Bogasari Flour Mills

millingandgrain.comVolume 130 Issue 10

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Bogasari Flour Mills• Technological advances

help millers meet consumer needs

• Extrusion brings versatility to food industry

•Riceflour-smallmillingunit CMU30A

• Fluidised bed mixing•BuildMyFeedmill-

Crushing roller mill

• SPACE Event review

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ISSUE HIGHLIGHTS 10

VOLUME 130 ISSUE 10

NEWS 12-42

44 Bogasari Flour Mills - Technological advances help millers meet consumer needs

56 Extrusion brings versatility to food industry

60 Rice flour64 Three reasons

why good meat is related to phytogenics

68 Purifier Norit MQRH

70 The feedase effect

72 How the type of starch can influence pelleting

76 Fluidised bed mixing

78 Build My Feedmill - Crushing roller mill

STORAGE 82 Expansion

project - valuable experience for Allstate

92 Bins VS Silos - Which is the best storage solution for your raw materials?

10 GUEST EDITORNaoji Otaki

120 INTERVIEWErik Visser

©Copyright 2019 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. More information can be found at www.perendale.comPerendale Publishers Ltd also publish ‘The International Milling Directory’ and ‘The Global Miller’ news service

EVENTS102 Event listings, reviews

and previews

COLUMNS24 Mildred Cookson34 Gustavo Sosa

FACES122 People news from the

global milling industry

TRAINING40 Introduction to Flour

Milling Course wraps up

PRODUCT FOCUS 42

CASE STUDY 92

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

October 2019

COVER IMAGE: Bogasari has installed Ocrim’s latest ‘modular’ milling system, a concept that allows mill managers to shut down parts of a plant when needed without reducing productivity - See more on page 44

FEATURES

Perendale Publishers Ltd7 St George’s Terrace St James’ Square, Cheltenham, Glos, GL50 3PT, United KingdomTel: +44 1242 267700PublisherRoger [email protected] Marketing TeamDarren [email protected] CornwellTel: +1 913 [email protected] NorwoodTel: +1 405 834 [email protected] America Marketing TeamIván MarquettiTel: +54 2352 [email protected] [email protected] Zealand Marketing TeamPeter [email protected] Marketing TeamNathan NwosuTel: +234 8132 [email protected] Marketing TeamMohamed BaromhTel: +20 100 358 [email protected]

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millingandgrain.comISSN No: 2058-5101

“Okome no Gakko” – Educational program to foster the understanding of Rice

Annual Subscription RatesInside UK: UK£100 Outside: US$150/€133 More Informationwww.millingandgrain.comhttp://gfmt.blogspot.co.uk

FOOD STORAGEPROCESS FEED

FLOUR

Technological advances help millers meet consumer needsAs new generations come to the fore, changes occur and no more so than in the milling industry. Milling and Grain visited Bogasari Flour Mills in Jakarta, Indonesia earlier this year to report on the refurbishment of three of its 15 production lines by Ocrim.

PAGE 44

FLUIDISED BED MIXING

Animal feed producer ups uniformity, cutscycletimeswithfluidisedbedmixingCountry Junction Feeds has produced animal feed products in Alberta, Canada for over 100 years.

PAGE 76

BUILD MY FEEDMILL

Crushing roller millHigh-quality ingredients and an optimal formula are the most important factors in animal feeding. The importance of the feed structure, however, often goes unmentioned, although recent findings of the feed industry have shown that it is an at least equally important factor for successful feeding and fattening.

PAGE 78

BINS VS SILOS

Which is the best storage solution for your raw materials?In Milling and Grain magazine we work together with a great number of companies each month to provide our readers with the latest information regarding how to get the most out of your storage facilities.

PAGE 86

Milling and Grain has a cooperative partnership with

COFCOET

It is my honour to be invited to write for Milling & Grain magazine as a guest editor, and I would like to take this opportunity to write about something other than Satake’s product, “Okome no Gakko” (literally “Rice School”), an educational program aimed towards local children.

Rice has been grown in Japan for thousands of years. It has

been considered an incredibly valuable farming product and our primary staple food. However, rice consumption in Japan has been steadily declining in recent years. Data from Ministry of Agriculture, Forestry, and Fishery shows a single Japanese person on average consumed 54.4kg of rice annually in 2016, 54 percent less than that of individuals in 1962.

One of the major reasons for this decline is that Japanese diets have changed dramatically during the rapid economic growth period following WWII. As the economy grew, more alternating carbohydrate sources became readily available, such as wheat noodles, bread, pasta, etc. This decline in rice consumption is now causing shrinkage in Japanese rice industry.

Rice production has decreased by 15 percent in the past 10 years. Not only the industry, but also the rice farming population, is decreasing and consequently resulting in deserted small farming towns.

Satake is the Japan’s first manufacturer of motorised rice

milling machinery, established in 1896. Although we currently manufacture processing equipment for all different grains in over 150 countries worldwide, Satake feels a strong need to support the Japanese rice industry as muc as we can.

One of the actions Satake have taken is to educate the youth. The Rice School started in August 2005 as a part of Satake’s CSR program. Its main theme is Shokuiku, food education, focused on rice. During the two-hour class, historical aspect of rice as a main staple food, its biological characteristics as a plant, how it is grown and processed are topics brought raised to the children to consider.

Most of the attendees are elementary school students, age between six and 12, from surrounding areas of Satake head office located in Higashi, Hiroshima. By 2019, we have welcomed near 10,000 students to the school, making it one of the most successful youth programmes for Satake.

The school typically consists of slide presentations regarding rice farming and processing in a classroom, hands-on experiments of paddy husking and milling with laboratory equipment, discussions on the history of rice-related equipment at Satake History Museum, and demonstration of equipment at the Sorting and Processing Integrated Centre. It is designed to be a fun and educational experience for children learning the proper knowledge of rice and related subjects.

Together, with many of other CSR programs Satake offers, we hope our efforts will eventually increase the rice consumption of Japan and revitalise the industry and farming towns in the near future!

Naoji “Ozzy” Otaki, CD, Manager, Public Relations Department, Satake Corporation

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In this rendition of Milling and Grain we are very proud to have an interview with Mr Erik Visser, CEO of Hamlet Protein. Whilst we always retain a key focus on feed in Milling and Grain, there are such a variety of aspects surrounding the feed industry that have so much room to undergo more exploration and research.

According to the Food and Agriculture Organisation (FAO), it is estimated that approximately 1,000 million tonnes of animal feed are produced globally every year, which also accounts for 600 million tonnes of compound feed. Whilst the vast majority of this is produced for poultry, pig and cattle feeds are produced in similarly high quantities.

Aquatic feed production itself remains fairly low, with 14 million tonnes of feed being produced for the aquaculture industry, but the demand for increased feed for both crustaceans and fish is now being recognised as a growing concern.

Protein is, of course, a key aspect of producing a good quality feed, but what makes protein so essential? Having feed contain an appropriate level of energy can only be truly accomplished by a thorough understanding of which proteins best suit which feeds, animal growth stages and individual animal needs.

Learning which protein sources reap which benefits is the best solution to ensuring a quality feed. Maize is known for a variety of optimal qualities, but also recognised for its lysine limitations. Soybean, similarly, lacks methionine and cysteine, but analysing the amino acid composition of these materials does not always reveal these details at tissue level in the animal.

Amino acids can, therefore, be grouped into three classes: ‘essential’, ‘semi-essential’ and ‘conditionally indispensable’, all of which play great effects upon a feeds effect on the immune system, antigenic factors and nutritional effects.

Alltech announces industry-wide survey on women in agriculture

The challenges associated with the ever-increasing global population have made it more important than ever for the agri-food industry to be able to perform at its full potential.

Inclusion and diversity in the workforce are essential to shaping a sustainable future — and yet, according to the Food and Agriculture Organisation of the United Nations, the gender gap in the food and agriculture industries is extensive. To gather real-world insights into the professional landscape for women in agriculture, Alltech has announced its support of an industry-wide survey.

Launched on September 10th, this global survey, conducted in partnership with AgriBriefing, aims to collect feedback about the barriers that impede progress and to identify the resources needed to ensure workplace equality.

The survey is open to women and men across all sectors of the agri-food industry, and the results will be revealed at the Women in Food & Agriculture Summit, to be held December 3–4th, 2019, in Amsterdam, the Netherlands.

This collaborative effort to reach across sectors and geographical boundaries in an attempt to improve the industry’s outlook reflects Alltech’s vision for a Planet of Plenty™. During ONE: The Alltech Ideas Conference, held in Lexington, Kentucky, in May, Dr Mark Lyons, President and CEO of Alltech, outlined the company’s vision for a future with enough nutritious and safe food for the rising population, with our environment and resources preserved for future generations. A diverse and inclusive workforce is among the most valuable of those resources.

“It is my experience that the most effective organisations embrace diversity and support inclusion,” said Dr Lyons. “The food and agriculture sectors include many talented female leaders, and we need to make sure young people see themselves represented and can envision a future career in the industry. Through this industry-wide survey, we hope to gain a better understanding of the challenges facing women in ag and identify opportunities for growth.”

Women and men in all sectors of the food supply chain are encouraged to contribute to this important global conversation about gender equality in agriculture by taking the survey which can be done at the link below:

www.wfasummit.com/survey

12 | October 2019 - Milling and Grain

Upgrade your roller mill by using Balaguer Rolls only.

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Evonik helps lay the foundations for IPC sustainability push

The International Poultry Council (IPC) has announced its commitment to the sustainable

development of the poultry meat sector, delivering benefits for both the planet and people globally.

It affirmed the sector’s commitment as a leader in transforming the world through environmental and sustainable practices, in agreement with the Food and Agriculture Organisation of the United Nations’ (FAO) Sustainability Development Goals.

Evonik is an associate member of the IPC and played a key role in convincing the organisation of the major impact poultry nutrition can have on the environment. It also helped to link the United Nations Sustainable Development Goals (SDGs) to the three-pillar sustainability model (environmental, economic and socio-ethical) promoted by the IPC,

and to identify the SDGs which are supported most by the poultry industry.

The five goals are: Zero hunger (SDG 2): Sharing good

practices and promoting sustainable production;

Good health and well-being (SDG 3): Promoting poultry as a healthy choice and sharing good management and manufacturing practices;

Quality education (SDG 4): Building capacity to ensure high quality and sustainable production;

Industry, innovation and infrastructure (SDG 9): Supporting innovative and sustainable industrialisation;

Climate action (SDG 13): Reducing greenhouse gas and other emissions.

Dr Andreas Lemme, Director Technical Consultancy at Evonik explained, “When we joined the IPC’s Environment and Sustainability working group, it became apparent

that there was a gap in expertise on poultry nutrition and feed production, yet their impact can be pronounced.

For example, SDG 13 emphasizes low emission feeding, minimising dietary nitrogen, optimising raw material processing and optimizing nutritional value of ingredients and finished feed. These are all aspects the poultry industry can take action on.

“The IPC’s commitment should ensure that the entire global poultry industry chooses strategies and concepts that lead to a more sustainable approach.”

This is the second official declaration on sustainability with FAO after a declaration with the International Dairy Federation from 2016.

At ANDRITZ, our aim is to give every animal feed miller the optimal combination of feed quality, safety, and capacity utilization. Whether you’re looking to achieve a unique nutrient blend, lower operating costs, or achieve complete

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UK’s most important innovation accolade goes to Bühler’s optical sorting

Bühler has received the United Kingdom’s most prestigious innovation award – the Queen’s Award for Enterprise

– for its optical sorting technology. In an official ceremony yesterday, in which the award was handed over by John Barber, representative Deputy Lieutenant for London Borough of Newham. Johannes Wick, Bühler Group’s CEO for Grains & Food, said, “This breakthrough technology will make the difference for us in the market for years to come. What is now in reach are applications to grade raw materials for composition and to remove invisible contaminations. This will be a major contribution to provide healthy and safe nutrition around the world.”

The Queen’s Award could be described as United Kingdom’s

“Innovation Oscar”, which this year acknowledges the leading technology position of Bühler. It is the highest award for British businesses which have excelled in the fields of international trade, sustainable development, or innovation.

This is the seventh Queen’s Award Bühler UK has won since 1968. This year’s win is in recognition of Bühler’s development of a unique camera technology used in sorting machines, capable of recognising the subtlest of colour and shading contrasts in materials and foods, thereby significantly increasing detection rates for foreign materials, potential choke hazards, or contaminated foods.

“Bühler are old hands at receiving these awards. After my first visit to the factory I could see why they have been constant winners. They have such a high standard of skills and technology, and are leaders in being good employers, as well as producing such high-quality products,” says John Barber, representative of Her Majesty The Queen.

He handed the award to Bühler’s Timothy Kelf, Head of Sensor Development.

“The fact that we have been so successful in a number of different market segments with this technology shows the strength and depth of our capabilities in cutting-edge technologies,” says Kelf, who received the Queen’s Award together with Senior Research Engineer Ben Deefholts. With their team, both have been instrumental in bringing this innovation to the market.

The technology is currently being used by food producers in Europe and the United States. They report an increase in detection rates of foreign materials by 10 percent, from 85 percent to 95 percent. A single Sortex optical sorter can control up to 150,000 single grains or 15,000 peas-per-second with a capacity of 12 tonnes-per-hour, securing highest food

standards.Bühler’s PolarVision uses the

industry-leading camera technology for the frozen vegetable market. Its technology can detect even the most challenging foreign material in frozen vegetable production lines. Ardo, one of the world’s largest producers of fresh-frozen fruit, vegetables and herbs, has introduced PolarVision in its European sorting plants.

“In our experience, PolarVision technology is one of the best digital-vision technologies when it comes to detecting foreign materials in the industrial frozen vegetables process. It’s a jump forward”, said Steven Van Engelandt, Ardo’s Group Project Engineer.

While the technology has so far been applied to detect foreign materials, future developments will also be able to detect mycotoxins and even pathogens.

The Bühler camera technology is also being used to detect lower-grade or discoloured polymers to ensure the highest grade recyclate can be achieved by plastic recyclers. By detecting such high rates of contamination, it is now possible to produce food-grade plastic packaging from 100 percent recycled material, cutting the need for virgin plastic production and levels of plastic being sent to landfill.

One of the criteria for a Queen’s Award is that the technology should not just be innovative, but has to be scalable, commercially viable, and to have resulted in a material improvement to a commercial process.

Since the introduction of the Sortex E optical sorter using BioVision technology, sales of Bühler sorting solutions into the nut sector have doubled. The technology is now being used by the world’s top nut producers globally to detect blemished nuts along with the smallest shell fragments in walnuts, pecans and pistachios.


Milling News

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Easy monitoring of health and microbial status of poultry flocks thanks to new ScreenFloX® service from Evonik

Evonik have recent released a new service product group that enables poultry producers to improve livestock production by monitoring the microbial status of entire flocks.

ScreenFloX® is the only environmental screening system that non-invasively quantifies the levels of certain pathogens, including Clostridium perfringens, from an entire flock with a confidence exceeding 90 percent. Evonik launched the new ScreenFloX® service at WVPAC in Bangkok.

The ScreenFloX® platform comprises a broad range of tests and is designed to help veterinarians, livestock production managers and farmers make smarter decisions to ensure animal well-being and food safety.

Dr Christoph Kobler, Head of Product Line Sustainable Healthy Nutrition from Evonik said, “Current common practice in animal diagnostics involves testing individual animals using invasive methods. This includes necropsy, histopathology and confirmatory testing which can easily take several days and are expensive.

“ScreenFloX® is an environmental screening system that enables poultry producers to detect levels of different pathogens for the entire flock using an unbiased, non-invasive method. The goal of using ScreenFloX® is to optimise overall livestock production through an ‘early warning system’. This gives producers the chance to react before it is too late to adjust the production process.”

The ScreenFloX® platform can perform multiple tests using a single sample and with minimal additional effort. Combining environmental screenings for avian and human pathogens saves costs and time for poultry producers.

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Milling and Grain - October 2019 | 21

Milling News

by Mildred Cookson, The Mills Archive, UK

The Flour Mills of East Scotland Part fiveMilling journals of the past at The Mills Archive

The final part of my series covering the mills involved in hosting the 1902 Edinburgh Convention is devoted to John F White’s Dundee Flour Mills. A report in Milling (May 31st, 1902) describes the mill as being “on the coast”.

The choice in 1876 for a new mill to be built in Dundee took into account the great advantages this would offer. The position chosen, at the east end of the city, was alongside two railway systems and the near modern docks on the River Tay suitable for large ocean-going steamers.

Between New York and Dundee, Dent and Company of Newcastle ran a regular line of steamers called the “Arrow Line”. The two-way shipping of grain and flour between these ports was about the same volume as that between Hull and New York, which made the reporter comment that it was extraordinary that Yorkshire millers should try to sell flour in this part of Scotland!

John White’s family had been in the milling trade for many generations, having for a long period worked a large millstone mill at Aberdeen known as Kettocks Mills as well as the Caledonia Mills at Montrose. Kettocks watermill had been driven by the waters of the Aberdeenshire River Don, famous as a salmon river. It eventually gave way to steam, and the flour it turned out was said to be second to none.

In 1876 the Dundee mills were erected as stylish and substantial buildings. They were first fitted out with a complete 14-pair stone plant, in conjunction with a number of well-made silk reels by Alexander Mather & Son of Edinburgh, the leading Scottish millwrights of the time.

The stones were fitted with Behren’s exhaust and other devices for high-class work. When the mills started work in 1877 they Robinson’s Double Horizontal Roller Mill

GT Smith’s Middlings Purifier Company


Milling News

were considered as model mills in every respect. Mr White quickly recognised the value of high grinding and in 1878 introduced into the mill, alongside the millstones, Wegmann’s porcelain rolls with Fender and Cuthbertson’s purifiers.

At that time, Wegmann’s promotion of porcelain rollers emphasised their superiority over rollers of chilled iron and dismissed millstones with the comment, “No remarks need be made as to the superiority of porcelain rollers over millstones, as it is a recognised fact by all. Porcelain rollers are the only rollers that will entirely supersede millstones and metal rollers”.

In 1887 the combination plant was cleared out and a complete 15-sack roller plant installed by Thomas Robinson and Son of Rockdale. The rolls were all driven from a line shaft in the basement, once used as the stone mill drive.

By 1902 only minor changes had been made to the Robinson plant as it was still running in perfect order. The alterations that were carried out on the system of milling rather than machinery itself. Use of a much larger roller surface resulted in increasing the yield of higher flour grades for which demand was high.

There were two lines of “Robinson” double horizontal roller mills arranged down one side of the mill and lengthwise the elevators were placed down the centre. In all there were 22 double mills, eight on the breaks and 14 on reductions.

The scalping of the first three breaks was done on three

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GT Smith’s Purifier finishing workshop

GT Smith’s Purifier assembly workshop

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You can now purchase the nabim training DVD. Written for and by millers.


®NOVUS and ACIDOMIX are trademarks of Novus International, Inc. and are registered in the United States and other countries. ©2019 Novus International, Inc. All rights reserved. 4284_Perendale

What’s in Your Pathogen Reduction Plan?ACIDOMIX® is a proprietary blend of organic acids – formic, lactic, fumaric - and ammonium formate that is encapsulated to ensure delivery to the lower digestive tract. In addition to a feed preservative, this acidifier has antimicrobial properties making it an important part of poultry or swine diets during vaccination-free windows and withdrawal times. It has also shown to aid in increasing feed intake.

Robinson double rotary sieves, the fourth on a reel and the fifth on a centrifugal. The purification was done on two Koh-i-Nor machines and seven GT Smiths.

The dusting, grading and dressing was done on 16 centrifugals and six reels. The GT Smith purifiers were imported from their factory in Jackson, Michigan, USA, illustrated by images from our holdings of The Northwestern Miller. These show the size of the factory and the workshops in the mid-1880s.

The Dundee mill’s wheat receiving house and silos occupied a separate building close to the railway. Half of its length was used as a flour warehouse, the other half covered four large silos which could hold 1,600 quarters each, and eight holding 600 quarters each.

The cleaning plant had the usual separators, graders, cockle and barley cylinders, scourer, washer and whizzer along with mixers and bins.

This building was detached from the mill by iron doors and on the top of the roof a large water tank was located for supplying

the Grinell sprinklers that were installed throughout the mill except for the silos.

The mill manager, WG Anderson, had been at the mill for 30 years, and was described as a practical miller with a full working knowledge of the technical aspects of his trade. The power plant for the mill was made up of a “McNaughted” beam engine with Corliss valves and jet condenser, together with a Lancashire boiler by Carmichael of Dundee which worked at 60lbs pressure. This was kept going as coal was cheap in the district.

Please email me at [email protected] if you would like to know more, or if you have any information, material or images that you would like to share.

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Bühler and Premier Tech form a strategic cooperation

Swiss Bühler Group and Premier Tech from Canada recently announced the formation of a strategic cooperation for industrial flexible packaging solutions. Both companies agreed to build a design

and manufacturing centre in China.“Combining the portfolio and expertise of Premier Tech

and Bühler will enable future packaging solutions which are significantly more efficient, accurate and food safe by using automation technologies”, says Johannes Wick, CEO of Bühler’s Grains & Food business.

“The two companies are complementing each other in a perfect way with Bühler’s strong footprint and market position in China and Premier Tech’s recognised know-how in the field of automated packaging technologies,” says André Noreau, CEO of Premier Tech’s Systems and Automation business.

In grain processing, packaging is the last step before transporting flour to bakeries and other food processors, rice to distributors or pellets to farms. In many cases – especially in developing countries – the bagging operation is still done manually.

This is not only inefficient, costly, and slow, but also implies a certain variation of weight and therefore a higher give away of the packaged goods. Palletising solutions are increasingly important to allow for efficient warehousing solutions.

The market and technology leading companies – Premier Tech in packaging and Bühler in grain and food processing – are now establishing this strategic cooperation to meet these market demands and create new cost-effective packaging solutions.

Bühler brings its know-how of high-quality manufacturing and supply chain management in China as well as its digital solutions, whereas Premier Tech contributes with its superior packaging expertise and technological leadership in this field. In bringing these competencies together, the strategic cooperation will develop automated, food safe and accurate bagging and palletising solutions.

The strategic cooperation will allow Bühler to provide better turnkey projects with competitive packaging

solutions from China while continuing to deliver high-end products such as Bühler’s bagging station Maia from its own manufacturing network in Europe.

At the same time, Bühler will continue to design and market their proven weighing portfolio. Their scales such as Tubex are not part of the agreement. With the partnership, Bühler will further improve its digital services allowing for full transparency and traceablity along the entire value chain.

Premier Tech will gain better access to the Chinese market by using the cost-effective and modern packaging solutions arising from the strategic cooperation, or by combining them to its internationally renowned CHRONOS technology portfolio in weighing, bagging, and palletising.

This strategic cooperation is planned to result in a joint venture for design and manufacturing during 2020, with Bühler focusing on sales of turnkey plants around the world, and Premier Tech on packaging systems in China. Both companies will continue to sell their products through their existing channels.

New addition to Satake’s REACH production line

On September 4, 2019, Satake Corporation recently announced a new addition to its oversea product brand REACH, System 3.0, a semi-assembled rice milling plant geared towards smaller scale rice processors mainly in Asian and African region.

The System 3.0 is a semi-assembled rice milling plant incorporating receiving, pre-cleaning, husking, milling, optical sorting, and packing stage equipment.

It is designed to maximise the installation efficiency versus cost performance by utilising unitised components manufactured in Satake’s Thailand production facility. The result is an astonishing two weeks of installation time compared to the usual three-to-four months. For regions where they experience two-to-three harvest times annually, this will allow rice mill owners to start up a production line before the next harvest season.

The initial REACH product line, System 7.0, a seven tonne-per-hour paddy rice mill, was introduced in the market in March, 2019. The new System 3.0 was designed with the same concept but reduced its processing capacity to three tonnes-per-hour. Larger capacity mills of up to 14 tonnes-per-hour, will follow in the near future.

Johannes Wick (left), CEO Grains & Food at Bühler, and André Noreau, CEO of Premier Tech – Systems and Automation, announced the formation of a strategic cooperation for industrial flexible packaging solutions


Milling News

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INNOVATIONS AWARDS

GRAPAS 2020:First Innovations Awards application is in!

With VICTAM Asia and Animal Health and Nutrition Asia taking place March 24-26th, 2020, Milling and Grain magazine are excited to announce that we will once again be hosting the GRAPAS Innovations Awards and GRAPAS Innovations Conference on March 24th, 2020!

Following a successful year of awards for 2019, the GRAPAS Innovations Awards 2020 are now accepting applications. If your machinery for the flour, rice or pasta processing industry was made available to the market no earlier than in 2018 then it is eligible to enter into the GRAPAS Innovations Awards 2020.

A member of your company must also be available on March 24th to give a presentation at the GRAPAS Conference at VICTAM Asia and Animal Health and Nutrition Asia in Bangkok about your product and why it is worthy of winning the GRAPAS Innovations Awards.

The 2019 awards were a resounding success with three winners crowned: Petkus’ OptoSelector 901t, Selis’ DAPS System and Bühler’s LumoVision. Also receiving the runner-up prize was Balaguer Rolls’ Optical Fluting Test 2.0, and we had other brilliant entries from companies such as Dinnissen, Eye-Grain, Brabender and Ocrim.

Applications close on January 19th, 2020.Simply email me at [email protected] for more

information or an application form.

Henry Simon’s HSPU-PurifierWe are thrilled to say we already have our first application

for the 2020 GRAPAS Innovations Awards; Henry Simon’s HSPU-Purifier!

The HSPU Purifier brings the advantages of a new design and technology together for higher efficiency in semolina purification and classification processes. The purifier stands out with its new look, and improved ergonomics and functionality for its users. The design work of machine has been carried out carefully in partnership with Italdesign Company.

This innovative solution for the milling industry already sets the standard very high for our 2020 awards, and we look forward to discovering what other innovations will join and compete for the GRAPAS trophy.

Secure your place at the GRAPAS Innovations Conference

Registration to secure your attendance at the GRAPAS Innovations Conference will also be available very soon on the VICTAM official website. Make sure to book your place

if you want to secure a seat at the conference and to see which milling innovations are crowned our GRAPAS winners!

From now, until January 1st, 2020, we have an exclusive deal on tickets. Early -bird tickets currently only cost US $30.

From January 1st, 2020 onwards, tickets for entry into the GRAPAS Innovations Conference will cost $99, so book your seats now and take advantage of this brilliant deal!For any enquiries regarding either the

Innovations Awards or the Innovations Conference, feel welcome to email me at

[email protected].

Rebecca Sherratt

Henry Simon’s HSPU-Purifier

Applications for the GRAPAS 2020 Innovations Awards close on January 19th, 2020.Simply email me at [email protected] for more information or an application form.


Milling News

In a previous article I wrote about the Define phase of LSS. Today we continue with the second phase of the DMAIC cycle of improvement. LSS is a data-driven methodology. As such, the measurement part of the method is what provides the critical information required to operate. We don’t make decisions based on hunches. Or at least, we try to avoid it when there is information available.

The objective of this phase is obtaining a view of the performance of the process. We already established what is important for us in the Define phase. Now it is time to effectively measure those variables.

Determine how the process currently performs

The current state of the process shall be recorded using a process map, which is some kind of flow chart. In LSS the standard is the Value Stream Map, that shows where value is added to the product and how, but there are different options that I may analyse in a future article.

Create a plan to collect the dataThe Define phase tells you what data is

important. Now you have to decide how to collect it. The process map becomes

invaluable to avoid duplication of efforts and to identify critical bottle necks. For example, checking for aflatoxins is important, but it is better to do it before milling the grain. That way, if a batch is defective, you can throw it away without wasting energy and hours in processing it.

The data collection plan is a spreadsheet defining what, when, who and how of the measurements.

Measure, the second phase of Lean Six SigmaGustavo Sosa

Measure(the important variable)

Data Type(objective or subjective, continuous or discrete, units)

Operational Definition (what, exactly, measures the variable)

Stratification Factors(how you group the data together)

Sampling Notes (time frame, frequency, location, or other instructions)

Who and How(person responsible and method)

Incoming grain Objective, continuous, kg

The net weight of the load in every truck entering the facility

Shift, or half shift The truck is weighed with the load when it comes in, and later the tare is obtained when it goes out.

The scale operator, using his computer.

Whiteness Objective, continuous, percentage

The degree of bran removal achieved in a rice batch.

Batch, shift. At the start and at the end of every batch processing, or shift changes. Taken after wet polisher.

Head miller or Lab assistant, using the automatic whiteness meter.


Milling News

Gustavo Sosa is a Mechanical Engineer and MBA who specialises in Project Management. He is the CEO of Sosa Ingenieria, a consulting firm performing mechanical design and FEA/CFD, and the Chief of Engineering at RONTIL, a major distributor of grain handling equipment in Uruguay and Paraguay. Gustavo has two decades of experience in grain handling and milling, including engineering design and project management for projects up to 60 million USD.In the past, he worked for three years as a professor, teaching fluid power, mechatronics, conveyor design and industrial instrumentation at UDELAR, the largest university in Uruguay. He also helped build the Mechatronics Laboratory there.

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Ensure the data is reliableThe instruments used should be always well calibrated,

according to a preventive maintenance plan. The data collection plan should be followed strictly, to ensure the measurements are comparable one to another.

It is also important to revise the operational definitions from time to time, to make sure we are collecting the data that is relevant for us.

For example, in a grain dryer it is important to keep grain temperature below some limit (according to grain and end use) and also to decrease moisture. Measuring temperature in the grain is very straight forward, but the majority of moisture testers are calibrated for static and cold grain, so they will give you nothing in a dynamic and hot environment. Thus, moisture measurements in grain dryers are usually unreliable. Some of them work perfectly, but to separate “wheat from the chaff” you have to be extra persistent asking for technical information and conducting tests. Contact Perry of Oakley for more information.

Gather the baseline dataBefore starting an improvement project, you have to take a

picture of the current condition of the process, listing all the variables with their values. This task involves gathering all the automatic information, all the manual information, and creating reports. It usually involves using Check Sheets, to follow a variable until you get a reliable measure.

Update your project charterOnce the baseline is ready, you keep collecting data. This

will provide more details about the process performance. The evolution of the variables in time will give clues about problems and opportunities for improvement.

It may also reveal that some variables are meaningless. The Project Charter (the description of the problems and goals of the project) should be updated accordingly.

Stratification Factor Date Issue Defect Category Follow-up Follow-up Date


Funding injection for successful trial boosting calf health and size at Bridgwater & Taunton College

Investment has been doubled for more tests in a livestock trial, delivering a drastic increase in yield and removing pathogens from water without the use of antibiotics.

WET Group, which supplied the technology used to clean the bore hole water commonly mixed with artificial nutrition feed and then fed to cows, worked with the Agriculture Innovation Centre at Bridgwater & Taunton College on the year-long trial on cows, and has decided to fund further trials in order to expand on initial findings.

The further investment from WET Group will introduce its upgraded successful mineral enhanced compact G.E.M. (Guided Enhanced Membrane) system in the final phase of trials which are due to commence in this month.

The initial trial, which was carried out on two groups of calves totalling more than 50 in numbers, tested water fed to cows finding that the potentially harmful pathogen, Clostridium Perfringens, was present and multiplied significantly in an untreated sample at room temperature (22°C).

However, when the same water was treated with technology from WET Group the pathogens were removed and there was a drastic reduction in bacterial growth under the same conditions.

These tests also demonstrated that with water treated by WET Group technology, (unlike the traditional method of cleaning water) the animal does not require antibiotics treatment as it delivered much improved calf health under the internationally recognised Wisconsin-Madison Calf Health Score system (WMCHS).

Simon Fry, Environmental & Filtration Technical Manager at WET Group, says, “The findings from the initial tests were so significant that they could revolutionise the industry and highlight that we are feeding our livestock exposed unhygienic water that is potentially damaging to them.

“This is why WET is to invest in further trials to provide 100 percent validation of its G.E.M. We have been careful with the initial test conditions, we now need to replicate them and prove to our British farmers that by simply using water that has been properly cleansed, filtered and enhanced when mixed with feed, could improve the lives and quality of livestock.

“We’re excited to start this next trial. The early signs are that this will be a landmark change for the health of livestock, the yield we get from livestock, and potentially the health of those who eat the product, as it raises important questions about the ripple effect created once these harmful pathogens enter the human food chain.”

Initial testing suggests that WET Group technology ensures that all water is clean and free from residual chlorine and microbe/bacterial infection while enhanced with mineral nutrition. This is done using the G.E.M system through a patented process of filtration, enhancement via controlled re-mineralisation providing a special functional water.

Ian Tremain, Agriculture Innovation Manager at Bridgwater & Taunton College, says, “We have been highly impressed with the initial trials.

“The trials show great promise for the agricultural sector in the UK with potential for farmers to deliver healthier calves with a reduced requirement for antibiotic treatment and ultimately higher yields and increased profitability from their dairy herd.

“It also shows that as farmers we can still improve methods by taking a methodical, scientific approach and investing in the right technology to make better lives for the people and animals we look after. The commitment WET Group has shown in making the investment to continue trials is proof of confidence in its technology and that it can make a major difference.”

To find out more about the research conducted in this trial or the technology tested please visit www.wet-global.com


Milling News

www.golfettosangati.com [email protected]

Mill owners, managers and directors without practical background experience are invited to attend the Buhler—KSU Executive Milling course at Kansas State University’s IGP Institute. This course, planned for November 4-8th, 2019, is designed to give participants knowledge and experience to bring back to their respective companies.

“Participants are exposed to several topics involving milling processing and procedures,” says Jason Watt, Buhler Instructor of Milling.

This includes subjects as raw material varieties and characteristics, cleaning systems, flow sheet technology, and finished product handling. Past participant Mark Harrison, engineering manager at SEPROD Limited in Kingston, Jamaica believes this training gave him a better understanding of the processes.

“Being able to understand the importance of particle size, different components and where they are in the process gives me a better understanding of the milling process. It’s better to have an overall knowledge of the process to understand how the mill can become

more profitable,” Harrison says.In addition to learning in a lecture setting, participants also gain

hands-on experiences using Buhler equipment in the Hal Ross Flour Mill.

“Hands-on activities help them apply their classroom learning. By working with the equipment, it helps them retain their knowledge,” Watt says.

Understanding food safety and regulations necessary to comply with the Food and Drug Administration (FDA) was the topic of the NGFA–KSU Food Safety Modernisation Act (FSMA) training held at Kansas State University’s IGP Institute. This course was held August 20-22nd, 2019 and hosted 50 participants.

“It was valuable to have such a diverse group so we can understand the requirements and flexibility of the Preventive Controls for Animal Food Rule,” says Cassandra Jones, course instructor and associate professor of animal sciences and industry.

The course offered certificates upon completion on the Food Safety Preventive Controls Alliance (FSPCA) and the Hazard Analysis Critical Control Points (HACCP). In order to receive certificates, each participant had to fully demonstrate the requirements by a “preventive controls qualified individuals” per the FDA’s regulation.

Participant Madelyn Tusha, Kent Nutrition Group plant engineer, shares that she knew the regulations, but wanted to get a more in-depth look as to why they’re in place.

“It’s important for people at the feed mill to understand the reasons as to why procedures are set in place,” Ms Tusha says. “It was helpful to dive deeper into what the FDA looks for and how they can help us.”

The course curriculum was developed by the Food Safety Preventative Controls Alliance.

In addition to supporting professional food safety training the IGP Institute also offers training in grain processing and flour milling, grain marketing and risk management, and feed manufacturing and grain quality management.

As part of the US Grains Council Trade Team experience, a training focused on DDGS and sorghum usage in feed was held at Kansas State University.

Food production technologies constantly develop due to the increase in global population. To keep up with the demand, those involved with food production are implementing new ingredients into their animal diets to include sorghum DDGS (dried distiller grains).

To help educate those following the rising trend, the IGP Institute and the US Grains Council (USGC) hosted the Myanmar and Philippines DDGS and Sorghum Seminar.

“We hosted participants from the Philippines and Myanmar who wanted to enhance the knowledge of adding sorghum DDGS into their feed,” says Carlos Campabadal, Feed Manufacturing and Grain Management outreach specialist.

Course participant Rochi Aldeguer, procurement associate for San Miguel PureFoods Company, Inc., shares what she will take away from her experience at the IGP Institute.

“This course was extremely beneficial to me, because we are looking into using sorghum DDGS as a part of our raw material ingredients,” Ms Aldeguer says.

Course offered for milling executives

IGP Institute presents training on animal food safety regulations

IGP Institute engages USGC international professionals

TRAININGMill

Matt Frederking, Vice President of Regulatory Affairs and Quality at Mid America Pet Food, discusses the importance

of implementing a food safety plan with the NGFA–KSU Food Safety Modernisation Act participants


PRODUCT FOCUS

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October 2019In every edition of Milling and Grain, we take a look at the products that will save you time and money in the milling process.

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Purifiers redefined- Bühler’s Norit PurifierPurifiers are responsible for the final quality of soft wheat, hard wheat and maize products. Bühler now presents the completely revised purifier Norit MQRH as the successor to the Puromat MQRF.A new machine offering reliable, consistent purifying for all kinds of grains. The new purifier has a streamlined and well-thought out design while focusing on what’s essential. The newly designed housing and inlet support a smooth product flow. All parts in contact with the product are made of stainless steel or food safe synthetics to ensure process and product safety.Rotary switches allow the air flow to be individually adjusted without tools. The new purifier Norit MQRH now stands on three rubber springs instead of four. See more on page 68

Alapala Bran FinisherAlapala’s new bran finisher machine uses a centrifugal action to gently separate the floury endosperm attached to the bran, thus reducing to the minimum the starch content of offal and ensuring high flour yield.It has a welded sheet structure, and a cover made of perforated sheet steel specially shaped to avoid internal turbulence.The product is thrown towards the screen by means of a wing - fitted rotor, which is rotated horizontally; consequently, the flour and bran are separated from each other. Due to centrifugal force, the product is thrown towards the screen whose size is selected beforehand. During the screening process, flour passes through the screen and larger sizes of bran are directed to the discharge outlet.

Petkus Belt DryerThe Petkus Belt Dryer unites drying effectiveness with quality results. An ingenious air flow solution allows for highly efficient, yet gentle drying. The integrated belt cleaner reduces manual labour and eliminates cross-contamination with materials such as chemical residues.The Petkus Belt Dryer was developed to gently and flexibly dry seed after chemical treatment. During the coating process large amounts of liquid are sometimes sprayed leading to moisture pick-ups of up to five percent.Warm air is fed from the side through two hot air channels by two separate fans allowing air to flow through the product homogeneously from below. The temperature can be individually regulated. Four temperature sensors allow for optimal monitoring and control of the drying process thus preventing product from overheating and preserving germination capacity/vigour.

Yemtar Dosing ScalesYemtar’s new dosing scales have a body made with St37 material. It is PLC controlled, and its final bag weight, total bag number and total weight can be seen on a handy command panel.Daily values can be deleted as required but the general total can be deleted by only an authorised operator. The scale resumes running in the case of a power outage. It has a scale sensitivity of t50 gr/bag. There is a special band for product feeding to scale, pneumatic gates to hold and leave product in scale, and a pneumatic bag holding system in the bottom hopper.

Zheng Chang’s SLHY Spiral Belt MixerZheng Chang’s spiral belt mixer offers high uniformity and moderate mixing with no segregation. It has a short mixing cycle and discharges quickly with very little residue. The two-way spiral belt rotor is made of high-quality alloy steel and the rotor is equipped with a ring cleaning device. Several atomized nozzles can be equipped to for liquid addition.

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FOCUS

SPECIAL FOCUS Some like it hot: Dinnissen Pegasus Mixer destroys mycotoxins with heat

www.dinnissen.com

Things are changing rapidly in meat production and the animal feed industry.Consumers have an increasing influence on animal welfare and the feed that the animals are consuming. Several feed additives that

were used to control undesired pathogens have already been banned in order to avoid negative effects and to produce a natural and healthy piece of meat.

Feed producers are challenged to deliver a healthy feed that is free from undesired pathogens.The natural way to sterilise a product is by means of heat treatment. When making pelletised feed the heat treatment step takes place

during the pelleting process. Mash feed, however, is usually produced in a cold process, so the absence of undesired pathogens in conventionally produced mash feed cannot be guaranteed.

Thermidor®, the Dinnissen system for sanitation of mash feed, is the answer to those challenges.The first step in the process takes place in a special Pegasus® mixer. By means of direct steam injection the mash feed is heated in a

very efficient way. The mixing action breaks up concentrations of microbes and tests have validated moist heat to be most effective at killing pathogens. In this way a uniform treatment of the entire batch is achieved.

After the heat treatment, the product is dried and cooled in the second Pegasus® mixer. The fluidised bed that is generated inside the Pegasus® mixer enables a quick and efficient drying/cooling process. Here it is also possible to add heat sensitive ingredients and liquids.

Besides the sanitation effect, this process agglomerates the fine particles with the bigger particles, which results in a dust-free and easy to handle mash feed.

The DINNISSEN Thermidor® process: Your tool to produce healthy feed.


Flour milling lines ‘H, I and J’ at this world-renowned site, which happens to be the largest producer of flour at a single facility and processing over 11,600 tonnes of wheat-per-day, are being upgraded with the latest Ocrim equipment. Over a four-year period, three processing lines have been replaced without losing any production. The whole project will be

completed and up-and-running in early November 2019.

Indonesia is a very long and spread-out country. Its population of 268 million people inhabit some two million square km spread over 16,000 islands. Bogasari is the country’s major flour producer and is continually striving to meet the ever growing demand for flour and milled products.

With lines ranging from ‘A-to-O’ that’s how the world’s largest single-site flour mill allocates its production lines - it has a total of 15 lines processing just over 11,600 tonnes of wheat-per-day in three shifts. All are Ocrim-equipped lines. Existing lines ‘H, I and J’ have been progressively replaced with up-to-the-minute advanced machines, replacing the earliest Ocrim milling lines.

Although Milling and Grain visited to look at the new lines and the planned silo development, I took the opportunity to ask Mr Welirang about milling in one of the world’s most populated countries.

by Roger Gilbert, Publisher, Milling and Grain

As new generations come to the fore, changes occur and no more so than in the milling industry. Milling and Grain visited Bogasari Flour Mills in Jakarta, Indonesia earlier this year to report on the refurbishment of three of its 15 production lines by Ocrim. The current upgrade is not just about new equipment and the latest technology, it’s also about the changing aspirations and purchasing trends of local consumers.

Perendale Publisher’s CEO, Roger Gilbert, talked to Franky Welirang, CEO of Bogasari, which is part of PT Indofoods Sukses Makmur, about his views on the future of flour milling as it tries to meet the food demand from a country with 262 million inhabitants spread out over 5,245 km from west to east and encompassing 16,000 islands.

Technological advances help millers meet consumer needs

Bogasari Flour Mills


F

Q: What makes Indonesia unique in milling terms?“Indonesia is often misunderstood. From east to west is the equivalent flight time

of Abu Dhabi to London, the spread of Indonesia is almost a 10-hour flight. It is comprised of five big islands: Sumatra, Java, Borneo (Kalimantan), Sulawesi and West Papua. 60 percent of our 270 million people are located on Java, the smallest of these five islands. Sumatra is three-and-a-half times the size of Java and West Papua is even bigger. In between there are over 17,000 small islands.

“Urban growth is not particular to Java but is occurring throughout the country and is bringing with it logistical problems for us. Logistics in Indonesia involves significant air, sea and land travel. The price of domestic transport is very high. This is one factor among many that limits our growth.

We would like to see every home kitchen in Indonesia with a 0.5kg of flour on the shelf, just like all the other essentials like salt, pepper, vinegar and sugar.” That’s the goal of Franky Welirang, the CEO of Bogassari, Jakarta, the largest single-site flour mill in the world.

Franky Welirang CEO (left), stood with Erwin Sudharma, deputy director, Bobby Arianto, SVP Manufacturing and Andry Wiryanto. Vice-president Engineering and Technology, his second generation management team at Bogasari in front of a portrait of the founders and first generation of company leaders. The third generation is ‘coming in,’ says Mr Welirang

Interview with Franky Welirang, the CEO of Bogassari

2020

Accepting entries for 2020 now!

THE GRAPAS INNOVATIONS AWARDSTo apply please contact Rebecca Sherratt ([email protected]) for an application form.

YOUR GLOBAL PARTNER

MARCH 24TH BANGKOK, THAILAND

A ONE-DAY CONFERENCE FOR MILLERS OF FOOD, FLOUR & RICE

Part of GRAPAS Asia 2020, March 24 – 26, the dedicated event for the grain and rice processing industries within Asia


F

Q: Is the company’s aim to provide for the bigger populations first?

“We see across Indonesian cities developing their urban areas. These urban areas are becoming a target for flour. In northern Indonesia there is increasing competition due to the close proximity to Penang.

“Our competition is in terms of costs, availability, consistency and service. Consistent quality requires standardised wheat; different wheat will give different character to the flour, even though it may have the same protein content. This is how we see the market and it is continuously growing and developing. We see Indonesia as it is within ASEAN.

“The major flour industry in the region is probably Indonesia. Over the past 20 years we have been the most competitive and fully deregulated in the flour industry. There are 25 factories in Indonesia. We are the biggest, with four locations. The biggest is here in Jakarta at around 11,600 tonnes-per-day and then Surabaya with around 6000 tonnes-per-day. We took over a company in West Java of 1100 tonnes-per-day and another mill producing 200 tonnes-per-day. All four of our mills are running well.”

When asked if the company had considered exporting flour to neighbouring countries, Mr Welirang said that efforts to develop markets for flour products in Myanmar and the Philippines had also been curtailed due to logistical costs.

“We do export to the ASEAN region but that is not our main focus. Besides flour, we also have by-products which we produce for feedmills. We do not have a feedmill yet. Around 50 percent of our by-product is exported to Taiwan, Vietnam, Philippines, Japan, Korea and Middle East.

The other 50 percent of our by-product is used domestically in our own feedmills. I believe that in the coming 10-15 years our current protein supply will not be enough, so we will need to produce a feed with higher protein content. This will come with improved technology. Indonesia has something like 100 feed mills and produces 22 million tonnes of feed,” he added.

Bogasari also produces pasta. In fact, it has the largest

manufacturing facility for pasta in South East Asia.“In the past, 70 percent of our pasta was exported and 30

percent consumed domestically. Now we export 50 percent and 50 percent is consumed domestically due to increased demand within Indonesia. So the domestic market is growing and we are expanding our pasta production lines as well,” he adds.

Q: Is the Indonesian diet changing in other ways?“There are two changes we have seen in the market. The

majority of our population are young millennials – below 40 years of age. Today’s businesses are on the brink of change which will occur over the next five years. I’m the ‘going out’ generation, and they are the ‘coming in’ generation. The first generation has passed, I am the second generation and the third is coming. If you look at the manufacturing side and the trade side, the distributors and the traders, you’ll see a passing of generations.

And new industries are arriving. Depending on how industries treat the market, that is a light on the big industries, medium and the small. Sixty percent of our business goes to small and medium industry, the remaining 40 percent to big industry.

“What I mean by big industry is biscuit producers, instant noodle producers and the big bread companies – all with modern facilities. These big industries will try to produce their own flours in the future. Then you have the 60 percent that makes up small and medium enterprises, ‘mumma-and-pappa’ style businesses producing breads, noodles, cakes, cookies, etc. If we take the modern large industries, they are so advanced, yet their margins are small but stable. Then when you look at the thousands of these small and medium enterprises, that must be included in our distribution, they are growing and have greater margins.

“These businesses need to be well equipped to handle the market. Not only that but the way they trade is changing the system. In short, you have the traditional kind of industries, and then you have the modern type which goes against them. So you have young millennial-type industries developing and they are

Pansifters were the first to be replaced in a two-step operation that did not hinder the output of the three lines being upgraded

The Bogarari management team is proud of its ability to train millers. An extension of the Ocrim Milling School, the Bogasari Milling Training Centre ensures all workers are fully trained in operating the latest technologies being adopted by the company

The wraps come off! The last of three production lines after a four-year upgrade of one milling section in this massive facility is complete. The three lines will be fully operational in November this year

RESEARCH & DEVELOPMENTMADE IN ITALYomasindustries.com

Leonardo Roller Mill

THE REVOLUTION IS UNSTOPPABLE

#MILLINGREVOLUTION

DEVELOPMENT | FUTURE | DESIGN | KNOW-HOW | UNIQUENESS


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RESEARCH & DEVELOPMENTMADE IN ITALYomasindustries.com

Leonardo Roller Mill

THE REVOLUTION IS UNSTOPPABLE

#MILLINGREVOLUTION

DEVELOPMENT | FUTURE | DESIGN | KNOW-HOW | UNIQUENESS

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using modern online methods including social media to sell their products.”

“It’s a very different approach to the way bulk flour is sold,” he adds.“To understand the pioneering of new industries, these are home industries. They grow through friends, birthday parties, marriage and also during festival seasons. The young generation is different—they identify through an online market as artisans - and they are making business through it! They pay a lot, many times the normal price and they queue for three months waiting for product. Their claims are health with good packaging and home delivery. The trade in grains is also changing, you have the traditional and the modern. In answer to your question I believe that all aspects of the market is undergoing these kind of changes.”

Q: How do you cope with being such a huge flour producer on a daily basis while customers are buying small and smaller packs online. Are there changes taking place in your company to address this?

“We normally sell in the 25kg bags, now we have 5kg, a 1kg and a 0.5kg. We also sell online, and the company keeps an accurate tracking of its sales through normal distribution channels", he adds. “Basically we are tracking our product, our distributors and our grocers. Flour is an intermediate product, it is totally about how to market it. For example, who is making cakes for sale, etc. The more people making cakes and bread the better our market is for flour.

Baking equipment is also very important. If it doesn’t exist here, the flour market is not growing. All of the mixers and such like

Mill Manager Inyoman Arthadana in the new treble-line mill’s control room shows that the roller

stands can be managed from his tablet, which provides the same information as he had access to

in the control room alone

There is more to this up-grade than just a replacement of the

roller mills

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*�Authorized�by�EU�Regulations�No�1060/2013,�1016/2013,�1115/2014,�2017/913,�2017/930�and�2018/1568�for�the�reduction�of�contamination�with�fumonisins,�aflatoxins�and�trichothecenes.

MYCOFIX�(IR-554780)�and�BIOMIN�(IR-509692)�are�registered�trademarks�of�Erber�Aktiengesellschaft.

ADSORPTION

BIOTRANSFORMATION

BIOPROTECTION

Powered�by�science�to�actively�defend�against�multiple�mycotoxins*�

With 3 combined strategies

Naturally ahead

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MYCOFIX


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need to be available across the whole of Indonesia. Secondly, the market for additives and yeast products must always be available.”

Q: There are thousands of islands that make up Indonesia. On the more obscure islands do people have access to baking equipment?

“That is the challenge we face. We are working together with a baking centre. We train people how to bake and make cakes, so people with no prior knowledge can make quality products at home. Our task is not merely selling flour, but creating new business people and job opportunities. What we have to try and promote is the end product of flour, jointly with those who make them. If we can do that then flour will be purchased. Promoting cakes and biscuits and pasta products promotes the use of our flours.”

Q: In the distribution system that you have, if you had an order online for 1kg of flour on a small island out there, can you deliver it?

“We try to identify all the shipping routes. Basically Indonesia is built up of provinces, regions and villages. We identified that there are 83,000 villages throughout Indonesia. Out of those, if 50,000 villages are developing we need to be present in those

villages. Our marketing needs to reach the smallest of the villages.”

Q: How much of Indonesia’s population is accounted for in these villages?

“Something like 70 percent. We supply urban and rural areas. Indonesia started life on 28th October 1928. Before this there was no nation of Indonesia. Today, it is a nation country, not a country of nations when we received independence from the Japanese in 1945. Prior to this it was kingdoms with many sultans and kings, which still exist. All of the regions still have their kings. The kings accepted Indonesia; they wanted to be together. We are different here in Indonesia, so we require a different approach.”

Q: Do you think that, looking towards the next generation, Bogasari will build more flour mills outside of Java?

“No. It should be more centralised in order to lower costs. We can beat the logistics by having a warehousing system that is subject to volume. And we must study how to manage our mills well. But we must also consider the logistics of wheat, the packaging used and market availability. When we go to a region we study these barriers.”

Three mills upgraded at Bogasari

Of the 15 lines at the Bogasari mill in Jakarta, three lines were deemed to require upgrading.

Each of these three older lines was processing 800 tonnes of wheat per day and within the same footprint each new line is now capable of outputting 1200 tonnes per day. To achieve this 50 percent production increase on the same footprint, Bogasari has gone for Ocrim’s latest ‘modular’ milling system, a concept that allows mill managers to shut down parts of a plant when needed without reducing productivity. The three lines also carry the latest ‘tablet’ connectivity using WIFI connections allowing the operator to move around the mill without relinquishing control or having to rely on an operator in the control room.

Other key improvements include the company’s latest RMX roller mills - which use predominately an all-stainless steel construction for food grade surfaces - through to the SFI/M modular sifters.

To minimise a reduction in capacity during the changeover, the existing lines were replaced one at a time. This allowed production to continue uninterrupted on two lines throughout the four years it has taken to make the upgrade. The first step in the process was to upgrade the cleaning systems for all three lines in a two-step process and to minimise downtime. Once that had been done, then work started on the mill itself.

This is a ‘swing mill’ which can run both hard and soft wheat. Each line is supported by eight plansifters. In total this three-line facility boasts 135 roll stands, and like the rest of the Bogasari site all equipment is provided by Ocrim. There is an energy-saving element to the mill with general inverters on the pneumatic system. And even the layout of the mill has been re-orientated to achieve energy savings.

Doubled-up roller mills for the first break are just one advancement of the new lines being installed at

the Bogasari flour mill


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Q: Are you fortifying flour in Indonesia and, if so, have you seen health benefits?

“Yes, it is obligatory for flour in Indonesia to be fortified. We started fortifying flour in 1999. I think we were the ones that promoted the idea to Africa. When we first started we tried to identify health improvements. In 2000-01 we went to primary schools and gave children two pieces of bread every morning and took occasional blood samples. Most village children go to school without breakfast. We gave them two pieces of bread because they would save one piece of bread for home and eat the other. If we had of only given one piece of bread they would have just taken it home.

“The bread was baked at nearby bakeries. We ran this program for one year and compared the blood results and found that the iron intake and fibre was greatly improved. This study was supported by the leader of the village and in that particular village people would follow their leader’s decision. This study was held at three primary schools in the village and it was great to see the positive results. We began our studies in 1998, as we were the biggest flour producer. We did this voluntarily and other companies followed suit.”

Q: In packaging 0.05kg and 1kg bags, what is the shelf life of a bag?

“One year. All of our 25kg bags are polypropylene bags and they are 100 percent bio-degradable, we offer the only bio-degradable polypropylene bag in Indonesia. Nobody respects this. Next we will be releasing a 1kg bio-degradable bag. Our bags take two years to bio-degrade, none of our competitors are using bio-degradable bags yet. We have received complaints from our customers because they can only use the bags one time—additional use causes them to break.

So you can see why we are not being supported with our bio-degradable bags. The argument is between bio-degradable and recycling. The world is still undecided on the two ways of looking at this.”

Q: Finally, does Indonesia produce its own wheat?“100 percent of wheat is imported. There is not enough suitable

land in Indonesia to grow wheat. We only have 190 million hectares, 50 percent of which is considered ‘tropical protected forest’. The land we can use is about 18 million hectares, and that is used by the population, as well as coconut, coffee and rice plantations.

The government policies are prioritised towards rice production. This does not mean that we cannot produce wheat in Indonesia; we developed and have had support in the past for developing what we called tropical seeds.”

Q: When you buy wheat internationally, where do you source it from?

“Basically the wheat we buy is dependent on competitiveness and quality. Our traditional suppliers would be Australia, America and Canada. We have the others, which are considered non-traditional suppliers, are Latin America, Eastern Europe, China, India or Pakistan, but generally there is more dust impurities in the wheat and so this decision is made subject to price.

“Australia has a close proximity and is usually our biggest provider, but in the past few years this hasn’t been the case due to weather and the resulting crop failure. In the past it has been typical for around 55 percent of Indonesia’s wheat to have been imported from Australia, I think today this is lower than 30 percent. Now we are importing more from the USA and Canada.”

Taking flour to the provinces is not a solution in itself. Providing the equipment to bake bread is being supplied by Bogasari using transportable, yellow, mini-bakeries that produce daily bread products where they are most needed


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New silos at Bogasari

Bogasari has broken ground to start the construction of foundations for its new 36,000-tonne nest of wheat silo storage at its dock side in Jakarta. Ocrim is the general contractor with GSI bins being installed. The silos should be operational by mid- to late-2020. There are two key elements of this new storage facility. The first will be its ability to transfer up to 1000 tonnes of grains per hour from jetty to silo.

When Milling and Grain visited Ocrim to attend its 2019 Open Day - ‘Wheat, flour and …’ - in mid-September we saw the new bucket elevator head and foot under construction. It’s an impressive piece of engineering and will pull 80-metres of 13mm rubber belt that will be 1.45m wide. This 13mm rubber belt will have a row of seven buckets across in a wave formation to help distribute the load and will have eight rows of buckets per metre.

A second and almost more impressive advancement in silo construction is the new ‘protein-based mixing system’ Ocrim is adding to the facility. It will blend based on protein content of the wheat coming in using inline NIR monitoring, rather than the traditional method of blending on volume.

The inventory operator will be able to blend to the protein requirement needed as the wheat exits the storage facility. This will replace an estimating system with a predictive approach.

This application is not only new from Ocrim but is new for the market and while it is based on regularly available NIR equipment the technology Ocrim has developed around the system uses Industry 4.0 standards with traceability in mind, and provides a unique concept designed and installed by the company.

The silo manager will also have access to accurate information from within the bins on content, levels and product temperature ranges. The storage system will also integrate with a truck movement and tracking system around the extended site, monitoring trucks are and what products they are delivering or up-lifting.

www.ocrim.comwww.bogasari.com

Above: A panorama image of the greenfield site where work has begun on 12 silo configuration to contain 36,000 tonnes of wheat

The dock-side is constantly active with ships from the largest 80,000-tonne Panamax unloading day and

night using two Nero unloaders. The new Ocrim/GSI silo storage facility will be built adjacent to the port

and a short distance from the mill complex

Below: The top and the bottom of it - The massive foot and head rolls of the bucket elevator take shape at Ocrim’s engineering plant that will lift grain some 40 metres on a 1.45m-wide belt with seven rows of buckets per metre to achieve 1200 tonnes per hour to be lifted

It is scarcely surprising that the range of grain-based food products produced using the extrusion process continues to grow steadily. Extrusion is perhaps the most versatile process available to the food industry. It is capable of producing a wide range of end products from a variety of different ingredients and rapidly switching between them. It can replicate products

made using other, less flexible, methods and the breadth of process options offers product developers plenty of scope for innovation.

Food with enhanced nutritional properties is a significant current growth area as diet awareness grows. High-quality snacks and ready-to-eat cereals form an ideal base for functional nutrition, and extrusion can be utilised to penetrate this expanding market for foods high in protein and fibre.

Snacks and cereals are a convenient and palatable carrier for these beneficial products, and development work by Baker Perkins shows that any existing extruded or co-extruded product recipe can be easily augmented.

The protein market, for example, is moving rapidly beyond body building into the mainstream to meet a variety of needs, including balancing diet, satiety and weight loss. Any existing extruded or co-extruded product recipe can be easily augmented by changing the product formulation.

Proteins from wheat, dairy, soy or nuts as well as fibre can be introduced to any extruded grain-based snack in powder form; soluble fibres can be added to co-extruded products. Whole grain or multi-grain formats could also

by Keith Graham, Baker Perkins Business Development Manager, UK

Extrusion brings versatility

to food industry


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be chosen to make a positive contribution to the nutritional profile, and strengthen the ‘feel good’ factor. Cereal flakes can be fortified with vitamins, protein and fibre.

Gluten-free is another category seeing rapid growth. Again, extrusion can help manufacturers respond to demand by using flours from gluten-free grains such as maize, rice, quinoa or buckwheat and also, incidentally, provide grain-free products by using vegetables and legumes. As with protein and fibre, the adaptable extrusion process can easily accommodate gluten-free recipes.

Wholegrain products have been growing for some time. They retain, after processing, all three parts of the original grain – the germ, bran and endosperm – in their original proportions. Multigrain products feature a combination of grains such as wheat, rye, corn, barley or rice; they offer the opportunity to develop new textures with a beneficial nutritional profile.

Baker Perkins offers several product concepts based on a whole or multigrain platform. They include shredded, expanded and cracker snacks with greatly reduced levels of saturated fat, overall fat content, and salt. Grains and other ingredients that add appeal and a healthy image are the hallmark of shredded style snacks with shape and texture generated by extrusion rather than frying.

There is also a discernible trend towards more adventurous products. The capacity of extruders to add virtually any colour and flavour allows products to be tailored to recreate tastes and textures from around the world.

In addition to familiar, conventional flavours, Asian, Middle Eastern and Hispanic tastes are increasingly popular. Chilli,

paprika, teriyaki, guacamole, sweet and sour, black bean sauce and a wide family of curries can be used individually or in combination to produce snacks with high consumer appeal.

Snacks and ready-to-eat cerealsThe snack and ready-to-eat cereal sectors are intensive users

of extrusion systems, and representative of the capability and adaptability of the extrusion process and the opportunities it creates.

Companies can enter the market with an uncomplicated system, usually consisting of an extruder, dryer and flavouring system, making standard, direct expanded curls, balls, rings and chipsticks with rapid changeover between runs of different

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products. As a business grows, or consumer tastes change, a Baker Perkins line may be extended to broaden or even completely change the range of products being made.

Companies that wish to expand their product offering beyond direct expansion often opt for co-extrusion. The co-extrusion die produces continuous cereal tubes filled with a savoury or sweet paste or cream. The tubes can be formed into a variety of formats including mini, bite-size or hand-held pieces in pillow, stick, bar or wafer shapes.

Fillings can be of virtually any colour or flavour – sweet and savoury creams, fruit pastes, cheese and chocolate praline are typical. Exotic flavours, plus glazings, frostings or chocolate coating, add even more appeal. The outer shell can appear to be plain or stringy, with surface textures such as grooves and highlights.

Extruding complete and part productsA rapidly growing business is the extrusion of ingredients and

inclusions for the food industry. Typical examples include soy or grain crispy pieces that add texture and functionality to bars and dairy products; modified flours and starches that act as clean-label thickeners and emulsifiers for soups, sauces, desserts and beverages; and standard or gluten-free breadcrumb and croutons.

Compared with traditional processes, extrusion can bring significant savings in space, equipment, energy and labour. Breadcrumbs are a typical example. The traditional process involves mixing, forming and baking bread before discarding the crusts and grinding. The same product can be made without waste – with gluten, or gluten-free - using only a twin-screw extruder and dryer.

Similarly, for soup and salad croutons; a bread-like texture can be developed in the extruder and the pieces cut to size at the die or a post-extrusion cutter.

Extrusion is also an excellent way of addressing the market for gluten-free bread products as it can handle with ease the various alternative flours and starches used to make the dough.

As an aside, new opportunities regularly appear for extrusion, not always in the food industry. One recent out-of-the-ordinary application proven in a Baker Perkins extruder replaces foam pellets used for packaging with extruded starch pellets – which have the great virtue of being biodegradable.

A new generation of extruderA new generation of extrusion equipment for the food industry

has been introduced by Baker Perkins. The SBX Master twin-screw extruder range for cereal, snacks,

ingredients and other food applications has been re-designed and a new pre-conditioner added to the range to increase flexibility.

The flexibility of the SBX Master extruder has been improved by increasing power, torque and speed. This, along with a range of barrel lengths, increases the variety of end products that can be made while barrel diameters between 50mm and 125mm give an output range from 500-to-2,300kg/hr.

Improved cooling also contributes to broadening the range of

products that can be made, and additionally improves quality and consistency. The new design features water distribution channels for cooling located closer to the internal surface of the barrel to improve both responsiveness and the rate of heat transfer. Flow rate is increased, and cooling can be controlled and adjusted to individual product profile.

The SBX Master is now a totally modular machine, so future extension of the barrel and all the associated services to expand or change a product portfolio is speedy and straightforward.

The arrangements for mounting the die and cutter have been simplified to make changeover, cleaning and maintenance faster and safer. The die is supported on a hinged arm that enables it to be moved quickly and safely, especially when hot, while the cutter slides in and out of position on rails.

This is a pneumatically-powered, pushbutton-operated system that automatically puts the cutter directly in front of the die as soon as the extruder is ready, leaving only fine adjustment to the operator. This minimises time and waste generated during set-up, changeover or, if a blade change is required, during a run.

A gearbox condition monitoring system that reduces unexpected downtime is available on all new SBX extruders and can also be fitted to existing machines. This simple system continuously monitors the frequency and amplitude of vibrations within the gearbox, allowing the ongoing condition of vital components to be measured.

The principal benefit is elimination of unforeseen loss of production due to gearbox repair or replacement: maintenance scheduling is significantly enhanced.

The preconditioner is a new addition to the Baker Perkins SBX Master range that increases flexibility and throughput, especially when applied to denser and/or shear-sensitive materials. It is particularly advantageous when processing pellets for flaked cereals, pet food products, and half-products formed in the extruder and expanded elsewhere – flaked cereals and multi-grain loops are typical. It is also ideal for protein products where energy input in the preconditioner replaces mechanical shear energy in the extruder in order to avoid protein damage.

Innovation centreA key advantage of working with Baker Perkins is the

Innovation Centre at Peterborough in the UK, with facilities to develop new products and processes, produce samples for test marketing, and conduct feasibility trials.

Companies from every part of the world find that thorough trials, often using their own raw materials, provide a reliable basis for trouble-free commissioning of a new plant or launch of a new line. The wide variety of process technologies available under one roof enables Baker Perkins to cross conventional process boundaries, and to offer a variety of process solutions for a single product.

The Centre contains a wide range of production and laboratory scale equipment dedicated to the snack industry.

www.bakerperkins.com


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Figure 3: Machine components

Rice flour is a generic term for rice flour made of both non-glutinous rice and glutinous rice. The rice flour type is shown in Figure 1. Rice is the only self-sufficient grain in Japan, but the annual consumption of rice-per-capita has been decreasing year by year due to the diversification of consumer needs.

On the other hand, in recent years, as the national policy aims at expanding the use of rice flour as a substitute for wheat flour in order to improve the self-sufficiency rate, products using rice flour have been developed in various places by improving flour milling technology and bread-making technology, and the use of rice flour has been expanding to various products such as bread, western confectionery, and noodles.

They correspond to the fine-grained flour of Figure 1. Fine-grained flours are expected to be used in new applications different from conventional uses such as Japanese confectionery and rice crackers. These can be divided into applications mainly

by grain size as shown in Figure 2.Satake’s flour milling machine in rice flour production - Small-scale flour milling unit CMU30A

We have flour milling machines such as our pin mill and roller mill primarily installed into wheat milling plants. This section describes small-scale flour milling unit CMU30A, which has been marketed in Japan since 2017 and mainly used for rice flour. As a small-scale mill, Satake has SRG05 with capacity of 5kg/h in white rice and SRB10 with 10kg/h. CMU30A is a 30kg/h milling unit with a larger capacity.

Concept of designing and function of CMU30ACMU30A is a unit system that can be easily moved and

installed and is an impact milling system for both dry and wet milling. It was developed based on the concept of compact design, easy maintenance and low-volume production.

It is possible to produce rice flour products with high quality, taste and processability by realising fine grinding with the average product flour particle diameter of approximately 40μm. It is designed to eliminate residual product inside and to increase serviceability, utilising lighter removable components, for

example.This milling machine realises a price suitable for

new entrants targeting a relatively small amount of flour millers, such as bakeries, roadside stations, and agricultural processing centres. Its main three features are as follows:

1. A milling capability of 5kg/h to 30kg/h enables small scale rice flour manufacturing by in-house milling

2. Unitised design of feeders, milling machines and dust collectors produces high-quality rice flour

3. The unitised unit allows for forklift transfer. After installation, rice flour can be produced simply by supplying air and power. A summary of the units is given in Table 1.

Machine name and processEach components of the unit is shown in Figure

3. The basic unit includes the control panel, feeder, milling machine, cyclone, air lock, suction pipe and dust collector. The control panel shows start, stop and alarm functions for each section.

The feeder quantitatively feeds the raw material loaded into the hopper to the milling machine. The mill mills the input raw material. While the flour is conveyed out of the mill by air from the dust

Non-gelatinized (β)

Gelatinized (α)

Regular flourNon-glutinous rice Fine-grained flour

Heated flour

Steamed-Roasted flour

Brown rice flour

Japanese/Western confectionery

Baby food

Bread, Noodle, Western confectionery

Japanese confectionery


Steamed-Dried flourSteamed-Roasted flour

Glutinous rice

Non-gelatinized (β)

Gelatinized (α)

Mochi flour

Wet-milling flourRegular flour Japanese confectionery


Japanese confectioneryJapanese confectioneryJapanese confectionery

NEW

Rice f lour by SATAKE’s small milling unit CMU30A

by Tsuyoshi Fujishima, Flour Milling Group, Technical Division, Satake Corporation

Figure 1: Types of rice flour

Figure 2: Grain size and applications of new rice flour


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collector, it is separated from air by a cyclone through the suction pipe.

Flour is discharged through the airlock in the lower part of the cyclone. When the optional small vibratory sifter is available, sifting check is performed using a 600 µm sieve size for large foreign material in the flour leaving the airlock. The milling process is shown in Figure 4.

Structure of milling machineryThe structure of the milling machine is shown in Figure 5. The

raw material fed from the centre of the upper part of the machine is conveyed to the milling section (outside of the casing) by centrifugal force of the rotor and the suction air generated by the dust collector.

In the milling section, the raw material is milled by impact between the raw material and against the wall surface. The milled raw material is wound up to the upper part along the wall surface and then rises by means of suction and the air flow generated by the rotor. This is discharged from the upper part of the milling section to the outside of the machine.

Characteristics of milling machineryThe milling machine is designed not only for optimal

milling performance but also easy maintenance and safety. Characteristics of four main components of the milling machine (milling section top cover, milling section cover, rotors, casing) are as described in Table 2.

Wet millingWhen wet milling is performed in CMU30A, hot air from a

hot air generator is introduced into the milling machine and the

Figure 4: Flour milling process

Figure 5: Structures of milling machinery

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flour is dried while being milled in the milling machine. The moisture content of the flour is adjusted by adjusting the temperature of the hot air generator according to the temperature at the outlet of the milling machine (See Figure 6).

Flour qualityWhen the raw material was supplied under ordinary

white rice at 30kg/h, the average particle size was 40 ± 10 μm. (Reference: 120 μm in the case of the small-scale flour milling machine SRG05C, and 90 μm in the case of SRG10). The particle size distribution is shown in Figure 7. Therefore, the particle size considered suitable for the making of rice flour bread and confectionery has been achieved.

In addition, wheat, oats, buckwheat, and other grains can also be milled. The damaged starch rate is 10-to-15 percent for white rice dry milling and four-to-six percent for wet milling. The difference between dry and wet rice flour particles can also be confirmed by electron microscope. In the dry process, many angular particles are observed, and in the wet process, many small round starch particles are observed (See Figure 8). The following Table 3 shows the reference data of the small-scale milling machine sold by Satake.

www.satake-group.com

CMU30A

Model

Milling Method

Capacity (kg/h) - White Rice

Power

Milling Screen

Mesh Screen

Optional Screen

Particle Size (μm) - Rice Flour

Subject Material

Hopper

Features

Product Usage

SRG10ASRG05C

Dry / Impact

0.2 ~ 5.0kg / h

1 Ph/100V/750W

Milling Screen

Mesh Screen

-

Avg. 120μm

White Rice, Brown Rice, Buck Wheat

3kg

Compact, quiet operation (70db)

Rice bread, Wheat bread, Noodle

Dry / Impact

10kg / h

3PH/200V/ 3.7kW+0.4kW x 2

0.05mm or 0.1mm

100 Mesh

120 Mesh

Avg. 90μm

White Rice

White Rice 15kg

Low temratrue, e�cient milling

Dry - Wet / Impact

5 ~ 30kg / h

3PH/200V/ 8.75kW

No Screen

Optional 600μm mesh screen

40μm±10μm

White/Brown Rice, Wheat, Buck Wheat

White Rice 20kg

Dry/Wet milling, easy installation

Japanese/Western confectionary, Rice bread

Table 1: Outline of small-scale flour milling unit CMU30A

Model CMU30A

Dimension (W)1,500mm (D) 1,500mm (H) 2,183mm

Milling capacity 5-30kg/h (white rice pulverisation)

Power 3-phase 200V, 8.75kW

Weight Ab out 800kg

Option Small vibratory sieve, hot air generator and feeder

Table 2: Characteristics of milling machinery

Top cover of milling sectionInlet pipe connecting the feeder and milling machine is equipped with a magnet. Magnetic foreign matter is prevented from entering the milling machine. When this cover s removed, the milling machine is not activated by the safwty device.

Milling section coverThe inlet of raw materials and the outlet of propducts are intergrated. Because it can be opened and closed by four handles, it is easy to detach and clean.

RotorIt rotates at about 3,500rpm. Becasue of the fan shape, air is generated and the raw material is fed into the wall surface of the milling section at high speed. Because it is attached with one bolt, it is easy to detach and clean

CasingThe raw materials are impacted with each other and the wall surface are milled. Only microgranuales lifted to the top are aspirated and conveyed to the product process. Less residue or sticking and easy cleaning and replacement of the consumable parts.

Figure 6: CMU30A wet milling flow

Figure 7- Particle size distribution of dry milling

Figure 8- Particles (dry and wet) of rice flour X750

Table 3- List of small-scale flour milling machine series

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I admit it. I am a passionate meat eater. Especially, with the beginning of the summer season, I am happy about my spicy pork steak, which is sizzling on the grill. Did you know that the tenderness and palatability of the meat is strongly related to the feeding of the animal?

Carcass and meat quality are not only influenced by the genetic line or the sex of the pig - it is also the feed and especially natural, phytogenic feed

additives that make a good piece of meat something special. The quality of pork meat is determined by the entire supply

chain - from feeding the animals on farm to the shop counter. While the consumer at the counter wants a high shelf life and food safety in addition to animal welfare, the farmer strives for the most efficient, sustainable and thus profitable production possible.

In addition to genetics, low stress handling, meat processing and, above all: feeding, play a major role when it comes to optimum meat quality and carcass characteristics.

Phytogenics, which include a wide range of plants such as herbs

spices and other plant extracts such as essential oils, not only have a positive effect on feed efficiency required in profitable meat production but also on meat quality and optimisation of carcass properties.

Thus, positive effects of phytogenics on protein deposition can be determined, which leads to carcasses with a higher lean meat content and a reduced lipid oxidation, which improves meat quality. Let’s have a detailed look at the reasons why phytogenics have beneficial effects on meat quality, carcass properties and consumer demand:

1. Phytogenics improve carcass characteristicsDid you know that phytogenics are able to modulate

intracellular signalling cascades that are involved in oxidative processes and insulin resistance? It’s true: several studies have shown that some phytogenics stimulate tissue insulin sensitivity and increase the activity of proteins involved in the insulin signaling cascade within the cell.

The upregulation of these functions leads to an increased expression of genes that are related to protein synthesis and cell proliferation and at the same time inhibit apoptosis. Thus, the feeding of phytogenic feed additives (PFAs) can ultimately lead to increased muscle growth.

Moreover, aromatic phytogenics, such as selected essential oils, increase the feed intake, as they improve the diets palatability. This increase in feed intake may lead to higher average daily gains which shorten the fattening period - resulting in higher profitability to the farmer.

In addition to an increase in muscle percentage, selected phytogenics are also able to increase protein digestibility, which

Figure 2: Meat quality characteristics of poigs fed PFA's

CON PFA

Shear force, kg 4.77a 4.21b

Drip loss, % 2.00a 1.59b

Cook loss, % 34 32.8

Means with different superscripts within rows are significantly different (p < 0.05

Three reasons why good meat is related to phytogenicsby Anne Oberdorf, Technical Communications, Delacon, Austria


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goes along with an improvement in other carcass characteristics: a study carried out at Freie Universität Berlin, Germany, showed that the addition of a PFA with selected active ingredients such as essential oils and saponins, specially tailored to the needs of fattening pigs, leads to an increase in digestibility of ileal protein by 3.7 percent (76 vs. 79%, p<0.05) and nitrogen storage by 8.8 percent.

The effects of more efficient nitrogen utilisation and deposition on carcass characteristics were also confirmed in a trial at the IRTA agricultural research institute in Spain (See Figure 1).

Computed tomography (CT) of live animals during the growing and finishing phase and of carcasses at slaughter also showed a significant increase on loin area (longissimus dorsi). The loin area at slaughter (110 kg live weight) was increased by 7.8 percent for the tested product compared to control.

2. Meat quality is improved naturallyNot only microbial spoilage, but especially lipid oxidation has a

negative influence on the quality of meat products. The products of lipid oxidation, such as lipid hydroperoxides and aldehydes, have a negative impact on the texture, colour, taste, nutritional value and safety of meat products.

To prevent or reduce this oxidative spoilage, synthetic antioxidants (e.g. butylated hydroxytoluene or butylated hydroxyanisole) are used, which are suspected of potentially causing negative health effects.

Thus, in June 2017, the European Food Safety Authority (EFSA) removed ethoxyquin, one of the most commonly used antioxidants in animal feed, from the authorisation list. This action drives the search for safe and natural solutions: α-Tocopherol, better known as vitamin E, is considered a highly effective lipid-soluble antioxidant and an acceptable supplement in animal feed.

Similar to vitamin E, numerous terpenes of aromatic plants from the Labiatae family, such as thymol or carvacrol from thyme or oregano, have proven antioxidant properties. These phytogenic antioxidants not only contribute to the protection of dietary lipids against oxidative damages but are able to influence the lipid metabolism in animals.

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In a study by Müller et al. (2012) in broilers, the intake of thyme oil or thymol had a positive effect on the production of the body’s own antioxidative enzymes superoxide dismutase (SOD) and glutathione peroxidase (GPx) as well as on the composition of polyunsaturated fatty acids in various tissues.

Thus, a study conducted by Zhang et al (2015) showed that supplementing fattening pigs with phytogenics can positively increase overall antioxidant capacity and GPx activity in muscle.

In addition, a reduced malonaldehyde content (MDA) in the muscle was observed at the same time. Since MDA is a by-product of lipid peroxidation, an increased antioxidative capacity can therefore be inferred indirectly.

This improved antioxidant status by phytogenics can increase meat quality. Meat shear forces, drip loss and cook loss were improved by the supplementation of PFA’s (See Figure 2). These parameters represent the meat tenderness and indicate improved meat quality.

Another study conducted by Ranucci et al. (2014) showed that supplementation of grower-finisher diets with phytogenics significantly reduced carcass and meat oxidation and improved sensory properties compared to control.

In the group receiving phytogenics, it was determined that antioxidative enzyme activity (GPx and glutathione reductase) was higher in Longissimus lumborum while lipid oxidation was lower. As result of the improved antioxidative status, the meat from pigs that had been fed with PFA-supplemented diets received higher scores for color, taste and overall liking in both the blind and the labelled consumer tests.

3. Phytogenics stand for safe and sustainable pork production

On the one hand, the use of improved pig genetics for a higher growth rate and a higher proportion of lean meat has led to a deterioration in pig meat quality. On the other hand, the demand for tasty and high-quality meat products is constantly increasing.

In addition to high animal welfare standards, restaurant chains, food retailers and consumer brands are increasingly focusing on a value chain of meat that is as sustainable as possible, without the use of antibiotics. It is part of a paradigm shift in animal nutrition that is largely driven by consumer demand.

Today’s consumers are increasingly demanding “clean labels” and food that is produced transparently. Meanwhile, pig producers are being urged to find solutions that support animal health and productivity without the use of antibiotics.

Consumer-driven market demands, coupled with antibiotic regulations that exclude the subtherapeutic use of medically important antibiotics to promote growth, are driving manufacturers to revise their nutrition strategies and test

antibiotic-free production systems. When meat producers think about their options, phytogenics are increasingly used as natural performance enhancers.

The development of phytogenic feed additives consists of selecting active ingredients from nature and using their mode of action for a specific effect in animal nutrition. The composition of phytogenics ranges from known ingredients to exotic sources such as Quillaja (soap bark).

This process of selection and development requires considerable scientific knowledge and research. Starting from more than 100 different natural substances, the ingredients are precisely combined and formulated to create phytogenic solutions for the challenges of animal nutrition.

For example, bitter substances from gentian or hops help to increase the secretion of digestive juices and thus enhance the digestibility of proteins, whereas tannins and saponins can help to reduce ammonia emissions.

Thus, in addition to improving meat quality, phytogenics make a valuable contribution to the reduction of greenhouse gas emissions, the minimisation of nitrogen excretion and environmental pollution.

ConclusionPhytogenics showed positive effects on feed efficiencyintake,

protein (muscle) deposition and reduction of fat oxidation, resulting in improved performance and meat quality. Phytogenic feed additives are thus an effective natural solution with high consumer acceptance for their safety and environmental sustainability.

www.delacon.com

www.almex.nl

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Sometimes very litte is necessary to make something good great. The all new improvised purifier Norit builds on the success of the Puromat MQRF that has proven itself over the decades. Along with the roller mill and the plansifter, the purifier is one of the key equipment in any modern flour, durum or maize mill.

Responsible for the quality of the end productA semolina purifier removes the last bits of bran with sieves and

air flow from the intermediate product after the first grinding pass in the roller mill and the first sorting in the sifter.

After the purifier, the cleaned semolina arrives in the finished product silos, or is sent for the further grinding to the roller mills of passes to make the finest flours. Whether wheat, durum or maize.

The semolina purifier is responsible for the ultimate quality of the end product in any mill. For processing common wheat for optimal yield of the lightest flours, for durum wheat to make the best semolina for high-grade pasta, or for maize to prepare excellent semolina for different kinds of end products.

Puromat successorBühler has been offering a reliable, high performing

and economical semolina purifier for years: the Puromat MQRF, which has proven itself in everyday operation. Now, as the successor to the Puromat, Bühler is presenting the completely revised semolina purifier Norit MQRH, a new machine for the reliable and consistent purifying of all kinds of semolina.

The new purifier has a streamlined and well-thought out design while focusing on what’s essential. Special attention has been given to the further improvement of food safety and sanitation.

All parts of the purifier which come into contact with the product are made of stainless steel or other food safe materials - including the sieve frames. Norit is equipped with the proven Bühler NovaPrime sieve cloth. Made of polyamide (PET) plastic yarn, it provides highest accuracy in terms of mesh size and uniformity over time. Just what you need to extract purest

semolina in your daily operation.Lastly, the design of the product intake was optimised and

undesirable dead space eliminated. New rotary switches mean that the air flow can also be individually adjusted without tools.

More stable on three legsSemolina purifiers from Bühler use air and a thrusting

movement for cleaning during handling of the product. They stand on rubber springs that are subject to a certain wear and need to be routinely inspected and replaced. The new semolina purifier Norit MQRH now stands on just three instead of four rubber springs. This improves the accessibility under the machine and thus cleaning and servicing. In addition, the three-point support reduces the tendency to drift, which has a positive effect on the efficiency of the machine. A display indicates the status of the rubber springs and proactively reports when it is time to exchange them.

Double capacity in the same spaceThe new semolina purifier Norit MQRH by Bühler has the

same capacity range as the proven predecessor model. The three sieve decks with a sieve surface of two-times 460mm x 2000mm and different mesh sizes allow up to three tons of semolina to be cleaned per hour.

The semolina purifier Norit is available as a single or double model. The advantages of the double model: Double the cleaning capacity can be installed on the same surface area. With the double model, the stacked units are connected by bent pipes, which are made of stainless steel to ensure top sanitation. The new design of the double machine ensures that both machines are optimally accessible. A track encircling them serves as a support for a ladder so that it can be freely placed. Not needing an additional frame means unobstructed access to the lower machine.

The new semolina purifier Norit has the same connection dimensions as the predecessor model, ensuring an easy replacement of the machine possible.

www.buhlergroup.com/norit

Purifier Norit MQRH: Fine-tuning a proven machineby Bühler Group, Switzerland


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The economic value of improving efficiency in poultry production is great. Bird performance can be optimised by improving feed digestibility using enzymes. However, simultaneous use of different types of enzymes has been a challenge, mainly due to the lack of technical data on the optimal way to combine them, resulting in large

variation of recommendations on enzyme combinations.A global enzyme solution enables significant reduction

in dietary nutrient levels and increasing nutrient retention. Trials have shown this improves poultry performance and can significantly help to reduce feed costs.

The indigestible fractionDiets fed to broilers and other livestock contain a considerable

indigestible fraction. In fact, 20-to-25 percent of the organic matter is unavailable for absorption in broilers. Because of

this, over the last three decades several enzymes have been developed to improve feed digestibility. The use of phytases and carbohydrases, has increased raw material options, allowed nutritionists to take advantage of local raw materials and helped to reduce feed costs.

Whilst the modes of action and substrates of phytases and carbohydrases are different, their effects on diet digestibility and performance are complimentary. The nutrient-capturing mechanisms of non-starch polysaccharides and phytate are not the same. Therefore, if both types can be degraded, nutrient release will be higher.

The ability of efficient multi-enzyme solutions to improve global feed digestibility is known as the feedase effect. By reducing the indigestible fraction of feed, as well as the effect of anti-nutritional factors, more nutrients are released.

Using phytase plus carbohydrasesPhytase addition, by reducing phytate in the diet, improves

the availability of amino acids and minerals (mainly P & Ca). It

The feedase effect improves the efficiency of poultry

production

Figures 1a and 1b: The addition of feedase to reformulated diets returned broiler performance (BWG & FCR) to that of the positive control.Source: Jlali M., Bello A., Cozannet, P., Alleno C., Ceccantini M. and Preynat A. (2018).Effects of a multi-carbohydrase and phytase complex (MCPC) on growth performance of broilers fed wheat-corn soybean meal-based diets reduced in metabolizable energy and nutrients. Proceedings of the 11th Asian Pacific Poultry Conference.

by Marcio Ceccantini, Scientific and Technical Manager for Feed Digestibility Category, Adisseo; Sofia Zenagui, Marketing Manager for Feed Digestibility Category, Adisseo


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also reduces the cost of mineral addition, decreasing associated pollution from organic manure and leaving more space for vegetable raw materials.

By increasing the standard inclusion level of phytase, phytate and its breakdown products are quickly and further degraded. Anti-nutritional effects are increasingly reduced, and performance further improved.

By breaking down plant cell walls, carbohydrases liberate more nutrient at the same time. Carbohydrases help to reduce digestive problems associated with feeding wheat and barley diets, by reducing viscosity of the digesta. In addition, the certain polysaccharides, presents in most common feed ingredients, the result of carbohydrases breaking down fibre in the feed, have a prebiotic effect that benefits the microflora.

These classes of enzyme have distinct but complimentary effects – one type, whatever the dose, cannot substitute the efficiency of a combination. Both kinds of enzyme degrade indigestible fractions within diet – in so doing they increase energy availability and nutrient value of the feed.

In order to take full advantage of this, the enzymes need enough ‘room’ in the diet. To maximise the economic benefits, specifications should be reduced in terms of metabolisable energy (ME), digestible amino acids (dAA), available phosphorus (avP), calcium (Ca) and sodium (Na).

Reducing nutrient specificationsA broiler pen trial was carried out at Zootests, France - to

evaluate the effect of a global enzyme solution containing a complex of several carbohydrases (specific xylanases, glucanases and arabinofuranosidases) and a super-dosed phytase (1000 ftu).

The formulation of the trial diets had lower specifications,

compared to the positive control. ME was reduced by three, four or five percent and dAA by three, 4.5 or six percent, in three different treatments, along with a fixed reduction of 0.174 percent avP and 0.157 percent Ca.

Performance of broilers fed the three groups, both with or without a multi-carbohydrase and phytase complex (MCPC) qualified as a feedase, was compared. A positive control was raised in parallel and all treatments used a corn-wheat-soybean based diets.

The reduction of ME, dAA, avP and Ca in the diet significantly reduced body weight gain and increased FCR (See Figure 1),

Figure 2: Adding feedase to re-formulated diets restored carcass, breast and leg yield to that of the positive control.Source: Jlali M., Bello A., Cozannet, P., Alleno C., Ceccantini M. and Preynat A. (2018). Effects of a multi-carbohydrase and phytase complex (MCPC) on growth performance of broilers fed wheat-corn soybean meal-based diets reduced in metabolizable energy and nutrients. Proceedings of the 11th Asian Pacific Poultry Conference

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similarly for the three NC diets; with no effect on feed intake. At 42 days-of-age these performance criteria were restored to the level of the positive control by the addition of feedase – irrespective of the diet re-formulation.

Carcass yield and bone strengthAt 42 days of age 60 birds-per-treatment were randomly

selected for carcass yield determination. At the same time tibia samples were collected from 15 birds-per-treatment (from one bird per pen replicate).

The lower specification diets (NC1, NC2 & NC3) significantly reduced carcass, breast, and leg weights of broilers at 42 days-of-age (See Figure 2). The inclusion of a feedase returned the carcass traits to positive control levels in all cases.

Carcass yield is a measure of the amount of saleable product for broiler producers. It is essential that any dietary manipulation doesn’t have a negative effect on this measure. Evaluating bone mineralisation and breaking strength – shows how able birds are to support optimal growth rates without suffering from leg problems. In addition, it demonstrates dietary sufficiency of essential minerals.

Overall findingsThis trial demonstrated that adding this global enzyme

solution to broiler diets would allow significant reductions in the specification - up to a five percent reduction in ME, six percent in dAA, 0.18 percent in avP and 0.16 percent in Ca.

The study showed that enzyme combinations make it possible to reduce feed costs and hence improve efficiency. At the same time maintaining broiler performance, carcass yields, bone mineralisation, and breaking strength, which is important for welfare and the profitability of broiler production.

Positive environmental effectsIn this trial, the feed treated with enzymes had 25kg less soy

oil, 8kg less phosphates and 20kg less soybean meal, for each tonne of feed. This was replaced by 53kg of corn, representing a saving close to 1.7 ha of arable land for each 1,000-tonnes of feed produced - due to the differences in productivity of soy and corn.

There was also a positive environmental effect on broiler emissions. Adding a multi-carbohydrase to the diet could decrease ammonia excretion by 13 percent (Geraert et al., JRA, 1997). And if the feedase diet is compared to one with no enzymes added, P excretion was decreased by 37 percent (Bello A. et al, APPC, 2018).

Advanced solutionThe combination of phytase and carbohydrases target the

main antinutritional factors in feed. Phytates and Non-starch polysaccharides are the most relevant anti-nutritional factors in feed, decreasing its digestibility. By acting on different substrates their activity is complementary and improves diet digestibility. In this way, the feedase effect results in significant improvements in poultry performance and sustainability.

In terms of cost-effectiveness, it is worthwhile using both classes of enzymes as long as appropriate re-formulation is employed. The feedase approach considers the global enzyme solution as a whole – defining its own unique nutritional matrix, instead of combining individual matrix values for each enzyme.

The use of a global enzyme solution, containing phytase and a complex of carbohydrases, therefore has the potential to significantly improve the efficiency and the consistency of poultry production.

www.adisseo.com

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Starch is one of the primary ingredients used in feed, together with protein. But starches from different sources offer a range of functional properties that need to be considered, not only from a nutritional perspective but also for technological aspects.

Starch structure and functionChemically, starches are polysaccharides that consist of

repeating glucose units. Starch molecules have one of two molecular structures: a linear structure, known as amylose; and a branched structure, known as amylopectin.

Amylose and amylopectin associate through hydrogen bonding and arrange themselves radially in layers to form granules. Starches from different sources vary from one another in the following ways - each of which may affect performance:

Granule size and shape: Starch granules come in a wide variety of sizes ranging from three microns to over 100 microns. Wheat starch, for example, has a distribution of both large and small granules while corn-starch has a narrow distribution of rather large granules.

Amylose- Amylopectin ratio: All starches are composed of varying proportions of amylose and amylopectin. The ratio varies not only among the different types of starch, but also among the many plant varieties within a type. Waxy starches are those that have no more than 10 percent amylopectin.

Standard wheat and corn starches contain 25-to-28 percent of amylose and 72-to-75 percent of amylopectin, not a big difference for this specific parameter. Other variations also exist in starches. In general, most such variations consist of the presence of non-starch components in the granule (or close to), such as lipids or protein. Those elements can highly influence gelatinisation, even at low concentration.

Corn: Four classes of corn-starch exist. Common corn-starch has 25 percent amylose, while waxy maize is almost totally composed of amylopectin. The two remaining corn starches are high-amylose cornstarches; one has 50-to-55 percent amylose, while the second has 70-to-75 percent. Granule size ranges between 15 microns and 20 microns, quite a narrow distribution.

Potato: Potato starch has about 20 percent amylose. Its granules range in size from 15-to-75 microns, quite a large distribution.

Rice: Common rice starch has an amylose: amylopectin ratio of about 20:80, while waxy rice starch has only about two percent amylose. Both varieties have small granule sizes ranging from 3-to-8 microns.

Tapioca: Tapioca starch has 15-to-18 percent amylose. Tapioca granules are smooth, irregular spheres with sizes ranging from 5-to-25 microns (large distribution).

Wheat: Wheat starch has an amylose content of around 25 percent. Its granules are relatively thick at 2-to-15 microns.

Starch experts universally agree that starch structure and composition affect performance. However, a direct correlation is not always obvious, and we should consider changes in several traits to explain main differences between starch sources. A review of what is currently known about how structure and composition affect performance follows. But first, here is a brief review of what happens during starch gelatinisation during pelleting.

When starch enters the conditioner, water penetrates the starch granule from the outside inward until the granule is fully hydrated. Once hydrated, the hydrogen bonding between the amylose and the amylopectin maintains the integrity of the granule and it begins to swell from the centre.

Once gelatinised, the swollen granules may increase the viscosity of the dispersion creating in most cases a good pellet, or when gelatinisation is not under control, blocking the dye.

Granule size and structureLarge starch granules tend to build higher viscosity, but the

viscosity is delicate because the physical size of the granule makes it more sensitive to shear. But bringing viscosity is not necessarily bad in pelleting. It can provide extra binding capacity, and that’s what we ask of starch-based raw materials.

Thus, more than the granule size, the narrow or large distribution of granule sizes has even more influence on gelatinisation. Wheat starch, for example, has a bimodal distribution of both small and large granules, and those granules

How the type of starch

can inFLuence pelletingby Mathieu Calmont, Borregaaard LignoTech, Norway


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will, therefore, gelatinise at different moments in the conditioner depending on heat and moisture available.

This permits smooth and easy control of the gelatinisation. Corn-starch has large granules with narrow distribution, and thus gelatinisation happens all at once, which can create blockage in the dye.

TemperatureGelatinisation temperature windows can vary with raw materials. Wheat is the first

starch to get, thus making it an easy binder for pelleting. Barley starch is also quite easy to pelletise. However, corn-starch only starts to gelatinise at 70-to-72°C where other polymerisation (see paragraph on lipids and proteins) can occur.

How to characterise starch in pelletingStarch experts universally agree that starch structure and composition affect

performance. However, a direct correlation is not always obvious, and we should consider changes in several traits to explain main differences between starch sources. A review of what is currently known about how structure and composition affect performance follows.

But first, here is a brief review of what happens during starch gelatinisation during pelleting: When starch enters the conditioner, water penetrates the starch granule from the outside inward until the granule is fully hydrated. Once hydrated, the hydrogen bonding between the amylose and the amylopectin maintains the integrity of the granule and it begins to swell from the centre.

Once gelatinised, the swollen granules may increase the viscosity of the dispersion creating in most cases a good pellet, or when gelatinisation is not under control, blocking the dye.

Lipids: Lipids are known to inhibit granule swelling. Maize contains approximately twice as much lipid as wheat and it can be one of the elements affecting the ease with which wheat starch gelatinises compared to maize.

Protein: During gelatinisation, if protein is directly available in the near environment of the starch granules, then this protein can get associated with the surface of the granule (polymerisation).

This creates a protein starch polymer, which increases the viscosity of the feed. This is the case when one uses corn gluten meal in a feed formulation, which is rich in protein and starch. Protein and starch will recombine during gelatinisation and generate a plastic mass into the dye, leading most often to blockages.

One can see that at the same moisture content, water activity is reduced by 22 percent when using LignoBond in the feed (1%). Water activity vs dry matter (DM) – LignoBond effect (1%) Lignosulfonate and lignosulfonic acids are well known surfactants.

These polyphenolic macromolecules have an important capability to bind water and thereby reduce water activity. Hereafter, two experiments on water activity: How using lignin-based pelleting aid LignoBond can help solve gelatinisation problems.

One can see that using one percent LignoBond can help to: Option A: Increase moisture content at constant Aw Option B: Decrease Aw at constant moisture content

This specific property of LignoBond is of great help in starch gelatinisation. By catching free moisture and converting it to bound moisture in the conditioner, LignoBond will bring heat and moisture in a smooth and regular manner to the starch granules.

LignoBond will start to absorb moisture around 45°C and will help starch to gelatinise gently. LignoBond, in that case, acts like a moisture absorption regulator, enlarging the temperature window where starch granules can start to absorb steam.

An additional remark: In the case of a challenged formula concerning starch source (a lot of corn gluten meal, no wheat and only maize), it can occur that a standard lignosulfonate won’t give provide enough benefit to overcome plastic gelatinisation and blockage in the dye.

In that case, the solution is to combine the moisture absorption effect with good lubrication of the dye, enabling the feed to pass through easily. A product capable of handling such a challenge is PellTech, the only purposely designed binder/lubricant on the market.

http://lignotechfeed.com


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by Steve Knauth, Marketing Manager, Munson Machinery Co., Inc., United States

fluidised bed mixingAnimal feed producer ups uniformity, cuts cycle times with fluidised bed mixing

Country Junction Feeds has produced animal feed products in Alberta, Canada for over 100 years. Today it offers a full line of organic wet and dry feeds for cattle, hogs, poultry, horses, bison, elk, goats and sheep. To improve batch consistency

and prevent damage when adding liquids to fragile ingredients, the company installed a fluidised-bed type mixer on its “wet feed” production line.

Dry feed in raw or pelletised form is typically pre-blended in a 2000kg capacity mixer. The wet blending process adds oils and/or molasses to rolled oats, barley, pellets and “bull ration” calf feed for nutrition and palatability as well as dust control.

To blend dry ingredients with liquid additions in batches up to 300kg, the company installed a Munson model MF-18-SS fluidised bed mixer.

“Fluidised bed mixing brought more batch-to-batch consistency than the previous auger mixer,” explains Mark Shantz, Country Junction’s Maintenance Manager, adding that it imparts less shear than the auger mixer, reducing product degradation, particularly with fragile materials.

How liquid additions are mixed with dry blends To initiate a mixing cycle, an operator enters a pre-

programmed recipe at a plant workstation. Individual ingredients, stored in outdoor granaries, are transported by chain drag conveyors to the aforementioned dry mixer for pre-blending.

Blended batches discharged into bins are then conveyed by either of two drag chain conveyors to the fluidised bed mixer. Load cells supporting the mixer transmit weight gain information to a PLC, which stops the conveyor once the preset batch weight has been gained, with +/- 1 kg accuracy.

Once mixing begins, a fluid volume of oil


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or molasses equivalent to 3-to-10 percent of the dry premix weight is automatically metered from a 20kg capacity vessel and gravity discharged into the top centre intake of the fluidised bed mixer.

Fluidised mixing zone improves dispersionThe machine’s fluidising effect is achieved by twin paddle agitators rotating at

36rpm within twin “U” shaped troughs at the bottom of the mixing vessel. The counter-rotating agitators cause material from the troughs to become airborne along the centreline of the vessel where it intersperses rapidly with liquids sprayed into the “fluidised zone.”

Mixing cycle times range from 10 seconds-to-two minutes, depending on recipe. Full-length drop-bottom gates open to discharge blended batches into a hopper,

which feeds a filling line for 20kg plastic fibre bags. Immediately after the bottom gates close, dry premix is loaded into the mixer, a pump refills the overhead liquid hopper, and a new cycle begins.

Shantz says, “We lift the lid and wash out the inside with water. The interior is smooth and free of obstructions that trap material, which eliminates the need to manually scrape away residue. It’s easier to clean than the auger, and not as time consuming,” he says.

Country Junction Feeds is a division of Wetaskiwin Co-op, a cooperative whose local operations in the area include a home centre, agro centre, food store, bulk fuel and equipment sales, and related services. Country Junction’s feed is sold in Canada, but Shantz says the company is looking at international sales.

www.munsonmachinery.com


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High-quality ingredients and an optimal formula are the most important factors in animal feeding. The importance of the feed structure, however, often goes unmentioned, although recent findings of the feed industry have shown that it is an at least equally important factor for successful

feeding and fattening.For this reason, the machine and plant manufacturer Amandus

Kahl has focused its research efforts on this field: For decades, the German company has manufactured the so-called crushing roller mill which ensures the ideal adaptation of the feed structure

to the needs of the respective animal species.As the name suggests, a crushing roller mill consists of two

rollers that crush the product. In addition to different types of grain, also legumes, oilseeds and feed mixtures can be processed. Unlike in the hammer mill which crushes the grain with maximum force, specific crushing takes place in this machine.

Thus, the obtained final product is not mealy or powdery, but a crushed and coarse-grained feed. Furthermore, the crushing roller mill produces a uniform grain size due to the individually adjustable gap. Owing to its structure, the crushed feed is particularly suited for use in pig, cattle or poultry farming.

The concept of crushing using the crushing roller mill includes even more technical features: Apart from the counterrotation of the two rollers, there is a differential speed of the roller pair. The

Feed industry professionals, academics and business people learned about inner workings of a feed mill at the Build my FeedMill Conference on March 13 at VIV Asia.

In conjunction with Milling and Grain, VIV Asia hosted 12 speakers who presented information about their feed mill and storage products. Those in attendance were led through the entire milling process, from intake and conveying to weighing, grinding, pelleting, drying and cooling and storage.

by Maren Weßels, Amandus Kahl, Germany

#5 Crushing roller mill


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crushing is achieved by a combination of shear stress, cutting and pressure.A special corrugation of the rollers contributes to the crushing of the product. The

roller diameter influences the product feeding and the size of the grinding zone. Multi-stage grinding with upstream screening ensures an optimized particle size distribution.

Which are the specific advantages of crushing for the feed industry? With regard to nutritional physiology and cattle feeding, the advantage of this crushing method lies in the fact that less starch degradation takes place in the rumen.

As ruminants, cattle generally require a coarser and more fibrous feed structure. The grains must only be halved or quartered using the crushing roller mill - further crushing of the husks is not required.

In pigs, mash feed may even cause diseases of the oesophagus and the stomach. Feeding of pellets is not an option, either, as pellets are too hard. For this reason, expanded feed produced with the Kahl annular gap expander ensures the best results in feeding.

Coarsely crushed wheat in the mixture produces less pathological changes in the gastric system, less diarrhoea, a lower mortality rate, and healthier pigs in general. A reduction of stomach ulcers is obtained in fattening, as the more solid consistency and coarser structure ensure a reduction of the pH value in the stomach.

Also poultry requires a coarse feed structure since the animals have a muscular stomach. This species is also known for its selective feed intake. Such feed selection is avoided by a uniform feed structure as produced with the crushing roller mill due to the individually adjustable gap. At the same time, feed losses due to the meal content which is not eaten are reduced.

The following raw materials and mixtures are excellently suited for processing on the crushing roller mill: wheat, oats, peas, maize, rape, structured feed for layers, barley, bean, lupins, soybeans, feed mixtures.

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Moreover, the low meal content produced during crushing of the respective product makes the Kahl crushing roller mill an economical solution for conditioning feed made from the above-mentioned raw materials for the animal feed industry.

In order to meet individual requirements, the crushing roller mill is available in a single-stage, two-stage or three-stage design. The capacity ranges from 10-to-60 t/h with a drive power of 22-t- 55 kW (motor with V-belt drive and gear). At a length of 1000mm the roller diameter is 300mm. If a length of 1500mm is desired, a diameter of 300-or-400 mm can be chosen.

All rollers are made of special steel, chilled cast iron. The modular design of the crushing roller mill ensures an easy capacity increase. Another major advantage is the fast and easy roller change.

Amandus Kahl is currently working on a technical modification of the drive. While the rollers are currently driven by a V-belt, the future of the crushing roller mill is a direct drive. As a result, there will be a separate drive for each roller (and not for each roller pair) so that the rollers can be driven at different speeds. This technical innovation is intended to ensure an even more uniform and faster crumbling of the product.

www.akahl.de

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by Erin Schmitt, Media Director, Pittsburg Tank & Tower Group, USA

valuable experience for Allstate

Allstate Tower has undertaken thousands of projects since it was formed in 2003, and in 2016, was eager to accept the challenge of a project for Grain Processing Corporation that is set to be completed this fall.

Founded in 1943, Grain Processing Corporation is a privately held corn

wet milling company based in Muscatine, Iowa. GPC’s products

include maltodextrins, corn syrup solids and starches for the food, nutraceutical and personal care markets; ethyl alcohol for beverage and industrial use; starches for the paper, corrugated box, textile and wallboard industries; crude corn oil and corn germ; and animal and pet nutrition ingredients.

In 2015, GPC approved a project at its Muscatine plant. Not long afterward, an Allstate salesperson reached out to the project’s millwright, Carl A Nelson & Company of Burlington, Iowa.

The project was eventually awarded to Allstate Tower in two phases; with the first phase totaling about 1.53 million pounds


STORAGEF

and the second one coming in around 800,000 pounds. Allstate Tower provided all of the steel support structures associated with this project. Throughout the two-phase project, Allstate has provided a total of 30 towers or vertical supports and more than 2,000 feet of catwalk to support the conveyor systems.

“When all is said and done, Allstate provided over 2.3 million pounds of structural steel,” said Ray Fulkerson, Vice President of Manufacturing for Allstate Tower.

For reference, a tower and a 60-foot catwalk are in the 20,000 to 40,000-pound range, said Fulkerson.

Allstate played a role in designing part of the structures for phase one, Fulkerson said. The in-house team of professional engineers employed by Allstate Tower is well equipped to tackle a project of this magnitude and has decades of combined experience designing all types of steel structures. All of the support equipment was fabricated and manufactured at Allstate.

“The catwalks were very large on this, so we used a different material, a custom style of catwalk specifically designed for that project,” said Fulkerson.

The large catwalks supporting most of the conveyors were a custom design that utilised WT-shapes for the top and bottom chords. WT-shapes are made by splitting W-shapes, or I beams, down the middle to create a “T” shaped structural member. This shape proved to be the most effective choice for the heavy top and bottom chords required for these catwalks.

Most of the steel has a hot-dipped galvanised finish. The OSHA-compliant handrails were painted safety yellow.

“There was a lot of pre-assembly of the catwalk sections that occurred at Allstate Tower to save time in the field,” said Fulkerson.

Most of the catwalk side trusses were pre-assembled at Allstate’s shop to ensure proper fit-up and then shipped out to expedite assembly at the job site.

“It’s up in the air, so the more that you have done and completed where they can just lift it with a crane, the better because it’s less time with labor,” said Alisha Saalwaechter, who is in charge of steel support sales for Allstate Tower.

The project scheduled required Allstate shop to work on the project for two years. The first phase of the project was finished and shipped out by summer 2019. The second phase is expected to be completed in the fall.

Dealing with the size of the project was challenging, said Fulkerson. The materials they worked with were larger and often different than on projects they had worked on before.

Allstate worked closely with GPC to ensure shipping was done to the corn wet milling company’s needs.

“That’s one thing they relayed to us; they wanted shipments a certain way,” Saalwaechter said. This involved staggering shipments so GPC could better store the steel. “Obviously they don’t need this item over here if they are trying to finish up this. They don’t want a bunch of steel in the yard.”

Part of the shipment was loaded onto flatbeds, while the pre-assembled parts were placed on over width load trucks. Hundreds of shipments were made throughout the entirety of the project. The GPC project was given top priority at the shop, with several shipments simultaneously in transport.

Shipments were scheduled in a manner to give the GPC project top priority at the shop, that way other customers weren’t coming in to pick up shipments at the same time. It also gave the shop plenty of room to work with multiple skids and trailers.

“With any project, it doesn’t matter the size, it’s very important to accommodate the customer’s needs and make sure that everybody is on the same page and that they are not only getting

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a quality product, but they feel good about the relationship,” Saalwaechter said.

“That way they feel good about the project from start to finish. They feel good and feel like, ‘oh yeah, Allstate took care of me, I’m going to reach back out to them.’”

Saalwaechter added that quality customer service is always important no matter the size of the project. “But obviously, with a project of this size, you definitely put your game face on with everybody.”

Allstate also worked closely with the customer to help eliminate downtime so the project could move along as quickly and efficiently as possible. This was made possible, in part, because of the team of Allstate Tower employees who were critical to completing the project.

Senior draftsman Will Ladd was responsible for producing the structural steel detailing. These drawings were then used to fabricate products in the shop. Project manager Matt Dalbec was in constant communication with the customer and

the contractors. Dalbec also oversaw scheduling shipments, resolving issues in the field, and invoicing.

As plant manager, Chris Hunt worked closely with drafting and project management on the project. Hunt also oversees all shop employees and coordinates the galvanising process, which is performed off-site at a facility in Nashville, Tennessee. He’s also responsible for the quality of the shipments and scheduling when to ship products.

“Chris and Matt keep a pulse on the project,” said Saalwaechter. This was the largest manufacturing project that Allstate has

ever undertaken. The GPC project has given Allstate valuable experience that it looks forward to putting to good use with future endeavours, and possibly even bigger projects.

“The project has positioned Allstate for future larger opportunities,” said Fulkerson. “Now, with this behind us, we are capable of producing larger projects like this.”

Allstate Tower is part of Pittsburg Tank & Tower Group, which is headquartered in Henderson, Kentucky.

AMANDUS KAHL GmbH & Co. KGDieselstrasse 5–9 · 21465 ReinbekHamburg, Germany

+49 (0) 40 72 77 [email protected] · akahl.de

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BINS VS SILOSby Rebecca Sherratt, Features Editor, Milling and Grain

STORAGEF

In Milling and Grain magazine we work together with a great number of companies each month to provide our readers with the latest information regarding how to get the most out of your storage facilities. We have worked extensively with storage companies to establish the do’s-and-don’ts of how to care for your raw materials and yet, when you go back to the basics, there are still a lot of fundamental questions that need answering.

Yes, there is a great deal to think about in regard to what specific type of silo or grain bin you need- but first things first- how do you know whether you want a silo or a grain bin? Which of these solutions will best suit your own unique needs?

To understand which solution works best for you, let us first establish what each solution offers consumers:

SilosProbably the more familiar of the two solutions to most

individuals, silos are tall, slender constructions with domed rooves that hold moisture and raw materials together in a very tight seal. Keeping the materials in complete quarantine, a silo’s intended purpose is to prolong the lifecycle of the materials.

These constructions have been a necessity of food production since as far back as the eighth century in Ancient Greece, the word silo (formerly ‘siros’) literally translating in Greek to ‘pit for holding grain’. The first wooden grain silo that can be seen as an influence for the very models we use today was invented in 1873 by Mr Fred Hatch in Illinois, USA.

Silos are employed for a range of bulk materials including grain, wheat, silage, sawdust, woodchips, coal and cement to name a few. Standard storage silos usually range in size between 30-275ft in height and 10-90ft in diameter and are built with wooden

staves, concrete staves, steel panels and/or cast concrete.To unload your silo of contents, farmers typically utilise

unloaders, but this is a notoriously tricky business. Emptying a silo completely, in order to give it its recommended two-to-three annual cleans, is never a simple task and build-up of encrusted materials can be difficult to manage in such a lofty, thin structure.

Grain binsGrain bins are the shorter and wider counterparts to the

shapely, towering silo. Used to store grains between use and sale, as well as between harvests, they share a great deal of similarities to the silo, but it is important to also understand they ways in which they differ. The materials stored in grain bins often tend to be slightly lighter in weight compared to silage and they can also store powdered material with greater ease.

These structures tend to often be suitable for a wider range of materials than when compared to silos, a key advantage if your farm deals with a wide variety of different produce. Grain bins are also widely adopted methods of storing soybeans, shelled corn, oats, wheat and a variety of seeds. Grain silos do not tend to store silage for livestock.

Which is the best storage solution for your raw materials?


Being shorter constructions, one of the major advantages grain bins possess is that they are much easier to maintain than their elongated brothers. There is less opportunity for raw materials to become encrusted or wedged in hard to reach places whilst being emptied and scheduled cleans prove much less worrisome for grain bin owners. Similarly, grain bins are much easier to fix, should any problems arise.

Which is for you?There are a variety of factors in which grain bins and silos vary,

here are just a few of the crucial ones to consider:

Preservation: One of the most striking differences between the silo and the grain bin is the level of protection they offer the raw materials inside. As previously mentioned, silos endeavour to keep raw materials completely isolated from any exterior factors, such as oxygen, liquids, insects, humidity or any other factors that could decrease the lifecycle of the materials. Through such strict preservation, the goal of the silo is to promote fermentation of the produce, in order to preserve the contents for as long as is possible.

In contrast, grain bins still endeavour to keep raw materials dry and undamaged, but aeration, as well as slight temperature and humidity variations, are permitted. The design of grain bins allows some exterior factors to slightly permeate the materials inside, as long as these parameters do not change so suddenly as to cause spoilage.

Pest protection: Unfortunately, grain bins being more open to external influences does also mean that they are also more likely to succumb to pest infestations, every farmers’ worst nightmare. Being both more open to exterior factors, as well as covering more low ground, mean that there are more opportunities for pests to enter a grain bin than a 270-foot tall, thin silo.

Grain bin foundations have also been known to crack over time, allowing pests to burrow underneath and lay waste to the materials inside. This can, however, be mitigated with the

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utilisation of metal forms around grain bin foundations, along with wire to reinforce the concrete.

With so much of the raw material in a silo being stored above ground in a much more protected manner, insect infestations are usually less of a common occurrence, but they are still often reported. The strict quarantine silos place raw materials in proves usually very effective at preventing infestation, but regular maintenance checks of your silos are needed to ensure no damage has occurred which enables small rodents or insects to burrow into the structure. Conducting deep cleans of your silo is also essential to prevent infestation.

Versatility: Grain bins come in all shapes and sizes, so if you are pressed for space or need a storage solution of a specific size, then a grain bin may prove a better choice. In contrast, although most silos follow the same shape and design, there are a variety of specialised silos that users can request that specialise in storing certain materials.

Aerated silos are silos specifically designed for the storage of

fine powders. Air is pumped into the bottom of the silo, aerating the material and causing it to behave like a fluid as the materials discharge from the bottom of the silo upwards.

Sealed silos are the most airtight and secure silos available, providing optimal insect control and protection from all exterior factors.

Low-oxygen silos do exactly what it says on the tin, providing a space where contents can remain secure in a low-oxygen area to prevent mould and decay, whilst also encouraging fermentation. Their unloader chutes are also sealed against air infiltration, to provide the ultimate protective experience for your raw materials.

Difficult decision to makeBoth grain bins and silos undoubtedly have their own pros

and cons, but it is up to the users to decide what they think is the optimal storage solution for their facility. Many companies which specialise in the construction of both bins and silos offer consultations and provide users with free advice regarding what they think their facility would benefit from the most- so make the most of this service and see what advice they have to give!

STORAGEFF


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StolzGrinding Line: Livestock – Fishfeed – Petfood

Whether in the context of the feed mill: traditional livestock, or fishfeed and petfood, Stolz, a company specialising in the processing of raw materials for animal nutrition, offers these adapted grinding lines.

Two types of grinding lines, widely tested and approved, are available:

• A line dedicated to fine grinding for aquaculture or petfood feed

• A line dedicated to traditional grinding used in the feed mill for animal feed production

The Stolz solution for fine grinding - with pneumatic lift and turbo-sifter - is an exceptional solution combining grain size quality and high throughput. It allows constant parameters to implement technical solutions that reduce grinding costs by


30 percent, by combining the costs related to electrical energy consumption-per-tonne of feed ground and spare parts compared to other available technologies.

For livestock this technology is used for all types of feed; poultry, pigs, cattle, horses, rabbits, sheep, goats and allows to adapt the rate and quality of milling and optimal electrical energy consumption.

These solutions implement:• Stolz’s top-of-the-range ABMS type

magnetic feeder-splitter which allows a homogeneous and regular feed over the entire width of the grinding chamber with frequency variation, regularity of amperage, improved lifetime of consumables: hammers and grids and is equipped with a safety device on the air inlet

• Stolz’s hammermill type RM/RMP equipped with a double direction of rotation, a change of grids when running using pneumatic cylinders, an option of automatic change of two or four grids

• Temperature sensors on the bearings and the grinding chamber

• Air flow control systemswww.stolz.com

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CASE STUDY

Technique and animal nutritionJoint research for innovative products and procedures—Practice-focussed research at the Research Institute of Feed Technology of IFF

CASE STUDYF

In Germany, approximately 80 percent of the produced compound feed is supplied in pelleted form. Since its foundation in 1961, the IFF Research Institute of Feed Technology has been establishing scientific basics for the production of pelleted compound feed and the research works go on since then.

The long-standing and manifold research and development works of the Research Institute of Feed Technology regarding milling, mixing and

agglomeration influenced the technological development of the production processes of the European feed industry significantly. On that basis, modern research appeals to the current scientific issues.

Research Institute and Research AssociationThe Research Institute of Feed Technology is maintained by the

International Research Association of Feed Technology (IFF). At present, about 80 national and international companies are combined in the Research Association. Membership is open to any interested company.

The Research Association was founded on the initiative of the

German Association of Feed Industry. It exclusively pursues scientific aims to clarify any of the technological issues or problems encountered in industrial compound-feed production through basic research and transfer of findings to real systems and to advance developments in the processes used in feed compounding. The fast and comprehensive transfer of the research findings is ensured by the wide range of seminars.

The most important body in the institute’s research focus is the Scientific Advisory Board, which is composed of representatives from relevant research institutions as well as industry and which actively supports research topics based on the requests and needs of the industry.

New project ideas are discussed intensively and launched together. The direct connection of the Research Institute to the industry ensures that current and future research work and results are geared to the application-relevant process development of compound-feed production.

Research is mainly carried out in the institute’s technical centre. This offers a variety of possibilities: e.g. for the process engineering investigation of single and compound feeds as well as additives.

The International Research Association for Feed Technology belongs to the German Federation of Industrial Research Associations – AiF in short – which is the leading national organisation promoting applied research and development benefiting Germany’s small and medium-sized businesses.

It builds up alliances together with partners from industry, science and government in order to turn ideas into successful products, processes or services in the market. As an industry-driven organisation, the AiF aims at initiating applied research and development (R&D) for small and medium-sized enterprises (SMEs), as well as qualifying the new generation of academics in innovative fields and organising the distribution of scientific knowledge.

100 industrial research associations with approximately 50,000 businesses, mostly SMEs, as members, 1,200 associated research institutes and the AiF’s affiliates in Cologne and Berlin contribute to the AiF innovation network.

The AiF manages public programmes of the German federal government to strengthen SME competitiveness. The AiF thus connects enterprises, research and government as well as providing a meeting ground for representatives of business and research.

The AiF’s core activity is the so-called Industrial Collective Research (“Industrielle Gemeinschaftsforschung”, IGF). Collective research is a mechanism enabling businesses to solve shared


problems through shared projects.This kind of pre-competitive research closes the gap between

basic research and industrial application. The results are available for everyone interested and the basis for individual adaptations within enterprises.

The AiF and its research associations provide comprehensive service support in research and development matters, helping small and medium-sized enterprises (SMEs) to meet the challenges of technological change. Each research association of the AiF represents a certain business sector, mostly SMEs, from specific branches of the economy or fields of technology.

By joining a research association and taking an active part in its committees etc., SMEs directly influence the association’s research agenda and priorities. Industrial Collective Research, funded by the Federal Ministry for Economic Affairs and Energy, gives SMEs access to a continuous stream of new knowledge which can be used to develop their own products, processes and services as well as giving them the opportunity to build up their individual innovation networks.

Research projects in industrial collective researchResearch projects, which are processed at the Research Institute

of Feed Technology, are for the most part carried out in the research programme of industrial collective research (IGF). Equal

research needs are bundled in a precompetitive way.The Project Accompanying Committee is a key element in the

design of IGF research projects. The industry representatives take an advisory and directional role in the implementation of the projects. The continuous reporting of project progress as well as the continuous evaluation of the interim results by the committee members ensure the practical relevance and take care for an early dissemination of test results already during the project period.

Currently, public research is concentrating on a collective research project led by the Research Institute of Feed Technology, which includes the establishment of a functional model for the industrial production of insects as a protein and fat supplier of feed.

The aim is to develop a process for the production of insect proteins on a production scale, with automation being a major research focus. Project partners are the University of Applied Sciences Bremerhaven (insect breeding), the Georg-August-University Göttingen (qualitative assessment of feed with regard to feed conversion and animal welfare) and the Friedrich-Alexander-University Erlangen-Nuremberg (functional model of an industrial production and fractionation plant).

The processing of the insects or individual components and their possible uses in feedstuffs are experimentally investigated at the Research Institute of Feed Technology. From the findings available so far, further research needs can be derived so that work on the

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CASE STUDY F

use of insects in animal feed will continue in future projects.

Industry research projects and project groups

Industry research projects bundle the research needs of companies or associations and are carried out exclusively for them. In recent years, the IFF Research Institute has carried out industry research to improve the sampling of compound feed as well as the influence of the stress intensity of mechanical hydrothermal treatment stages (pelleting, long-term conditioning, expansion) on the stability of additives.

In 2016, the start of an industry project on Salmonella positive – process optimisation for sound hygienic state of compound feed took place. With the closed research project, in which a total of 15 project partners participate in content and financially, data for the decontamination of single and compound feedstuffs using organic acids and a combination of hydrothermal treatment and simultaneous use of organic acids during conditioning will be determined. The results obtained shall serve to continue the research topic by means of public research funding.

Industry 4.0Industry 4.0 “How can we gain more together?” This question is

currently being addressed by several workshops and events at the Research Institute of Feed Technology.

Moreover, cooperation networks were established with other research institutes, universities and partners from industry. The digitisation of the agriculture and feed industry enables upstream and downstream production steps to be networked right up to the end consumer (human/animal).

Based on decades of experience in basic research and interdisciplinary cooperation within the framework of applied research, the Research Institute of Feed Technology can be able to act as a link between various branches of industry under the heading “Digitisation and Industry 4.0 in the compound feed value chain”.

Through an intensive exchange with animal feeders, fattening farms, additive and compound-feed companies, a common basis is to be created in order to learn from the multitude of recorded measurement data and process information. As a result, the value-added chain should be able to become more efficient, resource-saving and develop further in terms of animal welfare.

Research servicesThe Research Institute of Feed Technology offers a variety of

services both in the companies and in the institute’s technical centre. This includes:• Processing technological investigations on additives and feed

mixtures on pilot plant and laboratory scale• Laboratory tests on single and compound feeds (physical and

chemical analyses)• Testing the working accuracy (mixing homogeneity, cross-

contamination) of compound-feed and premix-production plants• Determination of the mixing quality of mixers• Advising on the implementation and use of HACCP in existing

quality-management systems in the feed industry• Safety-technical assessments within the meaning of 29b

German Federal Immission Control Act (German abbreviation: BImSchG)

• Creation of hazard assessments for explosion protection (explosion-protection document)

• Energetic process analyses and energy balances as well as advice on the implementation and use of energy-management systems

SeminarsThe special value of the seminar offer of the IFF is characterised by

the scientific basis. The main topics can be summarised in three points:• Basic knowledge of compound-feed production, feed law, feed

science and animal nutrition• Findings from research and development• Special knowledge of selected procedures and current topics

In addition, special courses for companies, also in English, are regularly carried out on the basis of specific conceptions.

Since 1965, the seminars for specialists and executives have a special tradition. In the seminar, current research results of the Research Institute are presented and supplemented by lectures by external speakers. The seminar is rounded off by a specific supporting programme. In 2019, the 34th seminar took place on 12th September.

IFF Generation FeedWithin the International Research Association of Feed

Technology, the Generation Feed formed up to connect a younger generation of feed industry employees, animal feeders, plant builders and researchers.

The Generation Feed members are leaders of tomorrow who today discuss current and future issues, laying the foundation for new research topics. In addition to networking, the focus is on formulating common solutions.

The Generation Feed currently meets twice a year in Germany. Outside the panels, factory tours are planned to give participants a broader view of the industry. It is also planned to meet on an international basis in the future.

ContactOn our website, not only the current event programme and a

wealth of information on the IFF but also the abstracts of final reports of individual research topics are available.

www.iff-braunschweig.de

:

As at January 2018 AiF e.V.

German Collective Research Scheme


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:

As at January 2018 AiF e.V.

German Collective Research Scheme

MAG1903.indd 66 25/02/2019 18:14

Fickle weather raising input costsIt’s not unusual for markets to turn choppy at this time of the year as traders and analysts start to put solid numbers on crops piling in from the main Northern Hemisphere grain and oilseed harvests – and 2019 has been no exception.

Choppier than usual might be fair comment this year after one of the wildest summers seen weather-wise, especially within the biggest producing country of all – the USA.

At this point in time, plenty of ‘unknowns’ persist on the supply front – mainly in the US itself, where major grain and oilseed crops have been sown and developed near or at their latest on record after an early-season washout.

But despite all the planting delays and some unhelpful cool weather since, the maize crop does seem to be within reach of the finishing line now amid a lessening risk of serious harvest weather damage.

If it reaches the USDA’s last forecast of 350m tonnes it will only be about 16m or 4.3 percent below last year’s crop and, with carry-in of over 62m tonnes (7.7m more than last year), could meet expected US domestic and export demand without eroding stocks to less than comfortable levels.

As noted in our last review, fears that the crop would run far below normal had been a principal driving force in US, European and other world feedgrain markets during the summer months, spilling firm price sentiment into wheat and oilseed prices too.

The later-developing US soybean crop’s outlook remains a bit more problematical but, if it too can avoid an early frost or harvest washout, it will, if smaller than last year’s, be adequate alongside abundant carryover stocks from last year.

In the wider context of a global soya glut, some might argue a smaller than expected US harvest would be no bad thing for prices, for farmers’ incomes and subsequent harvest prospects. USDA’s new forecast is about 98.9m tonnes – down by a hefty 24.8m tonnes on the year but, like maize, supplemented by large stocks – in this case a massive new record 27.4m tonnes – compared with the previous three year’s range of just 5.35/11.92m tonnes.

A competitive wheat export market weighs on prices

The third major factor in the US crop equation, winter wheat, has already been successfully harvested and production is turning out bigger than expected earlier – though some quality questions were earlier raised for the largest component, hard red bread wheat (HRW).

The smaller, quality-important spring wheat harvest is running later than normal but at this stage, is still expected to come fairly close to last year’s level and will, like the other components above, be supplemented by larger carryover stocks.

Elsewhere on the feed-grain map we have already seen the Latin American maize and soybean crops arrive in the late spring and early summer in largest-ever volume. These are still being sold into export channels at a record pace and along with its squabbles with China, keeping the USA’s market share for these at lower-than-normal levels.

The competition in the maize market has been further enhanced by Ukraine’s heavily export-oriented crop – originally seen lower than last year’s, now above even that record level, so also taking a larger market share at the expense of the US and others.

At the front of most reviews of the wheat situation

by John Buckley

At this point in time, plenty of ‘unknowns’

persist on the supply front – mainly in the US itself,

where major grain and oilseed crops have been

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afteranearly-seasonwashout.


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remains an estimated record global crop of 765m tonnes (plus 34.7m or 4.7%) to which can be added yet another huge carryover stock, the latter expected to expand by some nine million to an all-time peak of 286.5m tonnes by the close of the 2019/20 season (next June 30th).

That’s equal to almost 38% of global consumption needs – a very loose stock/use ratio indeed.

On the demand side of the market we have world total wheat consumption expected to increase by about 2.8% this season – its fastest expansion in three years after a slack period since – if still not enough to stop those stocks building.

Maize consumption – which grew 4% last season is actually seen dropping by 0.4%, a large part of that in the US itself but stocks are still seen tightening by 7 or 23 tonnes.

World soybean demand grew by a slower than usual 1.7% in the past season (2.4% in 2017/18 and 4.7% in 2016/17) mainly due to top meal consumer China cutting back usage in response to a domestic outbreak of African Swine Fever and tariffs blocking its purchases from the USA. As a result, world surplus soybean stocks are estimated to have jumped to 112.4m tonnes versus the (already high) range of 80/99m in the previous three years.

This overall picture of surplus for the three largest food and feed commodity sectors has brought an end to the mini-boom we saw in summer feed-grain and wheat prices. The retreat has been enhanced by recent news that European and Ukrainian wheat crops are turning out bigger than expected and, amid a plethora of choice of alternative sources, contributing to the current perception of strong competition for wheat export markets.

WheathaslostnearonefifthofitsvalueThe effect on prices that were looking so frisky in July has been

startling. The bellwether CBOT wheat futures market has shed about a fifth of its peak summer value, maize futures one quarter of theirs. Wheat would be even cheaper had Russia got the crop recovery most market observers expected earlier in the growing season and Australian output not been damaged again by dry weather.

Soybeans have fared rather better – down about 6% recently - but only because of uncertainty still, at this stage, about the eventual size of the US crop. Futures markets still suggest wheat could firm up over the coming year by 5% to 6%, maize by as much as 13.5%, soya showing less recovery potential.

Market weakness in wheat has recently been led by the usually more valuable hard winter and spring wheats, prices of which have hit 14 and 10-year lows respectively. Analysts cite this year’s bigger US hard red winter wheat crop and downward pressure coming to bear from a larger Canadian spring wheat harvest (+5%).

Earlier in the season, the only real concern in the wheat market was about the proportion of higher-grade milling wheat that might be available for flour-making. Those concerns appear now to be diminishing, underlined by the recent drop in export costs of US milling wheats to some of their cheapest levels in over a decade.

As well as a decent North American crop, top EU exporter France has higher proteins than last year, compensating for a probable drop in second largest supplier Germany’s quality in its Northern exporting regions which suffered from a rain-delayed harvest.

Russian and Ukrainian crops are reported to contain a higher proportion of good milling wheat this year too. On the downside,

Australia, normally a key source of quality milling wheat is into its third year of drought and may turn in a significantly smaller crop than earlier expected – but will still be in the running as a major exporter. Another former member of the ‘Big Five’ exporters’ club, Argentina, has meanwhile expanded its production and is stepping up sales of bread wheat.

Wheat prices will also be determined by the progress of major exporters’ sales. Despite all the gloom about competition and a strong dollar, US exports have actually been running over 20% higher than last year’s. If that pace continues (well ahead of the USDA’s official forecast +4%) it could steady up prices.

EU milling wheat prices have been under downward pressure after a slow start to the export season here. But even in the face of intense Ukrainian and Russian competition, the bloc’s shipments have since moved well ahead of last year’s, thanks to a weakening euro sharpening prices. Still, traders here are under no illusions about their need to stay competitive.

Will importers respond to the cheaper wheat prices and buy more or delay purchases as long as possible to benefit from possible even better bargains ahead? Traders will be closely watching big hitters like Egypt, Algeria, Turkey and Saudi Arabia for clues to buyer psychology in the weeks and months ahead. All have been quite active during late-August or early September.

EU milling wheat prices hit ‘life-of-contract’ lows this month, their cheapest levels in well over a year as traders here fretted about undercutting competition from Ukraine, Russia and Argentina. Ukraine is exporting a record crop and Russia likes to ‘front-load’ its sales before rivals are fully harvested.

It has been slow doing so this year, but its prices have been easing for some weeks now (despite its smaller than expected 2019 crop) as exporters try to compete with cheaper Ukraine and Russian sales have done well recently to top customer Egypt.

The big EU wheat exporters, France, Germany and Poland have also been looking anxiously at internal competition from good


quality, cheaper wheat from the bloc’s Northern Baltic States. France has a lot more to dispose of this year and could end up with larger carryover stocks.

German traders, usually more influential in the quality market, meanwhile expect protein downgrades in some key Northern exporting regions to push more of that grain towards North African countries normally buying French soft wheat. Overall, the EU needs to export about 18% of its wheat crop and has about 10% (13m tonnes) more to ship this year whereas the US has to export half its harvest.

Even if global wheat imports recover by some 3.4% as USDA expects, they will only be back to the average prior to 2018/19, accounting for under a third of the expected increase in world consumption (the remainder fed by domestic crop increases).

Maize cheapest since May Improving weather forecasts have brightened US maize crop

prospects and pushed prices down to their cheapest since May, close to their seasonal lows. The current outlook is for adequate supplies in the price-trend-setting US market where consumption in the feed sector, in ethanol fuel and exports are all looking shaky.

President Trump’s officials are racing to complete a rescue package for the ethanol industry which has been damaged by the administration’s earlier waivers on blending mandates. Ethanol absorbs over 40% of US corn – the world’s largest source of the grain.

Export potential remains under threat from this year’s larger South American crops, much of them still to flow onto world markets with another planting season just around the corner. Ukraine’s approaching record, harvest is also hanging over the global and EU feed markets. But it could have been worse, price-wise for farmers, had US planting not been delayed and downsized by rain and cold weather earlier in the year, causing a late harvest.

Brazil achieved a record 7.65m tonnes of exports in August aided by a big crop and its weak currency cutting fob prices in dollars. Argentina is also using a weak peso and a good harvest to sell into markets normally serviced by Europe or Ukraine but may swap some maize acreage for cheaper-to-grow soybeans this autumn.

US export sales for the season to date are running almost 18% lower than at the same date last year after losses in Asia, North Africa and Latin America. In the just finished 2018/19 season, the US has held a 30% share of the global maize export market versus Brazil’s 22%, Argentina’s 19% and Ukraine’s 17%. In the previous year the US took almost 42%, the LatAms 16% each and Ukraine about 12%.

Maize imports meanwhile continue to pile into the EU to meet another season of expected large deficit, albeit down a bit on last year’s amid better wheat supplies to compete in feed outlets.

China’s farm ministry cut its corn consumption forecast by 2m to 280m tonnes reflecting a pig herd downsized by African Swine Fever outbreaks. Chinese maize demand in total demand had grown by about 50m tonnes in the last four or five years to meet expanding pig and poultry needs but, holding huge stocks after years of surplus, it has been trying to curb production.

Plentiful soya likely to stay cheap If the late-running US crop can avoid weather damage prior to

harvest, record domestic and global stocks and continued larger

than usual crops from Latin America are likely to keep soya prices nearer the low end of the past year’s price range, encouraging for meal users, given soya’s dominant role in the sector. Current soya prices are actually surprisingly close to levels seen this time last year – before the full extent of current surplus was clear.

As well as final US crop progress, the market needs to see how much the Latin Americans plant next month for their 2020 crops and what sort of weather they get over the next four or five months. Dryness was recently raising the possibility of planting delays in Brazil’s top two soya states but that could fade if a wetter forecast proves accurate.

Soya prices will also be heavily influenced by the outlook for US trade with China. If they can get an agreement – which was looking more likely as we went to press (though past constant upsets demand caution) – China could start to buy more US beans, lifting values initially. That said, China’s Swine Fever outbreak could continue to depress its soya meal use, reducing bean imports in total – a concern that might slow the expansion in Latin American sowings this autumn.

Surprisingly, Brazil was recently reported to be getting low on stocks in its attempts to keep supplanting US beans on the Chinese market. If Brazil does find current and past crops have been over-estimated, that could support soya prices going forward. Lower than usual Brazilian proteins might also hurt its sales to China.

US proteins are, as usual, lower still than Brazil’s but ideas this situation might lead to tighter contract specifications, possibly needing some price discounting could be bearish.

Less rapeseed in 2019/20The global canola crop is turning out much smaller than expected

for the 2019/20 oilseed product season that starts October 1st. The latest USDA forecast is cut almost one million tonnes due to smaller than expected European and Australian crops although a wide range of estimates for top supplier Canada suggests some leeway for a possible upward revision too at some later stage. Also, Canada is carrying forward record canola stocks after losing at least 1m tonnes of trade to China over a political squabble.

Demand for the primary crush product – rapeseed oil – is no longer rising in Europe where massive use in biodiesel has flattened out in recent years. By drawing on stocks, global rapeseed crush should not be far off the average of recent years, keeping meal supplies up. In any event, adequate supplies of still cheap soya – the dominant factor in oilmeal protein consumption – should help keep prices in this sector grounded. So, should this season’s expected larger sunflowerseed crop, expected to compete with rapeseed more this season in European markets.

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K2 Godown, Dul Dul Business Park (Mlolongo/Sabaki Area), Mombasa Road, Nairobi, KenyaTel: +254 798211555 / +254 712686268

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INDUSTRY EVENTS2019 October

2-3Poultry Africa 2019Kigali, Rwandawww.poultryafrica2019.com

16-17 ☑JTIC 2019Lille, Francewww.jtic.eu

Jean-Philippe Hess, Vice President of AEMIC, explains what makes this 70th edition of the JTIC show so special: “The AEMIC network, which brings together more than 1,500 people, aims to link all professionals, students, job applicants and recruiters in the cereals sector. It will organise for the seventieth time the Technical Days of the Cereal Industries (JTIC), from 16-17th October, 2019 in Lille, at the Grand Palais.Initially focused on milling, AEMIC now brings together all stakeholders in the grain sector.This year, Lille was chosen to host the JTIC on October 16- 17, 2019.“We were previously based in Paris or in Champagne, in Reims” says Jean-Philippe Hess. “We wanted to move to the northern region, which is one of the major French grain regions. It was an opportunity for us to put this region in the spotlight.“In this same territory, we can find important players in the processing and marketing of cereals, as well as brewers and microbrewers. Also, AEMIC wanted to make a geographical refocus of the event, in order to put France in the spotlight and promote its influence on a European or international scale.”The Vice-President added, “We welcome professionals who can come from Africa, Turkey or even Spain. We want to highlight the French sector, while attracting more professionals from Northern Europe and England.” (Nearly 2000 visitors are expected on both days.)“AEMIC will offer a conference programme that will punctuate the two days of exhibitions,” Jean-Philippe Hess explains. “One will, for example, be proposed on the study of the variability of the raw materials and, therefore, their valuation. INRA or ARVALIS, which are key players in this field, will speak on this subject.“During the first day, interventions will be offered around the quality of malting barley in 2019 or on artificial intelligence, a real potential that can boost the grain industries. Topics such as the association of wheat with legumes will also be discussed: this is a rather recent approach in terms of association for pastry.The second day, the conferences will be more focused on the quality of wheat.Jean-Philippe Hess add, “Our goal is to bring together all the players in the sector and provide them with all the information they need. We bring this information in complete freedom, and always trying to be as neutral as possible.”Nearly one hundred exhibitors are expected for the next edition. They will present on their stand their innovations, their solutions and their know-how. Jean-Philippe Hess adds, “The link with schools remains at the heart of AEMIC’s missions. In this regard, we have more proposals than student placement possibilities. The industrialists know that we have this service. As such, the partner schools attend JTIC to present the training they offer.

17-20 ☑NAMA Annual Meeting 2019Colorado Springs, Colorado, USAwww.namamillers.org/meetings

29-30Organic & Non-GMO Forum 2019Minneapolis, Minnesota, USAwww.ongforum.com

31-2 ☑Livestock Taiwan Expo & ForumTaipei, Taiwanwww.livestocktaiwan.com

Livestock Taiwan Expo & Forum 2019 will take place at Taipei Nangang Exhibition Centre, Hall 1 from October 31-November 2nd. It is an exclusive trade show represents Taiwan’s premier, international and professional B2B trading platform that focuses on the state-of-the-art technologies in the field of livestock.With the rising issues of climate change and food safety, the livestock business opportunity has expanded potentially as well as the development of IoT and biological technology. Livestock Taiwan aims to provide diverse solutions which help optimise and upgrade the industrial facility and increase livestock productivity. As a result, it brings together manufacturers, wholesalers, and retailers to showcase animal healthcare products, biogas-oriented equipment, technologies for circular economy and automated devices.The annual Livestock Taiwan is held in conjunction with Aquaculture Taiwan and Asia Agri-Tech. The three-day grand tradeshow contains one-on-one business matchmaking programmes and over 50 thematic seminars and forums. Not only it reveals the strength and competitiveness of Taiwan’s supply chains, but also it enacts a perfect platform to see the world in Taiwan and Taiwan in the world.

2019 November

3-6 ☑IAOM MEA 2019Dubai, UAEwww.iaom-mea.com

6-8 ☑AFIA Equipment Manufacturers Conference 2019Florida, USAwww.afia.org/afiaevents

10-16 ☑Agritechnica 2019Hanover, Germanywww.agritechnica.com

At the world’s leading trade fair for agricultural technology, all the leading companies in the industry present their innovations. Agritechna is the showcase of the global agricultural engineering industry and a forum for the future of plant production.In attendance there will be more than 2750 exhibitors from 51 countries, more than 450,000 visitors from 130 countries, around 110,000 international visitors.There will be seven days of expert dialogue on the future of crop production, packed with exciting events, informative congresses and conferences, innovative special events and inspiring networking opportunities.

2019 December

8-10 ☑48th Annual Country Elevator Conference and TradeshowIndianapolis, Indiana, USAwww.ngfa.org

2020 January

28-30 ☑IPPE 2020Atlanta, Georgia, USAhttp://ippexpo.com

2020 March

21-24GEAPS Exchange 2020Minneapolis, Minnesota, USAwww.geaps.com/exchange-expo

24-26 ☑VICTAM Asia 2020Bangkok, Thailandhttps://victamasia.com

24-26 ☑VIV Health and Nutrition 2020Bangkok, Thailandhttp://vivhealthandnutrition.nl

24 ☑GRAPAS Innovations ConferenceBangkok, Thailandmymag.info/e/291

25 ☑Build My Feedmill ConferenceBangkok, Thailandbit.ly/bmfmbangkok20

2020 April

1-2Solids Dortmund 2020Dortmund, Germanywww.easyfairs.com

7-9 ☑124th IAOM Annual Conference and ExpoPortland, Oregon, USAwww.iaom.info

7-9Livestock Malaysia 2020Malacca, Malaysiawww.livestockmalaysia.com

☑ = Meet the Milling and Grain team at this event

102 | October 2019 - Milling and Grain102 | October 2019 - Milling and Grain

INDUSTRY EVENTS


Improving the milling quality of wheat: technical and economic evaluation of cleaning

Profile of the 2018 wheat harvest Partner: ARVALIS – Institut du végétal

Quality of 2019 malting barley Partner: IFBM

Baking: what challenges for tomorrow?

Artificial intelligence to boost the cereal industries

How to make the most of the variability of raw materials?Partner: Inra

70es

JTIC LILLEGRANDPALAIS

CONFERENCES

JOURNÉES TECHNIQUES DESINDUSTRIES CÉRÉALIÈRES

#JTIC2019 www.jtic.eu

16 & 17 OCT. 2019

MICHEL MEYERMiddle East & Africa Manager

Grains & Oilseeds, Cargill

W W W . I A O M - M E A . C O M | I N F O @ I A O M - M E A . C O M

WHAT’S AHEAD IN 2020: The Strategy and Thinking From the World’s Largest Grain Traders

DON CAMPBELLGeneral Manager,

International GrainCorp

GIOVANNI RAVANOSenior Vice PresidentGlobal Trade, Bunge

DAN BASSEPresident & Founder

AgResource Co. (USA)

PEDRO NONAY VELAHead, Europe, Middle East & Africa (EMEA)

Region and Regional Head of Grains for EMEA Louis Dreyfus Company

BAS VAN HOORNGlobal Trading Manager

Grains Department, Glencore Agriculture

GEOPOLITICAL AND ECONOMIC DEVELOPMENTS AFFECTING WORLD TRADE IN GRAINS

DJAMAL DJOUHRI CEO

Al Ghurair Resources International

Anniversary

th

NIR AcademyAB Vista, a global animal nutrition technology company offering pioneering products and technical services to the animal feed industry, recently held the “NIR Academy” seminar in Manila, Philippines, to share the latest developments in NIR technology on feed and raw material application.

Ms Marylan Rivera, Regional Sales Director at AB Vista – Southeast Asia, kicked-off the seminar by welcoming the delegates from Indonesia and Philippines as well as sharing the latest updates on raw material variability in individual markets across Asia.

This was followed by a presentation by Mr Chris Piotrowski, Director at Aunir, a division of AB Vista with an-award winning team of chemotricians, who are experts in the application of NIR. Mr. Piotrowski shared his perspective on the “Future of NIR”, discussing the new developments that have extended NIR applications beyond traditional proximate analysis, to the measurement of parameters such as phytic-P levels.

Dr Natchanok Amornthewaphat, Key Account and Technical Manager at AB Vista – Asia Pacific, presented on “In-Feed Mixability Quality Control and the use of NIR”. Dr. Amornthewaphat provided the audience with practical examples to demonstrate the importance of feed uniformity – how it will affect the growth of the animals and how can NIR help in determining mixability.

Following the presentations, guests were invited to watch a “live” NIR demonstration using AB Vista’s calibrations to analyse raw material and feed samples.

EVENT ROUND UPExpanded training program in Chile: Extrusion and Drying

Following their first Aquafeed Extrusion course in South America last year, Australians Dennis Forte and Gordon Young are working with the Catholic University of Temuco to present an expanded programme in November 2020.

In addition to the “Aquafeed Extrusion Technology” programme, a course in “Petfood Extrusion Technology” will be presented to provide a further opportunity to both aquafeed and pet food industries.

The three-day extrusion programme covers the principles of extrusion, the design of extrusion processes, and the formulation of extruded products. Topics cover the basics of extruders and their configuration, through what is happening inside the extruder barrel, to an understanding of extruder dies and extruder instability. Examples in product formulation and the design of extrusion processes demonstrate application of the theory.

The drying course is about understanding the drying technologies used commonly across the food and feed industries - and how we can use that understanding to improve current processes and products, or design/select new systems that are both effective and efficient.

Details of the courses available via www.foodstream.com.au/events.


The vehicle traffic clogging the roads of Rennes, France told the story: the 33rd SPACE expo was back in town again, running from 10-13 September 2019. As usual it seemed like half the population of Europe was homing in on the Rennes Exhibition Centre.

Every year, SPACE, or “Le Salon International Des Production Animals” (The International Exhibition for Animal Production) to give it its full title, provides agricultural professionals with one of the biggest exhibitions targeting livestock industry players with a show that covers a wide variety of species: bovine (dairy and beef), poultry, pig, rabbits, sheep, goat and, most recently, the fish farming sector. Rounding out the offerings are animal feed and nutrition, farm buildings, genetics, energy generation, animal health, milking, and livestock effluent treatment.

Innov’Space 2019The highlight of the four-day exhibition is

Innov’Space, a showcase for innovation in all aspects of livestock husbandry. These yearly awards recognise innovations in products, services, or tools that promise to have a profound impact on the industry.

This year, 46 different products were nominated for a trophy, which are awarded on a one-to-three-star scale. Interest in this aspect of SPACE remains as high as ever. Each application was carefully vetted by a multi-disciplinary jury (independent of SPACE) consisting of engineers from Chambers of Agriculture, specialists from technical institutions Indra (National Institute of Agricultural Research) and Inpi (National Institute of Industrial Property), livestock veterinarians and specialist press journalists.

Out of 135 applicants, the jury’s high standards

by Vaughn Entwistle, Managing Editor, Milling and Grain


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meant that entries were eventually whittled down to a shortlist of 46 award winners. The Innov’Space awards were divided into two categories based upon: First, the level of interest in the product, equipment or service for the breeder or the end user; Second, the level of novelty compared to already existing products on the market.

A special three-star designation was given for the judge’s Top Choice commendation. The prizes help keep the winning companies in the spotlight and make their show booths a must-see for visitors.

Espace pour demain (for the future)Climate crisis and how to cope with global warming is an ongoing problem that is already impacting every aspect of livestock

production. Because of this, SPACE and the elected officials of the French Chambers of Agriculture chose climate concerns as the main theme of the 2019 expo, and in particular, of Espace for the Future.


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Espace previewed many innovations in French agriculture currently being adopted in an ambitious response to the climate crisis. With this in mind, a special booth was set up in Hall 4.

A number of presentations were made with video recordings to be transmitted on Space TV. Many of these developments not only benefit the climate, but also the farmer, farm operations, and livestock health and well-being.

One example was the development of technology that automates manure recovery to facilitate biomethane generation. In these systems, methane is cleaned and added to natural gas supplies which are then used for farm heating and to power vehicles adapted to run on the gas.

In some instances, the biomethane is sold to local authorities and transport services where it powers buses while reducing a farm’s production of greenhouse gases and simultaneously creating a new income stream for the farmer.

The presentations also covered the development of electrically powered farm equipment such as “Porte Quetils tout terrain electrique por Extramate,” a multi-purpose articulated electric carrier for transportation, lifting and cleaning tasks on a farm.

Up to 30 attachments are available which enable the Extramate to carry out a wide variety of tasks on a farm, all while creating very little noise and producing zero greenhouse gas emissions.

Next, with climate extremes becoming commonplace, animal welfare was also addressed with automated climate control systems for swine and poultry sheds, and even cooled/heated mattresses for cattle to lie upon. To track weather conditions, portable solar powered weather stations can be located at farms to measure conditions in the local micro-environment.

A global presenceIn a sign of how SPACE is expanding to become an exhibition

of global significance, this year’s exhibition attracted more than 14,000 livestock and animal production stakeholders from more than 120 countries. More than 199 companies exhibited at SPACE for the first time, including 106 international exhibitors.

Also, for the first time, SPACE received a number of International delegations including Canada, Niger, Nigeria, Cameroon, Equatorial Guinea, India, Kazakhstan, Russia and China.

Special ConferencesIn addition to the massive show halls, the event hosted a

number of special conferences on a wide variety of specialty topics including, heat from biomass and animal performance, Pasturenet, the pasture management app, dairy sector and societal issues, biogas, and aquaculture among many others. While aquaculture has been covered in past exhibitions, this year the increasing role of aquaculture in feeding the world population was recognised, with two half-day conferences on aquaculture that were extremely well attended.

Next year’s SPACE is scheduled to run from 15-18th September 2020. Be sure to get there early to beat the traffic!

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Amino acidsEvonik Nutrition & Care GmbH +49 618 1596785www.evonik.com/animal-nutrition

Bag closingFischbein SA+32 2 555 11 70www.fischbein.com

Cetec Industrie+33 5 53 02 85 00www.cetec.net

Imeco+39 0372 496826www.imeco.org

TMI +34 973 25 70 98www.tmipal.com

Bakery improversMühlenchemie GmbH & Co KG+49 4102 202 001www.muehlenchemie.de

Bin dischargersDenis+33 2 37 97 66 11www.denis.fr

Morillon+33 2 41 56 50 14www.morillonsystems.com

Bulk storageBentall Rowlands+44 1724 282828www.bentallrowlands.com

Chief+1 308 237 3186agri.chiefind.com

Croston Engineering+44 1829 741119www.croston-engineering.co.uk

Lambton Conveyor+1 519 627 8228www.lambtonconveyor.com

Petkus+49 36921 980www.petkus.com

Silo Construction Engineers+32 51723128www.sce.be

Silos Cordoba+34 957 325 165www.siloscordoba.com

Sukup+1 641 892 4222www.sukup.com

TSC Silos+31 543 473979www.tsc-silos.com

CertificationGMP+ International+31703074120www.gmpplus.org

Colour sortersA-MECS Corp.+822 20512651www.a-mecs.kr

Bühler AG+41 71 955 11 11www.buhlergroup.com


Satake+81 82 420 8560www.satake-group.com

Computer softwareAdifo NV+32 50 303 211www.adifo.com

Inteqnion +31 543 49 44 66www.inteqnion.com

Coolers & driersA-MECS Corp.+822 20512651www.a-mecs.kr


Consergra s.l+34 938 772207www.consergra.com

FrigorTec GmbH+49 7520 91482-0www.frigortec.com

Geelen Counterflow+31 475 592315www.geelencounterflow.com

FAMSUN+86 514 87848880www.famsungroup.com

Manzoni+55 19 3765 9331www.manzoni.com.br


Soon Strong Machinery+886 3 9901815www.soonstrong.com.tw


Suncue Company [email protected]

Tornum AB+46 512 29100www.tornum.com

Wenger Manufacturing+1 785-284-2133www.wenger.com

Yemmak+90 266 7338363www.yemmak.com

Yemtar Feed Mill Machines+90 266 733 8550www.yemtar.com

Elevator bucketsSTIF+33 2 41 72 16 80www.stifnet.com

Sweet Manufacturing Company+1 937 325 1511www.sweetmfg.com

Tapco Inc+1 314 739 9191www.tapcoinc.com


Elevator & conveyor components4B Braime+44 113 246 1800www.go4b.com

Henry Simon+44 0161 804 2800www.henrysimonmilling.com

[email protected]






EnzymesAB Vista+44 1672 517 650www.abvista.com

JEFO+1 450 799 2000www.jefo.com

ExtrudersAlmex+31 575 572666www.almex.nl

Andritz+45 72 160300www.andritz.com

Extru-Tech Inc.+1 785 284 2153www.extru-techinc.com

Insta-Pro International+1 515 254 1260www.insta-pro.com

To be included into the Market Place, please contact Martyna Nobis +44 1242 267700 - [email protected]


Manzoni+55 19 3765 9331www.manzoni.com.br

Wenger Manufacturing+1 785-284-2133www.wenger.com



Feed nutritionAB Vista+44 1672 517 650www.abvista.com

Adisseo + 33 1 46 74 70 00 www.adisseo.com

Biomin+43 2782 8030www.biomin.net

Delacon+43 732 6405310www.delacon.com

DSM+41 61 815 7777www.dsm.com

Evonik Nutrition & Care GmbH +49 618 1596785www.evonik.com/animal-nutrition

JEFO+1 450 799 2000www.jefo.com

Novus+1 314 576 8886www.novusint.com

Nutriad +32 52 40 98 24 www.nutriad.com

PHIBRO+1 201 329 7300www.pahc.com

Phileo+33 320 14 80 97www. phileo-lesaffre.com

Feed millingChristy Turner Ltd+44 1473 742325www.christy-turner.com

Kay Jay Rolls+91 9878 000 859www.kjrolls.com

Ottevanger Milling Engineers+31 79 593 22 21www.ottevanger.com

Wynveen+31 26 47 90 699www.wynveen.com

Van Aarsen International+31 475 579 444www.aarsen.com

Viteral+90 332 2390 141www.viteral.com.tr


Grain handling systemsCargotec Sweden Bulk Handling+46 42 85802www.cargotec.com


Cimbria A/S+45 96 17 90 00www.cimbria.com



Sukup Europe+45 75685311 www.sukup-eu.com




HammermillsAlapala+90 212 465 60 40www.alapala.com


Christy Turner Ltd+44 1473 742325www.christy-turner.com

Dinnissen BV+31 77 467 3555www.dinnissen.nl


Selis+90 222 236 12 33www.selis.com.tr


Viteral+90 332 2390 141www.viteral.com.tr

Van Aarsen International+31 475 579 444www.aarsen.com




Zheng Chang+86 2164184200www.zhengchang.com/eng

Laboratory equipment Bastak+90 312 395 67 87www.bastak.com.tr

Brabender+49 203 7788 0www.brabender.com

CHOPIN Technologies+33 14 1475045www.chopin.fr

ERKAYA+90 312 395 2986www.erkayagida.com.tr

Next Instruments+612 9771 5444www.nextinstruments.net

Perten Instruments +46 8 505 80 900www.perten.com


Level measurementBinMaster Level Controls+1 402 434 9102www.binmaster.com

FineTek Co., Ltd+886 2226 96789www.fine-tek.com

Loading/un-loading equipmentGolfetto Sangati+39 0422 476 700www.golfettosangati.com

Neuero Industrietechnik+49 5422 95030www.neuero.de

Vigan Engineering+32 67 89 50 41www.vigan.com

Mill design & installationAlapala+90 212 465 60 40www.alapala.com



Genç Degirmen+90 444 0894www.gencdegirmen.com.tr

Golfetto Sangati+39 0422 476 700www.golfettosangati.com


IMAS - Milleral+90 332 2390141www.milleral.com

Ocrim+39 0372 4011www.ocrim.com

Omas+39 049 9330297www.omasindustries.com




Sangati Berga+85 4008 5000www.sangatiberga.com.br

Satake+81 82 420 8560www.satake-group.com



Tanis+90342337222www.tanis.com.tr



Zaccaria+55 19 3404 5700www.zaccaria.com.br

Moisture measurementBrabender+49 203 7788 0www.brabender.com


Hydronix+44 1483 468900www.hydronix.com

Mycotoxin managementAdisseo + 33 1 46 74 70 00 www.adisseo.com

Biomin+43 2782 8030www.biomin.net

Nutriad +32 52 40 98 24 www.nutriad.com

NIR systemsNext Instruments+612 9771 5444www.nextinstruments.net

PackagingCetec Industrie+33 5 53 02 85 00www.cetec.net

FAWEMA+49 22 63 716 0www.fawema.com


Mondi Group+43 1 79013 4917www.mondigroup.com

Peter Marsh Group+44 151 9221971www.petermarsh.co.uk




PalletisersA-MECS Corp.+822 20512651www.a-mecs.kr

Cetec Industrie+33 5 53 02 85 00www.cetec.net



Pellet PressPelleting Technology Netherlands (PTN) +3 73 54 984 72www.ptn.nl


Viteral+90 332 239 01 41http://viteral.com.tr



Pest controlRentokil Pest Control+44 0800 917 1987www.rentokil.co.uk

PlantYemtar Feed Mill Machines+90 266 733 8550www.yemtar.com

Zheng Chang+86 2164184200www.zhengchang.com/eng

Process controlDSL Systems Ltd+44 115 9813700www.dsl-systems.com



Safe Milling +44 844 583 2134www.safemilling.co.uk


RollsEntil+90 222 237 57 46www.entil.com.tr

Fundiciones Balaguer, S.A.+34 965564075www.balaguer-rolls.com


Leonhard Breitenbach+49 271 3758 0www.breitenbach.de


Roller millsAlapala+90 212 465 60 40www.alapala.com


Genç Degirmen+90 444 0894www.gencdegirmen.com.tr

IMAS - Milleral+90 332 2390141www.milleral.com




Pelleting Technology Netherlands (PTN) +3 73 54 984 72www.ptn.nl


Pingle+86 311 88268111www.plflourmill.com




Unormak+90 332 2391016www.unormak.com.tr


Roll flutingChristy Turner Ltd+44 1473 742325www.christy-turner.com

Fundiciones Balaguer, S.A.+34 965564075www.balaguer-rolls.com


Our directory, now in its 27th incarnation, has continued to provide those in the food and feed industries with the best source for contacts from around the globe. Every year, our directory only continues to expand, and new companies are joining all the time.The International Milling Directory reaches a massive group of industry experts and customers, as we regularly distribute copies worldwide at trade shows and various events.

Latest updates27TH EDITIONOUT NOWGET YOUR COPY TODAY!

Member newsThis month, we have had five new companies join our database:

• Bluesmart Solar Lighting – China• Tegapetex Iberica – Spain• Henan Sunwit Industry – China

Sweet Manufacturing Company has announced that Jamie Daugherty-Weaver has joined the company as its Marketing Specialist

Cargill and White Dog Labs agreement set to deliver a sustainable feed alternative to fishmeal

Bühler expands into insect portfolio with mealworms

Cargill to open Innovation Lab at University of Illinois, promoting modern global food and agriculture systems

The International Milling Directory is free to join.

List your company, products and services today at:

internationalmilling.com


Reclaim SystemVibrafloor+33 3 85 44 06 78www.vibrafloor.com

SiftersFilip GmbH+49 5241 29330www.filip-gmbh.com

Gazel+90 364 2549630www.gazelmakina.com



SilosBehlen Grain Systems+1 900 553 5520www.behlengrainsystems.com

Bentall Rowlands+44 1724 282828www.bentallrowlands.com


CSI+90 322 428 3350www.cukurovasilo.com


MYSILO+90 382 266 2245www.mysilo.com

Obial+90 382 2662120www.obial.com.tr



Silos Cordoba+34 957 325 165www.siloscordoba.com



Symaga+34 91 726 43 04www.symaga.com


Top Silo Constructions (TSC)+31 543 473 979www.tsc-silos.com

Temperature monitoringAgromatic+41 55 2562100www.agromatic.com


Dol Sensors+45 721 755 55www.dol-sensors.com


Supertech Agroline+45 6481 2000www.supertechagroline.com


TrainingBühler AG+41 71 955 11 11www.buhlergroup.com

IAOM+1 913 338 3377www.iaom.info

IFF+495307 92220www.iff-braunschweig.de

Kansas State University+1 785 532 6161www.grains.k-state.edu

nabim+44 2074 932521www.nabim.org.uk


VibratorsTanis+90342337222www.tanis.com.tr

Vibrafloor+33 3 85 44 06 78www.vibrafloor.com

Weighing equipment Imeco+39 0372 496826www.imeco.org

Mondi Group+43 1 79013 4917www.mondigroup.com


Yeast productsLeiber GmbH+49 5461 93030www.leibergmbh.de

Phileo+33 320 14 80 97www. phileo-lesaffre.com

Contact: [email protected]


YOUR GLOBAL PARTNER

Visit Milling and Grain at mymag.info/e/294

P Advertised products in this issue

98 4B > myMAG.info/e/60 myMAG.info/e/192

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51 ALAPALA > myMAG.info/e/218 myMAG.info/e/94

66 ALMEX > myMAG.info/e/98 myMAG.info/e/130

103 ALTINBILEK > myMAG.info/e/280 myMAG.info/e/281

85 AMANDUS KAHL > mYMAG.info/e/65 myMAG.info/e/257

14 ANDRITZ > myMAG.info/e/67 myMAG.info/e/100

75,77,79 BASTAK > myMAG.info/e/69 myMAG.info/e/102

67 BEHLEN > myMAG.info/e/70 myMAG.info/e/104

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25 NABIM > myMAG.info/e/217 myMAG.info/e/126

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PRODUCTS AND SERVICES FEATURED IN THIS ISSUE

myMAG is a short link system published in our print versions (and carried in our digital editions) that take you directly to the most relevant additional information about a company, a product or service, a video, or any other relevant content you might be interested in. On this page you will find direct links to more product information - as well as a company info link that will take to you the company information page on our website. Whether that content is a web page, a downloadable pdf, or a video - simply type the short link into your browser (or use the QR code on your smart phone) to be taken directly to the information you want to find! Often the information you need - such as the person to contact, a messaging service to reach them, telephone and other contact details along with a host of related product information - is already on our website so please to be sure to go there first.

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84 ZHENGCHANG > myMAG.info/e/32 myMAG.info/e/189


You have been involved in both animal feed and aquafeed throughout your career, with Provimi, and then Nutriad/Adisseo. What prompted you to move to Hamlet Protein?Hamlet Protein is a company with strong Danish roots that wants to expand internationally. It is big enough to cover the world, yet small enough to allow for a direct and personal relationship with colleagues and business partners. I enjoy being close to the market, customers and internal teams and feel that I can have a real and direct impact at Hamlet Protein in realizing the ambitious growth agenda.

As a young person, what sparked your interest in this industry?The variety of challenges that the global feed industry faces, to help feed a growing world population, attracts a group of talented people from business and academic backgrounds.Only real team work within companies and across the industry will allow us to produce more with less, increase the sustainability of our industry and deal with consumer demands and government regulations at the same time. Being part of that community is really exciting.

What in your education prepared you for this career?An academic background lays the foundation for a career, but experience across markets and geographies is what truly helped me in dealing with the broad spectrum of tasks that are part of leading any company. Having worked and lived in various countries exposed me to different cultures, allowing me to better understand how to relate to business partners across the world. I have been fortunate to have worked in best in class companies in the feed industry and with some of the most talented industry professionals. That network has helped me to develop the skill set I have today.

You have taken a position with Hamlet Protein as CEO. What are you hoping to bring to the company?The product portfolio of Hamlet Protein, soy based specialty protein for young animals, is recognised for its technical excellence. At Hamlet Protein we have strong scientific dossiers for each of our products. I believe we can further expand that portfolio and also do a better job of explaining how our technical capacity and support can bring real practical solutions to our customers. Increasing our commercial footprint, and getting closer to our current and future customers, is one of the first things I am looking at with the team.

Sustainability is a big issue in the animal feed industry. How is Hamlet’s soy-based protein able to fill the sustainability issue?Sustainability throughout the chain is very important for Hamlet Protein. Soy is nature’s most sustainable source for protein and oils in the world. We strive to source our soy from sustainable

sources. Hamlet Protein is actively involved in the Danish Agriculture & Food Council. We contribute to drawing up the policies on sourcing soy, especially from South America.Our production is a natural bioconversion process with no use of chemicals. Our only emission is carbon dioxide and water vapors. We are ISO 50001 certified and over the past 15 years we have decreased energy consumption with almost 50 percent per million tonnes produced. In 2019, we completed the reuse of heat from our production site in Horsens and we will start supplying that to 3,330 households.

Will Hamlet also produce aquafeed?Hamlet Protein is considered the benchmark product in soy protein specialties for young pigs. We also have strong track record in Calf Milk Replacers and are currently positioning ourselves in poultry. We certainly believe in the application of our technology in aquafeed but have not yet defined our go-to-market strategy.With the insights of our business partners, external consultants and Hamlet Protein technical team we are reviewing a possible approach into shrimp and fry feed.

Currently, Hamlet Proteins concentrates on feed for young animals. Does the company plan to expand their range of products for older animals/different species?With our technical competences and solid evidence based knowhow about application of our products, we have a good starting point in young animals. Hamlet Protein is definitely exploring opportunities to expand this and help create additional solutions for our customers.

We live in an age of climate crisis, dwindling resources and increasing regulation. What changes do you foresee in the feed industry over the next decade?Consumers will be the biggest driver of change across industries in general and the feed industry in particular. Regulations will follow. An increased demand for more sustainable production, focus on animal welfare and climate will drive the development of the feed industry. The reduction of antibiotics and zinc oxide in feed are the most recent examples that affect producers all across the globe. To be successful in addressing today’s and tomorrow’s challenges we will need to work together across the entire chain.

What you would recommend to young people who want to get involved in this industry?The industry will receive young people with open arms. There is room for technical and commercial talent. In joining the global feed industry, they will become part of creating solutions for global challenges: feeding a growing world population in a sustainable manner. Together with everyone in the chain, they will have the opportunity to make a real impact.

the interview Erik Visser, CEO of Hamlet Protein

Erik Visser has been involved in the animal feed industry for most of his career, usually in a high-ranking position, such as the company CEO. The companies he has worked for are among the leaders in the feed industry and include such prestigious names as Nutriad/Adisseo and Provimi.In mid-2019, he took a position as CEO of Hamlet Protein, a company headquartered in Denmark that specialises in soy-based specialty proteins used in young animal feed. Erik Visser’s skills as a CEO are known throughout the industry, where he is recognised as a role model and leader who demonstrates his passion for building solid teams.


PEOPLE THE INDUSTRY FACES

Adrian Redondo joins the US Wheat Associates team in South Asia

US Wheat Associates (USW), which represents the interests of US wheat farmers in export markets, is pleased to announce that Mr Adrian “Ady” Redondo recently joined the organisation as a Bakery Technician in its Manila, Philippines, office.

USW Regional Vice President Joe Sowers said there is a strong connection between increased imports of US wheat and the organisation’s investment in technical milling and food production support, which is the role Redondo will play in the Philippines and across growing Southeast Asian markets.

Born in the Philippines, Redondo earned a Bachelor of Science in Food Technology from the University of the Philippines in 2001. He went on to amass experience in quality assurance, research and development, production and sales in the thriving Philippines food and bakery industries.

Most recently, Redondo was a key accounts manager with Ingredion Philippines, Inc, a global ingredient solutions company manufacturing starches, sweeteners, nutrition and biomaterial ingredients for food, pharmaceuticals and industrial applications.

Daisy Rodriguez joins AFIA

Daisy Rodriguez has recently joined AFIA as its meetings and events coordinator. In a newly created AFIA position, Ms Rodriguez will be responsible for all meeting registration-related functions, including set-up, support and management of the registration technology system and on-site registration. She also serves as the

primary contact for registration and exhibitor questions for all meetings.Prior to joining AFIA, Ms Rodriguez provided administrative and event support for VersaTel

Solutions, the Laurel Ridge Elementary School Parent Teacher Association, Road Runner/Time Warner Cable and the law office of Shapiro and Burson.

AFIA hires new Meetings and Events Specialist

The American Feed Industry Association has announced the addition of Lynette Tucker as its meetings and events specialist. Tucker will assist in planning AFIA meetings and events, partner educational programs, committee meetings, board meetings, one-time events and webcasts.

Ms Tucker will also be responsible for sponsorships, researching venues, meeting room arrangements, speaker coordination, promotional materials, menus, tours, audio-visual equipment needs, signs, promotions, vendor contracts, hotel relationships and on-site management.

Prior to joining AFIA, Ms Tucker provided event management services and administrative and office management duties for small businesses and agencies. She has a long history of experience in meetings and administration, previously working for Plumbline Public Affairs, RML Strategies, Direct Design Communications, COSMOS Corporation and the Alabama Association for Justice.

Hailing from Manila, Philippines, Ms Tucker holds a bachelor’s degree in Management and Accounting from the University of the East Manila in the Philippines.

Pat Kahle joins D&D Ingredient team

D&D Ingredient Distributors, Inc recently welcomed Pat Kahle, who has joined the company as Sales Manager.

“I am pleased to announce that Pat has joined the D&D team,” says Ted Williams, Chief Operations Officer for D&D. “In the new role, he will serve producers,

veterinarians, nutritionists, and feed professionals focusing mainly on the Ohio, Michigan, and Indiana markets.”

Kahle earned his BS in Animal Science from The Ohio State University in 1987. Pat began his career as Account Manager with Pfizer and has served in various dairy-related capacities over the past 23 years with several companies including: Monsanto, Chr Hansen, and most recently Arm & Hammer. He also has served in a Human Resources capacity for several years with Perdue Farms. He understands the many labor components for small to mid-size businesses.


Innovations for a better world.

What the future of milling will look like is up to you and us. One thing is clear: Shaping a sustainable future requires efficient solutions. This starts with the construction and operation of a mill with less. And goes on with producing more with the same. Just as we do with Mill E3 and numerous pioneering digital services.

Join our journey: www.futureofmilling.com

Creating the future of milling – together.

Futureofmilling_2019.indd 1 05.09.2019 09:16:05

Bogasari Flour Mills

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