AUG 2016 - Milling and Grain magazine

Page 1

August 2016


In this issue:


• The antibiotic free movement: Enhancing the nutritional value of feed • Building digital bridges for your quality assurance • Feed weighing systems • Aerating stored grain • IndoLivestock

Event review

Volume 127

Issue 8

Preserves kernel quality Low maintenance High efficiency Self-cleaning option for reduced emissions

Chief Commercial Mixed Flow Dryer

“I have been in the grain business my whole life and was totally amazed with how many bee’s wings (red dogs) there are in corn. With this system you can actually watch the amount taken out.” -Doug Kavanagh, Operations Manager Glacial Plains Cooperative Murdock, MN

*Patent Pending

Our team of experienced Dealers and Staff will help you determine the system that will suit your needs. Chief Agri/Industrial has a full line of grain storage, conditioning, handling, and drying products that can be engineered to fit your site. At Chief we not only engineer quality products, We Engineer Relationships.


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COVER IMAGE: The roller floor at FWP Matthews' specialist mill in the Cotswold village of Shipton under Wychwood. The mill employs a fascinating mixture of vintage and modern equipment: the wooden silos, along with much of the internal construction of the roller mill section, are over 100 years old.

Perendale Publishers Ltd 7 St George’s Terrace St James’ Square, Cheltenham, Glos, GL50 3PT, United Kingdom Tel: +44 1242 267700 Publisher Roger Gilbert International Marketing Team Darren Parris Tel: +44 1242 267707 Tom Blacker Tel: +44 1242 267700 Mark Cornwell Tel: +1 913 6422992 Latin America Marketing Team Iván Marquetti Tel: +54 2352 427376 India Marketing Team Ritu Kala Tel: +91 93 15 883669 Nigeria Marketing Team Nathan Nwosu Tel: +234 805 7781077 Editorial Team Eloise Hillier-Richardson

16 - Milling journals of the past at The Mills Archive

Peter Parker Malachi Stone Andrew Wilkinson International Editors Professor Dr M Hikmet Boyacıog ˘ lu Dr Roberto Luis Bernardi Professor Wenbin Wu Design Manager James Taylor Circulation & Events Tuti Tan

The German Engineering Works of Messrs Seck Brothers




4 6-32





FEATURES 38 The antibiotic free movement

52 Building digital bridges for your quality assurance

48 Sortex

60 Micronutrient premixes with vitamins B1 and B2

44 Flour Mill Tour - FWP Matthews

56 Feed weighing systems


64 Aerating Stored Grain

68 Dust explosion protection

Antoine Tanguy Australia Correspondent Roy Palmer ©Copyright 2016 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 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


104 People news from the global milling industry


88 Event listings, reviews and previews


35 International industry personnel travel to US for wheat milling course


16 Mildred Cookson 25 Tom Blacker 26 Christophe Pelletier 30 Chris Jackson

2 GUEST EDITOR Roger Gilbert

82 MARKETS John Buckley

102 INTERVIEW Shawn Thiele



Milling4Life It is not often that we get an opportunity through our work to help others and make a difference. I believe Milling and Grain has the standing and stature – now that it is published monthly and is in five languages with a global reach into all sectors of the milling industry – to take up the challenge of ‘making a difference’ when it comes to how we meet the forecast demand for food for the next one or two generations that follows ours. Our grandchildren will look back at those of us who worked in the food supply chain and ask “What did you do to provide for the world’s poor?” should predictions of food demand outstripping supply become a reality. I have always said that once you know something you have a responsibility to respond; that response may be to do nothing, which is the prerogative of every one of us, but eventually we will be asked to justify our decisions. That is why the ‘opportunity’ facing Milling and Grain, which reports on and represents the best our industry has to offer for the milling industry, must be taken up. Many organisations and companies within our industry already have well-established programs to support the less advantaged both in their local communities as well as doing what they can for others abroad, but possibly not for millers directly. That is why we have established ‘Milling4Life’ - to encourage and organise millers to assist millers in need.

Why a millers’ charity?

You will all have heard that our world will be home to 9.5 billion inhabitants by 2050: that’s a statement I first articulated at an FAO meeting back in the early 1990s and which has been taken up by almost every sector of society when

assessing future food demand. So what does that mean for our industry? Milling and Grain has been compiling industry gathered compound feed figures (collected annually by Alltech) to show that where animal protein consumption is concerned, countries should be producing a minimum of 133.6kg/ capita if they want to avoid food insecurity problems. This figure is a guide only, and not an accurate benchmark for all countries, however, for the majority providing less compound feed per head of population it reflects poverty, hunger and even civil unrest. From the Alltech figures I have identified those countries under 133.6kg/capita and who over recent years have been improving their compound feed output. It is these countries that need our help and encouragement. The African Union (AU) body called ‘The New Partnership for Africa’s Development’ (NEPAD) which represents 53 out of the 54 African countries has agreed to identify recipients from selected African countries for the first modest program offered by ‘Milling4Life.’ I must quickly point out that the charity is not focused on animal and fish production but also on milling of cereals and oilseeds, etc, and aims to assist millers in these sectors to attend courses and training program. While donations will be all important as the charity’s activities develop, it is not the first goal. In the first instance we will be focusing on ensuring the requisite trustees are in place, that a website outlining its vision, mission and related activities are clearly stated and that its constitution is available for industry and public scrutiny. As the industry’s oldest, still-in-print, magazine we feel we have a duty to focus our attention on those in greatest need and activities that can help improve feed and food supplies most – a milling charity is a logical approach. Roger Gilbert Publisher

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

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

ISSN No: 2058-5101

More Information





The antibiotic free movement

From the Novus Media Jam that took place in June 2016, we report on one of the insightful talks that specifically concerned the Antibiotic Free Movement or ABF, where the ‘subtherapeutic’ use of antibiotics and the many alternatives Novus offer were discussed. See the full story on page 38

US Wheat Associates announces several staff promotions

USA STATS 147 Percentage average dietary supply adequacy for the USA in 2015, compared to a global average of 123 percent for the same year

Source: FAO

US Wheat Associates (USW), the industry’s export market development organisation, has promoted three associates to Vice President. See the full story on page 24

8.4 Yield, in tons per hectare for US cereals in 2014. The world average the same year was less than 4.3 10 Millions of tons of cereals imported by the US in 2013; it exported over six times this amount. The same year the Russians imported 1.6 million tons and exported 19 million; the figures for Canada were similar

4 | August 2016 - Milling and Grain



NOVUS CELEBRATES 25 YEARS This June Darren Parris and I embarked on the long but worthwhile journey to Novus’ International Global Headquarters in St Charles, Missouri, to celebrate their 25th Anniversary. Journalists and writers from across the globe were invited to the three-day event, encompassing a vast array of exciting excursions, talks and tours, organised by our hosts Brandi Hamilton, Global Marketing and Public Relations Specialist, and Jake Piel, Sustainability Manager. See the full story on page 74

Shawn Thiele from Kansas State University

Shawn is the current flour milling and grain processing curriculum manager for Kansas State University. See the full story on page 102


Walk The Italian Way

Walk The Italian Way

The things we produce today were utopias yesterday. Our task is to give shape to new ideas


and innovate what once was magic.


AUG 16


KSU Grain Science and Industry student receives undergraduate scholarship


ennel Milling Company contributes US$11,000 for Milling Science and Management Education. Kansas State University’s Milling Science and Management student Jessica Davis was awarded a scholarship toward her out of state tuition costs on behalf of Mennel Milling Company. The scholarship’s purpose is to provide financial assistance to full-time students enrolled in the Milling Science and Management curriculum at Kansas State University. The scholarship allows non-Kansas students to attend the university at instate tuition costs. Davis, now a junior at Kansas State University, says she is very grateful for this scholarship. “Having this financial assistance will allow me to better focus my time and efforts on learning as much as possible at Kansas State,” Davis says. The scholarship was established in 2010. Funds provided are to cover US$10,000 of out of state tuition, and an extra US$1,000 for travel costs. The scholarship is awarded to one student from any of these five states: Ohio, Michigan, Illinois, Indiana or Virginia. Scholarship recipients must also achieve a minimum cumulative grade point average of 3.0. Each student who receives the award is eligible for its renewal the following year. “Scholarships, particularly of the scale pledged by Mennel Milling, are an important component of our recruitment and retention efforts. Mennel, and in particular Ford Mennel, have the gratitude of our faculty and our students for their forward thinking generosity,” says Jon Faubion, Kansas State University professor of baking science.

6 | August 2016 - Milling and Grain

Over 200 aquaculture specialists, from governments around the world, met in Rome in early July under the FAO’s umbrella Committee on Fisheries, at the 32nd session of COFI 2016. During the week Roger Gilbert, publisher of Milling and Grain and International Aquafeed magazines and the former founder and secretary general of the International Feed Industry Federation, met with representatives from NEPAD (New Partnership for Africa's Development) an agency of the African Union. Mr Gilbert was invited to present information on feed production and livestock and fish feeding. He took the opportunity to introduce a new industry charity that aims to support training for millers from developing countries. The new charity set up under the name of ‘Aquaculture without Frontiers’ and ‘Milling4Life’ will focus on both animal and fish feeding in addition to traditional flour and cereal milling. “It was the culmination of work our magazines have been doing over recent years to engage with food production in Africa by presenting an industry-supported way forward in improving the feed milling capacity on the African continent,” says Mr Gilbert. “Our magazines are here to serve and support the milling industry everywhere and by establishing a charity we can carry out more meaningful work with feed and food millers in Africa through the NEPAD organisation which represents the interests of 53 of 54 African countries. “I was fortunate to be invited by Clifford Spencer, Goodwill Ambassador for NEPAD to meet with Haladou Salah, Senior Technical Adviser to the Rome-based African Ambassadors and Dr Hamady Diop Program Manager - Natural Resources Governance for NEPAD, to discuss how we might help,” he says.



Milling News

Anpario builds global presence and commercial infrastructure


uilding on recent successes, such as the Queen’s Award for Enterprise – International Trade, Anpario are strengthening and reinforcing their commercial infrastructure and global presence with the appointment of several Regional Commercial Directors and plan to open more regional offices.

Recent new appointments European Regional Sales Manager - Hayley Agnew

Hayley Agnew joined Anpario in mid-2015 in the role of European Regional Sales Manager. Hayley is responsible for managing sales, the sales team and distributors across Anpario within Europe – including

the UK and Ireland. Hayley previously worked for Alltech as Technical Sales Manager, as well as Promar, where she was involved in a number of face to face farmer and business customer roles, having been an on farm consultant and development advisor. Hayley’s extensive experience has allowed her to hit the ground running, building and driving her own team across Europe to support Anpario’s long-term strategy.

Asian Commercial Director – Dr Richard Chong

Dr Richard Chong joined the Anpario team in March 2016. Richard is heading up the company’s Asian sales office based in Kuala Lumpur and is leading their sales effort in the region. The engagement of Richard by Anpario is part of the company’s plan to provide improved local service to their regional partners and customers, spearheading their sales effort and promotion of best in class gut health products. Richard has significant sales, technical and commercial experience, having previously worked for Alltech, Gold Coin and more recently Anitox, where he was Commercial Director for Asia. He has a successful track record of

leading teams and developing markets such as China and Thailand. Richard’s multilingual skills mean that Anpario can work much more closely with their distributors and end users across the region.

Latin America Commercial Director – David Dinhani

David has joined Anpario in the role of Regional Commercial Director for the Latin America Region. David is multilingual and has significant sales, technical and commercial experience having successfully established Lohmann Animal Health’s vitamin and nutritional additives division for South America. David has previously worked for Ajinomoto, Kemin, BASF and Anpario’s distributor M Cassab, a number of years ago. David has a Master’s Degree in Animal Nutrition from the Universidade Federal de Lavras, Minas Gerias as well as an MBA in Agribusiness from FEA USP, Sao Paulo. From Anpario’s Sao Paulo office he will be responsible for all the company’s trading and product brands and distributors which make up the Latin American region. His commercial experience in the key markets in the region will bring invaluable leadership and vision in implementing Anpario’s ambitions to significantly grow their sales in Latin America.

MEA Commercial Manager and MEA office (to open in Dubai) - Zouhair Chadlaoui

Zouhair Chadlaoui MBA joined Anpario most recently, on 15 May 2016. Zouhair is heading up the company’s Middle East and Africa sales effort. Anpario has opened a regional sales office in Dubai as a central point for their sales effort in the Middle East and Africa. Zouhair is a business executive with cross-functional managerial experience including sales, business development and marketing. He has 9 years’ experience in the feed industry, including positions in Provimi MENA (The Netherlands), Nutriforce LTD (Belgium) and Timab based in Dubai. Zouhair’s multilingual skills, expertise and experience, teamed with his bi-cultural background, make Zouhair an invaluable addition to the global Anpario team.

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Milling News

Satake sales partner opens new showroom in Myanmar


t the end of May, Adipati, a sales partner of Satake in Myanmar, opened a new sales showroom displaying Satake products. Adipati have their own rice mill, and distribute white rice both within and outside the country. In 2010 they installed Satake optical sorters thereby increasing their white rice quality. Subsequently, they refurbished their existing rice mill with Satake’s expertise. Adipati President Mr Thein Toe decided to distribute Satake products throughout the country. In 2012, the company started to deal with Satake products as a sales partner, now having such confidence in Satake’s high quality. Since the showroom’s opening, sales to new Satake customers have been impressive. As a further sales promotion measure, the showroom was opened on May 31. On the same day, an opening ceremony was held with approximately 100 people from the rice milling industry in attendance. The new showroom displays a series of rice milling


process machines including: paddy husker, de-stoner, rice milling machines, optical sorter and packer. This is the place for business discussion and hands on checking of actual machines. Expectation is high for sales expansion in the future. Satake plans to hold a seminar to introduce its new products and optimal rice processing technology in Yangon in conjunction with Adipati to contribute to improving Myanmar’s white rice quality.

Self-cleaning EcoGuard System in Commercial Dryer hief Agri/Industrial, a division of Chief Industries, Inc announced on June 1 that they have developed new technology that significantly reduces maintenance and emissions that works alongside its Commercial Dryer series. The Chief Commercial Dryer, including self-cleaning EcoGuard System (patent pending), addresses the increased demands to reduce dust emissions in the grain industry. Chief considered engineering a system with these capabilities after a Chief representative saw a customer’s need for dust reduction and minimising maintenance. Chief’s engineering team responded with excellent customer service, attention to detail, and was able to engineer the EcoGuard System. “In 2014 we decided to purchase a dryer from Chief Industries. We knew there would be some changes to be made but Chief was willing to go the extra mile to help us and hopefully other communities in the Grain Industry. In 2015 Chief changed a couple of things to help ‘reduce emissions in the package’. “After the harvest season was complete the locals sent a spokesman to our office to let us know they were satisfied with the changes!!! I have been in the grain business my whole life and was totally amazed with how many bee’s wings there are in corn. With this system you can actually watch the amount taken out. It is worth seeing it to believe,” said Doug Kavanagh, Operations Manager of Glacial Plains Cooperative. “Chief is proud of the latest addition of quality products to broaden the range of Chief’s equipment offering and meet the needs of our evergrowing customer base.” said Roger Townsend, President of Chief Agri/ Industrial. 10 | August 2016 - Milling and Grain

Ohio bakery mix and packaging facility purchase agreed


he Mennel Milling Company are pleased to announce their tentative agreement reached with General Mills Inc, Minneapolis, Minnesota to purchase their Martel, Ohio bakery mix and packaging facility pending the finalisation of negotiations. They expect the closing of this sale to be finalised before November 1, 2016. “This is an exciting opportunity for the Mennel Milling Company to extend into the bakery mix business. It allows us to continue to add value to wheat flour and expand our product offerings to better serve our customer base. With this acquisition we will no longer be constrained to selling flour as an ingredient into baked goods or bakery mix. We will now be able to offer a full line of bakery mix products to our big box, commercial, wholesale and bakery customers and marketplaces,” said D Ford Mennel, President of the Mennel Milling Company. “Mennel has been a supplier to the Martel facility for over 40 years. We know the capabilities of the employees and the facility and we are excited to integrate them into the Mennel Milling Company.”

Milling News

CIGI-run programs which help 115 countries appoints Board of Director


he Canadian International Grains Institute elected its Board of Directors at its Annual General Meeting in mid-June 2016. New to the board is Kevin Bender from Bentley, Alberta. Re-elected members are Jim Wilson, farmer, Darlingford, Manitoba and Brent Watchorn, Executive Vice-President Marketing, Richardson International. Kevin, Jim and Brent will serve two-year terms. Continuing on the CIGI board with one year remaining in their terms are Murdoch MacKay, Commissioner, Canadian Grain Commission; Lawrence Yakielashek, General Manager, FarmLink Marketing Solutions; Randy Johner, farmer, Estevan, Saskatchewan and Henry Van Ankum, farmer, Alma, Ontario. The following officers were also elected: Murdoch MacKay, Chair; Henry Van Ankum, Vice-Chair and Jim Wilson, Secretary. Ron Nerland, farmer, Morrin, Alberta, retired from the board. Kevin Bender farms full-time with his father and brother in the Sylvan Lake-Bentley area in Alberta. He has contributed significant time and effort serving on various boards and commissions over the past several years, including the Alberta Wheat Commission, Western Canadian Wheat Growers and Alberta Canola Producers Commission. In January 2016 Kevin was elected Vice-Chairman of the Alberta Wheat Commission and he represents AWC on the Cereals Canada board. “We are very pleased to welcome Kevin to the CIGI board,” said Chair Murdoch MacKay. “His knowledge and history of involvement in the western Canadian grain industry are important assets as the board of directors work to build relationships and a broader understanding of CIGI‘s value with industry stakeholders.” On behalf of CIGI, MacKay also expressed appreciation to Ron Nerland who joined the board in June 2014. “As the CIGI board continued to evolve to reflect a cross section of the industry, Ron provided an important perspective on behalf of

farmers. He was a thoughtful contributor to our strategy, planning and discussions.” CIGI is an independent not-for-profit market development institute created in 1972. More than 44,000 people representing grain, oilseed, pulse and special crops industries from 115 countries have participated in CIGI programs and seminars. CIGI’s mission is to increase utilisation of Canadian grain and field crops through superior knowledge, technical expertise, industry leadership and collaboration, innovative

Caption: Kevin Bender, Henry Van Ankum, Randy Johner, Lawrence Yakielashek. Front row: Brent Watchorn, Murdoch MacKay, Jim Wilson, JoAnne Buth (Cigi CEO).

processing solutions and targeted training to customers around the world. CIGI is funded by farmers, the Government of Canada (AAFC) and industry partners.

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Milling News

BENEO announces results of technical trials for functional clean-label rice starch


unctional ingredient manufacturer BENEO announces that technical trials have confirmed the strong performance of Remypure - without the use of any chemicals. Remypure is the company’s first highperforming rice starch that qualifies for both natural and clean label status worldwide. Trial results in fruit preparations show an improved viscosity build-up equivalent to chemically modified starches, clearly reflected in comparable Bostwick

Figure 1: BENEO’s functional native rice starch, Remypure, shows comparable viscosity behaviour to modified rice starch

Trials indicate high performance comparable to modified starches values (see figure 1). In addition, sensorial evaluation demonstrated that BENEO’s functional natural rice starch supports a clean fruity flavour and a typical short and smooth texture. Remypure’s high performance also means that the starch remains stable under severe processing conditions. Trial results also show better tolerance towards acidity and heat than other clean label starches (see figure 2). Due to its unique molecular structure of amylopectin, which reduces retrogradation, Remypure provides an

12 | August 2016 - Milling and Grain

Figure 2: In comparison to clean label rice starch, Remypure, remains stable under heat and acidity

increased shelf life and freeze-thaw stability. The improved stability of Remypure is based on an innovative production process. BENEO, the worldwide leader in rice starch, is utilising only natural processes using heat in a lowmoisture environment to produce the new Remypure. With demanding conditions always being a challenge, Remypure is the ingredient of choice for manufacturers looking for a versatile clean-label starch with good functionality in both gentle and severe processing requirements for applications such as jarred baby food, sauces, and dairy desserts. It is available in a range of variants, therefore providing whichever texture is required, such as creamy or soft. “Remypure, our new functional native rice starch, supports manufacturers in the development of products that respond to the growing natural and clean label trend demanded by consumers,” said Jon Peters, President of BENEO, Inc. “Clean and simple information on packaging provides reassurance to consumers when buying food products containing Remypure.” In fact, BENEO research shows that 65 percent of consumers in the Americas consider natural products as better and 47 percent actively look for natural products when making food purchase decisions, which means that clean label and natural claims are becoming increasingly important in the creation of food products. Additionally, seven out of 10 consumers say they are interested in foods that contain only ingredients that they recognise. One of every two consumers agrees that rice starch sounds natural. Remypure can be utilised by manufacturers in a wide range of dairy and food products and is particularly wellsuited to applications that undergo demanding processing conditions including retorted sauces, jarred baby food, dairy desserts and fruit preparations.

Milling News

Flour fortification resulted in 35,500* healthier babies last year


*Total represents 13 percent of preventable neural tube defects

ast year an estimated 35,500 babies – an average increases the population’s blood folate levels. The World of 97 a day – were born without neural tube Health Organisation recommends a red blood folate cell defects (NTDs) in 58 countries which implement concentration above 400 nanogram/milliliter (ng/mL) in mandatory programs to fortify flour with folic acid, women of reproductive age to prevent NTDs. At these levels, according to research published this week in Birth Defects the NTD birth prevalence would be 0.5 to 0.6 per 1000. Research Part A: Clinical and Molecular Teratology. The Any prevalence higher than this should be considered as an research also notes that this figure only represents 13.2 epidemic and result in immediate action, Kancherla said. percent of all NTDs that could be prevented globally. A 2006 March of Dimes publication estimated that the “We have known that folic acid prevents the majority average global birth prevalence of NTDs was 2.4 per 1000 of NTDs for 25 years, yet only a small fraction of these live births. This figure did not include pregnancy loss, birth defects is being prevented worldwide,” said Vijaya still births, and terminations of pregnancies due to NTDs. Kancherla, one of the study authors. Kancherla is instructor Countries with mandatory fortification programs, such in the Department of Epidemiology and researcher with the as Canada, Costa Rica, and Australia, report less than the Center for Spina Bifida Prevention at Emory University in March of Dimes estimate of 2.4 NTDs per 1000 live births. Atlanta, Georgia, in the United States. “We urgently need For this research, authors calculated that 200 micrograms political will to improve the nutrition of women of reproductive age in all countries so that we can prevent serious birth defects that occur due to lack of enough folic acid in the mother.” The study estimates that 268,700 cases of folic acid-preventable spina bifida and anencephaly – the most common NTDs – would occur annually without any folic acid interventions. With spina bifida, the spine does not form correctly. Spina bifida health outcomes range from some loss of movement to loss of bladder control and paralysis. Children with spina bifida often do not live to be adults. Common causes of death are hydrocephalus, NTDs prevented in 2015 infections, pneumonia, and heart and No prevention: 0 percent prevention in countries consuming less than 20 mcg/day of folic acid from fortified flour daily lung problems. Anencephaly is caused Modest prevention: 50 percent prevention in countries consuming 100 by the brain not forming correctly; it is mcg/day (range 20-150 mcg/day) of folic acid from fortified flour daily fatal within days after birth. High prevention: 100 percent prevention in countries consuming 200 The recent analysis focused on 58 mcg/day (>150 mcg/day) or more of folic acid from fortified flour daily countries with mandates to fortify wheat flour alone or in combination with maize flour with at least one part folic acid per million parts flour. Countries were not included of folic acid a day would prevent most cases of spina if fortification mandates were not implemented or if bifida and anencephaly. That is based on experiences in fortification was voluntary. The study also did not consider the United States where adding folic acid to enriched grain whether other foods were fortified with folic acid. products contributes about 138 microgramsof folic acid a “We concentrated on mandatory flour fortification day to Americans’ diets. This is credited with preventing because it is a proven intervention that reaches the majority 1,326 NTDs annually. The US mandate has been effective of the population in the country equitably,” Kancherla said. since 1 January 1998. If the annual estimate of NTDs “It is safe, effective and extremely cost-saving. In contrast, prevented was consistent throughout the past 18 years, voluntary fortification, as seen in Ireland, does not reliably 23,868 birth defects have been prevented thus far due to prevent NTDs. Also, folic acid supplementation programs grain fortification in the US. often fail because most women do not take folic acid pills Infants born with spina bifida will undergo a lifetime before pregnancy, especially if they are not planning the of surgeries and face many health issues. Consequently pregnancy. So, mandatory fortification is the best strategy the healthcare costs that are averted when spina bifida is for quick, inexpensive, continuous results.” prevented can be tremendous. In the US, preventing spina The researchers found that Australia and Fiji plus bifida by fortifying grains represents a net savings of US$ most countries in North, Central, South America and 603 million annually. the Caribbean have a high degree of prevention due to Most countries do not have birth defect surveillance mandatory flour fortification. Several countries in Africa systems, which makes more accurate global estimates have achieved modest prevention. But Europe and most challenging. Country profiles on the Food Fortification countries in Asia and Africa had no NTD prevention from Initiative website include the NTD prevalence from other flour fortification (see map). sources if known and from the March of Dimes Global Adding folic acid, a form of vitamin B9, to flour Report if other country data is not available. 14 | August 2016 - Milling and Grain

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Milling and Grain - August 2016 | 15

The German Engineering Works of Messrs Seck Brothers Milling journals of the past at The Mills Archive by Mildred Cookson, The Mills Archive, UK Last month I described a mill that had been fitted in 1888 with the Seck system. This made me wonder what else we might find about the Seck Brothers in material held at the Mills Archive from that period. The Miller, 7 December, 1885 published a detailed description of this important German firm and I have supplemented this report with material from a newly acquired 1920 catalogue and modern photographs of a Seck mill kindly donated by the Director of the Robinson Brewery in Stockport, where the machine had been in use for at least 83 years up until 2012. The mill remains a showpiece treasure, much admired by visitors to the brewery. Messrs Seck Brothers traded from 41 Seething Lane in London but their works were at Darmstadt and Oberursel in Germany.

Seck Roller Mill at Robinson’s Brewery Stockport

16 | August 2016 - Milling and Grain

The Reform Purifier

Early days The founder of the firm, milling engineer, Wilhelm Seck, set up his factory in 1865 at Bockenheim near Frankfurt, where he manufactured his successful smutter and decorticating machine. This apparatus, popular both on the continent and in the UK, continued to feature prominently in the Seck range of machines. In 1870 Wilhelm took into partnership his two brothers, Charles and Christian and the new firm flourished. The amazing steps forward in the art and science of milling, after a long, almost dormant, period suddenly brought a demand for new tools, which engineers such as the Secks, could make and supply. The brothers, all originally millwrights, devoted themselves to the production and perfection of these “with rare energy and perseverance”. Not the least important of their machines was a semolina and middlings purifier, invented by Wilhelm, apparently before the partnership was formed. The Seck “Reform” purifier was immediately successful, especially on the Continent, and

Seck Brothers three-high roller mill

Free-swinging Plansifter

Milling News

Seck Bros works at Oberursel

The Seck Bros works at Darmstadt

was fitted into a great number of German and AustroHungarian mills. Henry (Heinrich) Simon, who set up in Manchester as an engineer and developed the first complete automatic mill in England, was allowed to use Seck’s Reform trademark on the “Henry Simon New Reform Purifier”. Although Seck had had teething problems during the initial trials of

Wilhelm Seck with brother and son

the Reform, of the 120 ones sold within two years, Simon bought over one hundred. In 1874 a branch of the firm was opened in Dresden, but later this was separated from the parent and became a distinct firm run by Charles and Christian, while the old business at Bockenheim was carried on under the direction of Wilhelm alone. Four years later, Wilhelm went into partnership with E.H. Blumenthal, and the works were significantly extended to specialise in casting chilled iron rollers. Even then, the firm was aware of the important part that the roller was about to play in the manufacture of flour, and their foresight brought its own rewards. Mr Blumenthal, an important person in the firm, was responsible for orders from the United Kingdom and British Colonies. He regular visited British and Empire millers and could judge their wants and needs. The Seck system Seck’s roller system for the gradual reduction of wheat, the outcome of a long and careful series of experiments, was fitted into mills of every capacity, not only in Germany, but also in Belgium, France, England and other countries. To meet the large demand for their rollers the firm moved this branch of the company to Oberursel. As business increased the pressure upon the Bockenheim works became great and it was necessary to find more Milling and Grain - August 2016 | 17

Sing a song of Sixpence

An English Mill, Rye, Sussex

Art in the Archive

Milling and Grain supports the aims and objectives of the Mills Archive Trust, based in Reading, England.

We are a charity that saves the world’s milling images and documents and makes them freely available for reference. We have more than two million records. We aim to cover the entire history of milling, from its ancient origins up to the present day Find out what we have and how you can help us grow

The history of milling no matter where it has taken place - is being archived by the Trust.


A Colonial MillMill, go

We are proud to present here, front cover illustrations from this valued and longserving publication as a visual reminder of the importance contribution past magazines provided to our industry.

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This is the Farmer that sowed the Corn

A most recent contribution to the Trust’s collection is a complete century of past edition of the now out-of-print ‘NorthWestern Miller’ from the United States. Blow Wind blow and go, Mill, go

For well over 100 years milling technology has been global with many magazines serving or having served our industry from flour and food to feed and oilseed processing and now to fish feeds.

Milling News suitable premises for production. As a result, extensive works were opened at Darmstadt, some fifteen miles from Frankfurt, which would provide the main part of the engineering and millwrighting work of the firm. The Bockenheim workshops were then used exclusively for the manufacture of the recently invented “Perfection” middlings purifier, which had the advantage of rendering a stive room superfluous. The illustrations and ground plan of the works at Darmstadt give some idea of the internal arrangement and organisation of this great factory. The foundry alone had 150 men working in it, and could produce both white and gunmetal. As the company did business all round the world, they employed clerks capable of corresponding fluently in English, French, German, Italian, Spanish and Russian. The firm trained up their own fire brigade from its employees, so that they would be ready for immediate action if required. The Oberursel works concentrated on the production of the chilled iron rollers used in the company’s roller mills. Motive power for the workshops was provided by two powerful engines and a large waterwheel that could on its own drive the heavy roller cutting and finishing plant. The workforce had almost 1,000 men which included 900 specialist tradesmen. They also employed another 500 workmen Roller-mill floor at Folch Brothers’ in workforces around Europe, engaged in the mill in Barcelona (1920) erection of the many mills which the firm fitted up in the course of each year. Even this number was not enough to keep up with the demand for the company’s machines as they were constantly taking on new employees. Early records One of the spacious buildings housed the roller mill shop The youngest member of the Seck family, Heinrich, where all kinds of rollers were fitted into their respective started his business in Frankfurt in 1893 then moved to frames and finished ready for use. A large space was Dresden to take the place of his brother Christian who reserved for the finished roller mills which were ranged had died in 1882. It was Heinrich who made the Dresden in two long rows to allow for careful quality inspection of business into one of the leading companies in Germany the finished machines. Moreover, before any machine left and Europe. A rare 1895 photo shows him on the left, the shop each roller mill was tested with two or three day’s just in the photograph. The man in the middle is Wilhelm actual work on the material it was built to treat. Seck senior with his son Willy (Wilhelm) on his left. It is sad that only a few photos and documents from the founding period of the factory at Oberursel Plan of the Darmstadt works exist, partly through a lack of continuity in the company’s history. New owners have unfortunately had the habit of throwing out old company archives! Sadly, some things do not change and this is why I feel it is so important to capture what is left while we can. I would welcome your help in achieving this as we build our Roller Flour Mill Archive and Library in Reading. Milling and Grain - August 2016 | 19

Milling News

Better drying, better bread

From Tornum, you can get everything you need for drying,storing and handling grain efficiently and profitably – from single components to turn-key production sites, in any size, custom built for your specific needs.

20 | August 2016 - Milling and Grain

Industry executive Bryan Ledgerwood to launch new flour milling company


newly formed milling company, named New Mexico Milling, will begin operations in Farmington, New Mexico in August of 2016, announced Bryan Ledgerwood, the President and CEO of New Mexico Milling. New Mexico Milling will operate the flourmill previously operated by Navajo Agricultural Products Industry. The facility was built in 2012 and is uniquely positioned to serve the Southwest markets, as well as the local four state region. The New Mexico Milling plant is equipped with state of the art packaging equipment with capacities of producing 2, 5, 10, 25, 50 lb. packaged products along with bulk vessels. New Mexico Milling will offer specialised blending capabilities to produce custom blends such as various bread, pancake and tortilla mixes. “This is a rare opportunity to operate an independent mill, during a time when the industry has seen continued consolidation into a select few large corporate millers,” stated Bryan. “As a result of the wheat sources in the area we see many opportunities to create efficiencies and provide for long-term sustainable growth.” Mr Ledgerwood understands the importance of serving the customer with quality products that will help set New Mexico Milling apart and will ultimately lead to opportunities for growth for not only New Mexico Milling but for the Navajo Nation economy. “Wilton Charley, CEO of NAPI has been a great resource in identifying tribal, city and state agencies to help bring economic growth and job stability to the Navajo Nation and its surrounding area”, says Bryan. Mr Ledgerwood brings nearly 20 years of executive experience in the milling industry to this new venture. He has worked in various senior leadership roles in ConAgra Foods, 21st Century Grain Processing, Viterra and most recently with Richardson International. Mr Ledgerwood has successfully integrated numerous plants as a result of industry mergers and acquisitions; he has a proven record of creating sustainable results through forming and unifying strong plant teams. Through his professional career, Mr Ledgerwood has been directly responsible for multiple flour and oat processing facilities located across the United States and Canada that achieved exceptional growth under his leadership. Bryan is excited to bring that experience to this entrepreneurial venture serving as President and CEO of New Mexico Milling. He is married to Ashley and has two daughters, Reagan and Ryann.

Milling News

US Wheat Associates announces several staff promotions


S Wheat Associates (USW), the industry’s export market development organisation, has promoted three associates to Vice President. Ian Flagg is named Regional Vice President for the organisation’s European and Middle Eastern, North and Eastern Africa regions. Jennifer Sydney becomes Vice President of Programs and Planning, and Dalton Henry becomes Vice President of Policy. In addition, Shawn Campbell is promoted to Deputy Director, West Coast Office, and Jim Frahm becomes Senior Advisor. Ian Flagg is based in USW’s regional office in Rotterdam, The Netherlands. Jennifer Sydney and Dalton Henry serve

in the organisation’s Headquarters Office in Arlington, Virginia. Shawn Campbell works in Portland, Oregon, and Jim Frahm works half time from his home in Charleston, South Carolina. “I have said many times how proud I am of the people who work at US Wheat Associates,” said USW President Alan Tracy. “These associates and the people who report to them are making a real and positive difference for USW and for the US wheat farmers we represent. Their commitment to their jobs and promoting US wheat is very strong and is clearly evident in the results of their work.”

Ian Flagg

Minnesota native Ian Flagg first served USW as Assistant Director, West Coast Office, then as Market Analyst in the Headquarters Office, before accepting a position in 2009 as Assistant Director for the Middle East, East and North Africa (MEENA) region in Cairo. He was promoted to Regional Director in 2014 and moved to Casablanca, Morocco, then transferred again to Rotterdam in January 2016 to direct activities in MEENA and Europe. Mr Flagg has a bachelor’s degree in economics from Minnesota State University, Moorhead, and a master’s degree in Agribusiness and Applied Economics from North Dakota State University.

Jennifer Sydney

Jennifer Sydney directs the preparation and submission of USW’s annual Unified Export Strategy proposal to the USDA’s Foreign Agricultural Service (FAS), manages FAS activity amendments, coordinates state funding and supervises USW Programs staff. Ms Sydney had similar responsibilities at the US Grains Council in Washington, DC, before joining USW in 2010. She is a native of Greeley, CO, and received a bachelor’s degree in Asian Studies from the University of Colorado.

Dalton Henry

Dalton Henry has lead responsibility for coordinating the USW policy team’s efforts and managing relations with wheat value chain organisations. He joined USW in March 2015 after five years with Kansas Wheat as Director of Governmental Affairs. Mr Henry grew up on and is still involved with a diversified crop and livestock operation near Randolph, Kansas. He has a bachelor’s degree in Agricultural Communications and Journalism from Kansas State University.

Shawn Campbell

As Deputy Director, West Coast Office, Shawn Campbell is responsible for liaison with the grain export trade and constituent state-level wheat commissions, hosting visiting trade delegations and additional support for headquarters and overseas office staff. Before joining USW in 2009, Mr Campbell was an agricultural economist for an Alberta, Canada, feedlot. An Oregon native, Mr Campbell earned a bachelor’s degree in Agribusiness and Agricultural Systems Management and a master’s degree in Agricultural Economics from the University of Idaho.

Jim Frahm

Jim Frahm has been with USW since 1978, serving most recently as Vice President of Planning. He coordinated long term strategy and program evaluations with and between USW’s overseas offices and USDA FAS. As Senior Advisor, Mr Frahm will continue to represent the organisation on wheat quality and sanitary/ phytosanitary issues and in other assignments. His first position with USW was in Rotterdam directing market development activities in Eastern Europe. He worked as a grain merchandiser for Continental Grain before joining USW. Mr Frahm received a bachelor’s degree in History and International Relations from Iowa State University. He also earned a master’s degree in International Affairs specialising in Russian area studies at Columbia University. 24 | August 2016 - Milling and Grain

Milling News

[ Museum Story No. 8 ]

The industry training resource Tom Blacker, International Milling and Grain Directory It gives me great pleasure to report a great development that has gone live on this month! Industry training is a topic that seems to come up a lot when we talk to you all at industry events throughout the year, and to address this topic we have implemented a new training section onto our website. If you visit the IMD website you will now find a tab that contains training courses from around the globe, that can be easily filtered to show you everything - or drill down to either feed milling or food milling courses specifically. Each course listed has an outline of the course content, along with all the other important information you will need to know. The number of courses listed is growing quickly, so if you are looking for industry training, this is the only place you will need to look. If you would like to list a training course with us, please get in touch with me and I can take you through the process (it is all free of charge). There is more good news from We are pleased to welcome eight new companies to the internationalmilling family - Pearsons Agro Limited from Bangladesh, Hefei Taihe Optoelectronic Technology from China, VFDS Manufacturer from China, Ard Machine MFG.Co. from Iran, Jesma BV Weighing Solutions from The Netherlands, Tritordeum from Spain, Willrich Precision Instrument Company from the USA and Cleveland Vibrator Co. from USA. All of our new members now have profiles with their products and services listed, so please head over to the website and do a simple company search to find out more about them. Being social This month the team would also like to thank all of our supporters on the social media platforms. We have just passed the milestone of 1,000 likes on Facebook (almost exactly a year after our twitter account went past the same number). It is great to talk to (and help out) our users across the social media platforms that we are on, so if you have a question that we can help you with (possibly about your entry into the up-coming 2017 print directory!) head over AND GRAIN to one of the sites below. @IntMD


“Wolfgang Amadeus Mozart”, portrait by B. Kraft

When Wolfgang Amadeus Mozart gave concerts at the court of Emperor Leopold, or on other ceremonial occasions, he wore his best wig. In the 18th century, wigs with curls arranged horizontally were the latest fashion. Those who wanted to keep up with the trend dusted their hair with powder – or in Mozart’s case with flour, the cheaper alternative. Grain was the beginning With its collection of over 3,000 flour sacks from 130 countries around the globe, the FlourWorld Museum in Wittenburg, near Hamburg (Germany), is unique in the world of grain. It is an initiative and cultural project of Mühlenchemie and a token of thanks to all millers. The museum shows the history of flour and its significance for mankind: FLOUR IS LIFE. Every new sack with an interesting motif is welcome in the Sackotheque and will find a permanent home there.

Milling and Grain - August 2016 | 25

Milling News

The Pelletier Column

Curiosity: it’s where the future starts

by Christophe Pelletier The challenges ahead are bigger than ever before, and rest assured that they will be even bigger in the future. The good news is that progress and new developments in science and technology are also now bigger and faster than ever, too. From a technical point of view, I would dare to say that the solutions to the challenges already exist or are very close. Often, the problem is that these solutions are not immediately economically viable. In such a fast-changing world, curiosity is undoubtedly one of the most desirable qualities to adapt in a timely manner and find new ways of running the business. Perhaps, it is because a lot of my work is about finding as much information and gathering as much knowledge as possible about all sorts of technologies, facts, systems, science and experiences that I find curiosity quite natural. Perhaps it is also because I have a curious nature. In my daily activities, I find that people are not curious enough. I can also see that the ones who have that quality are always ahead of the pack. What is really amazing is how much is already out there. The trick is to find it and to know about it. Often, the information originates from very different business sectors or comes from other parts of the world or is available in a different language. I can see regularly a lot of organisations busy reinventing the wheel, going through the pain of setting up research and spending vast amounts of time, money and resources to find out results that are already available and that they could have taken over and adjusted to their particular situations. Curiosity can deliver huge savings. Curiosity cannot be a random activity Curiosity is quite time consuming, that is a fact and its main drawback. This may be the reason why it does not happen enough. The quest does not always deliver, although for those who have a proper strategy, the yield is quite good. Curiosity, for a business, cannot be a random activity. It has to be structured and carried out with discipline. There is quite a similarity between curiosity and access to food, as there are those who know where to find the tasty mushrooms in the woods and those who get lost in the forest. It is the same thing when going out there to find knowledge. Some are talented and find it often and fast, whilst others just wander endlessly without spotting anything significant. Just as it is important to know the right spots 26 | August 2016 - Milling and Grain

to find food when hunting and gathering, there are some places where the good knowledge is. As with food, it is important to know the supplier and the origin of the knowledge. To pursue the comparison with mushrooms, some knowledge is good and some can be toxic. The supply chain is just as important; especially considering how fast and far social media can replicate and distribute information. When it comes to knowledge, the reliability, seriousness and quality of the sources is of utmost importance. A discerning knowledge consumer must be critical about what they find. A solid critical sense is of the utmost importance. Regardless of whether the knowledge is found through a hunting/gathering activity or comes from a knowledge farm, it is essential to double-check its validity. However, the packaging can be deceiving. Next to focused curiosity activities, it is also important to encourage what I would call open curiosity, in which there is no particular objective but just letting new findings lead to new discoveries. There is no business discipline involved. It more often research you would do in your free time. One piece of information generates interest to know more and you just follow. It is similar to a child-like exploration in which each answer triggers the next “why?” question. It is pure learning. There is no way to tell when or even whether the new learned knowledge will be useful, but there is no such thing as too much knowledge. The trick is to be able to retrieve it when it is needed. Linking experience to knowledge Another important aspect of curiosity is to link experience to knowledge. Usually, knowledge is the result of certain protocols. The knowledge itself takes its full dimension and value only through the use we make of it. Some people make good use and others do not. When gathering new knowledge, it is essential to also learn about the lessons from the experience of others. Why do certain things work in certain conditions and others do not? Which factors influenced the outcome and how would different conditions or a different environment affect the outcome? Getting the big picture is a very important part of curiosity. Expanding the scope and seeing how the pieces of the puzzle come together are the fundamentals of future successful strategy and adaptation. 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”.

Milling News

Evonik’s Biolys® plant comes on stream


vonik has commissioned a new plant for the biotechnological production of Biolys® in the Brazilian town of Castro in the state of Paraná. It will have annual production capacity of around 80,000 metric tons. Biolys® is an efficient source of the amino acid L-lysine and is used as a feed additive in modern animal nutrition. “With this investment we are strengthening our leading market position in feed-grade amino acids and are taking advantage of the opportunities to grow in the emerging markets of Latin America,” said Klaus Engel, chairman of the Executive Board of Evonik Industries AG, commenting on the start of operations. “This new plant will meet the rising demand we have seen for Biolys® in Latin America, and particularly in Brazil, for a number of years,” explained Reiner Beste, chairman of the Board of Management of Evonik

Nutrition & Care GmbH. “By producing locally, we are moving closer to our customers in Brazil and can offer even greater security of supply.” This will be supported by the outstanding logistical connections of the Castro site and an extensive network of warehouses in the region. Evonik produces Biolys® on site of the US-based company Cargill, from which it procures site and logistics services as well as locally produced raw materials. Agricultural products from the region are used as the main raw material for the fermentation. The plant will create around 100 jobs for highly skilled workers. Biolys®, a product produced biotechnologically from renewable resources, is globally known as a highly efficient source of L-lysine for animal feed, which helps to sustainably reduce costs in both feed production and animal breeding. And it is beneficial to the environment: In a life cycle analysis certified by TÜV Rhineland, Evonik proved that protein supply in animal feed supplemented by Biolys®, among other things, represents a particularly environmentally sound concept for the adequate, healthy nutrition of animals.

“With our amino acids and concepts for efficient animal nutrition we intend to make a contribution to meeting the world’s growing demand for meat, dairy, eggs, and fish in a sustainable manner,” said Mr Beste.

New contact number for Allstate Tower Inc


llstate Tower would like to let thier customers know that they have a new telephone number. From now on, you can get in touch with them at +1 270 830 8512 Allstate Tower is a full service, quality conscience, highly motivated tower company, with a driven focus to meet the needs, quality, safety and price expectations of thier customers. AST is committed to exploring new innovations and technologies to better serve customers. AST humbly asks for the opportunity to serve you, knowing the outcome will be above and beyond.

Milling and Grain - August 2016 | 27

Milling News

COMPANY UPDATES Regardless of politics the weather rules our lives by Chris Jackson, Export Manager UK TAG This month, the United Kingdom’s democratic process that we enjoy has surprised most of the politicians with the people voting in a referendum to leave the EU. Whilst the politicians have to sort out the short-term problems that this decision has caused, our trade and our farming industry will continue to work with the rest of the world along with R&D; which is not only crucial to sustaining environmentally sensitive production, but for ensuring that farming remains profitable. As ever, regardless of politics, the weather rules our lives. After a very late start to spring we are now having a wet summer, which is good news for growth, so let’s hope that the start of harvest is not too late so that yields are good. Primary producers needed more than ever So far the vining pea harvest in the eastern part of our country has suffered with poorer quality than expected. In world terms our industry is small and we can only produce 60 percent of the country’s food needs, but I was reminded last week that a secure source of food wherever you live is critical and something that the wealthy nations take for granted. They expect food to be available, with the increasing urban population so far divorced from production, they have no idea that all food production relies on climate, soil productivity and the skills of the rural communities worldwide. We are constantly reminded that the world population is possibly expanding to 9.5 billion by 2050, therefore the primary food producers are needed more than ever. We need our world’s very clever scientists to help us produce more-from-less and help to get more of the food produced to the consumer. In addition, the developing countries of the world are, with their reliance on agriculture, in a position to help deliver the food needed and raise the living standards of the local farmers. There already is a disparity between the growing world population and the earth's food growing capacity and as living standards increase so does the demand for livestock 30 | August 2016 - Milling and Grain

products; the very animals that we produce consume the same food as we need this applies both to agriculture and aquaculture. Genetics and technology are playing a leading part in alleviating this problem, in developing countries making use of local breeds that are already adapted to low input, with selective breeding increasing their output without losing their ability to produce on lower input systems. The need for high quality protein For monogastrics the need for high-quality protein has been well documented, therefore alternative protein sources are needed such things as duckweed or in the tropics cassava; whose dried leaves can produce 25 percent protein content. Insect production is also another solution. To make efficient and effective nutritionally balanced diets that are palatable and acceptable to all farmed species, we need the millers who have sophisticated production capabilities to make feeds of consistent quality using a great variety of ingredients of known quality and composition, thus allowing the farmers to maximise the genetic potential of their stock. In addition to increasing farming yields our scientists are having to turn their attention to the problems that farming practices are causing, I am thinking for instance of salt build up in the rice paddies of South East Asia along with reducing the amount of water needed to grow the crop. Waste reduction from farm to consumer relies on infrastructure, transport, storage, packing and refrigeration; with all of this requiring large capital investment along with farming working in synchronisation. The world tour continues At the end of July along with Perendale I will be attending IndoLivestock in Jakarta and running seminars demonstrating the need for high quality feeds to improve livestock production along with Aquaculture. I hope that we will see some of our readers at this event in a country whose Government has a determination to raise food production standards and safety. This visit will be followed by us being at VIV China, AgriLink in The Philippines and Vietstock in Ho Chi Minh City, Vietnam. @AgrictecExports

Evonik signed a purchase agreement on July 4, 2016, for acquisition of the probiotics business of the Spanish company Norel, a global supplier of animal feed ingredients. The agreement sees Evonik acquiring Norel’s probiotics product portfolio as well as the company’s site in León, Spain. The business will be integrated into Evonik’s Animal Nutrition Business Line. The parties have agreed not to disclose details of the transaction. Evonik is currently expanding its portfolio of sustainable and healthy solutions in the field of animal nutrition and striving to provide innovative solutions for antibiotic-free livestock management.

Chopin Technologies announced on 30 June that it has joined the KPM Analytics Group. KPM Analytics based in Milford, MA, USA was formed last year with the acquisitions of Unity Scientific and Process Sensors. The company’s premium brands provide instrumentation solutions for many industries and markets, from food quality and safety to environmental and agriculture. Chopin Technologies is a world leader in providing quality testing solutions to the grain and flour markets. Throughout Chopin’s long history, the company has focused on solving difficult challenges faced each day by customers involved in grain and flour production. The company’s more than 100 employees work from the headquarters in France as well as from subsidiaries in China and the United States. Marc Dolige will continue as CEO after the acquisition - as will the entire Chopin management team.

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Milling News

Global institutional capital investments in farmland top US$45 billion over last decade, HighQuest Consulting reports


just-published white paper – Agriculture: A new asset class presents opportunities for institutional investors – from HighQuest Group’s globallyrecognised advisory experts details farmland as growing asset class. This investable universe in farmland is more than three times the size of that for timber, with investments that have been growing annually at 8 to 10 percent, according to the paper. The paper, authored by Philippe de Lapérouse, managing director and head of HighQuest Consulting, highlights a number of different vehicles, including alternative real

32 | August 2016 - Milling and Grain

asset funds, private equity and venture capital that institutional investors can consider for allocating capital into agriculture. It also makes a strong case for investing in food and agriculture by tailoring a portfolio to meet return and risk objectives, allocating investments across three key variables: geography, production type and operating model. Interest in this asset class is evidenced by high profile investor groups such as TIAA, which in November 2015 raised a US$3 billion fund that included internallygenerated funds as well as limited partnership contributions from peer

institutions. This fund and others are making substantial commitments in the sector, acquiring farmland and/ or managing leaseholds in various regions around the world such as North and South America, Australia and markets in Eastern Europe and in Sub-Saharan Africa. “While farmland investments have been an integral part of the portfolios of wealthy individuals and families for centuries, in the current economic environment this asset class is attracting renewed interest from a wide range of institutional investors seeking alpha returns with inflation protection, which do not correlate with other paper assets and provide increased wealth protection during a period of market uncertainty,” said Mr Lapérouse. “These long-term fundamentals combined with historically uncorrelated returns generated by farmland investments make this an attractive asset class for the portfolios of many institutional investors.” Mr Lapérouse outlined the key attributes the sector provides that are attracting interest among institutional investors: • strong long-term fundamentals based on secular trends (climate change, increased urbanisation and rising GDP in emerging markets) • attractive historical returns (based on a mix of current income and capital appreciation) • uncorrelated returns with other financial instruments • a strong inflation hedge, and • preservation of capital. Additional investment opportunities exist along the entire value chain, said Mr Lapérouse, from upstream inputs of products and services to downstream inputs of transportation, logistics and value-added efficiency and risk management processes. Download the full white paper at

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The month of June in Kansas presents a perfect opportunity for flour millers across the globe to see US wheat production firsthand. Nine milling industry professionals did just that. June 19-July 1, 2016 participants in the Flour Milling Course for US Wheat Associates for Nigerian/South African Millers travelled to the IGP Institute Conference Centre to learn about US wheat production and see Kansas wheat harvest at its best.

International industry personnel travel to US for wheat milling course Shawn Thiele, milling operations manager and course manager, says the course emphasises the quality and importance of US wheat and focuses on understanding the US grading system, export practices and milling practices. Additionally, he says the education students bring with them is valuable. “The participants really make the course unique and bring a diverse level of milling knowledge and experience with them. The student participation and sharing of different practices and knowledge during the two weeks helps drive the success of this course and makes it enjoyable for everyone involved,” Mr Thiele says. The course covers many aspects of the wheat milling industry including flour and dough testing, wheat classes, structures

milling math, the US grain inspection system, milling systems and mill performance evaluation. Participants are also able to perform hands-on exercises in the milling and baking labs and the KSU Hal Ross Flour Mill. Traveling out of Manhattan, the group took a day trip to the Ardent Mills flourmill in Newton, Kansas. The participants also toured the Cargill grain elevator and a wheat farm during harvest in Salina, Kansas. “We’ve learned a lot and went into a lot of detail that will benefit us. There is a lot we can take away from that we plan on implementing,” says Zane Opperman, course participant and mill manager at Pioneer Foods in Bethlehem, South Africa. He adds, “What IGP does for the industry is a great way to improve on the process, business, each country and the world.” This is just one example of the educational opportunities offered by the IGP Institute. Along with trainings in grain processing and flour milling, the IGP Institute also holds courses in grain marketing and risk management, and feed manufacturing and grain quality management.

The training register For a long time the International Milling Directory website has acted as the go-to platform for members of the aquaculture and milling industries in order to stay up-to-date on tradeshow and conference events around the globe, by using it online Events Register. International Milling is promoted on multiple social media streams including Twitter and Facebook, on all Perendale Publisher’s blogs such as ‘The Global Miller’ and ‘The Aquaculturalists’, as well as via its weekly newsletter. On top of this the International Milling application for smart devices has been launched to further extend the content’s reach, allowing members of the industry to stay up-to-date while on the go. This month we have launched our new Training Register. It will operate on the same platform as the Events Register, running side-by-side. Our vision is to produce an easily accessible hub which will list aquaculture- and milling-related training courses, workshops and educational opportunities from around the world, much the same as the Events Register does for conferences and expositions. “We recognise that the only reason the Events Register has reached its current scale is due to the relationships we have built with the industry and the willingness of organisers to supply and update their information for us to promote. It is this that has led to International Milling Directory becoming such a reliable reference for industry events,” says Mr Roger Gilbert, publisher of the International Milling Directory. “If you, your company or organisation is organising a milling or aquaculture course we would like to hear from you. No training course is too big or too small for any of our readers to attend.” This promotion service is currently offered free-of-charge. Please send information on your training or course event to


T: +44 1242 267703 / F: +44 1242 292017 /

Milling and Grain - August 2016 | 35

Portable temperature monitoring

PRODUCT FOCUS AUGUST 2016 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.

Digital temperature sensor lances and portable handheld readers make it easy and affordable to monitor the temperature of grain, hay, or silage. Detect hot spots and spoilage in grain where cables are either impossible to install, cost prohibitive, or are just needed on a temporary basis. The rugged digital temperature sensor lance can be used to measure the temperature of grain in piles, warehouses, barns, railcars, wagons, trucks, or ships. It can also be used to detect high temperatures in hay or silage that could lead to combustion or compromised quality. This solution requires no power, no installation, and can be set up quickly and easily. Simply insert the lance into the grain, wait a few minutes, and the current temperature is displayed on the handheld reader. Alternatively, up to 20 lances can be inserted and daisy-chained together and left in place for longer term monitoring. Temperature data history can be transferred to a PC using a memory stick that comes with the handheld reader.

Perten IM 9500 Whole Grain NIR Perten Instruments’ IM 9500 Whole Grain NIR with Results Plus software tests whole grains for constituents such as moisture, protein, and oil in 25 seconds – making it the fastest NTEP approved analyser. The instrument is rugged and designed for use in elevator and grain processing environments. In combination with NetPlus Remote, users can administrate multiple instruments from anywhere in the world. NetPlus Reports allows users to view data from web-enabled devices 24/7 from anywhere in the world. Instruments are fully networkable allowing users to view single or multiple instruments’ results from any net connected device. Additionally, the IM 9500 is supplied with a synthetic sample to monitor hardware by checking wavelength scale, path length and test weight quickly and simply. It comes with a 5 year warranty on the monochromator, a spare lamp for maximum up-time, and includes all available calibrations at no additional cost.


Bühler introduce their new generation of pellet mill, the Kubex T. 'Designed by feed millers, for feed millers', boasting greater energy savings, die speeds and accessibility

MPE Chain-Vey

Roto-Disc II spherical valve

MPE’s Chain-Vey ® is ideal for the unique layouts and tight constraints of brewery facilities, but also provides a unique alternative when it comes to the transportation and clean-out of Spent Grain.

Roto-Disc, Inc, now offers a spherical valve for applications where the valve outlet has to mate to a downstream flange that matches the valve’s inlet orifice. When provided with an optional Inlet Flange Adaptor, the Roto-Disc II can mate to common ANSI 150# Flanges on both the inlet and discharge side, eliminating the need for flange and piping transitions while maintaining a full-orifice valve solution. Typical applications include hopper fill & discharge, blender discharge, loss-in-weight feeder re-fill, bulkbag unloading and other gravity or low-pressure applications.

Traditional cavity or fluid pumps used to transport spent grain to outdoor silos require more than routine maintenance and spare parts, eating into a brewery’s production time and bottom line. The Chain-Vey is the most reliable and robust conveying solution on the market, and with its completely enclosed design, it can easily adapt between dry and semi-wet materials. Additionally, the ChainVey is considered a “no-touch” machine, requiring zero unscheduled maintenance per year and less than $100 per year in consumable parts. Spend less time on your spent grain. 36 | August 2016 - Milling and Grain

Like the Roto-Disc, the Roto-Disc II slices through material build-up and wipes itself clean with each cycle. The sealing surfaces are not exposed to the flow of material and there are no hidden places inside for material to build-up. The valve maintains all other essential features of the original Roto-Disc spherical valve and all spare parts are interchangeable with equivalent sized Roto-Disc valves. The Roto-Disc II can be supplied in Airlock/Double-Dump assemblies for processing material into and out of differential pressure environments. Roto-Disc also offers a full line of splitter/convergers and piping and flange process transitions.



Bühler Kubex T

Developed in close cooperation with leading feed millers, the Kubex T pellet mill is different from anything else in the industry. A specially designed drive system (up to 585 kilowatts) powers the production of feed pellets with an unprecedented level of efficiency. The result is an output up to 80 metric tons an hour² - despite the machine being more compact and easier to use and maintain, than anything comparable on the market. Application – The Kubex T pellet mill has been developed for high-capacity pelletising of animal feeds. The machine can process even hard-to-pelletise raw materials with high fat or fiber content without a problem. The pellet mill is available as Kubex T12 (1,200mm die diameter and die widths of 265 or 320mm); or as smaller model Kubex T9 (900mm die and die widths of 200, 260 or 300mm).

Up to 585 kW motor power Equipped with the industry’s most powerful motors: The T12 model (470 or 585kW motor power), the smaller model T9 (320 or 410kW). In combination with large die diameters, this allows for ultimate production capacities up to 80t/h (T12) or 50t/h (T9) respectively.

The industry’s first direct drive concept. The direct drive system is a major factor in the efficiency. This is the first machine in the animal feed industry designed without a gearbox or V-Belts. The motor is directly connected to the main shaft, significantly reducing transmission losses, and resulting in energy savings up to 30 percent compared to conventional drive systems.

360° accessibility Thanks to large and wide-opening sliding doors on both sides of the machine, wear parts such as dies, press rolls and shear pins can quickly and easily be replaced. In addition, the slight overpressure in the machine housing prevents dust settlements in critical areas, hence setting new benchmark for accessibility and hygiene.

Variable die speed The direct drive system offers another important advantage: the circumferential die speed can be adjusted during production to suit any feed formulation. This allows formulation-specific optimisation of production process and pellet quality, in many cases without requiring a die change. Running the mill at the optimised speed may also result in a longer lifetime of the die.

The world’s most compact design There is no other pellet mill that crams so much performance into such compact dimensions. The Kubex T provides almost twice as much capacity with the same footprint as conventional pellet mills. This provides the perfect solution for feed millers looking to upgrade their existing pelleting lines to efficient technology, without costly building or process modification works.

Belt-and-gearless drive system The absence of gearbox and V-belts eliminates the need for timeconsuming and costly maintenance work, increasing machine uptime and reducing operating costs. The motor is cooled by an integrated closed-circuit water cooling system, and an automatic central lubrication system doses the ideal amount of grease to the main, motor and press roll bearings.

Milling and Grain - August 2016 | 37




THE ANTIBIOTIC FREE MOVEMENT Enhancing the nutritional value of feed by Eloise Hillier-Richardson, Milling and Grain In June this year Darren Parris and I visited Novus in St Charles, Missouri, to celebrate their 25-year anniversary. Among the revelries (including a personal highlight of a Cardinals baseball match) we were invited to some insightful talks at the Novus Media Jam. One of these talks specifically concerned the Antibiotic Free Movement or ABF, where the ‘sub-therapeutic’ use of antibiotics and the many alternatives Novus offer were discussed.


he use of antibiotics in animal feed was first approved in 1950 after it was proven that they were effective in reducing mortality and morbidity, increasing feed utilisation, and encouraging an increased growth rate. Now, many experts are expressing concerns that the ‘sub-therapeutic’ use of antibiotics, as opposed to therapeutic or disease treating uses, is having an adverse effect on the animals and are further reporting the development of antimicrobial resistant bacteria - a state of affairs which ‘ultimately compromises treatment of human bacterial infections’ (LM Gersema et al). The Antibiotic Free Panel included Dr Mercedes VazquezAnon, Senior Director of Animal Nutrition and Facilities at Novus, Dr Nasser Odetallah, Executive Manager for Global Technology Services at Novus and Dr Bob Buresh, Technical Manager of Poultry for North America at Novus. Amassing an impressive 70 plus years in the animal feed industry, this panel of experts offered an abundance of knowledge on the movement away from antibiotics, and outlined Novus’ role. All three panelists agreed that the movement away from antibiotics would not be easy for many customers, citing cost and psychological aspects - ie. the understanding that sub-therapeutic antibiotic use is almost guaranteed to prevent disease whereas less is known about the alternatives - as major aspects in the reluctance to move towards an antibiotic free future. As a result, Novus’ approach to create a culture of feed that is less reliant on the use of antibiotics, they knew, would have to centre upon the customer and their needs.

“Everything is focused around customers”

Customer focus is central to Novus’ ‘Triple S bottom line’ approach Solution, Service and Sustainability. “Our customers are currently faced with the growing challenge of

38 | August 2016 - Milling and Grain

considering the implementation of the production of their animals with reduced or removed antibiotics,” said Dr Buresh. “Each customer, even each individual production unit, will experience different challenges – we’ve got to help them adapt to that.” He went on to say that the challenges faced by a Chicken Producer in North Carolina will be different from those faced by a Producer in Missouri, which will again be different from one in Texas. Therefore, there was an obvious need to tailor alternatives for antibiotics to each individual’s requirements. Reinforcing this emphasis on customer service, Dr Odetallah broached the discussion from a more global perspective, acknowledging that the concept of sub-therapeutic antibiotic use and the ABF movement is an issue not only in the United States of America, but must be addressed across the globe, pointing out that issues which customers face in America are just an example of what Novus expect to find in other parts of the world. “Dealing with the customers is important”, he said. “We [at Novus] have really worked first hand with the customers; we have done a lot of work with them just to show the importance of the solutions to solve such problems.” He stressed the importance of dealing with customers on a “face to face” basis, saying they have already sat down with producers “in a couple of countries around the world.

The antibiotic free panel; left to right - Dr Nasser Odetallah, Dr Mercedes Vazquez-Anon and Dr Bob Buresh

F We had a few customers sit together and discuss the antibiotic treatment reduction and discuss what options we have, what alternatives [we have] to that path and [asked] why do they want to switch?” Of course, there is an element of risk and risk assessment involved when a customer comes to making such a big change. The panel alluded to a certain psychological aspect that governs people’s thinking towards the ‘unknown,’ prompting uncertainty about the outcome of the alternatives. They explained that in this instance they would help by suggesting what the issue is and how to overcome it, acknowledging that the customer “needs to know you’re not there to simply sell but also help”. Dr Odetallah expanded: “We come up with a solution that suits that specific customer in that specific situation under certain circumstances and that is how the expertise of the field work together to provide the solutions. We have had incidents in the past where we haven’t been able to help customers and we even recommended solutions that we don’t provide by recommending different practices which would best suit their production – that is the value that we provide to the customer and the same thing applies to the antibiotic free production”.


Improving agricultural and management practices

Novus have a vast selection of products available, including methionine, organic trace minerals, feed enzymes and eubiotic solutions. There are general standards that can readily contribute to their success, starting with what Dr Buresh cited as the three key areas: management, animal health, and nutrition. Dr Vazquez-Anon agreed that “there is not a simple solution for the removal of antibiotics,” and highlighted the necessity of multi-factoral and multidisciplinary solutions, where environmental factors, but also ingredient quality, nutrition and improving the animals’ immune system play an important role in the facilitation of going antibiotic free. “What might work in one place may not work in another place until we realise that we need multifactorial, multidisciplinary solutions that would really encompass management, nutrition and health,” she said.

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F Nutrition and ingredient quality

The challenge of prepping animals for optimal performance without antibiotics, Dr Buresh reasoned, begins with improving agricultural practices and overall flock and herd management, as he believes upon implementing ABF that nursery and brooding phases will be initially hit the hardest. He told us, “the customers are dedicating more attention and resources to overall flock and herd management, whether it’s pigs or cows or chickens or turkeys and initially they’re focusing on the brooding phase in chickens, the nursery phase in piglets - those are the phases that will be initially hit hard by either a reduction or a removal of antibiotics.” It is evident that for ABF to become a reality, conditions need to be created which allow antibiotics to be removed. For this to happen, the Novus team encouraged changes in environmental conditions and animal density, as well as increased downtime between batches and flocks and improved litter management. This “is a simple tool, but we have kind of forgotten it,” Dr Buresh said, citing how they have found that “in the chicken business [management] is key, the downtime between flocks is critical in maintaining health and performance of the flock”. When Dr Buresh first began his career in this field, he told us antibiotics were becoming more prevalent and their use encouraged; but now, he said, there are “a lot of things that have come full cycle here; basic production management practices that are going to become more and more important.” This renewed focus on ‘optimal animal health’ is key as Producers transition away from traditional antibiotic use. It points to disease prevention through more effective vaccination programmes and the use of pharmaceutical alternatives that support animal health and aid with this transition. To cope with the movement away from antibiotics, “our producers are going to be continually looking for an alternative. There is a line of people at their door offering the tools to help them through this transition period, away from antibiotics, and that’s what we are doing here at Novus. We are working on the development of pharmaceutical alternatives; with my team we are not necessarily trying to replace antibiotics but we are trying to create the conditions that allow for antibiotics to be removed for optimal performance of the animal. Ultimately we are looking at preparing the animal better for optimal performance without the use of antibiotics,” Dr Buresh said. 40 | August 2016 - Milling and Grain

The concept of nutrition and the impact it has on an animal’s health and wellbeing was a familiar area for all panelists, as this is their main area of expertise. Dr VazquezAnon said of the three key areas of management, nutrition and health, “the ones that we can do something about are nutrition and health, so those are the areas that we have been focusing our research on”. Where quality nutrition and quality feed ingredients have always been important, in the wake of antibiotics the panel put forward the argument that greater emphasis must be put on nutrition and ingredient quality to produce healthy and happy animals: “Feed quality, whether it be ingredient quality, has always been important but it is about to become even more important as you remove the antibiotics and it may even involve selection, removing specific ingredients, and removing specific suppliers if they don’t meet certain quality standards” said Dr Buresh. Improved ingredient quality and better nutrition have a direct effect on the gut health of an animal, an area where a vast majority of infections take hold, especially in the early stages of life. “One of our key areas is our protease enzyme and its ability to enhance the nutrient digestibility of a variety of feed ingredients, and that’s an area we are really working on,” the panel revealed. They admitted, however, that one of the hardest tasks for customers is trying to decide which ‘alternative’ path to take: “There is a line of people out the door ready to approach them with things like enzymes, probiotics, prebiotics, organic acids, phytogenics, a lot of the essential oils, oregano and cinnamon products, and some fairly exotic things. One of the challenges they have is trying to decide, and everyone comes in, Novus included, and we think we’ve got good science and a very good track record with this, with the best product on the market, so how does a producer make that decision?” One thing that Novus believe puts them ahead of the competition in this area is their research groups and technical services groups, as well as their research farm which attempts to simulate farm and production conditions. Taking these controlled research results and extrapolating the data into sometimes not so controlled production facilities is a very real challenge, there is the question of whether the feed ingredients will have the same effect in a less precise environment. Dr Buresh told us, “one of the things I am proud of at Novus are our research groups and technical service groups, and the amount of science and the commitment we’ve made to improving and developing products that help our customers and taking it to the next step and saying we’re willing to take this to your production facilities and help you from there, because that is where the rubber meets the road; we can do all the trials we want but our products have got to perform in their production facility.” Dr Vazquez-Anon explained that the sub-therapeutic use of antibiotics had, in some cases, allowed Producers not to pay attention to ingredient quality, even when this could be causing adverse health effects: “What happens when you have poor quality ingredients is that, the ingredient will make it into the

F cecum and that can lead to undesirable fermentation and that, as you can imagine, is when gut health can become a challenge. So we have come to realise that really, ingredient quality is starting to play a role when before we didn’t have to pay as much attention”. Such increased awareness is owed in part to work undertaken at the Novus research farm, where they house canulated pigs, rumen canulated cows and chickens, in order to better understand the digestibility of ingredients and look at the variability of those Novus are promoting. Dr Vazquez-Anon expounded: “We’ve been doing this to really help our customers predict the digestibility of the incoming ingredient, but then also to understand the role of enzymes and this is where we have been doing a lot of work with proteases, helping understand how the protease helps digest the protein sources and reduce that inherent variation of ingredients that we see.” Novus’ current line of research has been from an ingredient perspective intermingled with studying the conditions in which gut trouble spreads in order to figure out which products or programme of products works best under these conditions. “What we’ve been trying to do is really understand and create animal models that help us develop that mild gut trouble [which can be nascent and go undetected]. So that’s what we’ve been doing at our research facilities, creating that mild enteritis that hopefully represents the commercial conditions so then we can start to test all programmes and all products in a way that hopefully represents better what is happening in the industry without having to go to very severe animal models,” said Dr Vazquez-Anon. The outcomes of these models have been manifold, for example; providing information on what happens when the animals’ gut gets inflamed, revealing “the capacity of the tissues

to maintain their integrity so pathogens cannot get through the gut [causing] a lot of the inflammation and problems with performance,” as well as enabling the experts at Novus to study changes in microflora “to reduce toxidia, salmonella and ecoli”. The overall effect of the models, Dr Vazquez –Anon explained “has really helped us understand the role of our products, but a lot of the conditions we see in the field that would lead to chronic enteritis problems such as ingredient quality and off feed (where the chicken maybe hasn’t been fed regularly) – this has really helped us understand a little bit more about what has been happening in the field and finding solutions to it”.

“In all parts of the world they are talking about antibiotics, and they want to know what the costs are”

Of course, as previously espoused, the cost of production in the wake of sub-therapeutic antibiotic use is a major concern of Producers, as the removal of antibiotics, a fairly cheap feed additive, can see production costs dramatically increase; for example, “experts have predicted… meat prices would increase and meat quality would decrease if antibiotics are disallowed as a feed additive” (LM Gersema). Dr Odetellah addressed this concern: “In all parts of the world they are talking about what costs are… for example growth promoting antibiotics are very cheap feed additives, but it is very difficult to replace with a like for like solution as most of the time one product does not necessarily deliver or give the same impact as an antibiotic growth promoter would do. Therefore, we have to come up with a solution that might include one or two products which in certain circumstances could be expensive”. For Novus, it all comes back to working in close proximity with the customer to create affordable solutions so that they do not find

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F themselves wading through a veritable minefield of information, potentially adding unnecessary costs to their production. Dr Odetallah reminded us “we have a billion people in the world who sleep without having dinner, there are a lot of people who cannot afford food,” reinforcing the necessity of creating affordable solutions, he told us. “So we work with the customer first hand on finding the best solution that would help them, but also at a cost that would actually not impact the production, not impact the unit of production, whether it is a kilogram of meat, or whether it is egg prices, as that reflects on the end user as the consumer at the end of the day.” “So working closely with the technical teams, working closely with the research and development teams and with the customers directly, working with customers on a daily basis, asking them what they need and providing them with different types of solutions – we do case studies or case histories to understand from day one what they’re doing and what kind of feed ingredients they have and the feed additives that they have and then we sit together and we come up with a solution that suits that specific customer.”

Antimicrobial resistant bacteria

The long-term effects of consistent sub-therapeutic antibiotic use cannot be underestimated; there is scope to suggest that the use of antibiotics in animal feeds can have a negative impact further up the food chain, affecting the results of human antibiotic usage, the panel explained: “we all know about the cases of antibiotic resistance and how that might negatively impact the animal and also impact humans if it makes it into the food chain. Basically, there are regulations which do not allow the antibiotics to finally get into the food chain, but in the case that it does it might have a negative impact”. The negative impact on both animals and humans arguably reinforces the need for low impact, sustainable alternatives, Dr Odetallah explained: “As Mercedes and Bob mentioned we have an array of solutions that would actually help and these solutions, while they may not do or perform the function of an antibiotic it definitely provides a solution and help to the customer to avoid using antibiotics should they choose to, and help them cope with the situations that they have. The proteases and enzymes in general are a good example in how they improve the digestibility of the feed ingredients and we have seen a lot of how this works in different parts of the world, how they were actually able to reduce diarrhea, reduce ammonia emissions of the cows and how it helped them cope with the high mortality levels especially under heat stress and under intense production situations. These solutions Novus have been part of since it was established 25 years ago and sustainability is at the core of what we do with our customers.”

42 | August 2016 - Milling and Grain


What was clearly evident from the panel discussion was that for ABF to become a reality there needs to be an integration of disciplines, as the challenge cannot be solved by one team alone, it is not simply an issue of nutrition - feed quality, management practices, and improved animal welfare all play a vital role in the production of animals. A nutritional approach impacts mostly gut health, but it is equally important to ensure a hygienic environment as this will similarly reduce the need for antibiotics and reduce stress, which has a consistently negative impact on animal health. This echoes Dr Vazquez-Anon’s earlier assertion that the reduction in use of antibiotics calls for a truly multidisciplinary approach. She concluded, “It is this integration of disciplines that is really happening at all levels because we have a bigger problem that cannot be solved by one expertise. So that really has helped us to work as a team, with customers, and universities with veterinarians, with nutritionists and also with the production groups – so we really need to work together and sometimes it’s challenging but it is also very rewarding.” Similarly Dr Buresh announced “We at Novus, we understand that our customers navigating around and away from less or no antibiotics is not going to be easy for many of them, some have done it, some are there and are moving right along but with most of them it is going to require them to evaluate their practices, their additives; they are not going to be able to do things the way they always have and they’re going to have to remain flexible and open to alternatives that five years ago they just thought were unnecessary.” Interestingly, Dr Buresh went on to tell us that the variety of products Novus have to help customers move away from antibiotic usage were never developed intentionally for that purpose but were actually developed to help in other niche areas. Yet through such lines of research Novus have found that, through happy coincidence, their feed additives can solve many of the issues allayed by antibiotics, improving such things as microflora and the animal’s immune system. “We know that the industry is changing and it could be a threat but really I think it is an opportunity for us to bring new technologies, which before perhaps didn’t have a place but now really have a place in a changing industry” the panel advocated. There is evidence to prove that taking away antibiotics has not only enhanced animal welfare, but has also led to advancements in ingredient quality and the nutritional value of feed – the need to be more precise has resulted in long term sustainable improvements.

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The team from Milling and Grain joined a group from London South East Milling Society for their annual industry tour. This year we were invited to see FWP Matthews' Mill and to Campden BRI. This edition focusses on our tour of Matthews' mill, where the modern meets the traditional. Be sure to keep an eye out for our review of Campden BRI in our September edition.


s you travel through the beautiful Oxfordshire countryside, amongst the clusters of yellow-bricked houses, smatterings of wheat fields, braying cattle and leaping lambs, you may well chance upon the hidden gem that is FWP Matthew’s redbrick flourmill. Situated on the outer extremities of the beautiful Cotswold hills, in the village of Shipton under Wychwood, this traditional mill produces a wide range of quality organic and conventional flours. Matthews still use the original mill building that was commissioned in 1912, which housed a steam-powered mill that ground the wheat grown in local fields. Once the wheat had been turned into flour, it was then transported using eight dedicated rail carts, that delivered to their three original customers that included Huntley and Palmers in Reading, Peek Frean in Bermondsey and Jacobs in Dublin.

War to late nineties

In 1950, the 60HP gas turbine engines, which originally powered the mill, were replaced by electric motors. The 1960’s then saw the Matthews mill repurpose from making biscuits to making bread; specialising in the 50:50 or “national loaf” In 1992 FWP Matthews Ltd became certified by the Soil Association to mill organic flour. Buying local grain and supporting the community is still of prime importance to the company. In 2005 the mill was re-fitted with equipment to increase production and efficiency. Early capacity was 600 cwt of wheat per hour bettered slightly today by a staggering 6 tonnes per hour. Over the past 20 years, FWP Matthews have enjoyed an exceptional period of growth; with their turnover overall turnover increasing by almost fivefold. Back in 1998, they were turning over £1.5 million with just 12 staff. However, with a few tweaks and a great deal of hard work and investment, this has now grown to £15-20 million with 75 staff. Today the mill runs 24 hours a day 7 days a week to keep up with demand, with continued investment in new equipment meaning that modern techniques are combined effectively with 44 | August 2016 - Milling and Grain

traditional values; with the most recent sizable investment by FWP Matthews culminating with the opening of the Wychwood Building on 13th February 2009 by the Princess Royal.

Heritage meets modern techniques

FWP Matthews have 11 silo bins, with a wheat capacity in excess of 600 tonnes. With their ability to hold such a large volume for such a relatively small mill, they can receive as many as five vehicles a day, with each delivery of twenty-eight tonnes taking approximately one hour to unload. Before the incoming product is unloaded, it must first pass through the laboratory, where the wheat and flour is put through a series of rigorous tests before it is allowed to tip, such as protein level, moisture, Hagberg and hardness. The incoming grain is then put through a gluten wash to determine protein quality, then weighed, then it’s stretched on a ruler to determine its gluten content , which according to our guide Mark Riley is, old fashioned but it works. Once approved, the grain is then fed through the destoner, which works using an adjustable density yoke. The grain is then fed through a chaff remover or Winnower, which features a vibrating horizontal screen that actually sorts the wheat from the chaff, with the latter being removed via suction. Their new Satake Alpha Scan ‘colour sorter’ then separates impurities from wheat by colour, which in turn reduces the overall product waste , whilst “improving flour quality,” especially their stoneground and organic flours. FWP Matthews Ltd was one of the very first flour-mills in the UK to use this leading technology. Once destoned, winnowed and sorted, the grain then enters the screen room, where the grain is cleaned and water added. FWP uses French Grain to create some of their french products, as well as being the UK suppliers for Moul-Bie flour. They try and source as much wheat locally as possible. However, this is proving difficult as getting hold of English high protein organic wheat is hard to come by.

Now in the speciality market

Other than wheat, the Matthews team also mill spelt and a lot of rye too. However, spelt is apparently “horrible to mill as is very


varied, is low in starch – so doesn’t dress very well,” as well as being "weak by conventional standards, so doesn't make a very big loaf, although the many health benefits makes it a popular flour” Matthews were also keen to stress that although they do process a variety of different grains, they do take every care to ensure that they do segregate varieties, by either protein strength, or whether they are organic or not. With rye being the only low gluten product that Matthews produce. The next stop for the grain is the typically loud roller floor. The rolls shear open the grains of wheat, and in doing so, separates

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the white inner portion of the grain kernels from the outer skins. Then, passing through a complex arrangement of sieves that separate the particles of broken wheat grain. The white particles of endosperm and semolina are then passed into a series of smooth rollers for their final milling into white flour. The first step in the stoneground milling process sees the grain ground by four encased stones, that can be heard oscillating -- even through their seemingly bulletproof casing. No longer containing the original French burr stones, that have now long since been replaced by equivalent composite stones by Danish




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manufacturers Engsko, the loud whirring of the machines is somewhat silent compared to the familiar drone of the rollers. Matthews rolling arsenal consists of seven rollers by Czech manufacturers Chepos from 1969; with the set of eight completed with the relatively recent addition of a GPS Synthesis roller. A short climb up a narrow set of wooden steps takes you up to the second floor, which contained eight CPS – Semolina plansifters. These vast blue doored hulks gyrated wildly as the noise generated drowned out even the very loudest of voices, with the commotion creating a sensation that the floor itself was moving. To ensure the quality of the flour is consistent it is tested at hourly intervals. It is at this stage that the bran and wheat germ will be ‘streamed’ back into the flour for the production of brown or wholemeal flour. Other additives such as baking powder for self-raising flours and other legally required additives (such as calcium, niacin, thiamine and iron) are also added at this stage. The final stage is for the flour to pass into the packaging plant or the bulk bins ready for distribution.

Quality – they’ve got it in the bag

The packaging plant at FWP Matthews presented an ideal of synchronicity, with each segment of the assembled machinery carrying out a very specific task, symbiotically with the component that either precedes or follows it; allowing it to pack as much as one tonne in half an hour. The largest of the two bagging machines, manufactured by Belgian packaging solution providers Arodo only pack the 16kg bags, whereas the 1.5kg and 3 kg bags were packed using the Italpack bagging machine. The Matthews flour bag itself has recently undergone something of a redesign too. Now roll bottom bags, they are stitched instead of glued, as according to our guide, “glue doesn’t work.” FWP Matthews also don’t use pinch bottom, and only use roll bottom and block bottom 16kg bags (however 25kg bags are supplied by Moul-Bie) Once packed the flour is then stacked on wooden pallets before being transported to a nearby off-site warehouse. 46 | August 2016 - Milling and Grain

The winning formula

The mill at FWP Matthews presents the very best of both worlds. With both the traditional family orientated aspect, twinned with the application of modern technologies, the generations of millers at Matthews have adapted throughout the ages to accommodate to ever-changing demand. Matthews stands as a testament to the ‘adapt or die’ market forces that millers have now faced for many years. Matthews obviously have a winning formula, and one that should see them well for many more generations to come.



In May this year Milling and Grain Magazine were invited to the offices of Buhler Sortex located in their new premises at Gallions Reach, on the banks of the River Thames, in Beckton East London. ühler designs and manufactures a vast range of food processing machines including the SORTEX range of optical sorters, for a variety of products, such as grains, beans, pulses, spices, nuts, rice, vegetables and fruits, and plastics, as well as manufacturing complete processing lines for the rice, spice, sesame and

pulses industries. Optical sorting uses advanced camera technology, combined with sophisticated software, to detect anomalies in colour, size and shape, as well as non-visible optical properties, to enable the separation of bad product from good, as well as the removal of foreign materials that often pose a safety hazard. During our visit, we were treated to jam-packed sessions, replete with eye-opening discussions about the recent technological advances and innovations in optical sorting, customer care, and how Buhler Sortex continually manage to stay ahead of the game, rounded off with a look into the future of optical sorting and a tour of the Buhler Sortex factory.

Buhler Sortex: A History

On the approach to the Buhler Sortex offices and factory little, did we know that it was in the very same month in 1947 that ‘SORTEX’ first began. Almost 70 years ago ‘Beno Balint and Sons (Great Britain) Limited’ was established by the Balint Brothers – owners of Gunson’s Seeds - with the vision of eliminating the drudgery of handpicking seeds, by technological means, aided by Hungarian scientist Dr. Okolicsanyi and his assistant Herbert Fraenkel. Later that same year saw the first demonstration of actual sorting through a combination of optical inspection and electrostatic deflection of discoloured particles, which lead to the development of the first sorter – the G1 – Gunson’s “SORTEX” Electronic Separator. Achieving great success in the global market, through sales of this and subsequent machines, the manufacturing of sorting machines soon became a major activity for Gunson’s Seeds, and so a separate ‘SORTEX’ division was established in 1955. The SORTEX division was purchased by Bühler in 1994. The shared ‘family company’ ethos, and a shared drive towards innovation and, perhaps most importantly, customer satisfaction is perchance what facilitated such a simple integration of the two companies. This shared culture and commitment to Bühler values is why SORTEX had by then established itself as the worldwide leader in all markets.

What is next?

It is now over 20 years since SORTEX was acquired by the Bühler Group - a worldwide engineering solutions provider for the food, mobility and advanced technologies - and since then, 48 | August 2016 - Milling and Grain

has gone from strength to strength. Now fully integrated into the Bühler family, how has this branch of Bühler progressed, and what is next? Still recognised as one of the most trusted brands in optical sorting, Buhler Sortex remains a key contributor to Bühler’s success. It has an optical installed base of over 25,000 machines and with factories located worldwide - London, Brazil, China – to develop regional specific customer solutions, ensuring they are the leading global supplier of optical sorting solutions. During our visit we spoke to Carlos Cabello, Managing Director of Bühler Northern Europe and Darren Frost, Sales Manager for Milling and Baking, Bühler London. We also spoke to various members of the Buhler Sortex team; Charith Gunawardena Head of Optical Sorting, Neil Dyer – Global Product Manager, Ben Deefholts and Matthias Graeber, from the Research and Development department, and Tracey Ibbotson and Marina Green from the Marketing Department, about the progress made by Buhler Sortex and the future of optical sorting; as well as receiving a tour of the Buhler Sortex factory, guided by Peter Kinchin, and a product demonstration from Melvyn Penna, Applications Manager.

“It’s the automation that sets our machines apart from the competition”

“Four areas where Buhler Sortex excel are; efficiency, yield, capacity, and consistency” Charith Gunawardena, Head of Optical Sorting at Buhler Sortex, told us. It soon became clear that their ability to out-rival others in these areas boils down to their commitment to Research and Development, technological innovations and advances, and customer care. Bühler invests up to 5 percent of its sales revenue in research and development. The commitment to stay consistently at the forefront of developing innovative technology and finding new ways to optimise performance for their customers, is what Buhler Sortex believes is keeping them in their current leading market position. Working in partnership with its customers, industry


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specialists and research institutions, the Research and Development department capitalises on nearly 70 years of expertise to pioneer advanced solutions – a recent example being the SORTEX S Ultra Vision™ for rice processing. Ben Deefholts explains that SORTEX S UltraVisionTM has a lighting system specifically designed to enhance the difference between yellow and grey grains. It also includes the latest version of our self-learn and tracking software, a unique technology developed by us over 30 years ago, that allows the sorter to adjust automatically to any changes in the product colour and still provide a consistent quality of good product. You can see that R & D covers a wide range of disciplines, optics, mechanics, electronics hardware and software pneumatics, almost every area of physics is brought to bear to ensure our customers have the most consistent accept quality.” With constant developments and improvements, you may well think that the customer would have difficulty keeping their machine up to date but, as always, Buhler Sortex is one step ahead. We were told “Customer requirements change, so we are always one-step ahead in developing new machinery and technology, to meet our customers current and future requirements. Upgrade kits are made available, so that customers don’t always have to buy a new machine to benefit.” This is just one way Buhler Sortex strives to provide extensive customer care and optimisation of their machines – supporting all their customers, wherever possible.

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“The future of sorting is not just colour, shape or size”

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Towards the end of our visit, thoughts turned to the future of optical sorting; where we found out from Matthias Graeber that the future of sorting is not just strictly visible optical properties, in fact the further benefits of optical sorting, as a result of technological innovations, are manifold and help tackle more pressing issues such as diseased kernels and non-visible contaminations. “Improved cameras and IR sensors, for example, mean that it is easier than ever before to use optical sorters to sort for such things as; grains affected by mould and its toxic metabolites, commonly known as mycotoxins, or the removal of gluten-containing grains from gluten-free products, making optical sorters a workhorse of ensuring food safety at an early stage in the chain.” With contamination of mycotoxins being highly non-uniform (so-called hotspots), testing just a cross section of grains may not give a true reflection of the contamination. This is where the optical sorter can help, by pinpointing and rejecting infected grains, so that the entire crop is not wasted, due to mycotoxin contamination. Bühler have been a part of a European consortium, looking at mycotoxin risk management, throughout the entire chain, from field to fork. While it is evident that there

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is most certainly a need to reduce the likelihood of contamination from the outset, by employing good agricultural practice, thorough post-harvest cleaning and optical sorting are essential tools for risk mitigation and the reduction of contamination by mycotoxins. Typical reduction of contamination levels is 60 -80 percent, as demonstrated in multiple case studies. Separation, for the purposes of creating a gluten free product, can also be achieved through the use of an optical sorter, Matthias Graeber told us “The removal of gluten-containing foreign kernels in gluten-free product, is where optical sorting, in combination with mechanical cleaning processes, can significantly reduce the risk. An optical sorter will, in general, be more selective than mechanical pre-cleaning but a solid line of defence is ensured by the combination of different cleaning technologies.” So, when we asked about the price of an optical sorter, we were assured that the payback, both in monetary terms and in terms of satisfaction, can be realised extremely quickly, because of the increased yield and product consistency – leading ultimately to all-round customer approval.

Buhler Sortex factory tour

Our final activity of the day was a tour of the Buhler Sortex factory from Peter Kinchin. Sad to find out we were not the most important guests he has received, having presented a grand tour of the factory to Princess Anne, we were nonetheless eager to be shown around the facility, where each customer

50 | August 2016 - Milling and Grain

is offered a choice of precision-engineered, innovative optical sorting equipment, to fit their own specific sorting needs. On our approach to the office and factory that morning, one of the most striking things was the amount of security fencing surrounding the complex - something we initially found puzzling. However, we soon learnt from Peter that the packing area within the shipping section has been given aircraft security clearance, so that sorters do not have to go to an inspection warehouse and can be shipped directly to customers. This commitment to customer service is evident throughout the production of the machines. The shop floor is split into eight departments, in which each team leader has about seven people to direct. We were told that this new working arrangement meant additional but smaller and more easily managed sections, with the ultimate aim of getting the product right first time and improving daily productivity. Peter told us, “The jobs on each section are appropriately timed, so that each person can devote enough time to their part in the production line, so they are not rushed and to ensure they get it exactly right”. The operations are highly organised, with breakaway areas sporting wall-to-wall information on the progress of each customer’s order, ensuring all staff are up to date with where they are in the process. The factory floor certainly gives a feel for the dedication and organisation applied to each machine; for any visiting customer, contemplating a Buhler Sortex machine, it is a palpable display of Bühler’s strive to deliver customer-focused solutions, for even the most challenging of optical sorting applications. So, with all this in mind, is it any wonder that most customers who experience a tour purchase a SORTEX machine?

Humble beginnings to market leaders

With just under three quarters of a century of optical sorting experience, it is clear that Buhler Sortex has much to offer customers, looking to invest in optical sorting machines. From humble beginnings to market leaders, the Buhler Sortex portfolio shows total commitment to innovative, intelligent design, comprehensive customer service and modern manufacturing, guaranteeing their position at the top of the market.

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The Braben der MetaBridge is webbased, an d enables location an d pl independen atformt of measure monitoring ments – whether in the labora tory, the home office or w hen you’re out and abou t




he new Brabender MetaBridge software solution not only links the instruments and their measurement results, but also their users: internally within the company, across all sites, but optionally also suppliers and customers. The Brabender Farinograph-TS and the Moisture Tester MT-CA are now fitted with this new, intelligent network solution as standard. But there’s more: all instruments of the later generations, which have a USB port, can be fitted and therefore connected with the MetaBridge controller. All members of staff with the appropriate access rights can log in via a browser, and access every connected Brabender device. The really intelligent thing about the MetaBridge software is its web-based, and therefore site and platform-independent, user architecture. Multiple users can log in at the same time, so they can always communicate and comment on their data wherever they are in the world, using a PC/Mac, tablet or smartphone. This not only simplifies operational processes in the laboratory (or simultaneously in several!): the capability to directly track measurement processes is an important step towards online monitoring of processes – a dream come true for anyone involved in quality assurance. But the MetaBridge software’s network capability is not compulsory. Every device can operate totally independently, or alternatively, be integrated into its own network, without direct access to the company network.

More than just a new interface

This means that the MetaBridge is more than just a new interactive interface; rather, it makes laboratory work and results compatible. Multiple colleagues can simultaneously carry out, 52 | August 2016 - Milling and Grain

track or manage measurements – all using standard operating systems spanning Android and Apple via Blackberry and Linux to various Windows applications from Microsoft. The web-based software means that no local installation is required, which in turn enables equipment to be connected without problems occurring. And when it comes to security, this means that it has three plus points: • Password-protected login protects against unauthorised access; • The administrator mode enables you to individually customise access rights; • The Linux-based software architecture makes the system more secure on the web. The MetaBridge was developed by Brabender itself, especially for Brabender equipment, meaning that it is superbly geared to this equipment’s functions and measurement profiles. Thanks to adaptations for the widest variety of output devices, users benefit from consistent, company-specific, configurable performance. Multiple users can access the data at the same time, for example to track a current farinogram on various different end devices. This multi-access feature saves time, thanks to the continuous exchange of information between team members involved, but also when it comes to decision making on the part of those responsible for quality management. To this end, the MetaBridge solution has four important bonuses: • Info about updates of the instrument software is received automatically; • It is possible to receive feedback on measurement results directly from Brabender; • In the event of a fault, the Brabender service technicians can quickly help via remote access, removing the need for a site visit; • Within the device network, there are no charges for additional


In conjunction with the Brabender MetaBridge software, the new Brabender Farinograph-TS enables the flexible and easy yet standards-compliant qualification of flour.

Thanks to the new web-based MetaBridge software, the Brabender MT-CA enables location and platformindependent monitoring of moisture measurement.

user licences. In order that measurements can be carried out not only quickly, but also without errors, the MetaBridge offers system internal quality assurance, featuring several features for the prevention of errors. So, for example, the measurement range is set according to the specified instrument configuration; taring is automatic, and for farinograms, increments, timings and threshold values are already integrated. But of course, they can also be customised on a product by product basis. The MetaBridge ‘bridge builders’ have also built in further intelligent communication opportunities, which enable connection to existing laboratory management systems, and in particular optimise customer communication of measurement results. It goes without saying that Brabender applications can call up the widest range of international benchmarks and display them effectively. But custom parameters enable you to even integrate data from other types of equipment and to combine it into joint ‘printouts’. So, for example, various pieces of quality assurance data relating to flour products undergoing testing can be collated according to the customer’s specifications upon request and sent as an email or PDF with a letterhead in the company’s corporate design. What’s more, as a further sweetener, Brabender can set up a data export interface in existing databases that run under Microsoft Access or Excel (for example).

A new level of user-friendliness

The new software’s user interface boasts a contemporary tiled design. Behind the tiles there are a multitude of operatorfriendly applications and possible network options. This includes responsive web design. The intelligent software automatically adapts to each monitor resolution or screen size, meaning that

it is also ideal for end devices. What’s more, MetaBridge can optionally be operated via the touch screen, with the focus on intuitive user prompting and being able to quickly learn how to use it. But of course, it also works with a mouse or via classic keyboard operation. The MetaBridge records measurements and assists with the analysis and assessment of measurement results, for instance by integrating reference curves and directly comparing various values. This opens up the opportunity to prepare quality variants in a Farinograph on a ‘trial’ basis using menu commands. This goes a long way towards preventing operating errors by less experienced team members. This applies to independent devices at their respective laboratory workstations as well as – when linked via MetaBridge – to multiple devices, including at decentralised workstations, i. e. in home offices. So, for example, all a company’s measurement results can be saved and managed centrally, so that every authorised user has access to all the measurement data and documentation required for a defined equipment environment – at all times, and wherever he or she is. This simplifies the exchange of information between users. Additionally, a comment function on the graphical chart display enables the assessment or evaluation of measurement results to be discussed online.

Farinograph-TS plus MetaBridge: Flour quality testing in a new dimension

Today, reliable and reproducible testing of the processing characteristics and quality of flour products is a basic requirement in the milling and baking industry, in order to ensure continuously optimised flour quality for various baked or pasta products. The Brabender Farinograph has proved itself ideal for this task over Milling and Grain - August 2016 | 53


The Brabender MetaBridge can run anywhere, on the end device type of your choice. The user interface flexibly and automatically adjusts to the terminal’s screen width

the course of decades, making it the world’s most-used piece of equipment for determining the properties of wheat flour and rye flour. The farinogram shows the quality characteristics of the flour being tested in a rheologically realistic test for the dough phase. In the fitted temperature controlled measuring mixer, the flour/ water sample is mixed, and the mixing resistance is measured as torque, according to the viscosity of the dough. This enables water absorption, dough development time, stability, fermentation tolerance and the degree of softening to be reliably depicted. The MetaBridge records these measurements vividly, enabling monitoring, analysis and documentation of the measurement data – on the equipment itself, or, if required, on external monitors for others to see. As well as the standard analysis, the software offers countless possibilities for designing your own custom tests with the TS generation of the Farinograph, such as for example: • Shorter test length and/or higher mixing intensity via adjustable rotational speed (2–200 rpm); • Variable mixing intensity and energy input into the dough for applications in research and development; • Programming of more complex rotational speed profiles, e. g. premixing at lower rotational speeds, mixing at higher rotational speeds, or the definition of pause times for longer dough-making processes; • Analysis of charts with atypical farinogram profiles, such as with wholemeal and/or rye flours or with the observation of enzyme effects.

Moisture Tester MT-CA plus MetaBridge: interactive precision

The MT-CA electronically determines a sample’s moisture, according to the principle of the drying chamber with moving air. The drying oven method has been established as a reference method, which removes the need for special calibration for different samples. This moisture tester enables you to measure up to 10 samples at the same time: quickly, reproducibly and superexactly, to a degree of 0.1% water content precision. And also 54 | August 2016 - Milling and Grain

for this equipment, the MetaBridge optimises the measurement, analysis and administration functions: live monitoring, automatic saving of measurement data, interactive validation of the inputs and creation of a detailed test report.

Grounded competence and professional dialogue via MetaBridge

The software’s many features, along with the combination of instruments in networked interplay, increases its depth of rheological competence and experience. The model-like simulation of parameters makes it possible to test alternative processing procedures, such as for example the effect and observation – live on screen – of recipe additions to dough development during kneading. This makes professional dialogue between partners in the value creation chain much easier when it comes to making decisions on complex quality requirements, as well as providing documented data that can be used for certifications or audits. This is how the Brabender MetaBridge leads the way to a new dimension of quality assurance. Additional benefits of controlled reliability with the Brabender® Calibration Kit Regular control measurements for the Farinograph, using the Brabender reference material, guarantee reliability of the measurement data. The combination of specially prepared calibration flour and its reference curve offers direct comparison of an on-site device’s measurement values to the target measurement values. This is an easy matter using the calibration kit that can be obtained from Brabender®: Simply prepare the sample according to the specifications, carry out the test and compare the values to those of the supplied reference curve taken from the master equipment in the Brabender service laboratory. If the values are within the permitted tolerance range, you can rely on your equipment’s measurement values, as well as the validity of the measurement values in your application. If, despite repeated testing, the values lie outside the tolerance range, online and together with the Brabender experts, you can use the MetaBridge software to search for the cause and quickly rectify it.


Feed weighing systems


by Lukas Bruijnel and Tim Broeke, KSE Process Technology

he design of a premix, compound feed or petfood production facility has one main goal: how to get all the raw materials into the end product(s); of course in an accurate, time- and costefficient and flexible fashion with the desired capacity and footprint, while respecting any contamination groups. And last but not least, within budget. So there’s of course a lot more than just the one goal while designing the ideal process. That always makes for an interesting discussion on how to approach the design, since everyone in the production process has his or her own approach and requirements. Perhaps the three most important are nutritionist requirements, production requirements, and (of course) commercial requirements.

Nutritionist requirements

Nutritionists need a wide variety of raw materials to be available 24/7 to dose a large selection of recipes automatically – of course with minimum manual interferences and maximum accuracy. This allows the nutritionist to produce specialised formulas without manual dosing, and a lot of different materials readily available. Developments in nutritional science are producing more efficient compound feed and feed additives (premixes). They are also however increasing the demand for faster, more accurate and cleaner dosing, transport and mixing equipment. Generally speaking, there are nowadays more ingredients and often small doses.

Production requirements

Process requirements depend strongly on the type of production facility. Whereas a compound feed facility may focus on output and efficiency, a dedicated premix facility might focus on maximum flexibility in exotic or customer-specific premix production to serve demanding (niche) markets. This may allow longer batch times, but require more ingredients per dosing installation, and the ability to dose small and large components from a single silo. Flow characteristics of ingredients are often poor, and hygroscopic materials need to be treated carefully. This indicates different design parameters for storage and dosing equipment. Additionally, these ingredients often are considered difficult for health and safety and should be handled with much care. Minimal operator contact is therefore another issue to face when design a best in class plant. 56 | August 2016 - Milling and Grain

Many larger compound feed facilities are adding a dedicated premix line, bringing the supply of the most popular premixes in house and thus creating flexibility for themselves. That not only shortens lead time, it also provides a significant economic advantage. Depending on demand, in-house production can also dose in-line, dosing the various additives directly into the mixer. Some plants find it more efficient to create larger quantities of premixed additives and carriers in one go. Doing so allows larger dosing sizes, and the production of premix when time is available (not inside the batch time of the main process). Additional storage might provide a challenge here, but again each different process and facility will have to prove which way works best.

Commercial requirements

Commercial requirements include delivering a range of products with as short a lead time as possible, with low capital and operating costs, and without compromising quality. In our experience, the best starting points for a process design or redesign are a thorough analysis of (realistic) wishes, with a good balance of nice-to-have features and future-proof design. Don’t overdo the nice-to-have and future-proof parts, though. The optional extras might tick all the boxes, but blow up your budget all the same.


It appears that also the design of a weighing construction needs much attention in this process. It still happens frequently that not all the products end up directly on the scale, but (partly) on a funnel to the weigher. This gives false measurements and product mix up in the process. The weighed product should be dosed directly on the scale, and in such a way that there will be no ‘leverage effect’. Leverage

F will occur when, for example, the product arrives on the extreme side of the scale, by which the scale exerts a torque on a load cell. And of course, a scale should have sufficiently weight before the product is weighed. That sounds obvious, but in practice it is sometimes forgotten. In our years of experience, we have seen it all from dosings of <1kg on a 2000 kg scale to influences of hammer mills vibrating the weigher up and down to even ladders or equipment hanging directly on the weighing surface. The most common error, without a doubt, is insufficient ventilation. The air which is moving by the “to be weighed” product, must be able to escape without disturbing the weighing. A flexible sleeve of filter cloth (which is often nearly closed) is insufficient for the venting. By an influx of for example 50 kg/s wheat, 75 liters/s = 270 m3/hour of air must be drained. Otherwise this will again give over pressure in the weigher and give an under dosing or very long dosing time. Another important design point is the emptying of the scale, which should be smooth and complete (without residue).


The quality of a weigher in electronic aspect depends on the quality of the applied weigh cell (load cell or force transducer) and invertor (digitiser or indicator). In both cases you need to pay attention to the sufficiently large weight range (taking

into account a certain overload) and distinctiveness. This distinctiveness determines the smallest possible weighing unit. A distinctive character of for example 3000 steps – take into account 20% overload – 2400 steps remains for the actual weighing range. This is for a 100 kg-weigher a weighing unit of 42 grams. In practice, in this case, they will often choose to go down to 2000 steps, which create a better workable weighing unit of 50 grams. A large number of weighing units (slabs) aren’t able to give all the information and therefore it’s possible to receive false accuracy. It’s the combination of the mechanical and electronic properties of the weigher which determines the actual accuracy.


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F to connections with stabilisers and flexible cuffs. Yet it happens that this is correct, and then a stepladder is placed against the weigher or spilled product is hinder the weigher. Other external influences should be avoided whenever possible. Think of vibration, buckling floors or supports, compressed air leaks and wind, but also to over-or under pressure due to aspiration, pneumatic conveying or product movements in connected silos.

Quickly and accurately

Signal latency

Signal delay (latency), the time which elapses between the signal of the weighing unit and it’s processing by the controller; is by dosing weighers a misunderstood problem. The signal latency arises at electronic filtering and averaging to improve the stability of the signal. But also the delay through the network between weigher and controller should not be underestimated. A process control will calculate with outdated data because of signal latency. It is therefore more appropriate to speak of ‘backlash’ instead of ‘for lash’. The weight should constant be long enough for the final determination. The pitfall here is an electronic created stability that doesn’t match with the reality.

External influences

A well-designed weigher doesn’t guarantee a proper weighting. There are also external factors that can affect the weighing result. It is obvious that the scales should be free from interference due

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A good scale alone does not guarantee a correct dosing; the weigher is limited to establish how much is dosed. All systems of the triangle ‘Weigher-Controller-Dosing Tool’ are in business by proper dosing, in which these systems are optimally matched. The controller uses the information from the weigher to control the dosing tool. The dosing tool is able to work with a fixed or a variable dosing speed. With a variable speed it’s possible to realise more accurate and faster dosing. The exit point (trail) is standard corrected so that the final standard weight usually is within the tolerance. A variable dosing speed is only fully utilised as the ‘settings’ (turning points of dosing speeds) are constantly optimised. This is a labour-intensive activity, which mostly results in disappointing results. Modern software makes it possible to automate this optimisation, whereby the quality of the dosing strongly improves.

What your design will need to consider

Studying the process will tell you the best equipment and batch size for a specific project. You can gain insight by analysing the required production capacity for each of a selection of representative recipes. This can be a complex calculation, though. Process related variables include number of ingredients, batch cycle times, collection and internal transport times, and mixing times. Broader considerations include working hours, physical space, seasonal production peaks, and available budget. Once you’ve decided on the key process equipment and how to set up the process itself, next is to fit all equipment within the available footprint and height. In existing buildings, adding or extending production lines is often a challenge and needs creative design by experienced process engineers.


Extremely fine distribution as the highest quality criterion for micronutrient premixes with vitamins B1 and B2


y enriching flour, mills in many countries make an important contribution to nutrition and public health. Flour is enriched with iron, folic acid, and especially with thiamine (vitamin B1) and riboflavin (vitamin B2). The homogeneous, very fine distribution of the individual components is important for the quality of mixtures with these vitamins. Otherwise, agglomerated riboflavin can cause yellow streaks or yellow-orange spots in the final product. (see photo 1) The US, Great Britain and Canada led the way in enriching flour with B vitamins. In the war and the crises of the 40s, these countries recognised the importance of food supplements and passed laws requiring that flour be enriched with vitamins like thiamine and riboflavin. Today, in over 85 countries industrially made flour is fortified with vitamins B1 and B2 and micronutrients to protect consumers from nutritional deficiencies, voluntarily or by law. Vitamin B1 and B2: wide-ranging importance for health Thiamine is a water-soluble vitamin that occurs in many plants and animals, and performs important functions in the human metabolism and nervous system. Deficiency can present symptoms such as fatigue, memory loss, digestive and heart rhythm problems. A formerly widespread thiamine deficiency disease is beri-beri, which today is rare. Riboflavin is a yellow vegetable colourant that plays an important role in the body in extracting energy from fats, carbohydrates and proteins, and in protecting cells against free radicals. Deficiency symptoms include skin problems, visual and growth impairment, fatigue and weakness.

Compensation for nutrients lost in milling (see graphic) Wheat has a naturally high content of B vitamins and would

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therefore in principle be a good source of vitamins B1 and B2. But these micronutrients are contained mostly in the outer layers and the germ of the grain, so that they are lost to a great degree when grain is milled to get a lighter colour, since this removes the outer layers. Subsequent enrichment of the flour with the respective micronutrients can restore or even exceed their original content in the wheat. As a rule, the amount of thiamine added is 5 – 7 ppm (mg/kg flour). Thiamine mononitrate is most commonly used. This is a white powder that has relatively high stability for a vitamin, and can be processed without problems. Riboflavin, an intense yellow colourant, is a bit more difficult to work with. In order to be able to provide comprehensive advice on the use of vitamin B2, Mßhlenchemie has done baking trials and colorimetric tests with riboflavin-enriched flour at its Technology Centre. The results show that the colouring effect only comes into play at relatively high concentrations. For example, at 6 ppm the crumb of sandwich buns showed quite visible yellow discolouration. However, at industry-standard concentrations of 2-4 ppm no significant discolouration was detected. (see photo 2)

Yellow streaks and spots from clumped riboflavin (see photo 3)

So the problem for the mills is not so much the quantity as it is the quality of the riboflavin in the premix. The physical nature of the vitamin is what makes the difference. Riboflavin is an extremely fine powder that tends to agglomerate, so during compounding it needs to be distributed as thoroughly as possible. Coarse particles can have negative consequences in the final products. For example, light colour is an important quality criterion for Asian noodles, which are made from bleached flour. If the premix contains insufficiently homogenised riboflavin there is a risk that the colour particles can break down under the high mechanical pressure that occurs during rolling and stretching of the dough,

F leading to yellow-orange streaks. Undesirable effects can also happen with buns. Individual yellow spots in the crumb are a sure sign of clumped or coarse riboflavin.

Very fine distribution as a key quality factor

To prevent product defects of that nature, mills should use high-quality premixes and make sure the riboflavin is as finely distributed as possible. For the first quality check, there is a simple rule of thumb: well-mixed premixes look yellower than mixes with coarser particles, for the same riboflavin content. There is also an easy test that gives a good initial idea of the homogeneity of the premix without expensive equipment. Simply sprinkle some powder on a light surface and spread it out with the back of a spoon. If yellow-orange streaks appear under pressure, it is a clear indication of agglomeration and insufficient mixing of the vitamin B2 particles.

Raw Materials

Potency reduction resulting from light and moisture

In addition to choosing a suitable premix, mills should pay attention to correct handling of sensitive vitamins. The stability of thiamine depends primarily on the moisture content during storage. Tests have shown that flour with 12 percent moisture content retains 88 percent of its thiamine after 5 months in storage. If the moisture content is just six percent, there is no loss of potency. Thus, in humid tropical regions it is important to create dry storage conditions to protect vitamin functionality. The packaging material should also reliably protect the micronutrients from moisture. Liquid- and vapour-proof aluminium composite

Micronutrient losses during wheat milling Wheat is a great source of vitamins B1 and B2. Losses during milling can be compensated through flour enrichment.

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Above - Photo 2: Impact of vitamin B2 on the colour of bread: Adding 6 ppm riboflavin can cause yellowing of the crumb. But the standard in flour enrichment is 2 to 4 ppm, which does not cause discolouration.

foil is ideal for premixes that contain thiamine. This is also the packaging material of choice for vitamin B2, since riboflavin is extremely sensitive to light and aluminium inner liners offer full protection from it.

Proper handling

It is also important to reseal premix sacks immediately after use and not leave them standing open next to the feeder, as can happen at small mills using only small amounts of micronutrients at a time. Light getting into the open box has a devastating effect on the stability of the vitamins and greatly reduces their nutritional value. It should be noted that this vitamin loss is not visible, since riboflavin retains its yellow colour even when chemical deterioration is well under way.

Flour enrichment gaining ground worldwide

In the years ahead flour enrichment will become more widespread. To promote public health and improve economic performance, more and more governments are acting to ensure that the populace gets enough micronutrients. This makes flour mills very important in the health policies of these countries. Some mills may initially regard these regulations with scepticism, but as long as suitable premixes are sourced and are handled properly, vitamin and mineral enrichment can be integrated into routine operations without difficulty. 62 | August 2016 - Milling and Grain

Photo 3: Prevention of yellow spots and streaks in dough Simple quality check: Spreading out a premix containing riboflavin gives an indication of its homogeneity. If the agglomerates are too large, the particles come apart under pressure to form yellow-orange streaks. (left)



Aerating stored grain


by Peter Botta, PCB Consulting

rain aeration is a popular grain storage tool used in Australia by farmers, offering harvest flexibility, increased marketing opportunities and better control of grain quality. As the range of chemical control options is reduced, grain aeration provides a powerful non-chemical stored grain insect management

option. Through manipulating grain temperature and moisture, aeration cools the grain stack and achieves a more uniform bulk, delivering an optimal storage environment. Not only does this inhibit insect activity, but also maintains grain quality. Aeration of stored grain has four main purposes - preventing mould, inhibiting insect development, maintaining seed viability and reducing grain moisture. Without aeration grain is an effective insulator and will maintain its warm harvest temperature for a long time. Like housing insulation, grain holds many tiny pockets of air within a stack - for example 100 tonnes of barley requires a silo with a volume of about 130 cubic metres, 80m3 is taken up by the grain and the remaining 50m3 (38 per cent) is air space around each grain. Without circulation, the air surrounding the grain will reach a moisture (relative humidity) and temperature equilibrium within a few days. These conditions provide an ideal environment for insects and mould to thrive and without aeration the grain is likely to maintain that temperature and moisture for months.

the air in the head space heats and cools each day creating ideal conditions for condensation to form, wetting the grain at the top of the stack. This makes the top of the grain stack the most vulnerable to insect and mould activity and is unfortunately the last place aeration will get to. (See Figure 1) From the aeration fan outlet, air will take the easiest route to the top of the grain stack - the path of least resistance. Poor aeration ducting can result in pockets of grain not being aerated. The peak of grain in a silo is a common place that aeration bypasses. The path of least resistance is to the side, below the peak of the stack

Air movement within the grain stack

Grain at the top of the stack is the hottest, as heat rises through the grain. The sun heats the silo roof and internal head space, resulting in the surface grain at the top of the silo heating up. When grain is stored at moisture contents above 12 per cent, 64 | August 2016 - Milling and Grain

Figure 1: Air movement within a silo

F as it is a shorter distance from the aeration ducting. Considering silo size – height and width, grain types stored, ducting type and configuration and fan size output needed are all important factors. The system must be fit for purpose to ensure successful results.

Figure 2: Air flow rates

Cooling or drying

Grain aeration systems are generally designed to carry out either a drying or cooling function - not both. Aeration cooling can be achieved with airflow rates of 2–3 litres per second per tonne of grain delivered from fans driven by a 0.37 kilowatt (0.5 horsepower) electric motor. Aeration drying can be achieved with fans delivering 15–25L/s/t, typically powered by 7kW (10hp) electric motors. Low-capacity fans cannot push this drying front through the grain fast enough to dry grain in the top section of a stack before it turns mouldy. (See Figure 2)

Management for cooling or drying

Managing the aeration system is different for cooling or drying, with fan run times required at different times of day and at different intervals. An automatic aeration controller increases the efficiency of an aeration system by negating the need for manual fan control, but it’s vital to set the controller to operate the aeration fans for their designed purpose - either cooling or drying.

Aeration cooling

Changing grain storage temperature is a relatively quick process compared to changing grain moisture. Cool grain is far less prone to quality loss than grain at higher temperatures. To maintain grain quality and help avoid the build-up of hot spots or

mould or insects, regular air movement and changing of the air is needed. Once grain temperature has been stabilised, low flow-rate aeration cooling fans should regularly be turned on at appropriate times to move fresh, cool air into and around the grain storage. When first loading grain into storage, run the aeration fans continuously from the time the grain covers the aeration ducts for the next 2-3 days, until the cooling front reaches the top of the storage. However, do not operate the aeration fans on continuous

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F mode if the ambient relative humidity is higher than 85 percent for extended periods of time as this can wet the grain. After the aeration fans have been running continuously for 2–3 days to flush out any warm, humid air, reduce run time to 9–12 hours per day during the coolest period, for the next seven days. The goal is to quickly reduce the grain temperature from mid 30°Ct down near to low 20°C. An initial reduction in grain temperature of 10°C ensures grain is less prone to damage and insect attack, while further cooling becomes a more precise task. During this final stage, automated aeration controllers generally run fans during the coolest periods of the day, averaging 100 hours per month. (See Table 2) Grain temperature is gradually reduced as low as possible and then maintained throughout the storage period. In Australia it’s quite achievable to get grain down to 16-18 degrees Celsius where many insect pest can no longer breed.

Aeration drying

Table 1: Air for drying grain

Table 2 Air for cooling grain

Ambient air can also be used to dry grain. Here, high flow rates of air at a temperature and humidity that will remove water from the grain (see grain equilibrium moistures) is pumped through the grain bulk. Providing the air is of a quality that will dry and not re-wet the grain, the grain will dry from the bottom of the silo, with a drying front moving upwards through the grain stack. Aeration drying is a much slower process than aeration cooling or hot-air drying. The time it takes and the moisture content of grain after a drying front has reached the top of the grain stack is highly dependent on the quality of the air available for drying.

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Several drying fronts may be needed to dry grain to receival standards. If aeration is to be used for drying, check with your aeration supplier that the fan and ducting have sufficient flow rate and pressure to force a moisture change front through the grain in the silo quickly enough to prevent mould development. It is also critical to ensure that flow fronts are even and grain depth is not too deep. Air with greatest capacity to dry, occurs most during the day when temperatures are high and relative humidity low, but this is not always the case. (See Table 1) Very hot dry air can overdry and crack grain. The average quality of the inlet air determines the final grain moisture content.





dos and don’ts in grain and milling industries Mark Shannon from BS&B Safety Systems shares key tips on ensuring adequate protection from dust explosions and what mistakes to avoid

evastating grain dust explosions have been recorded for decades as the risk of flour dust ignition is so high. Without adequate controls and safety measures, grain flour explosions have been known to level entire milling facilities and take lives. While mill owners are making the effort to comply with DSEAR and ATEX regulations to ensure their staffs’ safety, the execution of preventive measures has not always been correct. Many milling facilities share common problems when it comes to the installation of protective equipment. In some cases, they inadvertently exclude “fail-safes” where necessary. Here are some examples of the most regularly encountered issues when it comes to protecting against dust explosion risk in grain processing and milling. These observations come from years of experience. Always seek the help of a professional to visit your site and make the recommendations bespoke to your facilitys’ needs.

The management of hot particles

By detecting and preventing sparks, embers and hot particles from reaching dust rich downstream process equipment, such as dust collectors; bins and silos, both fire and explosion risks can be managed. Dust explosion severity classifications are measured from St1 to St3. Grain dust has an St1 rating – not the highest explosion severity, yet grain dust can ignite at a fairly low temperature and that makes it a dangerous combustion risk. If a known risk may exist then a spark detection system should be installed to counteract the risk of severe damage and harm to personnel.

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Don’t forget to protect bucket elevators

Bucket elevators are high risk equipment because they have many possible ignition sources. What’s more, they are usually connected to the rest of the plant, so if there are sources of ignition, a primary explosion could easily spread to the other processes and a secondary explosion occur.

Overlooking isolation of connected equipment

If you fit an explosion vent to a dust collector, then there must be isolation of the dirty inlet duct and isolation of the clean air outlet duct if it returns to the process area. This is vital because the explosion could propagate along these ducts causing other safety risks to people and equipment. Non-isolated equipment could cause a chain reaction of explosions.

Explosion vent installation errors

Do fit an explosion vent duct, but make sure it’s done properly and that it’s the correct size for your process requirements. Failure to do so will result in a variety of dangerous health and safety risks: • The possible leak of combustible materials from an incorrectly fitted vent could result in burning materials being expelled at high pressure with a possible flame reach of between 10 and 30 metres. Factor in changes to the manufacturing process being used in relation to the size of vent required. i.e. if the materials that you are processing have changed and have a higher Kst and PMax value, then explosive pressures may have increased. • Vent ducting must be properly calculated and engineered to strict guidelines so that the flame path can escape freely to a safe area without any backpressure. Correct size and length of ductwork is key to the efficient performance of a vent. • Ensure that your vent discharge path cannot possibly endanger nearby personnel. If a hazard exists due to explosion venting,

F then clearly indicate the area with signage and cordon it off. • Do not obstruct the explosion vent path. • Do not try and make your own vent – have it professionally calculated and installed. Otherwise you are at risk of unsafe performance. • Once your vent is correctly installed ensure it is regularly inspected and that the inspection records are visible.

Unsafe ducting and pipework

Weak explosion ducts can encourage an ignition to transform into a destructive explosion. The strength of explosion vent ducts should be calculated so that they can withstand the maximum pressure of a vented explosion (Pred). Always avoid long horizontal runs of ductwork which attract uninterrupted dust build up.

Silos and storage bins inadequately protected

Venting is often the most appropriate preventive measure for silos because of the potential explosive pressure that can build up inside them. Vents should be placed on the top of the silo or on the sides at a height above the contained material. • Silos need to be able to withstand explosion pressures. The length to diameter ratio of the silo is important when calculating the vent area. Correct vent area sizing is critical so that the vent is large enough to prevent damage from explosive pressures. • Always test the material to be stored or handled and determine its Kst value and PMax. Both of these figures will allow for the size of vent area required in your silo. Guessing the Kst and the PMax is the lazy and unsafe option.

Electrical grounding and bonding not in place

Electrical sparking in a dusty environment just invites disaster. Ensure that grounding wires are not broken or unconnected. Do you know the MIE (Minimum Ignition Energy) of the dust? Dusts with an MIE < 10mj should be treated carefully. If there is piping across a flexible connection, make sure it is well bonded. Static is a big risk factor on dusts with low MIE values and it wouldn’t take much to cause a fire or explosion.

Improve housekeeping

Arguably the most obvious activity but the most overlooked cleaning up the dust. Dust accumulations in the ceiling spaces, beams and walls can fuel an explosion to the point of destroying a mill. Ensure your employees know where the dust accumulation ‘hot spots’ are and keep them clean. Do not use air sprays to remove dust, this just creates a dust cloud which is a secondary explosion risk waiting in the atmosphere.

Absence of risk management

As part of your risk management strategy, it’s important to seek advice from an explosion protection consultant who can provide the right advice on what controls you need. A new installation of any equipment handling dusty product must be based on measurable data, so that your mill will be sufficiently protected. So in summary before the installation of dust handling equipment, always carry out a combustible dust test and subsequently review your combustible dust classifications (KSt and Pmax levels) at regular intervals as process operations and materials change. This provision should be incorporated into Management of Change procedures.

Milling and Grain - August 2016 | 69

Storage News



AGCO extends its grain storage and seed handling business with acquisition of Cimbria AGCO, a worldwide manufacturer and distributor of agricultural equipment, announced today that it has agreed to acquire Cimbria Holdings Ltd. for approximately US$340 million from Silverfleet Capital. Cimbria, based in Thisted, Denmark, is a leading manufacturer of products and solutions for the processing, handling and storage of seed and grain. The transaction is subject to regulatory approval and is expected to close in the third quarter of 2016.

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Cimbria’s extensive products and services support the cleaning, drying, storage and conveyance of grain and seed through the development, manufacture and installation of individual machines, customised systems and complete turnkey plants, as well as project management and process control consulting. Cimbria sales, which are expected to reach approximately US$240 million in fiscal 2016, are concentrated in Western Europe with growing exposure to Eastern Europe, Africa and the Middle East.


Storage project SPS moves forward in the Setareh project, a grain storage facility in Iran The grain storage facility SETAREH in Iran is almost completed. It is constructed of a reinforced structure to withstand extreme snow and seismic conditions. The project includes two flat bottom silos 14.56/21, with a total storage capacity of over 6,500 tons of cereal. SPS has designed and analyzed the silos to provide the best solution that, in this case, is a non-standard model. The SPS Engineering team has strengthened the silo structure to support up to 0.35 g seisms and has included a support system for a snow load up to 140 kg/ m2 on the roof. The silo also has many accessories supplied by SPS, such as roof and side ladders, a double catwalk, maximum and minimum level detectors and a sweeper with a speed of 80 ton/h. SPS continue to start new projects and expand collaborations in Iran, by offering the best storage solutions to their customers. SPS has a large team of distributors in the country, with high technical skills and an after-sales service.



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2016 - Milling and Grain 01/08/2016 09:49


July 2015 | 63

Industry profile

F Novus Global Headquarters, St Charles, MO




‘Batting a thousand’ in innovation and sustainability

by Eloise Hillier-Richardson, Milling and Grain

his June Darren Parris and I embarked on the long but worthwhile journey to Novus’ International Global Headquarters in St Charles, Missouri, to celebrate their 25th Anniversary. Journalists and writers from across the globe were invited to the three-day event, encompassing a vast array of exciting excursions, talks and tours, organised by our hosts Brandi Hamilton, Global Marketing and Public Relations Specialist, and Jake Piel, Sustainability Manager. Our activities commenced on the afternoon of Wednesday, June 15 as Novus ‘hit it out of the park’ with a visit to Busch Stadium to watch the St Louis Cardinals take on the Houston Astros in our own private suites. It offered an excellent chance to mingle and get to know one another against a backdrop of good food, good sport and thankfully, air conditioning - as the temperature had reached a whopping 35 degrees centigrade.

LEED-ing the way in sustainability

Bright and early on Thursday morning a shuttle arrived to take us to Novus Global Headquarters, about 15 minutes north of our hotel. In 2009 the Novus Global Headquarters building was awarded the Platinum LEED (Leadership in Energy and Environmental Design) certification, highlighting a central aspect of their ‘Triple S bottom line’ approach, sustainability, at the same time as creating a superior work environment for all employees and reducing costs. Consolidating the Global Headquarters and the International Research Centre, the single facility encompasses 10 research laboratories, an employee customer training centre, a gym (with classes and a personal trainer) and a cafeteria. As well as this, the building incorporates sustainable design and ingenuity: it boasts the largest array of solar panels in Missouri; 10 percent of the total material costs are recovered from salvaged 74 | August 2016 - Milling and Grain

materials and 30 percent of total materials are recycled materials; the facility has floor to ceiling windows to maximise natural light, a landscape of Missouri native grasses and plants designed to require no irrigation (meaning thousands of gallons of water are saved each year) as well as their very own beehives.

The Media Jam

The Media Jam began with opening remarks from David Freidman, Vice President and Chief Financial Officer, and Koichiro Tago, Executive Vice President and Divisional Operating Officer Chemicals Division, Mitsui & Co (USA) Inc., part owners of Novus alongside Nippon Soda Co., Ltd.

Koichiro Tago

Mr Tago is the Executive Vice President of Mitsui, a Global Trading and Investment House in a vast array of businesses, boasting a USD10.9 trillion client base with sales close to USD10 trillion, 47,000 employees and in possession of 450 companies. In recent years they have invested in everything from mining to machinery to energy. They acquired Novus in 1991 along with Nippon Soda. Novus was instantly a more global brand with an emergent Methionine basis in the US, growing more than threefold. He told us, “Novus brought a lot of innovation to the market with technically advanced products… with a mission statement and corporate vision looking to meet the needs of the customer in a sustainable manner”. He revealed that Mitsui have a renewed emphasis in this area, opening a new area of the business dedicated to the Agribusiness sector. In fact, Mr Tago divulged that in May Novus recapitalised, issuing new stock, Mitsui then put more capital into Novus, now holding 80 percent of shares instead of 65 percent. He said, “No one thought that Novus would be what it is today in terms of size and [the types of] products available” sharing that Mitsui have a “very solid growth plan for Novus”. He told us that shareholders feel tremendous opportunities lie ahead for this business, and that they are ready and committed to support Novus’ future.

Francois Fraudeau

Our next talk was from Francois Fraudeau, President and Chief Executive Officer at Novus. Mr Fraudeau spoke to us about the market (explaining how Novus reach out to the market), the renewed focus on feed quality, as well as ways to achieve feeding the predicted nine billion people who will occupy the planet come 2050. When it comes to the market Novus have several strategies and predictions for better feed quality and increased production. In the feed business Mr Fraudeau predicted continuous growth coupled with the need for increased sustainability, largely due to population increase and therefore the predicted upsurge in protein consumption in developing countries. He emphasised the need for international collaboration, as feed production will increase but not necessarily where the product is consumed, thus creating new trade relationships and import and export deals. An example he used was China, which holds 21 percent of the population but only 7 percent of agricultural space – accentuating the necessity of trade negotiations as they will need to import materials. Additional strategies for optimising production included supporting GMO, as well as promoting larger investment into the Methionine business as it has been proven that the use of Methionine not only helps with the cost of production of animal meat, but encourages a more successful feed conversion rate resulting in larger animals, and improves genetics. Moreover, Mr Fraudeau revealed that Novus are investing 5 percent of sales back into research and development - a quasicyclical arrangement, he pointed out, given that all this funding comes from the customers who are in the end those who will reap the results of the research. In terms of ‘achieving feeding the nine billion’ Mr Fraudeau reasoned that we experienced the same challenge 100 years previously, where globally we saw a huge population increase. He once again put a strong emphasis on sustainability, promoting proteases - an additive that allows Producers to maintain or reduce protein content in feed by increasing the digestibility of protein.

Jeff Klopfenstein

For our third presentation at the Novus Media Jam, Jeff Klopfenstein, Head of Methionine Business, invited us into his world… Our challenge? To help decide the next site for Novus’ new Methionine plant. The methodology was quite simple; we needed to start by thinking about where meat will be produced over the next ten years, by identifying patterns of food production, to narrow down where the plant should be built. So, food production, coupled with water availability, population increase and ease of distribution, all contributed to whittling it down to just a few key areas. Mr Klopfenstein quasi-rhetorically put forward the question of where future food production will take place, answering himself only to say we cannot be certain of the answer. He told us, “I’m supposed to be delivering insight to you today about how the world will evolve during a period of unprecedented population growth - in terms of the number of new people on the planet this is unprecedented – so we can cite some concerns about the sustainability of the world’s food production systems – we can look at water, what is the water availability in each region, and all we can be sure of is that food won’t be produced in the same way it currently is.” We learnt that the decision of where to build is inextricably

Ballons line the entrance to Novus HQ to celebrate their 25 Anniversary

linked to food production and where food was going to be produced in the future. Mr Klopfenstein gave predictions for Brazil, China, and the US based upon hectares promoted to grain production, crop yields, crop production, meat production and meat production in millions of metric tonnes. He asked rhetorically about what could happen if they are wrong in their predictions, concluding that the several places Novus have in mind for the new plant could cope with up to a 7 percent variance in production each way, acknowledging that building on the US Gulf Coast can economically serve Asia, Latin American and Europe in both scenarios where Asia becomes more self sufficient and if Asia becomes less self sufficient in production. Following the individual talks were three panel discussions; The Antibiotic Free Movement with Dr Mercedes VazquezAnon, Dr Nasser Odetallah, and Dr Bob Buresh; Stories from the field: “Realise the hidden value” with Eduardo Galo, Dr Nasser Odetallah and Dr Ajay Bhoyar; and lastly Science vs. Sustainability: “Who’s driving the bus” with Dr Mercedes Vazquez-Anon and Jake Piel.

The Antibiotic Free Movement

The Antibiotic Free Movement discussed the movement away from sub-therapeutic antibiotic use in favour of alternatives, not only eliminating the risk of antimicrobial resistant bacteria which could compromise human antibiotic use but also promoting greater animal welfare, nutrition and management practices.

Stories from the field: “Realise the hidden value”

The concept of the hidden value of something lies in the premise of producing something superior, beyond what is

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Industry profile


As part of their sustainability pledge, the peaceful landscape surrounding Novus Headquarters incorporates Missouri native grasses and plants, as well as their very own bees to help with pollenation.

expected. Novus are firm believers that their products perform beyond their traditional function, bringing additional benefits to the customer. Getting more from your product, either expectedly or unexpectedly, is a vital USP and great incentive for customers as it can lead to an increase in profitability and minimise detrimental environmental factors. Novus maintain that by incorporating their feed ingredient solutions into animal feed customers can ‘realise’ extra benefits, such as reduced feed costs, optimised animal health and customer service. The second panel of the Novus Media Jam was centered on this concept of ‘Realising the hidden value’ where each panelist shared their ‘story from the field’, essentially sharing case studies of how Novus products have bought additional benefits to the customer.

Science vs. Sustainability: “Who’s driving the bus”

Novus uphold that the notion of sustainability is embedded in the core of their organisation, made clear in their Mission statement: “To make a clear difference in sustainably meeting the growing global need for nutrition and health”, and their tagline ‘Solution, Service, Sustainability’. The last panel discussion at the Novus Media Jam was named ‘Science vs Sustainability: Who’s driving the bus?’ a quasi tête a tête between Sustainability Manager Jake Piel and Senior Director of Animal Nutrition and Facilities Dr Mercedes Vazquez-Anon, regarding where Novus direct most of their energies – towards science or sustainability; two concepts that could arguably be viewed as pulling a company in opposing directions.

“In conversation” with Novus’s Chief Innovation Officer

The concluding talk, which followed an impressive tour of the LEED certified building, was named “In conversation” with Novus’s Chief Innovation Officer. Scott Hine, Vice President Products and Solutions and Chief Innovation Officer was subject to a Q&A session from Chris Winsor about what drives innovation and whether it is increasingly more evolutionary or revolutionary in nature. Mr Hine began his career in Research and Development 25 years ago, telling us how it is always a thrill to be part of an industry that is always transforming. The discussion followed the theme of innovation, and they discussed whether the next changes would be evolutionary or revolutionary. Mr Hine admitted that incremental improvements are always taking place but also admitted that he “does not believe we have reached peak innovation which would stop revolutionary changes”. They also touched upon how innovation comes about. Mr Hine told us that shareholders and customers are two key drivers, 76 | August 2016 - Milling and Grain

saying “shareholders have a say in what they [Novus] do” but ultimately it is the consumers who are “driving the need for innovation”. After all, necessity is the mother of invention and if the consumers or customers are in need of a new product, Novus must respond through innovation. This concluded our Media Jam session. In the evening we were treated to a meal at the Edgewild Winery, ahead of the third day of the Anniversary activities, which had us journey to the Novus Green Acres Research Farm.

Novus Green Acres Research Farm

On Thursday morning, the final day of the Anniversary celebrations, a shuttle met us to take us to the Green Acres Farm, located in Montgomery County. Purchased by Novus in 2009, the 12-acre farm also boasts a LEED For Homes Platinum certification from the US Green Building Council; the 1920s farmhouse located on site was completely renovated by Novus using natural, sustainable materials. The renovation involved gutting the entire premises, reusing the salvageable material, as well as utilising locally sourced material with a high–recycled content and materials with a low VOC. Additional improvements included the elimination of hardscape areas to ensure rain water is retained and returned to the site, the preservation of existing trees and the inclusion of drought resistant and indigenous grasses, the creation of rain barrels to capture and re-direct roof runoff for plant establishment, a solar panel system which includes 168 solar panels and finally a wastewater collection system, an engineered wetland septic system, and a fertiliser and mulch area. “There are not many farmhouses that have achieved LEED Platinum, but this is no ordinary farm,” said Tom Hampton, Manager, Product Research at Novus and Manager of Novus’s Green Acres Farm. “Green Acres Farm is a living laboratory for developing and demonstrating sustainable practices in the animal nutrition industry. Having a LEED Platinum-certified house at the farm underscores our mission of making a clear difference in sustainably meeting the growing global need for nutrition and health.” Novus also have their own feed mill and silo storage unit on site, where they mill and prepare sample pre-mixes. So what is the purpose of the farm? The Novus Green Acres Research Farm puts into action all the protocols that are developed at HQ. They perform trials on chickens, pigs and cows to understand more about the effects of nutrition and diets and the digestive system. They document food and water intake, temperature, humidity, any contributing factors, in order to get as accurate results as possible from each of the trials. All the feeding is done manually and all the tare weight is stored in the computers so they know

exactly how much food has been consumed, and all food is grown within a 25 mile radius of the farm, further expounding Novus’ efforts in sustainability. As we were being shown around our guide told us “A couple of things that everybody likes to hear about and understand is what we’re doing with these guys, cannulated pigs and the fistulated steers.” Unlike the chickens, the stomach content of the pigs and cows can be monitored day to day while they are alive and on the go. Each pig and cow that comes onto the farm is fitted with a cannula, for the cow this is fitted into the rumen stomach, the largest of the four stomachs. The procedures for fitting the cannulas have been established by vets from St Louis who work with Novus in fitting the cannulas, so that the surgery is safe and offers little disruption to the animal. The cannulas are fitted so digestive samples can be taken from the animals for analysis. “When it comes time to do a sample collection we’ve got another adapter that goes on here, so we’ll pull the cap off and pull the plug out we’ve got an adapter where we attach a small plastic bag and we’ll get that adapter and the plastic bag stuck on the side of the pig. “Most pigs get fed a six o’clock in the morning, we’ll put the bags on and collect digestive from those pigs for about 8 hours, generally samples are collected and bags changed every half an hour. Each animal has a container with a number on it and we keep the containers in the freezer. Once we get the collections done for one week they get taken away and homogenised to make sure we have one really good mix of samples and then send the digestive samples for analysis” our guide told us. For the cows, the samples can be taken manually, our guide told us “once we have the cannula fitted, we can reach in and put

samples in and take samples out”, joking that you need to be very tall or have long arms, as some of the steers end up growing very large, weighing almost 2000 lbs.

Novus 25th Anniversary Dinner and Concert.

The trip ended that same evening with a dinner and concert at the Sheldon Concert Hall in St Louis, where we treated to a lavish three-course meal and speeches from Novus’ major shareholders Mitsui, as well as former and current Novus CEOs. The entertainment was rounded off by a performance from Rick Springfield, and after a lengthy couple of days really afforded everyone the chance to let their hair down.

Delivering the ‘Triple S bottom line’

Thus concluded the Novus 25 year Anniversary celebrations. What was evident from the three-day event is Novus’ determination not only to be preeminent in feed additives, but also to achieve this goal sustainably, through rigorous research and development and innovation. They have acknowledged that sustainable animal agriculture and animal wellness is simultaneously a scientific subject, as well as a subjective and emotional one, and they must be sensitive to that; bringing more awareness to producers about the environment in which the animals live in, as well as their own management practices. Ultimately, they appear determined to continue in their deliverance of their ‘Triple S bottom line’ approach, of outstanding customer service, new solutions reached through innovation, and sustainability, to be able to provide, and continue providing, an affordable food source for all incomes.


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Milling and Grain - August 2016 06/01/2016 | 77




Time machine If you need further convincing of Christy Turner’s ‘built to last’ reputation, then the company’s recent restoration of one of its original E R & F Turner Flaking Mills is an impressive testament to the longevity of their machines


anufactured in 1937, the vintage 18 inch flaking mill - the equivalent of an E R & F Turner 460 today - is now back in situ at South Down Feeds in Northern Ireland following a five-week restoration. What is more amazing, a large part of the restoration work on the animal feed mill was cosmetic, with around 90 percent of the original machine still intact following the extensive work which involved stripping the machine back to the last nut and bolt. “The restoration of our 1937 flaking mill is a great testament to the longevity of our machines,” according to Managing Director Chris Jones, who added that, “It is amazing to see how this machine has stood the test of time, while knowing the lifespan of our modern mills will only get better. Today’s machines - with their modern materials, technology, robust cast and sound construction are even better equipped to withstand the high forces and vibration inherent in the flaking process.”

Building upon manufacturing skills and expertise since 1837

A consolidation of highly respected British brands E R & F Turner, Christy & Norris and Miracle Mills, Christy Turner Ltd is renowned for quality British engineering and innovation in the milling industry. Building upon manufacturing skills and expertise since E R & F Turner started production in 1837, while making the most of modern technological advances, Christy Turner continue to produce machines of choice for manufacturers around the globe. E R & F Turner’s flaking mills are possibly the most famous 78 | August 2016 - Milling and Grain

export of the Christy Turner brand family. Over 90 percent of the machines used by UK cereal giant Weetabix at Burton Latimer & Corby sites are E R & F Turner mills - many already offering up decades of service. Arriving at Christy Turner’s Ipswich workshop in 2015, the vintage machine, which weighs around 4.5 tonnes was lifted off the truck via an overhead crane ready for its makeover. It was met by an excited, but apprehensive engineering team. As Ian Butcher, Christy Turner’s Production and Service Manager who led the project, explained: “The biggest obstacle we faced was not having engineers familiar with these particular models and the innate historical knowledge of a 1930s engineer. As a result the rebuild involved a bit of research and we relied heavily on the Christy Turner archives, searching through microfiche to locate mechanical sketches relating to the exact model. While some of the fundamental principles were similar, many improvements have been added to our machines over the years, making them mechanically very different.” Ian added: “What struck me at first was that the machine was in remarkable condition for its age and it really just needed smartening up. Towards the latter part of its production life, which spanned some 80 years, a few small parts had started to fall off the mill, so the owners were keen to see it thoroughly restored and set it up for many more decades of service.” “It is a great advert for the construction of these original models that a restoration was actually a viable option for a business, almost 80 years on.”

Stripping the machine and restoring it, one area at a time

Engineers tasked with the restoration work set about stripping the machine back to its basic components restoring one area at a time. Impressively, almost all the core components were fully

CASE STUDY F restorable and in working order. The only large components which required replacing were two gears and a phosphor bronze bush. Other than that the work was mostly new pins, bushes, nuts, bolts, welding and painting. The chassis itself only required painting and welding to reinforce the frame. While it looks similar to E R & F Turner’s equivalent 460 model, Christy Turner’s modern base castings are actually even more substantial, making them stronger than the 1937 model. The rolls still had life in them, so the engineers simply reground and re-fluted them to the customer’s specifications. Ian explained: “Due to the nature of the milling process it is common for rolls to wear unevenly, resulting in a poor flake quality, so we restored these rolls to ensure they were parallel. Regrinding and re-fluting is a core part of our servicing business. The fluting on a roll acts like a saw tooth, so as the flake comes in it grabs it and pulls it through the rolls. The condition of the rolls greatly affects the efficiency of a machine.” A key difference between the vintage mill and the modern

460 is E R & F Turner’s latest mills have rolls that spin on a roller bearing, whereas the older machines relied on four Phosphor Bronze Bearing Bushes fitted to the shaft. Out of the four bushes on the vintage model, only one was so badly worn that it needed replacing, the other three were easily restored. A lot of the original guards and castings were also easy to restore, however the logo cover was replaced. The only other parts which needed fully replacing during the restoration were the drive gears that link the rolls together. These were badly worn. The original drive gears



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F CASE STUDY were from a casting, which was no longer available, so Christy Turner commissioned custom-made solid steel replicas from a specialist gear manufacturer. Ian said: “The basic principles of the model are similar and you can see it looks similar in shape and design, but there are some significant differences when you compare it against our modern machines. For instance, the linkage between the two rolls now operates via a more hygienic belt driven system, whereas the old model is driven by gears. This is why these gears needed to be custom-made, as they are no longer part of the modern machine. “Also the spring loader scraper adjustment is very different today. The scraper system controls the metal blade which fits against the roll, with the scraper peeling off the crushed flakes so they drop into the hopper. On the 1937 model this is a spring loaded system whereas today our machines include a pneumatic scraper system which applies constant pressure. This is one part of 0the machine that looks very different today. Similarly, the spring pressure assembly, which allows for movement when grain goes through the rolls, was modified in the 1970s. This element was restored to its former state, but we could not replace it with the new version. “We could not retro fit anything new on this model and the project was very much a rebuild with a view to making sure all the parts fitted well to modern standards. We didn’t actually want to alter the machine’s fundamental principles though, and neither did the owner, as it is such an impressive historic artefact. Our extensive work did, however, result in improvements to the strength, hygiene and safety of the machine and set it up for many more years of service.”

E R & F Turner’s historic, and continued, contribution to the world’s milling landscape

The stunning vintage model, which was featured in E R & F Turner’s centenary catalogue, is now on standby as a back-up mill at Southdown Feeds and remains a steadfast example of E R & F Turner’s historic, and continued, contribution to the world’s milling landscape. As well as supplying new and reconditioned machines, Christy Turner has a busy spares and service department, delivering everything from machine maintenance advice, on-site servicing and replacement wear parts such as beaters, screens, rotor parts, bearings and bearing housings. Chris said: “We are always happy to take on a challenge and the restoration of the 1930s mill certainly tested our engineers, but it was a very inspiring project and well worth the meticulous research. “We take quality of service very seriously, priding ourselves on our comprehensive test and development facilities and support and parts provision. While our products are renowned for their reliability and longevity, we nonetheless stock a broad range of spare parts in our large warehousing facility.” In 2012, Christy Turner, celebrated 175 years of supplying high quality robust and reliable Flaking Mills, Hammer Mills, Pulverizers, and associated plant for the human foods, animal feed, biomass, waste recycling, minerals, chemicals and pharmaceuticals industries around the world. Combining years of experience with innovative ideas, the latest design tools and sound engineering, Christy Turner still manufacture its machines on site in Ipswich, where E R & F Turner began its historic journey in 1837. 80 | August 2016 - Milling and Grain

MARKETS OUTLOOK Cereal prices on the floor

by John Buckley Although China is still a major contributor to global markets, USA and Canada are expected to make a comeback and be reinstated to the summit of world grain producers in the not too distant future

Constantly rising wheat crop estimates, record large global stocks of cereals in total and mostly ‘yield-friendly’ weather in the Northern hemisphere have continued to erode grain prices over the past month, resulting in US wheat trading near 10-year lows. Markets seem to have adjusted with remarkable speed to the loss of millions of tonnes of Brazilian maize exports to drought, confident that large US stocks will tide consumers over comfortably until the promised next round of better US, CIS, European and South American corn harvests. Neither have some significant quality threats to rain-interrupted wheat harvests in the US, Europe and the CIS countries offered much help to die-hard bulls. Breadwheat premiums over ordinary, biscuit and feed wheats might be up quite sharply but the price base from which they apply is well down. That traditional benchmark, the Chicago soft red winter wheat futures contract, for example, has been trading almost 23 percent below its recent highs. CBOT maize dropped too, by as much as 24 percent in the past month, setting its own near two-year lows and sharpening the competition between the two grains for US feed outlets. A similar story is emerging in Europe where the usual rivalry is expected to build between a larger feedwheat crop, a resurgent corn harvest and plentiful barley supplies. ‘Macro markets’ – equities, crude oil and other economic indicators have also remained bearish, especially since the shock outcome of the Brexit referendum. Despite the brave face put on things by the Brexiteers, analysts around the globe are nervous about the potential negative fallout – psychological and actual - on a still febrile world economy. As well as the Euro-zone’s problems, markets are also concerned that China is still slowing down, dragging with it emerging economies around the globe - which can’t be good for

82 | August 2016 - Milling and Grain

Table 1: Main maize producers 2015/16






























expanding demand for key food and feed ingredients. The reversal in crude oil markets after their short-lived rally, is another negative for crop markets to deal with, signalling a less encouraging climate for bio-fuels made from grains and oilseed products. Among all this gloom and doom (for the suppliers), the odd man out has been the soyabean complex, which has risen by almost 40 percent over the second quarter of the year to reach its highest level in almost two years. The accompanying increase in soya meal prices has been even bigger as flood losses to Argentina’s bean crop curbed supplies from this, the largest meal exporter. That too may be ‘topping out’ now, however, as traders take a more sanguine view of Latin American crop losses and the consequent surge in demand for US beans behind this unexpected rally. Cheaper grain and feed raw materials are, of course, good news for the consumer (soya meal aside). But with forward grain futures markets pointing to relatively modest potential for price recovery, the question is still posed, how long can cereal


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producers put up with the collapse of farmgate prices? The Latin Americans, Russia and Ukraine have been shielded to a large extent by their weak currencies, bringing in good returns from their dollar-traded commodity exports. But even amid the weak euro, European grain producers are disappointed with current returns, likewise their US, Australian and Canadian counterparts. While the large stocks will provide a buffer for one or two years going forward, growing markets will need a larger supply down the road. But the direction in which prices are pointing suggests that production gains will be increasingly coming from the weaker currency areas – Lat-Am and CIS countries while the US and other Northern hemisphere suppliers may have to think about reducing their contributions.

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Yet more wheat The USDA’s world wheat crop estimate has gone up by almost 4m tonnes in the last month and the International Grains Council’s by 7m- both now around 730m tonne mark. Increases have been made for the USA, Europe, Russia and Australia. In recent weeks, the European picture has been slightly less optimistic with rain damaging the French crop – yields as well as quality. Some closely followed analysts looking for a drop of about 1.5m to 2m tonnes to trim the EU total which the USDA has at 157.5m versus year’s record 160m and the IGC’s 154.6m (including 145.7m common wheat and just under 9m durum). Against that, a new government estimate has raised US planted area to 50.8m from the March planting intentions report’s 49.6m, implying about 1.3m tonnes to add to the last USDA forecast of 56.5m tonnes. Private and government analysts in Russia have meanwhile been talking the coming crop up as high as 65m tonnes, which would be a post-Soviet era record and 1m to 2m over the USDA and IGC forecasts respectively. In contrast, Canada’s official estimate of planted wheat area was updated in late June to show a 9 percent fall in spring wheat plantings offset by a 5 percent increase in durum. That’s a bit lower than the markets expected and may require some trimming of crops estimates currently around 28.5/29.5m from USDA & the IGC respectively. Australia’s crop meanwhile seems on course for at least the 25/25.5m tonnes seen by these two bodies – which would be among its larger crops of the past decade. However, dependent upon exports for 70 percent of their crop disposals, Australian growers are reported to be concerned about the global price fall and could consider cutting back planting next season, according to some observers. But in response to recent trade liberalisations under its new government, Argentina is expected to give a big boost to wheat sowings, expanding the crop by 3m to 5m tonnes, consolidating its return to the fold as one of the world’s largest wheat exporting countries. The USA’s June count of domestic wheat stocks meanwhile turned out a bit larger than expected – a 29-year high of over 27m tonnes and about 30 percent up on last year’s. With EU starting stocks of wheat also estimated to have risen by 35.5 percent on the year and world total stocks in total running at 36 percent of consumption needs, it is easy to see why wheat prices are cracking again. Another bearish figure highlighted by the IGC is the volume of stocks held by the major exporting countries. This is estimated to have grown from 54m tonnes two years ago to almost 68m and is expected to rise again to 72m by the close of the new season that started on July 1. Lack of consumption growth is another part of the bear story for wheat. The IGC has 2016/17 off-take rising by a mere 1m tonnes or 0.1 percent as increased demand from the food sector is offset by lower feed use - livestock producers using more of an expected bigger maize harvest. The one, relatively, firm spot in the wheat market is better quality wheat, able to command bigger and bigger premiums as milling crops in the US, Western Europe and the CIS encounter wet harvest weather. In the past few weeks, premiums demanded 84 84 | |August August2016 2016- -Milling Millingand andGrain Grain

for better quality (12.5 percent protein) over ordinary hard red winter wheat – the USA’s main export grade - have rocketed from around $9 to almost $30 per tonne on fob terms, if still quoted a lot cheaper than a few months ago. Although it started well, the usually high quality US spring wheat crop has seen its condition deteriorate amid dry weather recently, driving export fob prices for this class of wheat up recently, abeit from some of their cheapest levels of the last decade. In Europe, reports of lower proteins in the rain-affected French wheat crop, Europe’s largest, have been turning demand increasingly toward German wheat – not unaffected by the bad weather but probably mostly escaping the worst of its own rain interruptions. That in turn has been driving up German price premiums. The quality issue is also affecting EU export trade, with recent import tenders tending to favour either wheat from Germany or the unaffected Baltic States, able to offer better quality and more competitive prices. Thanks to better results this year in Hungary, Rumania, Bulgaria

and Spain, the overall EU wheat crop will still be relatively large at around 157m tonnes but along with currency weakness, the concerns about quality are expected to keep prices firm at the top end. Maize crop set for recovery Maize prices have recently dropped to near two year lows on the CBOT futures market after the USDA estimated US sown area at 94.1m acres - the third largest in 72 years and 500,000 over the Department’s March forecast. Markets had actually been expecting a reduction of 1m to 2m acres based on uncooperative sowing weather and a steep rise in new-crop prices of soyabeans – which can be sown later than maize. Based on the old figure of 93.6m sown acres, USDA had

expected trend yields to extrapolate into a 366.5m tonne crop versus last year’s 345.5m. An extra 5.3 percent of land would equate to a crop closer to 386m tonnes, easily beating any previous record. Piling on the pressure the USDA also estimated June 1 US maize stocks at a larger than expected 120m tonnes, their largest since 1988. That suggests the USDA’s already comfortable stock forecast for the start of the new season in September (43.4m tonnes) can also be uprated. While the Brazilian crop has turned out far smaller than expected (see table 1) world total maize production this season has continued to run neck and neck with consumption so drawdown of the comfortable global stocks carried in from 2014/15 will be minimal. For the season ahead, the combination of resurgent production and still large carryovers will mean total supply increases by about 2.6 percent or some 31m tonnes. Maize consumption is, as mentioned above, expected to grow far more rapidly than that of wheat in the more abundantly supplied – and cheaper – season ahead. The current USDA forecast expects it to grow by 45m tonnes, the IGC by 30m. Even than, world stocks carried out of the new season (in September 2017) are seen holding fairly steady, extending the period of comfortable supply. The main uncertainty on that front is a potential heatwave for the US crop in the July/Sep period as the El Nino weather phenomenon flips over a La Nina effect. Even then, the long-


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86 86 | |August August2016 2016- -Milling Millingand andGrain Grain

range forecast is for adequate rains in that period which should help reduce heat stress – and the crop has already got well into its crucial pollination period under the desired mild conditions. Further forward we can expected maize production to increase in Argentina as the trade and currency liberalisations introduced by the new Macri government earlier this year pay dividends in higher [planted areas. Brazil’s government is also looking at incentives to swing more land into maize crops, which have taken second place in recent years to everexpanding soyabeans. Nearer term, expect larger crops in the CIS countries to find their way onto export markets, before long, including top customer Europe; where the cheap coarse grain imports will continue to provide competition for locally produced and imported feedwheat. As the futures markets currently suggest, there is not much on the horizon to upset this ongoing picture of plentiful maize, with the usual caveat - normal, summer weather permitting. Protein price surge led by meal-rich soya Soya meal prices have seen a spectacular surge in second quarter 2016 – in US$ terms, monthly averages have risen by about 35 percent from March to June. The root cause has been the unexpected loss to floods of a least 2m tonnes Argentine and perhaps 3m of Brazilian production to flood and droughts respectively. That has led to world output actually declining by about 6.5m tonnes this season. While significant, the magnitude of this loss does seem to have invoked an over-reaction on the markets, helped by the usual culprits, the speculative funds. The current season did, after all, start with surplus stocks of 78m tonnes – 16m more than the year before, putting overall supply at 391.6m tonnes or 10m more than in 2014/15. Even with global crush rising by 16m tonnes, this still leaves soyabean ending stocks at a hefty 72m tonnes- which is hardly tight. In the immediate period before our press deadline, the markets seem to be gaining more of a sense of proportion with the CBOT futures reining back quite sharply from their near two-year highs. The reversal has been encouraged by the USDA raising its US planted area estimate from 82.2m to 83.7m acres, equating to a (potential) extra 2m tonnes or so of soyabean output. The USDA also estimated June stocks higher than the markets expected. Finally, the delayed South American harvests have accelerated and should now provide stiffer competition to US bean and meal exports, implying room for some price trimming. Further forward, the Latin American crops sown this autumn are expected by the USDA to expand by about 6m or 7m tonnes, contributing to an approximate 10m tonnes increase in global soyabean output. Other oilseed supplies will grow more slowly. European and Canadian rapeseed crops not far off last year’s levels suggest not much change in global supplies of the second most importat contributor to world oilmeal production. Sunflower supplies may expand by about 3m tonnes or 8 percent, however, with bigger European, Ukrainian, Russian and Argentine crops while cottonseed supplies are also expected to rise. Overall, oilmeal supplies should be large enough to cope with the coming season’s expected 10m or 3.2 percent increase in global consumption without further price rises and, as soya markets settle down, hopefully some reduction in costs.

Industry events The future of pig finishing


n 13-16 September 2016

SPACE 2016 Parc-Expo Of Rennes Airport La Haie Gautrais 35170 Bruz France

n 20-22 September 2016

Global Grain South America Buenos Aires, Argentina

n 27-28 September 2016

Summit 2016 – The Future of Farm Certification Damrak 243, 1012 Amsterdam, Netherlands

n 08-11 October 2016

International Baking Industry Exposition Las Vegas Convention Center, Las Vegas, NV, USA

n 19-21 October 2016

FIGAP 2016 Expo Guadalajara, Caballo Arete, Guadalajara, Mexico

n 19-21 October 2016

Vietstock 2016 Expo and Forum Saigon Exhibition & Convention Center (SECC), Ho Chi Minh City, Vietnam

n 24-27 October 2016

IAOM MEA Millennium Hall, Airport Road, Addis Ababa, Ethiopia

n 04-06 November 2016

CICFOGRAIN2016, CICFOFEED2016, CGOF2016 No. 50, GanJiang South Road, Honggutan New District, Nanchang, Jiangxi Province, China

n 09-10 November 2016

JTIC Paris Event Center 20 Avenue De La Porte De La Villette 75019 Paris - France

n 15-18 November 2016 EuroTier Messe Hannover, Germany

n 13-14 December 2016

Biomass Handling, Feeding and Storage Kent, UK


he way in which pigs are kept is no longer the focus of pig farmers alone. Increasingly, society in general is calling for more say in how animals are produced and the environment protected. In many countries, this has already resulted in policies being introduced to influence housing systems. But, how can we create enough confidence in the pig sector to encourage the investment required to improve existing housing and develop animal production systems that take into account these new environmental and animal welfare objectives? These questions will be answered at this year’s EuroTier special feature targeted at the pig industry. “The future of pig finishing”, organised by the DLG (German Agricultural Society) together with Bauförderung Landwirtschaft (BFL), follows on from previous specials examining novel ideas for the group housing of sows (2010), the management of farrowing sows (2012) and the care of piglets (2014). Future investment in the sector is likely to be mainly directed towards the optimisation of existing buildings, although there will also be money spent on new facilities and/or alternative housing systems. Another issue that is becoming increasingly important is the search for alternative marketing opportunities for pigs. This is not only driven by the poor current financial returns, but also the ending of castration without anesthesia, which will require alternative production methods to be adopted. Among the issues that will be highlighted in the ‘The future of pig finishing’ special feature are: • The management of different husbandry concepts • Combining different floor coverings and slats • Air-conditioning of pig housing • Managing animal and public health • Feeding concepts for pigs • Managing pigs with intact tails • Alternatives to castration without anesthesia • Alternative marketing channels for fattening pigs • Communicating with consumers • Data management and networking for pig production The EuroTier special feature will be closely integrated with, and sited near to the venue of, this year’s Pig Forum presentations. And independent consultants, as well as professional pig stockmen, will be present at the Special to answer visitors’ questions and discuss the topics being presented. EuroTier 2016 will take place at Hanover’s Fair Grounds from 15-18 November.

THE EVENT REGISTER Get comprehensive event information with our events register Visit for more information

88 | August 2016 - Milling and Grain

Industry events

7th GrainTech India 2016

- all set to break records with the latest machinery launches on the cards 7th GrainTech India 2016 is all set to break its past records. The organisers, Media Today Group, are very optimistic about the success of the event because despite a slowdown in the exhibition industry, GrainTech India has been growing in terms of size, participants and visitors. This year, the event will be held from 26-28 August at BIEC, Bangalore, India.

High demand for Grain Milling Technologies

As per trade sources, India wastes huge amounts of food grains every year, due to weaknesses in storage systems, techniques and deficiencies in the supply chain. It is unfortunate in a country where a sizeable section of the population goes to bed hungry. The need of the hour is to increase productivity of grains and build an effective supply chain to ensure that what is produced in the farm reaches the consumer in good shape requiring the use of effective available technology and modern storage systems to be built.

Meeting ground for entire grain milling industry

When GrainTech India was launched in 2010, along with India Foodex series, there was no professional platform for flour milling, rice milling, feed milling and allied interests. The industry required a common platform that could facilitate the exchange of ideas, knowledge, technologies, and machinery in the sector. S Jafar Naqvi, Chief Coordinator, GrainTech India, said “Looking at these shortcomings of the grain industry, we decided to launch GrainTech India in 2010. Since then this platform has brought together the machinery manufacturers, flour mill owners, rice millers, feed plants and pulses mill owners. It has now become the proven most prominent annual meeting ground for the whole grain milling industry for the sourcing of equipment, accessories, and taking decisions on the set up of new automated plants in India.” India has over 5000 Rice mills, 1200 Flour milling plants in organised sector apart from over 2000 in small scale, 200 Soybean plants, 2000 Spices crushing plants, 2000 Pulses mills, 2000 Oilseeds crushing units, 1000 Feed Units, 100 Bio-fuel and energy projects, 1000 Coffee plants etc., which are looking for new and better technology to upgrade their manufacturing, processing, packaging line. GrainTech India is aimed at reducing the technological gap existing in processing and supply chain. Greater use of modern machinery is now prerequisite in India, where plenty of produce is available for value addition and food processing, but due to inadequate exposure to high technology & inputs, a large chunk of the produce is wasted. As a result, India is emerging as one of the hottest destinations not only for Food Processing and Packaging Machinery & Equipment imports from European and South East Asian Countries, but also for Agro-Food products from international suppliers.

Quality conscious consumer

The noodles and bread episodes in the recent past, proved to be a blessing in disguise. The Indian consumer is now more quality conscious than ever before and is demanding nothing less than the best. To feed increasing domestic demand and also to achieve the export targets of food products, Ministry of Agriculture & Farmers’ Welfare, Ministry of Food Processing Industry and Agricultural and Processed Food Products Export Development Authority (APEDA) under the Ministry of Commerce are investing a substantial share of the budget to promote technological up-gradation and value addition in all 90 | August 2016 - Milling and Grain

segments of rice, wheat, pulses, oilseeds, spices, dairy & feed, and all other food sectors. The event will join hands with the government to support its efforts.

GrainTech India- the ideal platform for your products

GrainTech India is proven to be the ideal platform for launching your latest grain milling, processing and packaging, storage, and supply chain technologies. The event series have been aimed at facilitating interactions among producers, retailers, importers, and exporters of agricultural, dairy, and food products Buhler India, the largest grain milling and food processing machinery manufacturer, has confirmed the launching of innovative range of machines. Flourtech, Selis, Ortas Milling, Agaram, Buhler India, Unormac, Pingle, and Shri Vishwakarma have increased their display area by almost 50 percent and promise to engage the trade visitors with latest technologies and machinery. New product launches are also planned by Zaccaria (Brazil), Keplerweber (Brazil) & Delta Technologies Corporation (USA) through M. K. Associates, Bangalore; and Kuraray India will represent their Japanese principals. In order to promote holistic growth of the grain industry, the event has concurrent shows for the agriculture, feed and dairy, and food sectors – 8th AgriTech India, 8th India Foodex, and 6th DairyTech India. The latest addition to the series is India CropCare & Fertilizer Show (ICCF).

International Scope and Participation

Based on spectacular success in the past, the expo has become India’s largest agri-food and business platform, where 50 percent of displayed products are from overseas markets. 7th AgriTech India had witnessed the participation of almost 30 countries. The focus countries were the Netherlands, Turkey, Canada, Italy, Germany, Taiwan and China. Canada was a new entrant in the event; Taiwan’s participation was on a larger scale; and Turkey and China continued to be the major participants. The event series have helped in not only creating awareness, but even in promoting global agribusiness. “Foreign companies, manufacturing agricultural machinery and processing equipment, view India as a potential market, since interest in farm mechanisation, automation and on-site value addition have already escalated in India”, said Naqvi.

Strengthening ‘Make in India’ dream

Naqvi further added, “We hope that it will be a rewarding experience for the exhibitors as well as visitors. The event will certainly help in establishing India in the global market and strengthen the “Make in India” dream envisaged by the Government of India”. 7th AgriTech India series was a huge success. There were a record number of over 379 exhibitors and 37000 trade visitors. This year too, for 8th AgriTech India, companies from China, Korea, Taiwan, Japan, Canada, Holland, Germany, Turkey and many more have already confirmed their participation.

13 16 SEPT.

Rennes - France

SPACE: the Expo that offers a complete range of products and services for all sectors: cattle (dairy, beef), swine, poultry, sheep and rabbits:

More than 1.400 exhibitors in 11 halls and in the outdoor exhibit space. More than 106.000 trade visitors expected, including, more than 15.000 international visitors.


More than 700 animals on show. A net exhibit area of more than 156.000 m2. More than 370 journalists, including 87 international journalists. Tel. +33 223 48 28 80 - rennes




Aisha Feroza, Project Executive and organizer of IndoLivestock 2016 The organisers says that following some difficult years for the livestock industry in Indonesia, this year is proving to be a recovery year and one in which aquaculture is leading the way. The focus of IndoLivestock 2016 on fisheries and aquaculture in particular is reflected in the Thailand Pavilion primarily promoting its aquatic industries. “Fisheries and aquaculture have seen an increase this year, we are now much stronger in these areas than before,” says Oza Feronza , one of the organisers of this year’s event. “The Thai stand indicates that this is a growing sector and we also have The Ministry of Seas exhibiting in Hall B and the Minister himself will be attending.” Overall, this year’s IndoLivestock is significantly increased over last year, she adds. 92 | August 2016 - Milling and Grain

Sebastian Geers, of the sales department at Awila Anlagenbau GmbH, Lastrup, Germany Awila is over 100 years old and is based in the north of Germany in a city called Lastrup. “Our basic service is offering the planning and realisation of turnkey feed plants, ranging from five-tonnes-perhour up to 100-tonnes-per-hour,” says Sebastian Geers of Awila. In this case, at IndoLivestock 2016, for cattle, poultry and fish feed plants with information about in wood pelleting and biogas plants. In Indonesia the company has a joint turnkey project for a complete distribution system and some smaller five-tonne-per-hour capacity feedmills that it has assisted with over the past three or four years. we have tried to get into this market in the past three years. We want to meet our existing customers and many that we are in contact with so we can speaker to them and form relationships with them.

Dr Franz-Peter Rebafka from GePro Geflügel-Protein Vertriebsgesellschaft mbH & Co. KG, Diepholz, Germany Germany is approved to export products to Indonesia. “We have a huge list of animal proteins, particularly from poultry by-products, for local aquaculture industry use. We also have pellet binders, protein concentrates and bloodmeal products for the aqua industry here,” he says Our high-ash meat-and-bone meal from poultry and regular poultry meal are both approved worldwide for use in aqua feeds Our aim is not only providing proteins but aim to make formulations even cheaper by replacing fishmeal with specific animal proteins. This gives another benefit to the local industry of using our type of products. The Gepro stand at IndoLivestock 2016 is firmly focusing on aquafeed. “We can only use our products in petfoods and in aquaculture feeds. This is an EU regulation and in third countries we have to follow their regulations as well”. “The potential here is huge. “I’ve a figure - one million tonnes of animal proteins are needed and GePro can only supply a small share of this. If the whole world’s production were to supply Indonesia there would still not be enough to meet their demand!”

Alexandro, Export manager of La Meccanica from Italy La Meccanica of Italy expanding into Indonesia Alexandro is the export and business development mange for La Meccanica in South East Asia and is at IndoLivestockk too introduce his company’s products to the market and being the process of establishing a permanent presence in the country. “We promote our products and in particular our pellet mills and spare parts, such as dies and rolls, throughout this region. “We have crumbles, hammer mills, vacuums coaters and much more besides. All these products are interesting to feedmillers in this region today and particularly for poultry feed producers. “In this country people eat a lot of poultry, fish and some beef and for these reasons we have prepared a marketing communication oriented to this market, he says. When asked how long his company has been in Indonesia he replied saying, “We are looking for partner in Asia. We have sold machines but it happened because the customer came to us via our website. That’s how they heard about us. We need to create a commercial organisation in South East Asia and this is our intent over the next two years. In the first instance the company will be focusing on pelleting as “This is one of our main products, and probably the best quality in the market today,” he concludes.

Marco Prati of PLP Liquid Systems in Italy Great potential seen by PLP Liquid Systems in Italy Marco Prati is the owner and marketing director for the company PLP Liquid Systems from Italy which he says is worldwide sales operations in South America, Africa, Europe and parts of Asia. “Our core business is liquid application and the application of micro powers. We work for different sectors such as feed, aqua and food. “Our main markets in Asia include countries such as Thailand, The Philippines, Taiwan, etc, and we participating at this show to find and introduce ourselves in the Indonesian market.” At the moment the company is not active in Indonesia and is looking to appoint a full-time agent and/or distributor to support tits expansion into the market. “This is what we are focusing on,” he adds. “We produce different type of coating operations for pelleted, extruded and other types of feed for the different products that need to be applied - and for different type of species. The company provides handling and applications systems for fats and oils, molasses and enzymes. “We think this region has great potential - more than 250 million people and still growing. We think this should be a good potential market for us in the future.

Aria Kilic of the Sales Department at Agacli Automotive Gida Tic of Merkez Aksaray, Turkey Agacli Automotive Gida brings in the best silos Aria Kilic represented the Turkish company of Agacli Automotive Gida Tic which manufacturers silos for the feed industry. “We are not a new company but we have a new factory and we wish to serve the silo business.” Mr Kilic says the company wants to build on its domestic reputation throughout Asia. “That’s why we want to be known for our quality. For example, we are using 600g galvanised steel while most in the industry use 350-450g for feed bins between three and 50 tonnes. Our company has a mission to serve quality and the best service in the world and we have a strong brand in Turkey “Because our owner is a well-known political person in Turkey it’s important that we do not harm the company’s name through poor quality products,” he says. “This is our first time in Indonesia as our factory was only established last year. We will be exhibiting in other exhibitions in future. Silos are a very important product for the feed industry. Indonesia is a very big country and the industry is buying its silos from China. With our quality we believe that this should be a good market for us. Milling and Grain - August 2016 | 93

Paul Eijmberts, Area Sales Manager, Ottevanger Milling Engineers, The Netherlands Mills in a container from Ottevanger Milling Engineers Ottevanger Milling Engineers is Dutch based and has been active for 110 years in milling and the feed milling industries and has expertise in designing mills for animal feed production. We have widened our scope into fish feed production including sinking and floating feeds, into petfoods and premix and also cereal processing. Now a days we have moved into bio-mass production, making wood pellets for high-capacity power plants as well, says Paul Eijmberts, Area Sales Manager for Ottevanger. “This is the scope of our activities and we can supply single machines, to process lines to complete turnkey projects where necessary. “What makes OME unique is we also manufacture containerised, modular feedmills. This is a concept that starts at one tonne per hour and goes up to 45 tonnes per hour and in this range we can make very compact mills with all the equipment inside container frames which can be shipped as containers and certified by Lloyds as being contains. They also meet billing codes and we use the same work for the construction for the mills towers, etc,” he adds. The advantage of containerised feedmills are the short billing times, they are pre-tested before export, they contain steel structures, the civil work is done and there are saving by not having to hire people for erection and erection time is shorter - rather than months this takes just weeks. “Customers needing this type of plant, ones that can be built very fast, the fact that it is modular creates the possibility that it can be expanded at a later date in a very easy way to meet future requirements. These mills can produce premixes, animal feeds and a range of aquatic feeds with extrusion inside.” Ottevanger is part of the Triott Group that includes Wynveen International for complete feedmills, Inteqnion for process control, TSC for silo construction, PTN for pelleting technology and for extruders and expanders. "This is how we as a group of companies can take care of turnkey projects. “In Indonesia we focus on the name of Ottevanger as we have several projects supplied here with good success and we take care of our brand in the market and serve market in best possible way. “We are a one-stop-shop for customers with one door to knock on and we can arrange everything that is required.” 94 | August 2016 - Milling and Grain

David Bloom, manager of Hanpel Tech of Gyeonggindo in Korea Hanpel was established some 20 years ago in 1993 to produce a pellet binder based on gelatin derived from animal and fish bones and skins. It produces three product lines; for aquatic feeds and for pelleted feeds including poultry. “In the case of the Indonesian market there is a pelleting issue so we have to avoid using skins and bones from swine in this market,” says David Bloom, manager of Hanpel Tech of Gyeonggindo in Kore. “Gelatin is very stable in the water. For instance, I put a samples in bins for testing at the start of the show. Those without gelatin show that water pollution form quite quickly over a day while those in water containing gelatin is very clear after one day. The water is clean with no chance of encouraging diseases,” he says. “We are looking for a distributor here. We are the only manufacturer producing a gelatin binder in Korea,” he adds.

Susmarsongko Budi Prassetyo of Frontec Agritama Engineering in Sidoarjo Java Timur, Indonesia “Our company was established in 2008 and we provide complete feed milling equipment plus transport equipment for grain processing. We are very traditional working in silos but with a limited number of customers. Now we are working in the whole feed milling area and produce machines to service the industry such as cleaning, drying, transportation and grain handling systems. We co-operate with Obiol in selling silos and with Chinese companies for our conveyor system. Our factory is in East Java. “Because grain handling and transportation is still limited and Indonesia has a small feed industry, Frontec is a pioneer as an Indonesianowed company in this industry. All our competitors are foreign companies whereas we are local,” he adds.

Milling and Grain - August 2016 | 95

Damien Shapelier (centre), a FrenchBrazilian, and the new general manager for PT Bühler in Indonesia with Windy Lim and colleague From grain logistics to aqua feeds at PT Bühler Indonesia, Jakarta, Indonesia “IndoLivestock 2016 is important as we are assimilated with large scale projects here,” explains Damien Shapelier who has been PT Bühler’s general manager for six months, “but that’s not only the case anymore.” He says his company is now focused on the sale of dies for pellet mills and spare-part refurbishment as well as servicing customers through a local Indonesia workshop located in Surabaya. “We have a service technician, which is part of the sales package for single equipment. Customers are buying equipment, such as cleaners, hammer mills, pellet mills and so on which are important to us.” He says refurbishments include work to increases existing mill capacities as well as large-scale, silos and new feedmills. “That’s our target at this fair.” In Indonesia Bühler is strong in grain milling and grain logistics as there is a lot of new infrastructure in the country. “We are focused not only on feed and new facilities but in grain logistics and together with our colleagues and partners from Symaga Silos in Spain in grain storage. “We also service chocolate and cocoa production as Indonesia is one of the largest cocoa growers in the world and we have other divisions providing equipment for these industries such as die casting, grinding and dispersion, pigments, optics and glass coating as well as packaging to Indonesia. This is the first time the company displayed grain storage and processing the local production of grain drying for both large and small projects. Windy Lim, Bühler’s regional marketing manager for South East Asia and the Pacific, says the focus of the stand at IndoLivestock 2016, “is to further strengthen our participation in Indonesia and show our customers our commitment to aquafeed as well. “We are working together with industry partners not just in poultry but also in aquaculture.” Both Damien and Windy agree that the demand for aqua feeds in the next few years will grow and that it is a trend that will continue. 96 | August 2016 - Milling and Grain

Sedat Demirbas, purchasing manager now responsible for foreign trade (both export and import) with Altinbilek of Turkey “Indonesia has some 250 million people and is the biggest Muslim country in the world. We in Turkey share some things with Indonesian people and if you focus on the market it is a perfect environment for us,” says Sedat Demirbas, Altinbilek’s purchasing manager. “Indonesia is the best market in our sector, and for our products.” This is a great show it just needs to be promoted more widely. This is our first time here, he adds. Traditionally, Altinbilek is a silo and conveying company with over 40 years experience, but today it is representing a group of companies that have opened new divisions. “We now have feedmilling and feed processing in the group. We can provide turnkey projects for our customers. And we like to work with our competitors as well as directly with customers. We work well in the middle - with highquality products that promote our name in the market. If you focus on quality you protect your name and supply something good for your customers,” he concludes.

Channing Ke, international business manager with Zhanjiang Hengrun Machinery Company, China Hengrun is a feed machinery from south China. “Aquafeed equipment is our main product plus machines for processing poultry feeds. We produce, extrusion, drying and cooling systems. Our factory was original set up over 40 years ago and we have been producing aquafeed processing machinery for over 10 years. “We want to expand into the international market and Indonesia is an important market – we are here to meet customers, discuss proposals and hopefully enter into relationships with new customers. “I think there is big potential in Indo market – the country has a big population, a high demand for food and needs professional manufacturers of aquafeed equipment and we are specialised in this area. We have many very important customers in China for many years. We focus on these top level customers and help in their development.” The company’s major markets are South East Asia and Middle East - Egypt, Saudi Arabia and Sudan and Libya, etc and in China.

Tuti Tan live from IndoLivestock 2016 in Jakarta where she distributed both Milling and Grain and International Aquafeed magazines, manned the Perendale stand, ran an extensive Twitter report through the Global Miller blog site and completed this report Follow our next show report


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the interview

Shawn Thiele

Shawn Thiele was a graduate of the Milling Science and Management program with the Grain Science and Industry department at Kansas State University (KSU). After graduating from KSU, he spent the first eight years of his career working for Quaker Oats in Cedar Rapids, Iowa. His time with Quaker Oats was spent managing the operations and process improvement projects for the world’s largest oat mill, as well as a white and yellow corn mill, oat flour operations, and instant grit operations. In 2012, he moved back to Manhattan, Kansas to take the Milling Operations Manager role with the Department of Grain Science and Industry. He spent four years at KSU managing the Hal Ross flourmill and milling labs, teaching advanced undergraduate milling classes and labs, assisting with research activities utilising the school milling equipment, and teaching flour milling short courses at the IGP Institute. His past experience with both industry and the university has helped to transition him into his current role as the flour milling and grain processing curriculum manager.

You have been with KSU for a number of years, and worked in the industry for a long time before that. During your time, have there been many major changes in the industry and the way training is done?

The industry continues to see changes and is faced with new challenges every year. I feel some of the biggest changes are around consumer awareness of food safety and quality resulting in more rigorous food regulations, company consolidation, staying updated with new technology but still profitable, and a large retiring workforce in the next 10 years. Just as the industry is changing, training also needs to adapt to best resemble the policies and practices that industry is required to meet increasing quality and safety issues both with food and employees.

You have said you “hope to strengthen and expand the IGP Institute’s milling and processing courses through new and innovative teaching materials to provoke learning for participants and vest interest from the industry to energise the consumption of US grains worldwide.” What sort of new teaching materials or methods do you aim to use? And how do you envisage increasing industry interest? Continuous updating of teaching materials to stay current with the changing industry is required in order to be successful as an educational provider. This is done by not only delivering accurate information, but creating a course and material that is exciting and interactive among participants. Eye catching lecture material and more hands on training in the school mill and labs is critical to information retention and keeping the interest of the students. Student engagement through classroom and lab discussion and questions is also key to creating a productive and fun learning environment. I believe the success of a training course is directly related to the impact it provides for the industry. Companies invest ample amounts of money to send employees to the IGP Institute for training with the expectation of seeing a positive return on their investment. Effective training enables participants to practice what they have learned and showcase their newly acquired skills and knowledge at their place of work. Employees performing at a higher level drive positive results within a company. Investing in professional development has shown to be very valuable for organisations through increased motivation and improvements in productivity.

102 | August 2016 - Milling and Grain

According to the IGP website, last year the Institute conducted 61 courses for nearly 1500 participants from 51 countries and you expect this to increase in the future. Which regions do these students tend to come from? Why do you think that is and what could be done to attract students from other areas?

Individuals come from all over the world and those particular regions change depending on the economic climate. We would like to attract participants from other countries, especially developing markets, but marketing to those individuals poses a challenge.

According to statistics, fewer young people are studying at agricultural schools. The IGP Institute’s own increase in students notwithstanding, globally, might there be a similar drop off in the numbers of milling students? If so, how can this be remedied? Currently every industry is suffering from an increasing workforce age and impact of retirement for baby boomers now and in the next decade. The grain and milling industry is no exception and will likely see a vast loss of experienced people that will have to be replaced by the younger generations. This is, and will continue to create an immense need for continued education to help fill the gap of lost knowledge and experience from the retiring workforce.

Why do you think it is that the Institute is so highly regarded and attracts so many students?

An organisation is only as good as the people that drive it and the IGP Institute and the department of Grain Science and Industry at KSU has a talented and motivated team to lead courses and train participants. The IGP Institute offers courses in areas of flour milling and grain processing, grain marketing and risk management, feed manufacturing and grain management, HACCP and food safety, extrusion processing, and pet food manufacturing which reach out to a large audience across the world. Not only does the IGP Institute offer on-campus trainings, but also faculty led customised on-location workshops and distance education courses. These trainings are led by highly skilled KSU faculty with industry experience and industry professionals who are energetic and motivated about the opportunity to serve, train, and interact with participants to improve the industry and market preference.

PEOPLE THE INDUSTRY FACES Nestlé Board of Directors and Executive Board


t the 150th Annual General Meeting of Nestlé SA on 6 April 2017, Peter Brabeck-Letmathe, Chairman of the Board of Directors, will not stand for re-election in line with the company’s Articles of Association, having reached the mandatory age of retirement.

The Board of Directors has decided to propose Paul Bulcke, Nestlé’s current CEO, for election as Chairman at the next Annual General Meeting on 6 April 2017. In order to prepare for this future role as active, non-executive Chairman and respect a minimum cooling-off period, Mr Bulcke will resign from his present position as CEO on 31 December 2016.

Peter BrabeckWith this reconfirmation of the long-term strategy and the organisational integration in mind, the Board Letmathe today unanimously decided to appoint Ulf Mark Schneider as the new CEO of Nestlé SA, starting on 1 January 2017, and propose him for election to the Board of Directors at the 2017 Annual General Meeting.

Ulf Mark Schneider, 50 years old and a German and US citizen, has been CEO of Fresenius Group since 2003. He is a graduate of the University of St Gallen with both a graduate and a doctoral degree, and also holds a Harvard Business School MBA. In order to ensure a smooth hand-over phase, Mr Schneider will join Nestlé on 1 September 2016 for an introductory period.

Andy Hedgecock Joins FMC Agricultural Solutions as Global Regulatory Affairs Director


MC Corporation has named Andy Hedgecock as Global Regulatory Affairs Director for FMC Agricultural Solutions.

He joins the company this month to lead the worldwide regulatory affairs organisation and key advocacy programs for the crop protection business.

Mr Hedgecock comes to FMC from DuPont Pioneer where he was Director, Scientific Affairs and developed the DuPont Biotechnology Science Council. While at DuPont, he led engagement with Andy Hedgecock scientific organisations including the National Academy of Sciences and also served as an industry responder for GMO Answers, funded by The Council for Biotechnology Information.

Prior to DuPont, Mr Hedgecock worked for Monsanto where he progressed through a series of technical and management positions including Director of US Chemical Regulatory Affairs and Lead for Global Issues Management.

“Andy brings exceptional leadership, scientific and advocacy experience to our Regulatory Affairs organisation,” said Mark Douglas, President, FMC Agricultural Solutions. “A robust regulatory function is essential in today’s highly regulated crop protection business and I believe Andy’s strong industry background and experience makes him the ideal regulatory leader for FMC.”

Mr Hedgecock has a bachelor’s degree in Chemistry and a master’s in Industrial Chemistry from the University of Central Florida and an Executive MBA from Washington University. He serves on the EMBA Alumni Association Board at the John M Olin School of Business at Washington University and is a member of the American Chemical Society.

Diamond V announces new dairy team members


iamond V® welcomes its newest experts to serve dairy producers and the dairy industry: Management and production specialist Matt Bowen and nutritional health researcher Dr Preston Morris.

“Matt is the newest member of our East Ruminant Sales Team,” says Dr Ken Sanderson, District Sales Manager.

Matt Bowen

“He comes to Diamond V from Crop Production Services (CPS), Michigan Division where he held the position of Dairy/Silage Specialist and provided technical support and training for a team of 80 sales people.”

At CPS, Matt’s main responsibility was to grow seed sales with dairy and beef operations, working with leading producers across Michigan. Prior to CPS, he served as an Area Sales Manager for ABS Global, Michigan Division. Matt has Dairy Tech training from Michigan State University and lives in Addison, Michigan.

Preston Morris, DVM joins Diamond V in the role of Dairy Field Research/Technical Support, which includes working closely with field research directors and the company’s R&D team to provide research results on SmartCare® and NutriTek®.

Dr Preston Morris

Preston has a background in ruminant research, including studies ranging from mastitis-causing Escherichia coli bacteria to the effects of various fatty acids on rumen microorganisms. He did graduate work in the Ruminant Nutrition Lab at Clemson University, then he returned to the University of Tennessee where he received his DVM earlier this year. Preston will be based in Cedar City, Utah.

104 | August 2016 - Milling and Grain

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