt, Middle East Bashundhara Convention Centre, Dhaka, Bangladesh http://www.limraexpo.com
AgraME 2015 Dubai International Convention and Exhibition Centre http://www.agramiddleeast.com
n 16-18 March
AquaME 2015 Dubai International Convention and Exhibition Centre http://www.agramiddleeast.com/en/Aqua
n 25 March
AquaME 2015 The Wolfson Centre, Kent, United Kingdom http://www.bulksolids.com
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62 | Milling and Grain
n 09-11 June
FIAAP, VICTAM & GRAPAS INTERNATIONAL Koelnmesse, Cologne, Germany www.victam.com
Milling and Grain event: GRAPAS/Global Milling Conference Thursday June 11, 2015 http://www.gfmt.co.uk/grapas15
MORE EVENT INFO
at the Event Register international milling .com
GEAPS
PREVIEW
the conference is over, attendees and process grain more effectively. companions can take part in postBesides serving grain handling and 2015 processing professionals, the Exchange conference events featuring St. Louis egistration is now open for the baseball and breweries. is also an opportunity for students to Grain Elevator and Processing To make it as easy as possible for connect with industry professionals. At Society’s (GEAPS) 86th Student Day Monday, Feb. 23, students attendees to get to their hotels, GEAPS’ Exchange February 21-24 at America’s and accompanying faculty will receive Exchange 2015 Host Advisory Council Center in St. Louis, Missouri. The is providing free MetroLink passes an overview of the industry from Jim event features more than 30 hours of to conference-goers who fly in to Voigt, JFV Solutions, Inc., before educational programming, over 350 St. Louis International Airport. The participating in roundtable discussions exhibitors in the Expo and several passes provide complimentary passage hosted by grain industry leaders and types of networking opportunities. downtown, and a downtown trolley ride. time to network in the Expo Halls. Registration and a complete schedule Passes are available on Saturday, Feb. After attending education sessions are available on the GEAPS website. 21, from noon-7 p.m., and Sunday, Feb. and visiting the Expo Hall, attendees Educational sessions take several forms can connect with peers and suppliers in 22, from 7:30 a.m.-noon from a GEAPS at the Exchange. They begin Sunday, the grain industry at several networking welcome kiosk at the baggage claim. February 22, at 7 a.m. with the Opening Early registration for Exchange events. During the Exchange attendee’s Workshop, “Electrical Safety for Grain guests can take advantage of the 2015 is open until Friday, Jan. 23, and Processing Facilities,” presented by Companion Program, providing several provides a 25 percent discount off the 28/10/14 09:46 Page 1 registration fee. Doug Forst, CMC Industrial Electronics F/V/G(Island):2015 on-site entertaining tours across the city. Once Ltd.; Josh Mulder, Power System Engineering, Inc.; and Mark Wirfs, R&W Engineering. After the workshop, 13 companies will showcase new products and ideas that benefit the grain industry during the Idea Exchange at 10:30 a.m. The conference education program includes 20 hour-long individual education sessions on facility operations, grain handling equipment, grain quality management, human resources, safety, property risk management and other topics Monday, Feb. 23 and Tuesday, Feb. 24. The Exchange also features 12 educational Expo Pod sessions on basic maintenance issues. Expo Pods offer interactive 9 – 11 JUNE 2015 • COLOGNE EXHIBITION HALLS, COLOGNE, GERMANY education designed for smaller groups to foster discussion and allow hands-on opportunities with the equipment. “The sessions, in combination with the Expo, provide the latest and greatest in education topics Feed Ingredients Feed Production Machinery Flour Milling Technology and tie into the vendor displays. Nutrition Ancillary Equipment Storage & Handling Systems By attending the education Additives Formulation Quality Control sessions, the participants can Specialist conferences: For further information please contact: follow-up with the speakers The FIAAP Conference 2015 Victam International BV at their exhibits to further Petfood Forum Europe 2015 PO Box 197, 3860 AD Nijkerk, The Netherlands their questions, or to set up The IFF Feed Conference 2015 T: ++31 (0)33 246 4404 Aquafeed Horizons International 2015 F: ++31 (0)33 246 4706 E: expo@victam.com appointments after the show,” Global Milling Conference with said Allan Tedrow, McCormick Free online visitor registration is available GRAPAS INTERNATIONAL 2015 from 1st January 2015 at: Construction Co., GEAPS Biomass & Biomass Pelleting 2015 www.fiaap.com GMP+ International 2015 Exchange Education Programming www.victam.com Committee co-chair. www.grapas.eu In addition to the educational See us on Twitter, Facebook, LinkedIn and Google+ side of the conference, the Expo or scan the QR codes: also hosts over 350 exhibitors in nearly millingand 200,000 feet of space. Exhibitorsgrain.com present products and Please contact your local consultant: services to help attendees store and
2015
R
THE WORLD’S LARGEST ANIMAL FEED PRODUCTION & GRAIN PROCESSING EVENT
February 2015 | 63
North of England Flour Millers Association
T
he North of England Flour Millers Association held its February meeting at Monk Fryston Hall Hotel on Friday 6th February 2015, where it drew an excellent attendance of millers and allied traders from across the region. The meeting was opened by the current Chairman, Matthew Rogers of Hovis Limited, Selby supported by the Secretary and Treasurer, Stephen Brierley, who firstly asked all present to observe a minutes silence in memory of the recently deceased Patrick Donovan, former Chairman and Managing Director of Allied Mills and twice President of the National Association. They then dealt with the routine matters of common interest to the members before introducing the keynote speaker, Martin Savage, Trade Policy Manager from The National Association headquarters in London (nabim). Savage in his informative presentation gave a lucid update on the issues which currently dominate nabim’s efforts on behalf of the British and Irish milling industries.
Namely: 2014 wheat harvest. The total wheat harvested reached 16.6 million tonnes due to record yields after the favourable weather during the growing period. Regrettably the poorer weather during the actual harvest period resulted in a reduction to 9% (from the previous year’s 38) in grain meeting the full breadmaking specification. The premium for breadmaking over feed wheat remained around £50 per tonne. New varieties. Two new Group 1 winter wheat varieties, Skyfall and KWS Trinity which both have Argentinean parentage, are showing higher yields but lower protein levels. Other current policy issues. Matters discussed included the proposed amendments to the Bread & Flour Regulations, the measurement and control of possible contaminants such as nickel, alkaloids, glyphosates, endocrine disrupters and fungicides as well as mycotoxins, mainly DON, ZON and OTA. There is a study in progress to ascertain if there is any cause for concern regarding any presence of adventitious soya in wheat, mainly resulting from cross contamination from ship holds and bulk vehicles. Trials are being made to establish
L-R Martin Savage, Trade Policy Manager, nabim. Stephen Brierley, Secretary. Matthew Rogers, Site Manager Hovis Ltd, Selby. Ian Wilks, Operations Director, Allied Mills Ltd
whether electronic passports (e-passports) for parcels of wheat would be practical to implement. These would replace paper documentation of the history of grain handling and treatment and its mycotoxin levels. The Red Tractor crop assurance standards are being reviewed and will be re-issued after which the auditing process will be improved. Finally Savage reminded the group that the Milling Wheat Challenge, a competition to find the best grower of milling wheat, is now in its 6th year and winners have been geographically widely dispersed. The Chairman wound up the meeting by advising that the annual visit by the National President would be on Thursday March 26th and the AGM would be held on 8th May.
06 07 08 February 2015 An Exposition business to xpand....your xplore....your market
E
nsure....your future
New Grain Market, Karnal (Haryana) India
India's Largest Technology Oriented International Exhibition & Conference on Rice Milling Industry
Media Partners ATS ALL TIMES SOLUTION
Axis Publication Pvt. Ltd.
ADAMAS Events Pvt. Ltd.
REVIEW
SCO 27, IInd Floor, Mugal Canal, KARNAL-132001, Haryana, India RME.Intl@gmail.com www.ricemillingexpo.com 64 | Milling and Grain
Organizer
GEAPS
Grain Elevator and Processing Society
www.geaps.com
February 21-24, 2015 America's Center | St. Louis, Missouri, USA
EXPO
EDUCATION
NETWORK
The Industry’s Largest Over 350 Exhibitors!
An Outstanding Program Nearly 35 Hours of Sessions!
The Industry’s Best Networking Opportunities
The 86th Annual International Technical Conference and Exposition of the Grain Elevator and Processing Society
For details on attending and exhibiting visit www.geaps.com or contact info@geaps.com; (952) 928-4640
The Knowledge Resource for the World of Grain Handling Industry Operations
2015
REVIEW
IPPE
Milling and Grain magazine at the largest on IPPE on Record
2
by Olivia Holden, Executive Editor
013 saw the integration of the International Feed, Poultry and Meat Expos, creating IPPE. What used to be held as a bi-annual event has transformed into the largest annual poultry, meat and feed industry of its kind. The team at Milling and Grain travelled to Atlanta to take part in IPPE 2015, 27-29 January. A colourful booth provided the perfect backdrop to showcase copies of the International Milling Directory, International Aquafeed and Milling and Grain magazines. IPPE was the ideal opportunity to present the first edition of Milling and Grain magazine, formerly Grain and Feed Technology to the industry. Circulation and events manager Tuti Tan distributed over 3,000 copies of the IMD, International Aquafeed and Milling and Grain. The team could also be found modelling new look Milling and Grain shirts! This year, the growth of the show was clearly evidenced by a record number of visitors estimated to have been in the region of 30,000. I met with Miranda McDaniel of the American Feed Industry Association who confirmed that this year had seen a substantial increase, not only in the number of visitors, but exhibitors too. ‘Last year the show was held in halls A and B (of the Georgia World Congress Centre), this year, we have also used hall C’ she confirmed. In total, the show brought together 1,288 exhibitors with more than 490,000 net square feet of exhibition space. Clearly, IPPE is experiencing a tremendous level of expansion and worldwide recognition, ‘partnering all three organisations has shown nothing but growth’ McDaniel added. IPPE’s reach remains far and wide. After speaking with various companies, the general sentiment was that the show is attracting more people from Africa now that the continent is gaining more knowledge and experience in grain production and preservation. Many have experienced first hand that Africa has significant market potential and it will not be long until the continent become major players in the world grain supply. As well as the large exhibit halls, over 25 educational programmes were held ranging from a conference on antibiotic use to a programme about exporting feed and feed ingredients to the United States. AFIA also hosted their eighth annual pet food conference attracting 250 people. The conference examined the current state of the market both globally and domestically, looking key issues of sustainability and regulatory developments. To keep visitors and exhibitors entertained, the quest to find the best chilli in Atlanta generated huge momentum and did not fail to disappoint. The third annual IPPE chilli contest saw the highly coveted first place position awarded to Andrew Denaro, kitchen manager at the Hard Rock Café, Atlanta. 66 | Milling and Grain
Lambton Conveyors team (left to right - Ric Depooter, Christian juxdan, Sandra Dixon and Daniel Etulain) talk with Tuti Tan and Mark Cornwell from Milling and Grain magazine
On the left is Tom Schroeder on the right is Kirk Nelson, hard at work in the Behlen Booth
The team from Global Industries - left to right: Jon Sazma, Scott Stuhlmiller, Alejandro Mekino, John Haugh, Tom Magnus, Steve Frisbie, Tyson L’hereux and John Crawford
Terry Geraghty, Bruce Fagla and Micheal Cowl infront of the Tapco H1 Hummer (recently seen suspended from a Tapco elevator bucket in the recent adverts from the company on page 3 of this edition!)
Left to right: Pippa Pang, Richard Edwards, Ian Cockshott, Andrew Jackson, Murray Hyden, David Owsley, David McRobbie, Stephen Waite, Lisa Falconer
“Andritz showcased our well proven pellet mill 43-700. As something new, we deceided also to showcase our extruder EX1021, which attracted a great deal of attention from the visitors” Left to right: Christian Thøming, Mike Snyder, Jack Smith and Niels Bengt
“IPPE has always been a valuable show for Sweet because of the quality and quantity of attendees. We are able to meet our dealers, customers and prospects from around the world face to face, allowing us to build on our relationships and extraordinary customer service” Left to right: Martcruz Guillen, Alicia Sweet Hupp and Julio Contreras
Bill McLean(left) and Harold Mauck of Essmuller talk with Editorial Executive for Milling and Grain magazine, Olivia Holden
Matt McLean of Essmuller talks with the Directors of CP Foods
Carl Swisher (Sales manager - materials and handling) from 4B Braime and Editorial executive for Milling and Grain, Olivia Holden
Two members of staff at AB Vista pose next to a poster displayed at their booth.
Left to right: John Bowes, International Sales Director for Sukup and Material Handling Engineer , Bob Dieckmann
The team at Nutriad
Working to improve the sustainability of compound feed production
Responsible opeRations standaRd (Ros) foR Compound feed manufaCtuReRs Now Open for Public Consultation Deadline:15 February 2015
REVIEW
Find out how to participate at www.globalgap.org
68 | Milling and Grain
A
Chew on this tour bus stops at IPPE 2015
From left to right: Mike Nichols, Phil O’Grady and Rod Brown from the Bühler team
A panoramic shot of the Kahl booth
REVIEW
The drive to feed:
bout 870 million people worldwide don’t get enough food. Hunger kills more people worldwide than AIDS, malaria and tuberculosis combined. It kills more people than all forms of cancer combined. However, hunger isn’t just a problem in Third World countries. In San Diego, one in four children get their only meal of the today at school. In Kansas City, it’s one in five. In Boston the figure is one in eight. The Chew on This Tour, a unique, interactive road show traveling America to heighten awareness about one of the biggest problems facing our world today: hunger, arrived at IPPE in Atanta. Fronted by former NFL player and champion wrestler Bill Goldberg, the tour aims to educate about food sustainability. The bus has now traveled to over 40 states in America and shows no signs of slowing down. The short film shown on the tour bus demonstrated that a growing population requires more food. According to the United Nations, by the year 2050, the global population will be 9 billion. We will need 70 percent more food, and 70 percent of that food will have to come from efficiency-enhancing technology. In 1960, American farmers were on average, each growing food for 26 people per day. Today, this number has risen to 155 people per day. The Chew on this tour focuses on how farmers are aiming to safely and sustainably meet this rising demand. However, more can be done to meet the challenge of feeding. AgraMe2015 - 90 x 132mm.pdf
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16 – 18 March 2O15 | Dubai International Convention and Exhibition Centre
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February 2015 | 69
Lallemand showcase their latest products
Delacon strengthen their global presence at IPPE 2015
T
REVIEW
he Austrian family business Delacon recognised the potential of phytogenic performance enhancers 25 years ago, even coining the term ‘phytogenic’. Today the company is the global market leader in this ever-growing field, having recently expanded its sales structure in India and Latin America. At IPPE 2015, the company had their own booth for the first time showcasing the potential of its plant based feed additives composed of herbs, spices and essential oils. The vision of company founder Helmut Dedl to replace antibiotic growth promoters by phytogenic feed additives and thus to ensure sustainable, profitable production and food safety, still applies to the current CEO Markus Dedl as a guideline of corporate strategy. As pioneers, Delacon remain the first and only company to receive a zootechnical registration by the European Union for their product FRESTRA®F for swine, a 100 percent based plant feed additive. At IPPE Delacon launched Biostrong® Forte onto the U.S market, a sound replacement of antibiotic growth promoters which combines beneficial Biostrong® 510 effects with short and medium chain fatty acids. Biostrong® Forte helps to fight the common intestinal challenges found in antibiotic-free production. Upon its launch in 2000, Biostrong® 510 was the first phytogenic product range for poultry. The innovative formulation is based on in-depth knowledge, broad experience and extensive research. With the key advantages of Biostrong® 510, namely increased nutrient digestibility, improved feed efficiency and reduced noxious gas emission, Biostrong® Forte adds a complex of esterified fatty acids to control and reduce common critical intestinal health challenge periods in the bird’s life. This new product comes at a time when experts estimate that the market for natural feed additives will triple by 2020. Increased pressure in terms of food safety, raising concerns about animal health and environmental protection, increasing feed costs, increasing antibiotic resistance, strong global tendencies to reduce antibiotic growth promoters – these factors show that phytogenics are seen among the top solution platforms in animal nutrition for the near future. Delacon’s holistic approach is paying off. Their presence at IPPE further adds to the expansion of its global leadership. ‘Our mission is to improve the efficiency in animal nutrition, animal health and food safety by new combinations of natural substances while minimising the environmental impact. And this is the way we will continue’ says Markus Dedl, further adding, ‘It is our aim to make optimum use of the power of nature. In other words, we are performing nature and this will be our slogan for the future’.
Brandon Grubbs from Maxi Lift Inc
The team gather at Famsun for a group photo
REVIEW Lorraine Magney and the team at Novus
Two members of staff at Evonik pose next to a poster displayed at their booth
Left to right, Janeth Hernandez Baez, Yara Animal Nutrition Colombia and Salvador Ramirez, Yara Animal Nutrition Mexico and guests
The team at Ottevanger
Jefo were out in force at IPPE!
Todd Peteson manning the Bin Master Level Controls stand
“Wenger has been attending the IPPE/AFIA for many years and while we see many existing clients and colleagues we continue to uncover new opportunities with prospective clients from all over the world. We foresee our continued presence at the IPPE/AFIA exposition and look forward to the continued expansion of these related industries around the world in the future.� Left to right: Spencer Lawson, Universal Pellet Cooker - Process Manager and Stuart Carrico, Food & Industrial Products Division Sales
The team from Zhengchang
REVIEW
Schenck processstand at IPPE
The team from Biomin
REVIEW
MILLER’S
GATEWAY OPENING TO THE WORLD
23-26 April 2015 Istanbul Expo Center (CNR Expo) Halls: 1-2-3 6th International Flour, Semolina, Rice, Corn, Bulghur, Feed Milling Machinery & Pulse, Pasta, Biscuit Technologies Exhibition
Parantez Fair
www.idma.com.tr
THIS EXHIBITION IS HELD WITH THE PERMISSION OF THE UNION OF CHAMBERS AND COMMODITY EXCHANGES OF TURKEY (TOBB) PURSUANT TO THE LAW NUMBERED AS 5174
Extruders Almex +31 575 572666
Welcome to the market place, where you will find suppliers of products and services to the industry - in association with our sister publication The International Milling Directory To be included into the Market Place, please contact Tom Blacker +44 1242 267700 - tomb@perendale.co.uk
www.almex.nl
Colour sorters
Andritz
B端hler AG
+45 72 160300
+41 71 955 11 11
www.andritz.com
www.buhlergroup.com Dinnissen BV
Satake
+31 77 467 3555
+81 82 420 8560
www.dinnissen.nl
www.satake-group.com
Analysis R-Biopharm +44 141 945 2924
Adifo NV
www.r-biopharm.com
+32 50 303 211
Romer Labs
www.adifo.com
+43 2272 6153310
Cultura Technologies Ltd
www.romerlabs.com
+44 1257 231011
Amino acids
+1 515 254 1260 www.insta-pro.com JS Conwell +64 21 043 1027 www.jscextrusion.com Wenger Manufacturing
www.culturatech.com
+1 785-284-2133
Format International Ltd
Evonik
www.wenger.com
+44 1483 726081
+49 618 1596785
www.formatinternational.com
www.evonik.com
Bag closing
Insta-Pro International
Computer software
Feed processing
Coolers & driers
Ottevanger
Fischbein SA
Consergra s.l
+31 79 593 22 21
+32 2 555 11 70
+34 938 772207
www.ottevanger.com
www.fischbein.com/eastern
www.consergra.com
Bag design Cetec Industrie
Bakery improvers M端hlenchemie GmbH & Co KG
Rank Hovis
www.geelencounterflow.com
+44 1494 428000
+86 514 87848880
www.muehlenchemie.de
www.muyang.com
Elevator buckets
+33 2 37 97 66 11
Alapala
www.denis.fr
+90 212 465 60 40
Bulk storage Bentall Rowlands +44 1724 282828
www.croston-engineering.co.uk
www.vav.nl
Elevator & Conveyor Components
Silo Construction Engineers
4B Braime
+32 51723128
+44 113 246 1800
www.sce.be Silos Cordoba +34 957 325 165 www.siloscordoba.com TSC Silos +31 543 473979
www.cargotec.com
www.cimbria.com
+31 71 4023701
+44 1829 741119
+46 42 85802
+45 96 17 90 00
VAV
Croston Engineering
AB
+1 314 739 9191
www.stifnet.com
www.chief.co.uk
Cargotec Sweden Bulk Handling
Cimbria A/S
+33 2 41 72 16 80
+44 1621 868944
Grain handling systems
Tapco Inc
STIF
Chief Industries UK Ltd
www.rankhovis.com
www.alapala.com
www.tapcoinc.com
www.bentallrowlands.com
Flour
+31 475 592315
Famsun (Muyang)
+49 4102 202 001
Denis
www.wynveen.com
Geelen Counterflow
www.cetec.net
Bin dischargers
+31 26 47 90 699
+49 7520 91482-0 www.frigortec.com
+33 5 53 02 85 00
Wynveen
FrigorTec GmbH
www.go4b.com
Enzymes
Hammermills B端hler AG +41 71 955 11 11 www.buhlergroup.com Genc Degirmen +90 332 444 0894 www.gencdegirmen.com.tr Van Aarsen International +31 475 579 444 www.aarsen.com Yemtar Feed Mill Machines
Ab Vista
+90 532 5265627
+44 1672 517 650
www.yemtar.com
www.abvista.com
Zheng Chang
www.tsc-silos.com
JEFO
+86 21 64188282
Westeel
+1 450 799 2000
www.zhengchang.com
+1 204 233 7133
www.jefo.com
www.westeel.com
Certification
Equipment for sale
Laboratory equipment Aquar-System
ExtruTech Inc
+375 17 213 13 88
GMP+ International
+1 785 284 2153
www.aquar-system.com
+31703074120
www.extru-techinc.com
www.gmpplus.org
Bastak +90 312 395 67 87 www.bastak.com.tr
74 | Milling and Grain
Brabender +49 203 7788 0
Palletisers
Silos Cetec Industrie
Kepler Weber Group
+33 5 53 02 85 00
+55 11 4873-0300
CHOPIN Technologies
www.cetec.net
www.kepler.com.br
+33 14 1475045
Ehcolo A/S
www.chopin.fr
+45 75 398411
Doescher & Doescher GmbH
www.ehcolo.com
www.brabender.com
www.doescher.com
+44 1483 468900
Level measurement +1 402 434 9102
+49 5422 95030 www.neuero.de Vigan Engineering +32 67 89 50 41 www.vigan.com
Mill design & installation
07:18:17
www.buhlergroup.com GAME Engineering Ltd
C
M
Y
CM
MY
CY
CMY
K
Borregaard LignoTech
Symaga
+47 69 11 80 00
+34 91 726 43 04
www.lignotechfeed.com
www.symaga.com Tornum AB
Rentokil Pest Control
+46 512 29100
+44 0800 917 1987
www.tornum.com
Agromatic
Jacob Sohne
+41 55 2562100
+49 571 9580
www.agromatic.com
www.dol-sensors.com
Suffolk Automation
Visit us! www.pipe-systems.eu+44
1473 829188
Training
www.suffolk-automation.co.uk
Bühler AG
Recruitment
+41 71 955 11 11 www.buhlergroup.com
JCB Consulting +44 161 427 2402
IAOM
www.jcb-consulting.com
+1 913 338 3377
Rolls
www.iaom.info
www.game-engineering.com
+49 271 3758 0
Kansas State University +1 785 532 6161 www.grains.k-state.edu
www.breitenbach.de
Gazel Degirmen Makinalari
nabim
O&J Højtryk
+90 364 2549630
+44 2074 932521
+45 7514 2255
www.gazelmakina.com
www.nabim.org.uk
www.oj-hojtryk.dk
Ocrim
Roller mills
+39 0372 4011
Unormak
www.satake-group.com
+90 332 2391016 IMAS - Milleral
www.unormak.com.tr
+90 332 2390141 www.milleral.com
NIR systems NIR Online
+45 721 755 55
Fr. Jacob Söhne GmbH & Co. KG, Germany Tel. + 49 (0) 571 95580 | www. jacob-pipesystems.eu
Leonhard Breitenbach
+81 82 420 8560
Dol Sensors
Used around
+44 1522 868021
Satake
Temperature monitoring
all industrial Process control sectors.
+41 71 955 11 11 9/11/12
www.mysilo.com
www.jacob-pipesystems.eu
Buhler AG
Game Engineering logo FINAL.pdf
+90 382 266 2245
Pipe systems
Loading/un-loading equipment Neuero Industrietechnik
MYSILO
www.payper.com
www.rentokil.co.uk
FineTek Co., Ltd www.fine-tek.com
+34 973 21 60 40
Pest control
www.binmaster.com
+886 2226 96789
www.obial.com.tr
Pelleting aids
www.hydronix.com
BinMaster Level Controls
+90 382 2662120
PAYPER, S.A.
+49 4087976770
Hydronix
Obial
www.ocrim.com
Valves
Ugur Makina
+1 785 825 7177
+90 (364) 235 00 26
vortex@vortexvalves.com
www.ugurmakina.com
www.vortexvalves.com
Roll fluting
Rota Val Ltd
+49 6227 732668
Fundiciones Balaguer, S.A.
+44 1249 651138
www.nir-online.de
+34 965564075
www.rotaval.co.uk
Thermo Fisher Scientific
www.balaguer-rolls.com
+1 9786 421132 www.thermoscientific.com/
Safety equipment
quality
Packaging CB Packaging +44 7805 092067
Materials
+49 2961 740 50
+44 1476 566301
www.rembe.com
www.mogensen.co.uk
Sanderson Weatherall
Cetec Industrie
+44 161 259 7054 www.sw.co.uk
Sifters
Vibrafloor +33 3 85 44 06 78 www.vibrafloor.com
Weighing equipment Parkerfarm Weighing Systems
Mondi Group
Filip GmbH
+43 1 79013 4917
+49 5241 29330
www.mondigroup.com
www.filip-gmbh.com
Peter Marsh Group
Raw
Handling
www.cbpackaging.com
www.cetec.net
Mogensen
Rembe
Second hand equipment
+33 5 53 02 85 00
Vibratory equipment
Genc Degirmen
+44 1246 456729 www.parkerfarm.com
Yeast products Leiber GmbH
+44 151 9221971
+90 332 444 0894
+49 5461 93030
www.petermarsh.co.uk
www.gencdegirmen.com.tr
www.leibergmbh.de
the interview
Joel Newman, AFIA
Joel Newman is the American Feed Industry Association’s president, CEO and corporate treasurer. Newman has more than three decades of diverse executive experience in agribusiness, with United Cooperative Farmers, Maple Leaf Foods and Agway. He brought an exciting new vision to the association when he joined in 2004 and has effectively led the membership and staff through a landmark era of change. Newman represents AFIA on international issues and is a director of the International Feed Industry Federation, headquartered in Germany. He holds a bachelor’s degree in animal science from West Virginia University and a Master of Business Administration in finance and marketing from Syracuse University.
Can you tell us about your background and view of feed milling?
I just celebrated my tenth anniversary with AFIA, but was involved with the organisation as a member and served on its Board of Directors before that. I have been involved with the food and feed industry for 43 years, working on the business side of United Cooperative Farmers, Maple Leaf Foods and Agway, and that business experience has been very instrumental in my present position with AFIA. The feed industry provides animals with the necessary balanced nutrients for proper growth, development and maintenance. It also helps give nutrients and supplements that may be missing from an animal’s natural diet.
What are the main values of AFIA and both its longterm and short-term goals?
AFIA is committed to representing the total feed industry, as a key segment of the food chain, and member companies’ interests with one industry leadership voice. Our focus is on matters involving federal and state legislation and regulation, as well as global standards and issues; keeping members informed of developments important to them; creating opportunities to network and address common issues and interacting with key stakeholders essential to the success of the feed and animal agriculture industries. AFIA’s primary founding purposes were to promote and assure feed safety and to promote harmonisation of all state feed laws with uniform labeling and regulations, which is still very true today. Our staff are currently working on issues such as the Food Safety Modernisation Act, which we consider both a shortterm and long-term project, the Veterinary Feed Directive, continual improvement of our third-party feed safety certification programs and more.
What recent legislative developments have taken place with regards to the feed industry?
We are currently experiencing the largest rule change to happen to the animal food industry since the 1950s. AFIA and its members have worked closely with other industry groups to submit comments that best represent the feed industry’s praises, objections and suggestions. Currently FDA is reviewing those comments and have until August to do so. We have faith they will take our suggestions seriously, especially when it comes to the high cost of the rule if implemented as it was first posted as the proposed rule.
With a growing population predicted to reach nine billion by 2050, what pressures and demands has this placed upon the feed industry and what challenges does the feed industry face?
The growing demand to meet the demand is something that agriculture faces in the U.S. and globally. We will have to produce more with less; less land, less resources, less water, while protecting our natural resources and ensuring the economic well-being of customers, their communities and the industry. This is the definition of sustainability. Agriculture is a very sustainable industry, and has made continuous and significant improvements over the last 40 years. The feed industry’s ability to be sustainable also factors into that. AFIA and our members follow four focal points as we work to ensure a sustainable future for the industry: 1. Optimise the use of energy and natural resources for feed production. 2. Enhance production efficiency and productivity. 3. Promote understanding and appreciation of U.S. food production. 4. Support our local communities. In fact, we recently released our annual “Community Involvement and Charitable Giving Survey,” which correlates with focal point number four. To learn more about sustainability in the feed industry, watch our recently released video here: http://bit.ly/1An5ysN
Which countries do you predict will be at the forefront of global feed production in the future?
While all countries desire to be as self-sufficient in food production as possible, globally we will need to identify where feed and animal production can be most sustainable and intensify production in those regions. We also must share the education and technology to assist individual countries to continually improve their food production and sustainability.
What were the main focal points for AFIA at this year’s IPPE?
AFIA is one of three organisations that hosts the International Production & Processing Expo. AFIA along with the North American Meat Institute and the U.S. Poultry & Egg Association joined forces, co-locating their trade shows on feed, meat and poultry. AFIA hosted the following events on some of our main areas of focus: FSMA, trade and pet food. 1. AFIA’s eighth annual Pet Food Conference. 2. Exporting Feed and Feed Ingredients to the U.S 3. Food Safety Modernisation Act – Building a Foundation for Compliance.
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“AFIA’s primary founding purposes were to promote and assure feed safety and to promote harmonisation of all state feed laws with uniform labeling and regulations, which is still very true today”
PEOPLE THE INDUSTRY FACES Promotion at the Lincoln Grain Exchange
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he Lincoln Grain Exchange and the Board of Lincoln Inspection Service announce the promotion of Ms Danae Podraza to president of Lincoln Inspection Service, Inc., in the USA. In her new position, Podraza assists the board of directors in establishing and revising long-range goals, preparing yearly operating and financial budgets, supervising personnel and perpetuating customer relations.
A native of Sioux Falls, S.D., Podraza got her first taste of the grain business at the age of 12 by “walking the beans” on her grandfather’s farm in Worthing, S.D. She moved to Lincoln to attend the Danae Podraza University of Nebraska in 1991, joined the company in 1997 and continues to live in Lincoln with her husband, Scott, and their daughter, CeCe.
Lincoln Inspection Service, Inc. is an officially designated grain inspection and weighing service headquartered in Lincoln, with a full service branch office located in Farwell, Texas. Lincoln Inspection Service, Inc., provides services in accordance with the United States Grain Standards Act and the Federal Grain Inspection Service regulations thereunder. The agency’s designated service areas include Southeast Nebraska, Southwest Iowa, Northwest Texas and Eastern New Mexico.
Toygun Parlak joins Yemtar A.S
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r Toygun Parlak has moved from BBCA Storex to Yemtar A.Ş. After working 9 years in the silo sector, he decided to add new market to his professional career. In January 2015, Toygun moved to work on behalf of Yemtar A.Ş.
He said, ‘my main target is combining my silo experiences with feed mill projects and I also will give my all for growing the sales of silos for Yemtar’. He added, ‘we will present new face of Yemtar to our customers’.
Yemtar A.Ş. was established in Bandırma, Turkey in 1980. Since its inception, Yemtar A.Ş. has planned and delivered projects, manufacturers machines and installs modern feed mills. Yemtar Toygun Parlak A.Ş. offers value-added services and production in location for feed mills, galvanised silos, grinding systems, pelleting units, coolers, feeders and lots of modern equipment for projects whilst still offering value-added services and production in location. Yemtar A.Ş. targeted domestic market in its first years, and now it has expanded target markets to Africa, Middle East, Asia and the Balkans in a relatively short amount of time.
New Product Manager for professional products at Bayer
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teve Bishop is the new Product Manager for professional products at Bayer CropScience. He joins after five successful years at Polypipe, and says he sees his new role as offering an opportunity to combine his educational and commercial skills to best advantage. Steve achieved an Agriculture and Food Science BSc degree at Nottingham University (1996), and Masters in Environmental Science at Cranfield University (1998). He later also completed a two-year training programme with (as was) Rentokil Initial.
Steve Bishop
His new role will see him establishing a firm understanding of the market and its future challenges, ensuring Bayer is responsive to the rapidly changing industry while meeting customer requirements.
“I’m excited to be joining such a well-established company and am looking forward to supporting the team and our stakeholders.” Growing up in the Staffordshire countryside, Steve spent many happy years working on a neighbouring dairy farm. He is also a qualified falconer and attends annual hunt days, and a keen rugby player looking to move into coaching.
Ogle named Chief Financial Officer and Vice President, Finance and IT
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om Ogle has been named AIB International’s Chief Financial Officer and Vice President, Finance and IT. He will officially join the company on February 2nd, 2015. “We are thrilled to have Tom join the AIB team,” said Andre Biane, president and CEO. “As we streamline our dayto-day business and continue growing internationally, Tom’s expertise will be critical to AIB International’s long term success.”
Ogle has more than 20 years of experience with multiple financial functions along with information systems responsibilities. He has worked for large multi-national companies like IBM Corporation and regional companies like Continental Disc Corporation. Most recently he served as interim CFO for Alphapointe, a Kansas City based nonprofit organisation serving the blind and visually impaired. Tom Ogle
Ogle’s experience includes roles in controllership, cost accounting and financial analysis, managing working capital, the financial aspects of international startups, acquisition due diligence, accounting process improvements, employee pension and benefits enhancements, and guidance to executive teams and boards of directors. His information systems experience includes leading the implementation of enterprise resource planning systems, simplifying and integrating accounting and travel expense systems, and establishing appropriate levels of IT security and financial controls. Tom holds a bachelor’s degree in business administration from the University of Central Missouri, with a double major in finance and accounting, and a master’s degree in management from Purdue University. 78 | Milling and Grain
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