Aug 2015 - Milling and Grain magazine

August 2015

YOUR GLOBAL PARTNER

In this issue:

Feedmill of the future • Stabilising rice bran through high shear extrusion • Why India’s agri-food policies need a holistic review • Mycotoxins and mycotoxicosis in livestock production • Preventing bread waste millingandgrain.com perendale.com

Volume 126

Issue 8

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COVER PICTURE: It was a privilege for Milling and Grain to be invited to Sweden immediately after Victam in Germany to visit what must be the most advanced feedmill in operation today - Kalmar Lantmän. In recognition of the achievement this represents in terms of technology advances, efficiency or production and minimal environmental impact, we have devoted over 10 editorial pages to its review.

In short we are proud to make Kalmar Lantmän our cover feature. - Roger Gilbert, The Publisher

VOLUME 126

ISSUE 8 AUGUST 2015

Perendale Publishers Ltd 7 St George’s Terrace St James’ Square, Cheltenham, Glos, GL50 3PT, United Kingdom Publisher Roger Gilbert Tel: +44 1242 267700 rogerg@perendale.co.uk International Marketing Team Darren Parris Tel: +44 1242 267707 darrenp@perendale.co.uk Tom Blacker Tel: +44 1242 267700 tomb@perendale.co.uk Mark Cornwell Tel: +1 913 6422992 markc@perendale.com Latin America Marketing Team Iván Marquetti Tel: +54 2352 427376 ivanm@perendale.co.uk India Marketing Team Ritu Kala rituk@perendale.co.uk Nigeria Marketing Team Nathan Nwosu nathann@perendale.co.uk

52 Feedmill of the future

Editorial Team Olivia Holden Tel: +44 1242 267707 oliviah@perendale.co.uk

Our special feature on the feedmill of the future - the Kalmar Lantmän feedmill in Kalmar, Sweden

Peter Parker peterp@perendale.co.uk Malachi Stone malachis@perendale.co.uk

REGIONAL FOCUS

International Editor Professor Dr M Hikmet Boyacıog ˘ lu Tel: +44 1242 267707 hikmetb@perendale.co.uk

NEWS

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 ©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

Europe

4 6-24

PRODUCT FOCUS

28

CASE STUDY

74

FEATURES 30 Stabilising rice bran through high shear extrusion

38 Mycotoxins and mycotoxicosis in livestock production

34 Why India’s agri-food policies need a holistic review

FACES

44 Preventing bread waste 48 Pioneering UK wheat trials

94 People news from the global milling industry

EVENTS

82 Event listings, reviews and previews

52 Feedmill of the future Special feature STORAGE

66 Are ATEX powder storage silos disasters waiting to happen?

TRAINING

27 IGP institute feed manufacturing course

COLUMNS

8 Mildred Cookson 14 Tom Blacker 16 Christophe Pelletier 20 Chris Jackson 22 Els van der Boon

2 GUEST EDITOR Graham Hartwell

76 MARKETS John Buckley

92 INTERVIEW Görkem Alapala

Guest

Editor

Innovation and Stewardship Economy, society and ecology are key pillars of sustainability with the role of Innovation and Stewardship critical elements for stakeholders in the food value chain to ensure supplies of food and raw materials for the coming seasons.

Communication of innovation and the communication of stewardship are critical areas in the knowledge transfer process and are visible at the height of the technical ‘shows and demonstrations’ season.

In the UK the past month or so farmers have been aware of these processes as they watched their own cereal crops mature as ear emergence and grain-fill began.

At the same time wheat variety selection for 2016, the choice of current and future agronomy techniques, crop protection product choice and performance are all reviewed. This seasonality also needs to be balanced with changes in world markets and consequent market values, shifts in government policy and changes in biodiversity.

As the requirement for biodiversity areas increases, a balanced understanding of how to manage sustainability processes becomes paramount for all those involved in the food value chain.

Within BASF Plc, our strategy is based on a strong technical message, based on good science that delivers such technical messages and development concepts to a wide range of audiences throughout the food value chain and also to those who influence the agricultural industry from grass roots to Government levels.

In a world that appears to gain its knowledge from online searches and uses web-based information to influence decisions, it is

particularly rewarding to be able to encourage guests onto a farm to see, hear and touch agriculture first hand, and to allow them to ask questions regarding how agriculture works.

BASF is fortunate to collaborate with two family-owned private farms in the UK in the delivery of technical and biodiversity messages through a whole farm approach.

Profitable crops are key but are grown alongside well-managed biodiversity areas. A best practice stewardship ethos for applications of fertilisers and pesticides is part and parcel of the farm management so that precious resources of soil, water and wildlife are protected. Often simple changes to farm practice make this possible without detriment to the balance sheet and deliver a more sustainable farm management process - certainly with great levels of biodiversity and improved farm wildlife.

The two UK farms are part of a coordinated pan-European Sustainability Farm Network that runs to some 15 privately owned farms in six countries all designed to demonstrate sustainability principles through first hand experiences.

Developed with independent third-party experts to deliver practical solutions and to monitor the farms, we can share a balanced view of innovation and sustainability for the food value chain.

Significant positive changes in the Farmland Bird Index are noted on both farms by managing field margins and biodiversity areas to improve habitat value for birds, bees and butterflies.

Delivery of well-managed biodiversity alongside great agricultural crops uses farm management skills to bring the best of both worlds onto the farms.

I hope that you enjoy this month’s edition of Milling and Grain.

Graham Hartwell Environmental Stewardship Manager UK & Ireland BASF plc

Meet the Milling and Grain team The team are travelling across the globe to industry events.

16-21August - 17th Annual Practical Short Course on “Food Extrusion: Cereals, Protein & Other Ingredients

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REGIONAL FOCUS

EUROPE

SPECIAL FEATURE

Feedmill of the future How we feed the world’s ever growing population is the big question for the milling industry. Milling and Grain magazine goes in search of answers, on a behind the scenes tour of the Van Aarsen-built, Kalmar Lantmän project - the most modern feedmill in the world - to find out how the technology in this new mill sets a standard for the future.

See the full story on page 53

INDUSTRY PROFILE

European feed statistics This month we look at European statistics – both feed and specifically ruminants. We are using two sources of statistics; our regular contributor Alltech and FEFAC, the European Feed Manufacturer’s Federation.

Europe produced 224.6 million tonnes of compound feeds in 2013, the latest year for compiled statistics from the Federation.

See the full story on page 25

SWEDEN STATS 1 865 000 - the total amount of compound feed produced overall in 2014 (tonnes)

FEATURE

EVENTS

841 000 - the total amount of compound feed produced in 2014 for Cattle in Sweden (tonnes) 572 000 - the total amount of compound feed produced in 2014 for poultry in Sweden (tonnes) 1 436 000 - total livestock population of cattle in Sweden in 2014 1 469 000 - total livestock population of pigs in Sweden in 2014 45% - the total amount of compound feed produced for cattle in 2014 (Source: FEFAC)

Mycotoxins and mycotoxicosis in livestock production Cereal and cereal by-products, corn grains and corn silage are thought to be the most exposed ingredients to mold and mycotoxin contamination.

See the full story on page 38

Trends in ingredients at IBA People are increasingly complaining about food intolerances and allergies. In addition to that which is necessary, personal desire to avoid certain products e.g. animal products is also playing an increasingly big role.

See the full story on page 84

News

AUG 15

Milling

India’s pulses sector: trends, challenges and opportunities India is the largest producer, consumer and importer of pulses in the world. This is due to India’s enormously diverse culinary traditions that use many pulses and minor millets, says Raghavan Sampathkumar who comments on agribusiness from a political, socio-economic and cultural perspectives on the country’s food value chain.

He will be contributing to our ‘Commodities’ section in MAG from time-to-time.

However, India imports nearly three-to-four million tonnes of pulses annually, he says.

This is motivation “for India’s pulse and oilseed production to become self-reliant, with some aiming for this to be achieved by 2022.”

Based on current average yields, India would need nearly seven-to-eight million additional hectares of land to meet the gap in demand without imports. In order for India’s pulses sector to become self-reliant many obstacles have to be considered says Mr Sampathkumar, including: Indian agricultural and price policies: In India, generally, food means only two crops – rice and wheat. ‘Politics’ are always winning over ‘economics’, which is evident from entrenched policies such as MSP (Minimum Support Prices) and procurement systems that seem to favor only these two crops.

Issues around domestic marketing: There are no reliable marketing opportunities for farmers to sell their crop, so why grow something that you cannot sell? Archaic laws such as APMC (Agricultural Produce Marketing Committee) regulations prevent farmers from entering into direct supply contracts with a processor or retailer. The safest crops to grow would be rice or wheat, which have minimum support prices that are increased annually and have established procurement systems.

Limited crucial statistical data within the sector: There is a lack of reliable data on production, acreage and/or consumption. Estimates tend to vary greatly from different sources, not only for pulses but for all crops. It is obvious what will happen when policies are made without reliable data on these parameters.

What is clear is that if India is to achieve a self-reliant pulse and oilseed sector, it will require a holistic understanding of the food value chain and the agrarian situation in the country, a review of current ag-food policies and increased investment in Research and Development and infrastructure for storage, food processing and marketing, he says.

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.

An expanding Filipino milling industry sends a trade team to the US http://bit.ly/1DpFJuQ IAOM Annual Conference news: call for proposals http://bit.ly/1SNuFyv New FIAAP/VICTAM/ GRAPAS event to be organised in 2017 http://bit.ly/1KQmBZo Lallemand Animal Nutrition confirms its silage expert position at the XVII International Silage Conference in Brazil http://bit.ly/1K3JrXX

GF

MT

gfmt.blogspot.com

From Quern to Computer Milling Journals of the past at the Mills Archive

by Mildred Cookson, The Mills Archive, UK

I

am delighted to announce that here at the Mills Archive, we have been successful in gaining a grant from the UK’s Heritage Lottery Fund (HLF) for an exciting project that is about to get under way. Extending until 2018, we will use the £68,200 grant to preserve records of the history of flour milling, from its ancient origins up to the present day, and to tell this story to you and to people around the world.

Participatory elements in the project, “From Quern to Computer”, mean that individuals and milling firms will have plenty of opportunities to get involved, not only in learning about the story (even the most knowledgeable mill enthusiast may be surprised at what they discover) but also in actively shaping the story for future generations and ensuring that key moments in history are recorded and not forgotten.

8 | Milling and Grain

Connecting modern milling developments with what has come before

Humans have used milling methods over thousands of years to make bread and other food products, at first for survival and over time for enjoyment such as biscuits and cakes. While the methods may have changed, it is important to see all the events and developments as part of an evolving story about flour milling, and how this story is relevant to everyone.

We will capture the story of flour milling from 6000 BC Foundry drawing of waterwheel detail, 1895

The world’s first roller flour mill archive

For milling firms, the project provides the timely opportunity to ensure that their history is recorded for posterity. We invite suggestions of content to include in the story. We are interested not only in suggestions but the raw material as well.

As we are building the first specialist archive for roller flour mills and milling, we welcome the donation of original historical images and documents, so that we can provide a safe home for such items and in time make them available to the public. With over two million historical records of traditional mills and milling, we have acknowledged the need to preserve the story of the advances in milling technology over the last 150 years. This expansion of our original remit, means the Mills Archive Trust will now incorporate the world’s first roller flour mill archive, allowing firms and milling families from around the world to ensure their history is respected and preserved for future generations.

The records of the different elements of flour milling – particularly more recent roller flour mill records are at

risk of being lost forever. In some cases this is due in part to a lack of understanding of their historical importance, but more often than not it is because until now there has not been a suitable place to deposit such material. To truly understand the different flour milling “eras” one needs to have an awareness of what has come before and what has since developed.

Horizontal windmill, Islam Qala, Herat, Afghanistan, 1973

Post mill Diderot Encyclopedia, 1763

Great Barton Post Mill Suffolk, 1910

Milling News and hand-operated quern stones right up until the present day. The story will therefore capture traditional windmills and watermills as well as large roller mill plants such as those whom this magazine reaches. Related industries such as the firms that furnish these plants with roller mill machinery will also have an opportunity to feature in the story.

Bennett and Elton, attempted to tell the complete story in their seminal 4-volume History of Corn Milling written at the end of the 19th century. However, since then there has been nothing of the same scope and scale. Their books also reach only a limited audience. Things have moved on over the last century, not only in terms of flour milling technology but also the methods by which we can tell the story and make it available to the public.

Modern website technology will allow this project to record and display a detailed interactive timeline covering eight millennia and enable the public and those with involvement or interest in the milling industry to participate in its telling.

Primitive milling as an advertisement, 1908

“More than Pleased”, 1908

Opportunities online

Our website at millsarchive.org has a large global audience that primarily uses our online resources to access our existing archive. Our online catalogue already features some 40,000 digitised images and documents in 180 collections. We have invested a lot in improving the website to incorporate the new roller flour mill archive as well as the planned timeline. We already offer a number of interesting features and articles as well as a vast Mills Index, which will shortly be expanded to include roller flour mills as the donations come in.

In addition to developing our timeline as an online resource, we will be running competitions to encourage the public to participate in a Flour Mill Survey, which will use submitted data about mills and mill sites to enhance our Mills Index. So the list will expand as people start to tell us about mills we are not aware of, and we hope they will help in the important task of adding roller mills to the Index too.

The past shapes the future

In its essence, this is what an archive is really all about.

While historical records are preserved, this is so that future generations can understand and learn from the past when creating the future. These give us the opportunity to document and appreciate the work of the milling industry in serving humanity and enabling us to flourish.

Flour milling is not a disjointed story, and should not be alienated from wider events that encompass the economy and societal changes as well as advances in technology. By relating flour milling to these concepts, our hope is to engage different groups with a variety of interests and inspire an interest in milling in a wide range of people.

One of the goals of “From Quern to Computer” is to catalogue an additional 20,000 images and documents (no small feat) and link some of the best examples to the online timeline to illustrate and amplify the story of flour milling.

Out of the two million or so images and documents that we care for in our archive, we have so far only catalogued a fraction of what we have. With this project, we will be able to direct more resources towards better understanding that material and presenting it to a wider public.

The Cornwell Roller Flour Mill Collection

Milling & Grain’s own history needs telling

This timeline will be freely available to explore and will link not only to items on our catalogue but also external resources and the websites of participating mills and firms.

The public, as well as those involved in the project, will be able to suggest items, mills and historical events to be added to the timeline. Our goal is to work with mills, firms and individuals to tell the story of flour milling and to provide participants with the tools to tell the story to their own visitors, staff and volunteers.

We are grateful to Milling & Grain’s publisher, Perendale, for recognising the importance of the story of flour milling and for supporting us by getting involved in our work as an Archive Patron. We will involve this magazine – and, we hope, you, in the project by featuring the magazine’s long history from 1891 on the timeline.

Our project needs you

To make our project a success, we need you. We will be looking for contributions, suggestions and comments over the coming two years, and we would like you to help shape the story of flour milling and influence what future generations learn about the past and current mills and milling. You will be able to suggest events, topics, links and other interesting snippets to feature on the online interactive timeline.

Similarly we will welcome your help in taking part in the Flour Mill Survey – an exciting new initiative where you can put mills on their rightful place on the map.

You will hear more about this and other ways you can get involved over the next few months and throughout the duration of the project.

If you would like to find out more, please email me at mills@millsarchive.org and I would be happy to tell you more.

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Milling News

David Sugden 1937-2015

D

avid Sugden sadly died at the age of 77 at home in Suffolk, UK on July 8, 2015. He was 15th and last in the family line of preeminent flour millers, the Sugdens.

The family business - Thomas Sugden & Son Ltd’s mill was located in Brighouse, Yorkshire, UK. David was born on 22nd September 1937 in Yorkshire. He was the son of Richard Sugden CBE TD – former nabim President from 1955-56. He trained mostly at Henry Simon Ltd. Before his milling career, David served 10 years in the military, where, like his father he was commissioned in the Duke of Wellington’s regiment. From 1957 to 1959, David trained in mills in the UK, Norway and the Netherlands. He qualified with a City & Guilds First Class Final Technological Certificate (Milling). David then spent what would become 31 continuous years of service working for Associated British Foods (ABF). It was during these years that Thomas Sugden & Son Ltd was sold to Allied Mills/ ABF. David ran various mills around the UK, becoming product director of

12 | Milling and Grain

main subsidiary at Allied Bakeries, as well as technical and project director at Allied Mills. He became a successful miller inventing the world’s first commercial wheat least cost grist (wheat mix) computerised programme to save costs, implementing reinvestment initiatives, installing new plants, and much more.

During this time, David was an independent grain industries consultant for twelve years from 1980 to 1992. He was well attuned to working internationally in the milling trade, and attended many conferences overseas.

In 1989, David was the recipient of the Thaddeus B. Bownik Outstanding Service Award from the North American Association of Operative Millers (AOM), which is now known as the IAOM. Furthermore, he then became an honorary member of the Association.

David moved to work for Satake as the Business Development Director from 1992 to 1996. Whilst at Satake, David was instrumental with a special remit for establishing the Satake Centre for Grain Process

Engineering between the University of Manchester’s Department of Chemical Engineering and Satake Corporation, Japan and Satake in the UK. This was a specialist centre for post-graduate learning and research.

Following this, David then spent eight years there from 1994 to 2002 as a visiting Senior Lecturer.

Beyond his professional life, David was also active in the affairs of his community and church. In retirement he was Vice Chairman of Res-Care, the nationwide charity which supports those with learning disabilities and mental handicaps, as well as their families; an Associate Governor of Otley College, Suffolk, and a Church Warden at All Saints Church, Chelsworth. From 2001 to 2006 he was a member of the Department of Health Learning Disability Task Force monitoring “Valuing People”. With each of these four entities, he contributed greatly to society and the wider community in a volunteer capacity.

David’s leisure interests were in sporting events, boating and fell walking. His family, friends and the milling industry will miss him dearly.

Futurist Mike Walsh: Food producers must embrace innovation to succeed with next generation

T

he most successful food producers and manufacturers in the next decade will be the ones who harness the rapid advancements in science and technology to meet the demands of the first fully digital generation as they become adults, according to a July 13 keynote address by futurist Mike Walsh at IFT15: Where Science Feeds Innovation hosted by the Institute of Food Technologists (IFT) in Chicago.

“If you really want to understand the future, you have to start with the people who are going to live in it,” said Walsh, author of The Dictionary of Dangerous Ideas and CEO of the consultancy firm Tomorrow.

“And the most disruptive group of future food consumers, I believe, are people who are currently celebrating their eighth birthday. If you can understand how an eight year old thinks, you’re a long way toward really understanding a transformative

change in consumer behavior. ” Walsh said that age group is of particular interest because they were born in 2007 - the same year the iPhone was introduced. They are the first generation to be connected from birth, so they are growing up with a much different outlook on shopping, cooking and eating than other generations. They will expect products that are customised, readily available and - as already apparently on Instagram - look good enough to be photographed and shared on social media.

“When you think about an eight year old, how they will be making judgments about food, about food brands, eating and dining, it’s all going to be very connected to their experience on that smartphone,” he said.

“Look at the way the next generation forms their views on food today. Look at Instagram - there is some extent to which the next

Milling News

generation doesn’t want to eat a meal unless they are going to take a picture of it.”

Walsh said the challenge for the entire food industry is to be prepared to meet the demands of these tech-savvy, on-demand consumers while still producing enough food for a population expected to grow to about nine billion by 2050. He said that will elevate the discussion already taking place about whether to genetically modify plants and livestock to meet the population’s food needs.

“As a futurist, one of the things really that fascinates me is that intersection point where science and technology head-butts the realities of everyday human experience,” Walsh said. “As food scientists and technologists, this is something you encounter every day, because for all of the developments that you come up with, at the end you’re still talking about food.”

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10/02/2015 17:30

Milling News A Flour World Museum story No. 1

King-size king cake

International events VICTAM and GRAPAS boost the International Milling Directory Tom Blacker, International Milling Directory Hello! With many topical subjects this month to get through in this column I will begin immediately! The Northern Hemisphere’s harvest is now taking place.

It has been enlightening to see wheat harvests in my region come to fruition during long evenings and dry days. Farmers, storage co-operatives and the whole logistics chain are working together to provide the wheat for millers. Feed and flour millers are expectant of good quality and quantity. Perhaps this harvest will

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 devel-

see both coming together.

It is so impressive to see other harvests from around the world via the Internet.

You only have to search online social media sites for ‘#‎harvest2015’ to see many photos and accounts of wheat farmers harvesting their crop. Some impressive videos taken from drones flying above the fields also feature. It is worth looking this up to see the huge range and scale of coverage on social media. In my opinion, it is a great thing that wheat harvesters do this to encourage greater awareness for consumers to the origin of so much of the food in their diet.

We also report on some very sad news about David Sugden, formerly of Allied Mills is covered in this issue. Those who knew him in the milling community around the world will sorely miss him. Key individuals from milling families are always greatly admired and rightly respected. He leaves behind a long legacy.

Coming up soon, I am due to visit Holme Mills, best known as Jordan’s cereal mill in the UK. There has been a site at this mill for nearly 1000 years. The county of its location, Bedfordshire, had 400 functioning mills at its peak and was a critical industry. However, that is not the case today. This particular mill was milling flour up until the year 2000 and became the mill of a family of wellknown breakfast cereal brands. Despite the mill no longer functioning, the cereal products are still well known today. The legacy of the mill lives on as a visitor centre that provides leisure attraction where the story of milling can be retold.

My next column will report back from the visit. Look for this in the September issue!

opment and importance of flour. It is the only one of its kind in the world. www.flourworld.de

Tom Blacker Directory Coordinator

www.muehlenchemie.de 14 | Milling and Grain

PS: Don’t miss out on being included in our upcoming International Milling Directory for 2015/16. There is still time to place your advertisement, banner, product profile, logos, etc. Just contact me on: tomb@perendale.co.uk and I will help you through the ordering process.

Milling News

Lallemand Animal Nutrition confirms its silage expert position

L

allemand Animal Nutrition was pleased to take part in the XVII International Silage Conference organised by ESALQ (Luiz de Queiroz College of Agriculture, University of São Paulo) in Piracicaba, São Paulo, Brazil, from July 1st to 3rd, as platinum sponsor of the event, industry exhibitor and scientific contributor. This event gathered more than 300 attendees from 32 countries, among them some of the most important scientists and researchers on silage and many industry representatives. Moreover, it was the first time that the International Silage

Conference was held in the Southern Hemisphere.

Lallemand Animal Nutrition confirmed its position as global silage expert during this key event.

Two lectures were presented by the Lallemand silage team: Dr Pascal

European Investment Bank and FAO bolster investment in agriculture

T

he European Investment Bank (EIB) is expanding its collaboration with FAO, a move aimed at broadening and deepening investment in agriculture in countries outside of the European Union.

The two institutions have signed a five-year Memorandum of Understanding (MoU) that seeks to foster investment operations in the field of agriculture, private sector development and value chains that promote both EIB’s priorities and FAO’s strategic objectives.

The agreement, announced during the Third International Conference on Financing for Development, further marks the engagement of the EIB in the agribusiness sector and, for FAO, a partnership with the world’s largest multilateral financial institution that was signed in Addis Ababa in midJuly.

FAO’s expertise in investmentrelated policies and project formulation for investment, together with EIB’s access to international capital markets and prowess in devising robust investment operations,

are natural complements to one another.

Looking to neighbours and beyond

The cooperation will initially look towards the Eastern and Southern neighbour countries of the European Union and the member states of the African Caribbean and Pacific Group of States (ACP), with the first initiatives likely to focus on investment support in Georgia and Ukraine, leveraging the EIB’s existing credit lines.

Many of the ACP’s 79 member states are particularly vulnerable to climate change, a priority for both institutions. The articulation of the two institutions’ interventions in the region’s agricultural and food sector

Drouin, Forage Research Manager, and Bernard Andrieu, Lalsil Brand Manager. More than 15 posters presented concerned Lallemand strains or products.

Julien Sindou, Global Silage Product Manager, commented: “We are particularly pleased that the first International Silage Conference to be organised in the Southern Hemisphere is hosted by ESALQ at the University of São Paulo, who has been a privileged partner for Lallemand Animal Nutrition for some fifteen years; a fruitful relationship that has led to major achievements such as the patent for L. buchneri 40788 application in sugar cane.” will build on these common priorities.

EIB’s four priority areas for investment include boosting innovation and skills, climate action, strategic infrastructure and improving access to finance for smaller businesses. It recently agreed also to focus support towards young farmers and local initiatives favouring supply chains to boost rural incomes.

Supporting EU policy goals

The European Investment Bank (EIB) is the long-term lending institution of the European Union owned by its Member States. It makes long-term finance available for sound investment in order to contribute towards EU policy goals.

An intergovernmental organisation, FAO has 194 member nations, two associate members and one member organisation, the European Union.

It works to meet the demands posed by major global trends in agricultural development and challenges faced by member nations.

Send us your news Send your news items to oliviah@perendale.co.uk

August 2015 | 15

Milling News

The Pelletier Column

Adjusting strategies to changing consumption habits

by Christophe Pelletier The growing population is often perceived as a threat for the future. The challenges are there, indeed. Yet, looking at the glass half empty is not necessarily the best approach. The future needs to be looked at with a different perspective than the past and the present. Many things have to change and evolve. It is true, but it was true a century ago, too.

We should celebrate much more loudly than we currently do the fact that, although there are still close to one billion people hungry, an unprecedented number of six billion people can eat enough every day. We also must keep in mind that we achieve this performance in spite of substantial food waste and inefficiencies in both production and supply chains in many regions. If we need to change how we operate in these two areas, it is also crucial to be alert to adapt to a changing consumer market.

The growing world population is not so much about how many people there will be in 2050 as it is about what they will eat. The diets of the future will determine the sustainability of food supply. Proper nutrition education is an absolute necessity to get on the path of a sustainable agriculture. The exciting part of feeding the future lies in the dynamics of future food markets. The population is growing but not everywhere in the same way or at the same pace. Next to the growing number of people, their economic situation also evolves at different paces between the regions.

As the number of people joining the world middle class increases, they will look at food differently... and so must food producers. There are useful lessons to learn from the evolution of food markets in Western countries after World War II. Today’s emerging countries show a similar pattern. Food is not anymore a matter of daily survival for their populations. Food is not just for the stomach anymore but the psychology of food consumption evolves, too. That is exactly what Maslow described with his pyramid of needs. Once the physical need is covered, in this case food security, other needs appear. The social and emotional functions of food start to prevail. As they go up in the pyramid, consumers become more demanding and challenging. It is quite normal. It is how human nature works. It also has the amazing ability of disrupting the desire of the industry for well-standardized and costefficient processes; hence the frustration and the difficulty to get on the same wave length.

16 | Milling and Grain

With increasing absolute numbers of wealthier and more critical consumers, it is only normal to expect a strong growth of niche specialties. Such a trend started several decades ago in Europe and has been in full bloom in the US for some time, too. A similar trend is already growing in the leading emerging countries such as China and India, and it will only grow further and stronger. The future offers an amazing number of possibilities for niche markets. The reasons and possibilities for differentiation are and will be many. They range from physical quality to production methods to social, philosophical, political, ethnic and ethical issues as well as provenance, transparency and trust. Feel free to define subgroups in these categories and you will map a myriad of possibilities.

Such trends will be true for all food categories. Some food groups will keep showing very strong growth in the coming decade. That is the case for protein, and in particular animal protein. Protein crops will be in demand for animal feed production. Carbohydrate crops will increasingly be used for animal feed both in volume as in share of total consumption. Oil seeds and oil crops will also show a strong demand because of their many uses in industrial processes, not only as human food. It will also be the case of fruits and vegetables and of “pleasure” commodities such as nuts, cocoa and coffee.

Beverages, in particular wine and beer will also drive strong demand for grapes and barley. For these food categories, the growth will be on both volume and the number of niche specialties, which will create even more levels of opportunities. Other food groups will reinvent themselves mostly through quality schemes. Expect this to be the case for the food groups with a bad reputation such as edible fats and grain. The trend towards a change of heart regarding fats is already in motion and many prejudices are now being corrected. The same will happen with carbohydrates in the future. When that happens, consumption will not return towards undiscerning use of fats and carbohydrates in large amounts, but it will be about nutritional, sensory and health qualities.

The world is changing and opportunities will come up in different places than by the past. Anticipate, adapt and thrive!

Christophe Pelletier is a food and agriculture strategist and futurist from Canada. He works internationally. He has published two books on feeding the world’s growing population. His blog is called “The Food Futurist”.

2015 Alltech mycotoxin storage analysis:

M

Mycotoxins a growing concern for European ruminants

ycotoxins are increasingly causing a negative impact on farms in terms of higher costs and lower productivity.

Due to continuous development of moulds in storage, corn silage is now trending at high risk for mycotoxin contamination which contributes to a higher risk for total mixed rations (TMR), according to Alltech’s recent mycotoxin storage analysis for 2015.

Alltech has analysed more than 800 samples of European ruminant feed from September 2014 to July 2015.

Mycotoxicosis in ruminants is often the result of exposure to multiple toxins, due to preharvest infestation of feed materials by Fusarium species as well as from postharvest contamination of stored materials.

Due to multiple mycotoxins at lower levels, the damaging effects on ruminants may not always be evident by solely observing the animals.

“All mycotoxins are produced by moulds. Moulds are highly influenced by weather conditions and environmental factors. Factors that affect mycotoxin

production in fermented forages include plant stress prior to harvest, packing density, moisture [and] oxygen exposure,” said Dr Max Hawkins, a nutritionist with Alltech’s Mycotoxin Management Team.

Through Alltech’s Analytical Services Laboratory, the company’s 37+® mycotoxin analysis program evaluates the change in mycotoxin numbers and levels over time from harvest through storage. By analysing the number and levels of mycotoxins present, the program can provide a Risk Equivalent Quantity (REQ) of the increase in risk from harvest to feed out.

The most prevalent mycotoxins found in corn silage include Type B Trichothecenes and Fusaric Acid.

According to Dr Hawkins, corn silage in Europe is more contaminated than grass silage and appears to be representing a greater risk; therefore it is a more problematic ingredient.

However, this does not indicate that grass silage is risk-free. In terms of risk for dairy and beef, both are at

Milling News high risk due to presence of Type B Trichothecenes and Fusaric Acid.

REQ levels for dairy illustrate 60 percent high risk, 26 percent medium risk and almost 16 percent low risk.

The average REQ for beef cattle is at moderate to high-risk level. More than 83 percent of the corn silage samples are at moderate to high risk for dairy cattle. Total mixed rations (TMR) samples illustrate more than 60 percent contain at least three mycotoxins. Type B Trichothecenes, Fusaric Acid and Penicillium show significant prominence and influence dry matter intake, rumen function, milk/ meat production, gut health, low immune response and growth rate, which can affect the life time performance of dairy and beef cattle.

One-third of TMR samples from European dairy and beef cattle are at high-risk level.

“The TMR monthly average shows a definite increase over time originating from a low risk to well above a high risk. This is prevalent from the samples coming from Europe.

The trend since February 2015 has demonstrated a much higher REQ level to cow health and performance.

GLOBALG.A.P. AQUACULTURE STANDARD VERSION 5 NOW ONLINE

GLOBALG.A.P. COMPOUND FEED MANUFACTURING STANDARD Safe Feed - Safe Food Check out our website for events happening near you! www.globalgap.org/events

August 2015 | 17

Milling News

COMPANY UPDATES

Cooperatives supply a central cooperative

by Chris Jackson, Export Manager UK TAG This month I am writing my column from Indonesia having led a group of UK companies to the Indo Livestock exhibition held this year in Surabaya, the second biggest Indonesian city. Surabaya is located in the East Java region, one of the most important agricultural regions in the country.

Demonstrating the importance of agriculture here, the exhibition was opened by their Director General of Livestock and Animal Health Services, Dr Ir Muladno. Our exhibiters were kept very busy throughout the show, hopefully good business will follow benefiting both countries.

This is a country where the Government wants to see serious improvement to the agricultural sector for three reasons: • To cut their reliance on imported products • Establish a significant export trade using their abundant natural resources • Significantly improve rural incomes This week in East Java I have been shown farms that are already improving their incomes by making use of cooperative marketing. Government help has enabled them to create a tiered system for marketing dairy products, whereby a group of village cooperatives supply a central cooperative.

The central cooperative then, in turn, manufactures the milk with UHT treatment, adding flavours before proceeding to send to the supermarkets of Jakarta.

In addition to marketing, at village level the cooperative takes back the cows from the farmers when their lactations finish and return them to the dairy farmers once they have calved down again. This way they only keep cows that are producing an income.

In return for this service, the cooperative keep the calves, they sell on bull calves whilst retaining heifers for herd replacements and expansion.

An insemination service is also provided for the farms. Sexed semen of the Holstein breed seems to be the animal of choice, 20 | Milling and Grain

likely because it has a short production life and there can be difficulty in maintaining herd numbers.

East Java alone has about 500 000 milking cows, they want to double this number as currently there is market demand which cannot be met.

Milk production per cow is not high, but attention to stockman ship is good. We were constantly asked for information on feeding to improve milk yields.

Genetics also plays a key role; perhaps looking at some different breeding programmes to gain production in the first instance would be advantageous.

Additionally, using hardier breeds will probably, given the conditions, give as much milk as the Holstein but have other advantages in regards to replacement, longevity and health.

The animals are kept in herds of mostly up to five cows being the norm. Forage is cut daily from forested areas and taken to the cows. The grass is course and in its raw state is acknowledged to be difficult for the rumens to cope with. They do try chopping the grass to make it more palatable but that does not break the cellulose chain to make more carbohydrate available in the rumen.

For the larger herds imported lucerne is available. In the dry season grass shortage can be problematic as there are no facilities to dry or ensile the product when it is in abundance.

Locally bred bull calves are frequently used in the feeding lots with imports from Australia, again quality of feed is a reoccurring issue.

In addition to the farming we saw first hand the efficiency of cooperation. Small bio gas plants were utilising manure to supply several families who would then use the final dried waste to produce flowers and vegetables for Surabaya.

I have to say that if I were a young man I would really like to come to Indonesia to farm the opportunities here I think are fantastic.

Next month I will take a group of UK companies to China, I look forward to reporting on this event. @AgrictecExports

AB Vista opens first office in India to serve growing customer base.

On July 31, 2015 AB Vista has opened its first office in India, following extensive growth in the region during the past eight years.

The new office, located in Pune, will serve as a base for sales, technical, finance and supply chain functions, and is the first such headquarters in the region.

Alltech sponsors first mineral symposium at PSA annual meeting. For the first time in its 104year history, the Poultry Science Association (PSA) annual meeting, held in Louisville, Kentucky, July 27-30, included a mineral symposium. “Changing Insight into the Role of Trace Minerals” was presented and sponsored by Alltech.

This symposium reflected on the broad range of new information about trace elements and suggested several ways of putting this science to good use.

Anpario awarded the Queens Award for Enterprise. Anpario plc, Meriden Animal Health’s parent company, is delighted to announce that they have won The Queen’s Award for Enterprise for outstanding acheivement in International Trade.

The Queen’s Award for Enterprise is the UK’s most prestigious accolade, designed to recognise and reward the achievements of UK businesses that have shown outstanding and sustained growth. The awards are made each year by Her Majesty The Queen on the advice of the Prime Minister, who is assisted by an Advisory Committee including representatives of Government, industry and commerce and trade unions.

Milling News

Supplementary feeding of live insects as a source of protein for broilers ForFarmers and WUR start joint trial ForFarmers has launched a trial together with the Department of Entomology at Wageningen University in The Netherlands, to explore the impacts of live insects as a source of protein in the broilers’ diet.

Leon Marchal, Nutrition and Innovation Director at ForFarmers says, “The most important research question is whether the chicks are growing healthily and at a sufficient rate in comparison to a traditional diet.

“We also want to look at whether the broilers’ natural behaviour will improve as a result of the addition of live insects. If this project proves to be a success, it will be an important step towards further sustainability within the industry.”

ForFarmers have commented that early observations have clearly shown more lively foraging behaviours amongst the broiler chicks, and that it is known that more active Broiler chickens have less leg disorders.

The trial is being conducted at ForFarmers’ experimental farm in Nijkerk, The Netherlands, where a total of 1000 chicks are being fed in four different groups. A control group will be given a traditional diet, while the remaining three will be given 5 percent, 10 percent or 15 percent respectively of black soldier fly larvae. The high protein content of these larvae replaces up to 75 percent of a protein like soya.

“The larvae from this species are truly omnivorous and are relatively easy to grow,” according to Albert Dijkslag, Poultry Innovation Manager at ForFarmers.

“This will also result in profit for the farmer and increased sustainability.

These larvae are grown on residual flows from the food industry. These residual flows and the protein within

Leon Marchal and Albert Dijkslag, ForFarmers

these would otherwise end up in biomass (fuel), however now they are available as feed.”

“And if the trial proves successful, we will have found an alternative source of protein,” he added Natural nutrition and behaviour The initial results are expected in September. “The application is currently quite expensive. But it’s definitely a good first step and mindset. If we see positive results, we will continue with the further optimisation and development of the trial,” Mr Dijkslag explained.

Elaborating on the high costs of the application, and if possible, how this price might reduce, Mr Marchal responded with, “The cost of production of insects will reduce in the future. The two major contributors are automation and better feed efficiency/growth performance.

Currently the nutritional knowhow of how to best feed insects is still in its infancy if you compare it to the level we are at with for example pigs and poultry. The few small producers that exist generally protect their own way of operating and exactly what they are feeding. What is needed to really boast the rearing of insects is the development of publically available feed tables and nutrient requirements of the insects. This will create a common foundation on which others can build and compete again with each other as individual companies.”

Mr Marchal added, “The nice thing here is that chickens in the wild are naturally omnivorous and insects would feature as part of their diet, the outcome of the project therefore could be to help birds further express their natural behavior.”

ForFarmers wants to be a leader in sustainability, given its position in the food chain. ForFarmers is providing a contribution to an economically viable and sustainable food production by efficiently producing animal feeds and developing products and concepts which allow the animals to utilise the food in a healthier and better way improved feeding efficiency. This trial with live insects indicates ForFarmers is really giving substance to its sustainability ambition.

The various different parties involved think it will be some time before the large scale supplementing of diets with live insects can be introduced in practice. When I asked ForFarmers about this, they predicted that realistically speaking they expect the first steps to be taken in 2016 or 2017, but this greatly depends on whether they are able to create a market pull by implementation in a premium segment. Noting that currently there are several premium segments (besides organic) with attention to animal welfare or sustainability, and see live insect feed as possibly improving such premium segments further.

August 2015 | 21

Milling News

Mycotoxins and other hazards controlled by the use of FSP

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by Els van der Boon, Program Manager Feed Support Products, GMP+ afe feed and food starts with secure risk management. For this, GMP+ International offers their knowledge and information through the Feed Support Products (FSP). The Feed Support Products are intended to support all future GMP+ certified companies with setting up their company-specific HACCP system. The responsibility for use and implementation remains with the GMP+ certified companies, the Feed Support Products can offer support in this process. The FSP is also intended as a reference for the auditors within the framework of GMP+ certification.

The following products are a part of FSP: Fact Sheets - The fact sheets show background details regarding the hazards and the (explanation of the) severity of the risk to animals and humans. The content of the fact sheets is as follows: Nature, history and prevalence; Transmission to the environment, plants, animals and humans; Diagnose of poisoning; Potential hazards and adverse effects; Severity of the hazard; Standards; Analysis methods and Control measures. The company when undergoing a specific risk analyses can use the information. Fact sheets are available for several mycotoxins and other undesirable substances (hazards) in the Risk Assessments and for processing aids.

Generic Risk Assessments - This section of FSP contains about 200 risk assessments of feed materials for Foodproducing animals (including goats, poultry, cattle, sheep and pigs, but also horses and rabbits). Farmed fish will be included. The risk assessments in the FSP database are of a generic nature and represent a worst-case scenario.

The risk assessment gives information about a production process and the resulting possible hazards.

Product list - This list gives a short summary of all products available. There are about 600 products on the list that may be used as a feed material in the GMP+ Feed Certification scheme.

Product standards - Standards with maximum permitted levels have been issued by legislation and by GMP+ International for many hazards in order to be able to determine if a feed material is safe. All the standards are a part of the GMP+ FC scheme, GMP+ BA1 Product Standards. Also the standards for mycotoxins are included.

GMP+ Monitoring database - A service from GMP+ International is the GMP+ Monitoring database.

Companies can put their analyses into the database and can share these results with a group of companies or 22 | Milling and Grain

with the GMP+ community. Sharing is an option, not a requirement. Monitoring results can be used to assess the likely occurrence of a hazard. In the Database there are for mycotoxins analyses results available. It is possible to make overviews per product for a defined period.

The GMP+ monitoring database is an easy tool for storing and sharing analysis results, you can easily check if the products meet the standards.

Guidance’s - At the beginning of 2014 the first GMP+ guidance about implementation of a Feed Safety System in accordance with the GMP+ Feed Certification scheme had been launched. The D1.2 GMP+ guidance contains all needed information and steps and can be ordered via the webshop of GMP+ International.

Your benefits

FSP provides ease of use, a uniform source of relevant data, linking of relevant files and efficient searching. The benefits of use are: • up to date knowledge of risks of feed materials • up to date knowledge of undesirable substances; • assessment from independent experts; • a uniform source of knowledge; • automatic linking of all relevant files.

Core values

The Feed Support Products operates from four core values: Practical information - The information in FSP about processing, possible hazards, risk assessments and monitoring data is received from GMP+ companies.

Science based - The (generic) risk assessments of feed materials fully comply with the requirements referred to in the HACCP manual for the animal feed sector (2008).

To substantiate potential adverse effects of a hazard, the information is published in fact sheets for both undesirable substances and technical processing aids.

The severity of hazards indicated in fact sheets and risk assessments have been evaluated by scientists of RIKILT. Independency - The policy and technical aspects of FSP are reviewed by independent committees, the International Expert Committee Animal Feed (IEC Animal Feed) and the Technical Committee FSP (TC FSP), the latter acts as a HACCP team for the FSP. The TC FSP has members who are representatives of different subsectors and knowledge areas (chemical and microbiological) The meeting of TC FSP will at least take place two times a year. Besides the regular members of the TC FSP, ‘advisors’ can be invited to TC meetings. These advisors are either laboratory representatives, representatives of

Milling News

the Food and Consumer Product Safety Authority, or scientists (eg. Rikilt). Also independent advisors from certification bodies or consultancy agencies can be invited to (parts of) the TC. Transparency - GMP+ uses a transparent communication to all stakeholders as well as transparent working methods. Procedures for changes are described. Every change is communicated to the GMP+ community via the FSP newsletters.

How do we keep the FSP up to date?

The content of the different products continuously changes due to new feed legislation, regulations, emerging risks and new scientific information.

Changes include new feed materials/products, hazards, new “product-hazard combinations” and new standards (legislation). These changes are periodically processed by GMP+ International within FSP by a maintenance procedure.

Changes in a hazards severity or effect are processed in factsheets and/or risk assessments. If needed, changes in risk assessments, factsheets, GMP+ standards or monitoring program, are discussed within the TC FSP. Reasons for changes can be (among others): In general: • New feed legislation • Early Warning System (EWS) from GMP+ • Rapid Alert System for Food and Feed (RASFF) • Feed Crises • New scientific information/new hazards (eg. from TNO, Rikilt, EFSA) • Practical experiences from companies Information must be evaluated on the necessity for taking immediate action. In some cases, immediate action is needed, for instance in case of a newly emerging risk. Other types of information, for instance scientific information, can be processed in a later stage and will be filed for planned maintenance of FSP information annually.

If new non-conformities related to food and feed safety occur there must be a short-term evaluation about the consequence for feed (if it is a nonconformity from food) and the consequences for FSP. New hazards can be communicated in a short term to the feed sector.

GMP+ certified companies are being informed of changes in risk assessments and/or fact-sheets by means of newsletters. All newsletters can be found on the GMP+ portal www.gmpplus.org (under “In the Spotlight”).

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

August 2015 | 23

The industry’s most authoritative resource on feed production

European statistics

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his month we look at European statistics – both feed and specifically ruminants. We are using two sources of statistics; our regular contributor Alltech and FEFAC, the European Feed Manufacturer’s Federation.

Europe produced 224.6 million tonnes of compound feeds in 2013, the latest year for compiled statistics from the Federation.

Ruminants, including cattle, dairy cows, sheep and goats, and the focus of our ruminant review this month is also based on FEFAC statistics from 2013, showing some 32.5 million tonnes of compound feeds (or 27.5 percent) were produced by the EU 28. To this must be added FEFAC’s ‘others’ category, which is mostly made up of sheep and goat feeds and accounting for a further 10 million tonnes in 2013.

Mill

Training

Twenty-nine participants from eight countries learnt the nuances of large-scale industrial feed and much more, when they attended the feed manufacturing course held on July 7-10, 2015 at IGP-KSU. Feed mill supervisors and managers, plant operators, quality assurance managers, nutritionists and supplement manufacturers were some of the individuals who attended the training.

IGP-KSU Feed Manufacturing Training “Taking this course, participants were able to learn the new trends in feed manufacturing and to strengthen their knowledge on the crucial concepts that make the feed production process more effective,” says Carlos Campabadal, Feed Manufacturing and Grain Management Curriculum Manager and course manager.

The four-day course focused on grain storage, particle size reduction, batching and mixing, extrusion, animal nutrition, pelleting, quality control and advances in feed technology. The course encompassed lectures, workshops and tours of the O.H. Kruse Feed Mill and Kansas State’s dairy facilities.

Course participant Peter Dehn, feed mill manager from KJMM Pork & Grain, appreciates the networking opportunities he will gain by attending an IGP Institute course. New to the industry, Dehn decided to attend the course to understand what

his employees’ jobs entail.

“The fact that we can communicate back with IGP Institute after the course, that’s fantastic. This has been a top-notch, professional and classy course, top to bottom,” says Dehn.

Fellow course participant Ayoola Oduntan, group managing director of three companies, national president of the Poultry Association of Nigeria adds, “I’m now better equipped to manage the feed complex. I’m definitely going to get some of our managers to attend this course.”

In addition to feed manufacturing and grain quality management, the IGP Institute offers courses in the areas of flour milling and grain processing, and grain marketing and risk management.

T u r n k ey Feed Mill Systems Gear Driven Pellet Mill w w w. y e m t a r. c o m

600 Evler Mah. Balikesir Asfaltı Sol Taraf Cad. No:65 BANDIRMA / BALIKESİR / TURKEY P(+90)266 733 85 50 | F(+90)266 733 85 54 August 2015 | 27

Pellet cooler Coolex™

PRODUCT FOCUS AUGUST 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.

Bühler has launched the new pellet cooler Coolex™. Coolex™ provides efficient cooling of the hot pellets discharged from the pelleting process, this is the only way to obtain high-quality end products with optimal hygiene. With its integral production processes, using Coolex™ as an integrated cooling system component, Bühler supports feed manufacturers in increasing their product quality and hygiene while reducing their costs.

The innovative design of this system is based on the countercurrent cooling principle. Coolex™ offers regulation of the discharge gap, ensured continuous product discharge, uniform cooling, an optimal moisture content, and a consistently high pellet quality.

www.buhlergroup.com

Perry belt drier Perry launch brand new belt drier - The most significant product release in a decade Perry’s brand new belt drier is capable of drying everything from woodchip to cereals and granular products to recycled waste.

When drying wheat you can expect capacities of up to 60tph with a 5 percent moisture reduction. As standard it has fully galvanised, modular design (2.1m length increments) with 3 different widths available (1.5m, 2.2m and 3m). A full stainless steel assembly and a fully insulated model are additional options available.

It is available with either axial or centrifugal fans; axial fans allow for lower air speeds and pressure in comparison to the centrifugal fans and have a lower power consumption.

Processing equipment This month we look at the latest products available for processing lines

www.perryofoakley.co.uk

Semiautomatic screen changer

Density Control System

Dinnissen Process Technology is introducing its newest Hamex Hammer Mill fitted with a semiautomatic screen changing system. This latest model was developed to provide users who regularly switch from one product to another with increased speed, convenience and energy savings.

Wenger has integrated three successful, existing process components together to create a new Automatic Density Control (ADC) system for the control of wet bulk density during production of pet foods.

The semiautomatic screen changer allows the user to quickly change screens without stopping the grinding rotor. This minimises downtime during the grinding process and maximises production capacity. In addition, as the grinding rotor and the motor no longer have to be repeatedly switched on and off, it also saves a great deal of energy.

www.dinnissen.nl

28 | Milling and Grain

The Wenger ADC system incorporates a sampling and bulk density measuring device (Source Technology’s BDS) into a system that includes the Wenger back pressure valve (BPV) on the extruder barrel and Wenger’s integrated APM (automated process management) extrusion control system to automatically measure product density and adjust the process to maintain the desired density specifications.

Wenger’s ADC can be installed as part of a new system or retrofitted into a system that already has one or more of the three basic components.

www.wenger.com

FOCUS

SPECIAL FOCUS As an essential part of Famsun’s extruder machinery, the singlescrew extruder (for aquafeed, raw materials) is widely used in feed plants. The removal of screws has always been a problem in the operation of extruder machinery. Every manufacturer may have its own removal tool kit, yet few can offer satisfactory solutions.

To develop new efficient removal tool kits, the following three factors should be taken into consideration: To begin with, during peak production season, the machines have to stay operational as long as possible to cut the costs incurred by downtime. For instance, without an efficient method, removing the screw head can take anywhere between 30 minutes and one or two days with nothing but temporary tools at hand. Considering the time consumed, it is of significant necessity to make improvements in the removal process to meet the production agenda.

Second, to lengthen the service life of the screw head, it is necessary to minimise the damage done to the screw head when it is being taken off.

Third, a high degree of automation is necessary. So far, some of Famsun’s raw material extruders have been automatised and these machines are more operationfriendly than they used to be. But simpler, faster removal tools are still needed to improve the competitiveness of Famsun’s machinery.

Currently, the removal tool kits available are for raw material extruders. For TPH/PHY200, TPH260/PHY260 series extruder, the removal tool kit in use does not deliver satisfactory results. Because of its structure, the tool can only remove Spilt the first section of the screw. Besides, locking current removal tools also require specific sleeve screw leads. It also takes a lot of effort and time to manually turn the screw lever, especially when some screws haven’t Pull rod set been removed for years. For single screw extruders for aquafeed, however, the aforementioned method does not work.

Compared with earlier versions, the up-to-date removal tool kit can remove single screws of all types (TPH200/260; PHY200/260; SJPS135/165/215/265), not just the first section of certain types of screws.

The time needed to remove one section is less than 20 minutes.

Its structure and operating principles are as follows: Performance: • Time spent in removing one section of screw: ≤20min • Maximum thrust: 30TX2 • Ability to remove each section of the screw: yes • Number of operators: two Structure: • Double jack: to balance the force • Hand pump: easy to handle • Anti-deviation design: to ensure precision • Extension rod: to make it easier to drive the whole screw out

Famsun’s single-screw removal tool kit • Mounting plate: waist-shaped holes in the plate make it easier to readjust the hold hoops in different positions • Spindle position-limit mechanism: prevents the spindle from shifting position when it is being knocked out by the ejection mechanism (Patent No. 201320370871.3) • Screw ejection mechanism: The pair of jacks can be operated with the hand pump, their stroke synchronised by hand with less effort The mounting plate facilitates the fixation of the pair of jacks The waist-shaped holes make it easier to adjust the phase of the hold hoops in different positions The split locking sleeves are easier to install The anti-deviation design prevents the unsynchronised jack from getting stuck with the main spindle There are 20 extension rods included, to help remove the last screws.

Screw

Main spindle

Position-limiting mechanism: • The position-limiting mechanism is used to prevent the spindle from being damaged by friction caused by the spindle in the block and the main spindle (the current structure of the extruder only has a limit screw to bear backward thrust; without a limit screw to counter forward force, the spindle can only take a little forward-pulling force) • The front bezel is composed of two half-type panels fixed in the inner wall of the spindle • The backplate is composed of two quartered pieces fixed in the inner ring of the rear spindle • The front bezel and the backplate are connected by a stopper bolt • There are two M30 lock screws; each of them can bear an axial force of more than 30 tonnes.

www.muyang.com August 2015 | 29

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8

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Stabilising rice bran through high shear extrusion

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by Dr Nabil W. Said, VP Nutrition & Extrusion Technologies, Insta-pro International

Figure 1

ice is considered one of the world’s most important crops and is a major part of the food culture in Asia, Latin America, Africa and other parts of the world.

Global rice production is steadily increasing to meet the growing demand for food from a rapidly rising global population. The Food and Agriculture Organisation (FAO) – United Nations estimated that 2015 production of rice is around 500 million metric ton. Production of grains including rice is currently meeting and exceeding consumption. As more rice is being produced and processed, another part of the paddy, rice bran, is being generated.

Rough rice or paddy (see diagram) consists of the white starchy rice kernel, surrounded by a tightly adhering brown coating of bran and enclosed within a loose outer hull. During the rice milling process, the hull and the bran along with the rice germ are removed mechanically to access and polish the white rice, which is the principle sustenance for the majority of world’s population.

Due to the lack of a proper method for rice bran stabilisation in under developed and developing countries, rice bran was underutilised until low cost extruders were introduced in the market.

from raw or parboiled paddy.

Besides the protein and energy, stabilised rice bran is an excellent source of vitamins B and E and some antioxidants. It has been used as an ingredient in poultry, pet food, and ruminant animal diets.

The urgency for stabilisation of rice bran

Rice bran has a powerful enzyme system which is activated during the milling process and causes rapid deterioration of the oil by exposure to the enzyme lipase and, to a certain extent, oxidase. Enzymatic hydrolysis of the oil into free fatty acids and glycerol will start and the acidity increases (reduced PH) resulting in the development of a soapy off flavor.

The oil in the un-milled rice paddy is stable, as the Lipolytic enzymes are located primarily in the seed coat. Whereas most of the oil in the un-milled paddy or brown rice is stored in the germ and the Aleurone cells (the protein rich outmost layer of the endosperm), upon milling, the oil is subject to the activity of the powerful lipase enzyme causing the accelerated break down of the oil into free fatty acids and glycerol. The free fatty acids become susceptible to further decomposition through oxidative rancidity that will produce free radicals, cause soapy flavour and

General steps in the production and utilisation of stabilised rice bran

The separation of the hulls and the bran can be through one, or more stages. If the dehulling took place in one stage where both the hulls and the bran are mixed, the oil content will be low (below 10 percent), an economical separation of the oil is not possible. However, the use of two stage rice mills, in which the bran and the hulls are recovered separately, allows for an economical extraction of oil.

The hulls (about 20 percent of the rice paddy by weight) have no significant nutritional value as they consist mainly of cellulose, lignin and select minerals. On the other hand, rice bran (approximately 5-10 percent of the rice paddy by weight) is rich in protein (14-18 percent) and energy; mainly in the form of the oil it contains (10-20 percent). The percentage of oil in the bran depends on the milling process, the contamination of the bran with hulls and broken kernels and whether the bran is obtained 30 | Milling and Grain

Figure 2

F Figure 3

a reduction in the nutritional value. For this reason, it is of utmost importance to immediately stabilise the bran to prevent the deterioration and the rancidity of the oil.

Inactivation of enzymes through extrusion

High shear dry extrusion was developed by Insta-Pro International in the late 1960’s to inactivate the anti-nutritional factors present in soybeans. Those anti-nutritional factors are enzymes such as the trypsin Inhibitors, hemagglutinins, lipase, lipoxygenases, urease and other anti-nutritional factors. If

ingested in their intact state, the anti-nutritional factors will adversely affect the digestion of nutrients through their inhibitory effects on the pancreatic enzymes responsible for digesting the protein and carbohydrates. The high dry shear extruder generates heat through friction (mechanical energy) along with pressure.

The barrel of the extruder consists of segmented chambers with a shaft that rotates at constant speed.

Screws are fitted on the shaft separated by steam locks or shear locks designed to disrupt the conveying of the material and force some of it to revert back through channels in the wall of the barrel thus generating shear and friction that raises the temperature of the extrudate in a controlled manner (see the following figures).

Upon exiting the extruder, a sudden drop in the pressure takes place that results in rupturing cell walls, releasing natural anti-oxidants (tocopherols), partially dehydrating the product as some of the moisture will be flashed off in the form of steam.

This sudden drop in pressure also results into sterilisation of the product. As concluded from numerous scientific studies, viruses, bacteria, coccidia, mold and yeast cannot survive the extrusion conditions.

The inactivation of the enzymes takes place through altering the tertiary structure by breaking the disulfide bonds holding the amino acids strands together. The proper optimisation of the extrusion parameters allows for the denaturing of those enzymes without the adverse effect on the primary structure of the amino acids.

The cooking time takes only a few seconds and under the proper conditions of operation, the digestibility of nutrients in the extrudate would be at its highest level. The extruder has been used as one of the most effective tools to stabilise products through enzymes inactivation thus in the case of rice bran,

August 2015 | 31

F Figure 4

stabilising it immediately after milling.

Fresh milled rice bran oil normally contains 1.5-2.0 percent free fatty acids. Free fatty acids level of less than 5 percent is desirable. If not stabilised within few hours after milling, the free fatty acids in the oil will exceed the 5 percent level.

Exceeding 10 percent free fatty acids in the oil would indicate less recoverable edible oil.

Utilisation and benefits of stabilised rice bran

Figure 5

Figure 6

Stabilised and extracted rice bran oil is very popular as a cooking vegetable oil in China, Japan, Taiwan and other Asian countries. In the late 1800’s, it was discovered that East Indies sailors suffered from what thought to be toxins or infection generated from the white rice that they consumed. The disease is called Beriberi. It was later discovered that when the sailors were fed meat, vegetables and dry milk, the symptoms subsided and disappeared. It was then recognised that it was a nutritional deficiency in the polished rice that lead to the discovery of vitamin B1, thiamin. This vitamin stays in the bran upon polishing the rice. By adding rice polishing to the Beriberi inflicted chicken’s diet, the fowl were cured of the disease.

Because of its content of decent protein level, oil, fibre and antioxidants, stabilised rice bran can be used as an excellent source of energy, protein and fibre in animal feeds, human food and as a functional food or nutraceutical ingredient. Many claims have been made as to its benefit in lowering the cholesterol through its content of tocotrienols tocopherols, ß-sitosterol and γ-oryzanol. It is also been used as a stool-bulking agent.

In the feed industry, stabilised rice bran is being used as a palatable ingredient and excellent source of protein in pet food; energy and fibre in equine feed, poultry and ruminant animals.

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Game of Grains:

Why India’s agri-food policies need a holistic review

by Raghavan Sampathkumar, SmartAgBiz, Singapore

T

Milling and Grain has invited Raghavan Sampathkumar, an agribusiness professional, based in Singapore, to provide an overview of changing food policies on the ‘food basket’ in developing countries such as India.

Mr Sampathkumar analyses key trends in the global agri-food sector and writes commentaries and columns related to food prices, food crisis, sustainability, hunger and poverty

he term ‘food basket’ here in India actually means a real basket that an average Indian homemaker takes to shop for groceries and food. Some decades ago, her basket (nowadays, ‘his’ too), will contain plenty of vegetables, small millets and a rich variety of leafy greens in addition to staple grains, such as rice and wheat.

However, many of the above items had been vanishing, albeit slowly from the food basket, and most of these are not even known to the millennials and Gen X. Even the older generation, that is popularly called as the baby boomers, and who used to consume these diverse foodstuffs everyday had, to a large extent, forgotten them. The transformation of diet in India over the past few decades is mindblowing in the extreme and disturbing to boot.

In this article I would like to discus the key macro trends in the consumption of select food crops in India; possible causes of the transformation of diets; potential impacts on health and wellbeing and, finally, the importance of enabling policies that can augment not only food but the nutritional security of a country.

Although this analysis is primarily related to India, the recommendations and implications can be applied to any country that shares a similar agrarian, demographic and socio-economic profile.

Is shrinking diet diversity a serious concern?

If one might think how relevant or important diversity in diets is - that is, the different types of commodities and foods that supply nutrients - then they should consider this. In a recent study 34 | Milling and Grain

on how and from where population in different countries derive their calories revealed that in the past 50 years, more and more countries became dependent on fewer crops.

In other words, diets of majority of people in several countries across the globe are becoming homogeneous and the dependence on few key crops such as wheat, maize (corn) and soybean.

If harvests in any of the major regions that produce these crops face adverse weather, the ramifications go deeper and wider across the globe. Prices tend to soar, and producing countries may take knee-jerk reactive measures to curb trade which will further strangle global availability.

Any increase in food prices will push millions deep or deeper into hunger and poverty, particularly in the low-income food deficit countries in Asia and Africa. These issues may cause social unrest and may lead to unexpected situations like the recent Arab Spring.

Possible causes impacting diet diversity

Rising disposable incomes in tandem with economic growth are driving dietary changes particularly in favour of animal protein which in turn drives enormous growth in corn and soybean sectors.

The much-celebrated middle-class boom in Asia where more than a couple of hundred million people came out of abject poverty in the last three decades and growing affluence in the middle-to-high income socio-economic classes have also contributed significantly to this phenomenon.

However, these few major crops have gradually been replacing a huge variety of traditional and indigenous food crops across the world.

For example, in India, there used to be a time when minor

F millets, such as ragi (finger millet), cumbu (pearl millet) and foods like cassava, were important parts of regular everyday diets but were eventually replaced, over several decades, with food products derived from wheat, rice and/or corn.

As incomes rise, diets undergo faster and greater transformation and in the race to be affordable and available, obviously some food crops get sidelined.

Economists are conveniently blaming the country’s impressive economic growth and claim that people tend to move ahead to consume more food items that are “perceived rich” and less of those foods that are “perceived inferior” - but by no means nutritionally!

However, what these statistics do not reveal is the resulting impacts on human health, nutritional wellbeing and eventually productivity of the generation that misses out on important sources of nutrients from these diverse food crops.

Policy hi-jacking: Marginalisation of non-strategic crops

If one asks whether India’s green revolution has helped the country to achieve self-sufficiency in food, the obvious answer from the people of the highest echelons of policy making and politics would be a chest-thumping ‘yes’.

But, in truth, what was happening was literally “policy hijacking” by few groups with vested interests and the intent to maintain their status quo under the guise of augmenting food security.

In the process, nutritional security, health and wellbeing of the population have become collateral damages.

Apart from minor millets, one of the biggest casualties

happened to be pulses, possibly the most important sources of protein for majority of Indians. Following are some of the reasons that caused or hastened marginalization of pulses.

First, unsupportive ‘silo’ policies that are skewed and became more favourable towards few crops such as rice and wheat.

However, the difference between growth in maize and soybean versus rice and wheat is that the latter duo are primarily policydriven while the former are market or demand-driven, mainly

“Rising disposable incomes in tandem with economic growth are driving dietary changes particularly in favour of animal protein which in turn drives enormous growth in corn and soybean sectors” from the meat sector. Major portion of the animal feed consists of maize and soybean as raw materials.

Lack of appropriate support mechanisms including procurement; sufficient marketing opportunities beyond Government agencies; policies that hinder involvement of private players in sourcing directly from farmers; lack of processing infrastructure and value addition are some of the factors that

August 2015 | 35

F discourage farmers to take up any other crops unless there are absolutely no choices.

There is an entrenched belief that minimum support prices (MSP), that are increased every year for these minor crops, will motivate farmers to take up cultivation.

Unfortunately, that belief has been proven wrong at least in the case of pulses since domestic production has been languishing despite significant increases in MSP up to 87 percent over the last four years for some crops like pigeon pea.

If anyone claims lack of demand from the consumers for pulses as the cause for the negligible growth in production, the numbers speak by themselves. India’s pulses imports have grown over the last four years from nearly 15 percent in 2010-11 of the total demand to reach 21 percent in 2012-13 before falling to nearly 17 percent in 2013-14.

However, what limits creating more demand is clear lack of innovations in developing novel food products using pulses as ingredients and dwindling research and development (R&D) efforts and investments in this front.

Pulses, unfortunately, are perhaps the most under-utilised foods considering their rich nutritional profile. In the developed world, new market segments currently being explored with significant interest are protein-rich products targeted at athletes and body builders, and the partial replacement of cereals with pulse-based ingredients in extruded food products (eg noodles, pasta, etc).

Other popular foods, including granola bars and breakfast foods, have significant amount of pulses.

However, In India, research on these fronts has long been in its nascent stages. Maize (corn) has undergone such a phase of growth and exploration of unimaginable kinds of use options and has become almost ubiquitous in several every day food products. Similar efforts are needed to create demand for pulses.

In a different perspective, questionable policies on fertiliser pricing, particularly for nitrogen against other fertilisers, may be a limiting factor for increasing pulses cultivation. Urea is the cheapest of all fertilisers and an average farmer, without understanding nutritional requirement and soil health will obviously go for the cheapest fertiliser thinking it would result in bountiful harvest.

However, all these not only worsen the already awkward N-P-K ratio of the soil but impact the ecosystem, flora and fauna particularly marine life due to loss of excessive nitrogen through run off and leaching.

By taking a rational policy on this front will not only result in encouraging pulses cultivation but also can help enhance soil health, which is important from sustainability perspective.

Policy imperatives: Striking the right balance

A report from India’s National Council of Applied Economic Research (NCAER) suggests that cereal-based food security policies may not contribute significantly to achieve nutritional security of the population.

However, if one digs deeper, it is evident that the recent Food Security Act seems to indirectly support nothing but rice and wheat. All the measures taken up under the act are seemingly favouring these two crops while other minor cereals and pulses are eventually getting further marginalised.

Given that the country’s protein consumption is miserably stagnating at around 50–57 grams-per-day over the last decade, it is critical to give due importance to pulses and push through conducive policies.

India’s unique strength in the coming decade is its demographic dividend of having a median age of under 30 by the turn of the 36 | Milling and Grain

About the author

Raghavan Sampathkumar has worked 11 years in agro commodities, agri-inputs, GM/biotech crops and animal health and nutrition sectors across Asia-Pacific, and has an understanding of the complex political, socio-economic, environmental and cultural perspectives of the Ag-food value chain.

In his role as a consultant he has worked in international marketing with Saskatchewan Pulse Growers; as a freelancer with companies such as Promar Consulting, Japan and also in various capacities with reputed MNCs including Monsanto. He is the founder and principal consultant in “SmartAgBiz”, a boutique firm that focuses exclusively on market research for agribusiness sector.

Mr Sampathkumar graduated with distinctions in his Master of Agribusiness degree from University of Adelaide, Australia, and is also an alumnus of TNAU, Coimbatore, India. He regularly delivers lectures at various institutes. vnsraghav@gmail.com next decade. Food and balanced nutrition forms the basis of human productivity and wellbeing and when these are not given due consideration, the opportunity cost or lost, indeed, could be detrimental to the economic prosperity of the country in the coming decades.

Unjustifiable emphasis on rice and wheat resulted in a situation where these two crops contributing the biggest chunk of calories and protein. At a time when prices of pulses are surging, average Indian middle-class households and the poorest of the poor are the most affected as they usually spend more than half to twothirds of their monthly income on food.

Such rise in prices will cause huge cuts on consumption of pulses.

Cheaper carbohydrates will eventually replace the amount of protein from pulses and other foods in case of price spurts. It could possibly one of the reasons behind the emergence of a diabetes epidemic in the country.

It would not be a surprise if India, in the near future, pips China to claim the notorious throne of ‘the diabetic capital of the world’ with more than 100 million people affected: It would become a public health disaster of the century.

Although imports can help bridge the gap in demand, steps must be taken to encourage domestic production in order to avoid potential hostage-like situations particularly at times of limited availability.

All it requires is a: vision beyond vested interests and vote-bank concerns; strong political will to take concerted efforts in terms of increased investments in R&D and infrastructure across the value-chain; conducive and balanced policies that are based on holistic understanding of the realities of the agri-food sector on the ground.

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Mycotoxins and mycotoxicosis in livestock production

by Francisco J. Martínez and Fernando Aguado, Export Department, Nufoer SL, Madrid, Spain Cereal and cereal by-products, corn grains and corn silage are thought to be the most exposed ingredients to mould and mycotoxin contamination. This article by Francisco Martinex and Fernando Aguado at Nufoer

M

SL in Spain looks at the major mycotoxins and why it is important to test for an array and not for a single one in order to analyse feed quality and risks

ycotoxicosis refers to the different diseases caused by exposure to different mycotoxins, and it has a high occurrence in livestock production.

Mycotoxins are fungal secondary metabolites, toxic to humans and animals, produced by certain species of fungus.

The growth capacity of these fungi depends on several environmental factors such as moisture, temperature and availability of energy and nitrogen sources.

Likewise, the production of mycotoxins depends on specific environmental factors, and the presence of mycotoxigenic fungi does not imply a presence of mycotoxins and vice versa, since mycotoxins present great stability and can be present in feedstuffs even after the deterioration of the producing fungus.

Cereal and cereal by-products, corn grains and corn silage are thought to be the most exposed ingredients to mold and mycotoxin contamination, depending on various factors such as grain handling, processing and storage conditions.

38 | Milling and Grain

Mechanically damaged grain seeds are more prone to mold contamination than intact ones. Storage facilities with high moisture content (above 13 – 15 percent) and high temperatures (above 25–27ºC) facilitate mold growth and contamination of grain.

Depending on the feed contamination level, exposure, environmental factors, mycotoxin, fungal species and animal species involved, the clinical symptoms may differ.

However, mycotoxins rarely occur at concentrations high enough to cause clinical symptoms: mycotoxins are more frequently present in animal feed at low concentrations, producing subclinical symptoms over a long period of time, which are more difficult to diagnose and are of greater economic importance (Marquardt, 1996; Bryden, 2004).

It is important to emphasize that mycotoxicosis are often owed to the action of several mycotoxins ingested by the animals.

Indeed, different mycotoxins can occur simultaneously in feedstuffs, since some mycotoxigenic fungi are known to produce different kinds of mycotoxins, and feed raw materials are commonly contaminated with different fungi species at a time (Bottalico, 1998; Sweeney et al., 1998). In addition, a large number of studies have shown toxicological interactions between different mycotoxins, ranging from synergistic to antagonistic interactions (Grenier et al., 2011; Mallmann et al., 2011).

Therefore, it is important to test for an array of mycotoxins and not for a single one in order to analyze feed quality and risks.

Major mycotoxins in animal feed

There are over 300 mycotoxins discovered, but the main mycotoxins classes of concern in animal and human health are produced mostly by species of genus Aspergillus, Fusarium and Penicillium. In the European Union context, only a few of these mycotoxins (aflatoxins, fumonisins, deoxynivalenol, zearalenone and ochratoxin A) are subjected to legal regulations setting

F maximum levels or guidance values for the major mycotoxins in different feedstuffs for different animal species.

Aflatoxins

Aflatoxins are a group of mycotoxins produced by two ubiquitous species of Aspergillus. They primarily occur in crops produced in tropical and subtropical regions. Peanut cake, palm kernel, copra and corn gluten meal are considered to be the primal source of aflatoxin exposure (EFSA, 2004a).

Toxigenic Aspergillus flavus produces aflatoxins B1 and B2, while toxigenic Aspergillus parasiticus produces aflatoxins B1, B2, G1 and G2 (Cotty et al., 1994). Among those, aflatoxin B1 (AFB1) is considered to be the most prevalent and toxic compound for animals and humans (EFSA, 2004a).

Aflatoxins are liposoluble compounds, and therefore are easily absorbed in the digestive tract. AFB1 metabolism has been thoroughly studied.

It is known to be metabolized in the liver, resulting in five main metabolites, some of them with mutagenic, carcinogenic and teratogenic effects, and with the capacity of diminishing protein production (WHO, 1983; Nibbelink, 1986). Aflatoxin M1 (AFM1), one of AFB1 metabolites, is excreted through milk in significant concentrations, and it is thought to have an hepatotoxic and carcinogenic effects in humans (Henry et al., 2001).

Furthermore, AFB1 metabolites can also be found in muscular tissues of different livestock species (and therefore found in meat intended for human consumption) (Trucksess et al., 1983) and in eggs of laying hens (Herzallah, 2013).

In pigs, acute symptoms appear right after consumption of highly contaminated feed and the animals show depression,

anorexia, jaundice, hemorrhages, ataxia, diarrhea and death; Chronic intoxications result in long term economic losses because of drops in daily weight gain, feed intake, worsening in feed conversion ratio, etc.

Occasionally, animals can present scaly skin or purple coloring, lethargy and depression (Diekman et al., 1992; Radostits et al., 2000; Mallmann et al., 2011).

Susceptibility to aflatoxins varies among poultry species and breeds, being ducklings and turkeys the most susceptible species, followed by quails and pheasants, and finally chickens, which appear to be the most resistant species (Leeson et al., 1995).

Symptoms vary from decreased feed intake and weight loss to a drop in hatch-ability and fertility, egg production and weight (Leeson et al., 1995; Pandey et al., 2007, Herzallah, 2013).

Chronic intoxication in ruminants results in weight loss, abortions, abnormal estrus cycle, decreased milk production, mastitis, diarrhea and respiratory disorders (Cassel et al., 1988; Guthrie, 1979).

Fumonisins

Fumonisins are a group of mycotoxins mainly produced by fungi of the genus Fusarium. Among them, the most important toxins are those belonging to the B group (fumonisins B1, B2 and B3) (Cawood et al., 1991); being fumonisin B1 (FB1) the most toxic and frequent one (EFSA, 2005). They are toxic to both animals and humans and they are framed in the group 2B of carcinogenic substances (IARC, 1993).

Although fumonisins are almost exclusively found in corn, they can still be found in other crops (Bullerman et al., 1994). Corn and corn by-products are extensively used in animal nutrition.

Corn grain, for instance, because of its high energy content, is

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F one of the main components used in monogastric diets and cattle concentrates.

Moreover, corn silage is frequently used in cattle nutrition, and may represent up to 80 % of the daily ration. Corn byproducts such as corn oil, corn gluten or corn germ meal are also frequently used in animal nutrition. Since fumonisins are stable in high temperatures and resist fermentation, they can be found in processed feedstuffs.

Fumonisins chemically resemble sphinganine and sphingosine, responsible for the synthesis of sphingolipids, structural compounds of cell membranes and are present in different tissues, especially in the nervous system. These mycotoxins are able to disrupt the metabolism of sphingolipids, causing alterations in cell growth and differentiation, apoptosis and necrosis (Merrill et al., 1996; Norred et al., 1998).

The toxins are eliminated mainly through feces, but a certain amount can be eliminated through eggs and milk in laying hens and dairy cattle respectively when high doses of fumonisins are consumed.

Swine and horses are the most sensitive species to fumonisins, especially to FB1; while poultry and ruminants are apparently

Galtier et al., 1981; WHO/FAO, 2001; EFSA, 2004c; Völkel et al., 2011).

OTA inhibits protein synthesis by competition with the amino acid phenylalanine, and also promotes cell oxidation (WHO/ FAO, 2001; Marin et al., 2009). Furthermore, OTA is thought to be involved in the occurrence of Balkan Endemic Nephropathy in humans (Vrabcheva et al., 2004), though there might be other environmental agents required to develop the disease (Abouzied et al., 2002).

The pig is one the most sensitive species to OTA. The mycotoxin primarily affects kidneys (Krogh, et al., 1979), sperm production and quality reduction in boars (Biro et al., 2003).

Intoxicated animals develop polydipsia, up to four times the normal water intake, and polyuria as a consequence. These signs can be accompanied by diarrhea, bloody urine, decreased feed consumption, decreased feed efficiency and decreased weight gain (Szczech et al., 1973; Krogh et al., 1979; Cook et al., 1986).

Poultry species seem to be less sensitive than pigs to the effects of OTA, mostly showing altered performance: reduced feed consumption, feed conversion, weight gain and egg production (Duarte et al., 2011).

Zearalenone

Cereal and cereal by-products, corn grains and corn silage are thought to be the most exposed ingredients to mold and mycotoxin contamination more resistant. Chronic intoxication in pigs is characterized by low feed intake and weight gain, hepatic encephalopathy syndrome, hyperplastic oesophagitis, gastric ulceration and heart and pulmonary arteries hypertrophy (Casteel et al., 1994; Smith et al., 1999; Gumprecht et al., 2001).

In poultry, symptoms range from a decrease in feed intake and weight gain (Javed et al., 1993) to a decrease in egg production and mortality increase (Prathapkumar et al., 1997).

Dairy cows show a decreased feed intake and milk production (Richard et al., 1996; Diaz et al., 2000).

Ochratoxins

Ochratoxins are a group of secondary metabolites produced by species of Penicillium and Aspergillus. There are seven known ochratoxins. Among them, ochratoxin A (OTA) is the most important mycotoxin, because of its toxicological significance, carry-over capacity into human food, frequent presence in contaminated feedstuffs, stability against cooking and fermenting processes and possible significance as human carcinogen (classified as an IARC group 2B carcinogen in 1993). OTA is mostly found in barley, wheat and rye (Cabañes et al., 2010).

In ruminants, OTA is metabolized into a less toxic compound by the ruminal microflora. Once OTA reaches the bloodstream, it binds to serum proteins, especially to albumin, conferring OTA an elevated half-life in blood serum, and therefore can be found in blood-based products, such as bloodpudding or additives made of pig-blood or pig-plasma. Residual concentrations can be found in liver, muscle and fat tissues, eggs and milk (Suzuki et al., 1977; 40 | Milling and Grain

Zearalenone (ZEA) is a mycotoxin produced by different species of the Fusarium genus (Bennett et al., 2003), and almost always co-occurs with other Fusarium toxins such as deoxynivalenol (DON). ZEA is particularly found in corn grains cultivated in temperate and warm regions, but it can also be found in other cereal crops such as wheat, barley or rice, and occasionally in sorghum and soy beans (EFSA, 2004b; Zinedine et al., 2005). ZEA resists high temperatures, and shows good stability during storage and processing, and therefore it can be found in processed feed and food.

As a detoxifying mechanism, plants are able to chemically modify ZEA and DON via acetylation, glucosidation and sulfation (Berthiller et al., 2005). The resulting metabolites, which have been found to be toxic to animals, are often undetectable with standard laboratory techniques. To fail to detect them could lead to an underestimation of the toxic potential of feeds (Vendl et al., 2009). It has been reported that gut microbiota is able to hydrolyze those “masked” mycotoxins and release their native forms (ZEA and DON) (Gareis et al., 1990; Gareis, 1994; Berthiller et al., 2011).

ZEA is an estrogenic compound that binds competitively estrogen receptors in different tissues (especially uterus, mammary gland and liver) and generates estrogen-like responses. ZEA is metabolized mainly in the liver, resulting in two major metabolites, both also possessing binding affinity to estrogen receptors. Because of its estrogenic activity, ZEA affects females over males and young animals (particularly young females) over adults.

Pigs seem to be most susceptible to ZEA (Diekman et al., 1992), showing hyperemia, edematous swelling of the vulva, increase of uterine, ovarian and mammary gland size, and occasionally vaginal or rectal prolapse (Etienne et al., 1981; Haschek et al., 1986). ZEA also have teratogenic effects in piglets and affects embryonic survival (D’Mello et al., 1999). In males, ZEA induces a reduction of the weight of testes and sperm quality (Mirocha et al., 1977).

Poultry species are less susceptible to ZEA, and adverse effects are only observed at very high doses of the mycotoxin that are unusual in field conditions.

Cattle seem to be more resistant to the estrogenic effects of ZEA because of the ruminal degradation of the mycotoxin (Kiessling et al., 1984).

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F Trichothecenes

Trichothecenes are a group of chemically related compounds produced by a wide number of fungi and are classified into four different chemical groups: Types A, B, C and D (McCormick et al., 2011). However, those of concern in livestock production are those produced by Fusarium species, and include Type A and Type B toxins. Type A toxins include in turn T2-toxin and its metabolite HT-2 toxin, and Type B toxins include DON. DON, T2-toxin and HT-2 toxin usually occur with other Fusarium mycotoxins such as ZEA and fumonisins, in warmer climates. T2 toxin and HT-2 toxin concentrations in wheat, rye and oats were found to be highly correlated (Gottschalk et al., 2009; Edwards, 2009). Among trichothecenes, DON is the most frequently occurring toxin, but is about 100 times less toxic than T2-toxin. T2 and HT-2 toxins are significantly bound to the outer hull of cereal grains; therefore by-products for the feed industry obtained through de-hulling may contain greater concentrations of those two toxins.

Trichothecenes inhibit protein synthesis, interact with proteins and cause oxidative stress by generating free radicals (McCormick et al., 2011). T2 toxin also induces cell apoptosis in the digestive tract (Li et al., 1997). Pigs are very sensitive to DON while poultry species seem to be more resistant to its effects. In pigs, exposure to these toxins causes immunosuppression, vomiting, diarrhea, gastric and intestinal hemorrhage, dermatitis, feed refusal, weight loss and lower milk production, among other problems (Mallmann et al., 2011). Vomiting has been observed at high doses of DON in feed, making this toxin to be commonly known as “vomitoxin”.

Broilers and laying hens appear to be less sensitive to the mycotoxin. At low dietary concentrations in chicken, DON causes a reduction in feed consumption, and at high concentrations, weight loss, immunosuppression, and decreased intestinal nutrient absorption (Prelusky et al., 1986; He et al., 1992; Rotter et al., 1996; Awad et al., 2008). Ruminants are more resistant to DON, which is attributed to its metabolism by rumen bacteria (Seeling et al., 2006).

Animal products do not contribute in a significant way to human exposure to DON (EFSA, 2004b). Since no human diseases due to carry-over have been reported, DON’s importance remains primarily economic because of its decrease of animal productivity (Völkel et al., 2011).

Pigs are among the most affected animals towards the effects of the T2-toxin. Dietary exposure to the toxin resulted in reduced feed intake which led to reduced weight gain, in most cases without affecting feed conversion rate (Harvey et al., 1994; Rafai et al., 1995). Lesions caused by ingestion of T2-toxin are observed mainly in the upper digestive tract, mainly ulcerations and hemorrhages (Weaver et al., 1978). High concentrations of the toxin in feed can induce diarrhea and perineal lesions due to the contact with residual toxins in faeces (Mallmann et al., 2011).

Effects of T2-toxin on reproductive performance in sows have been reported (Glavits et al., 1983).

In poultry, acute intoxication leads to nervous symptomatology: hyperpnoea, lethargy, loss of balance and head dropping appeared after a few minutes and disappeared quickly. Soon after, digestive problems follow, characterized by repeated deglutition, diarrhea, feed refusal and hemorrhages in the digestive system (Grevet, 2004). Chronic intoxication is characterized by alterations in production and reproduction performance, skin and mucosa lesions, and immune system alterations in different poultry species.

42 | Milling and Grain

Though ruminants are more resistant to trichothecenes because of the toxin metabolism in the rumen, T2 intoxication in cattle causes feed refusal, gastroenteritis and gastrointestinal lesions (Petrie et al., 1977; Weaver et al., 1980), intestinal hemorrhages (Petrie et al., 1977), ruminal ulcers and even death (Pier et al., 1980). Decreased feed consumption, decreased milk production and alterations in the estrous cycle were the observed effects in dairy cattle (Kegl et al., 1991).

Because of the metabolism and biotransformation of T2 toxin, it is though that its accumulation in animal tissue is prevented.

However, it has been shown that transfer to milk is possible (Völkel et al., 2011).

Mycotoxicosis prevention

There is no effective treatment of the intoxication once the clinical signs appear and in some cases, even if the animal recovers from the intoxication, its performance will remain low. It is then important to highlight the necessity of preventing mycotoxicosis, either by preventing mold contamination and mycotoxin formation or by eliminating mycotoxins in feedstuffs.

Though preventing the formation of mycotoxins in the feed is the best measure to avoid mycotoxicosis, it is not always an easy or available strategy. And, as aforesaid, even if the mycotoxigenic fungi are eliminated from feed, some mycotoxins show great stability and can remain in feedstuffs. Thus, mycotoxin elimination measures in feed should be a secure way to prevent mycotoxicosis in animals.

Different methods for mycotoxin elimination in animal feed have been described, ranging from inclusion of natural compounds (such as organic acids) to physical methods (X-ray or UV light), microbiological methods (enzymes produced by microorganisms) and chemical methods (oxidant agents or mycotoxin adsorbents among others). Among all these methods for mycotoxin elimination in animal feed, the most implemented is the addition of natural clays, because of its low cost, simple application and the absence of adverse effects in animals. Those clays adsorb mycotoxins that may be present in the feed and prevent them to be absorbed (Van Kessel et al., 2010).

Our solution

Knowing the risks inherent to the presence of mycotoxins in animal feed and its repercussions in animal health and livestock production, NUFOER’s main concern has been to develop a product able to prevent and to counteract the impact of these fungal toxins while remaining affordable. Assuring the quality of the ingredients used, and excluding any drug or pharmaceutical compound, we developed a series of mycotoxin binders which we brought together under the brand NUFOTOX. Our binders’ product line range from basic mycotoxin binder (NUFOTOX) 100 percent made of natural clay (Hydrated Sodium Calcium Aluminum Silicate, HSCAS) to a most advanced binder (NUFOTOX ADVANCE), adding different ingredients such as organic acids, enzymes, plant extracts, yeast extracts or biopolymers, depending on the toxin binder required.

How so “depending on the toxin binder required”?

There are many different molds and mycotoxins that contaminate animal feed, some more complex than others, and affecting the animal differently. On this basis it becomes necessary to implement the binding activity of the HSCAS, control mold contamination levels, and sometimes, even help the animals’ recovery from the intoxication. Each of NUFOER’s toxin binders is designed differently in order to fulfill those different aims.

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F

Preventing bread waste - A national success story from Turkey

Feature

from the

2015

by Professor M. Hikmet Boyacioglu, Chairman of the Department of Food Engineering at Okan University, Istanbul, Turkey

O

ne-third of food produced for human consumption is lost or wasted globally, which amounts to about 1.3 billion tons per year.

Food is lost or wasted throughout the supply chain, from initial agricultural production down to final household consumption.

Food losses represent a waste of resources used in production such as land, water, energy and inputs, increasing the green gas emissions in vain.

According to Euromonitor International, globally 141 million tons of baked goods are sold each year and bread represents by far the most significant proportion of total baked goods sales, at over 85 percent, with retail volume sales of 120 million tons in 2013 which results in inevitable waste. Since there is no clear definition of food waste, it is difficult to estimate global bread waste although there is the need to minimise bread waste at all points along the chain.

Food loss, food waste and food wastage

Food loss refers to a decrease in mass (dry matter) or nutritional value (quality) of food that was originally intended for human consumption. These losses are mainly caused by inefficiencies in the food supply chains, such as poor infrastructure and logistics, lack of technology, insufficient skills, knowledge and management capacity of supply chain actors, and lack of access to markets.

In addition, natural disasters play a role. Food waste refers to food appropriate for human consumption being discarded, whether or not after it is kept beyond its expiry date or left to spoil. Often this is because food has spoiled but it can be for other reasons such as oversupply due to markets, or individual consumer shopping/eating habits. Food wastage refers to any food lost by deterioration or waste. Thus, the term “wastage� encompasses both food loss and food waste.

Food waste causes and scale

Food losses mainly occur at the beginning of the supply chain; during production, storage, transport, wholesale and processing 44 | Milling and Grain

while food waste mainly occurs at the end of the food supply chain; in the store, at restaurants as well as at home. Possible causes of food waste are summarised in Table I. Food losses and waste amounts to roughly US$ 680 billion in industrialised countries and US$ 310 billion in developing countries. Industrialised and developing countries dissipate roughly the same quantities of food -respectively 670 and 630 million tons. Per capita waste by consumers is between 95-115 kg a year in Europe and North America, while consumers in subSaharan Africa, south and south-eastern Asia, each throw away only 6-11 kg a year (Figure 2).

The total amount of food waste in the European Union is about 90 million tons per year or 180 kg per capita per year excluding agricultural food waste and fish discards. The European Commission is referring to this as an unacceptable example of unsustainability estimating that by 2020 without any effective measures 126 million tons food will probably be wasted per year.

Almost 50 percent of edible and healthy food gets wasted in EU households and supermarkets each year.

Food waste is expected to rise to about 126 million tons by 2020 without additional prevention policy or activities.

According to Rabobank, the European Food & Agribusiness (F&A) industry is currently losing 60 billion Euros of value each year through food that is wasted in the supply chain and never reaches the consumer.

In spite of above information on food wastage, figures on the exact amount of food waste in the manufacturing sector remain heavily debated due to lack of a clear definition of food waste, lack of proper data collection and methodological issues, such as diverse and not consequent interpretation of by-products.

Global bread production and trends

According to Euromonitor International, globally 141 million tons of baked goods are sold each year and bread represents by far the most significant proportion of total baked goods sales, at over 85 percent, with retail volume sales of 120 million tons in 2013.

Bread sales registered a decline over 2008-2013. The decline in bread volumes is primarily due to the fall in artisanal bread sales, which accounted for 78 percent of overall bread volume sales

F in 2013. Packaged bread was one of the best performing baked goods categories over 2008-2013, growing by two million tons and taking a considerable share from artisanal bread.

Bread wastage volumes

Since there is no clear definition of food waste, it is difficult to estimate global bread waste although there is the need to minimise bread waste at all points along the chain.

Pietrzak and Kawa-Rygielska indicated that annual global production of bread exceeds 100 million tones, and estimated wastage for bakery goods is about 7 - 10 percent so the annual production of wastes in this industry can reach 10 million tones worldwide. The major factor for waste formation in this field is that part of the bread produced is left unsold and returned to the bakery due to significant levels of staling and large amounts of bakery products which are produced in excess to fulfill consumers’ demands.

According to GIRA, 25 percent of bread products in highincome countries are wasted at retail and consumer level, during storage and processing.

According to the Association Internationale de la Boulangerie Industrielle (AIBI) the major International Association of Plant Bakeries, products at baking plants which cannot be sold are less than 1 percent. Almost all of this material is used as animal feed or as bioenergy.

Stale bread loses its sensory qualities. This results in a negative perception from the consumer even though the product is still healthy and rich in nutrients. Consequently, large quantities of bread are discarded which causes an important economic loss and makes waste bread a major component of the food waste problem.

Prevention of bread waste

In view of more efficient supply chains with high productivity to meet the growing demand, one of the challenges for agriculture is to reduce food loss and waste along the food chain. Reducing food losses and waste is gathering increasing global interest and action. Governments, research institutions, producers, distributors, retailers and consumers have all different ideas about the problem – the solutions – and the ability to change.

AIBI has already started to inform and to highlight the importance of this issue and to raise awareness among members.

It is a priority on the agenda of the AIBI Board and AIBI members are willing to participate to reduce food waste in the bakery chain.

Food waste in the United States represents a market opportunity worth over $160 billion for innovators who can reduce this waste and its impact. Food waste, which is estimated at 30 percent to 40 percent of the annual food supply in the United States, has far-reaching social, economic, and environmental ramifications. It also adds up to big money and big incentives to food technologists to develop new approaches and products for reducing, recovering, and recycling food waste. A closer look at food waste in the United States reveals where opportunities might lie.

According to Rabobank’ s latest report, it is vital that the industry looks to address the issue and F&A companies have much to gain themselves from doing so. Rabobank sees innovation as the most effective means of making an immediate difference to reducing waste.

However, for it to be successful, optimisation of supply chain processes and business models may be required. Rabobank suggests food processors and retailers should start to select

August 2015 | 45

F partners who see the benefit in reducing waste and have the potential to benefit from the additional effects on the supply chain. Nevertheless, companies should realise that innovation is not for all partners, but an asset that will attract like-minded companies and markets to becoming supply chain partners.

Bread staling continues to be responsible for huge food wastes all over the world. The phenomenon is still far from being fully elucidated. Despite new measurement techniques, such as NIRS, NMR, and X-ray, which give novel and interesting details on bread firming and also evidence of their importance as complementary tools to traditional measurement techniques, the real challenge still remains the knowledge of the precise mechanism(s) of staling. Further efforts must be exerted to explore and exploit the power of novel technologies in bread processing, particularly the nonthermal technologies (high hydrostatic pressure, ultrasound processing, pulse-light technology, and others), and their effects on the retardation of bread staling.

Whereas the points on avoiding food waste during processing are relevant to all food and drink manufacturers, possible solutions to reduce bread waste is cited in Table II. However, during efforts to reduce bread waste constraints could arise from legislation (e.g. requirement to sell bread at specific weights) and cultural and standardisation constraints (consumers traditionally buy specific types/weights of bread). The product is offered in too big portions or the consumer makes impulse purchases (people may be attracted to buy more than they can eat). There are financial constraints through a lack of investments and innovation by industry.

Turkey’s success story

According to Euromonitor International, bread sales reached 9.261.600 ton in 2014 (Table III). Turkey has one of the highest per capita bread consumption rates in the world although available consumption figures vary between 72 kg to 199.6 kg. Based on Turkish Grain Board study, 121 kg/person bread consumption in 2008 was reduced to 116 kg in 2012 in Turkey.

In 2013; The Turkish Grain Board, a subsidiary organisation of the Ministry of Food, Agriculture and Livestock, launched a new campaign called “Ekmegini Israf Etme” (Don’t Waste your Bread) which works to curb the amount of waste bread in Turkey through educational activities with regard to consumption of bread. The majority of consumers however still give prominence to the warmness and freshness of the bread while it is still a small group that gives prominence to whether the bread is wholegrain.

Additionally, leading packaged/industrial bread producers have been utilising this campaign by indicating that the consumption of packaged/industrial bread is a good way to alleviate the waste bread problem as these products can be re-heated and consumed for a long time.

From 1 July 2013, a new flour notice became effective which also aims to increase the consumption of whole grain bread while decreasing the amount of waste bread. Furthermore, the lowest weight for regular bread was decreased from 300g to 250g. This new weight reduction also aims to curb the waste bread problem and negatively affects the volume sales of unpackaged/artisanal bread. Last but not least, the new regulation prohibits the sales of unpackaged/artisanal bread in open spaces such as bazaars, butchers and green grocers.

The general trend in baked goods is higher growth rates for packaged/industrial categories. The main reason for this trend is the changing eating habits of Turkish consumers.

Companies within packaged/industrial bread will increasingly promote the “Don’t Waste Your Bread” campaign by indicating 46 | Milling and Grain

that packaged bread consumption is an effective way to alleviate the waste bread problem.

The Turkish Grain Board, conducted research in 2008 and 2012 on the production, consumption habits and waste of bread in Turkey. The results of these studies were alarming, because they showed that the bread waste in Turkey reached serious amounts.

As a consequence, a campaign was launched in January 2013 to inform and raise society’s awareness of bread waste. The aims of the campaign are to create public awareness, prevent waste in bread production and consumption, ensure bread is bought as needed and preserved properly, inform society on different ways of using stale bread and contribute to the economy by preventing waste.

At the end of 2013, the Turkish Grain Board carried out another study in order to evaluate the impact of the campaign on bread waste and consumption habits. The research results show that, between 2012 and 2013, daily bread waste in the country decreased by 18 percent from 5.95 million to 4.9 million loaves saving a total of 384 million loaves of bread.

On a per capita basis, these improvements resulted in a 19 percent decrease in daily bread waste to 16.2 grams. Furthermore, the campaign resulted in a 10 percent decrease in the daily total bread production and consumption. Based on calculations by the Turkish Grain Board, reducing bread waste saved USD 159 million and reducing unnecessary bread purchases saved USD 1.3 billion, for a total savings of USD 1.5 billion.

The bread waste campaign included a media campaign with estimated advertisement costs of USD 243 million, three spread on internet, TV commercials, newscasts, newspaper articles, a research book about bread waste, a stale bread recipe book and various brochures. Several conferences, exhibitions, press meetings, stale bread recipe competitions etc., have been organised with the co-operation of the universities, non-governmental organisations, the private sector and local administrators and reached all parts of the Turkish society.

As Turkey wastes less bread, it also saves more money.

According to the Turkish Grain Board, reducing unnecessary waste and excess purchases saved consumers an estimated US$ 1.2 billion in 2013.

To expand on early successes, Turkish Grain Board recently partnered with the Turkish postal service to release 100 000 commemorative stamps introducing the campaign and its message to a wider national audience. Further demonstrating that the country is serious about the issue, the Government of Turkey is including food waste prevention a priority in its national development plan through 2018.

With one-third of global food production currently wasted or lost, the international community is homing in on Turkey’s success. The Grain Board has shared its campaign model as a best practice, exchanging experiences with the United Kingdom’s Waste and Resources Action Program and with governments across Europe and Central Asia at last year’s FAO Regional Conference for Europe.

Final thoughts

Bread is the healthy basis of every day meals all over Europe.

The importance of bread is shown through the huge daily global consumption, which results in inevitable waste. There is the need to minimise food waste at all points along the food chain.

Among many possible solutions; extended shelf life of bread by natural ingredients and food safety measures, increase in bake-off production, shift from artisanal to packaged bread and raising awareness and information to the consumers will be utmost importance in prevention of bread waste.

F

I

Pioneering UK wheat trials

n June, it was a great time to visit and report on two wheat farms in six days: BASF East Midlands Agronomy and Sustainability Farm at The Grange, Mears Ashby and BASF Yorkshire Agronomy and Sustainability Farm at Tophouse Farm, Rawcliffe Bridge. In the UK, wheat is a vital commodity that traditionally faired well in these arable regions for centuries. Innovative work and research is now undertaken to farm wheat in new ways. It shows how effective land, resources and nature can be created in harmony with each other to provide sustainable environment and wheat for food.

Top House farm joined in partnership with BASF in 1996. This farm was a trailblazer, ahead of its time for agronomy trials.

Biodiversity monitoring was introduced in 2002-2003 as part of the Voluntary Initiative (The Voluntary Initiative is a UK-based programme sponsored by the crop and farming industry which works with the UK government to promote responsible pesticide use). With co-operation and support from the Hinchliffe family, owners and farmers of Top House farm, a remarkable story has been developing. There have been successes such as increasing farmland bird numbers through simple measures alongside informative agronomy work this has delivered excellent informative data for farmers.

The Grange joined with BASF in 2008 with biodiversity monitoring, in the words of Andrew Pitts, “to provide for my children’s future.” With fantastic guides at both sites such as Graham Hartwell, environmental stewardship manager, BASF plc and Paul Goddard, stewardship value manager, BASF plc, on

48 | Milling and Grain

both days, there was a lot of exciting and important subject matter to see, touch and understand.

At Top House Farm, Graham and Paul were joined by John Peck, head of technical management and stewardship, North Europe, BASF plc; Louis Wells, agronomy manager, BASF plc; and Rose Riby, variety specialist (north) from KWS. The farm owners were also there to assist with information and share their own perspective. Regarding the farms, a minority of the land

F is for the trial partnership. Graham said, “for great biodiversity on a site, only 2 percent of the land is required. This proves that the simple steps taken at both sites is possible without impacting the amount of land required to add this value. Records are made at the start and then regularly through the farm’s lifespan over many years.” An important point that Graham and his colleagues were keen to stress was that the data is gathered and recorded by independent third parties so the whole value chain has reliable, unbiased and trustworthy information.

Firstly, travelling over to the East Midlands was a very pleasant affair from the Milling and Grain offices. With a timetable set for the London and South East Millers Society (LSEMS) to stick to, plenty of time was allocated for travelling. There was time for a quick call to Graham Hartwell before the LSEMS programme got under way, it gave a taster of what was to come later in the day and discussion of another site BASF plc ran and whether the opportunity to visit there could be possible. It would make this article an exclusive as no other journalist had yet visited both trial sites to report.

Attendees numbered around 30 for the The Moor and 22 at Rawcliffe Bridge. There was a strong representation of the milling community, even though numbers were small.

Representatives from a wide range of companies such as Bühler, Allied Mills and nabim joined the tours.

The tours of the farms generally followed a pattern of an introductory talk and walking tours of what creates the right balance for success in wheat and success in biodiversity. We learnt of the crop rotation patterns, a three-year cycle at The Grange and a five year cycle at Top House farm (Table1).

These open days at the farms were hosted by BASF plc, the world’s largest chemical company. An ironic fact was that

August 2015 | 49

F

there were no chemicals or chemical products being promoted.

The promotion at both sites was of wheat farming. There is a Biodiversity Action Plan in place and constant monitoring by independent conservationists of the production of data. Over time, both farms were proven to increase biodiversity as well as increasing wheat volumes. Positively thriving nature relies and assists positively thriving wheat crops.

Table1 Farm site

Year 1

Year 2

Year 3

Year 4

Year 5

The Grange

Wheat

Wheat

Bean

-

-

Top House farm

Wheat

Wheat

Rapeseed

Wheat

Wheat

During the The Grange visit the group of around 35 was introduced to the concepts and reasons for the site. This lay in seeking best practice, quality data and quality food; whilst using fewer resources to meet the sustainability challenges, increasing wheat production and biodiversity. Countering uninformed public perceptions was also a key factor at the site. Since its inception, all sections of society in the UK have visited these two sites each year - school groups right up to governmental policy decision makers.

Flour milling relies on good quality wheat. This is where the Top House Farm site excelled in showing the groups winter wheat from the current nabim recommended lists and trialing future wheat varieties. This takes place in a matrix of 30 differently treated wheat varieties. Treatments and fertilisers are applied in precise amounts to gain understanding Solstice, Skyfall, Crusoe, KWS Trinity, Gallant and RAGT Illustrious from Group 1; Cordiale, KWS Lili and Butler from Group 2; Zulu, 50 | Milling and Grain

Britannia, Energise, Conversion and KWS Barrell from Group 3.

There were many more in the Group 4 varieties but as these are commonly used in animal feed, not food milling wheats.

In many ways, the superior amount of wheat at Top House farm within its 142-hectare site gave more detail and depth to the attendees. The 2014 - 2015 cropping of wheat reflected the current economic conditions, recovery from the very wet preceding seasons and the relationship within the group. The plots of wheat at Top House sat as a checker-board pattern across a large field categorised into five stages of treatments from the trials. Louis Wells was able to provide a lot of discussion about the untreated and treated wheat and the cost benefits in the data from the 2014 trials. At its most effective, normal treatment to wheat added more tonnes to the harvest from the same amount of land of 6 tonnes per hectare with the Conquerer variety of wheat. Providing more return on investment is about being sustainable and more secure in providing reliable harvests to meet or exceed expectations.

The biodiversity is created and nurtured through drilling seeds of specific plants which provide habitable food stores for birds and wildlife to thrive, installing bird boxes in strategic places assists the best practice management for wildlife.

My final thoughts are that the overlying theme was about making the right choice for the site. The vast number of variables depend on where the site it is located. The complexity is simplified with the experience and broad vision of the partnerships between farmers, agronomists, breeders and environmental stewards. It seems that we are all responsible for the environment and of wheat it produces, which we all depend upon. These tours are highly recommended for flour millers and members of the cereal industry, they provide a deeper comprehension of how beneficial our industry can be to the environment.

F

1/3

Feedmill of the future … here today-built for tomorrow!

How we feed the world’s ever growing population is the big question for the milling industry. Milling and Grain magazine goes in search of answers, on a behind the scenes tour of the Van Aarsen-built, Kalmar Lantmän project - the most modern feedmill in the world - to find out how the technology in this new mill sets a standard for the future.

by Darren Parris Milling and Grain

The Kalmar Lantmän feedmill in Kalmar, Sweden

T

The CHALLENGE

here is almost nothing more important in life than feeding the planet. A wise man once pointed out that we must feed nine billion people by 2050. However, as a humble writer, I have seen firsthand round the globe and on every continent, just how very difficult this task is going to be.

Having visited many mills throughout both the developed and developing world, I have become fascinated at the challenges facing the modern miller; when we consider probably upwards of 80 percent of everything we consume has somehow been touched by the milling process, be it the simple process of flours and grains for breads, biscuit’s, pastry, crisps etc or your rice’s, pasta and semolina’s or indeed your coffee or chocolates how we mill has become ever more important.

And, nowhere is this more important than the production of feeds for all the species that give us our milk, cheeses, meats and fish.

When we consider the Feed Conversion Ratio (FCR) for most species of edible animals, it is clear that we must get the feed right. As a quick recap, the FCR refers to how many pounds (lb) of feed it takes to produce a pound of gained meat for human consumption. Below are some typical examples of FCR for some of the most common eaten species: • Beef cattle - 5.5 to 6.5lb of feed for each pound of gain • Chickens - 2 to 3lb of feed for each pound of gain • Pigs - 2.18 to 5.91lb of feed for each pound of gain • Fish – 1.2 to1.8lb of feed for each pound of gain You can see that these FCR’s vary considerably depending upon the species, with fish and poultry being the most efficient and therefore considered the most sustainable.

Often some of the ingredients in feed pellets, etc contains food already suitable for human consumption. Therefore from a sustainable perspective it has become ever more important to make sure the final feed compound is containing all the right ingredients to allow it to be an effective feed that puts the right nutrients back into the food for human consumption.

It is at this point you realise just how much more complex the process is for milling feeds than it is for flour, chocolates, rice or coffee, etc. When we consider what we want from our meats, and that they should be nutritious for us, they must contain the correct levels of minerals, vitamins, amino acids, proteins and carbohydrates to mention just a few nutritional expectations.

Therefore, the art of farming good healthy and nutritious animals with a good FCR will often come down to a good feed supplies and as with many recipes in life, every farmer will have his own preferences about what goes into their feeds for their animals.

Animal feeds can be complex compounds, which for a balanced healthy diet will need to include some of these basic nutritional elements: • Minerals • Carbohydrates • Vitamins • Proteins • Water • Fat This is by no means a complete list, and by way of an explanation, if I just focus on proteins, these are composed of over 20 different amino acids, which are liberated during digestion.

Animals with a simple single stomach (monogastric), including

humans, swine, poultry and rabbits, require the correct amounts of the following 10 essential amino acids daily: arginine, histidine, isoleucine, leucine, lysine, methionine, phenylalanine, threonine, tryptophan and valine.

On top of this when you look at just some of the minerals that are essential for animal life, which include common salt (sodium chloride), calcium, phosphorus, sulphur, potassium, magnesium, manganese, iron, copper, cobalt, iodine, zinc, molybdenum and selenium. And, then if you keep in mind that the last six of these can be toxic to animals if excessive amounts are provided, you begin to understand the challenges facing feed millers to get feed right.

I point this out only to highlight the complex requirements that a feedmill of the future, as of today, would need to be capable of delivering.

With hundreds of potential ingredients, that would need to be added in exact doses and mixed and pelleted according to a farmers wish is almost unconceivable.

“Experts at VICTAM predicted dramatic changes for feed milling in Europe over the next 10 years” This does not even touch upon the additives in feed to improve gut health or palatability or indeed any probiotics and veterinary medicines such as antibiotics. This would all need to take place in hermetically sealed environments to avoid cross contamination in the mill across different species.

So already one can begin to build a picture of what tomorrows feed mill must be capable of.

The holy grail of the feed industry

In this era of improved sustainability, improved efficiency, improved automation in a more hygienic environment it is important to point out that this utopia of a futuristic mill meeting all these requirements and more has become the holy grail of the feed industry.

No surprises then that during the VICTAM Exhibition in Cologne, Germany recently experts in the feed technology field revealed how the EU feed sector should become more sustainable. These same experts at the VICTAM predicted dramatic changes for feed milling in Europe over the next 10 years. One of those commenting at VICTAM was Trudy van Megen, director of the Feed Design Lab, a Dutch research and education centre for innovation and sustainability in the feed industry, who went on to say, “The European feed sector has to do more with less and must reduce its dependence on imported grains such as soy for animal feed production to boost its sustainability profile.”

It was pointed out by a few experts at VICTAM that if a factory decreases variability in a pellet line and optimises the process in terms of capacity, temperature and machinery, it is possible to decrease consumption of electrical and thermal energies in pellet manufacturing.

Most notable of the speakers was Harm Klein, business developer for feed at Tebodin, who spoke specifically on the August 2015 | 53

F

F ‘Feed mill of the future’. Harm looked at the trends that are supporting shift in feed production 10 years’ from now. He said new feedmill constructions, in general, will take place in emerging economies, with only expansion or redesign of feedmills and not outright builds likely in regions like Europe and North America.

More and more feedmills in Europe, said Klein, will only supply concentrates to livestock producers and, thus, the production and storage process at feedmills by 2025 will have undergone a radical shake-up.

How right was Harm Klein? With the one exception it will not be in 10 years’ time, it is already here today.

What millers aspire to

Now, let’s be clear, I am not a trained feed miller nor a nutritionist or engineer, but I have visited my fair share of feedmills and feed additive companies and having spoken to many millers and farmers over recent years and I have learnt what each and every miller would like to aspire to.

I understand the business model of a feed company, those goals and objectives that must be met with the feed to either maximise sales or optimise the feed for the production of meat, milk, or eggs.

Operating a modern feedmill requires good decision-making on the part of the mill manager. The feed mill manager must understand how to use the key indicators that will increase profitability and productivity, as well as reduce costs. Each manager must select from the multitude of indicators that influence the operation’s productivity and costs. These indicators will vary based upon the primary business objective of the feedmill.

Commercial feedmills typically focus on profit margins, sales and customer service; whereas an integrated feed operation focuses on high volume production of feed at the lowest possible manufacturing cost.

Regardless of the business model under which a feedmill operates, there are indicators (KPIs) that apply.

Managers should develop KPIs for manufacturing and delivery

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processes, labour efficiency, manufacturing and delivery costs, safety and quality. These KPIs, along with an annual manufacturing budget, will help a manager recognise the strengths and weaknesses within the operation.

KPIs can be used in the development of both short- and longterm goals to improve the productivity of the feedmill. Typical areas to monitor feed mill productivity include: • Downtime • Tonnes per run • Tonnes delivered per load • Pelletmill changeovers • Load out waiting time • Bagged tonnes per day • Tonnes per man hour or man• Actual versus scheduled hours per tonne hours of operation Man-hours-per-tonne is typically measured in commercial feedmills where more labour is required for the manufacturing and packaging process of feed due to the production of small batches of specialty feed or production of feed based on individual customer orders.

Another area to monitor are the shrink/gain costs that are associated with the loss or gain of ingredients and feeds.

Feedmills typically experience a shrink in ingredients due to losses that occur during the receiving and grinding processes.

Receiving losses are typically in the form of dust or product loss, whereas during the grinding process there is a loss of moisture. A mill that produces pelleted feed may experience a gain in feed due to residual moisture left in the feed after the cooling process.

Mill managers may find it helpful to calculate the shrink and gain of both ingredients and feed separately, as well as the total shrink (gain) of the feedmill. The total shrink (gain) can be determined by the following equations (Emmerson, 2005): • Expressed by weight: (Beginning inventory + receipts) – (Ending inventory + shipments) = Shrink (Gain) • Expressed by percentage: Shrink (Gain) by Weight ÷ Shipments in Weight x 100 = Percent Shrink (Gain) • Expressed by monetary value: Shrink (Gain) by Weight x Monetary Value/Weight Unit = Monetary Value of Shrink (Gain).

www.symaga.com symaga@symaga.com

New spiral, flight & roof stairs, improved access to the top of the silo.

Visit us: AGROEXPO

09 - 20 July, Bogota, Colombia Stand: Hall6, Stand 229

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

GRAINTECH 21 - 23 August, Bangalore, India

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2/3 Feedmill of the future … here today-built for tomorrow!

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Kalmar Lantmän

The FEEDMILL

almar Lantmän is a leading feed manufacturer in Sweden, and with years of operational experience it had very clear goals for what it wanted to achieve with its new feedmill.

Kalmar Lantmän owned the site in Kalmar and already operated two feedmills on it. As part of the wishlist for Kalmar Lantmän, the new feed mill should: a) Replace the two existing feedmills b) Create lower production costs per tonne of animal feed c) Considerably reduce labour costs d) Be the very best in energy efficiency e) Offer the highest degree of flexibility and efficiency f) Use the highest degree of automation g) Highest degree of hygienic production h) Offer the highest level of fire safety and health safety i) Be environmentally friendly Arriving in Sweden with my colleague Olivia Holden we met up with Maril van Kempen and Hans van der Weijden from Van Aarsen International, the turnkey supplier of the feedmill and Åke Karlsson from Kalmar Lantmän.

My first impressions - this is an impressive structure, at 60 meters tall.

It sits on a foundation of 3000sqm supported by 924 concrete and steel piles each driven into the ground to find solid rock to support it. Considering the 8400 tonne foundation slab of concrete and the further 23,200 tonnes of prefab concrete used in the building, it needs these piles.

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So as we climbed the 13 levels, 18,000sqm of feedmill factory, to the top, you began to get a feel for the magnitude of this project. From the initial clearing of the old space to driving in the piles and laying the first foundation, Van Aarsen had to deliver the equipment required for each level as it was assembled.

As the prefabricated concrete was laid, Van Aarsen had to fit the equipment immediately as no one wants the project to stand still as the cranes for the build still had to be paid for!

The total project was expecting to come in at US$50 000 000 with some of the larger proportion of costs coming from the preparation of the building site, driving in the piles and the building structure itself.

The choice of contractor for Kalmar Lantmän turned in favour of Van Aarsen as the company proposed a new building design that would be 30 percent smaller than its competitors, making substantial savings in the build costs whilst still giving the feedmill the full function and layout as requested. But to top it off, the new design offered the additional possibility for a sixth line, all whilst saving 30 percent build cost.

This was a significant moment for Van Aarsen and Kalmar Lantmän.

Not only did this new design save on space and costs, it was also future proof.

It also solved one huge hurdle for Kalmar Lantmän: Its wish had always been to build the mill in concrete, with many wish list features specked out such as the intake should be on the south side of the mill, the height should be no more than 60 meters, the loading section should be on the north side with serious protection against the possibility of cross contamination of different species feeds.

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Rejne Erixon explains the original plans for the mill

Breaking ground: the foundations for the new mill are laid in April 2012

Building in concrete was the preferred option, but was also the most expensive choice, and was out of reach in the first designs; however, with a saving of 30 percent on the building size, the use of concrete became a reality.

With concrete there are no hidden gaps like you get with a steel construction. Everything can be hermetically sealed. With concrete floors in place a very special coating was applied; this involved a handmade, hand applied process, involving many layers including a primer, ground down sand and different layers painted on making a very solid and hygienically manicured floor.

It gets tremendously cold in Sweden with snow and ice, therefore there should be outside heated floors.

Lifting modern equipment into place

With the 30 percent saving in building costs, the project went ahead in the favour of Van Aarsen, it took a year to take away the old buildings and drive in the almost 1000 piles into the earth to form the foundations.

As each concrete floor was added, Van Aarsen arrived with the state of the art milling equipment, examples of which are on all 13 floors. I might add, it was a privilege to see first-hand, Sweden’s and most probably Northern Europe’s, largest in house commercial elevator, which was installed with a load capacity of 10 tonnes, it can reach each floor allowing any machines to be replaced at any time.

The building took shape throughout the Swedish winter or 2012, which would often slow down the drying time of the cement, therefore the project manager Åke Karlsson had to bring in industrial heaters to put on each floor as the construction took place.

Also, unlike buildings in metal with frames etc, concrete structures will need some well planned advanced ‘cuts’ to allow for piping, valves, elevators and cabling, so attention to detail was king in this construction. To get a high level of hygiene the design and flow of material was mostly by gravity, which whilst not uncommon, the use of gravity in this mill was extraordinary and many within the industry felt the plans of project manager Åke Karlsson unrealistic, with few believing that it could be done. However, he has proven them wrong.

Even the smallest attention to detail was put in place building this mill. All the cabling was copper wire, which allowed for

“Not only did this new design save on space and costs, it was also future proof” smaller tracks, with most cables designed to run vertically to avoid catching dust and positioned in every case for ease of accessibility with the added bonus that copper wires are also rat proof, should any ever get in.

One of the largest costs to a feedmill is energy consumption.

You have to power the machinery, steam boiler, compressor systems, lighting and heating, to name a few. Even when the feedmill is not producing there are still costs when its standing still. So getting the energy usage right was imperative.

Whilst every effort was made to fit energy-efficient machines with energy-efficient motors, such as all motors >30kW are August 2015 | 57

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Feedmill of the future … here today-built for tomorrow!

frequency controlled and all motors with >200kW are with a low harmonic frequency converter, allowing for waste electricity to be siphoned off and stored in back-up power cells for use later.

All of these efforts would have been in vain had the feedmill opted for the wrong level of intake transformers. Initial estimates suggested 5 x 2000kW transformers, which if agreed, would have involved a new mains cable to the substation at an additional cost of over €2,000,0000.

With the right machines, motors and power saving processes in place the project was able to operate with just 4 x 1600kW transformers. This is where knowing your mill is very important and Åke Karlsson from Kalmar Lantmän was adamant about the required power usage from the beginning as he was with the overall cost.

Producing small batches efficiently

Now, compared to some mills, the production at Kalmar Lantmän may seem relatively small. However, they are producing around 265,000 tonnes annually for the Swedish market. This is broken down to having around eight to 15 tonnes per order, again which for many may seem to be quite a small average or low level order.

One of the many delightful aspects of the mill build is that it was designed with several separate lines with a focus on producing small batches efficiently.

Not only can the mill produce small batches, it has been streamlined with separate production lines for the production of feed for each of the respective animal groups: all of this being done in such a way as to avoid cross contamination, which is evidently a very important factor in the mills operation.

Different feeds for different species is common, there are more ingredients for pigs and poultry and less for cattle.

The building is also separated into a raw material section ‘dirty’ and a finished product section ‘clean’. Another reason why the whole building was built in concrete as it is easy to clean and there are no little cracks for dirt to hide.

Whilst observing the mill in operation it was impressive to see the double-deck cooler system working, which allows the company, on the fly, to immediately change products. This system allows for a very short time to swap products. In The old mill this would have taken 20 to 30 minutes to administer a change of species feed for production.

Now the process only takes a maximum of two minutes, this allows the mill to switch over quickly and saves a huge amount of production time annually and allows them to react faster to customers’ needs.

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Serving a radius of 200km

Having produced feed for over 25 years they started with around 15 formulas for feed, today with roughly the same number of customers - though they have all moved on from having 10 or 20 heads of cattle to now many hundreds – the company produces some 200 formulations.

Within Sweden they have around 15 percent of the feed market with a turnover of around €140,000,000, with the closest next feedmill being 250km away.

However, as Kalmar is located on the coast the mill does not have a 360-degree circumference of business, though they do have the large islands of Öland and Gotland which they service. On the other hand as ferry prices and fuel rise they can logistically only deliver feed economically up to 150 - 200km away from the plant.

With so many farmers, each with their own specific preference

Darren Parris and Olivia Holden (Milling and Grain) with Åke Karlsson (outside left)and Hans van der Weijden (outside right) on our visit

for feed the mill has over 50 recipes alone for cattle and over 200 recipes for feed in total of which more than 150 are active at any given time.

Most of the Swedish farmers like to have their own mix and with this new mill and the systems inside they can produce bespoke mixes for every farmer even if the batch is only five tonnes.

Not only can they deliver tailored feeds for every farmer, it is all carried out in an extremely hygienic environment where hygiene has been foremost on the minds of the millers. With their high hygiene concept in place it allows for higher flexibility with no contamination problems.

As with many plants and in particular their old plant they would have to clean a line first before switching to a different recipe.

Their automated systems are superb, as is often required today

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Feedmill of the future … here today-built for tomorrow!

close automatically and the machinery is switched off after detection has been made.

Older equipment for sale

many farmers require various additives in their feeds to deal with everything from palatability, improved digestion, gut health, additional proteins, minerals, etc.

This is another area where this mill really sticks out; they have their own hammer mills and roller mills – a combination you don’t find everywhere - and they do the grinding for all their own materials.

Very little if any downtime and inventory accuracy

And yet, it gets more impressive as their dosing system allows them to carry out simultaneous dosing.

Each of the 52 silos holding specific additives is on their own individual weighing scale. A number of the silos can be used for dosing or grinding additives, the 52 silos are broken down into eight separate sections, again sitting on their own set of scales as does each silo. So in effect the whole 52 silos are one large-scale system.

When mixing and batching amounts, they can be calculated accurately across all 52 silos for an exact weight for a specific feed, allowing an extremely fast turn around and continuous flow in the plant with very little if any downtime.

With different products in each silo, they can still produce many different products in macro silos as all silos are standing on load cells of which there are between 800 and 900 pieces in the whole feedmill.

This allows excellent control of what they have in each and every silo and a clear understanding of the step-by-step process.

This also gives a very high degree of traceability.

This step-by-step breakdown of everything going into the mill and out of the mill is completely automated. Kalmar Lantmän buys its ingredients in kg or tonnes and sells their end feed products in kg and tonnes; it is the only feedmill in the world that can keep track of all of its ingredients in this way. If a lorry delivers short, they will immediately know, what ultimately goes out must equal what came in.

It also has a self-controlling system, if a silo deposits more than two tonnes on a load cell and the cell cannot take any more than two tonnes, then the system will send out an alarm.

With all the sensors, weighing systems, etc the mill can have data on everything - 100 times more data than previous, almost a data overload.

Of course, the important point is to know what data to use and how. Kalmar Lantmän has many possibilities and are consistently learning how to use the data to enhance performance.

In addition to the weighing sensors, at several locations throughout the mill, in the process, sensors have been fitted for spark, temperature and smoke detection. Valves within the circuit 60 | Milling and Grain

Talking with the company about the two older mills, it was explained that they comprised a mix of Andritz and Buhler equipment. Kalmar Lantmän is currently looking to sell all its older machines, ideally to one customer as a full working mill solution. It would be an ideal project for an African or Indian miller, and they could ship as a complete mill.

Due to the new mill being located at the small port in the town of Kalmar, it was important aesthetically that the mill did not look out of place; therefore much attention has been paid to the outside look of the mill so that it blends in with the town’s skyline. It is true; it does not resemble a feedmill, more like a hotel with its marble finish.

After our brief interview with the Kalmar Lantmän feedmill project manager Åke Karlsson, he supplied me with some overview facts and figures before we headed off for our complete tour of the mill.

Finally, I would like to thank Maril van Kempen and Hans van der Weijden of Van Aarsen International and Åke Karlsson of Kalmar Lantmän for hosting our visit to Kalmar.

Timeline – from wish-list to reality 2009 - Kalmar Lantmän, located in Kalmar, Sweden, decided to construct a new feedmill in Kalmar with the intention of replacing their existing two feedmills 2010 - Three companies made the short list of potential suppliers and partners in the project; these were Andritz, Buhler and Van Aarsen 2010 / 2011 - Each of the three companies worked closely with Kalmar Lantmän to submit their proposals for design, innovation and automation.

2011 – Van Aarsen International awarded the contract 2012 – In February, the final contracts were signed between Van Aarsen International and Kalmar Lantmän. For Van Aarsen, this is the largest independent order ever in the company’s history 2012 – April, the building started with a ground-breaking ceremony 2012 – April to September – building the foundation, drilling in almost 1000 foundation piles and completing the basement and intake pits 2012 – October started the prefab concrete construction from ground level 2012 – November to April 2013, continued construction throughout the winter, requiring heaters to dry the concrete to stay on schedule for machine delivery and insertion 2013 – May, finished walls and roof 2013 – June- December, connecting all the internal processing lines to the respective machinery, installing the many kilometers of electric cables as well as the piping for liquids, steam and compressed air 2014 – January-March, continued the close collaboration with the Kalmar Lantmän project management team to complete the project on the basis of ‘Just-in-time’ construction, by controlling critical delivery times for machines and prefabrication 2014 – April, the factory was officially opened by Price Carl Philip from Sweden 2015 – June, the feedmill was visited by Darren Parris and Olivia Holden from Milling and Grain Magazine 2015 – August, the feedmill report was published in the August edition of Milling and Grain

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3/3 Feedmill of the future … here today-built for tomorrow!

PROCESS FLOW

Raw material intake

As raw materials come into the raw material intake, and because of the unique location of the Kalmar Lantmän feedmill, there are several ways in which this takes place. They can be supplied by: a) Ship b) Trucks; with raw materials unloaded into one of two intake pits where the trucks reverse in and dump their contents c) Pneumatic unloading; minerals, such as lime stone and salt are blown into the storage silos d) Micro ingredients such as vitamins are supplied in big bags e) Liquids arrive in tankers at the mill’s dedicated liquid terminal When materials arrive they are checked for foreign objects using a magnet system and cleaner.

The intake Garage

Raw Material Intake Pit

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Grinding and hammer mills

The mill has the ability to grind raw materials in two ways; the most common is using one of two hammer mills with automatic screen exchange, which can deposit the ground materials into one of the 52 raw material silos.

The raw materials can be ground to any desired size.

What makes this particular operation so special is the hammer mills are operated with low harmonic frequency controllers with a low harmonic, so when the system is slowed down, i.e. the brakes are applied the waste perpetual electricity is siphoned off and re-used back into the building utilising a two-stage controller: Another example of energy saving. This coupled with the automatic screen exchange, which allows for three different screens, which means the hammer mill need not be stopped a screen change can take seconds as opposed to the previous process, which took a good 20 to 30 minutes.

In addition to this energy efficient set up of the hammer mills, each hammer mill is hermetically sealed in its own soundinsulated control room reducing the noise to a maximum of 55db. Even though the building itself has been built with a sound insulated concrete construction, additional measures have been taken to reduce further the more noisy equipment.

Hammers are also prone to producing sparks, which when coupled with dust can become a potential explosion risk. In the Kalmar Lantmän mill all the bins after the hammer mills are equipped with an explosion relief system.

For other feed products, such as specific chicken feed, the recipe has the possibility not to be transported through the hammer mill but is able to go through the roller mill instead.

Dosing

Liquid Intake

Located at the feed mill there are the following silos for storage: • 72 small ingredients silos • 96 finished feed silos • 52 raw material silos Each of the 52 silos holds 85 cubic meters; the silos have been constructed round to maximise flow. This makes up the most modern automated dosing system in operation.

All 52 silos sit on scales with a capacity of three cubic meters or

F Mixing

2000kg for each scale. Between all the silos, this is one largescale system which all work together.

Therefore, if you had a recipe that included 10 or 12 different raw materials all the silos would start dosing down to its scales simultaneously. At the bottom of each silo is either a doublescrew or triple-screw depending on the need for accuracy. I observed 10 stainless-steel triple screws which were designed for more aggressive products, of course in these cases the silos are also stainless steel.

In addition to all this control and automation, all the doubleand triple-screws are frequency controlled. This efficient system allows for all ingredients of a recipe to be dosed simultaneously allowing for 30 batches an hour of four tonnes each.

Each of the silos are 4mm stainless steel with the cones of the silos being 5mm, at the bottom of each silo are three load cells, which weigh exactly how much material is inside.

In fact if I stood, as I did on one of the 52 scales, it is automatically picked up in the control room and an alarm is raised.

And, whilst it has never happened, should the wrong dose ever be measured -because they are using long bridge scales with eight products in one scale - the operation can simply be stopped and the unused (wrong dosed) ingredients can be sent back to their original silo for re-use.

In older feedmills this would have simply been waste. Though this is an added insurance policy and avoids any contamination, one hopes it is never used.

With all these sensors and scales, the software supplied by Van Aarsen (Cofely) allows for many multiples and variations of adjustments and different parameters, with over 900 load cells the system offers a complete automated approach to the whole mill, allowing the whole operation to be dealt with by just one man in the control room, which significantly cuts down man hours required.

As the whole factory was built in concrete, planning was critical as the whole flow of the mill in relation to the piping and its silos, etc, had to be pre-cut out of the concrete before each level was build, this included pre-drilling and cutting all the holes for the possible sixth line that can be added in the future.

It was important to add in the possibility of a sixth line as to increase an existing mill is not easy and whilst this new mill has many innovations that put it significantly ahead in terms of design and automation, the possibility of a sixth line and the ability to move equipment and machinery between the floors with the 10 tonne lift make the mill to all intents and purposes, future proof, when taken in context of the average life cycle of a feedmill.

Each mixer holds four tonnes / 8000 liters. As with the silos, each mixer is on load cells, allowing the control room to consistently monitor, in real time, the exact weight of ingredients in each. The ingredients are mixed in fast homogeneous blending paddle mixers. There is a mixer for each species line of feed to avoid contamination; even spillages around the mixer are protected from cross contamination as each is hermetically sealed away from each other.

All the mixing is dry mixing. Ingredients such as molasses is processed, preheated before adding in doses. A dry mix is much more preferable as with liquid mixes, there is always a clogging of the paddles, which would require some down time for someone, once a week to enter the mixer and clean it out.

With dry mixing, you do not need to clean so often and you keep your lines running more efficiently.

And the innovations do not stop here; all the waste heat generated by the mixers is re-used and is filtered off to the compressor system to heat up water for the boiler.

Processing at 13 tonnes per hour the re-used heat can pre-heat the water to between 80 to 90 degrees, which in the winter the temperature of the water can start at the intake as low as seven degrees.

All the waste heat generated by the mixers is re-used and is filtered off to the compressor system to heat up water for the boiler

The pelleting line uses a C900 pellet mill, which has a unique die exchange system

Conditioning and pelleting

Before the pelleting process the whole mixture is conditioned with steam, after which it goes through a hygienization process where it is kept at 85 degrees for a maximum of four minutes, which destroys any build up of salmonella.

In keeping with their very high standards for health safety and the environment all waste steam goes through a condensing system, reducing the temperature to between 40-50 degrees and is extracted through a chimney in the roof.

In a further effort to save time and allow a more efficient feedmill process the pelleting line uses a C900 pellet mill, which has a unique die exchange system, which in turn enables the miller to change dies quickly should a different customer require a different pellet diameter.

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Feedmill of the future ‌ here today-built for tomorrow!

The coolers suck in air from the outside via a HEPA filter

Cooling

The coolers suck in air from the outside via a HEPA filter, similar to what you have in your car to clean the air of pollens, etc.

The intake is a large corridor probably 20 meters long, with a mesh to stop birds and animals coming in. Once in the corridor there are three intake filters with a much finer mesh to filter out smaller bugs and particles before going through the HEPA filter.

The coolers have been set up with a double deck configuration for a quick product change over and two of the lines are equipped with special meal coolers.

Also, as the winters can be very cold in Sweden, there is the possibility to warm up the intake air so it is not too cold. The same goes for any waste air pumped back into the atmosphere, it is carefully filtered to make sure there is no dust contamination and that any pollutants are below 3mg per cubic meter.

Crumbling, sieving and coating

The mill has the state-of-the-art crumbling machine where the pellets can be crumbled, for instance into chicken feed.

The pellets and crumbs are then sieved so as to free them from dust, with the dust being returned to the pelleting system.

As an additional service to its customers, Kalmar Lantmän also offers the possibility to coat pellets or add extra liquids at the final stage of the process. Each production line is fitted with a pellet coater where liquids such as enzymes, which are not resistant to high temperatures, can also be added.

Every completed batch of feed has a small sample automatically taken from it and bagged and tagged and sent automatically to the lab for quality testing.

The mill has the stateof-the-art crumbling machine where the pellets can be crumbled, for instance into chicken feed

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F Loading and distribution

Trucks will enter the mill on the north side where there are three separate loading lanes inside the building.

Once the process has finished, the final product goes into one of the 96 finished product silos, trucks will enter the mill on the north side where there are three separate loading lanes inside the building.

In each loading station there is a double robot-weighing outlet, which moves along the gantries, collects the desired feed and positions itself automatically over the truck for loading.

It was clear to me that this project had succeeded by using the very highest levels of automation available in today’s market.

The overall project consisted of smart engineering by making the building 30 percent smaller whilst maintaining all the five lines with space for an additional line.

Then installing high quality machines allowing the production of a low cost per tonne of feed. Outside of these key points, and the many others I have mentioned above, it ultimately succeeds because of its automation.

• Automation of the whole production process • Only two operators during the day and one at night • Operators can make any adjustments on the spot with a tablet • Remote controlled by Van Aarsen’s automation specialists for service and support • All silos, bins, mixers are equipped with weighing facilities, to see at any moment where all raw materials or finished products are in the process, as well as keeping an eye on actual stock levels • Automated sampling of finished product in combination with a fully automated sample packaging system.

Van Aarsen. The vital link to your feed chain

2015-07-23, Adv Milling and Grain 190x132mm.indd 1

August 201524-07-15 | 65

09:31

STORAGE

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ATEX powder

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Are ATEX powder storage silos disasters waiting to happen?

by Mark Stevenson and Nigel Allen, Hycontrol

evel measurement specialists Hycontrol have long had a background in the control of flour, grain, starch and animal feed, and have been designing specialist silo protection systems for over 20 years. As such, they have extensive experience of the potential problems that exist on sites, especially those handling products such as flour, sugar, grains and starch. According to Hycontrol’s MD Nigel Allen, many ATEX-rated powder storage silos are disasters waiting to happen, putting lives at risk and posing serious threats to the environment.

“Our findings are worrying to say the least and the photos taken by our installation engineers speak for themselves,” says Mr Allen. “Companies just don’t seem to understand the consequences of poorly maintained protection systems. It’s quite frightening that operators accept pressure blowouts via the pressure relief valve (PRV), erroneously thinking that ‘It’s ok the PRV is doing its job’. This couldn’t be further from the truth - PRVs are there as a last resort.”

“If the silo protection system is working correctly and is fitted with an automatic shut-off feature to prevent over-filling, the PRV should never be used. If a PRV blows then there’s an inherent problem with the system or the filling protocol and corrective action must be taken.”

“Material in and around a PRV is a tell-tale sign that there’s something wrong and a catastrophic blow-out is waiting to happen,” he continues. “The material blown out from the silos will almost certainly solidify over time and this will, at best, prevent the PRV from working correctly and, at worst, completely clog it up. Unfortunately many maintenance engineers just don’t realise the potential dangers that lurk beneath. They often think that simply cleaning off the material on and around the PRV is good enough. They don’t realise that if the PRV doesn’t lift next time an ‘event’ occurs the over-pressure could easily rupture the silo or eject the filter housing from the top. On an ATEX-rated silo the over-pressure could be sufficient to simulate an explosion and open the protective blast panels, resulting in costly loss of product and silo contents being left open to the elements.”

With regard to filter housings, Hycontrol engineers have witnessed another worrying practice at a number of sites where companies fit chains to prevent the housing being blown off the top of the silo, almost accepting blowouts as being inevitable.

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What Causes Over-Pressurisation Problems?

Silo protection systems are designed to prevent the damaging and potentially dangerous consequences of silo over-filling or over-pressurisation when powdered material is being transferred pneumatically from road tankers to silos. Unfortunately, perched out on the top of silos, such protection systems are all too often ‘out of sight, out of mind’ - until a major problem occurs!

Problems during the filling process usually arise through an inherent problem with the silo protection system or with the air filtration system on top of the silo. Problems can also occur through tanker driver/operator error. Delivery tankers are pressuretested vessels typically capable of withstanding up to two-bar (29 psi) pressure. Storage silos, on the other hand, are only designed to withstand the weight of material stored in them and can rupture at pressures as low as 1-2 psi above atmospheric pressure.

The consequences of over-filling or over-pressurisation include: • Serious or fatal injury to workers and the public • Catastrophic silo damage • Loss of material and production plus • Harmful environmental pollution • Damage to company reputation A key issue with many silo protection systems is that without adequate ground level testing capabilities, operators don’t know if they will work when needed. Working at height restrictions limit silo top inspections and maintenance, especially in adverse weather conditions. However, the main problem is: what can engineers actually do when they are at the top of the silo? How do you physically test a relief valve or pressure transmitter unless you remove them?

Even if the protection system does do its intended job and prevents a major incident, companies rarely investigate the root cause of the problem so that remedial work can be carried out to prevent the situation re-occurring. High-level events and highpressure events are routinely not recorded and often conveniently dismissed. Hycontrol have clear evidence that in practice there are more near misses than realised and that the situation is a ticking time bomb.

Filter housings on top of silos are designed to vent the silo during filling, whilst preventing dust escaping into the atmosphere.

Normally these are fitted with some form of self-cleaning system to keep filters clear, typically mechanical shakers or reverse jet systems. Although filter manufacturers give recommended check routines and filter replacement schedules, in practice it would appear these guidelines are regularly ignored. A range of issues,

F including blockages and the fitting of unsuitable or wrongly sized filters, can cause faulty operation. Most powders form hard compounds when mixed with water from the atmosphere, further exacerbating the problems at the top of the silo.

Effective Silo Protection

Other industrial areas are further ahead in dealing with this issue.

For example, the Mineral Products Association (MPA) publishes comprehensive guidelines for silo protection systems in UK quarries and cement works. But worryingly there are little or no such recommendations for powder silos used in a broader range of industries, including food and beverage, grain, starch, sugar, and animal feed. The primary principles are the same for protecting any pneumatically-filled silo, yet the issue is being routinely overlooked.

Even with guidelines in place, the benchmark for the effectiveness of any silo safety protection system can only relate to the last time all the components were fully tested.

Optimum Solution

The only effective solution is to take an integrated approach to silo protection design whereby the PRV, pressure sensor and high level alarm can be tested at ground level, prior to each fill.

Only when all these safety devices have passed the checks should the safety interlock allow the silo inlet valve to open and the delivery to commence.

As an added benefit, an effective protection system can serve as a powerful predictive maintenance diagnostic tool by recording critical near-miss events that occur during the filling process. This information allows managers to carry out effective predictive maintenance by means of a logical step-by-step root cause analysis (RCA) process to understand why the problems are arising. For example, high pressure and PRV lift events may be due to filter problems, prompting questions such as: • Are the filters the correct size?

• Is the filter-cleaning regime fully operational?

• Have the filter bags/ cartridges been changed as per manufacturers’ recommendations?

In parallel, the logs will also indicate if the tanker drivers are routinely over-pressurising during the fill process.

In summary, the optimised silo protection system should incorporate: • Pressure sensor, high alarm level sensor and PRV testing (essential) • Simple one-button press to test all components • Silo filling auto shut-off control • Pneumatic cleaning of pressure sensor

• Recording of the number of events on incidents of over-pressure (time / date stamp) • Recording of the number of events of PRV lift and opening (time / date stamp) • Recording of the number of events of high level probe activation (time / date stamp) • Filter ON / OFF output option to check filter status • Filter air supply monitoring alarm option There is strong empirical evidence that many silos are disasters waiting to happen. The practical reality is that powder storage silos can split or rupture at pressures as low as one or two psi above atmospheric pressure. Malfunctioning filter housings can and have been ejected at similar pressures.

Simply relying on cursory visual inspections of silo protection equipment is woefully inadequate. Therefore it is imperative that any installed safety system must be capable of providing reliable protection that can be easily verified by testing critical components before each and every delivery - without having to climb to the top of the silo. This approach will provide total silo safety; protecting assets, the environment and most importantly site personnel and the public.

August 2015 | 67

F

Storage project

ISU NorthWest Research Farm grain bin when nearly completed

GSI donates new grain storage system for Iowa State University Northwest research farm Iowa State University’s Northwest Research Farm now has its first grain storage system, thanks to GSI, which donated a 10 500 bushel grain bin, and its local dealer, C-S Agrow Service, of Calumet, Iowa, which donated the labour to install it.

Josh Sievers, manager of ISU Northwest Research Farm explains “the deal came about following last year’s harvest where a lot of wet grain had been wasted, he and his colleagues were driving past their local GSI dealer and decided to head in and try to strike up a deal. The local GSI made a request to their headquarters. GSI has gained some publicity and the farm has ended up with a 10 500 bushel grain bin on their site at the end of it”.

Mr Sievers cannot express his gratitude to GSI enough, exclaiming, “It was like the stars had aligned and the red carpet had been rolled out.”

The new bin will enable the research facility, based in O’Brien County, to store and dry corn more efficiently at harvest than continuing to transport it to a nearby commercial elevator.

According to Mr Sievers, “While the farm primarily functions as a research facility, it is also a production farm which has its own financial targets to reach, this new bin will make things easier. The donated storage bin can hold a third of our entire crop, not to mention it is highly automated and very safety conscious.”

In addition to the 30-foot bin, the new storage system includes GSI grain bin accessories provided by C-S Agrow

68 | Milling and Grain

at cost to ISU, including outside stairs, unloading auger, aeration floor, stirring equipment, a fan and heater. The dealer’s sister company, The Concrete Guys, donated labour to pour the bin’s concrete pad. GSI, based in Assumption, IL, is a leading global provider of on-farm and commercial grain storage bins, material handling systems, and grain conditioning and drying equipment.

“We are extremely grateful for these donations, without which this project would not have been possible,” says Mr Sievers. “This bin will not only allow us to dry and store grain on the farm, but also allow an earlier start on corn harvest without having to pay for off-farm drying and shrink charges. This new system will be put to good use for years to come.”

Bryan Halverson, sales manager for C-S Agrow, said it took six workers three days to complete the project, which is located about 1.5 miles south of Calumet. “The ISU Northwest Research Farms plays a key role in advancing agriculture for Iowa farmers,” says Mr Halverson. “As GSI’s largest dealer in the state, we’re proud give back to the community by providing this grain storage system to support their research efforts.”

Mr Siever says “The Northwest Research Farm which conducts research in a wide range of agricultural areas including pest treatment applications, water quality, and soil quality amongst other things, currently has no plans to expand further in the short-term but are always open to opportunities which might arise in the future.”

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Storage News

BinMaster and Eye-Grain announce strategic alliance

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inMaster of Lincoln, Nebraska, USA and EyeGrain of Denmark have announced their strategic alliance that will bring a new line of temperature, moisture and CO2 sensors to the North and South American grain storage markets. BinMaster will be manufacturing and marketing the revolutionary Crop-Protector™ line of sensor systems for monitoring stored grain under this exclusive agreement. This builds on the success of the Crop-Protector™ line of products in Europe, Africa, and Asia sold under the igrain brand name in international markets.

Crop-Protector™ solutions include state-of-the-art digital temperature and moisture monitoring cables for installation in bins and silos that are highly accurate and have a long service life. Portable sensor lances with handheld readouts are a cost-effective solution for monitoring flat storage, piles or occasional temperature data sampling.

The Crop-Protector™ CO2 sensor developed in 2009 was the first product of its kind on the market. Now in its third generation, it is a fast-growing new technology that detects carbon dioxide, which is an indication of undesirable biologic activity and infestation in stored grain. The CropProtector™ line also includes an advanced, easy-to-use Aeration Control System that includes rugged, professional weather stations required for accurate ambient weather

70 | Milling and Grain

information. The Dash Board Manager software can be operated on-site or via Cloud-based software and is designed to keep crops in optimum condition.

“Crop-Protector™ grain conditioning systems are already proven in grain storage facilities in many international markets,” according to Peer Hansen, biochemist and director of marketing and sales for Eye-Grain. “BinMaster’s ISO 9001:2008 (quality management) manufacturing and experienced staff will ensure that grain facilities get top quality products and personal service in the North and South American markets.” The innovations created by Peer Hansen and the current Eye-Grain products have served the post-harvest grain storage industry from farm level to major industrial customers worldwide since 2003.

The Crop-Protector™ monitoring and control solutions will be offered by BinMaster as complete systems including communication hubs, wall-mounted touch screens, and software for a turnkey solution with continuous monitoring of stored grain conditions, automated alerts, and other options. “Temperature and moisture monitoring systems are a perfect complement to BinMaster’s line of level controls and inventory monitoring systems,” stated Scott McLain, CEO of BinMaster. “Eye-Grain delivers the quality and innovation customers expect from BinMaster.”

Industry profile

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Selis - manufacturer of grain milling machinery

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by Tom Blacker, Milling and Grain magazine

elis is a well-known manufacturer of grain milling machinery. The sectors of flour, maize and semolina milling are its core industries and it undertakes turnkey projects regularly.

In 2014, Selis celebrated their 50th anniversary having been established in 1964. Selis is based in modern premises in Eskisehir, Turkey with a global reach. The company is a part of the larger Yükseliş group.

Darren Parris and Tom Blacker from Milling and Grain recently went to see the manufacturer in Eskisheir, Turkey. This visit took place after the excellent trade show, IDMA 2015 (for those who did not attend IDMA or are looking to return to the event, it has recently been revealed that the next IDMA exhibition will be held in April 2018).

When visiting Selis, we were shown the R&D facilities, roller miller assemblage halls and offices. The company is endorsed with management practices attaining to the certified standards in ISO 9001:2000.

Temel Hermankaya, business development director and food process engineer and colleagues at Selis. We were introduced to others such as Mr

72 | Milling and Grain

Sedat Kunduracı, general manager and Mr Mertcan Kunduracı, customer representative.

One new product we were shown was the Novitious roller mill. This is a roller mill for flour milling which develops the Fortimus product line with higher performance for millers. At the acclaimed milling industry exhibition in April, the Novitious was launched at an official ceremony. The industry took note of this new roller mill and we were granted special access in the Left to right: Mertcan Kunduracı, Sedat Kunduracı, Temel Hermankaya

assembly hall on our visit.

The Novitious roller mill features stylish aesthetics with their own ‘YSL Design’, however the technical and innovative advances on the inside of the machine are the most interesting of all. Contrary to the normal standard, smooth-ground rolls are used instead of fluted rolls. This is called the Dynamic Angled Positioning System and has worldwide patents pending. This is not just a roller milling evolution. It is a revolution.

The rolls in the Novitious are set at changeable angles and operated by computer control for optimum milling grinding. The Novitious has been designed with high-capacity mills in mind and there are middle combiner units, which offers advantages with multiple machines in mill lines for maintenance, sanitation and usage. The Novitious also comes in two size ranges with the SNTX – standard sized machine with two rolls and SCNTX – the larger and taller mill. One upgrade from the Fortimus is the control from a mounted panel of buttons to a combination to a touch screen and PLC where more functions can be controlled.

Readers can seek more technical features can be requested directly from Selis.

The Novitious was another product borne from the extensive

research and development that Selis conduct to raise the standards of their machinery. By doing so, they align products closer to market demands and can be ahead of the curve set by their competitors.

International sales of the product have already been received for the Novitious by Selis, and they hope that this product will prove to be a successful roller mill to export markets. Particularly of keen interest is the European market and it is being highlighted as a good match. Striking out from Turkey into Europe is nothing new. However, to see this as a prime market for customers is a sign of the quality and unique innovations contained and customers can realise potential benefits with this product.

Later on during the visit in the assemblage hall, another visit co-incided of over 20 Russian delegates took place to inspect the new Novitious roller mill and other products. Sedat, Mertcan and Temel then led us up to the impressively sized boardroom and facilities. We were told that many customers arrange and finalise their contracts here. We enjoyed the large maps, wall-adorned artwork and many international flags displayed too.

With broad horizons and a bright future, Selis seem to be supplying the industry with a great range of potential solutions.

August 2015 | 73

F CASE STUDY

CASE STUDY

Modern meets tradition at Molino Quaglia Molino Quaglia is a modernly equipped mill that feels an obligation to both family tradition and quality.

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by Thomas Ziolko, Bühler AG, Grain Milling

he northern Italian mill has been relying on Bühler as its technology partner for years. The Quaglia family owners are enthusiastic about the recently added Maia bagging station, due to its easy operation, low cleaning requirements and the new sealing system.

Molino Quaglia is a special mill in several respects, beginning with the founding of the mill over a hundred years ago. At the age of 13, Antonio Quaglia left his home in northern Italy, where his parents ran their traditional mill operation since 1856, and built his own mill just south of Padua. The truly unique part: The small stonegrinding mill floated on two rafts on the Adige River (the Fuime Adige in Italian) and was driven by the water over the mill wheels.

Industrial mill

In 1937, Molino Quaglia moved from the river to solid ground in the commune of Vighizzolo d’Este. Under the guidance of Annito Quaglia, the family-operated business grew into an industrially operated mill that often stood out within the Italian milling sector because of its innovations. For instance, in 1986, Molino Quaglia was the first Italian mill to install a grain roasting facility. The siblings Lucio, Chiara and Andrea Quaglia took over the management of the family business in 1989. As the first mill in Italy, they had Molino Quaglia certified step-by-step and successively expanded the production lines.

Partnering with Bühler since 2007

In 2007, Molino Quaglia purchased its first machinery from Bühler, a Primus/Ventus grain cleaner for pre-cleaning grain that had been delivered. The Quaglias immediately noticed improvements in the production capacity as well as the flour 74 | Milling and Grain

quality. Other Bühler machinery followed, such as a Light Peeler, the high-capacity grain cleaner VEGA, a Sortex color sorter and finally several Antares roller mills. In 2011, the Quaglia siblings selected the Bühler company to deliver a new automation solution which would merge all plants in the Molino Quaglia under one central control system.

Maia bagging station

Molino Quaglia’s partnership with Bühler is continuing. Based on the good experiences they had with the machines from Bühler, Molino Quaglia decided to purchase a new Maia MWPG bagging station as part of its refurbishment of the filling station. The compact machine has been in operation at Molino Quaglia since August 2014 and is primarily used for bagging whole wheat, bran and wheat germ in 12.5 and 25 kilo bags. These products comprise about 10 percent of the company’s sales.

Gluing instead of sewing for paper and woven polypropylene bags

Molino Quaglia is using paper bags and woven polypropylene bags for its product. The customer requested from Bühler a reliable closing station where bags would be glued and not sewn shut. “The adhesive closure of the Pinch closing station has proven itself excellently,” stated Andrea Quaglia. “The main advantage of the adhesive seal compared to the sewn closure is the lower maintenance costs and easier operation.” The new station has been working with high reliability since it started up.

Quaglia’s specifications have been met for sealing both paper and polypropylene bags.

Easy operation

In addition to dependability, Andrea Quaglia emphasises the easy operation and time-saving maintenance of the new bagging

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Do you have a project that you would like to see featured in the pages on Milling and Grain?

Share your project news with the world, by contacting Olivia Holden (oliviah@perendale.co.uk)

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CASE STUDY

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The modern mill facility Molino Quaglia has a capacity of 400t/24h. The mill also includes a stone mill, reconstructed in 2008, that processes grain using the latest technology but following an old tradition, producing flour of the highest quality. Molino Quaglia is a leading Italian manufacturer of flour for bread, baked goods, pastries, pizza dough and household consumption. It also produces flour from roasted grain and gluten-free flour mixtures.

“Maia meets all of our expectations to a high degree. The bagging station is very easy and intuitive to operate and can be cleaned in a very short amount of time. In addition, the new adhesive seal of the pinch closing station is a real advantage,” says Andrea Quaglia, Managing Director of Molino Quaglia.

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station: “Maia is very easy to operate. Changing out the types of bags is very simple and can be quickly performed. The clearly structured control panel with color touchscreen allows the machine to be simply and intuitively operated. The replacement parts can be identified and ordered without error thanks to the integrated spare parts catalog.“ Andrea Quaglia points out that the “biggest advantage” of the Maia bagging station, however, is the very low level of dust emission. “Because of the sanitation design of Maia, very little dust is created when filling the bags. And when the work is finished, cleaning the entire machine takes very little time. The entire unit as well as the surroundings are clean and in top shape within fifteen minutes.”

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August 2015 | 75

MARKETS OUTLOOK Crop weather scares receding

by John Buckley

“Demand for US soya will rise somewhat from domestic crushers while exports will probably slip under intense competition from the Latin American suppliers. At this stage, the outcome is expected to be substantial growth in US surplus stocks, from under 7m to about 11.5m tonnes”

76 | Milling and Grain

GRAIN and oilseed markets saw a surprise but, in the event, unsustainable run-up in prices during the period since our last review. Mostly this hump in costs was due to crop weather scares and funds making the most of these in hope of an easy profit. Many of these events were probably over-played, trading off uncertainties rather than major crop damage – so are now receding in importance. That said, one or two key questions still need to be resolved, notably the final size of maize and soya planted acreages in the USA, the world’s largest grain and oilseed producing country. There is also an unusually wide range of US yield forecasts for both crops. Markets also need to see the outcome of a European heat-wave, already trimming millions of tonnes off the maize crop, some changeable conditions at the tail end of an already weather-challenging season in Russia and Ukraine and, not least, the extent to which drought has reduced Canada’s wheat, durum and canola crops.

All of these factors have the potential to disturb prices further in coming weeks. However, there are also some important-price restraining factors at work on both the supply and demand side of the ledger. For the wheat market, these are led by better than expected crops (so far) in Europe and the Black Sea region (Russia, Ukraine, Kazakhstan) and, perhaps even more importantly, the USDA’s decision to make a big downward revision in its Chinese consumption forecasts (down 6m tonnes for 2014/15 and another 5m for 2015/16). The latter changes along with one or two other reassessments, have resulted in the USDA adding a hefty 16.5m tonnes to its forecast for global wheat ending stocks for 2015/16 (ends next June 30).

Because these are inside China, these stocks are effectively ‘off-market.’ They might also be considered a slightly academic number, based on as many ‘guesstimates’ as facts. Nonetheless, they do put a slacker slant on the global wheat supply situation and, if these really are anywhere near correct, they will have some influence on China’s maize consumption and import needs.

For maize and soyabeans, which we count with wheat as the three main market movers, there are some some further bearish developments, led by larger than expected South American crops. Looking at what’s emerging from local/national sources, some of these Lat-Am numbers are probably still being under-estimated by the USDA - and other ‘official’ analysts – both for the 2014/125 season nearing completion (August 31) and for the new 2015/16 marketing year .

Assuming the weather doesn’t suddenly turn nasty for the second half of the Northern Hemisphere wheat harvest – or the remainder of our maize/soya growing season, the outlook remains much as we summed it up in our last issue: another year of large production, backed by comfortable (mostly larger than average) carry-in stocks from last year. That ample supply, moreover is set against no more than moderate growth of global demand.

Without a fresh weather scare ( and it would have to be a big one coming sooner than later for now rapidly maturing crops) there is nothing much here to excite the speculator into another round of betting on grain price rises. Indeed, one or two of the banks that like to forecast agricultural market price trends are estimating grain values will fall below the levels indicated by the forward futures price ‘curve.’ At this stage, it’s hard to disagree with that.

Wheat stocks to stay high Apart from the larger Chinese wheat stocks mentioned above (estimated to cover about 40% of world supplies), inventories are looking pretty comfortable in some of the market-influencing centres too. The EU is reckoned to carry in about 14/15m tonnes this year and, assuming a crop somewhere around the 146/148m tonne level, it will leave 2015/16 with a similarly large ending stock. This assumes the EU consumes something close to last year’s volume of wheat, say around 124m tonnes, and again exports about 31m (which would be its third largest achievement, comfortable keeping Europe in the role of world’s leading exporter).

US wheat output, despite a number of weather problems, is expected to rise by about 3.3m tones to 58.5m. Allowing for say 2/2.5m more domestic consumption, it can still export (if it can find enough markets for its relatively expensive grain) about 3.5m tonnes more than last

season and, even then, end up with a larger stockpile than last year of almost 23m tonnes (20.5m). The only real caveat is a potential quality one after the soft red winter harvest got hit by untimely rains – but at this stage that seems to be having little impact on US or overseas prices, mainly because there is so much cheaper soft wheat available on the world market at harvest time. In fact, US soft red wheat for export is near its seasonal (and five-year) lows at around $206/tonne fob as we go to press. Even the US hard, higher protein milling wheats are relatively cheap by past comparison (see chart) – but often, still not cheap enough to compete on the world market. The main driving factor her is a stellar yield forecast for the US spring wheat crop – maybe even a record high – which is good news for millers seeking to use these to beef up the quality of their grists.

Looking at the other major wheat suppliers, the Canadian picture has been less encouraging after a drought hit the western half of the Prairie wheat belt. The country’s Wheat Board has just come out with a forecast of around 25m tonnes compared with 27.5m from a recent USDA report, last year’s 29.3m and the previous season’s record 37.5m tonnes. It will reduce Canada’s export role by about 5m or 6m tonnes (from 24.2m last season) maybe a little more or less depending whether or not recent improved rainfall gives the crop a late boost. Canada’s problems might be to the advantage of US exporters later in the season – or the gap might simply be filled by other suppliers - from the former

Soviet Union, Australia or even Europe. (In any event, world wheat imports are expected to drop by about 3m tonnes this season to offset Canada’s smaller crop somewhat).

Australia also has some dry weather problems, linked to the El Nino phenomenon, which may cut its production well below the expected 24-26m tonnes (last year 24m). That situation should become clearer over the next few weeks but at this stage, analysts are still looking for exports not too far off last season’s 17.5m tonnes. The other significant South Hemisphere wheat

supplier, Argentine has also had some problems with weather, delaying sowing and other disincentives (like government interference in trade) possibly cutting planted area by as much as 20% to what some say could be its lowest for 100-years.

Fortunately for foreign buyers, the markets have had a few years to adjust to Argentina’s shrinking export role (from 12m four

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August 2015 | 77

years ago to between 1.7m and 4m the past two seasons).

It has in any event, been long overtaken by the up and coming CIS suppliers. Their story has been a more complicated one this year – starting with damaging dry planting and autumn crop establishment, some very mixed spring and summer weather to date and the much-publicised challenge of getting enough imported fertiliser on crops at a time of collapsing Russian and Ukrainian currencies and other, general economic mayhem.

Strangely enough, it all seems to have worked out surprisingly well. Early yields are up and wheat crops are currently expected to be not much below last year’s at some 94.5m for the three main producers combined (97m).

Because exports last year were reined in at times (not least by Russia’s imposition of an export duty from February onward),

both countries are starting with larger than expected stocks.

In Russia’s case, these may not be mostly in the government’s strategic stock, as originally planned, but they are stil available as an extra supply cushion that can help influence a reasonably liberal export policy.

Confusion was reignited a few weeks back when the Russian government decided to introduce a new Rouble-based floating export duty – unpopular with the exporters who saw themselves getting into open- ended exposure when making foreign sales in dollars, then sourcing in (recently highly volatile) Roubles.

In the event, this has not stopped them stepping up foreign sales and, as they always seem to, setting the bar low for rival exporters at the start of the new season (big sales recently to Egypt and others, mostly beating the EU hands down on price).

How Russia’s (and other CIS) exports evolve in coming weeks and months is of key importance to the EU wheat market. In determining the world export price, it will feed into the EU market value of wheat and – if it continues to undercut – should bring benefits to EU users in terms of lower costs. We have already seen this on EU wheat futures markets which had jumped from €176 at the time of our last review to as much as €205/tonne at the end of June, when a French heat-wave and other weather issues were threatening a lower European crop. The collapsing euro during the Greek crisis didn’t help that situation, helping to drive prices higher. In the event, as mentioned above, wheat was mature enough to escape the worst heat damage and the euro, for now at least, has been

78 | Milling and Grain

displaying a bit of, albeit sporadic, resilience. But probably even more important in bringing the price back to around €181.50 recently, has been the renewed pressure on global wheat prices coming from the Black Sea region. EU wheat value will also be influenced, through the feed link, by the price of maize, again determined to a large extent by how much the CIS nations can produce and export and competition between the two grains for custom. If this progresses as it has done for the last few years, that may be another bearish factor in the price mix for feed ingredients before long.

Where will US corn/soya plantings end up?

US weather has been the driving force in feed-grain pricing over recent weeks as the trade tries to guess the impact of wet weather delays on planted area and yields for the two biggest crops – corn and soyabeans. The last analysis by the USDA (in July) had US planted area for maize at 88.9m acres versus last year’s 90.6m which with harvest acreage of 81.1m and a ‘trendline’ yield of 166.8 bushels – equated to a crop of 343.7m tonnes – about 17.4m under last year’s – but still the third largest on record. That was matched against prospective US consumption of 301.3m (unchanged from last year) and exports of 48m tonnes (46m), leaving US ending stocks at a very comfortable 40.6m. There is nothing overtly bullish in those numbers although several of them will doubtless be exposed to substantial revision – not least acreage and yield, for both of which the trade has a wide range of estimates – both sides of the USDA view.

Our hunch is that the acreage number may not be so far out and that yields will be at least as good as USDA suggests, bearing in mind all the moisture (‘rain makes grain’) and a recent drier, warmer spell to get crops moving – but no fierce heat on the radar to spoil the key pollination phase, now well underway as we go to press. Even if the crop were, say 10m or 15m tonnes under forecast, stocks would not be as tight as in some recent years unless the demand side of the 2015/16 equation had been under-rated. US feed use, it’s true, might turn out a bit better than USDA’s stable view - but only if US maize costs stay cheap. Corn ethanol, the other big US outlet, no longer seems to have much growth potential as demand runs up against the ‘blend wall’ set by the government’s usage mandate and world energy markets stay on the floor amid a bearish global macroeconomic environment. Also, US maize exports may not increase, as USDA expects, if the plentiful foreign competition continues to undercut, as it does now, from rival Latin American and CIS suppliers.

Globally, corn production is seen down slightly in the new season that starts September 1 at 987m tonnes versus last year’s record 1,002m, according to the USDA. The lion’s share of that drop is down to the smaller US crop, the rest to the EU (minus 9-10m), Brazil (-5m) and Ukraine (-2.5m tonnes).

The EU outlook has been a bit of a shock to the trade here, expecting a better result before unusually severe, dry, heatwaves developed across France, Germany, Czech Republic, Hungary etc during the past couple of months. However, the supply gap can be managed by increasing imports from the CIS group which, judging by recent market movements there, look likely to remain cheap.

Brazil’s next corn crop is probably well under-rated by USDA

at 77m tonnes and, for the second year running it has huge carry-over stocks to supplement its exports. The world’s second-largest corn supplier is already harvesting and shipping, undercutting US prices - as is its neighbour Argentina and the two main CIS exporters, Ukraine and Russia.

On the global demand side, the biggest factor outside the US is China, expected to consume 4m tonnes more maize next season than this. But China’s own crop is estimated to have jumped by over 13m tonnes and its surplus stockpile is seen ballooning from an already huge 80m to as much as 92m tonnes, almost half the world’s total corn stocks – so no big imports needed there.

World corn demand is expected to grow by a moderate 8.5m tonnes in total. Apart from China and the EU (+2m), a few other countries including Brazil, Argentina, Egypt and Canada will consume more next season than this. However, most of these are self-sufficient/in surplus, so the consequent impact on import demand will be modest. Overall there should not be much need for maize stock drawdown – perhaps 4m or 5m tonnes, leaving the total well above the low levels that fuelled big price rises on the global maize/feedgrain markets three or four years ago.

So, assuming the US crop comes through within the ballpark of recent estimates and no other weather disruptions occur, the world should be adequately supplied with corn to meet its needs at today’s – or perhaps cheaper – prices. Despite that, the CBOT futures market still has corn costs pointing ‘North’ to the tune of about 8.5% into mid-2016. However, a number of private analysts think that over-rates the impact of slightly lower global stocks. EU corn futures meanwhile suggest a more modest 2-4% price increase going into latter 2016, despite the domestic crop upset. That also seems to suggest confidence in adequate foreign supplies to fill the gap.

Soya surplus continues into 2016 Like the grains, soya products jumped in price during June as the Chicago market reacted to concerns about rain delaying and downsizing US plantings. For European importers of beans and meal, the price strength was enhanced by the weakness of the Euro as the Greek monetary crisis flared.

However, since mid-July, the US market has been in steep retreat with improving US weather and persistent market ideas that soya acreage there might have been under-rated.

Crop condition ratings are below last year’s when yields and production reached record levels but there is still plenty of time for improvement. So while the next US soya crop will likely be down from last year’s 108m tonnes it will probably not fall much and should still be the second largest ever.

Demand for US soya will rise somewhat from domestic crushers while exports will probably slip under intense competition from the Latin American suppliers. At this stage, the outcome is expected to be substantial growth in US surplus stocks, from under 7m to about 11.5m tonnes.

However, even that is eclipsed by what is happening ‘down South.’ Brazil and Argentina have not only already produced record crops for 2014/15 (recently harvested). Both are also carrying in record stocks of over 34m and 21.5m tonnes respectively. Moreover, both are now expected to plant large crops again this autumn for harvest in 2016. On present pointers, the USDA expects total 2015/16 soyabean supply to approach 400m tonnes compared with the past season’s 381m

80 | Milling and Grain

and the previous year’s 340m. Demand is not growing as fast, however, resulting in global stocks rising yet again to a new peak of almost 92m tonnes. That’s equivalent to about 73m tonnes of soya meal - even before the next crop is grown. To put that in context, world soya meal demand is only expected to grow in 2015/16 by about 10m tonnes.

The outlook is less encouraging for the two main oilmeal sources grown in Europe – sunflowers and rapeseed. EU farmers reduced plantings of sunseed slightly and now seem likely to get lower yields too. The crop has recently been estimated at 8.2m tonnes versus last year’s 8.94m but some analysts think that’s now a bit optimistic. Among the EU’s foreign suppliers, Ukraine

expects a smaller and Russia a slightly better crop. Overall, the CIS region should have just under 20m tonnes, similar to last year. Another key source, Argentina, expects slightly less output. Overall, world sunflower production is expected to drop by about 500,000 tonnes on top of a 3m tonne decline in the previous year.

Rapeseed supply looks far worse, however, with world production forecast by the USDA to drop to around 67m tonnes from last year’s record 71.7m, partly due to dry weather curbing yields and partly lower plantings (especially in Europe). Other estimates are even lower. Top producer Canada is expected to harvest 12.5/13.5m tonnes versus 15.6m last year and almost 18m the year before. Some EU estimates are below 21m tonnes compared with last year’s 24.3m. CIS production, some of which makes its way to European oilseed crushers is also seen dropping by 800,000 tonnes to 3.8m and Australia’s crop from 3.4m to perhaps 3m. Global rapeseed crush is expected to drop by about 3% - its first decline for some years - and even that will mean stocks tightening to their lowest for quite some time. Fortunately for oilmeal users, any lack of sunflower and rapeseed meal can be replaced with abundant supplies of soya – the market leader and price setter - although, obviously, that means more soya imports subject to fluctuations in the world

market and what happens to the euro/dollar exchange rate.

Hopefully the sheer weight of soya supplies will have the greater effect in keeping costs down. Soya meal makes up about 70% of world oilmeal supplies, rapeseed meal about 13% and sun meal around 5%.

KEY FACTORS AHEAD - WHEAT • The size of Russia’s crop – somewhere between 55m and 58m tonnes? Russian exporters are already taking an aggressive pricing role, intent on reclaiming their reputation as not only a cheap but reliable supplier. Ukraine also has a big crop and will compete for the role of floor price-setter in export markets against EU and other rivals.

• EU quality is still an unknown but some early pointers are promising for millers • World stocks of wheat carried into 2015/16 continue to offer a thick cushion against any crop weather problems in the months ahead.

• The further drop in wheat values back towards or, for some farmers, below cost of production remains an issue that may affect future sowing plans.

COARSE GRAINS • Will the US maize crop forecast be revised up if current ideal growing weather continues? Either way, hefty stocks should keep this market amply supplied in the season ahead.

• Ukrainian maize output will likely fall this year but remain

large in comparison with the previous decade, maintaining its role as a cheap exporter to markets including the EU. And Russia has more maize than last year to export.

• Along with ample maize supplies from Latin America, this should maintain the more competitive global export market for maize seen in recent years – another restraint on price.

• A forecast smaller EU maize crop this summer may need more imports but there should be no lack of supplies at competitive prices.

• Competition for coarse grain custom will continued between large maize, wheat and adequate barley supplies, again helping to contain feed costs.

OILMEALS/PROTEINS • Huge soyabean crop surpluses across the Americas continue to offer potential for cheaper global oilmeal costs as 2015 progresses, despite the downturn in alternative oilmeal supplies from rapeseed and sunflowers .

• Will lower costs and ample supplies of feed inputs encourage more demand than expected for these products in countries expanding their livestock production systems – China, India, Indonesia etc? Developed consumers like the USA may also use more as high meat prices boost profitability. There is plenty of room to meet bigger feed demand without tightening supplies or raising prices.

• Soya meal will continue raise its already dominant share of the protein market, demanding price restraint across the sector.

Precise and accurate analysis of incoming raw materials ensures high feed quality.

• AMINONIR - fast and reliable amino acid predictions save time and money • The right raw materials from the right supplier for the right price animal-nutrition@evonik.com www.evonik.com/animal-nutrition

0228_15_az_AMINO_NIR_190x132mm.indd 1

August 2015 06.07.15 | 81

08:07

Industry events 2015

n 03 - 06 August

International Grain Quality and Food Security Conference Kansas, KS, USA http://www.ksre.ksu.edu/news/story/food_ symposium042514.aspx

n 16 - 21 August

17th Annual Practical Short Course on Food Extrusion: Cereals, Protein & Other Ingredients College Station, TX, USA http://foodprotein.tamu.edu/extrusion/

n 18 August

GLOBALG.A.P. TOUR 2015 - Chile Puerto Varas, Chile http://www.tour2015.org

n 09-11 September

#FutureFortified Arusha, Tanzania http://www.gainhealth.org

n 12 - 17 September

IBA 2015 International Trade Fair: World Market for Baking Munich, Germany http://www.iba.de/

n 15- 18 September SPACE 20 Rennes, France http://www.space.fr

n 21-23 September

Livestock Asia 2015 Kuala Lumpur, Malaysia http://www.livestockasia.com

n 08-10 October

ILDEX Indonesia 2015 Jakarta, Indonesia http://www.vnuexhibitionsap.com/

n 27-29 October

Animal Farming Ukraine - Kiev Kiev, Ukraime http://en.animalfarming.com.ua

n 31 October - 03 November

26th Annual IAOM MEA Conference and Expo 2015 Dubai, UAE http://www.iaom-mea.com

n 04-05 November 66th JTIC 2015 Paris, France http://www.jtic.eu

n 17-19 November

Pneumatic Conveying of Bulk Solids - UK Kent, United Kingdom http://www.bulksolids.com

n 01-03 December

Food Ingredients Europe (Fi) & Natural Ingredients (Ni) Paris, France http://bit.ly/1c6GWmu

n 01-03 December

IFF Conference “Hygienisation in the Food Chain” Paris, France http://www.iff-braunschweig.de/index.php

n 04-08 April 2016

21st IAOM International Association of Operative Millers Annual Conference & Expo Renaissance Hotel and Cox Convention Center, Oklahoma City, OK, USA http://www.iaom.info/

New FIAAP/VICTAM/ GRAPAS event to be organised in 2017

A

t the press conference on June 10th, 2015 during FIAAP/VICTAM/GRAPAS International 2015 in Cologne, Mr Henk van de Bunt, General Manager of Victam International BV, announced that Victam will shortly be launching a new venture.

In conjunction with some of their conference organisers, Victam will organise a series of industry conferences spread over two days at a venue near Cologne in the early summer of 2017.

The typical delegate will be in the upper management of feed mills, flour mills, grain processors and biomass pelleting plants. Industry executives will comprise CEO’s, mill and plant directors and managers, nutritionists, feed formulators, etc.

The conference organisers will bring together acknowledged industry experts to produce a program of papers on each of the following subjects: 1. Animal feed ingredients and additives 2. Aqua feed ingredients and production 3. Biomass pelleting technology 4. Petfood ingredients and production 5. Flour milling and grain processing 6. Feed production technology There will be an additional area where companies will be able to have a small booth. An evening of dinner and entertainment will be organised on the first day for the conference delegates, the conference speakers and exhibitors. A small admission fee will be charged to the industry delegates to visit the exhibition and a separate fee will be charged for the conferences. www.victam.com

n 19-20 November

Farm 2 Fork New Delhi, India http://www.phdcci.in/

n 24-26 November

Agra Innovate Nigeria Lagos, Nigeria http://www.agra-innovate.com/nigeria/

82 | Milling and Grain

online • mobile millingand grain.com

Don’t miss IAOM MEA Conference & Expo 2015!

Join us from Oct 31st to Nov 3rd in Dubai

Registration and full program on: www.iaom-mea.com/IAOM-DUBAI Keynote Speakers

Mark L Palmquist (BBUS)

Keith Chambers

MD & CEO, GrainCorp

Dorie Clark

Marketing Expert to the Fortune 100 Founder, The Chambers Group

Global Grain Trade Trends - The Importance of the Supply Chain

Dr. William W. Wilson

Marketing Strategy Consultant & Speaker for Google, Microsoft, Yale University & The World Bank, CEO, Clark Strategic Communications

The Keys to Creating Brand Remarkability

University Professor, North Dakota State University Managing Strategies and Price Risks for Flour Milling Firms

Building Your Brand as a Leader

Feed Milling Technology and Trends

Buis Ebbinge

Dr. Roel Mulder

CEO & Managing Director, Daavision Mid Chain Fatty Acids (MCFA) – Application and its benefits in Agribusiness

Prof. John T. Brake, Ph.d., Pas

Secretary General, Worlds Poultry Science Association

Director of Graduate & Certificate Programs, North Carolina State University

Important Issues and Challenges in Poultry Industry

Reduced Feed Cost & Improved Performance with Altered Feed Particle Size

Dr. Ajay W Deoghare

Business Director, Bios AgriCorp Ltd. Binder Technologies for Food and Feed

Dr. Michael Richard Bedford Director of Research, AB Vista Feed Ingredients

Phytases - Their Use and Differences Between Sources

Check on the latest Flour Milling Technology and Trends

Dr. Lutz Popper

Head R & D, Muelenchemie

Vasilis Sotiroudas

General Manager, EcO2 and AgroSpeCom Reduction and Replacement of Azodicarbonamide in Baking Intelligent Fumigation in Applications Mills & Silos

Edouard Navarre

Pietro Barbalarga

Stephane Cochet

New Flour Evaluation Test for Soft Products

Leonardo Rollermill

Anylab - New Method for Quick Determination of Hagberg Value

Export Director MEA, Eurogerm

Commercial Director Grain Milling, Omas

Export Director, Chopin Technologies

Cristian Torri

Area Manager, Ocrim

Dr. Anna Zhenchuk

Technical Marketing Manager, BioAnalyt GmbH

MGA - Online Multifunction A Tool to confidently Market Grain Analyzer Vitamin Enriched Flour

What’s happening in the markets?

Vince Peterson

Vice President of Overseas Operations, US Wheat Associates, Inc. US Market Outlook

Hans Stoldt

Director, Ameropa SA Black Sea Market Outlook

Jean-Benoit Gauthier

Indrek Aigro

Director, Trading & Sales, CWB

Broker for Grains, Copenhagen Merchants

Canadian Market Outlook

Baltic Sea Market Outlook

Dr. Ali Ghanbari

Deputy Minister, Chairman & CEO, Government Trading Corporation of Iran

Andrew Vroland

Jean-Pierre Langlois-

Australian Market Update

President of France Export Céréales

Director Marketing, Glencore Grain B.V.

Iran Agri Trade Prospective

Berthelot

French Market Outlook

promilling

Simon Arnold

Managing Director, Quadra Commodities SA What This Means for the Miller

Industry events

Eat without worries:

Trends in ingredients at IBA 12-17 September 2015, Munich

P

eople are increasingly complaining about food intolerances and allergies. In addition to that which is necessary, personal desire to avoid certain products e.g. animal products is also playing an increasingly big role. “Bakers and confectioners have the unique requirement to react to their customers’ wishes using their skills and an extensive product range,” explains Peter Becker, the President of the International Union of Bakers and Confectioners (UIBC) and the German Bakers’ Confederation. The bakers and confectioners also have to respond to new nutrition trends and diet waves. IBA provides them with solutions on how to meet these needs.

Nutrition trends, an opportunity for the baking industry

The European Commission listed 14 ingredients, which has meant since that December 2014, bakers in the European Union must inform their customers if used in their products. This is because the number of allergic persons or customers with food intolerances is increasing, resulting in a corresponding demand for product alternatives.

Peter Becker sees this dietary change as an opportunity for the baking industry: “Bakers must respond to this demand and include corresponding offers in their product range”. For instance, instead of the conventional wheat flour, different ingredients that do not contain gluten can be used as substitutes for cereal. Currently trending is the chia seed. The seed from South America has healthpromoting properties, makes dough processing easier and presents a great potential for bakers. It is not only used in refinement of bread and other bakery products, but can also be processed as a substitute for wheat flour or eggs and is therefore ideal for vegans and persons who are allergic to gluten.

Recipe ideas and tips on the use of chia seeds will also be offered by the company Chia bia (Hall B4, booth 553) which will be participating at IBA for the very first time.

Together with the German baker, Martin Günthner, the company developed the first recipes for chia breads in early 2014.

A Chiabia recipe contest has in the meantime yielded close to 100 new recipes for bread, biscuits and bars, all which are compiled in a brochure that will be available at IBA. Visitors can also try out the various products from

84 | Milling and Grain

PREVIEW different bakeries at the exhibition booth. More tips on the use of the trendy oilseed for bread and bakery products will also be given by IREKS GmbH from Germany (Hall B4, booth 330) and Original Chia from Denmark (Hall B4, booth 154).

Martin Braun KG (Hall A4, booth 351) will, in addition to innovative pastry recipes, present a new service for trade visitors: the Infopoint Allergens. “Using a touch screen, interested persons can review details on the precise composition and nutritional values and allergens e.g. of our products in the LMIV portal. In addition, visitors can also email themselves the current iba concepts and pastry recipes directly from the Infopoint”, says Susanne Steinfort-Klass, Head of Communications of the Martin Braun Group.

Vegan delicacies made very easy

According to estimates by the German Vegetarian Union, more than ten percent of Germany’s population is vegetarian – a figure which is steadily increasing. Reliable global figures are not yet available, but statistics show that more than one billion people around the globe do not consume meat. The German Bakers’ Confederation sees this meatless nutrition trend as a great opportunity for the industry: Together with the Bundesakademie Weinheim, the confederation advises about the importance of producing vegan bakery products and snacks and provides its members with comprehensive information material – an action that PETA, the animal rights group, recently

honoured with the 2015 Progress Award.

At IBA, bakers and confectioners will, among other things, be given tips on how to adapt traditional recipes.

In the iba forum (hall B3), Bernd Siefert, Grand Pâtissier and newly elected World Confectionery Champion 2015 will on Wednesday 16th September at 11 am demonstrate that neither milk, cream, butter nor eggs are required for one to conjure delicious cakes and pies. The new area “SnackTrends” in hall B3 is also dedicated to the production of vegan snacks and other products. Snack experts will, in numerous workshops, take the central stage of the activity area with various presentations and shows as well as give tips on how to successfully market individual snack ideas.

The Austrian company, backaldrin (hall B2, booth 110, 111, 210, 310) has also taken the issue to heart. backaldrin has come up with different vegan snack ideas in cooperation with the TV chef and author Sebastian Copien. These range from soy spread with all sorts of berries to carrot quinoa salad. Basis of the snacks is “Vegipan”, a yeast-free, vegan whole-meal bread which is now also available as a bar. At iba, Sebastian Copien will be serving bread-snacks and will also share tips on how this can be integrated in one’s own business.

IBA will be held from 12th to 17th September 2015 at the Fairground Messe München. The grounds are open from Saturday to Wednesday between 9:30 am and 6:00 pm, Thursday from 9:30 am to 5:00 pm. www.iba.de

SOLIDS Dortmund 2015 Trade show for granules, powder & bulk solids technologies

04 – 05 Nov. 2015 Messe Westfalenhallen

Dortmund In parallel with:

RECYCLING-TECHNIK 2015 Trade Show for recycling &

Free ticket exclusively for Milling and Grain readers!

Register now with code

4040 :

www.solids-dortmund.com

environmental technologies and urban mining Premium partners:

August 2015 | 85

Industry events

Flexible solutions in response to changing conditions in the milling industry at IBA 2015

T

hree ingredient specialists from the Stern-Wywiol Gruppe, including the ingredient specialists Mühlenchemie, DeutscheBack and SternEnzym will be presenting their latest solutions on a joint stand (Hall B5, Stand 370) at the upcoming IBA 2015 to be held in Munich from September 12-17, 2015.

The systems designed help manufacturers of baked goods enhance their processes and products, increase profitability and take up market trends with optimum results.

Besides drawing on the skills of the individual specialist firms, users benefit from a network of cooperation between the three companies within the group.

This cooperation makes it possible to develop customised solutions all from one source. The services offered extend from consultation and product development together with the customer through applications trials to production of the functional ingredients.

Mühlenchemie

This year, the flour treatment specialist Mühlenchemie will present solutions that enable companies to respond to changing conditions in the raw material markets.

One example is flour improvers based on different enzyme systems that make it possible to adjust the falling number of flours.

For bakers and millers, the falling number is the measure of the flour’s natural enzymatic activity and is considered to be a quality parameter. The falling number determines the properties of the dough and the crumb and also the impression of freshness created by the bread.

The addition of enzyme-based flour improvers enables millers to compensate for fluctuations in the baking properties of flours.

The product range includes current solutions such as EMCEmalt, Betamalt 25 FBD, Alphamalt VC 5000 SN and Alphamalt FN which lower the falling number according to the usage level. The company will also explain the product series EMCEgluten Enhancer. The enzyme compounds compensate for a low gluten content of the flour and boost the effect of the existing gluten.

The weaker the gluten in the flour, or the smaller the

Livestock Asia 2015 Expands

A

sia’s International Feed, Livestock and Meat Industry biennial show will return to Malaysia at the Kuala Lumpur Convention Centre from 21 - 23 September, 2015. Recognised as the flagship event of the other Asian Livestock series, Livestock Asia 2015 continuously provides on-going support to grow and develop Malaysia’s livestock industries.

The event has developed an outstanding reputation since 2001 as Asia’s leading event for the feed, livestock and meat industries and received strong support from the Department of Veterinary Services, the Ministry of

86 | Milling and Grain

percentage present, the less satisfactory are the stability of the dough and the baked volume.

EMCEgluten Enhancer counteracts such a loss of quality and ensures better results from the baking process without the addition of vital wheat gluten. These enzyme compounds also compensate for deficiencies in the raw materials and permit excellent results even when lowgluten wheat is used.

As a flour treatment specialist, Mühlenchemie offers different enzyme systems to solve a host of problems that occur in milling. Its products are exported to over 100 countries.

DeutscheBack

DeutscheBack will present its current range of solutions that enable bakeries to meet the latest consumer trends in a financially viable manner. TopBake Fresh XL2 1% and TopBake Fresh XL3 1% keep bread fresh longer with flours that tend to bake dry. The addition of 1% to 1.5% of the enzyme compound results in a much softer and more succulent crumb.

Whereas TopBake Fresh XL2 1% was developed for rye and mixed wheat and rye bread, TopBake Fresh XL3 1% is intended for wheat and mixed wheat bread.

A small dose is enough to achieve noticeable and longlasting results. TopSweet Black 50 is a fifty-percent baking premix for brownies and muffins. The use of TopSweet Black 50 results in baked goods with a very dark colour and a distinctive flavour.

The typically American products are pleasantly soft and succulent. TopBake 1-2-Korn is a spelt premix containing einkorn (one-grained wheat) and emmer. It enables bakeries to meet the demand for bread and rolls with a slightly nutty taste. Einkorn is an ancient cereal, practically unknown nowadays.

SternEnzym

SternEnzym will be showing tailor-made enzyme systems designed to simplify processes and make the production of baked goods more profitable.

Mulgazym DX improves the stability of the dough, reduces stickiness and increases fermentation tolerance.

The enzyme complex can be used for all yeast-raised products such as rolls, baguettes and sandwich loaves.

Mulgazym DX achieves attractive results even with weak flours and complex processes such as retarded fermentation or freezing.

Agriculture and Agro-Based Industries.

‘Feeding AEC’s Future’, the 8th edition of Livestock Asia show is expected to attract more than 7 000 trade visitors and delegates representing integrators, veterinarians, livestock farmers, feedmillers, wholesalers, retailers, food processors, importers and distributors.

Uniquely, Livestock Asia 2015 will include face-to-face networking which take a regional and whole value chain approach to increasing the potential and competitiveness of the feed, livestock and meat industries in Asian countries to benefit not only domestic markets, but also to drive export opportunities.

www.jtic.eu

International Milling and Cereal industries meeting

+ 110 international professionals + 2 000 attendees on 2 days Workshops Posters - Job Session

4 & 5 NOVEMBER 2015 PA R I S E V E N T C E N T E R - F R A N C E

INFORMATION & REGISTRATION ON WWW.JTIC.EU 4 M U LT I L I N G UA L C O N F E R E N C E S Air cont r ol and t reat m ent Milling and Bior ef ining Q ualit y of wheat t his year I nnovat ion in indust r ial baker y

Lycée

de l'alimentation

ENILIA•ENSMIC

JTIC

66 e

AEMIC - 51 rue de l’Echiquier – 75010 Paris - FRANCE Tel : +33 (0)1 47 07 20 69 6 - Fax : +33 (0)1 44 24 56 25 / info@aemic.com / www.aemic.com Aemic Paris | @AemicFR #JTIC

INTERNATIONAL

www.jtic.eu

JEFO +1 450 799 2000 www.jefo.com

Equipment for sale ExtruTech Inc

To be included into the Market Place, please contact Tom Blacker +44 1242 267700 - tomb@perendale.co.uk

+1 785 284 2153 www.extru-techinc.com

Analysis

Colour sorters R-Biopharm

B端hler AG

+44 141 945 2924

+41 71 955 11 11

www.r-biopharm.com

www.buhlergroup.com

Romer Labs

Satake

+43 2272 6153310

+81 82 420 8560

www.romerlabs.com

Amino acids Evonik Nutrition & Care GmbH

www.satake-group.com

Computer software Adifo NV

+49 618 1596785

+32 50 303 211

www.evonik.com/animal-nutrition

www.adifo.com

Bag closing

Cultura Technologies Ltd

Fischbein SA

+44 1257 231011

+32 2 555 11 70

www.culturatech.com

www.fischbein.com/eastern

Extruders Almex +31 575 572666 www.almex.nl Andritz +45 72 160300 www.andritz.com Insta-Pro International +1 515 254 1260 www.insta-pro.com Wenger Manufacturing +1 785-284-2133 www.wenger.com

Format International Ltd

Yemtar Feed Mill Machines

Cetec Industrie

+44 1483 726081

+90 266 733 85 50

+33 5 53 02 85 00

www.formatinternational.com

www.yemtar.com

www.cetec.net

Bakery improvers

Coolers & driers

M端hlenchemie GmbH & Co KG +49 4102 202 001 www.muehlenchemie.de

Bin dischargers

Feed nutrition

Consergra s.l

Berg + Schmidt GmbH & Co. KG

+34 938 772207

+49 40 2840390

www.consergra.com

www.berg-schmidt.de

FrigorTec GmbH

Biomin

+49 7520 91482-0

+43 2782 8030

Denis

www.frigortec.com

www.biomin.net

+33 2 37 97 66 11

Geelen Counterflow

Delacon

www.denis.fr

+31 475 592315

+43 732 6405310

Morillon

www.geelencounterflow.com

www.delacon.com

+33 2 41 56 50 14

Famsun (Muyang)

DSM

www.morillonsystems.com

+86 514 87848880

Bulk storage

www.muyang.com

Bentall Rowlands

Suncue Company Ltd

+44 1724 282828

sales@suncue.com

www.bentallrowlands.com

www.suncue.com

Chief Industries UK Ltd +44 1621 868944

Elevator buckets

www.chief.co.uk Croston Engineering +44 1829 741119 www.croston-engineering.co.uk

+41 61 815 7777 www.dsm.com Evonik Nutrition & Care GmbH +49 618 1596785 www.evonik.com/animal-nutrition JEFO +1 450 799 2000

STIF

www.jefo.com

+33 2 41 72 16 80

Kemin Industries Inc

www.stifnet.com

+1 800 752 2864

Tapco Inc

www.kemin.com

+1 314 739 9191

Novus

Silo Construction Engineers

www.tapcoinc.com

+1 314 576 8886

+32 51723128

VAV

www.novusint.com

www.sce.be

+31 71 4023701

Sibelco Europe

Silos Cordoba

www.vav.nl

+ 44 1270 752 700

+34 957 325 165

Yemtar Feed Mill Machines

www.siloscordoba.com

+90 266 733 85 50

TSC Silos

www.yemtar.com

+31 543 473979 www.tsc-silos.com

Elevator & Conveyor Components 4B Braime

Westeel

+44 113 246 1800

+1 204 233 7133

www.go4b.com

www.westeel.com

Lampton Conveyer

Certification

+1 519 627 8228 www.lambtonconveyor.com

GMP+ International +31703074120 www.gmpplus.org

Feed milling Nawrocki Pelleting Technology +48 52 303 40 20 www.granulatory.com/en Ottevanger +31 79 593 22 21 www.ottevanger.com Wynveen +31 26 47 90 699

Enzymes AB Vista

88 | Milling and Grain

www.sibelco.co.uk

www.wynveen.com

+44 1672 517 650

Van Aarsen International

www.abvista.com

+31 475 579 444 www.aarsen.com

Pelleting aids

Yemtar Feed Mill Machines

FineTek Co., Ltd

+90 266 733 85 50

+886 2226 96789

Borregaard LignoTech

www.yemtar.com

www.fine-tek.com

+47 69 11 80 00

Loading/un-loading equipment

Flour

Neuero Industrietechnik

Rank Hovis +44 1494 428000 www.rankhovis.com

Grain handling systems AB +46 42 85802

Pest control

+49 5422 95030

Rentokil Pest Control

www.neuero.de

+44 0800 917 1987

Vigan Engineering

www.rentokil.co.uk

+32 67 89 50 41

Cargotec Sweden Bulk Handling

www.lignotechfeed.com

www.vigan.com

Pipe systems Jacob Sohne

Mill design & installation Alapala

www.cargotec.com

+90 212 465 60 40

Cimbria A/S

www.alapala.com

+45 96 17 90 00

Bühler AG

www.cimbria.com

+49 571 9580 www.jacob-pipesystems.eu

Used around all industrial Process control sectors.

DSL Systems Ltd

Fr. Jacob Söhne GmbH & Co. KG, Germany Tel. + 49 (0) 571 95580 | www. jacob-pipesystems.eu

Visit us! www.pipe-systems.eu+44

+41 71 955 11 11

Yemtar Feed Mill Machines

www.buhlergroup.com

+90 266 733 85 50

Nawrocki Pelleting Technology +48 52 303 40 20

Golfetto Sangati

www.yemtar.com

115 9813700

www.dsl-systems.com

+39 0422 476 700

www.granulatory.com/en

www.golfettosangati.com

Suffolk Automation

Alapala

Gazel Degirmen Makinalari

+44 1473 829188

+90 212 465 60 40

+90 364 2549630

www.alapala.com

www.gazelmakina.com

Bühler AG

IMAS - Milleral

International Aquafeed

+41 71 955 11 11

+90 332 2390141

+44 1242 267706

www.buhlergroup.com

www.milleral.com

www.aquafeed.co.uk

Hammermills

Publications

International Milling Directory

Nawrocki Pelleting Technology

Dinnissen BV +31 77 467 3555

+48 52 303 40 20

www.dinnissen.nl

www.granulatory.com/en

+44 1242 267703 www.internationalmilling.com Milling and Grain

Oryem

Genc Degirmen

+44 1242 267707

+90 332 239 1314

+90 332 444 0894

www.oryem.com.tr

www.gencdegirmen.com.tr

www.millingandgrain.com

Rolls

Satake

Van Aarsen International

Leonhard Breitenbach

+81 82 420 8560

+31 475 579 444

+49 271 3758 0

www.satake-group.com

www.aarsen.com Yemtar Feed Mill Machines

www.suffolk-automation.co.uk

www.breitenbach.de

NIR systems

O&J Højtryk

+90 266 733 85 50

NIR Online

+45 7514 2255

www.yemtar.com

+49 6227 732668

www.oj-hojtryk.dk

www.nir-online.de

Zheng Chang

Thermo Fisher Scientific

+86 21 64188282

www.bastak.com.tr

Unormak Cetec Industrie

+90 332 2391016

+33 5 53 02 85 00

www.unormak.com.tr

www.cetec.net

Brabender +49 203 7788 0 www.brabender.com

+90 (364) 235 00 26

+43 1 79013 4917

www.ugurmakina.com

Palletisers

Safety equipment Rembe

+33 5 53 02 85 00

+44 1483 468900

Ehcolo A/S

www.binmaster.com

www.balaguer-rolls.com

Cetec Industrie www.cetec.net

+1 402 434 9102

+34 965564075

www.petermarsh.co.uk

Hydronix

BinMaster Level Controls

Fundiciones Balaguer, S.A.

+44 151 9221971

www.chopin.fr

Level measurement

Roll fluting

Peter Marsh Group

+33 14 1475045

www.hydronix.com

Ugur Makina

Mondi Group www.mondigroup.com

CHOPIN Technologies

www.doescher.com

www.alapala.com

Packaging

+90 312 395 67 87

+49 4087976770

+90 212 465 60 40

www.thermoscientific.com

Bastak

Doescher & Doescher GmbH

Alapala

+1 9786 421132

www.zhengchang.com

Laboratory equipment

Roller mills

+45 75 398411 www.ehcolo.com PAYPER, S.A. +34 973 21 60 40 www.payper.com

+49 2961 740 50 www.rembe.com

Sifters Filip GmbH +49 5241 29330 www.filip-gmbh.com

Symaga

nabim

+90 332 444 0894

+34 91 726 43 04

+44 2074 932521

www.gencdegirmen.com.tr

www.symaga.com

www.nabim.org.uk

Genc Degirmen

Silos

Ocrim

Tornum AB Alapala

+46 512 29100

+90 212 465 60 40

www.tornum.com

www.alapala.com

Westeel

+39 0372 4011 www.ocrim.com

Valves

Bentall Rowlands

+1 204 233 7133

+1 785 825 7177

+44 1724 282828

www.westeel.com

vortex@vortexvalves.com

www.bentallrowlands.com

www.vortexvalves.com

Temperature monitoring

Chief Industries UK Ltd

Rota Val Ltd

Agromatic

+44 1621 868944

+44 1249 651138

+41 55 2562100

www.chief.co.uk

www.agromatic.com

Global Industries, Incorporated

Dol Sensors

+1 308 384 9320 www.globalindinc.com

www.rotaval.co.uk

Vibratory equipment

+45 721 755 55

Mogensen

www.dol-sensors.com

Handling

+1 519 627 8228

www.mogensen.co.uk Bühler AG

www.lambtonconveyor.com

Vibrafloor

+41 71 955 11 11

MYSILO

+33 3 85 44 06 78

www.buhlergroup.com

+90 382 266 2245

IAOM

www.mysilo.com

+1 913 338 3377

Obial

www.vibrafloor.com

Weighing equipment

www.iaom.info

Parkerfarm Weighing Systems

IFF

www.parkerfarm.com

+44 1246 456729

+90 382 2662120 www.obial.com.tr

+495307 92220 Silo Construction Engineers

www.iff-braunschweig.de

+32 51723128

Yeast products Leiber GmbH

Kansas State University

www.sce.be

+49 5461 93030

+1 785 532 6161

www.leibergmbh.de

www.grains.k-state.edu

Silos Cordoba

Materials

+44 1476 566301

Training

Lampton Conveyer

Raw

+34 957 325 165 www.siloscordoba.com

India

the world’s second largest market

SESSION 1

de Hy

19

rabad Ind ia

-20 15 August 20

SESSION 3

Trends in flour miling industry

Value of quality for sustainability

Trend and Developments in Feed milling

Procurement and Storage issues

Innovation for quality production of milled products for India

Quality and sustainability with upgrading mills Modern Flour Milling

19-20 August 2015

Hyderabad, India

SESSION 2

SESSION 4

Food and Feed for Globe – “Feeding 9 billion by 2050”

The way ahead “Adopting quality control programs & regulations”

Global Outlook

Food Safety and Regulatory Regime

Challenges to feed the masses Challenges to secure nutrition security

Organised by:

www.assocom-india.com/gmc 90 | Milling and Grain

The worlds premier Directory for the feed, flour, rice milling and grain handling industry is about to publish it’s 24th print edition

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YOUR GLOBAL DIRECTORY The International Milling Directory 2014/15

FEED GRAIN STORAGE HANDLING

M lling

International

Directory

23 Edition

Edition 23

2014/15 Get the IMD on your smart phone

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M lling

International

Directory

23 Edition

Edition 23

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The International Milling Directory 2014/15

ONLINE | PRINT | MOBILE

03/12/2014 12:28

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03/12/2014 12:28

the interview

Görkem Alapala

Gorkem Alapala was born in 1981, in Corum, Turkey. He is the Chief Strategy officer and Vice chairman of Alapala Group. After completing his university degrees in the USA, he has been active in family businesses with the vision to be one of the most outstanding organizations in milling technology industry.

Alapala is currently investing in 2 new manufacturing facilities for flour and feed milling and a new R&D Center. Alapala recently awarded the prestigious Grapas award for innovation for their Similago 2 roller mill at the recent Victam International event held in Cologne, Germany.

Can you tell us a little bit about the origins of the Alapala group?

Alapala’s founder, Mehmet Alapala started his working life in the late 1930s at a very young age with his father Abdullah Alapala by building wooden construction parts. Years later, he founded his own carpenter’s manufacturing business.

Mehmet Alapala was actively involved in construction of Hatap Flour Mill built in Çorum in 1961 by a British manufacturer.

That experience started a new era for both Mehmet Alapala and generations to come. Milling machines were being made out of wood during those years. Mehmet Alapala started manufacturing plansifters to be used in flour mills thanks to his experience gained during such works. He commenced selling sifters to all factories in Turkey very soon after. He gave much importance to quality and worked meticulously. At the time, he was the only person who carried out this business in Turkey. He laid the foundations of Alapala, succeededing in becoming one of the top companies in its sector.

Mehmet Alapala later, together with his sons Nurettin and İsmail Alapala, started manufacturing all machinery for flour mills and turn-key mills. He started Alapala Feed Mill in 1982 and Alapala Flour Mill in 1984, laying the foundations for Alapala Group.

In 1981, Alapala made its first export and in 1989 Alapala made its first turn-key flour installations abroad in Jordan and Italy. Today Alapala Machinery supplies turnkey flour, semolina, maize and feed plant food storage systems in every capacity and industrial steel construction buildings, has turnkey references in over 85 different countries and offices in more than 30 different countries.

How was the Victam International event for Alapala and what did the company find useful?

For Alapala it was good to see more exhibitors and attendance to Victam from the flour milling sector as Victam is an exhibition which is mainly associated with the animal feed, aqua feed and pet food production. As we are now increasing our manufacturing facilities, we also plan to increase our feed milling range of machinery and by meeting the feed millers it has given us a better insight to the market requirements. I would like to thank the organisers and all those who were involved for a well organised exhibition.

How important are international shows to Alapala’s marketing strategy?

International shows and exhibitions, for Alapala are vital for our sales and marketing strategy as this gives us an interaction with our existing and future customers. They allow us to exhibit new products, services and machinery, which we can physically speak about while demonstrating. They also give us a deep insight into what the market trends are, the competition and their products.

92 | Milling and Grain

What does it mean to Alapala to win the GRAPAS award, a prestigious innovation prize?

Winning this award is a great honour for Alapala and we thank everyone involved in bestowing this honour to us. By winning this award it has shown to the industry the capabilities of Alapala and how it is innovative. We know that the Similago II, with its advanced engineering, will be a very successful roller mill, which will perform efficiently for many years to come

Does Alapala have any new innovations on the horizon?

With our new Research and Development facilities we have completely new innovations that are currently in the prototype stage. Mainly they will be in the cleaning and milling sections of the mill. As you well understand, I cannot reveal any further information at this stage. Side by side, we are always updating our machines with new suitable technologies when they are available. We are also upgrading our manufacturing facilities with new innovative manufacturing processes and machinery.

Your father was at the helm of a prestigious family heritage, what have you learnt from your father, and what do you hope to bring to the business going forwards?

What I learned from my father is that our reputation, the Alapala name, is the most important asset we have and it is the way we treat our suppliers, employees, and clients that matters. My father developed relationships with his clients and built a reputation for being a good engineer who can be trusted for offering the high quality with good value. I work with the same principles, which I learned from my father and grandfather.

What is Alapala’s philosophy and mission statement?

Do you have your own ethos?

In short, a passion and dedication to the grain milling industry. A company owner once said, “A company succeeds not because how long it is established or how big it is. It is because there are men and women in it who live it, sleep it, dream it, and build great future plans for it.” This sums up our commitment to be firstly, a solution provider to our clients, second, to manufacture high quality with advanced technology and the most important after sales service with parts back up.

PEOPLE THE INDUSTRY FACES Delacon appoints Mohamed Taleb as Sales Manager Middle East

D

r Mohamed Taleb has joined Delacon as Sales Manager Middle East. Located in Cairo, Egypt, he will be responsible for sales in Egypt and the Gulf region and reports directly to Bernard Paumelle (Area Sales Manager Italy, Middle East, Africa).

“Dr Mohamed Taleb has sound experience in health and nutrition management in poultry and large animals. Furthermore, his knowledge about the Middle Eastern area will help Delacon to establish phytogenics as the reliable alternative to antibiotic growth promoters,” says Bernard Paumelle, Delacon’s Area Sales Manager Italy, Middle East, Africa.

Mohamed Taleb

“The Middle Eastern poultry and large animals market is growing steadily and shows huge potential. Antibiotic growth promoters have been banned in some Middle Eastern countries and are imminent to be banned in the rest of the Middle Eastern countries. Most customers are aware of this situation and demand phytogenic feed additives”, explains Dr Taleb.

Before joining Delacon, Dr Taleb served as Marketing Manager for Gozl Trading in Saudi Arabia. Prior to that, he worked as a Product Manager at Delacon’s Egyptian distributor IFT, at whom he was responsible for the product launch of Biostrong on the Egyptian market. Dr Taleb holds a doctor’s degree in Veterinary Medicine (DVM) from Cairo University.

Joerg Seifert appointed new FEFANA Secretary General

J

oerg Seifert has been appointed as the new EU Association of Specialty Feed Ingredients and their mixtures (FEFANA) Secretary General

Mr Seifert is of German nationality and holds university degrees in food technology and in business administration. He has gained major professional experience through working at technical director level with the trade association representing the global dairy sector and partnering with many other livestock sectors since 1998.

Joerg Seifert

He succeeds Didier Jans who has left the association earlier in April after fifteen years. Dorothea Schiemann – who has been serving the association as ad interim Secretary General in the meantime – will ensure a smooth handover.

In the words of FEFANA President, Marco Bruni: “Joerg is fully motivated to lead the association through forthcoming changes to build a stronger FEFANA effectively addressing our industry’s challenges of today and of the future.”

Joerg Seifert strongly believes that the European Specialty Feed Ingredients industry has a vital role to play in the feed and food chain for achieving sustainable food security and that FEFANA is the only organisation that can defend an appropriate policy and regulatory framework in the EU to secure product innovation and growth of the industry.

Biorigin appoints new sales manager for the animal nutrition sector in North America

Bruno Mazzer de Oliveira Ramos

B

iorigin has a new technical sales manager in North America, Bruno Mazzer de Oliveira Ramos.

Ramos has a degree in Veterinary Medicine by the State University of Londrina, Brazil, and a PhD in Ruminant Nutrition by the same university.

Working as a consultant, Mr Ramos has more than 13 years of experience in the market, with the last six years as technical and product manager of an important animal nutrition company.

At Biorigin, he will be Technical Sales Manager in North America for products of all animal species.

According to the Global Feed Business Manager, Roberto Vituzzo:

“the goal of Biorigin Animal Nutrition is to expand our market in North America, and Bruno Ramos will be essential for this process, considering his experience and technical knowledge on this market. We have been competitive in North America and we expect to double our sales until mid-2016 by increasing the sales to our current customers and obtaining new clients.

We will expand our presence and focus in that region to further enhance our service to our customers, as well as explore new business opportunities in the US and Canadian markers, where there are huge possibilities for application of our products.”

Erica Oakley joins US Wheat Associates as programs manager

U

S Wheat Associates (USWA) welcomes Erica Oakley to its Arlington, VA, headquarters office staff as programs manager effective July 6, 2015. In that position, Oakley will help implement export market development activities planned and managed by USWA’s domestic staff, including consulting assignments, board team trips and assistance with customer conferences.

She will report to the director of programs and planning, Jennifer Sydney.

Erica Oakley

“We are pleased to have Erica join us in an important position,” Ms Sydney says. “Her experience and interest in international food marketing and assistance is exceptional.”

Ms Oakley joins USWA after serving as an associate at Humanitas Global, Washington, DC, since 2012. There she managed programs in food and nutrition security, food sustainability, agriculture and public-private partnership development. Members and funders of this non-governmental organisation include the World Food Prize, the Food and Agriculture Organisation of the United Nations and the World Health Organisation.

A native of North Carolina, Ms Oakley earned a bachelor’s degree in International Studies at Meredith College, Raleigh, NC, and a master’s degree in International Relations from Utrecht University in The Netherlands.

94 | Milling and Grain

Bagging station Maia – consistent and efficient bagging.

The Bßhler Maia bagging station stands for a fully automated bagging process for powdered, free-flowing and friable products. Aligned process steps result in a constant filling accuracy and a high bagging capacity. Not only top sanitation but also a unique design complete this new bagging unit. The outcome is compelling: an unparalleled operational reliability for clean bagging, designed for bags with a capacity of 20 to 65 liters. Maia – consistency and efficiency at the highest level. www.buhlergroup.com/milling

Maia bagging station.

Consistent and efficient bagging.

Flexible in use For powdered, free-flowing and friable products.

Top sanitation A dustproof bag spout with a built-in aspiration provides clean bagging.

Unique operational reliability Ensures high efficiency and low operating costs.

Innovations for a better world.