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Global Milling Advances is a magazine for agriculture professionals worldwide

Issue 13 / November 2015 Bagging systems

Hammer Mill Technology

Paper Bag Innovation

Mining Strength Materials

Premier Tech Chronos

Mondi Effusion Bag

A century of innovation from Dinnissen

Christy & Norris Hammers

Advancements in Mycotoxin Testing

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The world’s top events related to milling from around the world, listed on p. 21

10-2 Minutes reduction in Mycotoxin testing time.

New concepts and rapid testing, reducing the capacity for human error and delivering more consistent results.


Read more on p.15


Innovating the paper bag Read more on page 6

Published by Nisa Media Ltd

Bagging systems for 10-50kg


A century of innovation


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Issue 13 / November 2015 Bagging systems

Premier Tech Chronos

Welcome to the November 2015 issue of Global Milling Advances. This month we take a look at the latest devbelopments in milling technology, including bagging systems, Hammer Mills and Mycotoxin advances. As always we strive to provide relevant and useful information to our professional readership; as such contributor submissions, press releases and feedback on our publications is always welcome.

Paper Bag Innovation Mondi Effusion Bag

Mining Strength Materials Christy & Norris Hammers

Keep up to date with events happening in your industry! Download your copy of our 2015 wall planner today at

Hammer Mill Technology

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Keeping in touch with Global Milling follow us on: Twitter: Linkedin: Scoop it: Pinterest: Facebook:

A century of innovation from Dinnissen The worldâ&#x20AC;&#x2122;s top events related to milling from around the world, listed on p. 21

>> Published by: NISA Media Ltd 14 Clarke Way Cheltenham GL50 4AX United Kingdom > Editorial Manager Nicky Barnes Tel: +44 117 2306494 Email:

> International Marketing Manager Sabby Major Tel: +44 117 2306493 Email: > News Editor Martin Little Email:

Global Milling Advances / November Issue 2015

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enables a wide range of bag sizes to be accommodated. It has a compact design for installation in sites with restricted space, in-built dust control features for clean operation and all through the filling process control of the bag top is retained. The OML-1080 is easy to clean and maintain and can be supplied with integrated nett or gross weighing systems matched to the output requirements of the installation. Different types of bag material can be handled on the OML-1080 and all common types of bag closing system can be integrated into the packer; as can bag turning systems. Closed bag â&#x20AC;&#x2DC;push-offâ&#x20AC;&#x2122; can be either top or bottom first. The OML-1080 is PLC controlled and is supplied with a user-friendly HMI (human machine interface). The in-built diagnostic display provides instructions to the operator for trouble shooting of the various operating functions.

Precision, high-speed bulk material bagging systems Premier Tech Chronos (PTC) has been providing manual, semi-automatic and fully automated solutions for bagging a wide range of materials in the grain and milling industries since 1881. Building on these years of experience PTC is now recognised worldwide for its innovative and customised weighing, bagging, palletising and load securing solutions for various process industries. Premier Tech Chronos has developed a comprehensive range of equipment to meet the specific needs of handling a variety of dry bulk materials found in mills around the world. This includes several innovative open mouth bagging systems to accurately handle most free-flowing materials precisely and at the speeds required by the dry-bulk material sector. As the European Business Unit of Premier Techâ&#x20AC;&#x2122;s Industrial Equipment Group (IEG), PTC is an integral part of the number one worldwide supplier of Industrial Flexible

Global Milling Advances / November Issue 2015

Packaging solutions. The company has a global presence both in terms of countries, and market segments served. PTC is also recognized worldwide for its innovative and customized solutions based on deep technological knowledge and expertise. Some of the latest bagging solutions offered by PTC can be found in the following sections.

> OML-1080 Compact Open-Mouth Bagger The OML-1080 is a compact open-mouth bagging unit that has a packing rate of up to 800 bags/hour. Built with stainless steel contact parts this machine is suitable for bagging free-flowing materials into open-mouth bags. OML-1080 can handle bag sizes 5 to 50kg; and is suitable for products such as grains, flaked materials and some powders. An innovative part of the OML-1080 is an automatic bag spout adjustment facility that

> OML 1140 High-Speed Open-Mouth Bagger The OML 1140 offers high-speed bagging at rates of up to 25 bags/minute (1,500 bags/hour) and features a modular design for optimum versatility and maximum output, whatever the product being bagged. Typically it operates for bag sizes in the range of 5 to 50kg. This innovative and versatile bagging system can be easily used for any application that uses pre-made open-mouth [pillow or gusseted] bags made of paper, plastic or woven polypropylene. The result is a highly effective system for bulk material bagging of animal feed, grain and other free-flowing materials from the milling sector. OML 1140 uses field-proven technologies for continuous reliable bag transfer and it retains total bag control throughout the entire packing process. This ensures high speeds are maintained without compromising the quality and efficiency of the bag closing process. OML 1140 also features a unique bag separating system that can accommodate all types of bag and is designed for quick change-over in less than 5 minutes. Proven in many different installations since

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it was originally introduced to the North-American market in autumn 2006, the OML 1140 has now been adapted to the European and Asian markets and is now available worldwide. Specific features include: fully automatic operation; total bag top control; high speed bagging; empty bag handling for all bag types; advanced control software; easy to clean; simple to adjust.

> PTR-1030 Series â&#x20AC;&#x201C; Robotic Bagger The versatile PTR-1030 Series Open-Mouth Bagger (patent applied for) for European sales was launched in 2014 The innovative open-mouth bagging system can pack dry free-flowing materials at rates of up to 1,000 bags/hour and is suitable for use with a range of bag types and sizes. An upgrade option is also available that allows the PTR-1030 to successfully handle porous woven polypropylene bags. PTC has used its well-proven experience as a certified FANUC Robotics integrator to carefully incorporate two robotic arms into the PTR-1030. One robotic arm handles empty bags to accurately position them on the filling spout; while the second robotic arm removes the filled bag for transfer to the closing system. By separating out these basic operating functions to different robotic arms has enabled PTC to enhance the speed of the PTR-1030, which has also benefited from the proven reliability of the FANUC Robotics, which is an international leader in the manufacturing of intelligent robotic solutions.

bag changeover times, when changing to a different packing schedule, a different product or a different type and, or size. The empty bag handling robot can also be upgraded with a vision system, which realigns the top of the bag during the empty bag placing motion, thereby optimising the bag shape for subsequent bag closing process. All machine contact parts are made of 304 stainless steel and the filled bag transfer robot has been designed for compatibility with all types of bag mouth closing systems. To help ensure a clean filling process the PTR-1030 incorporates a bag-on-spout detection system to avoid any product spillage. The compact design and footprint of the PTR-1030 allows its easy incorporation into sites with limited space and restricted heights. Its robotic operation means it requires less maintenance than conventional baggers and it â&#x20AC;&#x2DC;learnsâ&#x20AC;&#x2122; to make its own optimisation adjustments. The use of smart wiring technology enables simple and speedy on-site installation / commissioning.

Company contact details: Premier Tech Chronos B.V. Meerheide 40 5521 DZ Eersel The Netherlands Tel: +31 (0) 497 514988 Fax: +31 (0) 497 514953 Email: Website:

PTC is able to offer the right bagging solution to meet individual customer requirements. This can be achieved by installing standard equipment, or by working with them to design a customised equipment solution to meet their specific site requirements.

PTR-1030 is the most versatile robotic open-mouth bagging system available to industry. This versatility is achieved by its ability to handle a wide range of bag types and sizes. This includes: gusseted or pillow type open-mouth bags; made from either paper, polyethylene; laminated woven polypropylene; and porous woven polypropylene bags. Bag widths in the range 279 to 610mm; and bag lengths of 457 to 1016mm can be successfully handled. The way the robotic arms are programmed allows the PTR-1030 to provide optimum

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Selecting the right bagging system Configuring a bagging line for a milling operation for 10-50kg depends on various factors Configuring a bagging line for a milling operation depends on various factors.

is basically an interchangeable mill product.

> Open-mouth or valve bags?

> Bagging material

Bagging the end product is a work-intensive processing step in a milling operation. That's why this part of the plant is automated as much as possible. At the same time, the bagging line capacity is directly linked to all of the up- and downstream processes. This demands close coordination of the bagging with the production logistics and the following storage and distribution logistics.

The woven plastic bag and the paper bag have mostly superseded the traditional jute or cotton bag. The paper bag, as a disposal bag, corresponds to today's requirements for sanitation. The extensive cleaning work as well as the removal of bugs and contamination is dispensed with. While Europe, North America and Australia primarily use paper as a packaging material, Latin America, Asia and Africa use woven polypropylene for 10 to 50 kg bags. In addition to just the habits of the end customers, the climate conditions or bags being handed with too little care speak for the use of the inexpensive, woven polypropylene bags.

For small bagging volume and low sanitation requirements, bagging with valve bags is the simpler solution for automated bag placement as well as for no bag closure. In addition to improved sanitation, bagging in open-mouth bags offers more accurate weights, more flexibility in regards to bag size and bulk weight of the product, and easy opening for the end customer. These advantages explain the trend towards bagging in less expensive, open-mouth bags when packaging milling products.

In Europe, North America and Australia, the majority of milling products are filled into trucks as a bulk product. In Latin America, Africa and Asia, bagging into open-mouth or valve bags is predominant. Globally, open-mouth bags are the most widespread, because this is advantageous for packaging milling products. In addition to the simple function of packaging, more and more mills are using flour packaging also as a marketing tool. The surface of the bag, the type of closure and/or the material used permit a company to up-value themselves to a unique and distinctive brand through what

Global Milling Advances / November Issue 2015

The ecological balance, however, is influencing the discussion about packaging material in Europe as well. Since the manufacturing of paper is very energy intensive, the ecological balance of woven plastic bags when correctly recycled is preferred.

> Manual or automated? Selecting a manually operated plant or an automated one depends directly on the product, the local conditions and the size of the operation. For designing a bagging plant, criteria such as bag weight, bag size, bag quality, required bagging volume, closure type and logistics can be considered. Single spout bagging stations are suitable

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for paper, plastics and fabric bags holding 10 to 50 kg. Depending on the type of single spout bagging station, the bagging volume for flour in 25 kg bags is approximately seven bags per minute. For higher bagging volume, bagging machines with multiple spouts can be used. These can also be operated with different kinds of bagging material. If they are operated with woven polypropylene bags, the bag quality must be suitable for automated filling as a prerequisite for high operational safety. The new Bühler bagging station Maia, for bags of 10 to 32 kg, provides a low-energy consumption alternative for bagging milling products. It offers high operational reliability and sanitation for fully automated bagging of powdered, free flowing or friable products.

> Upstream processes Consideration of the upstream elements – such as bins, product feed and weighing – when configuring a bagging plant is important. In many plants, they are the limiting factors for bagging capacity and therefore need to be adjusted to the desired volumes. Properly dimensioning them is also a requirement for a high weight accuracy and for the reproducibility of the bagged product.

low, but needs for personnel and space are high. Flow storage is suitable for the milling industry and is distinguished by its ideal price-performance ratio at higher turnover rates. Pallet storage in the milling industry is done on a first in, first out principle (FIFO principle). High-bay storage provides many functional possibilities with high space utilization and requires preventative maintenance for smooth operation.

> Control of bagging systems

> Downstream processes

A reliable control system guarantees efficient control of the bagging plant. The skills of the operating personnel must also be taken into consideration. Hardware which is resistant to influences such as vibration, dust and temperature is decisive for high reliability.

Expanding bagging plants with direct loading for bags onto trucks using palettes increases productivity since the bagged goods can be provisionally kept in pallet storage. This increases bagging line productivity because downtime for the bagging plant is decreased. Pallet storage additionally supplements storage capacity for finished products in the storage silos.

With an integrated control system, all processing units can be centrally controlled from the bagging bins to the finished palettes. The module permits flexible and user-friendly plant operation: It includes the bin discharge and product feed, all scales, including the filling of them, the bagging stations and bag sealing as well as bag transport and palletizers.

Pallet storage is an advantage for very low logistic costs and generous space allotment, or as a preparation zone for loading pallets. Shelf storage allows every pallet to be accessed. Costs for storage installations are

Bag closing systems for open-mouth bags For closing open-mouth bags, sealing, gluing, sewing or combined systems can be used. Depending on the bag material, bagging volume and degree of automation,

Higher productivity by reduced personnel costs, traceability and availability of product as well as permanent inventory options are increasingly important.

Global Milling Advances / November Issue 2015

different systems for manually or automatically sewing the filled bags closed may be used. For sealing bags with pre-applied adhesive (pinch bags), no consumables are needed and the bag feed must be very secure. Bag closures using hot seal are very user friendly (tear strips, sealing ribbons) and suitable for conventional open-mouth bags.

> Summary The proper design of an automated bagging plant for milling products in the 10 to 50 kg range requires competent advising. Questions such as bagging volume, discharging elements, weighing systems, bag types, bag sealing options, palletizing, storage logistics, etc. are decisive in the planning, but so are considerations of the up- and downstream process steps as well. Customers should also increasingly be able to include the desired bag volume per shift or day in their decision instead of a short-term volume per minute. Very close coordination of the bagging with the production logistics and the following storage and distribution logistics can only be made possible through a long-lasting, complete solution. >> For more information: Bühler AG Switzerland Web:

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Innovating the paper bag In recent years, Mondi has made major efforts in innovation. That has led to more reliable bags for the food industry, with reduced environmental impact and attractive added-value features. One of the key drivers behind this continuous innovation process is the fact that Mondi is a fully integrated supplier. All steps involved in producing an improved paper bag can be handled in close collaboration between paper mills and bag converting plants.

> Initial steps towards innovation Generally, the first step towards an improved industrial paper bag is to develop new or improved grades of sack kraft paper. As part of R&D activities at Mondi’s R&D Innovation Centre in Frantschach, Austria, kraft paper and industrial bag team members analyse and assess existing and proposed materials, including kraft pulp, with a view to

Global Milling Advances / November Issue 2015

>> In recent years, Mondi has made major efforts in innovation. That has led to more reliable bags for the food industry, with reduced environmental impact and attractive added-value features. One of the key drivers behind this continuous innovation process is the fact that Mondi is a fully integrated supplier. All steps involved in producing an improved paper bag can be handled in close collaboration between paper mills and bag converting plants.

improving paper strength, de-aeration properties and mechanical qualities of paper and bags. These R&D activities are often oriented to achieving steady improvement, with the overall goal of taking industrial bag solutions to a whole new level. Claudio Fedalto, Deputy COO, Mondi Industrial Bags, points out the importance of co-operation between business segments within the Group: “Being in direct proximity to our sack kraft paper colleagues helps the bag development process, as we can work closely together on each project.” The launch of Mondi’s Advantage Protect sack kraft paper and the recently introduced Splash Bag, a bag developed especially for the needs of the cement and building industry that shows a higher water-resistance than normal paper bags, is just the latest example of this close internal collaboration.

> Rigorous testing The next stage of the development process involves rigorous testing. Application

engineers at Mondi’s Bag Application Centre analyse bag strength, de-aeration properties and behaviour during filling and under different storage conditions. To test bag construction, simulations of specific situations are performed using advanced technology, e.g. a high-speed camera (1,000 images per second) for observing behaviour during drop tests, and a climate chamber for measuring performance under hot, humid or other demanding conditions. In 2014, the Bag Application Centre performed drop tests for around 400 bags, the water vapour transmission rate was assessed for around 300 bags, and over 900 Mega Gurley tests were performed.

> Adding value by listening to the customer Collaborating with customers and listening to feedback is also important. In keeping with the Mondi principle of “In touch every day”, Mondi encourages customers with specific requirements – e.g. a bag needs to be

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developed or adapted – to collaborate closely during the development process. Recent examples include, for example, collaborations with cement producers: one bore fruit in the shape of the world’s first biodegradable industrial bag, the Terra Bag®. Another resulted in the above- mentioned SplashBag, a bag that is resistant to rain for two hours and can withstand moisture ingress for up to 12 hours.

> The benefits of filling expertise Mondi also recognises the importance of having a filling equipment producer in house. It therefore owns Natro Tech, a company near Milan with a 90-year history of designing and building filling systems for granular and powder products. Natro Tech focuses mainly on filling equipment for industrial bags – valve bags as well as open mouth bags. This in-house filling equipment expertise is unique in the industrial bags market and is well received by customers, as Natro Tech’s technicians visit fillers on site to provide input on how to optimise bag construction.

> Emphasis on sustainability Nowadays many food companies have sustainability targets, either regulatory or

voluntary. Suppliers such as Mondi which are fully integrated across the paper and packaging value chain – from the growing of wood and the production of pulp and paper to the conversion of the packaging paper into industrial bags – are well positioned to help their customers meet such targets. Accordingly, Mondi offers a comprehensive range of green solutions, which are optimised to save natural resources and reduce waste and have internationally recognised sustainability certifications. In addition to the above-mentioned innovative products, Mondi has developed a number of important industrial bag innovations suitable for the food industry over the years. Its current industrial bags portfolio includes the following solutions:

+ The Easy Seal valve is an optional feature developed by Mondi that can be applied to any valve bag and adapted to specific customer requirements. Easy Seal employs thermo-media technology to ensure strong, fast and leak-proof valve closure. A special coating on the inside of the valve reacts to uthe heat and pressure generated by ultrasonic welding. Since the coating is non-adhesive, the valve cannot get blocked before the filling process. Therefore, bags

with Easy Seal valves are ideal for high-speed filling processes, as filling and sealing can be carried out with minimum downtime.

+ Mondi’s Effusion Bag combines precise dosing with optimal protection of the filling. Thanks to this innovation, end users can better dose the filled good via a funnel-formed effusion opening. With a few quick hand movements, the opening can easily be formed. The sturdy bag and a handle on the bottom of the bag additionally facilitate a convenient and controlled discharging of the bags' content. The paper bag itself is designed for best product protection and encloses the filling material tightly. By using a PE-free film as a second ply, further protection against humidity and an extended storage life of the filled bags can be achieved. Not only do customers benefit from this innovation, industry experts have also recognised its value in numerous product competitions. Mondi’s Effusion Bag is winner of the Emballissimo Award 2008, the WorldStar Award 2008, and the EUROSAC Grand Prix Sack of the Year 2011.

>> About Mondi Industrial Bags Mondi Industrial Bags, a business segment of Mondi’s Europe & International Division, is the leading international producer of industrial paper bags, selling around 5 billion bags per year. Thanks to its broad range of bag specifications, Mondi Industrial Bags serves major industries including cement and building materials, chemicals, food, feed and seed. The business segment operates a dense sales and service network, the specialised filling equipment department Natro Tech, as well as its Bag Application Centre, where researchers develop and test innovative packaging solutions.

Global Milling Advances / November Issue 2015

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Mining Strength Materials Increasing Service Life of Christy & Norris Hammers by up to 30%

E R & F Turner's flaking mills are possibly the most famous export of the Christy Turner brand family. Over 90% of the machines used by UK cereal giant Weetabix at Burton Latimer & Corby sites are Christy Turner's E R & F Turner Flaking Mills - many offering up decades of service - validating the company's 'Built to Last' reputation. The company's hammer mill brands have an equally rich heritage, built upon over a century and a half of engineering expertise and innovation. Managing Director Chris Jones said: " As OEM supplier for Christy & Norris & Miracle Mill hammer mills, grinders & pulverizers, we are constantly working to improve the machinery we supply and the wear parts that go with them across all our machines.

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. Christy Turner are currently offering customers the opportunity to trial its new Hardox hammer parts. Contact Jeff Cook, Parts & Service Manager on 01473 742325 for more details.

manufacturers of Hardox wear plate, Christy Turner have created a line of superior quality hammers with market-leading longevity. Chris explained: "Hardox has a combination of hardness, impact toughness & yield strength that make it an ideal material for heavy duty hammer mills. The result is even some of our previous wear-optimised hammers can have service life increased by around 30%." While Hardox hammers are now available across the range of Christy & Norris and Miracle Mills machines and replacement parts, Christy Turner continue to work alongside SSAB's Tech

In recent months we have been particularly focused on improving the wear characteristics of our hammers, sometimes referred to as 'beaters', by introducing new materials & profiles. By reviewing new materials & grades proven in the mining industry we are able to offer the best combination of wear resistance and impact strength." Working in partnership with internationally recognised wear-part experts SSAB,

Global Milling Advances / November Issue 2015

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Support and Wear Technology Group, drawing upon a huge amount of data and wear plate expertise. Speaking about the cooperative project, Technical Development Manager at SSAB, Aaron Middleton, said:â&#x20AC;?Life-cycle cost, given by the material cost divided by the service life, has become such an important aspect of material selection for material handling industries, it has driven us to continuously develop harder and tougher Hardox grades that can offer better economy for the end-user. Ranging from a worn sock to 4% of a nationâ&#x20AC;&#x2122;s GDP, the cost of wear on a country-scale is extensive and cooperative projects such as this ensure we are using a higher performing material with an improved life-cycle costâ&#x20AC;?. Chris added: "As part of our continuous development work we want to make sure if new grades become available, which provide even further optimisation, that we are at the cutting edge and can quickly deliver these benefits to our customers. To determine the optimum milling solution we have access to test records and reports from the 1940s to the present day. When combined with the latest advances in technology and materials, it is not surprising that our machines remain market leaders." He added: "We have worked hard to gain an excellent reputation for supplying countries around the world with durable, versatile equipment of the highest standard and we are committed to maintaining this position. Investment in development has a key role to play in us achieving this."

Chris cautioned: "While it may be tempting to go for cheaper replacement parts, you need to take a good look at whether false economy is at play, a bit like buying cheap batteries that last a fraction of the time of good quality ones. At a time when every penny counts, our machines are engineered to last a lifetime with minimal maintenance, and when our repairs or maintenance services are called upon our goal is to provide solutions which will similarly offer years of trouble free production." The service life of hammers is an important consideration for businesses, that need to factor in the cost of replacing worn hammers, including parts and labour, plus

the time it takes to change them, which leaves busy production machines out of action. Inferior quality hammers can also affect the quality and consistency of output and result in increased energy consumption which is generally the highest running cost of any business. As a hammer wears the rounded edge changes the particle distribultion increasing the percentage of fines in the ground product and results in a decrease in efficiency. This is particularly noticable at higher throughputs, where this has been demonstrated to be as much as a 15% increase in power consumption (see Christy Turner chart on the next page).

Christy & Norris, which was established in 1858, offers a range of high speed dual rotation swing beater hammer mills with direct drive, including the X380, X660 and X960, ideal for grinding cereals for livestock feed, pet food and aquatic feed; size reduction of wood waste for animal bedding or pelleting and size reduction of biomass materials for power generation. It also produces a range of heavy duty pulverizers used for limestone, plasterboard and general recycling. While Christy Turner's family of respected brands are robust and long-lived, to maintain many decades of reliable service, all milling machines will need spare parts during their years of service.

Global Milling Advances / November Issue 2015

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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 journey in 1837. It is certainly true that the company has a long and distinguished collective history: in 1837 the roots of the company were formed when brothers Edward Rush and Frederick Turner began making steam engines from St Peter's Works in Ipswich. The company pioneered machine engine design and in 1851 exhibited to more than six million visitors at the famous Great Exhibition, held at Crystal Palace.

Chris added: "The introduction of superior strength Hardox hammers across our range offers operational cost-saving benefits for most customers in the long run." 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 take quality of service very seriously, priding ourselves on our comprehensive test and development facilities and our esteemed support and parts provision. While our products are renowned for their reliability, flexibility, and longevity, we nonetheless stock a broad range of spare parts in our large warehousing facility that can be despatched and fitted as fast as you need them to be." Chris added: "It is important to use genuine parts to guarantee reliability and performance. All Christy Turner replacement parts are guaranteed to be manufactured from the most suitable wear materials and to the correct dimensional specification and all our parts have full material traceability, essential for quality control in any food or feed production." By maintaining casting patterns for every machine in its current range, Christy Turner can also guarantee compatibility of all

Global Milling Advances / November Issue 2015

genuine OEM parts. Christy Turner's dedicated team of experienced engineers carry out site visits to determine the best equipment for a client's needs, offering expert advice, follow-up support and a full repairs and maintenance service. Speaking about the bespoke service, Christy Turner's Technical Manager Matt Bloomfield said: "Fast rotating hammers in a grinder are subject to a combination of sliding wear & impact wear. We can optimise designs to give best impact angle in the mill for increased wear life." He added: "Our customers can benefit from discussing applications with us so that we can match optimal material & design. For example a plant processing highly abrasive material that doesn’t subject hammers to high shock loads could be gaining a vast improvement in wear life over simply using a traditional part. We are also rolling out improvements to wear life of other key consumable mill parts." 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

Meanwhile, in 1858 the Christy Brothers’ business was established to manufacture a range of pulverizers, grinders and hammer mills. The merging of Frank and Fell, Christy’s Chelmsford stronghold, with another local machine manufacturer in the early 1900’s saw Christy & Norris continue to grow significantly and expand its product range. Businesses looking for high quality flaking equipment for breakfast cereal and animal feed production, hammer mills with a reputation for reliability and longevity or excellent spares and servicing can comfortably place their trust in a Great British brand with a rich heritage of the finest UK engineering. In addition to the machines at Weetabix's Burton Latimer & Corby sites, E R & F Turner Flaking Mills, are also installed at Weetabix sites in Kenya, South Africa & Canada. Over 650 E R & F Turner Flaking Mills are operational across the globe with mills installed across sites in the UK, Europe, Australia/New Zealand, South America, Middle East, Kenya, South Africa and Canada. The company's rebrand, to bring a family of leading UK manufacturers under the Christy Turner umbrella, saw the launch of a new, updated web site designed to allow customers, both old and new, to view all the products in its extensive range. Chris added; "At Christy Turner, as well as continuing to provide support for our legacy equipment, we are committed to furthering the evolution of our range of machines. We maintain an ambitious development program, which ensures that our machines remain market leaders in their field and we continue to be the preferred supplier of equipment for many household names."

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Dinnissen Hammer mills in development A century of innovation

Dinnissen Process Technology specializes in the development and production of process technologies and equipment for the feed, food, pharma and chemical industries. Dinnissen offers an extremely wide range of hammer mills that provide an effective solution for any challenge when it comes to grinding and screening even the most difficult ingredients. The hammer mills are characterised by a broad range of capacities and product output particle size as well as flexibility and special add-on functionalities, making them real multitasking machines.

A crucial feature of the hammer mills is the enormous range of screening panels, surfaces and perforations available, as these features determine the capacity, quality and effectiveness of the screening process and make it possible for Dinnissen to offer its clients an effective solution for practically any grinding and/or screening challenge. Two rather striking members of Dinnissen’s product range are the small Easy-to-Clean DINNOX Mill and the D-Topline Hamex® Hammer mill with (semi-) automatic screen changer.

Enormous range of screening panels, perforations, and functionalities

From the small Easy-to-Clean DINNOX Mill

Hammer mills are particularly suited for grinding soft to medium-hard products such as grains, herbs, spices, protein-rich ingredients, nutrients, premixes, and minerals. Dinnissen’s range of multitasking hammer mills enables the user to screen output particles ranging in size from 3 mm down to 150 microns. Single hammers or double hammers are used depending upon the specific ingredients to be grinded down.

Global Milling Advances / November Issue 2015

The Easy-to-Clean DINNOX Mill is a very compact mill. It is fitted with exchangeable grinding rotors, providing it with a variety of breaking, cutting, and grinding functionalities, as well as exchangeable screening panels and adjustable RPMs. This allows the user to easily and quickly switch between an almost endless variety of grinding and screening applications, depending upon the specific ingredients processed and the desired end result. In

spite of its very compact design, the new Easy-to-Clean DINNOX Mill is also fitted with completely detachable grinding rotors and extra-large inspection hatches, making it easy to access all the components, including the screening panels, and to clean everything quickly and thoroughly. The Easy-to-Clean DINNOX Mill is available in stainless steel 304, SS 316L, and polished or electrolytically polished SS. It can also be fitted with an automatic cleaning system based on compressed air, CIP, or hot steam/air for extra hygienic applications, and complies with all EHEDG requirements.

Up to the D-Topline Hamex® Hammer mill with automatic screen changer The D-Topline Hamex® Hammer mill with automatic screen changer can handle grinding capacities of up to 45,000 kg per hour, and the screen changer has space for 4 to 6 different sets of screening panels. The mechatronic screen changing system automatically selects and places the appropriate set of screening panels in the hammer mill. After the production process

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has been completed, it also removes and stores the screening panels in less than 40 seconds. This makes it possible to change screens extremely quickly and greatly reduces downtime. The Hamex® Hammer mill features a new and ingenious design which greatly increases the surface area of the grinding and screening panels inside the hammer mill, which in turn provides increased grinding and ringing capacity. The screen storage facility is also fitted with an extra-wide chamber that can be automatically opened. This makes it easier to carry out maintenance and remove damaged screens if necessary, thereby minimizing downtime. The new hammer mill has a maximum speed of 1800 RPM, giving it a longer usable lifetime and in lower energy consumption than its predecessors. Dinnissen had the performance of the hammer mill measured over a period of one year, during which time 25,000 client batches were analysed. The results of this study made it clear that Dinnissen’s newest hammer mill performs even better than expected. The Hamex® hammer mill turns out to be extremely reliable and delivers 20% higher capacity in combination with a very homogeneous end product as well as reduced waste flows.

manually inserts the new screens. The semiautomatic screen changing system then automatically inserts the screen holder back into the hammer mill. As a result, the grinding step never needs to be the limiting factor in a production process. The investment needed for a semiautomatic screen changing system is also relatively limited. In its newest (semi-) automatic hammer mill, Dinnissen has improved the inflow of ingredients by integrating rock traps and magnets into the design. This innovative feature prevents damage to the screens from iron particles or hard objects. In the new Hamex® Hammer Mill, the screen holder is also fitted with an extra-wide screen opening that opens automatically, making it easier to carry out maintenance and/or replace worn-out screens and further minimizing downtime. Finally, Dinnissen further improved the design of the screen holder, thereby eliminating the loss of product to other parts of the production process. The end result is that damage is prevented to the screen panels and waste is minimized.

Less waste and a much better and more homogeneous end result Dinnissen also had a study carried out into the quality and homogeneity of the ground products. The study made it clear that the new Hamex® hammer mills not only delivers a more homogeneous end product per batch but that the homogeneousness of the end products remains much more consistent over time. The innovative design used by Dinnissen to integrate the hammers into the grinding rotor minimizes wear and tear and delivers more homogeneously ground products. The same holds true for the usable lifetime of the screen panels. Finally, Dinnissen further improved the design of the screen holder, thereby eliminating the loss of product to other parts of the production process. The end result is that damage is prevented to the screen panels and waste is minimized.

And on to the latest development: the semi-automatic screen exchanger Like its predecessor, the newest Hamex® Hammer Mill with semiautomatic screen changing system also has a completely new design for housing the screen panels, grinding panels, and hammers inside the hammer mill. This semi-automatic hammer mill also has a very robust design and operates at a maximum speed of 1800 RPM, making it much less sensitive to vibrations and malfunctions. This is not only beneficial for the operator but also makes the new hammer mill extremely reliable in operation and very user-friendly in terms of maintenance. When using the Hamex® hammer mill with semiautomatic screen changer, the screens are automatically removed from the hammer mill but, in contrast to the automatic screen changer, the operator manually removes the screens from the screen holder and

Global Milling Advances / November Issue 2015

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Hammermills producing excellent feed Feedtech International BV is an innovative feed mill equipment manufacturer offering you customized solutions for small, medium and large enterprises.

Our formula:

With our R&D, Marketing in Eindhoven High Tech Campus, we provide you with the essential framework of best solutions and services for your future business in the feed mill industry.

We offer you Hammer mills producing excellent feed quality, perfect milling performance with highest durability and advanced screen surface, which guarantees you double efficiency level on low cost.

In FEEDTECH Int BV we consistently venture performance improvement and meet customer requirements of our customers. Our feed mills are individually designed and constructed specifically to meet our customers’ detailed demands.

The production can be fixed from 5 up to 60 tons / hour depending on type of product, perforation of the screen, humidity of the product. Furthermore, our Hammer Mills are suitable for grinding through total aspiration, interchangeable screen cassettes, central inlet and rotation to both direction with screen surface up to max. 1,70m². With rotation speed varying from 1500rpm to 3000rpm, we guarantee powerful and effective working process.

We carefully identify your machinery expectation (starting from requested design, power, safety, budget, training up to the planning and recipe of your feed choice. Our machinery guarantee you high quality feed for any purpose.


Various options include automatically cleaned filter installation, discharge conveying systems, sifter installation above hammer mill etc. We provide our customers with high quality mixing equipment with different capacity according to their needs and budget. Our products enables application of the perfect feed mixture necessary for your recipe and animals. Filling levels are from 10% to 100% of net volume. Our Double Shaft Paddle Mixer is designed for the mixing of dry powders and granulates, irrespective of the bulk density and/or the shape. Fluids and/or solid substances can be added also. Whereas, our Ribbon Mixer LM is great for Mixing of grinded mixtures at Animal feed factories, pet food plants, fish feed factories. We manufacture also the Molasses Mixer, which is used for homogeneous and stable mixing

We manufacture three types of efficient and high quality mixers:

1. Ribbon Mixers

2. Double Shaft Paddle Mixers

3. Molasses Mixers




Capacity: 1000 – 12000 liters

Capacity: 200 – 12000 liters

Capacity:20 – 80 tons / hour

Line Capacities: 5 – 70 tons / hour

Line Capacity: 1,5 – 120 tons / hour

Mixing Time: max. 4 min

Mixing Time: 10 – 120 seconds

Min. content: 25% of the nominal content

Min. filling degree will be 25% of the nominal content

Maximum amount of molasses to be added: 8% depending on absorption characteristics of raw material and method of adding molasses

Variation co-efficient (CV): less than 3,5% U-shaped body Pneumatic operated discharge slides Filling levels from 10% to 100% of net volume.

Variation coefficient (CV) less than 1,5% Mixing accuracy: 1 / 100.000 Bomb door Low energy consumption

Applied after mixing before pelleting lines Adjustable knives Interchangeable knives Big inspection and cleaning doors V-belt drive Filling levels from 10% to 100% of net volume

Global Milling Advances / November Issue 2015

Page 13

of molasses to feed mixtures. The capacity is up to 80tons per hour, as the maximum amount of molasses to be added is 8%, which depends on absorption characteristics of the raw material and method of adding molasses.

Ribbon Mixer

Our expert project management team and long market experience gives us more confidence to acquire expertise in every phase, which on the other hand enables us to understand your needs better, to cautiously plan and deliver you projects within Time, Budget and Quality.

Hammer Mill JPT

Clear communication and good relationship with all clients is important for all our projects. For this reason, we provide you with an easy and direct data flow between your office and our project team responsible for highest customer satisfaction. Experience based competence promises you effective project management from consultation and design up to construction, manufacturing, training and best customer service possible.

Mixer DPMA


GHM Hammer Mill

Global Milling Advances / November Issue 2015

Page 14

Advancements in Mycotoxin Testing at the Grain Intake Mycotoxins have become a heavily discussed area of grain testing in the last decade due to the introduction of EU residue limits applied to Foodstuffs during 2006. Depending on the commodity and region of the world different toxins may be prevalent but currently within the Grain & Feed sectors it is focused around 6 main toxins Aflatoxin, Deoxyvalenol, Fumonisin, Ochratoxin, T2/HT2 and Zearalenone. In order to accurately detect Mycotoxin contamination appropriate sampling and testing regimes are essential.

for Falling Number sample preparation. The consistent grind removes a potential source of error especially critical when looking at low ppb levels of contamination. There are a number of different Mycotoxin testing approaches. Reference methods are used mainly for confirmatory purposes where a result is contested. The practical use of HPLC or GC/MS chemistry based analysers is not common at a Grain intake site due to its complexity, but also the time

and expense is prohibitive. Alternative testing platforms have become the standard for Grain and Feed companies such as Lateral Flow strips where the speed, ease of use and lower cost per test allows decisions to be made quickly and with a good degree of precision. There are many developments and opinions on how Mycotoxins will be tested in the future and these are discussed at regular scientific and industry events around the world. For example at the 2014 World Mycotoxin Forum in Vienna a new way of sampling and testing Grain Dust was introduced which is being correlated with results obtained from physical grain testing. More recently at the AACCI Centennial Meeting (Cereal Chemists) in Minneapolis a pre meeting workshop and hot topic was built around suppliers of technology using Near Infra-Red and Colour methods to separate contaminated grains rather than sampling a small proportion of the load.

Contaminated grain is not usually uniformly distributed in a load. This makes it possible for one sample to contain a spear or sample from a hot spot (common in storage toxins such as Ochratoxin) while the next contains no contaminated grains. Different forms of Mycotoxins are measured at variable levels depending on their toxicity, for example Ochratoxin (OTA) is measured at extremely low levels: 5ppb (parts per billion) for EU Limits on unprocessed cereals. Others such as Deoxyvalenol (DON) have EU limits of 1250ppb for unprocessed cereals. To put this into context, one ppb is equivalent to one second in 32 years. It is therefore essential that sampling regimes are followed to give comparable results between testing facilities. Building on from the sampling errors, the next source of error when testing a grain sample is the preparation of the samplegrinding. Simple coffee grinders are sometimes used which do not control the particle size of the sample to be extracted. For best practice and performance the use of a laboratory grinder such as Pertenâ&#x20AC;&#x2122;s Labmill 3100 is recommended, especially as it is also used

Global Milling Advances / November Issue 2015

Contaminated/Damaged Grain

Page 15

One such technology with good potential is the BoMill (Sweden) system that Canadian Feed Research Centre have been using to separate Fusarium damaged grains containing the highest levels of DON.

ROSA and EZ-M Testing Platform

For now though we have to consider methods that have approvals. In the USA test kits are submitted to GIPSA for accreditation against performance criteria, and in the UK individual projects have been commissioned to assess the suitability of rapid test kits for use at Grain intake- HGCA Project report 394 extension ( r394-final-project-report-extension.pdf). One of the main things assessed in these studies is the performance in accuracy against reference methods so confidence in results can be high. Unfortunately many methods of analysis have overly complicated or numerous steps for the operator to complete which means the operator has a lot of influence on the result especially if the laboratory is under time pressure. It also means that under normal laboratory conditions the tests can be operated smoothly but the reproducibility between labs can vary tremendously.

toxin of interest (kit manufacturers generally refer to the test time as the temperature incubation period). However, there is an extraction procedure from the ground grain which in the case of the ROSA system is simplified with a limited number of steps and the removal of hazardous chemicals such as Methanol with the new ROSA WET (Water extraction technology) kit range.

As grain intakes may have a requirement for detecting multiple toxins, the practical element of running different tests, with different extraction procedures, and different detection levels, can prove very complex and again is a major source of human error. Charm Sciences have minimised this issue with developments in the ROSA testing platform and the EZ-M analyser.

The ROSA tests require minimal operator training as methods are similar across kits using lateral flow strips. This process is made even easier with the use of the new EZ-M reader/Incubator, all the operator needs to do is prepare the extract as normal, the reader automatically detects the test type, selects the correct incubation time and temperature. At the end of the incubation the reader automatically displays and stores the result even if the operator has left the room.

Charm lateral flow mycotoxin tests offer a consistent procedure for extracting the toxins and recent enhancements have reduced the test time considerably from 10 to as low as 2 minutes depending on the

In comparison older methods of analysis produce larger variability in results commonly associated with a pressurised grain intake environment. In summary the Charm ROSA platform produces a fast

reliable result minimising human error. The flexibility of this system suits the needs of the modern testing facility as frequently at Calibre we experience different testing requirements from our customers. This varies season to season and means we can react to changes in laboratory needs or a specific food safety issue. Further developments are on the way with portable (cordless) readers and incubators moving the analysis to the field which will help breeders assess disease resistance and farmers improve yields and agronomy.

About Calibre: Calibre have been involved in Grain and Flour testing solutions for nearly 30 years and represent the worldâ&#x20AC;&#x2122;s leading providers of test equipment in addition to manufacturing their own C-Cell analyser which is used globally for Quality Control of Wheat Breeding and Baking sectors. Further information can be viewed on in_Mycotoxin_Testing

Test Procedure for ROSA Mycotoxin tests

Global Milling Advances / November Issue 2015

Page 16

Accurate, sensitive, reliable screening for multiple mycotoxins Mycotoxins are a group of naturally occurring toxins produced by certain fungi, commonly known as moulds. They occur in a variety of different crops, including cereals and grains that are colonized with filamentous fungi and in food products contaminated during processing and storage. Climate, region, temperature and high humidity all have an effect on their occurrence.

Why should mycotoxin levels be monitored in feed/grain? The consumption of mycotoxins can result in significant adverse health effects in humans and animals. Aflatoxin, for example, produced by the moulds, Aspergillus flavus and Aspergillus parasiticus, is a secondary metabolite that is highly toxic for human and animal health if ingested. Aflatoxin B1 is the most potent natural carcinogen known where it can cause acute aflatoxicosis. This illness has been reported in humans across the world including India, Kenya and Taiwan where the condition can be categorised with abdominal pain, fever, vomiting, coma, oedema of legs and pulmonary edema through the ingestion of infected maize. These symptoms can occur similarly in animal species. Other mycotoxins have a range of other health effects including kidney damage, gastrointestinal disturbances, reproductive disorders or suppression of the immune system.

Globally, however, the requirement for mycotoxin screening is varied. There are a number of special import conditions currently in place for some foods from certain third world countries (Africa in particular), where the risk from aflatoxin contamination is increased, which further improves consumer protection. Compliance with internationally acceptable limits for mycotoxins (TDI) can be challenging for the food industry, requiring good plant protection, adequate storage and good manufacturing practices in order to keep levels below the limits.

These effects from ingestion of mycotoxins therefore have influenced international food standards recommending that food producers carry out screening for mycotoxins. To protect consumers, a tolerable daily intake (TDI) has been established which estimates the quantity of mycotoxin which someone can be exposed to daily over a lifetime without it posing a significant risk to health.

Currently aflatoxin B1 is the only mycotoxin with maximum permitted levels (MPLs) set under Directive 2003/100/EC. Given the nature of the illnesses this toxin can cause to human and animal health, the directive has set its MPL to as low as rationally attainable. For example, all feed materials have an MPL set at 0.02ppm. Despite this being the only mycotoxin with a legal MPL, other mycotox

Global Milling Advances / November Issue 2015

Figure 1. Biochip wells and DTRs ins have been given recommended MPLs as guidance for producers and regulators. These include, Deoxynivalenol, Zearalenone, Ochratoxin A, Fumonisin B1 and B2 under Commission Reccommendation 2006/576/EC.

How are mycotoxins currently being assessed? Currently chromatographic, LC-MS, HP-LC and immunoassay based techniques are used for the detection of these toxins. Confirmatory methods though can be expensive and time consuming. Randox Food has developed an alternative method to assess the occurrence of multiple mycotoxins simultaneously. Biochip Array Technology (BAT) provides a platform for the simultaneous determination of multiple drug residues from a single sample using miniaturized immunoassays with implications in the reduction of

Page 17

sample/reagent consumption and an increase in the output of test results.

Figure 2. Thermoshaker

The biochip: the core of the technology The core of the system is the biochip (9mm x 9mm), represents the platform in which the capture molecules are immobilized and stabilised in pre-defined x,y coordinates defining arrays of discrete test regions (DTRS) on a preactivated surface (Figure 1). Up to 25 tests can be carried out per biochip. The biochip is also the vessel where simultaneous chemiluminescent immunoreactions take place. The biochips are supplied in carriers containing 3 x 3 biochips, which is equivalent to nine reaction wells per carrier, where samples and reagents are added. A carrier handling tray is provided with the system, which allows the simultaneous handling of six carriers (54 biochips). The kinetics of the immunoassays are controlled by incubating the biochip carriers in a custom thermoshaker unit provided with the system (Figure 2). After completion of the immunoreactions a signal reagent is added for the detection of chemiluminescence produced at the different DTRs on the surface of each biochip. The addition of sample, reagents and washing steps are carried out manually, whereas the detection and processing of test results are automated operations performed by the biochip analyser Evidence Investigator.

Figure 3. Evidence Investigator

Evidence Investigator analyser: the biochip test platform for drug residues The biochip carrier is inserted in the light-tight compartment in the image station of the semi-automated bench-top analyser Evidence Investigator (Figure 3). The chemiluminescent signal from each DTR on the surface of the nine biochips contained in a carrier is simultaneously detected and recorded using a Charge -Coupled Device (CCD) camera. Image processing, quantification and validation are carried out by instrument specific software.

accreditation. The participants data are analysed statistically providing assigned values to the test sample and individual z-scores for the sample result submitted from each participant (in normal circumstances about 95% of z-scores will lie in the range -2 ≤ z ≤ 2 over time). Test material from the scheme was assessed by Randox Food using the Mycotoxin Array with data produced for Aflatoxin BI (AFBI), Deoxynivalenol (DON), Ochratoxin A (OTA) Zearalenone (ZON) and total T-2 and HT-2. The mycotoxin biochip assays results lie comfortably within the optimal range, when compared with other testing methods,

Randox Food is a regular participant of the FAPAS® proficiency testing scheme. With over 2000 participants in over 100 countries, FAPAS® is the largest and most comprehensive in the food testing sector providing an independent check of laboratory’s procedures ensuring delivery of quality results. Involvement in the scheme can also help laboratories gain and maintain ISO/IEC 17025:2005

Figure 4. Mycotoxins detected simultaneously with Randox Food biochip arrays. Global Milling Advances / November Issue 2015

Page 18

underpinning the superior screening solutions offered by Randox Food, (Figure 4).

Sensitive, accurate, reliable MycoFlex is the latest innovation in mycotoxin screening. It is a labour saving, multi-analytical solution for the accurate quantifiable screening of the world’s most prevalent mycotoxins to comply with global regulations. It is an novel product allowing the user the choice to screen from 3 to 10 toxins offering a customised resolution for individual laboratory requirements. The mycotoxin screening solutions range offered by Randox Food is shown in Figure 4; Myco 10, 7 and Mycoflex.

Benefits of Randox BAT at a glance:

• Straightforward screening for up to10 mycotoxins from a single sample

Global Milling Advances / November Issue 2015

Figure 5. Data from test material from FAPAS® assessed with mycotoxin biochip arrays.

• Quantitative results for up to 54 samples ready in under two hours • No false negatives and less than 5% false positives in studies •

Only positive samples require confirmatory testing, saving laboratory’s money

• Robust and easy to use with simple sample preparation

is tried and tested by many of the world’s leading food producers and is leading the market in mycotoxin screening. Randox Food is at the forefront of the safety revolution striving to increase global consumer confidence by improving food safety.

With global controls on food safety and contaminants becoming ever more complex, having the right technology is key to meeting those challenges now and in the future. Randox Food Diagnostics technology

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Milling News from around the world

Events in detail December

Click this link to download our events planner today and tent/plugins/download-monitor/download.php?id=13.php?id=2 keep up to date with the latest industry meetings 1 2016 year planner


Fats & Oils Istanbul/Feeds & Grains Istanbul 3-4th December Turkey

120th IAOM Annual Conference & Expo 4-8th April USA

Agro Innovate Kenya 8-10th December Kenya

15th ICC Cereal and Bread Congress 17-21st April Turkey

January MVC: Cereals-Mixed Feed Veterinary â&#x20AC;&#x201C; 2016 26-28th January Russia 2016 International Production and Processing Expo 26-28th January USA February VIV MEA 2016 15-17th February UAE GEAPS Exchange 2016 27th February -1st March USA March AFMA Forum 2016 " Feeding the Future" 1-3rd March South Africa Victam Asia 29-31st March Thailand

Global Milling Advances / November Issue 2015

5th Global Feed & Food Congress 2016 18-20th April Turkey 9th International Feed Regulators Meeting (IFRM) 21 April 2016 Turkey XXVII The European Feed Manufacturers Federation FEFAC Congress 21-22nd April Turkey

August GrainTech India 2016 26-28th August India November CICFO Grain 2016, CIFCO Feed 2016, CGOF 2016 4-6 November China 67th JTIC International 9-10th November France Eurotier 2016 15-18th November Germany

May Food Ingredients Istanbul 2016 4-6th May Turkey PIX / AMC 2016 - Australian Milling Conference 29- 31st May Australia June Cereals 2016 15-16th June UK

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Global Milling Directory Company A-Z Events Products & Services

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Global Milling Advances November 2015 -  

Welcome to the November 2015 issue of Global Milling Advances. This month we take a look at the latest developments in milling technology, i...

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