january | february 2013 - grain & feed milling technology magazine - full edition

7/29/2019 January | February 2013 - Grain & Feed Milling Technology magazine - full edition

1/68A subscription magazine for the global flour & feed milling industries - first published in 1891INCORPORATING PORTS, DISTRIBUTION AND FORMULATION

In this issue:

Efficientbarge

unloading

technology

Feedenzymes

in animal

nutrition

Controlling theexplosion risks

within hammermills

Use of computerprogrammingin animal dietformulation

Recycling surplusfactory foodinto quality animal feeds

January-February2013

first published in 1891


2/68


3/68

GRAIN &

FEEDMILLINGTECHNOLOGY

Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom.

All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers

accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published.

Copyright 2013 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.

volume: 124 number 1 issn no: 1466-3872

January - February 2013

Published by

Perendale Publishers Ltd

7 St Georges Terrace, St James Square

Cheltenham, Glos, GL50 3PT

United Kingdom

Tel: +44 1242 267700

Fax: +44 1242 267701

[email protected]

Publisher

Roger Gilbert

Tel: +44 1242 267707

[email protected]

Associate Editor

Alice Neal

Tel: +44 1242 267707

[email protected]

Design and Page Layout

James Taylor

Tel: +44 1242 267707

[email protected]

Circulation & Subscriptions Manager

Tuti Tan

Tel: +44 1242 267707

[email protected]

International Marketing Team

Darren Parris

Tel: +44 1242 267707

[email protected]

Lee Bastin

Tel: +44 1242 267707

[email protected]

Tom BlackerTel: +44 1242 267707

[email protected]

Latin America Marketing Team

Ivan Marquetti

Tel: +54 2352 427376

[email protected]

Pablo Porcel de Peralta

Tel: +54 2352 427376

[email protected]

India Marketing Team

Assocom-India Pvt Ltd

Tel: +91 47 675216

[email protected]

Annual Subscription Rates

Inside UK: UK70

Outside: US$140/ Euros110

More information

www.gfmt.co.uk

http://gfmt.blogspot.co.uk

News:US corn crop high quality, despite drought 3

Third scientific exchange meeting for Pancosma 3

New mycotoxin product from Romer Labs 3

Adisseo launches real time web platform for NIR predictions 4

The MPE Chain-Vey for pet food 4

Alapala opens two new flour mills 5Cloud solution improves information interchange in feed industry 5

Hope dawns for aging feed mill 6

4B increases capacity of STARCO steel elevator buckets 7

Success for IPPE 7

Alltech feed survey findings: world increases production to 959 million tons 9

Features:Controlling the explosion risks within hammer mills 10

Recycling surplus factory food into quality animal feeds 12

Efficient barge unloading technology for grain handling on inland waterways 16

Raising standards to improve profitability with Econase XT Mixer Liquid Application 22Yeast in aquaculture 26

Profitable aquafeed 32

Use of computer programming in animal diet formulation 34

Factors affecting silo demand and design 38

Die and pelleting equipment maintenance 42

Commodities:Raw material outlook, by John Buckley 44

In the footsteps of Broomhall50

iNdustryeveNts 52IAOM Annual Conference & Expo 53

VIV Asia 56

IDMA 58

thegFmtiNterviewHao Yun - ZhengChang Chairman 60

iNdustryFaces64An optimised sales network at Pancosma

North American Millers Association announces new chairman

New management appointments at Glencore following Viterra takeover

Danish Centre for Food and Agriculture bags new director

THEGlobal

Miller


4/68

First, Id like to thank the publishers of Grain &

Feed Milling Technology for the opportunity to

contribute to this issue the first of 2013. For

those of you who may not know me, Im currently the

executive vice president of the International Association

of Operative Millers (IAOM). My background is in

communications and Russian and East European

area studies. Its been a terrific eight years with

the association, during which time Ive learned a

great deal about the grain processing industry.

It was 117 years ago in January that IAOMs precursor,

the Fraternity of Operative Millers, was founded in

order to elevate the profession of flour milling in the

eyes of mill owners in the United States. In 1919, the

name was changed to Association of Operative Millers,

and in 2003, international was added to the name to

reflect the organisations membership growth outsideNorth America. A little less than half of the associations

membership is located in our four international districts:

Eurasia, Latin America, Mideast & Africa, and Southeast

Asia.

Today, IAOM continues to focus on its core mission

of enhancing the proficiency of professionals in the

international grain milling industry by providing continuing

education and training opportunities through a professional

development programme.

As I travel to our district meetings around the

world, it is evident that the entire membership faces

similar challenges, regardless of location. Food safety and

traceability is becoming a critical issue across the globe.

End users are demanding that more safeguards are in

place to protect the food supply. At the same time, millers

are faced with increased volatility in grain prices, making

the business of procurement even more crucial to a mills

profitability.

In several countries, subsidies for bread products are

being phased out, creating even more pressure on millers

to keep their costs low. As new technologies emerge and

demand increases, the proficiency of millers will become

even more critical. Training programmes and continuing

education will play an ever-increasing role in the grain

processing industry.

At IAOM, there is a variety of opportunities for milling

professionals to continue to develop and learn about

the different aspects of milling. IAOM members indicate

that sessions in which participants are able to share a

challenge, best practice or accomplishment are extremely

beneficial. They also profit from attending the annual

meeting, committee and

district meetings, and resident

milling courses.

Senior executives

understand that a highly-

skilled workforce offers a

competitive advantage and

they are making investments

in their employees. There is

also evidence that professional

development opportunities

contribute to employee

retention something thatthe industry has struggled with

from time to time.

Throughout the food-

processing chain, opportunities

are available for professional

development from a variety of

sources. Make it a priority in

the new year for you and your

staff to participate in activities

that can provide both formal

and informal opportunities for

education and training.

Start by taking advantage of the articles in this issue

learn about good silo design, explosion prevention for

hammer mills and grinders, recycling food manufacturing

waste as animal feeds, maintenance for dies and pellet

machinery, and an overview of enzymes.

And, if you see me at a meeting, please be sure to

stop and introduce yourself. I love meeting people, and

IAOM is always seeking out ways to build on synergies

and increase learning opportunities through collaboration

with other organisations and groups.Guest

-EDITORSOBSERV

ATIONS Guest editor - Melinda Farris,IAOM

Happy New Year!

Melinda Farris, executive vicepresident of the International

Association of OperativeMillers, USA

You might have noticed that GFMT has put on a bit of weightover the winter. However, you wont find us on a faddy diet orhitting the gym: we have no intention of shifting this extra bulk.

The increase in size is down to a concerted effort to makesure the magazine accurately reflects the concerns of you,our readers.

We know that grain and feed milling is not just aboutwhat goes on inside the mill. Thats why weve expandedour content and added a strapline, incorporating ports,distribution and formulation.

Grain handling facilities at ports are using bigger and moresophisticated equipment every year. They really are the placeto see bulk handling technologies in action.

Transport meanwhile is the backbone of the grain and feedsupply chain, be it delivering products to and from the mill,

or around the plant itself. We start this new focus by looking

at loading and unloading equipment for barges.We all know that in milling, profit margins are tight sodelivering the safest and most efficient product is vitallyimportant. Ingredient selection plays a crucial role inproducing consistently high-quality products so we willcontinue to feature articles on nutrition and formulation.

Lastly, after the success of our managing maintenance articlein September/October 2012, weve given maintenancea regular slot in the magazine. This month we look atrefurbishing die and pellet machines.

I hope you find these new sections a useful addition toour regular subject matters. If you have any comments orsuggestions, please get in touch with me by email: alicen@

perendale.co.uk

Alice Neal, associate editor, Grain and Feed Milling Technology

NOTE FROM GFMT

Gi&fd milliG tcholoG2 | January - february 2013


5/68

The overall quality of the

2012 US corn crop is

high and improves upon

last years very good marks

across a range of test factors,

according to the US Grains

Councils Corn Harvest Quality

Report 2012/13.

Total US corn production fell in

2012 due to the worst drought

in decades, but despite the

drought, the 2012 crop showed

a year-over-year improvement

in average text weight, protein

levels, and density, as well as

lower moisture and BCFM than

the 2011 crop.

This is the second year for

the councils Harvest Report.

The Harvest Report assessesthe quality of the US crop

as it is delivered from farms

to local elevators, the first

step in entering international

marketing channels. It will be

followed in April 2013 by the

second annual Corn Export

Cargo Quality Report, which

assess quality at the point of

export.

The council produces the

reports so global importers

will have access to reliable and

comparable data from year

to year, with samples being

gathered and tested using

transparent and consistent

methods. With an increasingly

competitive global market,

the availability of accurate

information is in the long-term

best interest of US farmers,

exporters and international

buyers, says Erick Erickson,

USGC director of global

strategies. We received atremendously positive response

to the inaugural reports from

internat ional buyers , so

certainly there is a need for this

type of information.

For the harvest quality report,

samples of US corn were

gathered from 12 states that

combined are the source for

99 percent of US corn exports.

Tests conducted on the samples

cover grading factors like test

weight, physical factors such as

stress cracks and other items

such as moisture, protein

starch, oil and mycotoxins.

T h e s a m p l e s t e s t e d

demonstrate that the 2012 US

corn crop, while smaller due to

the drought, is of outstanding

quality overall, says Erickson.

Data indicates the average

test weight for the 2012/13

crop was 58.8 pounds per

bushel, an increase over 2011

and more than two poundsper bushel above the grade

limit for No. 1 US corn. At the

same time, broken corn and

foreign material (BCFM) was

lower, as were the number of

damaged kernels. Moisture, at

15.3 percent, was also lower

than last year.

Prote in numbers were

generally higher, starch was

marginally lower and oil content

was unchanged, says Erickson.

The frequency of stress cracks,

which indicate the relative

susceptibility of kernels to break up

during handling, are up marginally,

which could be an indicator that

the crop will be more susceptible

to breakage during handling,

information that may turn up in

the Corn Export Cargo Quality

Report in the spring.

Er ickson notes that the

Counci l s Corn Harvest

Quality Report 2012/13 only

assesses the quality of the

current U.S. corn harvest as it

enters merchandising channels,

as quality can be affected byfurther handling, blending,

storage conditions and other

downstream factors.

The full report is available at www.

grains.org.

US corn crop high quality, despite drought

Romer Labs, Austria haslaunched the MycoSpinTM

400 Multitoxin

column - a new product for

an effective clean-up prior to

multi-mycotoxin analysis,

enhancing the performance of

LC-MS/MS methods.

The MycoSpinTM 400 Multitoxin

cleanup columns, in conjunction

with BiopureTM 13C labeled

internal standards, achieve new

performance levels in LC-MS/

MS analysis. Using this approach

means straightforward sample

preparation and no limitations

by molecular mass of the

analyte.

Furthermore, BiopureTM 13Ci so tope - l abe l ed i n t e rna l

s t a n d a r d s o v e r c o m e

the i on i z a t i on e f f e c t by

stabilising the system to the

effects of signal suppression

and signal enhancement.

Romer Labs has developed

a s e r i e s o f m e t h o d

applications using this new

approach of a MycoSpin TM

c l e a n u p w i t h B i o p u r e TM

internal standards. These

methods are val idated for

the simultaneous detection

of mult iple mycotoxins in

cereal grains, mixed feeds,

and corn, inc luding corn

by-products.

After two success-

ful editions and

continuous demands

from the market, Pancosma

renewed its own scientific

congress in Madrid, Spain from

December 5-6, 2012.

The Swiss feed manufacturer

took advantage of its scientific

network to organise the annual

Pancosma Worldwide Scientific

Exchange.

Titled Gut Languages, the 2012,

meeting focused on Pancosmas

research strategy on gut

immunology, gut microbiome

and gut sensing to improve

animal. In this context, Dr

Soraya Shirazi-Beechey of

Liverpool University spoke

about the continuation of the

Gut Effects project, already well

known through the outstanding

results of SUCRAM in swine.

She developed the applications

and extension to the ruminants

species. Dr Gay, Dr Furness,

Dr Finlay, Dr Lillehoj also

revealed the last results of this

year of research completed with

Pancosma.

Proud of this success, the

Pancosma team is already

working on the program and

on the guests list for the 4th

edition, to be held in January

2014.

New mycotoxin product from RomerLabs

Third scientific exchange meeting for Pancosma

News January - February 2013 NEWS

Gi&fd milliG tcholoG January - february 2013 | 3

PPLAPPava

ilab

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H

ERE

GFMT's Global Milling News

portal, highlighting industry and

company news! Now available on

your mobile

PPLAPP

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6/68

Adisseo launches realtime web platformfor NIR predictions

T

his service enables buyers, nutritionists

and quality managers to find out the

nutritional values of their raw materials

in real time. Thus, feed manufacturers can

instantaneously obtain values of apparent

metabolisable energy, total and digestible

amino-acids, total and phytic phosphorus

contents of raw materials through NIR

predictions. The poultry digestibility values

are based on in vivo trials conducted at CERN

(Centre dExprimentation et de Recherche

en Nutrition), Adisseos experimental facility

located in Commentry, France.

Offering over 20 raw materials, this web

platform is available in five languages: English,

Spanish, Portuguese, French and Chinese.This web platform allows the customer to adapt

diet formulations according to the results.

"Considering the sharp rise in raw material

price, this unique tool offers to customers a

major technical and economic improvement

since it allows to optimise the formulations

in real time by benefiting from the expertise

and transverse management of Adisseo teams,"

says Ccile Gady, manager of research on raw

materials and PNE service.

Developed with the collaboration of Bruker

and Foss, "this web platform is a major,

unequalled innovation dedicated to Adisseo

customers from all over the world. This

project goes far beyond a mere web interface,

it is also a technological feat, although with

the key objective to enable a simple and

ergonomic customer interface," says Jean-

Baptiste Gosset, web department manager,

Adisseo.

To see the PNE web platform visit: pne.adisseo.com

The MPE Chain-Veyfor pet food

Modern Process Equipment Corporation

(MPE) has created a tubular drag

conveyor exclusively designed for

the transport of pet food products. The MPE

Chain-Vey can handle everything from raw

ingredients to finished, ready-to-package

goods.

Its flexible design and compact footprint is sure

to fit virtually any configuration. MPE claims

that the dust-tight enclosed design protects

pet food from the surrounding environment.

The MPE Chain-Vey also features clean-in-place

capabilities with automated wash cycles for

sanitary conveying needs.

NewsJanuary - February 2013NEWS

Hello Millers

The Global Miller blog is great place to catch up on industry news and event.

In the column this issue, we take a closer look at recent company buyouts,

developments and acquisitions.

Cargill is to invest $20 million to support animal nutrition in sub Saharan

Africa. A new deal will give the company's animal nutrition and premix business,

Provimi, a majority shareholding and assume managerial control of NuTec

Southern Africa. As part of this investment the company plans to build a new

premix and base mix facility at NuTecs existing location in Pietermaritzburg

to expand its animal nutrition capabilities in sub Saharan Africa.

http://bit.ly/XdZGJl

Material handling equipment manufacturer Intersystems has been bought by the

Pritzker Group for an undisclosed price."We see great opportunities for Intersystems in the world grain and feed

markets, says Tom Schroeder, chief executive officer, Intersystems.

"The resources of The Pritzker Group will ensure our continued growth by

helping us add new products and services to better meet the needs of our

customers." "Intersystems has grown significantly under Tom and his teams

stewardship, and we are proud to partner with them, says Michael Barzyk,

vice president, Pritzker Group. Intersystems serves as a great example of our

strategy to invest in leading companies serving the global agricultural market."

http://bit.ly/S2TmXT

DSM has completed a US $634 million buyout of Fortitech. The acquisition is

the ninth addition to DSM's nutrition arm since 2012.

http://bit.ly/X7g4L9

Lallemand Animal Nutrition has announced that it acquired Microbial

Developments Ltd, the UK based manufacturer of Aviguard, on December

31, 2012. Aviguard is a well-established avian competitive exclusion product

that aids the rapid establishment of normal gut flora in day old chicks thereby

minimising colonisation by transient pathogenic bacteria such as Salmonella,

E. Coli and Clostridium perfringens. Aviguard is sold in over 36 countries and

is widely used in broiler and layer breeders, parent and grandparent stock.

Yannig Le Treut, general manager of Lallemand Animal Nutrition says, Aviguard

is a well established and cost ef fective competitive exclusion solution used by

many of the worlds leading poultry breeders and integrators to help prevent

the colonisation of the gut by salmonella and other pathogenic bacteria. With

ever increasing consumer and regulatory pressures on the poultry industry to

minimise the routine use of antibiotics, we believe Aviguard is well positionedfor the future and will complement our existing port folio of poultry products,

which includes Bactocell, Alkosel, Agrimos and Levucell SB.

http://bit.ly/13DrAUA

We would love to hear from you. Tell us what you think at

http://gfmt.blogspot.com

THE GLOBAL MILLERA blog dedicated to professionals - including nutritionists - in the transportation,

storage and milling of grains, feedstuffs, rice and cereals, globally.

This monthwe have added our pictures from VIV China to our Facebook

page - take a look at:

http: //www.facebook.com/GrainFeedMillingTechnology

Gi&fd milliG tcholoG


7/68

In December 2012, Turkish

firm, Alapala opened two

new flour mills in Tokmok,

Kyrgyzstan and Darkhan,

Mongolia.

The official opening ceremony

of the Tokmok flour-milling

plant, which has a capacity of

250 tons/24 hours, was held on

December 2, 2012.

The milling section consists

of 18 units of roller mills, six

units of purifying machines and

six units of sifters. The plant

feature new generation milling

equipment including 12 roller

mills, four purifying machines

and two plan-sifters. Reducing

the amount of grinding and

sifting equipment minimised the

energy-output ratio.

The flour-milling plant was

complete ly renewed and

modernised by Alapala with

finance from Khazkh investors.

Alapala claims it is the onlywheat processing

plant in Kyrgyzstan

which completely

conforms to the

international

standards.

M e a n w h i l e o n

December 6, 2012 in Darkhan,

Mongolia the opening ceremony

of a 300 tons/24 hours capacity

flour-milling plant took place.

The project included designing

and erecting a steel flour milling

plant, designing a diagram of the

milling section, assembly and

start up.The plant is one of the biggest

wheat processing plants of

Mongolia which produces

three types of flour. As the

flour-milling plant is completely

automated, the number of the

staff is minimised.

Nutr i t ion so f tware

supplier Adifo has

launched a cloud-

based collaborative platform as

an extension to BESTMIX, its

profit-driven feed formulation

and recipe management system.

The company hopes the

extens ion p l a t form wi l l

revolutionise the information

interchange between nutrition

experts and the outs ide

world to the benefit of all

parties involved, including feedadvisors, external partners and

customers.

The Formu l a t i on a s a

Service solution securely

implemented in the cloud

gives users online access to

part of a nutrition companys

BESTMIX database. Users

can retrieve minute-precise

market data, rely on up-to-date

equations and use state-of-the-

art formulation functionality at

any time. They can also record

project or customer-specific

data such as purchase costs and

specifications.

Adifo has pioneered a new

way of working which will

dramatical ly improve the

col laborat ive interact ion

between all parties in the

nutrition companys value chain.

For example:

Account managers and

independent consultants

will simulate adaptations

to recipes to meet specific

customer demands and

evaluate immediately

the cost impact of their

adaptations.

Internal departmentssuch as marketing, sales

and quality assurance

will produce their own

data and reports without

compromising core data.

External interested

parties will be able to sign

knowledge contracts with

the nutrition company

and take advantage of

nutritional know-how.

Research centres will want

to use the system to unlock

their nutritional knowledge

to interested parties all

over the world.

The formulation

department can learn

about evolving customer

preferences by analysing

adaptations made by the

client.

The Formulation as a Service

platform has the additional

advantage of being easy to set up

and use. There are no worries

for the customer; the solution

even eliminates the need for

setting up and maintaining

dedicated laptops for account

managers or consultants.

Whats more, Adifo backs

up the data and updates the

software continuously, leaving

the customer care- free.

Cloud solution improves information interchange in feed industry



Alapala opens two new flour mills


8/68

New infrastructure will

help UC Davis assess

livestocks environmental

footprint

Its the 21st century on most of

these 50 acres of pastures and pens

two miles west of the main campus,

where renowned scientists

produce ground-breaking research

on animal welfare, livestock

production and environmental

quality. This is where you will find,

for example, the multimillion dollar

environmental chambers and

bovine bubbles where UC Davis

Professor and UC cooperative

extension specialist Frank

Mitloehner and his team work to

minimise unwanted nutrient losses

by animals which affect water andair quality and increase those

nutrient values in the products we

consume.

But its also where youll find one

of the most antiquated feed mills

around. Built in 1960, the rusty

UC Davis feed mill is better suited

for a museum than preparing

the precise mixtures of grain

and additives needed to conduct

world-class science and educate

a new generation of agricultural

leaders.

That mill is badly outdated, says

John Pereira, managing partner

with Frontier Ag, a merchandiser of

agricultural and feed commodities

based in the Sacramento Valley.

UC Davis has a top-rate animal

science programme thats making

a huge difference in our industry,

keeping agriculture productive and

sustainable. They absolutely need a

new feed mill.

Leaders from the industry are

working to make that happen.

Pereira is president of the CaliforniaGrain and Feed Association

(CGFA), which recently started

the effort and donated $150,000

towards building a new UC Davis

feed mill - $100,000 now and

$50,000 once construction begins

in early autumn 2013.

Its our way of supporting

the work UC Davis and Frank

Mitloehner are doing, which

is some of the worlds finest

research, says Pereira.

Mitloehner was recently selected

to chair a United Nations Food

and Agriculture Organization

committee to measure and assess

the environmental impacts of

the global livestock industry. The

international effort is the first step

toward improving the sustainability

of the livestock sector, particularly

as the global consumption of meat,

dairy products and eggs continues

to rise.

As chair of the new committee,

Mitloehner will lead representatives

of national governments, livestock

industries, and nonprofit and

private sectors in establishing

science-based methods to quantify

livestocks carbon

footprint, create a

database of greenhouse

gas emission factors

for animal feed, and

develop a methodology

to measure other

environmental

pressures, such aswater consumption and

nutrient loss.

A new feed mill will

really help that effort,

says Mitloehner. We

very much appreciate

the California Grain

and Feed Associations

contributions. Were

also reaching out

to conservat ion

groups and other

stakeholders, because

quantifying livestocks

environmental

footprint is important

to us all.

The new feed mill

will cost $5.3 million

- $2 million of that from in-kind

equipment donations already

pledged from industry and $3.3

million in monetary donations. The

UC Davis College of Agricultural

and Environmental Sciences

contributed $100,000.

All the preliminary work hasbeen done, says Dan Sehnert,

animal facilities coordinator for

the UC Davis Department of

Animal Science. With the help of

an industry planning committee,

we have a site map, an approved

Environmental Impact Report,

and everything else we need to get

started once we have the funds.

UC Davis animal scientists are

awarded millions of dollars in grant

funding, but that money cant be

used to support infrastructure, like

a new feed mill. The current feed

mill was a gift from the California

Cattle Feeders Association in 1961.

It was state-of-the-art at the

time, says Mitloehner, leading a

recent tour of the feedlot. And it

has served us well. But now, it is

totally outdated.

Mitloehner pauses by the tarnished

feed mill, its pieces patched and

repatched where maintenance

crews struggle to keep the

equipment running.

Couldnt UC Davis contract with

commercial mills to meet its animal

feed needs?

No, because researchers are

doing a lot more than keeping the

animals (cattle, swine, goats, sheep,

horses, poultry and others) alive

and well, says Sehnert, who has

joined the impromptu tour. They

carefully control and monitor

what goes in and comes out of the

animals, testing for things such asfeed efficiency.

Mitloehner adds, For example,

we integrate additives into feed

to reduce the nitrogen that leaves

the cow. We work with very

small amounts of additives, which

need to circulate thoroughly

throughout the feed. Much of our

research depends on the ability to

customize feed.

Mitloehner leads us past pens

where he and his team measure

the methane in a cows exhale,

using machines they built that exist

nowhere else in the world. Two at

a time, the cows breathe into a

clear, plastic box which captures

their breath.

What is the carbon footprint of

a gallon of milk? Mitloehner asks.

Our research will help answer

that question. We need good data

to understand the true impact of

agriculture on the environment.

Industry and society depend on

the data UC Davis is producing,

says Ken Zeman, feed mill

superintendent at Harris Feeding

Company and chair of the industry

planning committee that supports

a new UC Davis feed mill.

Dr. Mitloehner is one

of a kind, Zeman says

from his office at Harris

Ranch outside Coalinga,

California. His programme

is providing good, reliable

information. His research is

recognised worldwide, andhis students are going on

to become leaders in our

industry. We need to do

all we can to support that

program.

T h e r e a r e 1 , 0 0 0

undergraduates and 100

graduate students in the

UC Davis Department of

Animal Science. One of

those graduate students

is Clayton Neumeier, who

is here with Mitloehner

outside the methane-

measuring pens, preparing

feed in a cement mixer.

Yeah, its pretty low

tech, Neumeier says with

a smile.

UC Davis animal scientists deserve

better, says Chris Zanobini, chief

executive officer for the California

Grain and Feed Association, based

in Sacramento.

Im thrilled our association

has made the first industry

gift, because when you have aprogramme that good, you want

to do all you can to support it,

Zanobini says. I know others

will join us, because the work

Frank Mitloehner is doing with air

quality along with all the work

in the animal science department

is important to our operations.

Its vital to our future, not just

for our industry but for our state,

our nation and our world.

To learn more about the new

feed mill and how you can help,

please contact Frank Mitloehner

at [email protected] or

Martha Ozonoff, director of major

gifts for UC Davis, mjozonoff@

ucdavis.edu

Hope dawns for aging feed mill

Dr Mitloehner and old feed mill

Grad student Clayton Neumeier




9/68

Mo r e t h a n 1 , 1 8 0

exhibitors and 25,000

attendees took part

in the revamped International

Production and Processing

Exposition (IPPE) show, which

ran from January 29-31, 2013

in Atlanta, USA. The addition

of the American Meat Institute

(AMI) to form a triumvirate of

processing organisations with

the American Feed Industry

Association (AFIA) and the US

Poultry and Egg Association to

form the new IPPE, has been

hailed a great success.

The combined event took over

430,000 net square feet of exhibit

space at the CNN-Phillip Arena-

Georges World Convention

Centre, making it one of the

worlds largest annual poultry,

feed and meat trade shows.

As the old saying goes, we have

learned that the whole is greater

than the sum of its parts. We have

been pleased that exhibitors and

attendees alike have recognised

the significantly increased value

that integration of the three trade

shows brings. From the breadth

of the education offerings to

the number of exhibitors to the

strong attendee interest, the

excitement has been building,

remarked the organisers at the

ribbon cutting ceremony.

After an initially quiet first

morning for IPPE, the end of day

one and the morning of day two

proved very popular. Not even

the short-lived tornado that

struck the CNN-Phillip Arena-

Georges World Convention

Centre around midday on day

two could keep people away.

Visitors had much to see and

do despite the odd bucket that

had been strategically placed to

catch drips from leaks in the

roof.

Whi le meat and poultry

exhibitors were presented in

either the live production and

processing, live production

or live poultry production

areas, feed-related exhibitors

maintained their own section

of Hall A and drew together

ingredient, equipment and

other suppliers. It was a great

display of the diversity of feed

manufacturing essentials.

From GFMT's point-of-view

the show has yielded many

new contacts both in terms of

new readers, subscribers and

contributors to our pages. We

were fortunate enough to have

a team of three in Atlanta for

the event. Our Spanish-language

edition was well-received as

was the International Milling

Directory. We cant wait until

next year!

Success for IPPE

4B has invested in tooling toincrease the capacities of

its STARCO steel elevator

buckets; as a result, all 4Bs

STARCO steel buckets now

have the same or greater

capacities than comparable

buckets of their competitors.

The STARCO bucket was

originally invented by 4B

Braimes French subsidiary,

SETEM, in the 1980s and was

the first low profile elevator

bucket to use centrifugal

discharge on a parabolic

elevator head to achieve

much higher capacities on a

given elevator leg.

The Starco elevator bucket hasbeen engineered to provide

perfect fill and discharge for

a wide range of products. Itoperates at wide speed range,

up to 4.55m/s.

The company has carr iedout a range of tests pitting

its STARCO bucket against

competitors. 4B found

that many buckets have

a lower capacity what

i s c l a imed on paper

and that the quality of

the bucket i tse l f can

b e v e r y d i f f e r e n t

depend ing on the

production process

a n d t h e q u a l i t y o f

t he s t ee l u sed . On

request, 4B can provide

test resul ts and f ie ld

evidence to show the

d i f f e rences between

different models.

4B increases capacity of STARCO steel elevator buckets




10/68

NEWS IN BRIEFIndustries Confederation has announced that its annual conference for the

supply industry Agribusiness 2014 will be held at the East of England

Showground, UK on Wednesday November 13, 2014. Details of the

programme will be posted to the confederations website www.agindustries.

org.uk

The Food and Agriculture Organization of the UN (FAO) and The

International Feed Industry Federation (IFIF) have launched a Chinese languageversion of the 'Feed Manual of Good Practices for the Feed Industry'. The

Feed Manual, the first of its kind, was published by IFIF and FAO to increase

safety and feed quality at the production level, and was officially presented in

Rome at FAO Headquarters to the Chinese Feed Manufacturers Association

(CFIA).

Alexandra de Athayde, IFIF Executive Director, says, the Feed Manual is

designed to increase safety and feed quality at the production level both for

industrial production and on farm mixing. Ms de Athayde added, We are

very pleased that we have launched the Chinese language version of the Feed

Manual. China is the number one producer of animal feed today and only

by working together can we continue to ensure feed and food safety, while

meeting the demands of 60 percent more food for 9 billion people by 2050

and to do so sustainably.

Canadian governments are to invest C$6.5 million in crop-related research

projects. The Federal Agriculture Minister, Gerry Ritz and Saskatchewan

Agriculture Minister, Lyle Stewart hope the funding will keep Canadian

agriculture growing. The 38 projects are aimed at improving disease control

and weather tolerance

Although much of the world has suffered from a slow down in grain

exports in 2012, due in part to bad weather, India has fared much better.

The country is set to triple its wheat exports to a record six million tonnes in

2013. Over the last five years Indian farmers have stockpiled large quantities of

grain which will help plug the global shortfall in lower-quality grain.

A new research centre in Western Australia aims to crack the genetic code

of wheat. The Researchers at the Australia-China Centre for wheat at

Murdoch University hope they can do for wheat, what the human genome

project did for DNA.

UK bread maker, Hovis has abandoned its commitment to use 100 percent

British wheat. The company claims the poor UK harvest left the company with

no choice but to import from the EU.

Poland has become the eight EU member state to ban the cultivation of GM

crops approved by the European Food Safety Authority as safe. Two crops

will be affected by the ban: Monsantos MON810 maize and BASFs Amflora

potato. The decision came into effect on January 28, 2013.

Thailand has lost the top spot as the world's biggest rice exporter. Both

India and Vietnam have overtaken the Southeast Asian country as exports

fell 35 percent in 2012. Thai rice exports reached 6.9 million tonnes of ricelast year, compared to 10.6 million tonnes in 2011. In the same period, India

shipped 9.5 million tonnes and Vietnam sold 7.8 million tonnes overseas,

according to the Thai Rice Exporters Association.

More than a million rice framers in Vietnam are now using innovative

growing methods says Oxfam. 1.3 million growers have adopted the System

of Rice Intensification which promises better yields while using less water,

fertiliser and seeds.

Iran will reach self-sufficiency in rice production in the next Iranian calendar

year (to start March 20, 2013), Iranian Deputy Agricultural Jihad Minister

Jahangir Porhemmat has announced. According to the Agriculture Jihad

Ministry's plan, Iran was supposed to reach self-sufficiency in the rice

production field by the end of the current Iranian calendar year, but officials

announced in November that the plan needs some more three years forcompletion.

Hello and welcome to the inaugural

column for Grain & Feed Milling

Technology by Tom from the

International Milling Directory (IMD). These

two publications are normally separated by the

different purposes and also by the buildings

walls here at the Perendale offices.

T h e I M D

coordinator job

changed hands

at the end of last

year and I am

pleased to have

taken up the post

for the 2013/14directory. There

is much to get

done and our

ambi t ions are

h i g h e r t h a n

ever before. Were determined to produce

a reliable directory with a broad depth of

information and real benefits for investing in

a listing.

Teamwork from others in the team and an

extra assistant from early February will be

essential for its success. This will be especially

true when I exhibit the IMD and other

publications of Perendale at GEAPS Exchange

in Louisville, Tennessee, USA in late February;

it would be fantastic to meet members and

users of the IMD there.

The current edition has mostly been

distributed - so place an order now before

they are all gone!

The 2013/14 directory already has advanced

pre-orders and will be going to several

conferences around the world after Julys

publication of the 22nd edition.

I am also delighted that new companies

in many fields have registered themselves

for the new edition. These include CanadaTrading Inc., FrontalRain Technologies, Yasar

Group, Personalized Nutraceuticals, Parantez,

Finetek, Borg Mills and Biochem GmbH.

Do update or register your companys listing

now at www.internationalmilling.com. Free

and paid options are available online or

through our own media file - please contact

me for a media file and registration forms.

Check out daily news and updates on the IMD

blog at www.millinginternational.com.

More Information:

Tel: +44 1242 267700

Email: [email protected]

Tom Blacker, sales manager and directory

coordinator, International Milling Directory

Tom Blacker




11/68

The world is producing

959 million tons of

feed and has increased

its production by at least

four percent in the last year,

according to the 2013 Global

Feed Tonnage Survey released

by Alltech. Alltech assessed the

compound feed production of

134 countries in December

2012, through informa-

tion obtained in partner-

ship with local feed associa-

tions and Alltechs sales team,

who visit more than 26,000

feed mills annually.

The 2013 publication of theannual year-end assessment by

Alltech is being released as an

industry outlook resource for

the new calendar year and will

hopefully allow governments,

non-governmental

organisations and the greater

public to appreciate the value

that the feed industry is

generating globally, said Aidan

Connolly, vice president of

Alltech and director of Alltechs

annual Global Feed Tonnage

Survey.

Among the 134 countries

assessed in Alltechs survey,

China was reaffirmed as the

chief producer of feed at 191

million tons and an estimated

10,000 feed mills. Consistent

with late 2011 assessments,

the United States and Brazil

followed with 179 million tons

produced by 5,251 feed mills

and 66 million tons produced

by 1,237 feed mills respectively.

Overall, a 26 mill ion ton

increase was observed in BRIC

countries (Brazil, Russia, India

and China) year to date.Asia continues to be the worlds

number one producing region

at 350 million tons and this is a

13 percent increase compared

to the figures 12 months ago.

Over 43 percent of the total

pig feed production comes from

this region and more than half

(56%) of the global aqua feed

is produced in Asia. However,

Africa exceeded Asia in percent

growth over 2011 results,

increasing its

tonnage nearly

15 pe rcen t

from 47 million

in 2011 to 54

million in 2012.

Globally, the

survey identified

26,240 feed mills,

with China serving

as home to 10,000

of them. Together with

the other Asian countries

this number reaches 12,149.

The Middle East was estimated

to have the largest feed mills,

with an average of more than

63,000 tons produced per millwhich is significantly higher

to the Asian figures of 28,818

tons. Sixty percent of feed

produced globally is pelleted,

with percentages particularly

high in Europe.

When analysed by species:

Poultry continues to dominate

with a 43 percent share of the

feed market at 411 million tons,

likely due to religious and taste

preferences as well as cost.

It grew by approximately 8

percent over 2011 estimates

globally which is lower than

the growth of over 13% inAsia .

Sixty percent of all poultry feed

tonnage is dedicated to broilers,

with the rest fed to egg layers,

turkeys, duck and other fowl.

The pig feed sector matched

poultrys 8 percent growth,

moving to 218 million tons

globally. Asias share is 94,5

million tons of it which is more

than 13 percent increase as of

last years figures. The ruminant feed market,

comprising dairy, beef and

small ruminants, grew more

than 13 percent between late

2011 and December 2012, and

now requires 254 million tons.

The annual growth in this area is

also more dynamic in the Asian

continent (15%; 94.1 million

tones).

Equine feed tonnage increased

almost 17 percent to 10.8

million tons.

Aquaculture is the fastest

growing species sector by

tonnage with growth greater

than 55 percent since 2011. Out

it this, Asia was responsible for

25.6million tones.

Pet food represents 20.5 million

tons, 40 percent of which is

produced in the United States,but Brazil continues to make

considerable advances in this

sector.

As we look to the demands of

the future, chiefly the feeding

of 9 billion people by 2050,

these survey results should

stir optimism and resolve

within our feed and food

industries, said Dr. Pearse

Lyons, president of Alltech.

Our global feed industry is

rising to the challenge, and

were seeing growth across

the board. Moreover, were

seeing it in some particularly

key areas BRIC, Africa and

aquaculture.

Global feed production has

traditionally been difficult

to quantify because many

countries lack a national feed

association. For this reason,

Alltech began in late 2011 to

leverage its global presence

to obtain a finer estimate of

the worlds feed tonnage. Theresults of the annual year-end

assessment are announced in

January as an industry outlook

resource for the new calendar

year.

Connolly presented the 2012

Alltech Global Feed Tonnage

Survey findings at a joint

meeting of the International

Feed Industry Federation

and the Food and Agriculture

Organization (FAO) in October

2012. The meeting identified the

need to collect more detailed

information, a request to which

Alltech responded, engendering

a deep appreciation for what

the feed industry is delivering

worldwide.

Alltech Feed Survey Findings:World Increases Production to 959 Million Tons

200 years - commercial grain mills have operated inCanada

1851 - Year that the grandfather of all Canadian millingwheat was introduced to the country

55 - Commercial wheat and oat mills in Canada

8 - of Canadas 13 provinces and territories have commercialscale wheat and oat mills operations

3.5 million tonnes - of wheat, oats and barley areground in Canadian mills each year

75% - is produced in western Canada

30 - countries import Canadian milled grain

1,400 - people work in milling production

20% - of Canadas grain mills are less than 15 years old$1.5 billion - is to be invested in Canadian grain millingfacilities

Source: Canadian Grain Millers Association

NUMBERCRUNCHINGCanada




12/68

Grain and feed processed within

hammer mills is common fuel for

dust explosions due to the nature

of its handling and storage. Any time that

feed such as grain, meals and flours is

handled or moved, the fine organic dusts

are at risk of burning and exploding.

Explosion causesA fire or explosion results from ignition

of combustible material (dust, gas or vapour)when mixed with oxygen in the air. When

this takes place inside a grain silo, process or

storage enclosure, the rapid rise in pressure

could cause a violent explosion in millisec-

onds, placing personnel and property at risk.

Just a few burning embers entering a

dust collector are enough to trigger a dust

explosion. Likewise, combustible material

conveyed into a storage silo could become

the nucleus of a fire. Sparks or smouldering

particles from hammer mill operations may

spread from the mill to other more vulner-

able equipment.

Most materials handling, processing and

storage equipment is not designed to resist

the pressure of an expanding flame ball

which proceeds below the speed of sound

in air known as a deflagration as com-

pared to a detonation, which exceeds the

speed of sound in air. Most grain dusts are

combustible and can cause an explosion, but

some types are much more dangerous than

others, especially dust associated with corn

or sugar.

The effects of accidental fires or explo-

sions can be devastating in terms of lives

lost, injuries, damage to property and the

environment, and to business continuity.

Serious secondary effectsGrain dust explosions can have a cascade

effect. Grain dust that has settled on floors

or walls can be thrown into the air by a dust

explosion, thus providing fuel for secondary

explosions. Often, these secondary explo-

sions cause more damage than the first. In

this way, a dust explosion can jump from

room to room or from silo to silo. This

is a common phenomenon in grain dust

explosions. For example, one of the most

dangerous areas for grain dust explosions is

in the bucket elevator or conveying system

linked to a silo. The grain is always in motion,

so dust is constantly generated.

Protection measuresAn explosion risk assessment will typi-

cally recommend that a series of protection

measures be implemented. These range

from investment in protection equipment

to improvements in housekeeping to elimi-

nate the build-up of deposits of combusti-

ble dust which may accumulate on beams

in the factory. These may be disturbed by

a primary explosion in the process equip-

ment and result in a more severe secondary

explosion.

Codes and standards are now very clear

in requiring isolation of vented equipment to

prevent secondary explosions, which typi-

cally have much greater potential for damage

and destruction.

Controlling the explosion riskswithin hammer mills

by Kevin Spiess, EMEA sales manager forexplosion protection, BS&B Safety Systems,

United Kingdom

SparkEx Spark Detection andExtinguishing system


FEATURE


13/68

Bespoke systemsMy organisation, BS&B Safety Systems,

has launched a bespoke combustible dust

fire and explosion prevention system for

hammer mills based on established systems

developed for other

industries. The SparkEx

Spark Detection and

Extinguishing System

is designed to detect

hot particles, sparks and

glowing embers that

might become the igni-

tion source for a fire

or explosion if allowed

to travel on through

pneumatic ducting and

conveyors towards

other material handling

equipment.

By preventing sparks, embers and hot

particles from reaching dust rich down-

stream process equipment such as dust

collectors, bins and silos, both fire and explo-sion risks can be managed.

Using infrared detectors, the system

detects the radiated light emitted from

sparks, glowing embers and hot particles

travelling past the detection point and acti-

vates control circuits. The greatest sensitivity

occurs when these sensors are employed

in a dark area such as closed ductwork,

although optional daylight detectors are also

available for use on open conveyor belts and

for applications where light is likely to be

visible. Upon detection this system provides

several options to manage the ignition risk:

An electrical signal generated by

the sensor activates control circuits

typically used to operate an automatic

water-extinguishing curtain. Sparks

can be extinguished without stopping

production.

An automated shut down of the

process can prevent the feed of

combustible material.

Alarm and control systems can be

activated upon the detection of hot

particles for other control devices such

as diverter valves.

The system detectors and control unitare ATEX certified for use in a dusty work-

ing environment. This means there are no

expensive costs for additional wiring to run

from detectors to remote mounted control

units and plant personnel have direct access

to the status of the equipment. In the event

of an alarm condition, the operator can see

immediately which process is at risk. A web

based monitoring system, which allows plant

managers to receive system alarms and faults

to their smart phones, as well as monitor-

ing the systems live on the internet, is also

available.

In addition to this preventative sys-

tem, systems for protection are avai lable ,

should an explosion occur. A chemical

isolation system isolates an explosion and

prevents it from affecting interconnected

processes. If unprotected, the ductwork

and piping, as well as all the connected

vessels and equipment are at risk. This

system is used in combination with explo-

sion protection equipment on each vessel,

bin, or dust collector and could include

chemical suppression, explosion venting or

indoor venting.

Regulations, codes and standardsBecause of potential health problems,

laws exist to ensure employers in the EU

protect their workers from being harmed

by dangerous substances in the work-

place. In the UK, under the Dangerous

Substances and Explosive Atmospheres

Regulations 2002 (DSEAR), all work-

places where substances that could

give rise to fire

or explosion

are handled or

stored must be

ful ly assessed

and protected.

Employers

must carry out

risk assessments,

and take steps

to ensure they

prevent or

adequately con-

trol exposure.

It is important

to include in

the assessment

foreseeable inci-

dents and main-tenance work

and plan for

measures to be

taken in these

circumstances.

ATEX is the

name com-

monly given to

Directive 94/9/

EC which pro-

vides the techni-

cal requirements

to be appl ied

and the relevant

conformity

assessment pro-

cedures before

placing equip-

ment and protective systems intended for

use in potentially explosive atmospheres on

the European market .

By investing in explosion protection,

organisations can safeguard themselves eco-

nomically, follow appropriate health and

safety standards and protect workers from

potential risks.

More InforMatIon:

BS&B Safety Systems

Tel: +44 161 955 4202


Website: www.bsbipd.com


FEATURE


14/68

When food is manufactured, a

number of by-products are

created and a proportion of

the finished product cant be placed on

the market for consumption by humans.

This can be for a variety of reasons such

as packaging defects, or for technological

reasons such as the wrong size or weight

biscuits, over-baking, trial runs or over

ordering and out of date stock.

Many of these former foodstuffs, includ-

ing biscuits, bread, breakfast cereals, grain

products, crisps and confectionery can have

a very high nutritional value being a source

of high quality fats, sugar and carbohydrates.

After checking their safety and traceability

and therefore suitability, SugaRich converts

them into high quality ingredients for use inanimal feed, avoiding waste from food that is

not destined for human consumption.

After processing, the foods are blended

to the required feed formulation, then sieved

and ground to create a free flowing meal.

Finished feed is delivered direct to the com-

pounder, blender or farm.

With so many other issues to man-

age within busy food production sites or

supermarket chains, getting the surplus food

disposed of as waste may seem like the

simplest choice, even if this results in a cost

being levied to the business and the waste

potentially ending up in landfill. However, by

working in partnership with feed compound-

ers, blenders and farms, we provide food

businesses with an environmentally friendly

alternative.

According to a United Nations study,

Global Food Losses and Food Waste , a

third of the worlds food is wasted and we

all have a part to play in solving this problem.

Former foodstuffs should be regarded as a

resource, not a waste product.

Diversion of food waste from disposal is

becoming an increasing priority for the UK

government. Under current European Union

waste regulations, the waste hierarchy gives

the highest priority to waste prevention, fol-

lowed by re use through the development

of markets for valuable products, recycling

and recovery. Disposal of waste products

through landfill should be avoided wherever

possible.

Business and environmentalbenefits

This closed-loop recycling, by which the

waste from one product is used in the mak-

ing of another product, brings measurable

economic gains to businesses and long-term

benefits to the environment.

Food loss and waste are a major squan-dering of resources - water, land, energy and

labour - and contribute to greenhouse gas

emissions. Food sent to landfill biodegrades,

releasing methane into the atmosphere that

has damaging effects on the environment,

while incineration may cause harmful green-

house gas emissions.

The recovery of former foodstuffs and

by-products for use as animal feed is a sus-

tainable and economically beneficial solution

for all major food businesses, encouraging

zero waste to landfill, cost savings and even

revenue generation.

Preventing food waste makes good busi-

ness sense. Revenue is generated not just

by the money saved from sending waste to

landfill and the associated charges involved,

but from the waste itself. Using materials

more efficiently, and managing waste better

enables manufacturers to reduce costs, make

money and decrease the environmental

impact.

From our work with the largest European

food manufacturers, supermarkets and dis-

tributors, over 350,000 tonnes of surplus

food per annum has been diverted from

traditional waste disposal routes.

Many businesses are unaware of how

significantly waste impacts on their bottom

line. We replace the term waste with

resource, working with organisations to

help them ensure compliance in respect of

the waste hierarchy, encouraging them to

reduce, reuse and recycle. Organisations

need to think differently about waste to

move beyond waste reduction to actively

eliminating waste from the supply chain.

Legislative complianceAnything designated for feed use will

ultimately be re-entering the food chain, so

strict adherence to regulations are essential.

When former foodstuffs are used to pro-duce animal feed, certain legal obligations

are placed on the factory of production. By

law, the factory is deemed a Feed Business

Operator and has to be compliant under

the Feed Hygiene Regulations EU 183/2005,

which applies to all businesses that make, use

or market animal feed.

Feed businesses in this context include

manufacturers selling by-products of food

production into the feed chain, livestock

farmers and arable farms growing crops for

feed use. The regulation applies at all points

in the supply and use of feed, and requires

feed businesses to comply with standards in

respect of facilities, storage, personnel and

record-keeping.

Hygiene standards are very important

in the disposal of the surplus foodstuffs.

Recycling surplus factory foodinto quality animal feeds

by Paul Featherstone,group director, SugaRich,United Kingdom


FEATURE


15/68

Products no longer intended for human

consumption, which may be destined for

farm animal feeding, must be kept separate

during transport, storage and dispatch to and

from a supermarket returns depot or food

manufacturing plant.

Our services are fully accredited to the

Feed Materials Assurance Scheme (FEMAS)

standard ensuring that all feeds are fully

traceable from source to supply giving both

quality controlled service and products. The

scheme is based on Hazard Analysis Critical

Control Point (HACCP) principles, an inter-

nationally recognised system of hazard analy-

sis. Over recent years HACCP has become a

central requirement of food and feed safety

legislation.

The logistics from foodproduction to the feed industry

Each food production site has differ-


Are you social?Keep up to date with us in-between issues by

following us on any of our social platforms

Take a look at our newly re-vamped Facebook page,

that now covers updates from GFMT as well as all of

the very best of The Global Millers news

http://www.facebook.com/GrainFeedMillingTechnology

See our previous editions online for free

ww.gfmt.co.uk/archive.ph

suscri tin magazine forthe globalflour&feed millingindustries- firstpublished in 1891

In thisissue:

NIRinpractice

Riceandcontract

terms

NewweighingsoftwareforUKco-operative

y-Jun 2012

LC-MS/MS:TheNewReference

Method forMycotoxinAnalysis

Fast, reliableand flexible:theworld of modern bulkweighing

Mould controlin grain and feed preservation

F T12.03.indd 1 22/06/2012 08:48

Asubscription magazine forthe globalflour&feed millingindustries - firstpublished in 1891

In thisissue:

Improvingsupply fromfarmto fork

VictamAsiaProductShowcase

Globalgrain &feedmarkets

M ar ch - Ap ri l 2 01 2

Assessingcereal qualityparameters

ControllingInsectswith heat

Grindingby aprovenconceptmakesyourchoicesimple

F T12.02.indd 1 17/04/2012 13:05


In thisissue:

Increasingstoragecapacity

Digitalmicrowave

moisturemeasurement

Global grain &feed markets

January-February 2012

Bulkstorage&handling

PreservativesPreservativesarea recurringtopic in public discussions

EfficiencyEnergy savingin flourmilling

F T12.01.indd 1 02/02/2012 10:12


In thisissue:

Mycotoxinsan overview

Databaseforanimal dietformulation

techniques:Aglancetolastdecade

Food safetyin thegrainmillingindustry

Recentadvancesin

rapid graintesting

November -December 2011

AfricanadvancesAnimalfeedmillingisoneof themostbuoyantactivitiesintheagrirelatedfield

Optical sorting Opticalsortinghascomeof

ageandshouldbeconsideredasaseriousoption forinclusioninanymodernwheatcleaningplant

Getin lineProcessanalysissolutionsopennewopportunitiesforimprovedprofitandquality

F T11.06.indd 1 30/11/2011 17:28

Asubscription magazine forthe globalflour&feed millingindustries- firstpublishe in

In thi

S a m lp re p r i nof fe n

f or a r a na l i

1 5- Y r C el e r i n :

Fortifyin ithf o li c ci r n t2 2 ,0 i r th

defect nnully

G lo lMar :W he t u l y grow n r

ascorn cr shrin

October 2011

ProducingFlakedreakfastCereals

DirectCold Plasma:Theinnovativeanswertoodourcontrolinthefood andfeedindustry

MillingTechnologyRedefined

FT11.05.indd 1 05/10/2011 09:49

FEATURE


16/68

ent challenges. Our expert team audit the

whole location and production processes to

identify the areas where there are issues to

be addressed and highlight possible hidden

revenue sources. Tailor-made surplus food

handling installations are designed and built

to suit each individual food factory site, with

on-going maintenance, reporting and review.Critical control points for food safety are

implemented through our HACCP systems

which prevent the mixture of any non-

food waste and ensure feed materials are

free from any chemical or microbiological

impurities.

Where inedible products or products

prohibited from inclusion in feed (such as

meat or fish) are stored or handled on the

same site as surplus foods intended for

feed use, there must be physical separation

between these products and the feed prod-

ucts. This will ideally be full physical segrega-

tion of buildings and equipment. Detailed

records of disposal of non-feed products

must be maintained.

To make the process of segregating the

waste as straightforward as possible, the

total waste management side of our busi-

ness, SugaRecycle, can help with the stream-

ing and managing of all waste products from

plastics and oils through to card, packaging,

metal and more.

Sealed containers with surplus food are

collected and returned using specialist vehi-

cles. All containers are clearly marked toavoid any chance of confusion between

surplus food materials and waste.

The surplus food is then transported

to our purpose built reprocessing centres

where computer generated formulations

manufacture a feed material to exact cus-

tomer specifications. SugaRich produce a

range of bakery, biscuit and confectionery

meals to suit feed compounders, blenders

and home mixers. This includes SugaRich

Premier Biscuit, a high oil biscuit meal suit-

able for inclusion in both broiler and high

intensity pig feeds.

Quality feed within the foodchain

Remember to take the advice of a

nutritionist on feed mixtures and ensure

they are used as part of a balanced diet

paying particular attention to an adequate

supply of long fibre. Animal feed plays

an important part in the food chain and

has implications for the composition and

quality of the livestock products (milk,

meat and eggs) that people consume. Our

high-quality feed is delivered direct to thecompounder, blender or farm. This high-

energy livestock feed helps to improve

livestock productivity.

The Food Standards Agency is responsible

for drawing up the rules on the composition

and marketing of animal feed. The Agency's

main aims in this area are to help protect

consumer and animal health. Another aim

is to ensure that those buying the feed are

provided with sufficient information to allow

them to make informed choices.

In summary, by recognising that former

foodstuff is a resource and not a waste prod-

uct, the feed industry and food businesses

can work together to reduce the amount of

waste sent to landfill every year, save costs,

turn waste into revenue and lessen environ-

mental damage.


FEATURE


17/68


18/68

Transporting grain by barge is an

ecological and cost-efficient alterna-

tive to railway and truck haulage.

Bhlers low-maintenance Bargolink

unloading system makes this mode of

transport even more competitive.

Since time immemorial, ships have been

used to deliver bulk goods over long distanc-

es, using the river current as a natural force

to carry them downstream or yoking draft

animals for upstream transport. Although

trucks and trains have taken up a large part

of this task in the modern age, barges are still

a viable alternative for many goods. A barge

carrying one ton of cargo can travel five

times as far on five liters of diesel as a truck

with the same freight 500 km compared to

the trucks 100 km of range overland. A ship

carrying 3,000 tons of goods is equivalent to

50 railway cars or 100 trucks.

Another plus is the ability to use an

existing network of rivers, canals, and locks,

which decongests the overland highway

system. Continental Europe is crisscrossed

by waterways. From the gateway ports on

the English Channel and along the northern

Mediterranean, grain is distributed to the

inland markets of Western and Central

Europe by barges. The Bargolink serves theneeds of customers all along this system

of waterways mainly grain handlers and

processors whose business model depends

on short berthing times and reliable high-

volume unloading capacities.

Straddling dry land and waterBhler has developed its Bargolink to

unload barges of up to 5,000 DWT at

capacities of 150 to 300 tons per hour.

Here is how it works: a marine leg is

positioned amidships in the material to be

unloaded, where the marine leg moves

through the product. To improve the feeding

of the unloader, the marine leg is equipped

with a fixed mounted feeding screw (hinged

in order to equalise the inclination of the

vessel) which digs into the grain in the ships

hold and lifts it up onto a horizontal chain

conveyor that carries the cargo to the ports

storage units.

These state-of-the-art ship unloaders are

available as mobile or stationary versions.

The stationary unit is fixed on the pier andthe barge is automatically towed by winches,

taking the role of moving the barge for

continuous unloading. The mobile version on

rails is equipped with a travelling gear, so the

barge can stay fixed at the pier. As a result,

the Bargolink enables customised terminal

plants according to specific requirements,

taking into account the available space for

unloader and barge.

The mechanical process is not only

easier on the wheat, causing less wast-

age and defects and keeping the grain in

a higher grading; it is also more cost- and

energy-efficient than pneumatic unloading.

Furthermore, the Bargolink is less susceptible

to breakdowns. A pneumatic systems fan

is easily degraded by the fine particles it

conveys; the Bargolinks mechanical process

Efficient barge

unloadingtechnology forgrain handlingon inland

waterwaysby Sandro Suppa, sales

manager, terminalsand Vincent van derWijk, product manager

Bargolink, Bhler,Switzerland


FEATURE


19/68

means longer uptime, lower operating costs,

less expenses on maintenance and spares,

and half the energy usage. This makes the

whole unloading process more economical

and environmentally sustainable, especially

considering the added demurrage costs to

vessels if a pneumatic system breaks down.

Lastly, the Bargolink operates at lower noise

levels and does not generate lower frequen-

cies than pneumatic systems whose loud

droning and changing volumes may consti-

tute a health hazard.

Already three customers in China,

Croatia and France have been convinced

that they can benefit from Bhlers Bargolink.

Altogether, Bhlers Bargolink offers an

investment-friendly, highly flexible and effi-

cient solution for unloading systems used for

inland water transportation in the genuine

Buhler manufacturing quality combined with

best in class components.

More InforMatIon:

Bhler GmbH

Grain Logistics, CH-9240, Uzwil, SwitzerlandTel: +41 719 551111

Fax: +41 719 553949


Website: www.buhlergroup.com


VIGAN Engineerings.a. Rue de lIndustrie, 16 B-1400 Nivelles (Belgium)Phone : +32 67 89 50 41 Fax : +32 67 89 50 60 Web : www.vigan.com E-mail : [email protected]

VIGAN manufactures dry agribulk materials handling systems:

Portable pneumatic conveyors or grain pumps (100 - 250 tph);

Pneumatic Continuous barge & Ship Unloaders (160 - 800 tph);

Mechanical Continuous Ship Unloaders (up to 1,500 tph); Mechanical loaders (up to 1,200 tph).

as well as complete storage systems in ports and the agricultural industries.

From project design to complete turnkey bulk handling solutionsand port terminals with mechanical and/or pneumatic

reliable and cost effective equipment.

PYEONGTAEK PORTSouth Korea1 NIV 400 tph

On rails with cable reels

LATTAKIA PORTSyria2 Mobile T200

2 x 250 tph

SWINOUJSCIEPoland (BUNGE GROUP)1 Loader 600 tph

An afliate company of VAN DE WIELE group.

Latest references

Visitour

website

www.viga

n.com

i i

FEATURE


20/68

Enzyme technology is an integral

tool for the brewing, baking and

textile industries. In agriculture

there is great potential for enzymes

too but this is yet to be fully exploited.

However, animal nutrition is one area

in which the use of feed enzymes is

becoming increasingly important.

There are three driving factors in animal

production that are leading to the develop-

ment and adoption of feed enzyme technol-

ogy. First, the worlds growing population

has meant global demand for food and in

particular meat and meat products have

increased substantially. In addition, produc-

ers are also continually looking for novel

methods of increasing their efficiency and

productivity and the cost and availability of

raw materials for animal feed is the second

factor continuing price rises are a major con-

straint to meeting demand. The third factor

is concern over the environmental fragility of

the planet and the pressure on agricultural

industries to reduce their reliance on vitalresources.

Major ingredients in monogastricfeeds

The major ingredients used in most

monogastric feeds are of vegetable origin

including ground cereals such as maize,

wheat and barley or vegetable by-products

such as wheat middlings and rice bran. It

also includes processed protein ingredients

such as soybean, or rapeseed extractions

and unprocessed materials such as peas or

beans. All these materials have a complex

structure of carbohydrates, protein and oil

and the carbohydrates are further described

as sugars, starch and non-starch polysac-

charides (NSP).

Digging deeper, the NSP components

can be further divided into beta-glucans,

celluloses and pentosans. Indeed, many dif-

ferent types of enzymes are secreted within

the digestive tract but there are cases where

the enzymes that are necessary for complete

digestion are not produced by the animal

or are only present at very low levels. In

monogastric animals it is the enzymes that

are required to breakdown the NSP fraction

of the diet that are missing.

Increasing feed value throughenzymes

The NSP fraction of barley and oats con-

tains beta-glucans which can hold significant

amounts of water causing high gut viscosity.

Young pigs and poultry lack the required

beta-glucanase enzyme to break the link-

ages of the molecule and this is a problem

because it has an anti-nutritional

effect by blocking the absorption

of nutrients. Increased viscosity also

reduces the rate of passage thus

lowering feed intake with the end

result being reduced growth rates,feed conversion and the appar-

ent metabolisable energy of the

diet. Increased viscosity additionally

results in wet litter which in poultry

leads to conditions such as necrotic

enteritis, hock burns and breast

blisters.

Similarly in wheat, a common

cereal choice in temperate climates,

the NSP fraction contains a high

level of arabinoxylans. Xylanase is

the enzyme that pigs and poultry

require in order to break these

compounds down but they are

also deficient in them and, it was

not until the development of beta-

glucanase and xylanase enzymes for

animal feed in the 1980s, that this

issue was addressed. Now these enzymes

are commonplace, certainly in Europe,

where poultry diets are principally com-

posed of wheat and barley.

Recent enzyme developmentsMore recently, positive effects in animal

performance have also been noted with

non-viscous cereals such as maize and sor-

ghum (Choct, 2006). The digestive system

in pigs differs slightly from poultry and the

issue of increased viscosity from wheat and

barley is not a problem in these species. The

addition of feed enzymes in pig diets has

also demonstrated positive effects (Dierick

and Decuypere, 1994) and it is recognised

that beta-glucanases and xylanases are able

to degrade plant cell wall which leads to a

release of nutrients from grain endosperm

Table 1: Optimal temperature and pH properties

from some fungal endoxylanases (adapted from

Corral and Villanseor-Ortega, 2006)

SOURCE OptimumTemperature(Oc)

OptimumPh

Apergillus kawachii

A

B

C

60

55

50

5.5

4.5

2.0

Aspergillus niger

XynA I

XyanA II

50

45-50

5.0

4.5

Penicillium Capsulatum

XynA

XynB

48

48

4.0

4.0

Talaromyces emersoniiXyn I

Xyn II

XynIII

Xyn IV

Xyn V

75

77

73

77

80

4.7

4.3

4.2

4.3

4.2

by Elizabeth Norton, nutritionist, Anpario plc, United Kingdom


FEATURE


21/68

FEATURE

and the aleurone layer cells and therefore

improves the energy value of the feed.

Reducing pathogenic bacteria inthe colon

A third possible mechanism by which the

nutritive value of feed is increased by feed

enzymes is through the release of oligosac-

charides (Choct and Cadogan, 2001). These

can be formed during the degradation of

storage and cell wall carbohydrates by sup-

plemental enzymes and are able to resist

further degradation by digestive enzymes

and so able to reach the colon. Once in

the colon these oligosaccharides are a nutri-

ent source for beneficial bacteria such as

Bifidobacterium and Lactobacillus spp which

suppress the growth of pathogenic bacteria

such as Salmonella, Clostridium, Campylobacter

and Escherichia coli. It is well established that

reducing pathogenic bacteria in the colon

improves weight gain and the feed conver-

sion ratio in pigs and poultry.

Cost saving feed formulationRegardless of the mechanism by which

the energy value of feed is increased, the

fact that it occurs is of significant importance

for producers and nutritionists. This allows

for greater flexibility when formulating diets

meaning that alternative feed ingredients,

which are traditionally of lower nutritive

value, can be utilised in the formulation. This

can result in significant savings in feed costs

for producers where, for example, some of

the wheat-based portion of the diet can be

replaced with cheaper barley, providing a

suitable blend beta-glucanase and xylanase

enzymes are incorporated into the diet.

Phytase developmentThe 1990s saw the development of the

next enzyme of significant importance in ani-

mal nutrition, phytase. Phosphorous is a very

important and valuable mineral element in all

species as it is crucial for bone development

and metabolic processes.

In plants, the majority of phosphorous is

stored in the form of phytate. Monogastrics

are unable to utilise the phosphorous in

phytate so it is a major source of animportant nutrient that is norm

january | february 2013 - grain & feed milling technology magazine - full edition

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