Mar 15 - Milling and Grain magazine

March 2015 YOUR GLOBAL PARTNER

In this issue:

Modular silos • Marriage’s Mill - milling since 1824 • Extrusion as an innovation driver • Taking NIR beyond feedstuffs

• GEAPS 2015

Show review

millingandgrain.com perendale.com

Volume 126

Issue 3

The Chief Advantage...

One-stop solutions with unmatched personal service

Aeration

Material Handling Catwalk Systems

Bulk Storage

Storage Bins You can trust Chief to offer reliable and innovative grain storage, aeration and material handling equipment for your total grain management needs.

• The One and Only Chief 1.1 — The Giant of Grain Storage • • • • • •

with a peak capacity of over one million bushels!

Largest 105' diameter grain bin – up to 801,086 bushel (20,348 MT) capacity Largest 92' diameter grain bin – up to 658,110 bushel (16,716 MT) capacity Caldwell centrifugal and axial fans Bucket elevators, conveyors and accessories Lemanco bulk storage Storage bins to fit your exact needs

Agri/Industrial Division of Chief Industries, Inc.

P.O. BOX 848 • KEARNEY, NE 68848 USA (308) 237-3186 • 1-800-359-7600 www.agri.chiefind.com

We Engineer Relationships

©

VOLUME 126

ISSUE 3

MARCH 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 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 Nigeria Marketing Team Nathan Nwosu Tel: +234 805 7781077 nathann@perendale.co.uk ©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

Grain & Feed Milling Technology magazine was rebranded to Milling and Grain in 2015

26 Milling since 1824 The Marriage family have been flour millers in Essex since 1824 and farmers in the local area since the seventeenth century.

Milling and Grain take a tour of the facility.

REGIONAL FOCUS

Africa

NEWS

4 6-20

FEATURES 26 Milling since 1824 Marriage’s Mill special

PRODUCT FOCUS

24

CASE STUDY

78

42 Taking NIR beyond feedstuffs

34 Colour at first sight

46 The fundamentals of pellet quality

40 Making food go further

54 Improving the quality of milled grains

36 Extrusion as an innovation driver

FACES

98 People news from the global milling industry

50 A call to action!

STORAGE SPECIAL 58 Modular silos

60 Temperature monitoring 64 Elevator buckets

72 Storage news and projects

EVENTS

62 Event listings, reviews and previews

TRAINING

23 The Wolfson Centre for Bulk Solids Handling Technology

IN THIS ISSUE COLUMNS

8 Mildred Cookson 10 Dik Wolters 11 Tom Blacker

2 GUEST EDITOR Roger Gilbert

80 MARKETS Robert S Zeigler

96 INTERVIEW Yoshimasa Tomoyasu

Guest

Editor

A word from our publisher It’s my privilege to step in as ‘Guest Editor’ for this the March 2015 edition of Milling and Grain.

There are a number of reasons why I feel it appropriate: This is the third edition under our new name; the third monthly magazine in a row we have produced and the first edition to go over 100 pages in a very long time! These are quite some milestones.

But it’s not just about the numbers. It’s also about information contained.

Coming to terms with the demands of a monthly publication means we can publish more timely (our editorial deadlines are the end of each month for publication the following month) and we can report on-going developments as they progress.

We have also been able to expand our content with the additional pages to cover grain storage and handling in a much more meaningful way and this – as some will be aware - is our S&H edition.

Milling is not just about the roller mills or the grinder and pellet press. Milling is about all the components that go into the end products that have been milled. For example, we should not overlook new digital technologies the impact all aspects of the equipment used in milling, nor the formulations systems that in turn rely on quality ingredients and additives and finally the macro ingredients – the wheat, rice, barley, maize, oilseeds, fishmeal and by products - that we transport, store and process.

To this end, we as Milling and Grain report on the whole of the milling process and then some. For example, in this edition we make reference to ‘International Women’s Day’ and the impact women make in agriculture, especially in regions such as Africa, which takes place as we go to print.

We now bring you the very latest industry news. The most recent being the opening of he 11th TUSAF (Turkish Flour Industry Federation) Congress in Antalya, one of the world’s most important flour milling industries – both in terms of equipment manufacturers and the output of milled flour – is taking place.

TUSAF Chairman of Erhan Ozmen, opened the Congress this morning with a focus on ‘Wheat and Health’ and addressing the issues regarding the movement towards “not to eat white foods including breads.”

Mr Ozmen, along with Milling and Grain, says the milling industry needs to recognise International Women’s Day on March 8, by retelling the story of 1857, where 129 New York women campaigned for their rights and lost their lives in demonstrations. He says that current thought of: a) a man is successful until he fails while b) a woman is a failure until she succeeds is changing, but must change faster; it is the women who care for and nurture our young, “… just like Mother Earth who supplies us with wheat which we have been consuming for thousands of years.”

His words are reflected particularly in one of our two key features this month, one ending hunger in Africa and the other on a call to action so that our industry can gather data and challenge the trend towards gluten-free milled products.

Furthermore, our February edition of Milling and Grain was completely translated into Turkish and distributed at the TUSAF event!

Roger Gilbert, Publisher, Milling and Grain

Beef exports to Thailand

20 years post BSE crisis, the Thai government announced yesterday (March 10th) the re-introduction of British beef and lamb to Thailand. In celebration, senior government officials and leaders of the UK meat processing industry were hosted by the British Ambassador at a dinner held in Bangkok.

Annual Subscription Rates Inside UK: UK£100 Outside: US$150/€133

ISSN No: 2058-5101

More Information www.millingandgrain.com http://gfmt.blogspot.co.uk

40 YEARS OF TESTED STRENGTH

One Tapco Nylon Elevator Bucket Supports a 9700 Pound* H1 HUMMER Ambient Temperature: 17 °F (-8 °C)

TAPCO’S CC-XD (Xtreme Duty) gray nylon elevator bucket supports a 9700 lb. H1 Hummer vehicle. Testing confirms that it will support over 20,000 lbs., more than two Hummers!

TAPCO’S CC-XD (Xtreme Duty) blue polyethylene bucket will support 9,000+ lbs.

Tapcoinc.com

TAPCO’S CC-HD (Heavy Duty) blue polyethylene bucket will support 5,000+ lbs.

314.739.9191 / St. Louis, Missouri USA No 814

*4399 kg

REGIONAL FOCUS

NEWS

DTMA launches new project in Eastern Africa

NEWS

Drought Tolerant Maize for Africa Seed Scaling (DTMASS) project will improve the demand for and availability of highquality, affordable, certified seed of drought-tolerant maize varieties for small-scale farmers across eastern and southern Africa. See the full story on page 11

Chad recieves climate change grant PARSAT, which will consolidate the acquisitions of previous investments

by IFAD in target areas in the country, will contribute to the long-lasting improvement of food and income security for rural dwellers. See the full story on page 9

COMMODITIES

Africa to expand rice production area Between 2014 and 2031, Africa will expand its rice production area by almost 50 percent to become a global leader, according to analysis on the global rice production and demand according to IHS Inc See the full story on page 80

AFRICA STATS

50,133,000 – Population of South Africa 1, 430, 000 – Domestically produced wheat (metric tonnes) 4 | Milling and Grain

FLOUR

Cargill completes US$12.5 million investment South Africa animal feed facility upgrades production capabilities and demonstrates growth in Africa See the full story on page 6

FEATURE

A call to tackle hidden hunger in Africa Today one in nine people – 805 million worldwide, many of whom reside in Africa – still go to bed hungry every night. Many more suffer from micronutrient malnutrition.

See the full story on page 48

News

MAR 15

Milling

Cargill completes US$12.5 million investment South Africa animal feed facility upgrades production capabilities and demonstrates growth in Africa

D

riven by an increase in demand from customers throughout the region for animal feed products, Cargill has completed a USD $12.5 million expansion of its premix facility in Pietermaritzburg, South Africa. The expansion includes new equipment, technology and resources to increase the plant’s efficiency and improve product quality. This investment demonstrates Cargill’s commitment to an animal production market in sub-Saharan Africa that is experiencing significant growth.

The facility produces poultry, ruminant, swine and pet food vitamin and mineral premix and base mix products for animal producers marketed under the Provimi brand throughout sub-Saharan Africa.

The state-of-the-art facility combines the latest feed safety technology and product quality capabilities, including automated barcode scanning and ingredient dosing. The design provides operational flexibility and minimal crosscontamination risk. The Pietermaritzburg facility positions Cargill to achieve its growth plans through increased production capacity and flexibility in product manufacturing, packaging and logistics.

“Our team of dedicated people take great pride in producing high-quality, safe animal feed products to meet our customers’ expectations,” said Gudo klein Gebbink, Cargill’s regional director for the Provimi brand in Sub-Saharan Africa.

“Cargill’s resources and know-how will play an important role in strategically supporting our customers’ future growth needs through on-farm management and technical expertise.”

Following the acquisition of half the interest of joint venture partner Astral Foods, Cargill became a majority shareholder with 75 percent interest in the company in 2012 and assumed managerial control. Astral Foods owns the remaining 25 percent interest in the company.

“In addition to producing animal feed products that contribute to feeding billions of animals which ultimately reach the dinner tables of more than 1 billion people every day, our Pietermaritzburg facility employees support the local community and provide assistance to many worthy organizations,” added David Webster, president and business leader of Cargill Animal Nutrition’s premix business.

6 | Milling and Grain

A blog dedicated to milling industry professionals globally

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.

Which is healthier enriched white or whole grain? bit.ly/1aJT2sG Chad receives IFAD agricultural grant against climate change bit.ly/1zEo2yN Kenya’s Unga Group half-year profit rises 59 percent bit.ly/18JoiYc Stone age Britons were eating wheat 2000 years before they farmed it bit.ly/1wH4BuI Monsanto says GM corn trial in final stage in India bit.ly/1zUTOJ9

GF

MT

gfmt.blogspot.com

ABCA announces important scientific information on selenised yeast technology at VIV Asia 2015

A

BCA is once again attending the VIV Asia 2015 in Bangkok, Thailand from 11-13 March. Besides showing the latest developments in its specialist yeast product portfolio, ABCA will present why a new addition to the products providing supplementary organic selenium should be viewed as the next generation of selenium yeast.

A new scientific paper from senior academic Prof Wayne Bryden,” Seleniun Biochemistry and Bioavalability –An Update” reveals how a new generation of organic selenium containing predominantly “Selenohomolanthionine” obtained from a proprietary strain of Torula yeast is rewriting scientist knowledge about selenium yeast. It is apparent that Selenomethionine is not the only effective form of organic selenium in feed supplementation. In independent trials,” Selenohomolanthionine” (ABTor-Sel) has been shown to have a greater effect in boosting the selenium status in livestock and with potential benefits of wider and more sustainable distribution of the element in the body tissues. Prof Bryden is the Professor

Animal Science at The University of Queensland, Australia and also is the Editor-in-Chief of Animal Production Science.

ABCA will hold a short technical session at ABCA’s booth F013, Hall 103 on 11 March at 3.00pm. Damian Moore, independent technical nutritional consultant (co-author of this paper) will be presenting some of this breakthrough information, summarized in his topic “Selenohomolanthionine – changing organic selenium mindset”.

Light refreshments will be served.

AB Tor-Sel is ABCA’s new high potency (4000ppm) organic selenium, produced through unique technology in Australia providing this highly effective form of supplementation. Most recent trials have shown its application across a number of species and this information is available for discussion with its technical team.

ABCA will also take this VIV platform to present its wider and developing range of yeast based feed ingredients. Its products are currently available in many Asian countries and it continues to develop its partners for distribution into new geographies.

Milling News

COMPANY UPDATES

Alapala recently completed a semolina mill with a capacity of 400 tonnes per day for Oba Macaroni in Gaziantep, Turkey next to an existing mill.

The new semolina mill incorporates state-of-the-art milling technology including Corum, Turkey-based Alapala’s new generation milling section models Similago II Roller Mills and Aurora Purifiers.

Significant growth for Bühler in 2014

T

he Technology Group Bühler closed 2014 with significant growth signals. The company’s order intake grew organically by 9 percent to CHF 2.6 billion, while its orders on hand grew by 20 percent to CHF 1.6 billion – both record results in the company’s more than 150-year history. Due to long project durations, turnover remained stable at the previous year’s level of CHF 2.3 billion.

In 2014, Bühler once again invested heavily in research and development, with a total sum of just under CHF 100 million (4.2 percent of turnover), and launched a considerable number of new products into the market.

The introduction of restructuring measures and capacity adjustments led to further improvements in profitability and all of the key financial performance indicators.

The EBIT grew by 4 percent to CHF 145 million or by 40 percent to CHF 195 million, when adjusted for onetime effects. Net liquidity rose by 23 percent to CHF 464 million, while equity increased by 8 percent to CHF 1.1 billion (equity ratio: 45 percent).

“These strong results confirm our strategic direction as an industrial solution and service provider,” says Bühler CEO Calvin Grieder. The company is approaching the significant appreciation of the Swiss franc from a position of strength. “I am proud of our employees, who worked with us, to quickly and pragmatically agree on the necessary immediate measures in order to safeguard our competitiveness,” says CEO Grieder. “Despite the changed circumstances, we are eager to continue our growth path and we look ahead to the 2015 fiscal year with cautious optimism.”

Founded in 1966 in Gaziantep, Oba Macaroni has always been a leading company in the sector.

The Özgüçlü family took over the facility and the brand in 2005.

According to its Indonesia Office, Muyang has delivered two paddy rice storage facilities in Karawang and Sragen for TPS Rice - a subsidiary of the TPS-Food and the largest rice manufacturer in Indonesia in the past two years, and the third project in Ngawi now is under construction.

March 2015 | 7

Knapp Roller Mills Christchurch near Bournemouth Milling Journals of the past at the Mills Archive

D

by Mildred Cookson, The Mills Archive, UK uring my researches at the Mills Archive in Reading, England, I sometimes come across material from the beginning of the last century relating to successful country mills. As a water miller for 30 years, albeit with French millstones, I have always found these fascinating accounts. Over the next few months in Milling and Grain I will highlight some of the more interesting.

This first appeared in The Miller in March 1904.

The water-powered, Knapp Roller Mills were situated in the beautiful open countryside approaching Christchurch, near Bournemouth, on the river Avon under the shadow of Christchurch Priory. The mills were in the ownership of Messrs Barnes and Maidment at the time the article was written and The Miller was taken round the mill and explained the workings by a Mr Troke, “one of Mr Armfield’s able representatives”.

In 1898 the mill was gutted by fire, but rebuilding commenced immediately and the mill was fitted out with a JJ Armfield & Co, model one and a half sack plant. There were three double sets of 24 x 7in rolls for three breaks and three reductions.

By a clever arrangement there were two undershot waterwheels, one at each end of the main line shaft. This was said to equalise the strain and add stability and regularity to the whole structure. Each of these wheels could, however, be run independently when required; particularly when, for instance, the auxiliary provender plant, which was a valuable addition to the mills business was needed. The water wheels were both 14ft diameter by 5ft wide.

The mill was fitted out with the usual complement of cleaning machinery, along with the usual arrangement of Armfield’s in putting the machinery on two floors only of the mill.

8 | Milling and Grain

Above the rollers are the purifiers, one double scalper, a chop reel, three centrifugals and a bran duster.

The mill owners did not follow the usual custom of other mills in the making three or four runs of flour from the same mixture of wheat, but studied the individual requirements of its customers and were able to make practically straight run flour, which met all the requirements of their competitors.

The Mills Archive Trust, a registered charity is actively collecting material, records and anecdotes relating to the early years of roller flour milling as well as more contemporary material where that is available. If you would like to help please email me at mills@millsarchive.org

Milling News

Chad receives IFAD agricultural grant against climate change

T

he Government of the Republic of Chad and the United Nations International Fund for Agricultural Development (IFAD) on the 17th February signed an accord on the financing of the Project for the Increased Resilience of Agricultural Systems in Chad (PARSAT in the original French).

PARSAT, which will consolidate the acquisitions of previous investments by IFAD in target areas in the country, will contribute to the long-lasting improvement of food and income security for rural dwellers in the GuĂŠra region and the Fitri and Dababa departments, respectively in the Batha and Hadjer-Lamis regions.

It will likewise improve the resilience of agricultural systems and home economics in the face of climate change and external impacts.

The PARSAT treaty particularly concerns the catchment and management of water, with ten thousand hectares to rehabilitate or allocate a use to, the intensification of production systems for dry cereals (millet and sorghum), and complementary cultures such as peanuts, sesame, black-eyed peas, legumes and small-scale livestockfarming.

PARSAT will likewise permit the opening up of many zones of production and the improvement of crop storage facilities; it will also promote revenue-generating activities such as the drying, preservation and processing of crops.

The financial accord was signed at IFAD's headquarters in Rome, by Rosine BaĂŻwong Djibergui Amane, the Republic of Chad's Minister for Agriculture and the Environment, and Michel Mordasini, Vice-President of IFAD. Costing a total of US$36.2 million, including a US$17.2 million IFAD grant and a further grant of US$5 million from the Trust Fund for the Smallholders' Agriculture Adaptation Program, the project is also co-financed by the Least Developed Countries Fund and the World Environmental Fund to a total of 7.3 million dollars, and by the Government of Chad in the region of 6.1 million dollars, added to which is a contribution of 0.6 million dollars by the beneficiaries themselves.

An estimated 35,000 households, or about 175,000 producers - of whom 40 percent are women and 30 percent children - will benefit from PARSAT. Since 1992, IFAD has financed eight projects and programmes in Chad amounting to more than 163.5 million US dollars, of which 113.5 million are from its own resources, and directly benefiting 148,350 Chadian households.

IFAD invests in rural populations, increasing their autonomy in order to reduce poverty, increase food security, improve nutrition and strengthen resilience.

Since 1978, we have granted over16.3 billion US dollars in the form of low-interest loans and grants towards projects affecting 438 million people. IFAD is an international financial institution and a specialist U.N. organisation based in Rome - the UN's nutritional and agricultural nerve-centre.

March 2015 | 9

Milling News

Chain approach in feed safety control is crucial Dik Wolters, Project Manager, GMP+ International A crucial lesson we have learnt from the past, is that a safe feed can only be produced and delivered to a farmer when the whole feed supply chain is involved in feed safety assurance.

GMP+ Feed Safety Assurance started in The Netherlands in 1992. At that moment, the scope of the scheme only covered the production and delivery to farmers of compound feed and single feed. Practical experiences showed us that, although these companies controlled all their processes, feed was still contaminated: the source of contamination was often related to feed ingredients, supplied via the supply chain.

The Dutch feed industry imported about 75 percent of the feed ingredients from other part of the world, from Europe as well as Asia and North and South America. These feed ingredients are shipped in large volumes to North-West Europe. In case a feed ingredient from a certain origin was contaminated with an undesirable substance, a huge volume of contaminated ingredient arrived at country of destination.

Two examples are given to illustrate previous experiences. The first one is about contamination of Brazilian citrus pulp (byproduct of citrus fruit processing industry) with dioxin in 1998. Triggered by detected increased level of dioxin in raw milk, it was found that about 150,000 tons of contaminated citrus pulp from Brazil was distributed in Germany, The Netherlands, Belgium and North France.

A more recent experience in Chile is about cadmium contamination of copper sulphate in 2008. In export destinations of pork, produced in Chile, increased levels of cadmium were detected. The source was contaminated copper sulphate used in pig feeds.

Due to these kinds of experiences, the scope of the GMP+ Feed Certification scheme was extended to involve the whole feed supply chain. From 2000 onwards, also producers of feed ingredients, traders, storage and transport companies can participate in the GMP+ FC scheme. Special standards were published, created together with the industry; with conditions for implementing and operating a 10 | Milling and Grain

proper feed safety management system.

Assuring the feed safety in whatever phase or stage in the feed chain is build on the same principles, laid down in a similar way in all these standards: a sound prerequisite programme, a detailed and exhaustive hazard plan, and a supporting management system.

These three pillars are the bases of a complete management system for assuring the feed safety. Specific requirements for suppliers are meant to create a feed supply chain where all involved companies assure the safety of the feed in all stages of production and distribution. With a GMP+ certificate, they can demonstrate they meet the highest standards for feed safety.

It is crucial that risks are controlled, where they might occur during production, storage and transport. Every entrepreneur in the feed chain must show responsibility for the safety of the feed, placed on the market, and implement proper measures to control these risks. This will avoid, or in case of failure of the control measures for any reason whatsoever, reduce distribution of contaminated feed ingredients lots.

Three related requirements were also introduced at the same time: (a) proper traceability system, (b) the duty to inform customers in case of contaminated deliveries and (c) the duty to recall of delivered lots of contaminated feed products. On top of this set of instruments, we introduced an early warning system (EWS). That means that, in case of a feed contamination, GMP+ International informs all certified companies, respecting confidentiality aspects: the level of the detected contaminant, the name of the feed product involved and the country of origin. This alert enables other companies to take actions and control measures in case they are sourcing the concerned product from the same origin.

The international coverage of GMP+ Feed Safety Assurance with over 13,400 certified companies in 65 countries enables to act properly. This is in the interest of all links in the feed chain, and also of farm animal and aqua feed producers and the following livestock and aqua production links.

During VIV Asia GMP+ International will held a free of charge one-day workshop “Introduction to the implementation of a GMP+ Feed Safety Management System. For more information check www.gmpplus.org (seminars).

KSE Process Technology BV nominated for Weighing Review Reader’s Choice Awards

K

SE Process Technology BV has been nominated for several Weighing Review Reader’s Choice Awards.

KSE is nominated for ‘Best Weighing Company 2015’.

It is also nominated for ‘Best Weighing Software 2015’ with its ALFRA dose & weigh machine control and for ‘Best Dosing, Filling and Packaging solutions 2015’ with its ALFRA Medium Component Dosing System.

“It’s an honour to be nominated for these awards.

It’s a stimulus to keep developing and improving our ALFRA dosing and weighing systems so we can serve our customers in the best possible way”, says Richard Biessen, Head of Product Management.

These awards are a part of the second annual edition of the Weighing Review Readers’ Choice Awards, the only global voting competition that covers the major innovations and best products in weighing technology. Through an online nomination and voting process, the Weighing Review Awards recognises and honors the best companies and the products and solutions in 18 categories.

The Online Voting is now open and it will end on Friday, March 20th 2015. The winners will be announced on the Weighing Review Portal and on the Weighing Review Social Media pages on Monday, March 23rd 2015.

Milling News

DTMA launches new project to improve seed scaling in Eastern Africa

B

orn out of the Drought Tolerant Maize for Africa (DTMA) Initiative and other CIMMYT-Africa maize projects, the Drought Tolerant Maize for Africa Seed Scaling (DTMASS) project will improve the demand for and availability of high-quality, affordable, certified seed of drought-tolerant maize varieties for small-scale farmers across eastern and southern Africa.

“DTMASS aims to produce close to 12,000 tons of certified seed of drought-tolerant maize varieties by the end of its fifth year,” said Tsedeke Abate, DTMA project leader who will also lead DTMASS, speaking at the Uganda launch of the project in Kampala on 4 February.

“This will benefit approximately 2.5 million people through the increased production and productivity of maize and the adoption of improved certified seed.”

According to Abate, DTMASS will strengthen the formal seed system, thereby reducing counterfeit seed use, lowering the risk of seed-borne maize diseases and helping to maintain productivity as climates change.

Working in Ethiopia, Kenya, Malawi, Mozambique, Tanzania, Uganda and Zambia, DTMASS will encourage cross-country learning and collaboration, Abate explained: “We have the knowledge and technology – what remains is translating knowledge to action.”

DTMASS countries account for 41 percent of maize area and production, and over 252 million people in sub-Saharan Africa.

A pillar of the project will be its strong partnerships with private and public seed companies, community-based organisations, non-governmental organisations and national extension systems. Fifty-three seed companies have already agreed to produce seed of 71 drought-tolerant varieties.

These partnerships enable increased and improved certified seed to reach smallscale farmers, increase farm production and enhance productivity, according to Dr. Imelda Kashaija, deputy director at Uganda’s National Agricultural Research Organization (NARO).

“This project is at the right place at the right time,” she said.

DTMASS launched officially on 17-18 November 2014 in Addis Ababa, Ethiopia.

The goal for Uganda in 2015 is to produce 1800 tons of improved maize seed.

Internationalism and social media Tom Blacker, IMD The International Milling Directory received some excellent distribution and comments from North America this past month. GEAPS (The Grain and Elevator Processing Society) Exchange (annual conference and exhibition) in St Louis, Missouri, USA resulted in all-round successes for the North American industry. You can read more about the GEAPS Exchange later in this magazine. Feedback from the 500 copies distributed to the industry at this important annual conference and exhibition was very good indeed.

As we all know, a lot of the grain industry works together on projects in supplying, upgrading, distribution and even combinations of equipment that result in effective solutions for the grain miller, grain handler or grain transporter. This has always been part of a pattern of users of the 23rd print edition that use the International Milling Directory for a variety of reasons.

With a globalised industry, spreading from the older markets of the West outwards, North Americans are seeing the value of international publications more than ever before.

The international market place is looking towards the developing markets of Eastern Europe, Northern, Western and Eastern Africa, and also to the Middle East. Our team is regularly in those regions alongside the industry as it develops. Watch this space for this magazine bringing you great things later this year.

Users are increasingly using our online services. Social networking is becoming a larger part of our reach, just like most industries. This digital part of our audience keeps on growing faster and faster! In our social media, the International Milling Directory now has over 170 Facebook ‘likes’ – with most of those people liking our page based in Egypt, Turkey and India but most people reached located in Europe.

As would be expected for this industry, 89 percent of these users are male but we want to promote our Facebook page to female users in the industry so we invite you all to ‘like’ us at https://www.facebook.com/ internationalmillingdirectory.

Also, our successful Twitter page, over 672 followers on Twitter and our tweets made 1,500 impressions in the whole month of just 28 days of February. Follow us: @intmd (www.twitter.com/intmd). The directory is proud to be “connecting the milling industry worldwide”, as our biography on Twitter says.

Lastly, we hope you are finding the main website useful. One good thing to do is to register for the e-newsletter. Please go to the homepage at: http:// www.internationalmilling.com/ and go down to ‘Keep in touch’ and simply enter in your email address and click ‘Go’. That is all it requires!

Tom Blacker Directory coordinator March 2015 | 11

We Mean Busin Cost Effective Solutions That Get Results!

Smart companies don’t buy names. They buy results. Results that don’t vanish when things get tough. Results that deliver when projects … and reputations … hang in the balance. At times like these, the trust placed in your equipment suppliers will either pay dividends or spell disaster.

Global Industries has provided results-based grain systems for more than half a century.

Single component? Total project? Doesn’t matter! Global works to understand your

needs to deliver durable and efficient solutions to drive your business forward.

Lots of companies sell grain equipment, but few can match the quality, service and support Global delivers to every customer, every day. Smart companies understand that trust is earned through consistently meeting expectations. That’s why Global customers stay Global customers.

You expect results. Global delivers.

Innovative Engineering • Precision Manufacturing • Delivering Value & Trust Global Industries, Inc. 2928 East US Highway 30 Grand Island, NE USA 69902 E-mail: international@globalindinc.com Ph: 308-384-9320 Fax: 308-389-5253 www.globalindinc.com Visit Us On Facebook

ness

Milling News

1945-2015:

Seventy years in the milling industry

O

n Wednesday, March 25, 2015 Ocrim will celebrate seventy years of life. The company was founded in 1945 by the judicious Guido Grassi, Member of the Order of Merit for labour, with the invaluable contribution of his brother Ettore and his cousin Luigi Grassi, in a place with a great agricultural tradition.

Ocrim was born as a small workshop located in Cavatigozzi, with no more than 25 employees, while the administrative and commercial activities took place in a commercial studio in the center of Cremona.

Today, Ocrim is owned and managed by the Antolini family. Primo Antolini is the President and his sons, Alberto and Sergio, are respectively Managing Director and Vice President.

A series of changes have occurred with the Antolini family, not only in trade and economic terms but also in relational, cultural and social terms, while preserving what has always been the tradition of the company. In fact, the Antolini family, despite not having Cremona origins, give great importance to the bond that OCRIM has always had with the city of Cremona: its citizens are often involved in events and projects, both of cultural and educational import, and this year they will be even further involved in various events and occasions organised by the company, with the goal of making people feel that they are an integral part of this great family.

Seventy years of research, design, production and creation of milling plants, feed mills and cerealprocessing systems have placed Ocrim at the forefront of a global industry. After seventy years of activity in the mechanical industry, Ocrim is proud to keep production in Italy, despite great difficulties. This has all led to the

14 | Milling and Grain

preservation and the excellence of ‘Italian Made’ as a genuine trademark for Ocrim.

To celebrate this milestone, Ocrim will present to the world its most competitive and updated solutions for the sector. These are amazing innovations in the field of technology and engineering and will be the stars of an important event scheduled for May 21st at the IPACKIMA 2015 exhibition, where the company will participate with great enthusiasm.

At the Ocrim booth, the team will welcome visitors as they exhibit a preview of these innovations that will be told and shown through ‘alternative’ languages; they also reflect not only the personality of the company, but will also refer to the artistic and cultural Italian realities to which Ocrim is so closely linked.

Ocrim also confirms its continuous commitment to an important and determined investment in the Research and Development sector. Ocrim has always believed that giving importance to this sector was a decisive choice to stand out and excel with a spirit of innovation and a thirst for knowledge.

Professionalism, innovation and tradition are therefore the key words that distinguish Ocrim. The combination of these three elements is well represented by projects linked to Ocrim’s ‘Italian Made’ trademark: customisation of limited-edition machines in the presence of clients; the ‘Wheat, flour, and…’ event; and the ‘Ocrim core’ museum and the International School of Milling Technology.

All this is the result of the passion, competence and fairness that the Ocrim Staff work by every day, because sometimes the important and beautiful things are not made by only one person, but by a team.

www.symaga.com symaga@symaga.com

Symaga, the first industrial silo manufacturer obtaining CE Certificate

Visit us:

GRAIN TECH MIDDLE EAST

23-25th February, Cairo, Egypt Hall 19

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

VIV ASIA

11-13rd April Bangkok, Thailand Hall 106 Stand C020

SIAM

23rd April - 05th May, Meknes, Morocco

Milling News

The International Maize and Wheat Improvement Centre (CIMMYT) celebrates International Women’s Day 2015

I

nternational Women’s Day on March 8th offers an opportunity to recognise the achievements of women worldwide. This year, CIMMYT asked readers to submit stories about women they admire for their selfless dedication to either maize or wheat. In the following story, Judith Oyoo writes about her Super Woman of Maize, Jane Ininda, an agricultural scientist.

Dr Jane Ininda is an agricultural scientist who has been making great strides in agricultural research with remarkable results.

She was born in humble surroundings, in Mbeere District, in Kenya. Her parents were farmers whose crop yields were far from satisfactory.

“I remember as I was growing up that there wasn’t enough food; we used traditional methods and you could never be sure there would be enough food in the year,” Ininda recalled.

A graduate of Iowa State University, she began her academic journey in Easter Province, Kenya at Kaaga

Girls High School, University of Nairobi where she earned bachelor’s and master’s degrees before joining Iowa State University to study for her doctoral degree.

Dr Ininda has released 26 commercial maize varieties during a career that spans more than 30 years. In collaboration with other partners she has released more than 180 hybrid maize varieties that have been commercialised.

She has contributed to food security, employment and wealth creation to smallholder farmers in Africa.

Dr Ininda believes in the saying: “Give a hungry person a fishing hook and they will never be hungry again in their lifetime.”

In this case, the “fishing hook” is crop varieties, especially disease-resistant, high-yielding maize with improved taste and the ability to mature early.

In addition to her professional excellence, she has mentored many upcoming young scientists without considering gender.

She is hardworking, determined, focused, intelligent, humble and soft spoken, although she is a giant in the world of research.

She believed in me when I was naïve, having recently graduated from Kenya’s Egerton University. She involved me in her project, taught me how to carry out experiments, data collection and teamwork.

I gained invaluable research experience under her mentorship, although informal. One way to sum her up: “Priceless gem to Africa.”

With thanks to CIMMYT. AgraMe2015 - 90 x 132mm.pdf

1

11/1/15

5:23 PM

Under The Patronage of H.E. Rashid Ahmad Bin Fahad, Minister of Environment and Water

The Region's Leading Agribusiness Event

ONLINE AUCTION on behalf of our client of equipment concerning

FLOUR MILLING

Grow your business at AgraME

31620 Huarte (Navarra) - Spain

Flour, starch and gluten processing FLOUR MILL PLANT - cap. 200 t wheat/day incl. 9 MILLS

“Sangati”; hammer mill “Ceasa”; dispersers “Sangati”; plansifters “Sangati” S-61 and S-63DSA; 4 air separators “Sangati” incl.

SCVD-7; purifiers “Sangati” PS-50; sieves; scales; transporters; bag filters incl. “Sangati” FP120; rotary locks; cyclones; air compressors “Ingersoll Rand” (2013) and “Abac” (2005); modern laboratory incl. alveographs “Chopin” Alveolink NG, MA95, distillation units “Foss” Kjeltec 8100 (2013), moisture analyzer (2014) etc.;

GLUTEN-STARCH PLANT - cap. 96 t flour/day incl. 11 CENTRIFUGES “(Alfa-Laval) Sharples” P-3000 / P-3400 / P-2000 and “GEA” DA-100-76-117 (2005), 2 gluten drying lines incl. extrusion unit and cutter mixer/chopper, 2 starch drying systems incl. mixer, breaker, cyclone etc.; 2 centrifugal conical sieves, hydrocyclones “Alfa Laval”, mill “Chopin” Moulin CD1 (2013); ± 15 tanks, 17.000 - 850 l, plate heat exchanger “Alfa Laval”, boilers, 5 raw material silos “Grundfoss”, cap. 30.000 / 10.000 kg; gluten kneading bass drums, separators, starch rotary filter; autom. baggers;

16 – 18 March 2O15 | Dubai International Convention and Exhibition Centre

WHY VISIT Meet over 250 exhibitors from more than 30 countries Exclusive product launches & demonstrations Attend conferences focusing in depth on the industry’s most relevant topics Network and meet face to face with industry leaders from around the world Secure an opportunity to see the leading names in agribusiness and related industries under one roof

Register online for free fast-track entry at

www.agramiddleeast.com

Offers for the total plant are accepted until Fri 20 March at 14.00 hrs

CLOSING: Thursday 9 APRIL

+971 4 336 5161

info@agramiddleeast.com

www.agramiddleeast.com

Viewing: Thursday 2 April from 10.00 till 14.00 hrs

www.TroostwijkAuctions.com 16 | Milling and Grain

STRATEGIC PARTNER

www.agramiddleeast.com

ORGANISED BY

The industry’s most authoritative resource on feed production

AFRICA EXPERIENCES GREATEST GROWTH IN FEED - WHILE PIG FEEDS MADE THE GREATEST GAINS

2

015 marks the fourth consecutive year that Alltech has conducted a global feed survey analyzing feed production - says Aidan Connolly, chief innovation officer and director of Alltech’s Global Feed Tonnage Survey, And there were many areas of ups and downs in worldwide production, impacted by both positive and negative influences such as slow markets, shifting raw feed material costs, fluctuating governance over import/ export standards and animal diseases such as PEDv in pigs and bird flu in poultry, he says.

His estimate of the feed industry’s net worth globally is US$460 billion, based on average materials prices throughout 2014.

“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. Yet, each year, better information is discovered and more is learned about how farmers around the world feed their livestock.”

The Global Feed Survey assessed the compound feed production from 130 countries in December 2014 through information obtained in partnership with local feed associations and Alltech’s sales team, who visit more than 31,000 feedmills annually.

2014

Average price pig finisher diet

Africa

$390.00

Asia Pacific

$390.00

Europe

$361.00

Latin America

$452.00

Middle East

ND

North America

$429.00

Overall average

$427.00

When grouped in regions, Africa and Latin America saw the greatest growth in 2014, with Africa experiencing growth in all species.

With regard to pigs, Pigs and pets saw the largest percentage of growth in 2014, pigs up to nearly 256 million tons and pets up to nearly 22 million tons.

How the survey was conducted • Estimates compound feed production • Based on information collected from: - Feed industry associations - More than 600 Alltech sales-force visiting 31,000 feed mills globally • Data gathered from 130 countries • Definitions of feed terms can vary from country to country - does not include forages • Survey conducted Dec. 2014

March 2015 | 17

Milling News

Bühler celebrates significant contract with TPS Group in Indonesia with grand signing ceremony

T

Pictured from left to right: Harsinto Huang, Syambiri Lioe, Joko Mogoginta, Dieter Voegtli, Tomas Soleman

he Bühler Group, a global leader in rice processing, today underlined its position as first-choice supply partner for rice processors across Indonesia and South East Asia, with a high value agreement to supply the TPS Group, an Indonesian rice and noodle producer, with two, 17 tonnes per hour rice reprocessing lines valued at USD 7 million.

The contract, signed today at the JW Marriott hotel in Jakarta, Indonesia marks a further milestone in Bühler’s continuing expansion in rice processing across Asia and a significant step forward for the TPS Group, following its entry into the rice business in 2010. At the signing ceremony, the Tiga Pilar Sejahtera (TPS) Group were represented by Joko Mogoginta, CEO and Sjambiri Lioe, CFO. The Bühler Group was represented by Dieter Voegtli, President of Bühler Asia, Rustom Mistry, Director, Head of Rice Processing, Asia and Tomas Soleman, Managing Director of Bühler Indonesia.

The installation of the rice reprocessing plants at Sidrap, South Sulawesi, will increase the TPS Group’s total production capacity by 240,000 tonnes per year, with warehouse capacity increasing to 30,000 tonnes. The project by Bühler will be commissioned by mid-year 2016.

TPS Group currently has three rice processing plants across Indonesia, including PT. Jatisari Rejeki (CikampekWest Java), PT. Indo Bears Unggul (Cikarang-West Java)

and PT. Sukses Abadi Karya Inti (Sragen-Central Java), with a total capacity of 480,000 tonnes. Investment for the TPS Group’s South Sulawesi sites, valued at IDR. 682 billion (USD 53 million), will increase the manufacturer’s total production capacity to 810,000 tonnes per year while underlining its commitment to achieve a five percent share of milled rice production volume in Indonesia by 2020.

Rustom Mistry, Director, Head of Rice Processing, Asia for Bühler, said: “The agreement with the TPS Group demonstrates Bühler’s commitment to develop state of the art processing solutions and an acknowledgement of our global capability to supply complete process engineering solutions, driven by our leadership in rice research and technical excellence. By choosing Bühler to support its rice processing lines, the TPS Group is well positioned to meet its plan of achieving a significant share of the milled rice production in Indonesia. We look forward to continuing our relationship with the TPS Group.”

The deal demonstrates Bühler’s significant investment in its customer partnerships, technical innovations and localised service and support, which is serving the demands for processing and optical sorting solutions from rice processors around the world. This significant agreement is further evidence of Bühler’s reputation as the number one technology partner of choice in rice processing.

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

internationalmilling.com

20 MD_214x110.indd 1

| Milling and Grain

10/03/2015 11:09

All

NIV: up to 800 tons/hour Average efficiency 75%-80%

es of gra p y t

in

9

Pneumatic or Mechanical Ship Loaders & Unloaders Port Equipment - Turnkey Projects

A win-win solution between customer expertise and VigAn know-how VIGAN Engineering s.a. Rue de l’Industrie, 16 • 1400 Nivelles (Belgium) Tél.: +32 67 89 50 41 • Fax : +32 67 89 50 60 • www.vigan.com • info@vigan.com

Mill

Training

The Wolfson Centre for Bulk Solids Handling Technology is a specialist consultancy, research and training provider based in Kent, which has been working with industry since 1973. The team of consultants at The Wolfson Centre have substantial experience with all kinds of bulk materials handling problems. A result of the high demand for their services has been the development of a range of one and two day training courses for Industry designed to help end users and equipment manufacturers understand how and why materials processing problems occur and to ensure awareness of compliance requirements for DSEAR/ATEX.

The Wolfson Centre for Bulk Solids Handling Technology System Design

Whilst off-the-shelf equipment works for the majority of powders and particulates, there are often problems with the bulk materials that exhibit poor flow behaviour or have special storage requirements – and it is the characteristics of these bulk materials that should be understood in order to specify or design appropriate bespoke equipment to operate reliably. In many instances the supplier blames the materials for the cause of the problems and the client blames the equipment. If both sides took time to assess the interaction between the bulk material and the equipment being used, these problems would be far less frequent. In many situations budget constraints are the main factor in selecting equipment, but savings in procurement are frequently dwarfed by costs incurred through subsequent production problems.

It is important that both the equipment manufacturers and the end users are aware of the importance of understanding the behaviour of the materials being handled, and that they understand the potential (sometimes) catastrophic results that can occur when no pre-design characterisation is undertaken.

For this reason, having spoken to the end users and system designers, and delegates attending the basic courses, two new ‘advanced’ short courses have been organised, to delve deeper into the design issues of general hoppers and silos, as well as complete pneumatic conveying systems. For both courses, delegates will need to have existing sound knowledge of system operation and for that reason we are offering discounted course fees to anyone attending the advanced courses who have previously attended the basic courses at the Centre.

As a design engineer of bulk materials equipment or plant manager, you should not miss the opportunity to come on these courses.

12- 13 May: Advanced Course; Design of Equipment for Storing and Discharging Bulk Materials - A course developed with specification writers and equipment designers/ suppliers in mind 9 – 10 June: Advanced Course: Pneumatic Conveying System Design - Here you will be taken through an in-depth exploration of detailed calculations and design for pneumatic pipelines

DSEAR/ATEX Compliance

Not only should system designers take into account the compatibility issues of material and equipment, but they should also be aware of the requirements of DSEAR/ATEX. Explosions and fires from combustible materials are a known hazard and can give rise to serious injury as well having as the potential to cause extensive plant and buildings damage.

Legislation introduced in 2002 - the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) rationalised workplace assessment for fire and explosion hazard identification, and methods of prevention or mitigation. DSEAR requires all workplaces where substances that could give rise to fire or explosion are handled or stored must be fully assessed and protected.

The Wolfson Centre has been providing training in DSEAR/ ATEX compliance for Industry both at its training centre in Kent and on site at plants around Europe 21 April: Dust Explosions – How to Demonstrate DSEAR/ ATEX Compliance - The one-day course gives an introduction to the subject and the simple measures that can be taken to reduce the hazard of a dust explosion. It includes a brief overview of current legislation and the safety precautions required to demonstrate compliance and provide a safe working environment for employees.

Full details of all the courses available at the Wolfson Centre for Bulk Solids Handling Technology can be found at www. bulksolids.com or contact the consultants for more details Email: wolfson-enquiries@gre.ac.uk Tel: +44 20 8331 8646

Want more industry news?

Get daily news updates on the Global Miller blog gfmt.blogspot.com March 2015 | 23

K-Obial速 ULV6

PRODUCT FOCUS MARCH 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.

Bayer CropScience - K-Obial速 ULV6 is a modern liquid pyrethroid formulation containing deltamethrin, synergised with piperonyl butoxide for the control of a wide variety of stored product insects known to infest grain and pulses. This [pyrethroid formulation is an ideal alternative to organophosphate formulations. Available in two formulations in a single admixture treatment can provide protection for up to 12 months. With unrivalled efficacy against the most common insect pests K-Obial速 ULV6 is the product of choice for the treatment of grain storage facilities and as an admixture for longer term grain storage. Used as part of an Integrated Pest Management (IPM) approach K-Obial速 ULV6 will provide the highest level of protection for your valuable stored crops. K-Obiol is accepted for use by the Brewing Research International (BRI) and the National Association of British and Irish Millers (nabim).

www.bayer.com

TTS-500-H/TTS-500-V table top sealers Fischbein Saxon - Horizontal and Vertical mounted open mouth polypropylene and polyethylene bag closing devices. They can also both be used on paper bags with a polypropylene or polyethylene inner liner, bags laminated and with gussets. The sealer is designed to be placed onto a work bench or a table. It has been designed to be used for a short duration or in very low production runs, where it is not possible to justify purchasing an industrial sealer Saxon. It features an integral conveyor which can take a maximum weight of 10kg.

The nominal width of the seal is of 14mm, this can vary according to the possible shrinkage of the bag.

AS SEEN AT LAMMA 2015 This product was featured at LAMMA 2015 at the Peterborough Arena, UK

IN OUR NEXT ISSUE See the full review of the new Dinnissen range of hammer mills

www.fischbein.com

Silo Sweep Auger Guttridge - The introduction of the Sweep Auger to our product range means that we are now able to supply equipment for every aspect of grain handling. As well as the Guttridge range, we manufacture the Carier range of grain handling equipment. Carier were a well-known, well-respected manufacturer of grain handling equipment in the their own right.

D-Topline Hamex Hammer mill The new D-Topline Hamex Hammer mill with automatic screen changer can handle grinding capacities of up to 45,000 kg per hour, and the screen changer has space for 4 to 6 different sets of screening panels.

The mechatronic screen changing system automatically select and places the appropriate set of screening panels in the hammer mill.

Guttridge Ltd bought the intellectual property of Carier in 2004 and Guttridge also employs three ex-Carier staff, who are available to help people with Carier conveying equipment with spare and replacement parts.

We recently supplied Carier conveyor spares to a machine that is still running after 40 years!

After the production process has been completed, it also removes and stores the screening panels in less than 40 seconds. This makes it possible to change screens extremely quickly and greatly reduces downtime. The D-Topline Hamex Hammer mill features a new and ingenious design, which greatly increases the surface area of the grinding and screening panels.

www.guttridge.co.uk

www.dinnissen.nl

24 | Milling and Grain

FOCUS

SPECIAL FOCUS

Sukup support towers

Sukup is expanding its Material Handling line-up with the addition of Support Tower Structures. Sukup Towers are ideal for supporting Sukup Bucket Elevators. They also may be used to attach conveyor catwalks or support a Sukup DoubleRun or a Sukup Distributor.

Angled cross bracing and square tubing corner posts provide solid support for various heights, seismic zones and wind speeds. The cross bracing is located high on the base section

Material Handling line, Sukup is erecting a 100,000 square foot Sukup Steel Building to house the increased production.

This building is the latest in the continuous expansion occurring at Sukup headquarters in Sheffield, Iowa.

Sukup Manufacturing Co. is a family-owned grain storage, drying and handling equipment manufacturer located in Sheffield, Iowa, USA. Sukup has been providing top quality products to agricultural producers since 1963. The product

to allow for easy access to the equipment inside the tower.

Sukup Towers are available with both switchback and wrap around stairs. “Sukup has had a comprehensive material handling line for several years now; it just makes sense that we would offer towers too. This falls in line nicely with our goal of being a one-stop shop, providing everything our customers need,� says David Brownmiller, Sukup Engineering Manager.

With the addition of Towers and the expansion of their

line includes on-farm and commercial grain bins, portable and tower dryers, centrifugal and axial fans and heaters, stirring machines, bin unloading equipment and bin floors and supports.

Sukup also manufactures a line of material handling equipment that includes bucket elevators, drag conveyors and chain loop conveyors, as well as a line of steel buildings. Sukup products are sold throughout the US and Canada, as well as in over 50 foreign countries.

www.sukup.com

Want to see your products featured in this section?

YOUR GLOBAL PARTNER

Send your product information and images to: oliviah@perendale.co.uk

March 2015 | 25

#

3

F L O U R

W & H MARRIAGE & SONS LTD

MILLING SINCE 1824

The Marriage family have been flour millers in Essex since 1824 and farmers in the local area since the seventeenth century part 1:

The flour mill

“Everyone wants things to be better,” he adds. And consumers of flour are no different.

Flour milling, says George,

by Roger Gilbert and Olivia Holden, Milling and Grain magazine is the same process no matter where in the world you are.

“The technology used is similar.

It’s the materials used in he Great British Bake Off, a television programme manufacturing the equipment that has changed, such as the that has captured the imaginations of the British bearings and drives and resulting energy savings.” viewing public, has provided companies such as W Another significant change is in the control systems used in a & H Marriage and Sons Ltd of Essex in the UK with modern mill. increasing demand for its artisan flours for bread making and “Today everything is controlled and recorded by computer. baking.

“For example, we are operating from a building built in 1899 Mr George Marriage, who is from the ‘William side’ of the and which started out producing just three-quarters of a tonne of family and therefore flour mill orientated, is responsible for the flour per hour. Today, we house much newer equipment, and our overall operation of the mill and says, “The quality drivers for colour sorter and computerised control systems combined with flour today come from the marketplace.” our laboratory mean we can control, trace and test quality at all Making a comparison, he says, “Nobody wants a cheap car these stages throughout the process using our own laboratory services.” days” and there is a universal awareness of quality throughout It was in 1997 when a seven tonne-per-hour roller flour mill was the flour and food industry that is being better understood by installed which took the factory from a line shaft driven mill over consumers through programmes such as the Great British Bake to direct drive for its roller mills.

Off.

The Great British Bake Off starts with quality flour and Marriage’s

T

26 | Milling and Grain

F

Still a fifth and sixth generation family run company, Marriage’s produce premium quality wheat flour for home bakers, as well as supplying traditional independent artisan high street bakeries and bulk contract customers.

Marriage’s mill a broad range of white, brown, wholemeal, rye, spelt and barley flours; stoneground wholemeal flour is a speciality, traditionally milled on horizontal French Burr stones

However, being unique in the marketplace is critical and Marriage’s are no different in defining what makes them special.

“It’s our customer services that are unique and provide us with our selling point.

“Comparing our industry to others, we know ours will always be there.”

A tour of the flour mill

Mr Andrew Thain, the Head Miller at Marriage’s, took us on a tour of the factory when we visited in February. He explained that his first visit to the company was as a schoolboy in college.

“That was 28 years ago. Something just clicked and I knew this would be the job for me.”

To this day he doesn’t know what it was about the flour mill ‘that clicked’, but he treats his job of head miller as a vocation and not simply a job. His dedication and attention to detail when Milling and Grain visited was obvious and reminded the writer of the principles of milling extolled in the past by our feature-writer Jonathan Bradshaw in these pages: that a miller must walk the floors of his mill every day looking over all the equipment and looking out for anything out of place. It was

Mr George Marriage stands alongside portraits of his ancestors

fascinating to see this discipline in action.

From the intake that can take in up to 60 tonnes of wheat per hour - or two (30 tonne) lorry deliveries an hour - to the reception control room where it takes just four hours to send and receive all the necessary test results from the company’s laboratory, to the roller mill floor itself, passing along all floors on the way while the writer was learning all the time about the uniqueness of this facility.

The mill has off-site storage but holds up to 700 tonnes on site with the new UK crops coming in between August and end of December.

Storage on site includes some 35 bins of varying capacities: 45 tonnes, 21 tonnes and a couple of 18-tonne bins.

“The range of storage helps us to handle the mill’s requirements,” says Andrew.

The mill’s emphasis is on producing strong, predominantly white flours; organic is an important consideration for some customers; flours made from high protein Canadian wheat can be selected by the customer; wholemeal flour traditionally milled on the French burr stones is also popular. Spelt, barley and rye are speciality flours that have been recently launched.

This company supplies a wide range of flours, including March 2015 | 27

F A Flour World Museum story No. 1

King-size king cake You can get it as a dry cake, with cream, truffle chocolate, or in worldrecord size – king cake, eaten in Mexico since the 16th century at Epiphany. To celebrate 200 years of Mexican independence, Mexico City bakers made a truly king-size "Rosca de Reyes" weighing ten tons and measuring 2360 feet long. The massive cake took 16,684 pounds of flour, 56,880 eggs and 8157 pounds of butter, and cut nicely into 254,000 pieces. But no one knows who found the porcelain figurine that is hidden in every Rosca de Reyes. This will no doubt remain a mystery, for whoever finds it must make tamales for all the guests, later at the "Fiesta de la Candelaria". With this gargantuan cake that would be an impossible task.

The Mühlenchemie FlourWorld Museum in Wittenburg is an expression of our company culture and the responsibility we feel towards the miller and his flour, as one of the most important staple foods. The museum is a journey through the millennia, illuminating the development and importance of flour. It is the only one of its kind in the world. www.flourworld.de

www.muehlenchemie.de 28 | Milling and Grain

Olivia Holden from the Milling and Grain team taking a tour of the Marriage’s flour mill

speciality and traditional stoneground varieties to high street and artisan bakeries, caterers and pizza manufacturers as well as an extensive range for home bakers.

And that was the surprise to the visitor – seeing a room housing a four-yearold Bühler colour sorter, going about its work in an orderly and accurate manner driven remotely by a computer housed in a cabinet on the wall and inspected occasionally, to the ‘stone room’ where four of the five large 100-year-old French Burr stones were in operation. The fifth was being dressed, resharpened by hand in the traditional manner that has been carried out down the centuries – what an impressive sight!

And what a juxtaposition these two images created - the very old competing in a modern marketplace with the very new! How can the two operate in the same mill just a flight of stairs and a room apart from each other?

Obviously, they are doing quite different jobs, but the irony of the traditional Burr stones – producing just half-a-tonne per hour of flour - and the modern Bühler colour sorter processing some 25 tonnes per hour, located almost side-by-side and intricately involved in producing a product that the UK’s leading bakeries and manufacturers are calling for, was hard to comprehend.

Quality control

Marriage’s undertake stringent quality assurance procedures throughout the milling process. They are Campden Research affiliates and are BRC Certificated.

“Our onsite technical laboratory tests the wheat from intake for factors such as protein quality, content and moisture levels and throughout the milling process,” says George.

Marriage’s end flour is baked into various products by their onsite master baker.

This is vital, as the most important thing for Marriage’s customers, be they a

F L O U R

professional artisan bread baker or someone baking at home for pleasure, is that they receive a consistent product every time.

Marriage’s have produced organic certified flour varieties since 1986, and Sampson David Marriage (fourth generation family member) was interested in organic production long before it became so high profile. George Marriage played a key role in the early development of the Organic Food Federation and served as Chairman for several years. Marriage’s have been active in organic industry research projects across the agricultural, milling and baking industries.

In the milling process, the best possible wheats are selected to ensure consistent flour quality. Marriage’s source English wheat from local Essex farmers where possible, including from the family’s own arable farms near the mill. This local commitment helps to keep food miles to a minimum. All of the farmers that Marriage’s source wheat from are members of the Assured Crops Scheme. Many of the farmers that supply Marriage’s have been farming families for generations – the same is true of many of the

“Marriage’s produce a range of organic flours; its registration body is the Organic Food Federation (OFF) and all its products display the OFF symbol as part of its organic status”

smaller independent family bakery firms that purchase Marriage’s flour.

In addition, Marriage’s source high protein Canadian Red Wheat; this is world renowned for quality in bread, pasta and pizza making.

Marriage’s have been members of the National Association of British and Irish Millers for many years. George Marriage is Chair of the Pre-Pack Flour Committee.

Marriage’s are also committed to supporting artisan bakery customers, many of which are small family run businesses.

Marriage’s have sponsored National Craft Bakers’ Weeks since 2009 and Hannah Marriage is the Chairman of the week in 2015.

Marriage’s ongoing professional development of staff includes milling staff going to Switzerland for milling training.

“The foundation of Marriage’s trusted reputation has been built on our focus upon customer satisfaction.

“Marriage’s dedicated sales and technical teams are available to support customers face to face – for example visiting bakeries and production sites to ensure customers are achieving consistent production results. As a company, Marriage’s retain core family values yet are always looking ahead - one of the reasons the business is still thriving after almost two centuries. In the UK there are now only about thirty full scale milling firms, and Marriage’s are in a minority of family run companies.

March 2015 | 29

F E E D

W & H MARRIAGE & SONS LTD

MILLING SINCE 1824

The Marriage family have been flour millers in Essex since 1824 and farmers in the local area since the seventeenth century

U

part 2:

The feed mill

with easy access to the markets of Norwich, Ipswich and

by Roger Gilbert and Olivia Holden, Milling and Grain magazine London, and eventually proved useful for raw materials coming in from overseas.

The mill remains in the same location today, K Essex farmers William and despite the conversion of other local factories into apartments, Henry Marriage diversified their most notably that of Marconi, the builder of the first radio.

17th Century farming operations in Future developments suggest that it will become ever more 1824 by installing a mill to process grain, with some branny co-product important to be close to the road network, as road haulage is now the only form of transport in and out. being used as fodder for the farm Most recently the company has bought a pet food production animals. That was the starting plant in Driby, Lincolnshire, to complement the output in Essex. point for one of today’s oldest UK “Our commercial poultry and livestock feed production is all milling operations. done here in Chelmsford,” says James.

Since then, William’s side of the family has been the flour “The Driby site specialises in coarse mixing of bird food and millers, while Henry’s descendants continued to farm the land. small animal feeds, amongst other light processing.”

In the 1970s, compound feed was added to the manufacturing “Chelmer Mills has a strong reputation for making starter diets facility by Peter Marriage and he continues to run this today with for poultry. We have a number of other niche areas, such as cousin James, a sixth generation descendant of Henry Marriage. medicated, organic and non-GM feeds.”

The board of directors has always contained between three and “Organic output has waned in the UK in recent years, despite six family members. There are currently three directors from the some support around Europe, particularly in Germany, where sixth generation and three from the fifth. the ‘BIO’ or non-GMO movement is strongly supported. South 115 years ago the mill moved from outside Chelmsford - where American countries now take some persuading to produce it had been located for wind power and access to water - into the organic or even non-GM soya.” town itself and started to use mechanical power. Distribution also “We are proud of the traceability and reliability of our became more of a factor when competing with other flour millers.

The railway running through Chelmsford provided the company products.”

32 | Milling and Grain

F E E D

UK Essex farmers William and Henry Marriage diversified their 17th Century farming operations in 1824 by installing a mill to process grain, with some branny co-product being used as fodder for the farm animals.

That was the starting point for one of today’s oldest UK milling operations.

Since then, William’s side of the family has been the flour millers, while Henry’s descendants continued to farm the land.

In the 1970s, compound feed was added to the manufacturing facility by Peter Marriage and he continues to run this today with cousin James, a sixth generation descendant of Henry Marriage.

“We also make absolutely sure that the service is there, which retains customers in a competitive marketplace.”

Having the flourmill on site provides essential high quality coproducts, such as the wheatfeed used in the feed mill. Retailers will also buy bran alongside compound feeds.

Wheatfeed produced during the roller milling of white flour is sold to pig farms where it is milled and mixed on-farm.

Local farms, including the family’s own 2000 acres to the west of Chelmsford, provide feed wheat, oats, barley, peas and beans direct to the mill.

“The cover we carry is about a month and a half, which may be extended if the futures markets are low.”

The mill imports fishmeal and soya, the former providing an exceptional and often essential form of protein.

Emphasis on poultry feed

“In recent years the feed mill has been producing up to 35,000 tonnes,” says James.

The emphasis is on poultry feeds, mainly layer hen, duck and turkey, which together make up almost 90 percent of production.

The are now ever fewer pig and dairy farms in the area and this has partly driven the change. The company does like to have a speciality like poultry but also wishes to retain an interest in all areas of agriculture. Being a relatively small feed mill and having its own transport has led to the company providing excellent service to the small farms in the area.

Compliance and accreditation

Accreditation and compliance become more important every year. The site has to accommodate up to 10 independent audits per year from various customer- and organisation-based services.

“These audits are taken very seriously and prepared for with a technical team, specific related procedures and processes and internal audits”.

In addition to this the company has a third-party pest controller who specialises in wheat mills and food stores.

Staff

Chelmer Mills has approximately 100 staff at any one time: 40 in the two mills, 20-30 in the transport department and 40 in the office, including sales teams.

March 2015 | 33

F

Colour at first sight

Cimbria SEA:

T

by David Thompson, Cimbria UK

he changing requirements of our modern world have encouraged advances in technology for the development of Optical Sorting equipment. Traditional colour sorters for separating impurities from grains and commodities using monochromatic cameras are still used today but due to the advances in Optical Sorting equipment they are not only able to operate successfully on Grains but also in the recycling industry and for use with finished food products. The needs of these industries and the ever tightening human food standards have driven the requirements for greater efficiencies in identifying impurities. With the use of camera and software capability able to work beyond the light spectrum of the human eye, we can now identify impurities with similar colours, textures and shapes.

This technology for which the highest sorting accuracy is required means that impurities in grain such as fusariums, elements containing gluten sorted from gluten-free cereals (maize, rice, buckwheat) and previously difficult separations like prime Wheat from Barley and vice versa are now possible. Non food products such as plastics, metals and glass can be purified sufficiently for use as the raw material once again to be re-used in manufacturing processes.

SEA have been at the forefront of this development in grain and recycling sectors for well over 40 years at their manufacturing base near Imola, Italy. Their colour sorters were first imported into the UK in the 1990’s initially into the waste and recycling industries and by 2004 the company, All Controls based near Cambridge, took on the UK business setting up a sales and

34 | Milling and Grain

support infrastructure for their customers. For some time Cimbria had been looking for a partner in the Colour Sorting world to compliment their considerable range of grain processing equipment and in 2011 they purchased SEA. The business has flourished in England with Cimbria UK’s knowledge of the grain and seed industry there are already several seed plants and commercial grain facilities using Cimbria SEA optical sorting equipment.

Demand for colour sorting equipment continues to rise as an ever increasing number of standards are tightened and customers respond by installing colour sorting equipment as a necessary part of seed and grain processing plants today. Cimbria UK has been working with these companies to satisfy their needs for higher standards.

The first Cimbria SEA colour sorter supplied into the UK agricultural/food sector was a Pixel Next 5 MR+MR complete with the InGaAs cameras with a 4+1 channel layout. The colour sorter was commissioned in August 2013 and has been used to remove ergot from cereals running in standard set up and when using the InGaAs cameras they have been able to separate wheat from barley and barley from wheat.

Cimbria SEA have recently launched the SEA Chrome optical sorter, available from 1 to 7 chutes, to satisfy

F

any production capacity, equipped with high resolution full color RGB trichromatic cameras which, combined with HIS software system, allow a near human eye vision color sorting technology.

The SEA Chrome can also be equipped with NIR and InGaAs cameras available for texture and shape sizing function integrated into the system, to sort impurities according to their geometric characteristics.

The hardware system is organised with easily replaceable electronic boards, using the ultimate SMD and FBGA technologies. Self control functions (auto diagnostics and auto calibration) ensure excellent operational stability. LED lighting and background systems, exclusively designed for Cimbria SEA sorting machines, allow the most precise focusing of the beam on the inspection line.

Program settings and adjustments are performed through user friendly software, which displays the real image picture directly on the sorter touch screen, to help identify the defective elements for

sorting out.

SEA Chrome represents the state of the art optical sorting technology, which is able to match the increasingly stringent requirements of the food commodities and seed industries, with the ability to detect and reject products having a similar color but with different shades ensuring that safety, and purity requirements are met.

Flour Milling Training Seven steps to success Safety, Health and Hygiene

● Internationally recognised distance learning programme ● Developed for millers by industry professionals ● Studied every year by hundreds of millers worldwide

Wheat and the Screenroom Mill Processes and Performance Product Handling, Storage and Distribution Flour Power and Automation Flour Milling Management

Enrol students and you will benefit from more knowledgeable and competent millers and colleagues, with consequent improvements in performance.

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 March 2015 | 35

F

Extrusion as an innovation driver

by Dieter Preim, Brabender®, Germany

E

xtruder products rank among the pioneering opportunities for product innovation in the food sector with promising opportunities on the market.

This is why practically relevant equipping with extrusion equipment is a fixed constituent of the “toolbox” that is required for product developers in the food industry. New developments in snack products, breakfast cereals, flat breads, sweets, pet food and other special products can be prepared on a laboratory scale using this modern key technology.

Brabender® provides suitable instruments for experimental trials of potential product lines with extrudates in a wide range of shapes, colours and flavours. They are compact and can be put to versatile use in innovative food laboratories. They make it possible for modern foods to be developed under realistic process conditions. This means that ongoing production is not impacted, which saves money but is still consistently quality oriented.

Laboratory extruder as sensible alternative for practical applications

There are few procedures with as much potential for completely redesigning a product matrix. In order to develop innovative food textures and structures, the parameters of pressure, temperature, and shear can be varied during extrusion without changing the final product. Continuous operation in a closed system combines complex production steps into a constant, continuous production process. If product developers have to experiment on extruders during live operations in order to do this, this can lead easily to operational disruptions. This is why laboratory extruders are a sensible alternative for everyone involved in the development and testing of new processes and products – regardless of existing traditional processes, and with potential prospects for creating something completely new.

Six arguments speak in favour of practical product development with laboratory extruders rather than experimental interventions in the production process: • You get to know new processes, and are able to test textures and sensory characteristics before trials have to be conducted on a production scale.

36 | Milling and Grain

• You can vary your application ideas in a wide variety of ways: in terms of raw materials, composition, machine or product.

• You require significantly less material to carry out your trials, and hardly any product waste occurs.

• You don’t have to worry about impacting your current quality management system.

• You can establish methods for measuring your quality from raw material to end product in advance, in order to be in a position to react to quality variations in a better way at a later date.

• You can easily achieve a return on investment with an appropriate philosophy of innovation within your company.

Triple extrusion expertise from Brabender®

The corporate group has many years of global experience with extruders and the practical deployment thereof: Thanks to the transfer of technology between plastics processing, With the LabCompounder KETSE 20 / 40 D, Brabender® offers a twin screw extruder as miniature scale with application to the food and animal feed industry for material research and process simulation

the pharmaceutical industry and the food sector, Brabender can provide extrusion expertise in three essential fields of application.

The use of measuring extruder systems in food laboratories provides reliable results for the fine tuning of optimal production conditions and to providing constantly high product quality.

As is to be expected from Brabender®, the extruder technology that is provided is suitable for a wide variety of uses, especially in the field of grain products, and can be networked with other ‘classical’ quality measuring processes.

Single-screw and twin-screw extruders or the modular expansion make it possible to adapt the processing conditions to the many different of products and tasks in the best possible way, customised to suit your operations: • Quality control and analysis of raw materials • Product development and recipe optimisation • Testing of the extrusion properties of different materials • Research and optimisation of processing characteristics • Binding of active ingredients and aromatic substances to a carrier material, such as in snacks • Measurement of rheological properties of material combinations • Extrusion of degradable products • Product manufacturing on a laboratory scale At the same time, studies with laboratory extruders have a range of technical process advantages over other procedures such as the practicallyoriented measurement of extrusion conditions with small sample volumes, rapid changes in trial conditions, and simple operation and cleaning.

Three equipment lines that are specially oriented to food laboratory requirements are introduced here as examples of our extensive product range: ®

F

Entry-level single-screw extruders

The Brabender® KE 19 is an “entry level” model for measurement extrusion: a robust, autonomously operating singlescrew extruder, also known as a single-shaft extruder, that is ideal for laboratories and technical institutions. Based on a broad selection of screws and tools, this machine is the ideal solution for • Developing new materials and products, including viscosity measurement • Testing processing behaviour during recipe development and product monitoring in the incoming and outgoing goods areas • Quality control during production and throughout processes, with production of a company specific quality profile for the consistent manufacture of products that comply with specifications • Optimisation of production conditions, full machine capacity utilisation, and minimisation of waste A comprehensive range of die heads is also available that makes it possible for a wide range of product ideas to be developed and tested.

The performance features of this compact device are rounded off by powerful and user-friendly software packages that work on any version of Windows, the storage of operating and evaluation parameters in a database, and the capability of exporting the data into the usual Office programs. As well as operating standalone, this machine can also be optionally integrated into local data networks in PC-controlled mode.

Twin-screw extruders for sophisticated applications

Twin-screw extruders are the number one choice for sophisticated, complex applications. The Brabender® TSE product range is particularly attractive because of its wide

Your global technology process supplier for the animal feed industry ANDRITZ is one of the world’s leading suppliers of techno­ logies, systems, and services relating to advanced industri­ al equipment for the animal feed industry. With an in-depth knowledge of each key process, we can supply a compatible and homogeneous solution from raw material intake to finished feed bagging.

ANDRITZ Feed & Biofuel A/S Europe, Asia, and South America: andritz-fb@andritz.com USA and Canada: andritz-fb.us@andritz.com

www.andritz.com

March 2015 | 37

F The BrabenderÂŽ KE 19 is a sturdy, directly driven stand-alone extruder for laboratory and pilot plant stations.

range of applications and maximum flexibility. The screw and cylinder construction kits that are available in different sizes are designed in such a way that all process stages (feeding, conveying, plasticising, dispersing, reacting, degassing) can be carried out in the best possible way. The combination of several work steps into one continuously operating extruder turns these twin-screw extruders into modern inline compounders. The

38 | Milling and Grain

additional equipment that is required such as measurement and control systems, dosing systems and downstream facilities are also available, making it possible to build up entire modular extrusion systems that are tailored exactly to individual user requirements.

As well as the TSE 20/40 D and the co-rotating TSE 25/16 48 D twin-screw extruders that have proven themselves time and time again in practice, the new Lab-Compounder KETSE 12/36 D is now available, a miniature-scale twin-screw extruder with engineering that originates from material development and process simulations in the plastics industry. The combination of the scale down of the production machine, the comprehensive adaptation capability to any processing task and the ease of operation of the system are the reason for its distinction as an outstanding laboratory measuring device.

The processing unit in the TSE 20/40 D and the TSE 12/36 D consists of a hinged horizontal cylinder. This allows individual preparation steps to be visually assessed, and easy screw removal and quick cylinder cleaning are also possible.

Furthermore, various mechanical material tests can subsequently be conducted on the extrudate. In this respect, online diagrams provide a quick overview of measurement data and evaluation results, even while measurement is in progress.

The test data is stored in a database and can be processed using the usual Office programs, and can then be integrated into your own reports.

BrabenderŽ and its modular device designs show a practicable way toward practical implementation of extrusion technology in the food industry – one step at a time: The laboratory professionals develop creative innovation expertise, and companies safeguard their future with affordable investments.

F

Making food go further

W

- where saving cracked rice could help

by Dr Ye Aung, rice technician and consultant

e face urgent challenges as we move ever closer to 2050, when it is predicted that the world’s population will reach more than 9 billion and our growing global population will face food shortages if we cannot double food production. An important contribution to this effort can come from reducing food waste. Improved food production processes and innovations in technology must play a part in ensuring that from field to fork, food wastage is significantly reduced.

In terms of meeting this growing demand, the outlook does not look promising in light of prevailing circumstances around the world. Drought areas are expanding rapidly, while natural resources are drying up faster than expected. Further still, the denial of global warming by some means that we do not have a clear picture as to how urgently we need to act. However, organisations such as the International Rice Research Institute are playing a pivotal part in the development of high yielding, drought resistant rice varieties.

Under these circumstances the only sensible response is to work to save food throughout the production process. Food saving is not only a matter for the future, but a thing we must turn our attention to now.

If we consider today’s post-harvest handling, at every step there are tremendous losses involved in turning crops into food.

In the rice milling industry alone, the yield of finished rice can be as low as 40 percent, with 30 percent broken rice resulting as a by-product. However, broken rice can still be processed into usable rice, with specific characteristics, with the help of state of the art technology. Bühler is just one company at the forefront of producing top quality reconstituted rice that is indistinguishable from the natural product.

In terms of the overall process about 15 percent of rice is lost, as a raw material, when it makes its way to the milling facility.

A further 20 percent is lost due to moisture problems giving a

40 | Milling and Grain

total loss amounting to about 35 percent just in raw material form. Therefore broken rice production in the milling process should be regarded as a serious issue. Milling machines are generally blamed for breaking rice but, with the right technology, the cracking of rice can be minimised. Rice is a delicate natural material and should be treated as such.

Cracked grains are the product of excessive breaks, which are formed in the grains by the drying operation and during storage.

Grain is often cracked under the influence of stresses, namely 1) moisture stress, 2) thermal stress, and 3) mechanical stress.

Mechanical stress is easily understandable and happens during milling. Moisture stress is created by the accumulation of moisture on the grain surface or retained within the grain itself.

Thermal stress is generated by heat - either by internal heating (the respiration process) or by external heat (during drying).

Grains are still alive even after they have been cut from the plant and they will continue to breathe. Like other living things they produce heat, carbon dioxide and moisture. If this heat and water are not taken away immediately they create stresses in the grains, which lead to cracking.

Freshly harvested paddies contain a lot of external moisture that must be removed immediately. In storage paddy rice can accumulate heat by the respiration of grains. This is harmful - not only in terms of the grain cracking but for other qualities too.

Thus effective removal of heat during storage is essential.

If the cracking of rice cannot be avoided, cracks that form during the drying process should be minimised at the very least.

There is a balance between the damage that might be done by the heating involved in drying the grain and the damage done by too much moisture. The two extremes are demanding and the drying work should be carried out with extra care, particularly when drying the grain’s interior. Removing moisture from the peripheral parts of the grain is relatively quick and carried out using a higher temperature.

However, heating the inner parts of the grain requires more heat, which risks burning the surface and therefore the temperature should not be too high. This temperature control will mean that the rice is exposed to heat for longer, during which time the moisture is able to expand within the rice grain.

F Having energy, warm moisture moves along the passages exerting pressure against the cohesion of the rice cells. Therefore the heat should not be too great lest the movement of moisture be too fast, which could immediately turn the grain’s internal passages into cracks. In this scenario heating should be halted to slow the moisture-flow. If heating continues it could create turbulence since moisture moves from inner to outer where heat comes from outer to inner.

Turbulence in the passages could weaken the rice cells’ integrity and can quickly split them. Therefore, heating should stop at the correct time – when the heat reaches the internal moisture. Then the stoppage time should be long enough to stop the flow of moisture completely. This kind of interval is usually called ‘tempering’.

Therefore, the drying process is carried out in two stages with different settings for external and internal moisture removal.

In an experiment, just putting tempering bins into the drying sequence slashed daily broken turnover significantly. Air

“As we move ever closer to 2050 when it is predicted that the world’s population will reach over 9 billion. Our growing global population will face food shortages if we cannot increase food production twofold” temperatures were also reduced in the later phases of drying.

Apart from stress cracks, grain suffers from another kind of crack - ignition. This is activated by humidity pressures inside the grain and is prevalent when the internal humidity pressure is not equal to the ambient humidity pressure.

Grains release moisture into the atmosphere when the latter has lower humidity. A reversed scenario takes place when grain has lower humidity than the ambient atmosphere. If this action repeats frequently, cracks appear in the grains. This often happens during storage when the stock is affected by respiration heat and released moisture. This activity will stop when the level of humidity on both sides is the same. The moisture content of the grain at that time is called ‘equilibrium moisture content’ (EMC) and this condition can be created by ventilation at correct times and with correct settings. Cracked grains are easily broken, even by the slightest impact of milling machines. Therefore it is crucial that when designing a plant the right equipment is carefully selected and specified by expert consultants.

If we are able to minimise (if not prevent completely) the cracking of grains, our world will benefit greatly. If we can save a further one percent of the total grains harvested annually from cracking, we will gain an extra 6 million tonnes of milled rice out of the 600 million tons of paddy presently produced every year.

Fortunately, innovative technology is playing an important role in minimising breakages during processing. It is also playing an integral role in converting any broken or cracked grains into other useable forms: ground rice, used as an ingredient in other products, and extruded fortified rice grains with an appearance like that of natural rice. Saving cracked rice saves food.

A u s SO cn lai nne

Introducing NIR calibrations on demand.

Analyse your proteins and cereals using the new online service - AusScan Online.

For more information visit

www.aunir.co.uk

Die and roll re-working machines

www.oj-hojtryk.dk Phone: +45 75 14 22 55 Fax: +45 82 28 91 41 mail: info@oj-hojtryk.dk

O&J Højtryk A/S Ørnevej 1, DK-6705 Esbjerg Ø CVR.: 73 66 86 11

March 2015 | 41

F

Taking

NIR beyond feedstuffs

- analysis to enhance pork production profitability

S

by Hadden Graham, AB Vista Feed Ingredients and Chris Piotrowski, AB Vista Feed Ingredients and Ming Yang Tan, Aunir Singapore

wine production has been facing substantial economic challenges in recent years, due to poor crop yields and increased competition for raw materials from the biofuel industry.

As a consequence, feed prices have been variable and more industrial by-products have become available. At the same time, we have experienced increasing sustainability demands on animal production, for example to reduce nutrient release in effluent, while producing more and cheaper food for an increasing world population. All this has driven the swine industry to implement more professional, accurate and precise practises.

With feed costs accounting for 50 to 80 percent of total variable production costs, nutrition continues to be an area of major focus.

The key target for nutritionists is to provide the animal with the correct amount of nutrients to support optimal performance. Both excess and a lack of nutrients are likely to result in economic

Unfortunately, the majority of these analyses are time-consuming and expensive which restricts the number of samples that can be analysed and creates a delay between sampling and receiving results of the analyses. Alternatively, a Near Infra-red (1100-2500 nm wavelength) Reflectance spectrometer (NIR) can be used to predict composition, as this technology is cost effective and fast.

This allows nutritionists to get almost immediate feedback on in-coming ingredients and out-going feeds, and to analyse many more samples at a much-reduced cost. However, NIR has much greater potential uses in animal production. This article will discuss the use of NIR in feedstuff analysis and diet formulation, and opportunities to extend this technology beyond standard analysis to support greater efficiencies in swine production.

Predicting feed composition

NIR can predict chemical and physical properties by relating vibrational spectra obtained on a set of known samples to reference analytical methods performed on the same sample set.

The resulting calibration can be used to predict Table 1. Range in DE (MJ/kg as fed) and intake index (0-100) of cereal grains in pigs (from Black and Spragg, 2010) the composition of As-fed basis Wheat Triticale Barley Sorghum Pearl millet1 Rice1 unknown samples of the Faecal DE (kcal/kg) 12.8 - 15.1 11.3 - 14.6 10.8 - 14.7 14.1 - 15.2 13.9 - 14.4 14.5 - 14.6 same type of materials.

Ileal DE (MJ/kg) 9.34 - 13.40 7.99 - 12.90 6.08 - 12.9 11.5 - 13.7 12.6 - 13.3 13.7 - 14.0 NIR offers important Faecal DE intake index 40.0 - 85.0 42.0 – 100.0 34.0 - 90.0 37.0 - 96.0 advantages over traditional methods, in that it is rapid, nonlosses, through higher costs and/or lower animal performance. destructive, requires no chemicals and hence produces no waste.

Thus, it is important for the nutritionist and raw material It is easy to operate, once calibrated, and requires minimal sample purchaser to have correct information on the composition and preparation. nutritional value of available ingredients. Accurate and regular It is common practice for nutritionists to formulate diets with analysis of feedstuffs and complete feed, to confirm diets are average compositional data for ingredients, taking either a correctly formulated, is a key quality control measure. book value or actual analytical data, and often a safety margin To ensure consistency in diets, nutritionists traditionally based on the expected variability in the data. Safety margins used proximate analysis from approved laboratories where can vary, depending on the formulator and the feedstuff, usually ingredients and feeds are analysed for their nutritional contents. varying between zero (average data used) and one standard 42 | Milling and Grain

F

e ad

any • Made in

erm

G in

•M

REAL BREWERS‘ YEAST

de in Germany

in G

ermany • M a

de

Feedstuffs are usually purchased on the basis of parameters such as test weight and crude protein content, both unrelated to a greater or lesser degree to their value in feed. Consequently, Rao (2012) indicated that approximately half of incidences of poor performance in a US commercial broiler company were related to the use of incorrect feedstuff nutritive values. The traditional method of predicting the energy value of feedstuffs

M ade i n G e rm y • an an

a •M

Predicting nutritive value

rm

y

deviation from the average. Adjusting the nutritional value of the ingredient based on the standard deviation ensures that the majority of feeds produced will provide the expected level or higher of any nutrient.

NIR has been used in the feed industry for over 30 years, and is now approved by the AOAC to determine moisture, nitrogen (crude protein) and acid detergent fibre (ADF) in feed and forages. However, there is some scepticism across the industry regarding the accuracy of NIR to predict feed composition relative to wet chemistry. Some of this is due to the use of poor or inappropriate NIR calibrations, and some to poor sampling techniques; NIR can only predict the composition of samples similar to those used to develop the calibration, and the variation can never be less than that of the methods used to provide the data build the calibration.

It is common to assume that a wet chemistry result is always better than a NIR result; however, Undersander (2006) reported that when crude protein results differ, a re-run of the wet chemistry agreed with the NIR 80 percent of the time. This demonstrates that, as might be expected, there is less risk of making a mistake when taking a NIR spectrum than when running a laboratory analysis. However, the real advantage of NIR is that it is cheaper and quicker to analyse a number of samples for a range of analyses than to run one wet chemistry analysis, giving the formulator a much more complete real-time picture of the overall composition as well as variation within feed ingredients.

Ge

EXCELLENCE IN YEAST – EXCELLENT FOR PIGS

Leiber brewers’ yeast products Excellent for: Cell regeneration Immune system Fertility/Performance Digestion Prebiotic effect Coat/hooves/claws

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

March 2015 | 43

F or feeds is to use any of a number of published equations to calculate the productive energy from the analysed nutrient content. These equations are usually developed from trials where a diet of known composition was fed to the target animals and the productive value, such as net or digestible energy, determined.

The weaknesses of this approach are well known; for example, the assay methods used to develop the prediction equations may be different from those used to analyse the feedstuffs in question, and the feedstuffs or diets used in the animal trials may not represent those used commercially. Further, animal trials are prohibitively expensive and time-consuming. The production advantages of accurate feed formulations, based on NIR analyses rather than book values, in promoting extra broiler performance was recently demonstrated by Soto et al. (2013).

Starting in 1996, a major research program has been undertaken in Australia to develop NIR calibrations to predict the nutritive value of commonly used feedstuffs across several animal species, including ruminants, pigs and poultry. Close to 4000 cereal grain and protein feedstuffs were surveyed, and over 350 of these were fed to animals (>100 for swine) to determine available energy and intake index as well as composition, reactive lysine and standardised ileal amino acid digestibility (Black and Spragg, 2010, Black et al., 2014). The energy value (faecal DE) of cereals for pigs varied within and between cereal types (Table 1), ranging to as high as 4 MJ/kg for barley. It was estimated that, taking cereals at US$250/t as an example, a 1 MJ/kg difference would be worth between US$15-20/t in swine feed. With well over 100 million tons of cereals used in swine feeds per annum, this equates to potential savings of several billion dollars to the swine feed sector worldwide for energy alone!

Analysing all incoming feed raw materials, even by wet chemistry, would be both time consuming and expensive and the delay in receiving results would make this practically ineffective.

However, this Australian project has used animal data to develop NIR calibrations to predict energy content and intake index (from 0 - 100) as well as composition, allowing incoming raw materials to be quickly analysed and segregated on arrival at the mill. The value of using NIR to determine the composition of in-coming feedstuffs has recently been demonstrated by an integrated UK company. By simply segregating in-coming wheat and soybean meal into either high- and low-protein bins for each, this company was able to save over US$3 per ton in feed formulations as well as close to US$20000 per annum on wet chemistry costs.

As indicated above, extending this to the more variable energy value would save much greater sums.

High phosphate prices, increasing environmental pressures and more effective enzyme products have encouraged feed manufacturers to increasingly replace inorganic phosphates with phytases. However, the extent of phosphorus release by phytases depends to a large extent on the phytate content of the diet. As phytate levels can vary between and within feedstuffs, it is difficult to accurately predict the phytate content of a final feed. While several laboratory methods are available to determine phytate levels in feeds, these are all relatively expensive and time consuming. Recently, NIR calibrations based on an enzymatic laboratory method were developed to give the real-time prediction of the phytate content of feedstuffs and diets, allowing feed manufacturers to maximise phytase inclusion and thus feed cost savings (Santos and Bedford, 2012).

Delivering NIR services

Today NIR equipment is usually laboratory based and loaded with appropriate calibrations. This presents some challenges; for example, sample delivery to the laboratory can result in delays 44 | Milling and Grain

Table 2. Influence of mixing time on mixer profile (percent CV) as determined by NIR or the chemical analysis of several feed constituents Mixing time (min)

NIR

Sodium

Crude Protein

Crude fat

1.0

19.2

81.4

40.3

49.5

2.0

4.4

55.5

8.5

9.3

3.0

2.9

8.1

4.0

6.3

4.0

1.0

11.1

3.2

3.8

5.0

3.4

5.9

4.0

5.5

that eradicate the advantages of speed of analysis. Further, calibrations quickly become outdated; this requires updated calibrations to be updated on a frequent and on-going basis.

Recent developments in NIR hardware have allowed the production of robust, portable, battery-operated units. This allows the analysis to be carried out at the point of interest, for example at the grain silo or feed mill intake. Further, in-line NIR equipment is currently available that allows feedstuffs to be monitored during harvesting or feeds to be continually analysed during production in the feed mill. Software and communications developments have allowed web-enabled NIR services, where spectra are downloaded to a master machine containing all appropriate calibrations, with instantaneous feedback. This has several advantages; for example the analyst can pay on an “as-used� basis rather than paying a fixed up-front fee for a calibration, independent of sample numbers. This can also give the analyst access to a wide range of calibrations, and the calibrations can be updated regularly as they essentially sit on one computer.

Novel uses of NIR

Beyond the standard prediction of dietary composition, NIR use has recently been extended into, for example, sample identification. Work in other areas suggests that, providing suitable standards are available, NIR can be used to confirm the growing condition of feedstuffs. Another example of an extension of NIR technology is the determination of mixer profiles in feed manufacture. Mixer profiles are usually determined by analysing the variation (percent CV) in components such as salt/sodium or protein/nitrogen in 5-10 feed samples. However, this approach will include the variation in the assay procedure used to analyse the component chosen, and the result could thus be considered to only apply to the specific component analysed. Thus, if sodium is chosen, the mixer profile will reflect primarily the variability in the dispersion of added salt. This can be overcome by looking at the CV across the NIR spectra of a series of samples. The CV as estimated from ten samples of feed taken from a mixer run for 1-5 minutes clearly shows an optimal mixing time of 3-4 minutes, and that the NIR gives the same result as the analysis of specific feed components, but with lower variability (Table 2).

NIR is currently used to analyse feedstuff and feed compositions for quality control within the swine feed industry.

However, developments in hardware and software present the possibility of using this technology to determine the value of incoming raw materials as well as to control in-line and in realtime the accuracy of feed formulations. This is potentially worth several billion dollars in terms of feed cost savings and more predictable animal performance for the worldwide swine industry.

In the future we can expect to see laboratory, hand-held and inline NIR equipment used widely in the purchase feedstuffs and in feed manufacture.

References available on request.

FEATU

RE FRO

F

M

Waking up to the fundamentals of pellet quality -

Dr Keith Benke gives the Anitox Breakfast Lecture at the IPPE in Atlanta “Mixing and pelleting are the most expensive operations you’ll find in a feedmill” says Dr Keith Benke (consultant, formerly of Kansas State University’ Grain Science and Industry Department in the US) to delegates invited to the Anitox Breakfast Lectures on the opening morning of the 2015 IPPE Exhibition in Atlanta, Georgia in January.

D

r Benke was one of two specialist invited to address nutrition and health issues in poultry and pigs.

Mixing is not expensive but if not done right it will have an adverse impact on chickens and pig production, he says.

“The objective of mixing is to achieve a uniform mixture of both solid and liquid ingredients in a formula, without nutrient destruction and in the minimum amount of time.”

Most feed manufacturers will be following the recommendation of the mixer manufacturer as to total time from last ingredient added to the drop of the mixed batch.

“How do you know what is long enough?” he says he has frequently asked feed manufacturers.

“Many says they ask the mixer manufacturer who will say just mix for two minutes!”

However, mixing dry ingredinets first and then adding wet ones is the correct approach. Don’t add wet ingredients too early, he advises.

“If we don’t mix the dry ingredients well before adding liquids you take the risk of slowing the mixing action – let’s use at least a 20-30 second period before wet additives are added.”

The importance of mixing can’t be overstated

Using tracers such as synthetic methionine and Lysine is often a good choice when checking the mixing accuracy.

Co-efficient variation should be less than 10 percent on whatever you’re looking at, he explains when reviewing past results of trial work undertaken by Kansas State University for industry.

“How well does the broiler industry do? Looking at methionine and Lysine as tracers, about 50 percent of industry within the 10 percent CV threshold while 30 percent was between 10-20 percent CV. The balance – about 25 percent were over the 20 percent CV mark.

That means that half the mixers profiled were in the right region, under the defacto threshold. The 25 percent that were over the 20 percent threshold represents a lot of tonnage and in turn 46 | Milling and Grain

means that farmers have a problem.

“There are mixers out there that are not doing a good job.”

“I can guarantee that if your mixing is greater than 20 percent coefficient variation, your effecting animal performance. There are animal out there not getting the nutrient mix they need because the right job has not been achieved in the feedmill.”

Concluding the section of his presentation on mixing he added ‘salt’ to the list of useful tracers.

The impact of poor mixing

Dr Benke explained that while a 180lb (80kg) pig may not exhibit the impact of nutrient shortfall in in one day - provided the pig gets a balance of nutrients over a period – the same cannot be said of poultry. They exhibit no differences that can be traced back to poor mixing in the mill.

However, the same cannot be said of poultry.

“The pig ate three to four pounds (1.5-2kg) of feed per day while the chiken on a starter diet eats only 100 grams.”

Meal size is very important when reviewing the need accuracy at the mixer, he says. His comments are based on work done where mixing times and CVs were compared.

“What does this mean in an actual mill that has, for example, a four tonne mixer?

“The 4000kg of mixed feed, contains four million grams in each batch. For a starter diet for a day old chick the ration is just 10g.

That means there are 400,000 one-day rations in one batch for one day rations for a starter feed for chickens?

“What is the chances of those one-day 10 gram rations being exactly right as the nutritionist predicted them to be? Probably not too much.

As you go through starter, grower to finisher and withdrawal feeds, the meal size gets bigger and the pressure on the mixer uniformity probably is a little less as the meal sizer become larger, he says.

“But you can’t cut the mixing time down! That uniform random mixer is very important even at these latter stages.”

The mixer needs to be clean – and cleaned safely – otherwise they build up layers of materials that will ultimately alter the mixing profile.

Dr Benke warned that cleaning mixers is a dangerous task.

“While an operator may have ‘locked out’ the mixer, but has he not overlooked the fact that the discharge doors are controlled by air cylinders and are on another circuit?”

By entering from below he is at risk of injury or worse if he has not done both, he adds..

F “There are lots of mixers in the pig and poultry industries that are clogged with fat on their mixer spokes.

“Mixing for five minutes in an un-cleaned mixer will still leave the mixed feed in the higher CV range. Whereas, with a clean mixer its almost down to the 10 percent CV threshold after five minutes and within the range at six minutes,” he says.

He concluded this section of his presentation saying uniformity can be measured using chloride ion, sodium ion, dyed iron particles, elemental ayalysis, antibiotics/drugs and crystalline amino acids.

“All of these are useful methods,” he added.

The impact of fines

There are food safety issues involved with too many fines in pelleted feeds, Dr Benke went on to say.

“And if we can’t do better than 30-40 percent pellets in the feed at the farm, we might as well turn the pellet mill off,” he adds.

With 25 percent pellets and 75 percent fines in a finished feed at the farm is a problem when 60 percent of what chickens consume is pellets. Almost all the chickens ignored the fines completely.

“Broilers are very selective eaters and will select pellets over fines. We all know this,” he says.

The ratio of pellets to fines impacts performance. Eating pellets

Hydronix Moisture Sensors Accurate and Reliable Hydronix digital, microwave moisture sensors provide accurate and cost effective moisture measurement and control in feed meals and pellets, grain, cereal and pulses.

• •

Control moisture in the grain drying process to save energy and ensure quality Control moisture content during the pelletising process

Hydro-Probe XT

The Hydro-Probe XT measures moisture as the material flows over the sensor head. Install in or under a hopper / silo or in the material on a conveyor

“The industry over many years has gone too far in the direction of saving money, trying to limit costs, instead of spending money wisely and particularly on good feed manufacturing technology”

Hydro-Mix

means birds will eat and then sit, not burning energy. Chickens forced to eat fines utilize more energy doing so and partition their energy differently.

Dr Benke says the causes of fines occurring in feed pellets is 40 percent due to the formulation and just 20 percent due to pelleting “We can’t formulate for pellet quality successfully. The ingredients that go into a feed have a major impact on pellet quality.”

The Hydro-Mix measures moisture in a mixer or an auger or before / after grain dryers.

Hydro-View

The Hydro-View displays a simple way to calibrate, configure and display readings from up to 16 Hydronix moisture sensors

enquiries@hydronix.com

www.hydronix.com March 2015 | 47 GFMT half page vertical 90 x 270 plus 3mm bleed not left.indd 1

20/01/2015 13:03:17

F

Fineness of grind – generally speaking the finer the better the quality – the better the pellet as finer particles have more surface area to absorb steam dueing the conditioning process.

“We can’t solve a pellet -uality issue by just looking at the pellet mill. Conditioning is much more important than the die.

And conditioning is anything we do to the feed after it leaves the mixer and before it gets to the pellet mill. Usually that includes just steam conditioning,” he says.

Conditioning

Long-term, or two-pass conditioners with some having up to four-pass conditioners, creates longer conditioning times.

“Thirty to thirty-five seconds is probably enough if we get enough steam and moisture in. In my opinion pellet quality is establish in the conditioner and not in the pellet die.

“Therefore we want to use the thinnest die we can get away with as it will impact throughput. We need to maximise conditioning.

“By conditioning we are activating the starch on the surface of particles. We are cooking, gelatinising the starch, on the surface of the particle. That doesn't affect the animal at all. We rely on cooked starch to hold the particles together. If we don’t, we get weak bonds and pellets will break apart and that’s how we end up with only 30-40 percent pellets in the feed out in the field.”

In-line moisture control

What happens to pellet quality if we precisely control moisture?

He asks.

A trail with a moisture meter in the mixer allowed the operator to calculate how much moisture was needed to bring the feed up to what was required.

The device was extremely accurate, says Dr Benke, and worked very nicely with no recording our by more than 0.2 percent.

“If a pellet mills sees the same moisture in the feed coming through hour-after-hour, then a lot of the variability in pellet quality simply goes away,” he says.

48 | Milling and Grain

Energy at the die

The only source of heat at the die is friction. Moisture is acting as a lubricant with the load on the motor going down.

“There’s still a huge amount of pressure in there – up to 20,000lb/square inch - forming the pellets. If we can cut down on that frictional heat, which is electrical energy being converted into heat, will not mean the pellet quality is going down. If we can cut down on energy we can save rather than just paying to convert electrical energy to friction at our expense.”

He says there is still controversy over adding addition water at the feedmill that millers see as simply hauling water from the mill to the farm with its implications for additional costs.

Dr Benke says there is still a huge amount of resistance to adding water at the feedmill as its claimed that for every percentage of water added there is a reduction in animal performance, or feed conversion, of two points.

“However, if I can improve pellet quality and keep the pellets between 70-80 percent of the feed and keep it there all the way to the bird in the end of the shed, I can match that with a five percent improvement in feed conversion – just through pellet quality.

“Besides we can get most of that moisture out through the cooling process these days. But we need to understand cooling much better than we do and the impact it has on pellet quality.

Coolers need to be run much better.”

In conclusion, Dr Benke summarised several key points he had highlighted during the breakfast meeting: • Pellet quality is critical to animal performance • If millers do a good job they can improve animal performance • Nutrient uniformity is critical especial in the starter diets • Meal size is important • Use water intelligently. Water is critical to pellet quality and should be managed as an ingredient • Is it necessary to spend money to make money? Yes it is “The industry over many years has gone too far in the direction of saving money, trying to limit costs, instead of spending money wisely and particularly on good feed manufacturing technology.”

F

A call to action - The cereal foods supply

chain must share responsibility for public health

by Fred Brouns - Health Food Innovation, Human Biology, Maastricht University, The Netherlands; Luud Gilissen - Plant Research International, Wageningen University & Research Centre, The Netherlands and Department of Plant Biology and Crop Science; Peter Shewry - Rothamsted Research Centre, United Kingdom; Flip van Straaten - Dutch Bakery Center, Wageningen, The Netherlands

In November 2014 a proposal to initiate an evidence-based evaluation of the effects of wheat types and food processing in the context of wheat and gluten avoidance was presented to the European Health Grain Forum. This proposal addresses a global issue and has significant precompetitive importance for all grain/cereal food chains.

W

orldwide an anti-gluten and anti-wheat hype has developed over the past four years, with significant impact on all parts of cereal supply chains. This has resulted in significantly reduced sales of bread, breakfast cereals and pasta products in various markets impacting also on the supply chain (see Figure 1).

Of all grains, wheat is most widely cultivated worldwide.

Wheat is third among all cereals, behind maize and rice, in total global production, which is over 700 million tonnes annually. The demand for wheat for human consumption is also increasing globally, including in countries, which are climatically unsuited for wheat production, due to the adoption of western-style diets.

Wheat is relatively rich in micronutrients, including minerals

50 | Milling and Grain

and B vitamins, and supplies up to 20 percent of the energy intake of the global population (1).

Nevertheless, an ever-increasing demand for gluten-free and wheat-free products has developed in recent years.

Apparently, social media statements that gluten and wheat cause overweight and health problems, as well the new consumer ‘free from’ trend play a major role in this development.

About 95 percent of the wheat that is grown and consumed globally is modern bread wheat (Triticum aestivum), a relatively new species, having arisen in southeast Turkey about 10,000 years ago (2).

Cereal (including wheat) proteins that may cause allergies and intolerances (including coeliac disease) have been reviewed in the context of reducing the incidence of such diseases (22).

Allergens in cereals

Recently it has been suggested, based on the analysis of alpha amylase trypsin inhibitors (ATIs) genes, that ATIs (which are known as allergens in cereals) are low or even absent in ancient wheat (Einkorn) (19, 20) compared with modern bread wheats.

However, coeliac disease affects 1-3 percent of the population, whereas true wheat allergy is very rare, affecting only <0.2 percent of the population.

Accordingly, the question arises why so many individuals (>40 percent in the USA, >15 percent in Australia, increasing numbers in other regions) feel more comfortable on a gluten-free or wheat free diet?

Several popular nutritional plans, such as the Paleolithic diet (6-9) and diets more recently proposed by Davis, in “Wheat Belly” (10) and Perlmutter in “Grain Brain” (21), have suggested that wheat consumption has adverse health effects leading to

F

Fig 1: The wholecereal supply chain carries responsibility in terms of feeding

Fig 2. Experimental red line

numerous chronic diseases. Such suggestions are based on different hypotheses relating adverse health effects to wheat gluten, wheat lectins and wheat protein digestion-derived opioid like peptides, including impacts on eating behavior.

With this, the authors of these books follow a recent trend to relate the cause of obesity to one specific type of food or food component, rather than to multi-factorial causes including food over-consumption and inactive lifestyle in general (11, 12).

Hundred of proteins

The wheat grain contains many hundreds of individual proteins, which may have structural, metabolic, protective or storage functions (as reviewed by Shewry et al., (3)).

They include the gluten proteins, which are the major storage components and may account for up to 80 percent of the total grain protein (4). Higher intakes of whole grain products, which in the US and Europe are mainly based on wheat, are associated with reduced risks of Type 2 diabetes, cardiovascular disease, some types of cancer as well as a more favourable weight management (5).

For the general population whole grain consumption in general should be considered as healthy, helping to reduce chronic disease risk significantly (24).

As reviewed recently (13, 14) hard data about adverse human health effects of wheat components such as gluten and lectins (beyond coeliac disease and wheat allergy; 22), including aspects of weight management and insulin resistance are, however, not available and as well as there are currently no grounds to advise the general public to not consume this common dietary staple.

This conclusion is further supported by the outcome of a recent cohort, where it was observed that individuals who consumed recommended amounts of (whole) wheat had the least amount of abdominal fat accumulation (15).

However, a few recent scientific publications in animals and humans do raise certain potential concerns about wheat consumption for reasons of weight gain, inflammation and intolerance.

For example, in one study in rats, excluding gluten from the diet showed a favourable impact on reducing fat tissue increase (16).

TX-3000 RAISES ThE BAR ON AQUATIC FEED PRODUCTION Our business in life is not to get ahead of others, but to get ahead of ourselves.

—Stewart B. Johnson, Dutch Artist

Leave it to Wenger to redefine aquatic feed production via twin screw extrusion. Based on the proven Wenger Magnum twin-screw series, the new TX-3000 features barrel geometries that allow greater capacities than any other extruder in its class.

The combined features allow increased production capacity of up to 30 percent compared to previous and competitive aquatic machines — totally redefining cost/benefit. The TX-3000 can be equipped

with either the High Intensity Preconditioner (HIP) or the High-Shear Conditioner (HSC) to match specific process and capacity requirements, making it ideal for processing a full range of aquatic feed products.

Contact us now. With new concepts and visionary leadership, we’re ready to help you select the right tools for your extrusion and drying needs.

Turning ideas into opportunities.

PROGRESSIVE AQUAFEED PROCESSING

Imagine the possibilities wenger.com BElGIUm

Wenger14.TX3000.Ad.210x147.indd 1

TAIwAN

BRASIl

ChINA

TURkEy

INDIA

March 2015 | 4/9/14 51

7:34 AM

F The authors concluded that gluten exclusion may help to reduce body weight and can be a new dietary approach (in humans) to prevent the development of obesity and related sickness.

The latter is a conclusion, which, lacking any supporting human data, seems rather premature.

Ancient verses modern wheat varieties

Another trial aimed to study the effect in humans of Khorasan wheat (Kamut, a putative ancient grain related to “ancient” tetraploid durum wheat), replacing “modern wheat in the diet”, on cardiovascular risk parameters (17).

Based on the obtained data it was concluded that a replacement diet with ancient wheat products could be effective in reducing disease risks.

The publication gave no information on the recipe of the products and the way they were processed before consumption, giving rise to many questions.

In a more recent study the same research group (18), studied the effects of consuming organic, semi-whole-grain products derived from Triticum turgidum- subsp. turanicum (ancient wheat), replacing a modern wheat based diet, on irritable bowel syndrome (IBS) associated symptoms and inflammatory/biochemical responses.

The authors reported a significant improvement of gastrointestinal symptoms after the ancient wheat intervention period.

In addition, a significant reduction was observed in inflammation markers.

Also in this study no data were presented about the product recipes and the processing and final composition of the products.

Although the authors stated that ancient wheat resulted in improvements, it cannot be excluded that compositional changes as a result of food processing may have played a role.

More or less simultaneously, it was suggested that a high content of so-called FODMaPs (fermentable oligo-, di-, monosaccharides and polyols) plays a role in intestinal intolerance (23).

However, these carbohydrate compounds are not at all specific to bread wheat, and also occur in many other foods.

Roughly six percent of the general population seems to benefit from a gluten-free or wheat-free (or low-FODMaP) diet, although the degree of the benefit (as well as the severity of the original symptoms) is less well described.

Based on the findings listed above and the current social media drive to reduce the consumption of gluten-containing grains, it can be expected now that withdrawal of grains/cereals from the diet will result in an undesired replacement by less healthy, less nutrient and dense foods.

The cereal supply chain is being blamed to feed the world with sick making cereal products, much based on flawed interpretations of research data and/or statements of blogging activists. On the other hand NO SOLID comparative data are available on ancient vs. modern grains and the effects of their specific processing e.g. in bread making, let alone on the influence of consumption on gastrointestinal and general wellbeing.

Call for action

The entire cereal supply chain must respond to these developments.

We consider there is an urgency to perform double-blind ‘placebo’-controlled human intervention studies addressing the effects of different wheat types, their components and their processing steps towards end products to investigate the effects 52 | Milling and Grain

of consuming these completely analysed foods on human metabolism and health parameters.

Such human intervention trial addressing the effect of wheatbased foods, as consumed “as part of a typical daily human diet”, is the only way to obtain reliable data useful for future human dietary recommendations and appropriate food processing and product development.

To obtain reliable data the following research questions are proposed: 1. What is the true composition of common bread wheat, spelt wheat and emmer wheat (proteins, carbohydrates, fibres) 2. What are the compositional changes that take place during food processing: controlled dough preparation (yeast “short” fermentation verses long fermentation using sourdough starter) and subsequent baking? Controlled extrusion and subsequent pasta or breakfast cereal making.

Additionally, what is the final composition of the baked breads and produced pasta/breakfast cereals with regard to the components that potentially may lead to intestinal symptoms 3. What are the in vivo effects (metabolic, functional – that is, breath, blood and stool analyses - and symptom occurrence) of the consumption of the obtained foods, (resulting from Step 2, including control) in a highly controlled cohort of IBS patients, in the context of gluten and FODMAP contents and composition?

4. Do NOCEBO effects play a determining role in the perception of post-consumption effects?

This can be studied by supplying three food types (depending on country/region bread, pasta, breakfast cereals, or their combination, with related composition information and labelling, in a specific design) To carry out the proposed project significant funding is required. In this respect we are requesting funds from four to six multinationals, with additional financial support of at least 15 other partners representing: farmers and millers, processing technology companies, food producers, NGO bodies.

Shared responsibilities

Interested ‘Gold Sponsors’ will be invited to build a strong core team and be active members of the steering team which will address the details of the program: design, methods, execution, communication, etc.

Additionally, they will be active member of the international communication working group.

Interested ‘Silver Sponsors’: Additional companies/ organisations bringing in smaller funding contributions are invited to: 1) give written input on the program design, methods, execution, communication, etc; 2) will obtain regular news about progress, about gluten-free science and gluten-free market developments for the entire project period of three years.

References available on request

Brock Grain Systems

Storage | Handling | Conditioning | Structures

BROCK GRAIN SYSTEMS

A Division of CTB, Inc. A Berkshire Hathaway Company

+1 574.658.4191 www.brockgrain.com brock@brockgrain.com

F

Improving the quality of milled grains

a call to tackle hidden hunger in Africa

T

commonly consumed foods including grains - has been ranked by the World Bank and the Copenhagen Consensus as one of the best investments in development in terms of cost-effectiveness and cost:benefit because it improves people's health while indirectly boosting productivity and economic progress. It has led to the virtual eradication of goitre, pellagra, rickets and beriberi in the North and evidence is building of its impact in Asia and Africa.

Globally, this intervention has gained traction and gone to scale.

79 countries now have mandated wheat flour or maize meal fortification and more undertake it voluntarily. It is estimated that 31 percent of the world’s industrially milled wheat flour is fortified with at least some iron or folic acid through mandatory and voluntary efforts. In Africa alone, 21 countries have now mandated the fortification of wheat and/or maize meal.

Solutions

GAIN: The Global Alliance for Improved Nutrition in Africa

by Greg S. Garrett, Director, Food Fortification at Global Alliance for Improved Nutrition (GAIN)

oday one in nine people – 805 million worldwide, many of whom reside in Africa – still go to bed hungry every night. Many more suffer from micronutrient malnutrition. This ‘hidden hunger’ is of great public health concern. Vitamin A, iron and folate deficiencies are debilitating: vitamin A is critical for preventing childhood blindness and protecting the immune system; iron helps prevent iron deficiency anaemia; and folic acid can prevent life-long neural-tube birth defects. These deficiencies hold entire populations back. Children do not develop fully, parents cannot work efficiently and far too much money is spent on the medical treatment of nutrition-related health problems.

However, there are affordable and easy solutions which work and which can be implemented by the private sector. For example, staple food fortification - the practice of deliberately increasing essential micronutrients during the processing of

79 countries now have mandated wheat flour or maize meal fortification and more undertake it voluntarily

54 | Milling and Grain

GAIN has been leading many of these efforts over the last decade to catalyse national flour fortification in Africa. GAIN believes that food fortification should be an integral part of African countries’ nutrition strategies where existing food supplies and limited access fail to provide adequate levels of nutrients in the diet.

In Africa, GAIN has provided grants or technical assistance to Egypt, Ethiopia, Kenya, Morocco, Mozambique, Nigeria, South Africa, Tanzania, Uganda, Zambia and Zimbabwe as well as throughout West Africa.

Created in 2002 at a Special Session of the UN General Assembly on Children, GAIN supports public-private partnerships to increase access to missing nutrients in diets necessary for people, communities and economies to be healthier.

GAIN is a Swiss foundation headquartered in Geneva with a special international status granted by the Swiss government. It is the only international organisation exclusively focused on ending malnutrition.

F

“GAIN is committed to helping address bottlenecks to sustainability, compliance and impact of fortification programmes”

GAIN works in more than 30 countries to support fortification of staple foods and increase access to nutritious foods; demonstrates large-scale impact in maternal and child health; integrates agriculture and nutrition; provides locally relevant solutions specific to the needs of poor communities; builds capacity along the value chain; and helps shape the global nutrition agenda by setting standards and establishing platforms.

Today, thanks to the efforts of GAIN’s many public and private sector partners including milling companies, over 350 million people in these countries and regions in Africa are receiving more nutritious wheat flour and maize meal. This has led to reductions in neural-tube defects in South Africa and iron deficiency anemia in Nigeria and Morocco, and very high coverage in Senegal resulting in the majority of poor women of reproductive age receiving higher intakes of iron and thus contributing to better health.

Next steps to ensure milled grains contribute to better health in Africa

While this success is worth celebrating, there is so much more to do to harness the power of the world’s most affordable development intervention. Many of the countries in Africa that still suffer from high rates of hidden hunger have populations which consume high levels of wheat flour and maize meal. For these countries, the private and public sectors should come together and aim to adequately fortify all industrially milled wheat and maize. In many countries where there are national flour and maize meal fortification programmes, ongoing maintenance 56 | Milling and Grain

and strengthening is required. For example, quality, compliance and coverage issues plague many of these existing programmes, which in turn adversely influences potential for impact. There are also other quality and safety needs of grains which should be addressed by the fortification programmes and associated regulatory monitoring, thereby linking fortification to overall value addition processes and practices.

GAIN is committed to helping address bottlenecks to sustainability, compliance and impact of fortification programmes. Working with African governments and the industry as well as with partners like the World Food Programme, UNICEF, the Food Fortification Initiative, PATH, HKI and the Micronutrient Initiative, GAIN aims to support and drive continent-wide replication, new innovations including fortification and testing technology and raise the profile of wheat flour and maize meal fortification. Market-based delivery, school meals, public distribution and humanitarian assistance all can play a part to ensure fortified foods are consumed throughout the continent by those that need them.

From 9 to 11 September 2015 in Arusha, Tanzania, hundreds of leaders from around the world representing the public and private sectors, civil society, financiers and academia will be gathering for a global summit on food fortification.

This international gathering will be an opportunity to review successes to date in tackling hidden hunger, understand the gaps in fortification programming and agree on next steps to ensure one of the world’s most cost effective interventions is delivered to many more hundreds of millions across Africa. GAIN hopes to see the milling community actively participate at this event as we aim to purge hidden hunger from Africa.

STORAGE

F

Modular silos

T

and the benefits of a ‘flat pack’ design

Andy Vanparys, Managing Director, SCE - Silo Construction & Engineering, Belgium

he global demand for food is becoming greater and greater with an everincreasing population, which is why companies will have to produce more efficiently and effectively. SCE are playing an active part in helping companies with this by designing silos that take up little space and are quick to assemble in any production unit.

SCE’s first silo was constructed in Belgium 26 years ago and is still in use daily – a testament to the quality of build and design.

The company now boasts an impressive global portfolio, of which silos for animal feed are also a part. SCE have completed projects in China, Denmark, Indonesia, Switzerland, Poland, Great Britain, and the Netherlands.

Flat-pack wins - fair and square

SCE square (flat pack) modular silos have achieved global recognition within the feed industry. Time is the biggest risk and cost-driver in a construction period, regardless of whether it’s a feed mill or a flourmill. Through experienced engineering and new technologies SCE offer the fastest erection cycle in the business. A square silo offers 25 percent more storage than a round silo on the same ground surface. The mill building can also be attached directly to a square modular silo, resulting in great efficiency profits to the customer.

“We have gained the trust of many milling companies and machine manufacturers because of our long experience within the grain-processing and mixed-feed industry,” says Andy Vanparys, Managing Director.

“My father - the founder of the company - was born and raised in feed mills so the passion to keep on improving feed mill buildings is in the genes of our company.”

58 | Milling and Grain

Strong, swift steel

The selection of structural steel for a building’s framing system brings numerous benefits to a project. All other materials are measured against the standard of structural steel and it is still the material of choice. Little surprise, then, that it is the favoured material for SCE silos.

The rapid design, fabrication and erection cycle with structural steel allow the structure to be finished sooner and available earlier to other construction partners. The building process can start and finish earlier which leads to a lower total cost of ownership. 3-D interoperability technology allows close cooperation between the erection crew and the mill designers, thereby saving both time and dollars in the construction process.

Light and renewable

Not only is structural steel a stronger material, it also has a much higher strength-to-weight ratio than other materials. This results in the building being lighter and therefore requiring less extensive and costly foundations. Sustainability is structural steel’s middle name: It is the most recycled material on our

F planet – today’s structural steel is made of 88 percent recycled material. It is fully recyclable in the future and can be reused without further processing.

Saving water

The production of structural steel also conserves water. The only water used is ‘make-up water’ added to a closed-loop recycling process. Structural steel mills discharge no water into the environment.

It is not used in the fabrication process and no water is used or discharged at the project site.

Simple, global solutions

Over the 25 years SCE have been catering for the feed industry, there have been numerous technical innovations in silo construction. The improvement in types of high-yield steel products has made it possible to make lighter components without any loss of strength. New research and development for the grain industry has led to square bins which can hold up to 400 tonnes without any need for extra measures.

Silo blocks can now be built without using any nuts or bolts.

SCE’s ‘sliding principle’ for connecting pieces together is the fastest in the business and results in a hygienic storage environment. This simple construction method also greatly reduces the need for highly-trained labour. SCE silos can be – and have been – erected virtually anywhere in the world by just one

SCE supervisor instructing a local work crew.

SCE have also recently developed a new silo outlet that further increases the outflow of any product, winning accolades from many in the flour and milling industry.

Such innovations, combined with the latest design and production technology, have made life easier for project managers and workers alike. Little surprise, then, that from the Philippines to Uganda, from Madagascar to Indonesia, SCE are going from strength to strength.

DESIGN BUILD

Norwood and Company

EXPAND With four generations of experience in the grain, feed, flour milling and wood industries our family would be more than happy to help you design, build, repair or expand any new or existing grain facilities We also offer a large variety of new and used grain equipment to help meet your needs norwood_hp.indd 1

REPAIR Contact us on: Fred Norwood, President; Tel: +1 405 834 2043 Brandon Norwood, Vice President; Tel: +1 785 822 4109

www.norwoodandco.com March 2015 | 5917:30 10/02/2015

STORAGE

F

Picture 1: In a silo plant actually designed to move three million tonnes of wood pellets, shows the Agromatic solutions being incorporated

The importance of temperature monitoring

A

gromatic AG was founded in 1979 in Switzerland by a group of experts from the grain industry with electronic backgrounds.

The operational business started with the development and manufacturing of temperature monitoring systems for silos and level indicators.

The monitoring systems supplied by Agromatic received wide acceptance right from the start and the company closed its first operational year with a positive result.

The key milestones for the company include: • 1982 the first automatically regulating dampening system for grain has been supplied to an Austrian mill • 1984 erection and move-in of own company building • 1986 opening of subsidiary in Germany • 1987 opening of different country representations • 1991 operational business in Austria At the same time new monitoring units and products were evaluated, designed and manufactured. Nowadays, Agromatic manufactures about 230 different units for the grain and feed processing industry. The range of its own developments has been enlarged by adding specially selected external products, which are partly marketed under the name of Agromatic.

Before an ‘external product’ is introduced to the market by Agromatic, it undergoes extensive quality testing.

“The continuing success we are achieving proves that we can solve the problems of our customers, increase the quality of their

60 | Milling and Grain

products and optimise the efficiency of their production,” says the company.

Products for the grain industry

Improved and continuous monitoring of temperature during storage is essential and has been a goal of Agromatic development since the company’s beginning in 1979.

Managing grain throughout the storage process pays off. It is necessary to enhance the quality control of grain from production to processing.

Thus, safety of grains has to be maintained at every stage, thst is from harvesting, in storage, through transportation, processing and storage of processed food.

Often storage quality control is adversely affected due to a number of prevailing circumstances such as: • Unintended temperature effects • Missing competence and management regulations • Failure to adhere to regulations Nowadays, the most important considerations are to avoid include: personal injury, damages or the ignition of an explosive atmosphere; following all equipment safety procedures during commissioning and respecting necessary security requirements; complying with all specifications in the ATEX directives, as well as international standards and insurance cover recommendations.

Renewed certification

Agromatic is pleased to announce it has renewed certification for all silo temperature cables and control systems, achieving its new ATEX accreditation.

F

Temperature monitoring at Silo AG, in Wil, Switzerland Monitoring over a long period and in considerably large plants is best carried out either by thermistor systems or, nowadays, by modern one-wire digital sensor technologies. The cable protecting the temperature line is made of high-grade steel, which can be up to 100 meters long and can contain numerous sensors

Temperature monitoring in flat silo storage combined For extensions to flat silos a wire-based installation is usually impossible due to the loading and unloading of materials. In such cases a wireless spear probe system offers an elegant, convenient and cost-effective solution

Picture 7-8-9: Temperature monitoring in metal silos combined All combinations are possible. The new digital wired system, monitored by only one control unit is actually the most common, is modular and thus extremely extendible

Picture 10-11-12-13: Temperature monitoring in concrete silos combined Monitoring temperature in concrete silos using Agromatic state-of-the-art sensing technology minimises installation costs while offering high performance and value for money. Combining temperature measurement with high-level monitoring detection systems from Agromatic also reduces instalment work and saves costs

March 2015 | 61

F

STORAGE

The systems are versatile, usable in existing plants, in new plants or in plants with periphery expansion.

High value has been placed on the best possible and cost-benefit ratio that sets a target for modular and wellfunctioning temperature-monitoring systems, and to meet the essential and strategic aims of all types of storage.

The choice of a system should be made based on various provisions and should ensure long-lasting results over the years, aimed at removing the need for continuous interventions and costs.

Furthermore, it should facilitate effective monitoring considering all structural arrangements and conserving the benefits achieved.

This feature offers a range of illustrations covering many of the aspects of temperature control and safety management within a grain storage and handling facility, but also uses other materials as illustrations.

Recording, storing and documenting performance data informs any necessary adjustments. The SM2010 central control system stores all temperature data and can instantly display and print the measured values.

Agromatic have provided temperature-monitoring solutions and equipment for plants all over the world. The company is exceptionally proud to offer systems that fully conform with the latest 2014/34/EU ATEX guidelines, and can provide all necessary certification.

Picture 14-15-16: Temperature monitoring data processing For data processing, several control systems are available and can be combined in modular construction according to the customer’s requirements. Either under independent control or as a web-based connection - modern systems offer all kinds of solutions

Milling and Grain 3.2015.pdf

10.03.15

11:36:14 Uhr

‚‚SAFE YOUR GRAIN‘‘ by monitoring the temperature Wireless access point

Wireless spearprobe

Digital with One-wire sensors ADT bus system

C

M

Y

CM

MY

CY

CMY

Display unit

K

Agromatic Data Transfer - possibility of combining all systems - existing systems can easily be integrated swiss made

Agromatic 62 | Milling and Grain

CH-8637 Laupen / Switzerland / T: +41(0)55 2562100 www.agromatic.com / info@agromatic.com

DESIGN DOES MATTER • Behlen puts steel where it counts for outstanding strength and durability.

• Largest capacities in the industry better installed cost per ton.

• Wide selection of sizes to meet customer needs.

UNIQUELY DESIGNED WALL SYSTEM. • Flat-sided trapezoidal corrugation provides a superior weather seal.

EXTRA HEAVY-DUTY TENSION PIPE. • Structural eave tension/ compression ring provides superior resistance to wind damage to silos, full or empty.

www.behlengrainsystems.com 800.553.5520 Behlen Mfg. Co. has been ISO registered since 1999.

STORAGE

F

ELEVATOR BUCKETS

Bucket Stax

How does Maxi-Lift Inc stack up against the competition?

Darren Parris from the Milling and Grain team talks to Maxi-Lift on their stand at GEAPS Exchange 2015, about the Stax elevator bucket launch

D

uring the GEAPS Exchange Expo held in St Louis, Missouri in the USA last month (from February 22-25), Maxi-Lift was comfortably stacking on the competitive pressure. Having started trading in 1973, over 40 years ago, the business has continued to grow both domestically and globally with operations in over 70 countries and a client list that continues to grow year-on-year. With more than 300,000 square feet of production, manufacturing, and warehouse space, MaxiLift is the largest elevator bucket manufacturer in North America.

With such a global network of clients, the logistics involved has developed over the years to the point where the company has distributors throughout the world offering the full catalogue of Maxi-Lift Inc products, which are available to fulfil the diverse needs of their customers.

Talking with the Maxi-Lift team at the GEAPS Exchange, I was reminded that their products are used across the World on rice farms in Guyana, elevator upgrades in Romania, new feed plants in China, large river and port projects in North America, and the largest soybean processing plants in Argentina.

The team further explained to me that the Maxi-Lift name is known internationally for outstanding product quality and service. This is why they are proud to call themselves the global leaders in the industry.

Transformation

Much has happened over their 40 years in business. Starting off selling primarily elevator buckets, Maxi-Lift has transformed itself into a global leader in elevator components.

One only has to look at the significant, growing catalogue of products to realize that this is a company with true innovation and foresight.

64 | Milling and Grain

Talking with Business Development Manager, Mr Wade Spencer, at GEAPS, he told me, “At Maxi-Lift, we are defined by our strong brands, innovative products, technical expertise and friendly customer service.

“These are just a few of the many reasons our customers consider us the global leaders in plastic and metal elevator buckets.”

Mr Spencer has over 27 years of experience in the grain and feed industries. He joined Maxi-Lift two years ago after an extensive career in grain industry maintenance. His career to that point was split between working for EarthGrains and more recently for ADM as a maintenance supervisor for a major grain facility. He also spent three years using his maintenance and millwright knowledge for Lewis-Goetz and Company which produces rubber belting among other products.

Wade is a current GEAPS member and is active in the Great Plains chapter. He has also given preventative maintenance seminars for The Kansas Grain and Feed and The National Grain and Feed Association.

Maxi-Lift offers the expertise to help customers understand the technical side of their equipment including screw, drag and belt conveyors with bucket and related equipment.

Bucket launch

As a strong customer-focused company, MaxiLift is always looking for the best ways to please its customers. Whilst maintaining the continuity of quality, new innovation is always just around the corner.

With their customers in mind, Maxi-Lift chose GEAPS in St Louis as the international platform to launch their HD-STAX elevator bucket. I met with Mr. Spencer on their impressive display at GEAPS – it was the one where buckets were displayed to represent the 190-metre Gateway Arch that identifies this city and port. Maxi-Lift had gone the extra mile to honor both the city and their new bucket line.

Stacked up to 20-feet high and forming an impressive entrance to their stand, the ‘Bucketway Arch’ stood triumphant - made entirely of

F the company’s new stackable HD-STAX Buckets. Not to be completely overshadowed by an Arch, its expo team was cheered on by none-other than the St Louis Rams Cheerleaders to show support to the vibrant city.

It was here that Mr Spencer demonstrated the positive attributes of the HD-STAX Buckets compared to other industry leading buckets. With their overseas customers in mind, the HD-STAX bucket can be stacked one inside the other for better storage, stacking and shipping.

With maximum ‘stackability’ comes maximum savings. In many cases when compared to other buckets, you can stack, for example, nine HD-STAX buckets compared to three identical buckets giving improved efficiency.

During their launch at GEAPS, Paul Phillips, President of Maxi-Lift, said “We are always looking at innovative ways to help our customers solve their problems.

The new HD-Stax allows our customers to move more buckets, in a smaller space, more efficiently while also giving our customers longer life, more reliability, and better long-term value.” It’s a win-win for everyone.

Five new product lines have been added in the last 15 years to the already over 700 different buckets which come in different shapes and sizes. All designed to handle very specific materials whilst always focusing on a better reliability, longer life, and a lower cost.

So confident is this company in their product, they invite any potential or existing customer to contact them (info@maxilift. com) with details of your current usage including: Average bucket

Not all buckets created equally

life; current bucket brand; size and style now in use; current bucket problem; material being elevated; current belt spacing; hole punch spacing and belt width. Maxi-Lift’s experienced staff is willing to offer capacity optimization, elevator design, and trouble shooting for new or existing grain elevators. So, in answer to my initial question, it seems Maxi-Lift is stacking up nicely.

Having travelled the globe on behalf of the Milling and Grain magazine, I have witnessed first-hand the many different companies making buckets. The global competition has many faces with many different qualities and it is clear that not all buckets are created equally.

GEAPS visitors overshadowed by the ‘Bucket-way Arch’ in St Louis The Maxi-Lift team in front of the Maxi-Lift buckets - displayed to represent the 190-metre Gateway Arch that identifies St Louis city and port

March 2015 | 65

THREE PROVEN BRANDS ONE POWERFUL TEAM

PROVEN & DEPENDABLE™

| W W W. G R A I N S Y S T E M S . C O M

ELEVATOR BUCKETS

STORAGE

F

The science behind a show stopper

At the GEAPS Exchange in St Louis last month, the must see attraction was on the Tapco stand. Can an elevator bucket really be strong enough to lift a 9700 pound H1 Hummer?

Darren Parris visited Tapco on their stand to witness the demonstration, and then visited Tapco HQ to find out how it was possible

A

ttending Geaps exchange 2015 as I did last month in St Louis was a privilege. Once again, the Grain Elevator and Processing Society converged on the chosen city. This year it was St Louis, home to some of the most iconic sights and world class sports teams in America, such as the Cardinals baseball team, St Louis Rams NFL team, Missouri Botanical gardens and the globally recognised Gateway Arch, the gateway to the west. And last but not least of course, we should not forget Tapco Inc. which is also based in St Louis.

The Hummer

Upon entering the GEAPS exhibition hall, you simply could not miss the Tapco booth, as it dominated the entrance with their 68 | Milling and Grain

large blue H1 Hummer parked up all resplendent and awaiting the challenge to be lifted off the ground: it's complete four tons to be hoisted in the air with a simple plastic Tapco bucket supporting its whole weight.

This demonstration has to be seen to be believed.

So acting as the third party unbiased adjudicator, I took up my position, on the floor, perpendicular to the under chassis, camera in hand and recorded this momentous feat.

The electric crane came to life and as the bucket and frame of the crane took the strain, the Hummer began to move. And with seemingly no effort at all, was lifted clear of the ground. No sooner was this task completed than the critics raised their heads.

There were comments of "it's fakeâ&#x20AC;? and â&#x20AC;&#x153;there is no engine in the Hummer" and "the safety cord between the crane and fastening to the bucket is taking some of the strain" followed by "the Hummer is empty".

So, the gauntlet was thrown down. If I was to lay witness

F

Michael C. Cowl, and Yassine Abbad demonstrating the Tapco stackable buckets

I had to understand, what was it that made these buckets so strong, after all it's a simple plastic injection moulded bucket off a production line, right?

How wrong was I. Upon arrival at Tapco and meeting with the global sales team it was clear to me in the first 15 seconds that I was surrounded by a team that truly believed in the superior quality of their product.

From here I was taken on a tour of the inner sanctum of the behind-the-scenes working of Tapco Inc. It was here that I was furnished with the intricate attention to detail that goes into every single bucket. No photos allowed as I was taken through what makes a Tapco bucket so special.

First, only the highest grades of plastic pellets are used on their more than 90 sizes of elevator buckets. Tapco has spent years researching the many brands of materials on the market to find

on behalf of Milling and Grain magazine and all its readers to a specific act of strength and durability professed by a company of its bucket, it was imperative that all these concerns were dispelled.

Without hesitation, the hood came up to reveal the Goliath engine underneath, which caught the interest of many petrol heads at the show.

The crane fastening was reattached with hood up and engine in full sight, all safety cords were removed, leaving just simply the bucket completely on its own to support the weight.

In addition to this, myself and other spectators inspected the inside and we were all happy that this was the fully armoured and fully functional Hummer we had previously been led to believe.

With no further ado, the electric crane came alive and with no ceremony the blue Tapco Hummer was once again lifted clear of the ground.

The watching crowd acknowledged the lift and we are happy to give Tapco the "As Witnessed by Milling and Grain" seal of approval!

So frequent were the lifts throughout the Expo, same bucketmultiple lifts that the novelty wore off and it was clear the bucket had passed its test with flying colours.

Visiting HQ

Being in St Louis I had to make time to visit the Headquarters of Tapco Inc. March 2015 | 69

ELEVATOR BUCKETS

STORAGE

F

Above: Darren Parris from the Milling and Grain team confirms that the Tapco Hummer is indeed the real deal !

Right: Image from the Tapco advert that was re-inacted at the 2015 GEAPS Exchange Below: The Hummer on the Tapco stand before the lift

the toughest resin used to make their buckets. Second, each size of elevator bucket is made in its own single cavity mold assuring the full injection of the strongest material to make the final part.

This combination of the strongest material and mold design sets Tapco apart from their competitors by supplying the Industry with a strong reliable elevator bucket.

Pre-made buckets in every size

It is here Tapco come into their own. As we left the factory floor we walked for what felt like miles and miles through multiple storage warehouses, where from ceiling to floor stood over one million pre made buckets in every size as well as multi millions of bolts and fasteners available in both metric and imperial.

This represents a multi-million dollar investment in pre-made and pre-paid stock by Tapco. Nothing is owed, everything is paid up and Yassine Abbad, Vice-President of Sales at Tapco, was quick to point out that this represented just how important their customers are to them.

They have invested millions in what is essentially an insurance policy for their customers, by holding stock ready to go in every 70 | Milling and Grain

size, all orders received before 15:00 are despatched the same day.

Yassine went on to explain that broken or old buckets in a mill meant downtime for his customersâ&#x20AC;&#x2122; production which could cost US$10's if not US$100's of thousands, therefore a prime aim of Tapco is to exceed their customersâ&#x20AC;&#x2122; expectations on delivery time.

So important is this ethos of supporting the customer, I was taken to a second warehouse complex just a block down the road, which was as big again as the first, bringing the total storage space to over 160,000 square feet; it was currently being kitted out with shelving to store the expanding range of buckets to meet the ever growing global demand.

It is here that I had time to play with the Tapco Hummer, as it is kept in this warehouse between exhibitions. Just another opportunity to confirm its all real and working.

Before leaving, Michael C. Cowl, Strategic Accounts Manager for Tapco and Yassine Abbad demonstrated the Tapco stackable buckets, again in blue and sporting the high quality plastic construction.

So there you have it, a million reasons tucked away ready and waiting, at your beck and call to back blue.

Turnkey-Delivery

Flour & Semolina Production Plants

23-26 APRIL 2015 CNR EXPO / İSTANBUL

HALL: 1/ STAND: B-9

Storage News

50 years of Lambton Conveyors

O

by Robert Nieminen

ne source. One solution. As company mottos go, Lambton Conveyor Limited has hit the mark. A onestop solution for grain handling operations, Lambton offers grain storage, material handling, and drying and cleaning equipment and continues to expand their line.

The family-owned company will celebrate 50 years this summer and has emerged as an industry leader in a time when mergers and acquisitions are almost the norm. Lambton is one of Canada’s leading manufacturers of grain storage and handling systems.

From Regional to Global

Lambton Conveyor Limited is a privately held corporation founded in 1979 as a grain storage distributor. Its predecessor firm was a construction company established in 1965 by founder Ray Moorhouse. In the 1980s, Lambton began manufacturing grain handling equipment and developed a full line of chain conveyors and bucket elevators, essentially everything on the grain and bulk handling side of the business. It wasn’t long before Lambton started expanding its reach and manufacturing complete elevator systems, everything from small grain bins to hopper tanks to a complete accessory line.

From there, the company shifted gears, and by the 1990s, Lambton had become “an OEM supplier,” producing equipment for other grain equipment suppliers, which has been a catalyst for the company’s international growth and expansion.

Today, Lambton provides an ever-expanding line of innovative and practical products, including silos, bucket elevators, drag conveyors, grain cannons, screw conveyors, flow system accessories, bin unloaders, bin dryers, hopper tanks and custom fabrications. Almost all of the equipment produced by Lambton is fabricated using galvanised steel, which ensures a long service life and a low maintenance finish. Most products are also available in

stainless steel and painted mild steel upon request depending on the application.

Modular Design Principles

Lambton’s modular design principles allow the flexibility to custom-fit each assembly. It offers a global network of factorytrained field consultants to develop, build, and support grain systems for specific operations.

Jordan notes that many of the company’s distributors and suppliers are located in the United States and that the domestic North American market is a big focus for the company, in addition to its expansion into global markets in recent years.

The company has grown from a regional manufacturer to a global operation, with global network field representatives in more then 25 countries around the world, with a new manufacturing facility of 200,000 square feet headquartered and rooted in the rich southern Ontario farmland of the Great Lakes region. A second manufacturing facility is located in central China.

“We are fortunate to have great representation worldwide. Even with all of the turmoil going on, we continue to experience growth globally,” says Jordan.

What sets Lambton apart from the competition, he says, is that while the company has expanded representation in domestic and international markets, the company’s reps still treat customers as though they are family and give them the tools they need to succeed. Whether it’s helping to establish or strengthen engineering guidelines, offering assistance with trade shows, or simply being there to support the customer’s needs, Lambton offers a complete package of products to its customer base regardless of where they are located.

This focus on partnerships is what has enabled the company to continue developing its product lines, expand the business, and maintain its market share.

“We continue to value our close personal connections with customers and associates around the world,” says Depooter.

“We’re offering modular design principles, which give us the flexibility to custom-fit every assembly to suit the customer.”

Depooter says the engineering and support team is committed to giving customers the most productive and most cost-effective solution, from the factory to the farm.

“Our know-how design team constantly is expanding our range of Lambton-built components and accessories, to achieve the best delivery and costing for our customers,” he adds.

Storage project

Sympathetic Barton silo design blends with rural setting

B

arton Fabrications, the UK’s largest aluminium silo manufacturer, has recently installed several silos at an environmentally sensitive site in England. Installed at a food processing site, the silos have been designed to keep within the factory roof line and to be visually sympathetic to the local countryside.

The 21 metres high silos have a capacity of 90 tons and are all fitted with maintenance free beige coloured cladding.

Commenting on the success of the silo design and installation Mark Barton, Managing Director, of Barton Fabrications said: “The client was very conscious of their rural setting and wanted to ensure that the new storage silos were in keeping with the local area. Our environmentally sensitive design met this challenge, giving the required storage capacity, whilst harmonising with the rural landscape.”

The Barton half penthouse design supplied to the customer provides safer working conditions at the top of the silos and double doors at the bottom allow full access to the base. In addition to an environmental design, the silos are also fitted with load cells and a hygienic skirt, which prevents rodents and insects entering via the base.

72 | Milling and Grain

Industry profile

F

Industry profile

A global company with a local outlook

W

地域に根ざしたグローバル企業

Darren Parris from the Milling and Grain Magazine travelled to Hiroshima in Japan to take a tour of the Satake Corporation head quarters, and took a tour of the Satake museum and sales hall hen you first visit Satake Corporation, it is immediately evident that they are a company who care about their global impact. Although this may sound like a cliché, the ethos of caring or ‘the satake spirit’ as it I known to those at the company, is so ingrained into Satake culture, it is overwhelming.

Satake are very proud of their heritage and close links with the city of Hiroshima having been based there since 1896. One cannot think of Hiroshima without remembering the very tragic events of August 6th 1945 when at 08:15am the Enola Gay dropped the Atomic Bomb named Little Boy on the city.

Detonating about 1,900 ft from the ground, it created a blast equivalent to 16 kilotons of TNT killing some 80,000 people immediately with a further 80,000 to 100,000 dying over the coming months. I can simply say that everyone I met in Hiroshima had a family member affected by this event.

During my visit I was taken to a beautiful memorial Peace Park in remembrance of the lost city. The park now serves as a strong message as well as a very proud statement for the community that pulled together to rebuild the city.

Satake have never left Hiroshima since their inception.

Furthermore, the corporation played an integral part in supporting the growth and rebuilding that followed the events of August 6th 1945.

Today, Satake’s efforts have culminated into building a first class globally recognised corporation which can quite simply be summed up as –The Satake Spirit. The Satake spirit is comprised of the following sentiments: Think nothing is impossible Be intellectually humble Understand the hearts and minds around you.

If you are a miller and you think of Satake, you would be forgiven for thinking of them primarily as an optical sorting 74 | Milling and Grain

company. Having spent a week in Japan, I would like to expand upon this.

A company with 119 years of history

When you take into account the Satake Spirit and learn about Satake’s future aspirations, their drive comes from a continued commitment to improving the health of a global population through superior taste and nutrition.

To explain where Satake are today, it is important to look back at what Satake has achieved over the last century looking at their unbridled list of ‘Firsts” and unsurpassed list of ‘Awards’.

Undoubtedly this list of firsts and plethora of awards is impressive. The global awards truly underpin the drive for excellence that you witness at every level. Since its inception, Stake now has 12 global offices servicing over 150 countries with just under 3,000 employees.

With between 50 percent to 98 percent of the “Global Rice Mills’ market, depending on the region, there is no doubt as to why they are the number one choice for many millers.

And of course its not just rice, Satake has five sectors to its business, which are: 1 Rice Milling, which includes everything from Laboratory Equipment, Farm Processing Machinery, Conditioning and storing through to rice milling for both food and breweries.

2 Wheat & Corn, which includes debranning machines, maize degermer, rollermills through to the famous PeriTec Flour Milling Plant 3 Food, which includes Rakumeshi Packed Rice, Instant rice, Kitchen Rice Mill to Instant Pasta.

4 Environmental Systems, which includes Biomass, composting plants, snow utilisation facility to biomass boilers.

5 Industrial Machinery, which includes Plastic recycling systems, Optical sorters, plastic Pellet Polishers to the Satake Induction Motor (SIM).

F An interview with

Kazuyuki Kihara Senior Managing Director

I would like to start with your history - Over the years Satake has won many awards such as Blue Ribbon and the Order of the Rising Sun. I understand the Emperor gave the latter? Are there any other awards Satake are working towards?

The highest prize we have been given was from the Emperor. It was given for the contribution Satake made to advancements in technology for over a century. It was not given just to the president and CEO, but to the whole company.

This was a company wide award.

What new innovations are you looking at?

At its founding, Satake developed the machinery for the production of sake. As you probably know only the very centre of the rice is used for making sake, the outside is waste.

Before Satake developed and engineered the machinery for the production of sake, it was all milled by hand. So Satake tried to modernise

this process with the invention of the first power driven rice milling machine.

So we now take care of many different types of grains, but for the purpose of this conversation I will focus on rice. The biggest function of the rice mill in the past was to produce milled rice. However as the economy grew, the needs of the consumer changed and whiter rice was less important and no longer the key, because people began looking towards the functionality or taste of rice.

So we had to find solutions and develop machinery to meet the demands of the diversity of the market.

From its foundation Satake was a producer of sake machinery. Only the centre of the rice is used for sake. This was milled by hand.

Satake innovated the automation of the milling process.

One of the innovations with respect to functionality concerns GABA (GammaAminobutyric Acid). Our latest technology is able to enrich the GABA from the rice, nothing is added, and this is 100 percent natural.

So each country in the world has different consumer demands and therefore different priorities. Examples of their priorities are: a) Quantities or Yield, this is the most important priority for a developing country as many people are starving and need feeding. b) Appearance, for many milled rice is better. c) Then as I have already said, palatability and taste functionality is what is demanded in more modern societies.

We have installed rice mills in Malaysia, Vietnam and Myanmar in recent years. These countries are still very much focused on yield and appearance, they are not focused on functionality, taste or palatability. Their priority is to supply enough rice to the population.

On Wednesday you will go to a rice mill near Tokyo, during your visit you will see no polishing machinery just to improve the appearance of the rice. Here in Japan the appearance is taken for granted.

Japan is now more focused on factors such as functionality, taste, palatability and of course not forgetting safety and reliability which contributes towards peace of mind.

These are the advancements in technology we have made with rice.

Our advancement in England in 1991 just after our purchase of Henry Simon and Thomas Robinson is part of our strategy to expand our product from just rice to the other grain and flours, particularly wheat flour.

We are proud that we have been able to take our rice technology and enhance it for the wheat flour milling industry. The traditional wheat milling process is a gradual system of grinding, purification and sieving to separate flour from bran, but our technology the PeriTec is debranning, so it just removes the outer bran layers of the wheat kernel bran and this is a break through in the wheat flour milling industry.

The wheat industry has gradually accepted and adopted these de-branning advancements

March 2015 | 75

Industry profile

F

Heritage While taking a tour of the Satake museum it is easy to see the care and attention to detail that is the foundations of the company. You can view the artifacts and read about the exploits through the history of Satake from 1896 to the present day, which in itself sits beside an expansive wall of grains that can be processed through their optical sorters.

As impressive as it is, adjoining the museum are a succession of laboratories and in the main hall a full size working rice mill which is onsite and available to demonstrate to customers the many Satake machines that are available in the rice milling process.

The history 1908 The first Vertical Abrasive Rice Milling Machine is invented 1896 Riichi Satake invents the first power driven rice-milling machine

Below is just a small selection of the highlights from Satake’s history in the industry

1950 Toshihiko Satake awarded the Blue Ribbon Medal of Honour for achievements in Rice Milling 1940 The first ever concise book is written on ‘The Theory of Rice Milling’

1944 Riichi Satake is the first person from the foodprocessing sector to be awarded the Blue Ribbon Medal of Honour - Japan’s highest civil award

The sales hall

After touring the very impressive factory, I spent some time in the sales hall. I can only describe this as their very own exhibition arena. It is like attending Euro Tier, or Victam or VIV, but in this arena every exhibitor is Satake, every machine is on display and can be tested or demonstrated.

It is here I challenged the Satake team to demonstrate to me the Grand Optical Sorter. I collected a bowl of inferior grains. I weighed them out to be exactly 1lb (0.4535kg). I then mixed them in with a very large container of good quality grain; we made sure it was well mixed in.

We then poured the container into the optical sorter and set it to work.

In just over one minute all the grains had passed through and the optical sorter had split out the inferior grains from the good. We poured the inferior grains back into a bowl and it weighed exactly 1lb. This was a very impressive demonstration and showed a 100 percent sort rate.

This was a very impressive end to the tour of the Satake Head Quarters.

I would like to thank Takaya Hirase and Hiromi Saita for looking after me and hosting me throughout the visit to Japan.

After my visit to Satake, I headed north of Tokyo and out to the country to visit an ultra modern rice mill. My interview with the rice mill manager and my tour of the rice mill will be appearing in an up-coming edition of Milling and Grain.

76 | Milling and Grain

1956 The first ever One-Pass Rice Milling Machine is invented

1968 The first Tempering Dryer is developed that dries rice up to 10 times faster 1964 The first three Country Elevators are built

1974 The first husker with oscillating paddy separator is invented – The Rice Master

F

1986 The worlds first Rice Taste Analyser is produced 1988 Toshihiko Satake – Awarded a Doctorate of Agriculture from University of Tokyo

1993 Toshihiko Satake – Awarded a Doctorate of Agriculture from Tokyo University of Agriculture 1989 The world’s first AC motor with high torque and low current is developed

1995 The first consumer quick rice is introduced to the market – Magic Rice 1994 Their Imperial Highness Prince & Princess Hitachi honour Satake by a visit to their Head Office

2002 Robert S. Satake receives the Mori Engineering Award from Japanese Society of Agricultural Machinery 2000 The first rinse free rice production system is launched – ‘New Tasty White Process’

2009 The company receives the Engineering and Technology Award

2013 The company receives the “Economy, Trade and Industry Ministers Award” for Intellectual Property Merit

軌 跡

Live colour sorter demo

Staff from Satake demonstrate the colour sorting system in the Satake sales hall

March 2015 | 77

F CASE STUDY

CASE STUDY

Flawless Project Delivery Since moving to its new state of the art facility in May 2013, Famsun Feedmill Solutions has put a real focus on Flawless Project Delivery (FPD)

T

he key to FPD is not only the manufacturing process itself, but a continued development in the knowledge of the team involved, the integration of new tools in the manufacturing process and ensuring that manufacturing standards are put in place at every stage of the process.

By working closely with tool manufacturing companies, Famsun has been able to successfully integrate advanced production technologies such as CNC machining centres, welding robots and chain assembly systems into its own workshops, while improving the manufacturing management process at the same time.

This has added another layer of precision and high quality levels for every piece of Famsun machinery on the production line, right through from material processing to machining, onto painting and assembly. The manufacturing unit has also installed the first grinder assembly line in the industry.

Famsun is now able to produce all of its machines including spare parts and other per-fabricated parts for various feed mills.

Since moving to the new site, and using everything that they have learned from the new processes, Famsun has managed to achieve an ‘on time delivery’ rate of over 99 percent, with virtually 100 percent of items coming off the production line meeting the stringent quality controls that have been put in place.

The manufacturing process is not the only area that has allowed for this success rate however. Close scrutiny has been applied to the logistics side of the business as well, allowing plans to be put in place and resulting in more efficiency.

Computer systems and data are also an area where big improvements could be made. By improving and automating the ordering processes, the company has now ensured that the accuracy of its data has been greatly improved.

78 | Milling and Grain

Continuous Improvement Process

By organizing a Continuous Improvement Process (CIP), the company has solved more than 60 problems that had previously occurred in the product polishing and welding lines, and put forward 101 quality improving suggestions to be implemented.

In carrying out these improvements, the team has also successfully applied a national patent for a Automatic Assembly Device.

Through all of these measures, the product quality has been improved and customer’s satisfaction has been raised.

In 2014, the manufacturing team also carried out an environmental responsibility plan to eliminate noise and control fire risk, improving standards for the workforce.

Manufacturing skill competition

The quality of every Famsun product depends on not only cutting-edge manufacturing tools, but also dedicated workmanship of the operators and their knowledge and experience, as well as the outsourcing of parts with same quality standards.

As a way of ensuring that this remains a focus in the business, on November 6th, 2014 Famsun held ‘The second manufacturing skills competition’ in Famsun’s workshops. The 2014 competition attracted 217 participants, not only from within the Famsun staff but also including 87 of its suppliers.

The skill competition included processes such as argon arc welding, gas metal shielded arc welding, lathe machining, painting quality troubleshooting, SAP operation, material identification, forklift truck driving, etc. After a fierce competition, one of the local suppliers won the ‘Best Group Award’, and 57 other participants where awarded first, second and third prizes for various categories.

OVER 50 YEARS OF ENGINEERING SOLUTIONS™ Sukup Manufacturing Co. continues to Engineer Solutions® to meet the challenges of the grain industry. As the world’s fastest-growing bin company we offer commercial bins with clear span roofs and holding capacities up to 1.5 million bushels. We also have a complete line of drying, storage, and material handling products, as well as steel buildings - all engineered to revolutionize grain processing and storage, making it easier, more efficient, and more profitable.

Sukup Manufacturing Co. • www.sukup.com • info@sukup.com • Sheffield, Iowa 50475-0677 • 641-892-4222

RICE RESEARCH

Africa to expand rice production area by half to become global leader

B

Dr Robert S Zeigler, IRRI

etween 2014 and 2031, Africa will expand its rice production area by almost 50 percent to become a global leader, according to analysis on the global rice production and demand according to IHS Inc the leading global source of critical information and insight.

IHS has been in business since 1959 and became a publicly traded company on the New York Stock Exchange in 2005. Headquartered in Englewood, Colorado, IHS employs approximately 8000 people in 31 countries around the world.

Key findings of new IHS analysis: 1) Africa’s rapid expansion of areas for rice production will be the fastest globally in percentage terms 2) Asian demand, mainly from China, is driving a majority of the growth in rice consumption during 2014/15 3) However, Africa’s rice import demand is driving much of the world’s long-term import growth 4) With a lower Indian rice production estimate due to issues relating to a later monsoon, India is forecast to lose its spot as top exporter in 2014/15 to Thailand

Africa out-paces the rest

Africa’s rapid expansion of areas for rice production will be the fastest globally, in percentage terms. Across sub-Saharan Africa, the development of the agriculture sector is viewed by many countries as a way to: Diversify their economies away from excessive dependence on the mining sub-sector; increase employment prospects and enhance poverty reduction.

“Cote d’Ivoire plans to spend US$4 billion on agriculture development in order to improve crop yields and, in four years, become a rice exporter,” said Karanta Kalley, chief economist for Africa at IHS.

“The Government of Burundi and IRRI share the same vision: to provide sustainable methods of growing rice to improve the well-being of rice producers and consumers, to reduce poverty and preserve the environment”

The Ebola question mark

However, economic development, especially in West Africa, has a question mark hanging over it.

“Right now, the question on everyone’s mind is what the impact of Ebola will be on the economic growth of sub-Saharan Africa,” Kalley said.

IHS expects real gross domestic product (GDP) growth to be curbed significantly for 2014 in Guinea, Sierra Leone and Liberia as a result of the ongoing Ebola outbreak.

The IHS real GDP growth rate forecasts have been cut between one-half and nine-tenths of previous forecasts, with Sierra Leone’s economy projected to have the highest rate of growth at 3.1 percent followed Guinea at 2.0 percent. IHS foresees only a marginal real economic growth rate of 0.8 percent for Liberia’s economy.

The spread of Ebola is still a concern for Nigeria, the region’s economic and population giant.

“Public awareness and facilities in Lagos are better than in the Sierra Leone-Guinea-Liberia triangle, so the chances are fairly good that Nigeria can restrict its outbreak,” Kalley said.

“Although agriculture has dropped from 35 percent of the Nigerian economy to 22 percent due to the recent data criteria change, prospects for Nigeria’s real economic growth for the rest of 2014 are bright.”

Asian demand drives global rice Table 1: Top global rice exporters (in thousand tonnes) growth in 2014/15; Africa drives 2013/14 2014/15 long-term growth World rice demand for 2014/15 is Thailand 9000 10,041 forecast to rise to 478 million tonnes, India 10,000 8388 a 4.4-million-tonne increase from the Vietnam 6500 6614 previous year. For 2015/16, world rice Pakistan 3900 4055 demand is expected to increase by 4.5 United States 3011 3462 million tonnes, to 483 million tonnes.

“Asian demand, mainly from China,

80 | Milling and Grain

is driving a majority of the growth in rice consumption during 2014/15,” said IHS senior economist Brandon Kliethermes.

“However, Africa’s rice import demand is driving much of the world’s long-term import growth.”

World rice yields in 2014/15 are expected to soften year over year to 2.96 tonnes per hectare, but world production is projected to increase by a little over one million metric tons.

With a lower Indian rice production estimate due to issues relating to a later monsoon, India is forecast to lose its spot as top exporter in 2014/15.

“Thailand is forecast to regain its spot as top exporter,” Kliethermes said. “With the military government in Thailand aggressively trying to find a solution to their large rice inventory, Thai rice exports are expected to increase.”

Longer term, Thailand and India will battle for the top exporter position, with both exporting more than 12 million metric tons per year.

Burundi rice development hub

Burundi has turned its rice research capacity up a notch to improve food security in Eastern and Southern Africa by establishing a regional rice research and development hub with the International Rice Research Institute (IRRI).

In his speech at the official opening of the new ‘Robert S. Zeigler’ building that will house IRRI’s Eastern and Southern Africa Regional Office, First Vice-President of Burundi, His Excellency Bernard Busokoza stated that the government strongly supports further collaboration between IRRI and Burundi to improve the region’s rice production and support the fight against food insecurity.

Poverty reduction

Mr Busokoza said that the Government of Burundi and IRRI share the same vision: to provide sustainable methods of growing rice to improve the well-being of rice producers and consumers, to reduce poverty and preserve the environment.

The regional office focuses on developing and testing new rice varieties matched to the different rice production ecologies across Eastern and Southern Africa.

To support IRRI’s activities, Mr Busokoza also announced that the government had granted IRRI use of a 10ha plot of land at Gihanga for its rice research.

IRRI’s objective in Burundi is to enhance the national capability in research on rice and rice-based systems in the country.

IRRI first started working in Burundi in 2008 when a Memorandum of Understanding (MOU) between the country and IRRI was signed. The beginnings of this agreement were first born when current IRRI Liaison Scientist and Coordinator for Burundi, Joseph Bigirimana, attended the Rice Research to Production Training Course at IRRI in 2006 where he met with IRRI management.

By October 2013, key government, IRRI and Africa Rice officials gathered for the inauguration of the regional, as part of the IRRI Board of Trustees meeting in Bujumbura, Burundi. The new building was named after IRRI’s current director general, Dr Robert S. Zeigler.

Dr Zeigler was recognised for his many years of work in development agriculture as a scientist and research leader in Africa, Latin America, Asia and the United States.

“I’m very optimistic that this regional hub will substantially contribute to the development of the rice sector in Eastern and Southern Africa, and build our collaboration with our partners in Burundi and the greater region,” Dr Zeigler added.

Interim director general of Africa Rice Dr Adama Traoré also attended and highlighted the importance of Asia-Africa knowledge exchange that has been made possible by the CGIAR Research Program on Rice, known as the Global Rice Science Partnership.

IRRI’s deputy director general for research Dr Achim Dobermann highlighted areas where IRRI can contribute to rice research and development with the substantial support of stakeholders.

“It is our vision for Burundi to become a leading regional hub for excellent, high yielding, rice varieties that also have good grain quality,” he said.

IRRI and the Burundian government started collaborating in 2006 through the initiatives of Dr Joseph Bigirimana, who is now the IRRI Regional Coordinator for Eastern and Southern Africa.

The first joint project with CARE Burundi was established in 2010, with support from the Howard Buffett Foundation, to train ex-combatant women in rice production.

In 2011, two IRRI-bred rice varieties, Vuninzara (IR77713) and Gwizumwimbu (IR79511), which were developed especially for Burundi, were released. Farmers rank these varieties higher in grain quality of un-milled, milled, and cooked rice than previously popular varieties. IRRI is also sharing rice breeding lines with Burundi that are being tested at a number of IRRI field sites around the country.

March 2015 | 81

Industry events 2015

n 19-21 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

n 16-18 March

AgraME 2015 Dubai International Convention and Exhibition Centre http://www.agramiddleeast.com

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 19-23 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 05-07 April

Middle East Aquaculture Forum 2015 DWTC, Dubai, UAE http://www.meaf.ae

n 09-11 June

FIAAP, VICTAM & GRAPAS INTERNATIONAL Koelnmesse, Cologne, Germany www.victam.com

n 23-26 April

IDMA 2015 FAIR Istanbul Fair Center – CNR Expo Halls http://www.idma.com.tr/

n 09 June

IGC 2015 Grains Conference Grosvenor House Hotel. London, UK http://www.igc.int/en/conference/confhome.aspx

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 24-26 June

Livestock Philippines 2015 Expo SMX Convention Center Seashell Lane, Mall of Asia Complex 1300 Pasay City, Metro Manila, Philippines www.livestockphilippines.com

Grain, milling and processing professionals to convene in Palm Springs for IAOM 2015

T

he 119th International Association of Operative Millers annual conference and expo will be held between May 4-8, 2015 at Renaissance Palm Springs Hotel and Palm Springs Convention Centre, Palm Springs, California, USA. Grain milling professionals consistently find that the IAOM conference experience affords them an opportunity to enhance and advance their careers through comprehensive education programs, to connect with their industry peers at exciting networking events, and to develop relationships with vendors who offer the products and services they need to efficiently do their job.

The IAOM Annual Conference & Expo is the premier educational event for grain milling and seed processing professionals. The annual event gathers milling and allied trade professionals from around the world for three days of education, networking and fellowship. Educational and technical programs presented at the conference assist millers in improving yields, productivity, customer satisfaction and safety. The programs are presented by seasoned professionals in the field who have experienced the issues affecting millers first-hand.

In addition, the annual conference also includes the world’s largest Expo for milling professionals, typically featuring over 100 companies displaying milling and processing equipment and related services.

82 | Milling and Grain

World Expo Milano 2015

May 1 - October 31, 2015 ‘From wheat to bread across the EU food supply chain’ - The EU Pavilion

“

W

heat is truly the grain that binds Europe together”. Throughout history, every European culture has developed a traditional bread specialty, a unique expression of hearth, home and sustenance. While each country expresses this staple food in a different way, the presence of bread at the centre of the table ties European to one another.

“The ‘Founding Element of European Civilization’ it is also the first source of protein in our diet.”

The ground floor of the EU exhibition space will be dedicated to the visitor experience. It will lead the visitor through a story line covering the EU food supply chain and concentrating on the example of wheat and bread.

The European Flour Millers General Assembly meeting will take place on May 22, 2015 in Milan, Italy.

Food and nutrition as the centre of life for all citizens is the perspective introduced by Expo Milano 2015: having healthful and widespread food from agriculture is first of all a social necessity. Nutrition represents the vital energy of the whole planet, the condition for a sustainable development based on giving proper and consistent nourishment to the body, but also on respecting each human being’s life habits, on healthcare and on technological innovation.

REVIEW 200 professionals in Europe 2015

Summits capture the attention of more than

T

Oilseed Congress and Women in Agribusiness

a food and beverage multinational company. “It was a great experience to see so many women connect and be enthusiastic and passionate about similar concerns as well as eager to actively participate in skills sessions for personal development,” said Joy O´Shaughnessy, director of both events from HighQuest Group.

Keynote speaker Michèle Mees, author of “The Balanced Leader” and co-founder of The Centre for Balanced Leadership, provided tips to increase the balancing of masculine and feminine energies in a company.

Mella Frewan, director general of FoodDrinkEurope, spoke on The Changing Food Consumer: The Role of Agribusiness in Meeting the Demands of Today’s End User.

In response to the positive feedback received from the participants at both events, plans are being made to bring these European events to Barcelona again next year.

For more details about both events, visit www. oilseedcongress.com and www.womeninageurope.com.

28/10/14 09:46 Page 1

he inaugural events of the Oilseed Congress Europe/ MENA and Women in Agribusiness Summit Europe were met with positive response having attracted more than 200 participants in the agribusiness sector, during 9-12 February at the Hotel Arts in Barcelona. The events were organised by HighQuest Group.

More than 150 professionals attended the Oilseed Congress Europe/MENA from 9 to 10 February, where discussions focused on the global overview of the main challenges and trends of the oilseed complex in Europe and the Middle East/North Africa.

One of the key speakers at the Congress, Thomas Mielke, director of Oil World, said “we have probably seen the low for soy in the last few weeks,” while also reporting that in the past 16 years, soybean production almost doubled to 312 Mn T (now 60 percent of all oilseeds).F/V/G(Island):2015 Additionally he said that in 2014 production of biodiesels exceeded expectations and rose 2.3 Mn T to 29.2 Mn T. “While the global oilseed stocks/ usage ration is set to increase further in 2014/15, stocks of oils and fats relative to usage will be declining; meal prices are overvalued, and vegetable oil prices will appreciate,” Mielke reported.

Oilseed Congress attendees were invited to participate in the overview of Oil Markets panel, with the moderator Jorge de Saja, general manager of AFOEX (National Association for the Advancement of companies Oilseed and Extraction), and 9 – 11 JUNE 2015 • COLOGNE EXHIBITION HALLS, COLOGNE, GERMANY José Angel Olivero Garcia, sales director at Lipidos Santiga S.A. Networking opportunities were plentiful for those in attendance from across the agribusiness value chain: importers and exporters, merchandisers and traders, service providers, and primary processors Feed Ingredients Feed Production Machinery Flour Milling Technology and downstream consumption Nutrition Ancillary Equipment Storage & Handling Systems Additives Formulation Quality Control markets in feed, food, biodiesel and industrial applications.

Specialist conferences: For further information please contact: Nearly 80 women participated The FIAAP Conference 2015 Victam International BV Petfood Forum Europe 2015 PO Box 197, 3860 AD Nijkerk, The Netherlands at the co-located Women in The IFF Feed Conference 2015 T: ++31 (0)33 246 4404 Agribusiness Summit Europe, Aquafeed Horizons International 2015 F: ++31 (0)33 246 4706 E: expo@victam.com 10-12 February 2015. “I really Global Milling Conference with Free online visitor registration is available GRAPAS INTERNATIONAL 2015 appreciated the fact that this was from 1st January 2015 at: Biomass & Biomass Pelleting 2015 a solutions-oriented event that www.fiaap.com GMP+ International 2015 also brought up current trends in www.victam.com www.grapas.eu our market. Besides this, have you ever seen an agricultural See us on Twitter, Facebook, LinkedIn and Google+ or scan the QR codes: event with only women? Me, never! I´mmillingand so happy I´m part of it!” sharedgrain.com an executive from

THE WORLD’S LARGEST ANIMAL FEED PRODUCTION & GRAIN PROCESSING EVENT

Please contact your local consultant:

March 2015 | 83

PREVIEW 2015

Award for innovation

A one-day conference for flour, rice and cereal millers Hear keynote speakers address topics of relevance to today’s milling industry.

Covering: Flour and Rice Milling Technology / Storage and Handling Systems / Quality Control Three two-hour sessions: Food Safety /Quality Control Nutrition / Milling Technology Markets / Storage / Handling Visit the GRAPAS International Exhibition at the Cologne Exhibition Halls from June 9-11, 2015 and wrap up your visit by attending the one-day Global Milling with GRAPAS Conference on Thursday, June 11 at the show grounds.

GRAPAS International is a co-located exhibition with Victam International 2015 and FIAAP International 2015.

Organised by Milling and Grain magazine

If you display an innovation on your stand at GRAPAS in Köln, Germany, in June 2015, you can enter the competition through the online Exhibitor's Manual, which contains the application form.

All companies nominated for an award will be highlighted in the Show Guide handed to all visitors. You will also receive an 'Innovation Shield' to display on your stand to indicate your innovation. The award itself will be presented at the Exhibitor Reception at the end of the first day in Köln.

Milling and Grain (and the online Global Miller) will publish details of nominees and winners both before and after the show.

How to apply?

Each exhibiting company has been issued with login details to reach the Exhibitors' Manual on the Victam website. Once logged in simply complete the award application form. Milling and Grain will do the rest.

The application deadline is: April 1, 2015

Previous GRAPAS Award winners and runners up include: • Amandus Kahl • Bühler • CPM Europe • European Machine Trading • Golfetto Sangati • 4B Braime

World Milling Industry counting the days to the big meeting

I

DMA, the biggest meeting platform for the world grain and pulse processing industry, is preparing to gather millers around the world for the sixth time in the Istanbul Expo Center between 23 and 26 April 2015.

Thousands of professional sector representatives and investors from 139 countries are expected to participate in the exhibition where more than 200 brands will exhibit their latest technologies.

More than 200 brands will participate in the exhibition which will be held in 3 halls over a 33 thousand square-meter area.

Having started their preparations intensely for the exhibition, the technology manufacturers and suppliers will present their latest technologies to the taste of the sector in IDMA 2015.

Investors have their eyes on IDMA

Growing almost 100 percent in terms of exhibition area and number of exhibitors compared to 2013, IDMA aims to double the success of the previous exhibition in terms of the number of visitors in 2015 along with its exhibition hall.

From all over the world, brand representatives making investment plans are waiting for the IDMA Fair where they can see all the technologies and different alternatives millingand together.

grain.com

84 | Milling and Grain

Alternative technologies at IDMA

IDMA will gather even more alternatives in a larger area in 2015. Visitors to the exhibition will be able to find a wide range of machinery, products and services for their companies, all under one roof.

Visitors will get a chance to get up close and examine the latest technologies in their own specialist fields.

They will also have the opportunity to meet with the biggest companies in the sector and to compare similar technologies.

GEAPS Exchange 2015 Key Stats 3,215 attendees from 31 countries 354 exhibitors in nearly 200,000 square feet in the Expo 35 hours of educational programming (education sessions, Idea Exchange and Expo pods) presented by approximately 55 speakers Darren Parris, Mark and Martha Cornwell wish to thank everyone who visited the Milling and Grain booth throughout the event. It was great to see our valued customers, old and new.

Fred Norwood having his shoes shined at the Agri Associates booth

Chief Industries - Dan Elwood, Travys Woodside, Brent Whitefoot, Ross Carlson, Ed Benson, Brandon Schade, Thane Meyers

Visit us: booth 5.2 C063

Lab-Compounder KETSE 20/40 Revolution in product development - saving time and money Simulate your production more efficiently Develop your products more effectively ■ Efficient optimisation and new development of recipes ■ Product manufacturing on a laboratory scale ■ Quicker change of experimental conditions ■ Ensuring a constantly high product quality ■ Reduction of development costs ■ Minimisation of production waste ■ Simple and easy cleaning ■ No disposal costs for rejects Brabender® technology optimises the quality of your raw materials and ensures your success.

Brabender® GmbH & Co. KG · www.brabender.com

86 | Milling and Grain

AZ_Lab_Compounder_E_190x132.indd 1

10.03.2015 13:02:26

Sukup Manufacturing Co – Kerry Hartwig, John Hanig, Bob Dieckmann, Charles Sukup, Randy Marks

GSI – Front Row, left to right – Marguerite Johnson, Melissa Miller, Carrie Ward, Lena Swearingen, Mike Johnson, Steve Tomlinson, Ray Vrtiska, Craig Jones Back Row left to right – Matt Heckel, Jeff Schwab, Randy Stauffer, Bob Petruzzi and Ted Sondgeroth

Sioux Steel Company - Mitch Golleher Executive VP of SIOUX STEEL far right LARRY STUBBE on the left, Mark Cornwell of Milling and Grain in the middle

Rolfes: From left to right, Wayne Sanders, Dennis Maze, Kevin Miles, Ryan Moorman, Greg Abbott, Mark Coventry, and Chris McMillan

Fieramilano, Milan - Italy 19 - 23 May 2015

Opening time: 10.00 am - 5.00 pm Entrances: East, South, West Gates Pre-register on www.ipack-ima.com

Being part of innovation.

The future is IPACK-IMA 2015 – the most comprehensive, valuable showcase for the food and non-food supply chain. The global standard-setting exhibition for the Grain Based Food industry and the place to be for health & personal care, chemicals and industrial goods. An innovative meeting place for the fresh food and distribution sector.

A great exhibition of the world’s top production.

Co-located with:

Connected events:

An unparalleled, integrated, synergic collection of technology and innovations for processing, packaging, converting and logistics, the extraordinary conjunction with the Expo 2015, a great not-to-miss event.

Be sure to be there.

POWERED BY FIERA MILANO AND IPACK-IMA

Promoted by:

With the support of: This event is being covered by professional packaging journalists from IPPO

Organized by:

UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION

Ipack-Ima spa - Corso Sempione, 4 - 20154 Milano - Italy tel +39 023191091 - fax +39 0233619826 - e-mail: ipackima@ipackima.it - www.ipackima.it

March 2015 | 87

REVIEW

ESSMUELLER - (3rd) row and from left to right: Mike Resner, Matthew McLean, Jamison Anding.

Middle Row, also left to right: Bill McLean, Harold Mauck, Jeff Aplin, Glen Jarmey.

Front Row, again left to right:Bev Resner, Pat McLean, Jan Mauck, and Kelly Aplin

Westeel - Cory Tymchuk, James Weeda, Bruce Allen, Denis Tetrault, Dusty Oliver and John Messner

The team at Brock, Terry Nielengarten, Tim Shreckengost, Daniel Chanley, Mark Myers, Tom Brown, Bill Winchell, Tyler Ginder, Larry Agler, Deb Good, Roger Fredrick, Rich Geiser

Brandon Fultz – Sweet manufacturing

VIV Asia 2015 March 11-13, 2015 | BITEC, Bangkok Thailand Special Events

REGISTER NOW for FREE entrance and high quality conferences at www.viv.net

The world’s most promising meeting point to boost your business from Feed to Meat.

VNU14-0231 ads VIV Asia 01-2015 192x132mm.indd 1

88 | Milling and Grain

02-02-15 11:48

REVIEW Maxi-lift - Wade Spencer (Outside Sales of Maxi-Lift, Inc.), Angela Richardson (Inside Sales Manager/Marketing Manager of Maxi-Lift, Inc.), Bo Fisher (Vice-President Domestic Sales of Maxi-Lift, Inc.), Brandon Grubbs (International and Domestic Sales Account Manager of Maxi-Lift, Inc.)

The team at Behlen Grain Storage Systems

Seedburo - Sean Morgan is on the left and Grant Ratcliff is on the right

Martha and Mark Cornwell with Johannes and Susanna Karcher of Frigortec

connecting great ideas & great people Working to improve the sustainability of compound feed production

www.globalgap.org/cfm Connect with fellow millers and industry power players for two days of education, inspiration and conversation.

Presentation topics include: • Gluten-free or Gluten Free-for-All • An Arbitrator’s 7 Tests for the Workplace • Revival of the Grist Mill

GLOBALG.A.P. COmPOund Feed mAnuFACturinG StAndArd

• Ag Safety and Rescue Initiative • Assessing Dust Explosion Hazards • The Steel Cut Process – A Crucial Step in Oat Milling • Carbon Fiber Reinforcement in the Milling Industry

Safe Feed - Safe Food

• Preserving Roll Integrity • Wheat Traceability

www.iaom.info/annualmeeting

Check out our website for events happening near you! www.globalgap.org/events March 2015 | 89

Kepler Webber – João Tadeu Franco Vino and Bruno Santos

REVIEW

Maxi lift - Brandon Grubbs (International and Domestic Sales Account Manager of Maxi-Lift, Inc.), Angela Richardson (Inside Sales Manager/Marketing Manager of Maxi-Lift, Inc.), Jake Everdeen (Premier Components), Paul Phillips (President of Maxi-Lift, Inc.)

26-28 NOVEMBER 2015 MYANMAR EVENT PARK, YANGON

Brandon and Mandy Norwood (The Norwoods)

Lambton - Brent Johnston, Sandra Dixon, Christian Jordan with customers on the Lambton stand

15

MYANMAR’S NO. 1 INTERNATIONAL FEED, LIVESTOCK AND AGRICULTURE INDUSTRY EVENT 26-28 NOVEMBER 2015 MYANMAR EVENT PARK,YANGON To Book Your Booth at the Expo, Contact: Mr. Darren +95 9798435634 or darren@ambexpo.com To Visit the expo or get more information, contact Ms. May at may@ambexpo.com or Ms. Thu Thu at thu@ambexpo.com

darren@ambexpo.com

90 | Milling and Grain

REVIEW The team at Schenk process

Mole-Master – Michael Bailey

Bühler - David Chow, customer service manager, Karl Ledergerber, sales account manager – grain logistics, Marco Gallo, director of automation, Al Fischer, CSI department manager, Samantha Kukowski, marketing generalist, Mark Larson, director of sales – brewing, malting & grain logistics, Don Uglow, sales account manager

Mark Cornwall from Milling and Grain talking to colleagues on the show floor

perendale IDL 15 1-2 hal cetak.pdf

1

2/23/15

5:11 PM

C

M

Y

CM

MY

CY

CMY

K

March 2015 | 91

REVIEW

The team from 4B Braime

Mike Mossage from BinMaster Level Controls

Lots of copies of Milling and Grain magazine where handed out and enjoyed at the show

The team at the Cimbria stand

VIV Russia 2015 May 18, 2015 SUMMIT | May 19 - 21, 2015 EXPO | Moscow, Russia

REGISTER NOW for FREE entrance at www.viv.net

Special Events

The international Feed-to-Meat platform for Russia and the surrounding CIS region

92 | Milling and Grain

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

Colour sorters

Andritz +45 72 160300

B端hler AG

www.andritz.com

+41 71 955 11 11

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.buhlergroup.com

Insta-Pro International +1 515 254 1260

Satake

www.insta-pro.com

+81 82 420 8560 www.satake-group.com

Wenger Manufacturing +1 785-284-2133

Computer software Adifo NV +32 50 303 211

Analysis

www.wenger.com

Feed processing

www.adifo.com

Mechanika Nawrocki

R-Biopharm

Cultura Technologies Ltd

+48 52 303 40 20

+44 141 945 2924

+44 1257 231011

www.granulatory.com/en

www.r-biopharm.com

www.culturatech.com

Romer Labs

Format International Ltd

Ottevanger

+43 2272 6153310

+44 1483 726081

+31 79 593 22 21

www.romerlabs.com

www.formatinternational.com

www.ottevanger.com

Amino acids

Coolers & driers

Wynveen

Evonik

Consergra s.l

+31 26 47 90 699

+49 618 1596785

+34 938 772207

www.wynveen.com

www.evonik.com

www.consergra.com

Bag closing

FrigorTec GmbH

Fischbein SA

+49 7520 91482-0

+32 2 555 11 70

www.frigortec.com

www.fischbein.com/eastern

Geelen Counterflow +31 475 592315

Bag design

Flour Rank Hovis +44 1494 428000 www.rankhovis.com

Grain handling systems

www.geelencounterflow.com

Cargotec Sweden Bulk Handling

+33 5 53 02 85 00

Famsun (Muyang)

AB

www.cetec.net

+86 514 87848880

+46 42 85802

www.muyang.com

www.cargotec.com

Cetec Industrie

Bakery improvers M端hlenchemie GmbH & Co KG

Elevator buckets

+49 4102 202 001

Alapala

www.muehlenchemie.de

+90 212 465 60 40

Bin dischargers

www.alapala.com STIF

Denis

+33 2 41 72 16 80

+33 2 37 97 66 11

www.stifnet.com

www.denis.fr

Bentall Rowlands +44 1724 282828

B端hler AG +41 71 955 11 11 www.buhlergroup.com Dinnissen BV +31 77 467 3555

www.vav.nl

Elevator & Conveyor Components 4B Braime

Croston Engineering

+44 113 246 1800

+44 1829 741119

Silo Construction Engineers

Hammermills

www.tapcoinc.com +31 71 4023701

Chief Industries UK Ltd

www.croston-engineering.co.uk

www.cimbria.com

+1 314 739 9191 VAV

www.bentallrowlands.com

www.chief.co.uk

+45 96 17 90 00

Tapco Inc

Bulk storage

+44 1621 868944

Cimbria A/S

www.go4b.com

Enzymes

+32 51723128 www.sce.be

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

Silos Cordoba

www.dinnissen.nl

Zheng Chang

+34 957 325 165

JEFO

+86 21 64188282

www.siloscordoba.com

+1 450 799 2000

www.zhengchang.com

TSC Silos +31 543 473979

www.jefo.com

Equipment for sale

www.tsc-silos.com Westeel +1 204 233 7133 www.westeel.com

Certification GMP+ International +31703074120 www.gmpplus.org

94 | Milling and Grain

Laboratory equipment Bastak

ExtruTech Inc

+90 312 395 67 87

+1 785 284 2153

www.bastak.com.tr

www.extru-techinc.com

Brabender +49 203 7788 0

Extruders

www.brabender.com Almex +31 575 572666 www.almex.nl

CHOPIN Technologies +33 14 1475045 www.chopin.fr

Doescher & Doescher GmbH

Palletisers

Silos

+49 4087976770

Cetec Industrie

www.doescher.com

Kepler Weber Group

+33 5 53 02 85 00

+55 11 4873-0300

Hydronix

www.cetec.net

www.kepler.com.br

+44 1483 468900

Ehcolo A/S

www.hydronix.com

+45 75 398411

Obial +90 382 2662120

www.ehcolo.com

Level measurement

www.obial.com.tr

PAYPER, S.A.

BinMaster Level Controls

+34 973 21 60 40

MYSILO

+1 402 434 9102

www.payper.com

+90 382 266 2245

www.binmaster.com

www.mysilo.com

Pelleting aids

FineTek Co., Ltd

Borregaard LignoTech

Symaga

+886 2226 96789

+47 69 11 80 00

+34 91 726 43 04

www.fine-tek.com

www.lignotechfeed.com

www.symaga.com

Loading/un-loading equipment

Pest control

Tornum AB

Neuero Industrietechnik

Rentokil Pest Control

+46 512 29100

+49 5422 95030

+44 0800 917 1987

www.tornum.com

www.neuero.de

www.rentokil.co.uk

Vigan Engineering

Pipe systems

+32 67 89 50 41 www.vigan.com

Mill design & installation Bühler AG +41 71 955 11 11 www.buhlergroup.com

Temperature monitoring Agromatic

Jacob Sohne

+41 55 2562100

+49 571 9580

www.agromatic.com

www.jacob-pipesystems.eu

Dol Sensors

Used around

all industrial Process control sectors.

+45 721 755 55 www.dol-sensors.com

Mechanika Nawrocki

Fr. Jacob Söhne GmbH & Co. KG, Germany Tel. + 49 (0) 571 95580 | www. jacob-pipesystems.eu

Visit us! www.pipe-systems.eu+48

52 303 40 20

Training

www.granulatory.com/en

Golfetto Sangati

Bühler AG

+39 0422 476 700

Suffolk Automation

+41 71 955 11 11

www.golfettosangati.com

+44 1473 829188

www.buhlergroup.com

www.suffolk-automation.co.uk

Gazel Degirmen Makinalari +90 364 2549630 www.gazelmakina.com

IAOM

Rolls

+1 913 338 3377 Leonhard Breitenbach

www.iaom.info

IMAS - Milleral

+49 271 3758 0

Kansas State University

+90 332 2390141

www.breitenbach.de

+1 785 532 6161

O&J Højtryk

www.grains.k-state.edu

Mechanika Nawrocki

+45 7514 2255

nabim

+48 52 303 40 20

www.oj-hojtryk.dk

+44 2074 932521

www.milleral.com

www.granulatory.com/en

www.nabim.org.uk

Roller mills

Satake

Unormak

Ocrim

+81 82 420 8560

+90 332 2391016

+39 0372 4011

www.satake-group.com

www.unormak.com.tr

www.ocrim.com

Ugur Makina

NIR systems

+90 (364) 235 00 26

NIR Online +49 6227 732668 www.nir-online.de

www.ugurmakina.com

Roll fluting

Thermo Fisher Scientific +1 9786 421132

+34 965564075

www.thermoscientific.com/

www.balaguer-rolls.com

Safety equipment

Packaging

Rembe CB Packaging

+49 2961 740 50

+44 7805 092067

www.rembe.com

www.cbpackaging.com Cetec Industrie

Second hand equipment Sanderson Weatherall

+33 5 53 02 85 00

+44 161 259 7054

www.cetec.net Mondi Group +43 1 79013 4917 www.mondigroup.com Peter Marsh Group +44 151 9221971 www.petermarsh.co.uk

+1 785 825 7177 vortex@vortexvalves.com www.vortexvalves.com

Fundiciones Balaguer, S.A.

quality

Valves

www.sw.co.uk

Rota Val Ltd +44 1249 651138 www.rotaval.co.uk

Vibratory equipment Mogensen

Raw

Materials

Handling +44 1476 566301 www.mogensen.co.uk Vibrafloor +33 3 85 44 06 78 www.vibrafloor.com

Weighing equipment

Sifters Filip GmbH

Parkerfarm Weighing Systems

+49 5241 29330

+44 1246 456729

www.filip-gmbh.com

www.parkerfarm.com

Genc Degirmen +90 332 444 0894 www.gencdegirmen.com.tr

Yeast products Leiber GmbH +49 5461 93030 www.leibergmbh.de

the interview

Yoshimasa Tomoyasu, Executive Officer and General Manager of Asia Business Division Satake

Yoshimasa Tomoyasu originates from Hiroshima. Having joined Satake as an engineer, he was engaged on a series of projects supplying flour mills. Rising to the position of Manager of the Flour Milling Division, in 2007 he was appointed General Manager of the Asia Business Division. He is now an Executive Officer of Satake Corporation, and concurrently President of Satake Australia Pty, Ltd.

Where do Satake focus their sales and marketing?

If you imagine the global rice market like a pyramid which is split into three levels, traditionally Satakeâ&#x20AC;&#x2122;s market structure has focused on the top level of the pyramid, this is a smaller number of companies, this often represents the wealthier countries where they can afford to purchase the highest quality milling machinery to produce the highest quality rice for both their home market and for export. So here at Satake we have only been able to work for the customers at the top of the pyramid with people who can invest in our technology.

As we now have very high percentages of this business we are very happy and we are now looking at the middle part of the pyramid, which if you can imagine that the top represents 500 customers, the middle can be 100 times this, so potentially 50,000 customers.

It is for this reason we have heavily invested in R&D as there is a requirement for both economical and social quality of the machines and of course the rice. When we talk about technology and innovation we always have to consider the stage of demand. First they must satisfy the hunger, then the next stage is they look at the appearance, and the third stage is taste and the fourth stage is safety and peace of mind. The next stage in Japan is health which contributes to the persons sense of wellbeing.

If we now look at the middle of pyramid we see customers who donâ&#x20AC;&#x2122;t necessarily focus on taste but they are looking at appearance. Therefore they may only need the machine for the appearance of rice. After doing more R&D we are looking to expand into areas of Africa like Nigeria, Uganda and Ghana, this we are doing now. And needless to say there is also some top of pyramid customers in these countries.

So, where would a country like Myanmar appear on your pyramid?

This is a good question, because many years ago Myanmar was a huge exporter of rice and, as you may know they have had a number of quiet decades. So many years ago we supplied the government in Myanmar with twenty sets of rice mills. Then 6 or 7 years ago when democracy came to Myanmar, all the mills that were owned by the government were sold off to private companies. Many of these companies would see that everything was made by Satake and would ask, who are Satake?

We were contacted once more and now they are investing in more modern machinery and they are again exporting which allows them to pay for improved technology.

So what about markets like India for Satake?

India is one of the big markets for Satake. We are working with the top of the pyramid companies here who export to some countries, so they can afford to invest in new machinery for high quality rice for export. We at Satake enjoy the business in India but to expand our business in India we need to enter the middle countryside of India. Therefore our office in India is its own independent business with many sub branches geographically located around India. So now we are ready to really penetrate the whole market. Our factory in Thailand supplies many of the machines here.

96 | Milling and Grain

Is part of Satake strategy to produce cheaper machinery in your factories such as Thailand and China?

Well, to answer first, our policy when we build and invest in a country abroad is to build the same quality machinery for that local market. If there is surplus and we can afford to do something outside of the country we will do that.

After we comply with the requirements in the country, the factory is located, and as the labor costs in these countries is lower than in Japan we can produce the machinery more cost effectively. If we work for the middle part of the pyramid in India, even these machines are not right for them on price as we can not compete with competitors who follow Satake.

However having said this, our advantage apart from our high quality is the after sales service and training.

Why would I buy a Satake optical colour sorting machine rather than buying one from one of your competitors, what are your USPs?

Now we have a very interesting story, we now have clients that have purchased colour-sorting machines from other companies. In the beginning our customers could not tell the difference between a Satake machine and that of a competitor. After 6 months it was completely different. The technology deteriorates and they cannot give good after sales service. Many imitator companies never touch the machine after the sale. So, many companies, having used these inferior services, are now returning back to Satake.

So your question is very difficult, if a customer is looking towards inferior and cheaper options then we sell on performance and after sales service.

That makes sense when selling against cheap options, what about if you are selling against another quality brand?

Customers at this level are looking for quality performance and precision. We are confident that our machines can be adjusted to sort the tiniest defect. So we are confident of our superior flexibility to adapt to a customerâ&#x20AC;&#x2122;s individual requirements.

Why is the small rice milling unit so popular in Japan?

To answer this I must explain a little about the rice culture in Japan, rice is treated very much like fresh fruit or vegetables.

Whenever we buy rice in Japan we look at the date and time it was milled and in a shop we choose the most recent or the freshest. There are many rice millers that will start milling at midnight to produce fresh rice. This is why the small ricemilling unit is so popular.

What makes the PeriTec system so special and what is its closest competition and have there been any new developments?

The PeriTec produces very high quality flour, by this we mean very white. There are significantly fewer specks in the flour and because of the way it works the grain, it leaves a much higher level of minerals in the flour. As many millers still test the ash content of flour to designate its quality, the PeriTec system may not be suitable as the high level of minerals produce more ash.

â&#x20AC;&#x153;I must explain a little about the rice culture in Japan, rice is treated very much like fresh fruit or vegetables.

Whenever we buy rice in Japan we look at the date and time it was milled and in a shop we choose the most recent or the freshestâ&#x20AC;?

PEOPLE THE INDUSTRY FACES 4B Braime appoints David Wolstencroft as operations director at 4B Chains

David Wolstencroft

4

B Braime Elevator Components, a worldwide manufacturer of material handling and electronic components for bucket elevators and conveyors, has promoted David Wolstencroft to the position of “ Operations Director – 4B Chains”, within 4B Braime UK.

“This appointment recognises both the huge contribution that David has made to the rapid growth of our Chain business and the role we need him to play in continuing its future growth”, said Nicholas Braime, Chairman of the 4B Braime Group.

David first joined the company over 20 years ago as a young graduate engineer working under the guidance of Jim Mawson, before moving to the USA to work for 4B USA as Technical Sales Manager of the Material Handling Components.

On his return to the UK, David took control of the Group`s Chain Division, managing the supply of Chain to all 4B’s subsidiaries, helping them with the Technical Support for chain customers, and assisting them to significantly grow the Sales of Chain across the Group. At the same time, David has continued to greatly improve the operating efficiency of the UK Chain business.

l’Anson Brothers Ltd appoints technical sales manager

I Philip Stockill

’Anson Brothers Ltd, one of the UK’s leading, independent, family-owned farm feeds businesses has appointed a technical sales manager to support the company’s continuing growth. Philip Stockill brings over 30 years’ experience to the role and is based at the company’s plant at Masham, North Yorkshire. Formerly an I’Anson customer in his previous role at Primary Diets, Philip has also held various nutritional posts at agricultural feed businesses including Four-F Nutrition, Harbro and SCA Nutec.

Philip’s main priority is to drive I’Anson Brothers’ sales in the UK market, where he will be responsible for supporting the sales team and merchant customers, as well as leading on new product development.

Now into its second century of business, I’Anson Brothers is one of the UK’s leading manufacturers of animal feedstuffs and has been serving farmers in Yorkshire and the North of England since 1900 when it was founded in Masham. It is highly regarded for its high quality product range and commitment to outstanding customer service.

Philip said: “I’m delighted to be joining the team at I’Anson Brothers and to have been given the opportunity to play my part in helping the business develop further. I’Anson Brothers is a business built on strong values and I’m really looking forward to strengthening the relationships it already has with customers as well as developing new ones.”

Commenting on the appointment, I’Anson Brothers Chairman and Managing Director Chris I’Anson, said:

“Philip brings a wealth of experience and a deep understanding of the nutritional requirements of livestock to this role which forms an important part of our continuing growth plans. I also know that he shares our commitment to producing high quality products and delivering excellent customer service.”

I’Anson Brothers is one of the UK’s most successful specialist suppliers of farm feeds for sheep, dairy and beef cattle as well as micronized ingredients.

In 2008, the firm was awarded a Queen’s Award for Enterprise in the Innovation category in recognition of its development of the revolutionary quick-soaking sugar beet feed Speedi-Beet, which has become a market leader in the demanding equine feed sector. Speedi-Beet is now exported to 26 countries, including Australia, the Middle East, Europe, the USA and Canada.

Mondi’s consumer goods packaging business has appointed Thomas Gröner as its new head of innovation

M

ondi’s consumer packaging business has a strong focus on product development and innovation, and continuously invests in developing value-added solutions. In close cooperation with strategic partners, customers, suppliers and research institutes, Mondi anticipates new technologies and offers cutting-edge products. Thomas Gröner has joined Thomas Gröner Mondi’s consumer goods packaging business as Head of Innovation, working closely together with the sales and the Consumer Packaging R&D Centre, to develop value-added packaging solutions for our diverse customer requirements.

“We have got to be at the leading edge of product development to ensure our customers’ future success,” says Thomas Gröner, describing one of the strategic priorities of Mondi’s businesses. Cross-functional teams with dedicated experts and clear responsibilities are the basis for innovative project management and key to successful product development.

Thomas Gröner has more than 20 years of experience, including working as Packaging Manager Europe at Nestlé Purina PetCare and leading packaging development teams across Europe with a track record of successful projects. Coming from one of the major global FMCG companies, Thomas will support the consumer goods packaging innovation team to understand and fulfil the needs of customers and consumers even better.

98 | Milling and Grain

Strong partner in Grain Management.

One of the big challenges of our age is to supply all the people worldwide with food. Every year, millions of tons of grain are collected, stored, and handled around the globe â&#x20AC;&#x201C; and the upward trend is unbroken. Only the most up-to-date plant and equipment can guarantee rapidity and quality while minimizing raw material losses. In order to meet the increasingly stringent challenges, BĂźhler Grain Logistics provides with its capabilities the best possible solution â&#x20AC;&#x201C; for conveying, cleaing, drying, storing, dedusting or loading and unloading the most important commodity on earth.www.buhlergroup.com

Innovations for a better world.