November - December
2011
In this issue: •
African advances
Animal feed milling is one of the most buoyant activities in the agri related field
•
•
•
Mycotoxins an overview
•
Database for animal diet formulation techniques: A glance to last decade
Get in line Process analysis solutions open new opportunities for improved profit and quality
Optical sorting Optical sorting has come of age and should be considered as a serious option for inclusion in any modern wheat cleaning plant
•
Food safety in the grain milling industry
•
Recent advances in rapid grain testing
A subscription magazine for the global flour & feed milling industries - first published in 1891
GRAIN &
FEED
MILLING TECHNOLOGY
November - December
News:
Enzymes: how to obtain the most cost effective inclusion in your formulation? Perten Announces Formation of a Dedicated Process Instrumentation Department Borregaard LignoTech appoints sales staff in Asia-Pacific and western USA Indian order for enclosed ship unloader includes Cargotec’s Siwertell Sulphur Safety System Next generation green palletisers
2011
Publisher Perendale Publishers Ltd 7 St George’s Terrace, St James’ Square Cheltenham, Glos, GL50 3PT United Kingdom Tel: +44 1242 267700 Fax: +44 1242 267701 info@perendale.co.uk
African advances: Animal feed milling is one of the most buoyant activities in the agri related field Get in line: Process analysis solutions open new opportunities for improved profit and quality Database for animal diet formulation techniques: A glance to last decade Mycotoxins: An overview Optical sorting Food safety in the grain milling industry Recent advances in rapid grain testing
Nicky Barnes Tel: +44 1242 267707 nickyb@gfmt.co.uk
James Taylor Tel: +44 1242 267707 jamest@gfmt.co.uk
5 5 6 7
Features:
Editorial Manager
Design and Page Layout
4
8 12 16 20 22 26 28
Commodities: Raw material outlook, by John Buckley
36
Circulation & Subscriptions Manager Tuti Tan Tel: +44 1242 267707 tutit@gfmt.co.uk International Marketing Team
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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 2011 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form
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volume: 122 number 6
issn No: 1466-3872
Guest - EDITOR’S OBSERVATIONS
Guest editor - David Webster, Satake
I
would like to thank Grain & Feed Milling Technology magazine for the opportunity to write this guest editorial. I’m sure most readers of trade magazines will have read enough editorials discussing the current financial climate so I’ll skip that part and move onto the opportunities that times like this present to a cereal milling engineering company such as ourselves. We’ve consistently maintained focus on our goals of developing machines and processes that deliver either improved performance or reduced operating costs; preferably both. Even though investment purse strings are more tightly held than usual we always find that projects that deliver payback will go ahead. Coupled with the above are ever-improving standards for finished products safety and a large part of our development has targeted these areas.
Improved performance or reduced operating costs; preferably both
The sorting machine technology is continually improving to deliver ever higher machine capacities with ever improving product separation accuracy required by customers. The new Satake ‘Evolution’ range of colour sorters demonstrates this continual technical advance and delivers the results required. For cereal milling the use of colour sorting equipment as part of the grain cleaning process continues to increase and proves to be commercially beneficial when higher quality grains are being processed. In addition colour sorters provide an additional layer of protection with their ability to remove imperfect raw material and foreign objects. Cereal processing industries have continually increasing demands put upon them and in turn they look to suppliers to help provide solutions to meet such needs. The need to provide the right solution and an economic solution becomes more important year on year. At Satake Europe we endeavor to keep a close eye on the industries we serve with a view to understanding customer requirements and being able to respond to current and future needs. We look forward to a continued relationship with GFMT and hope readers will enjoy and learn from the articles in this issue and the news of developments around the world.
Whilst looking at ways to adapt to the current market situation we have also taken the opportunity to look inwardly and see how best we might structure our business to suit. The last twelve months has been a busy period within the Satake Corporation UK businesses, not only from a sales and business activity point of view, but also due to a re-organisation within the business. The Satake facilities here in Stockport accommodates the Satake Cereal Milling business covering the UK, mainland Europe, Africa and the Middle East. The Vision Systems business shares the same facilities and covers the same territory for sales and service of colour sorting equipment. With effect of April 2011 the Satake Corporation Directors confirmed the amalgamation of the Cereal Milling and Vision Systems (formerly ESM Ltd) under the new company name of Satake Europe Ltd. As part of this re-organisation Satake Europe became a member of the Satake USA Group of Companies, all of which are 100% owned subsidiaries of the Satake Corporation. This amalgamation has proved to be a very positive move as it allows full inter-change of skills and experience between the Cereal Milling and Vision operations enabling customers to benefit from the broader technical and project engineering capability. Vision customers now have the opportunity to have a fully engineered solution to meet their project requirements. Colour sorting equipment is an important requirement within processes which are handling products such as nuts, pulses, beans, seeds, cereals and even plastic pellets.
&feed milling technology
Grain 2 | November - December 2011
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Visit us at Victam Asia 2012, stand C065 Bangkok International Trade & Exhibition Centre (BITEC) 88 Bangna-Trad Road (Km.1), Bangna, Bangkok 10260, Thailand
Daniit A/S · Jyllandsgade 30 · DK-6400 Sønderborg Tel. +45 7342 3636 · www.daniit.com · mail@daniit.com
Exhibition dates and opening times Wednesday 15th February 2012: 10.00 – 18.00 Thursday 16th February 2012: 10.00 – 18.00 Friday 17th February 2012: 10.00 – 17.00
With our compliments
&feed milling technology
We look forward to greeting you
Grain
Supported by Thai Ministry of Agriculture & Co-Operatives, Thai Department of Livestock Development, Thai Department of Fisheries, Thai Feed Mill Association, Thai Rice Milling Association, Thai Chamber of Commerce Thailand Conference & Exhibition Bureau
November - December 2011 | 3
Grain&feed m techno11 NEWS
27/06/11
16:12
November - December 2011
Page
Enzymes:
how to obtain the most cost effective inclusion in your formulation?
BUCKET ELEVATOR COMPONENTS
BUCKET
E
nzymes have become a key solution in resource efficiency. Phytase is known to raise the available or digestible phosphorus (P). However, the power to release digestible P out of plant phytate is not linear. This means that it’s no use adding (expensive) phytase to the feed unlimitedly. But how to deal with this non-linear effect? How to obtain the most cost-effective use of enzymes in your formulation? In other words: How to formulate easily the cheapest compound with the most optimal inclusion of enzymes?
Enzymes: how to obtain the most cost-effective inclusion in your formulation? Resource efficiency Formulation managers have an increasingly strategic role to play in a complex market. Resource efficiency has become a key word in feed formulation. Breaking down the plant phytate to release more digestible Phosphorus by adding phytase in animal feed has become common practice. Fast facts Phytase is an enzyme that increases availability of phosphorus in animal diets Phytase lowers the amount of supplemental phosphorus required in the diet Because of improved dietary phosphorus utilization, less phosphorus is excreted in the manure.
UNDER SPEED MONITOR BELT ALIGNMENT SYSTEM
Non-linear behaviour of phytase : challenge for feed formulation programs
ELEVATOR BELT
Z.A. de la Lande 49170 ST-GEORGES-SUR-LOIRE - FRANCE Tél. : 33 2 41 72 16 82 - Fax : 33 2 41 39 32 12 E-mail : sales@stifnet.com - Web : www.stifnet.com 4 | November - December 2011
How useful adding phytase to feed may seem, tests have shown that the power to release digestible P out of plant phytate is not linear. This means that the first 250 FTU of phytase will release more digestible P than the second 250 FTU you include in a compound. This ‘non-linear behaviour’ forms special challenges for feed formulation programs, as these are based on linear programming. Adifo’s least-cost feed formulation program BESTMIX ® is the first and only tool that offers a sound solution for optimising with “non-linear” effect. The software breaks down the effect of Phytase into linear phases to simulate the non-linear effect. This way, the formulator can apply Phytase as if it were any other ingredient, resulting in the same values: the optimal inclusion rate, the shadow price, the total consumption, etc. BESTMIX® uses a full optimisation, resulting in a dynamic inclusion rate of Phytase and the lowest possible compound price.
Detailed analysis of the result There is more. BESTMIX® also gives insight in the behaviour of the enzyme in the composition. It compares the composition and the price of the compound twice: Once with the use of phytase and once without the use of phytase. This way, the nutritionist can analyse the behaviour of phytase in all details.
Anti-nutritional effect of enzymes Phytase not only releases extra digestible Phosporus. Thanks to its anti-nutritional effect, it also raises the level of protein, amino-acids and energy values in the feed. These extra advantages are made visible in BESTMIX® . The software clearly shows to the nutritionist the effect of phytase in the compound feed for all nutrients.
Most cost-effective use of Phytase in the formulation Not all phytases available on the market have the same effectiveness. Nor the same price. With BESTMIX® , it is easy to evaluate every single type of phytase, making you see which phytase brings the highest value to your specific compound.
NSP enzymes The BESTMIX® feed formulation software not only offers a solution for working with Phytase, but also with any kind of NSP enzyme. This means the formulator can set up a NSP-enzyme in such a way, that its effect on the nutritional value of certain other ingredients is defined. In other words, you define exactly on which ingredients the enzyme has an actual effect. This way, your ingredient matrix is kept clean. It has proven to be a far better solution than to create different series of a certain ingredient, with adapted nutrient values for every NSP enzyme and every possible enzyme activity combination.
Conclusion Using the state-of-the-art formulation tool BESTMIX ® to calculate the cheapest compound with the most optimal inclusion of enzymes is a real money saver. More
information:
Adifo NV Industrielaan 11B 9990 Maldegem Belgium Tel: +32 50 303 211 Email: sales@adifo.com Website: www.adifo.com
&feed milling technology
Grain
News
News
November - December 2011 Perten announces formation of a dedicated Process Instrumentation Department
P
er te n I ns t r ume nt s Americas has for m e d a P roce s s Instrumentation Department to meet the needs of its on-line/in-line analysis customers. Perten Instruments, Inc. responsible for sales and support in the Americas is pleased to announce the formation of a dedicated Process Instrumentation Department. Ralph Hewitt Manager-Process Instrumentation, heads the process instrumentation group. Ralph’s experience includes various roles in plant operations and QC management at large grain processing and food processing facilities with companies such as Cargill, ADM and Pinnacle Foods. The group includes Brian Schultetus, product specialist systems integration, Darin Crossland product specialist applications development, and Magnus Nilsson product specialist hardware and customer care. In addition to t he dedic ated st af f, Per ten Instruments has spent much of the past 18 mont hs est ablishing a ne t wor k of ve nd or s capable of assisting Perten in responding to the needs of their customers. The de p ar t me nt ’s
functions and mandates inc lud e si t e ev a lu at io n visits, installations, systems integration, applications development, training, and support. The group’s initial focus is on t he Per ten diode array based nearinfr ared ( N I R ) proce ss analysers. The group will continue to expand as new process instrumentation is added to the Per ten product por tfolio. Many new advances in product development are scheduled for release in 2012. “Process instrumentation is one of our largest areas of growth” reports Gavin O ’ Re i l l y, P r e s i d e n t o f Per ten Instruments, Inc “We are very excited to have this highly qualified group to ser ve our process instrumentation customers.” “The formation of the Process Instrumentation Department is a further demonstration of our commitment to our customers and our mutual success” adds Ralph. More
THE GLOBAL MILLER I will be blogging the latest news from around the world that relates to the movement, storage, milling and use of all types of grains and cereals for the food and feed industries. To receive my reports regularly why not sign up to this blog directly or follow us on Twitter and Facebook?! - The Global Miller by Martin Little, Blog Editor
http://gfmt.blogspot.com
information:
Business Development Manager Tel: +46 8 880 990 Fax: +46 8 881 210 Email: wshadow@perten.com Website: www.perten.com
&feed milling technology
Grain
NEWS
November - December 2011 | 5
November - December 2011
NEWS
Indian order for enclosed ship unloader includes Cargotec’s Siwertell Sulphur Safety System
C
argotec has received an order for a Siwertell ship unloader t ype ST790 -D from the Indian Farmers Fertiliser Cooperative Ltd (IFFCO), Paradeep Unit. The enclosed screw-type unloader will be used to discharge rock phosphate and sulphur at a rated capacity of 1,800 t/h. “IFFCO wanted a tot ally enclosed system for both environment al and safet y reasons,” said Anders Paulsson, Sales manager, Bulk handling. “The company specified a screwtype unloader for high efficiency and chose a Siwertell system from Cargotec because we have by far the most knowledge and experience of this technology he first Siwertell system designated for sulphur was delivered in 1980. Of the four main types
6 | November - December 2011
of continuous unloaders screw, pneumatic, chain and bucket chain only the Siwertell screwtype has been demonstrated to solve the three main problems caused by unloading sulphur: a high explosion risk, extreme corrosion , and s t ringe nt regulations for environmental protection.” Cargotec’s Siwertell Sulphur S afet y System ( ‘4S’ ) was developed to minimise the risk of explosions and detect fires. The 4S is designed to prevent sulphur dust explosions in the conveying line and to evacuate explosion pressure in case a dust explosion does occur, without causing damage to equipment and endangering the safety of operators, personnel and other facilities. To prevent explosions and fires, the Siwertell unit is equipped with nozzles that
spray water at the inlet feeder and in the conveyor transfer points. An automatic lubrication system lubricates and cools down end bearings and intermediate bearings. “ E ve n w i t h p reve n t at i ve technology in place, there are rare occasions on which an explosion occurs or a fire starts, so Cargotec has designed a system that reacts immediately upon detection and extinguishes any fire,” Mr Paulsson said. “Fire detectors along the conveying line automatically stop the conveyors and start spraying water from the fire extinguishing system. To manage an explosion, the conveyor’s steel casings are reinforced with extra-thick steel, and explosion-venting valves fitted along the conveyors and dust collectors relieve pressure.” A specially designed conveying
line wit h st ainle ss ste e l components ensures that a Siwertell unit is protected from corrosion and it is also practically maintenance-free. This is the third reference for Siwertell fertiliser unloaders in India: in 2003 a 400 t /h Siwertell 490-F was delivered to Coromandel Fertilisers for unloading fertilisers and sulphur from 40,000 dwt ships, and this was followed in 2005 by an order from Paradeep Phosphates for a 1,600 t/h Siwertell 640-D handling sulphur, phosphate and fertilisers. Components for IFFCO’s system will be manufactured in Sweden and China for erection on site in Paradeep Port, Orissa, India. With a delivery time of 12 months, the unloader is expected to be in operation by early 2013.
&feed milling technology
Grain
News
News
November - December 2011
NEWS
Next generation green palletisers Ehcolo of Denmark has introduced the world’s first fully automatic palletiser, which uses the same technology as hybrid cars to recover energy consumed through braking.
P
alle tiser mot or s are constantly starting and stopping, often at the same rate as the number of units per hour handled. Consequently, there is a lot of braking energy which is converted to heat, usually by mechanical braking, which creates noise and significant wear and tear on all the components and equipment. The Ehcolo palletiser used to use frequency converters on all its motors, which was OK, but caused significant heat, which would be wasted. However, the new servo controllers are interconnected in KERS ( Kinetic Energ y Recover y System), which means that all braking energy is collected and re-used, offering a substantial saving in power consumption. The Ehcolo palletisers, which feature automatic pattern set-up, have been further developed to
offer a higher level of accuracy and increased speed with the ser vo control using encoders mounted on all positioning motors. The use of soft start and stop on all motors results in low noise and long equipment life. An operator friendly 15 -inch colour touch screen is used, allowing new patterns to be easily produced by the automatic pattern set-up system. This is achieved by simply choosing the pallet size and keying in the product dimensions. There is a range of possibilities for data communication and standard the control includes a internet router, so that remote control from anywhere is possible. Ehcolo has 14 different models of
palletiser for all types of bags and boxes on all types of pallets, with capacities from 300 – 2500 units per hour. The palletiser is designed for container transport shipment around the world. Assembly at customers site takes only two days, and as all palletisers are pre-tested with products in Ehcolo factory, full production can commence on the third day. Ehcolo are also manufacturing
container bulk loaders and un-loaders. At the Victam Asia 2012 Ehcolo is also introducing to South East Asia complete turnkey packing ( FFS bagging-palletisingwrapping) lines, which has been widely supplied in Europe to animal feed- and fish feed producers as well as grain- and seed producers. See E hcolo at t he Vic tam Asia 2012 Exhibition 15 – 17 February BITEC Bangkok Thailand More
information:
Ehcolo A/S Smedevej 10 DK-6683 Fovling Tel: +45 75398411 E-mail: post@ehcolo.dk Website: www.ehcolo.com
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Ehcolo is introducing to South East Asia complete turnkey packing (FFS bagging-palletising-wrapping) lines, which has been widely supplied in Europe to animal feed- and fish feed producers as well as grain- and seed producers. As the first and only in the world, Ehcolo is now supplying its palletisers with servo control and a kinetic energy recovery system, which collect all the motors braking energy for re-use, so we can supply the first ”green” palletisers, saving 15-20% compared to others
Se 15 Asi e u – a sa Ba 17 201 t t ng Fe 2 he ko br Exh Vic k ua ib ta Th ry iti m ai B on la IT nd EC
Ad_Ehcolo.indd 1
&feed milling technology
Grain
• Products: all bag types and sizes • Capacity palletisers: types from 300 to 2500 bags per hour • Turnkey FFS packing lines: up to 1500 bags per hour • We also supply robot palletisers http://www.ehcolo.com
24/11/2011 08:45
November - December 2011 | 7
FEATURE
African advances
by Bryan McGee, a milling industry consultant and freelance writer (bryan@bcmcgee.co.uk)
T
echmach Technology of South Africa aspires to be Africa’s leading general engineering company in the Agri sectors. It is building on its longstanding activities in cereal milling, animal feed milling and seed processing complemented by its diverse know-how in other related fields such as grain handling and plastic separation by optical colour sorting. Techmach carries out the design, manufacture and commissioning of individual machines or complete plant on a turnkey basis in these and related sectors from its 10,000 square metre site in Chamdor, 30km West of Johannesburg – an area once famed for its gold mining but now more for its food processing and light engineering activities. Under the leadership of the second generation of its founders, Techmach, having invested more than 16 million Rand ( US$1.0 = SA Rand 7.9) in its facilities, now has a turnover of over 150 million Rand and employs over 100 personnel at its main site as well as a further 20 in the field. Juan-Paul Farinha disclosed that “We have been able to double our turnover in five years by substantial investment in our design and workshop facilities and by acquiring new skills and developing new equipment and processes both in-house and with our overseas partners.” The strength of the business is underpinned by its longstanding partnership agreements with ‘blue chip’ manufacturers; Cimbria in Denmark and Austria, for seed and cereal cleaning and materials handling; Satake in Europe and Japan for cereal milling and optical colour sorting; Andritz Feed & Biofuel in Denmark for animal feed milling; Meyer Machines in the USA for specialist bucket elevators and Balaguer in Spain for rollermill rolls. Maize and wheat provide the staple diet for the growing population of South Africa which, partly due to continuing cross-border immigration, now approaches 50 million. For 2011, maize plantings are estimated to be 2.5 million hectares to produce a crop of 11 million to 12 million
8 | November - December 2011
tonnes of which four to five will be available for export. Over 75 percent of the planted area was devoted to genetically modified varieties. The quality is likely to be variable this year due to unseasonal rains in the harvest period. In the year to March, nearly 4.2 million tonnes was processed for human consumption of which over 3.8 was of white varieties (source SAGIS). In contrast, the wheat crop for 2010 at 1.5 million tonnes was well down on previous years and thus imports, at world market prices, will be required to provide the balance of 60 percent, to meet domestic demand. The deregulation of the wheat and maize sectors has opened up opportunities for both consolidation within the major millers and the introduction of smaller plants in rural areas.
Maize milling The Techmach/Satake degerming system has effectively revolutionised maize processing for human consumption in the region and, since its introduction in 1998, more than 100 of the core VBF degermer systems, each capable of handling six tonnes/hour, are now in operation. The original pioneers of the system, Allem Brothers of Viljoenskroon in Free State Province, are now investing a further R25 million in another complete production unit to be integrated with their existing plant and raise their capacity by 260 tonnes per day. Other current major maize projects include a R15 million modular degerming plant for GP Victor in Frankfort and an interesting extruder based system for Tiger Brands in their R20 million project to produce an instant maize meal breakfast food at five tonnes per hour.
Wheat milling The deregulation of the milling and baking industries has resulted in far more consumer choice in terms of variety and quality of baked goods including bread. Smaller and medium sized milling companies are able to satisfy some of these niche markets thus complementing the larger consolidated groups.
A recent example is Kromdraai in Frankfort who operate a new Techmach engineered Satake PeriTec debranning system and more recently OVK in Clocolan in Free State province who have ordered a 150 tonne PeriTec mill, to be built on a modular basis. In Windhoek, Namibia, the company is installing a complex flour handling, blending and dispensing system incorporating the new TMS scales to feed a series of pasta production lines and another similar handling system for Bokomo in Olifantsfontein for their new biscuit lines.
Feed milling Animal feed milling is one of the most buoyant activities in the agri related field and Techmach are the dominant supplier of plant in this sector. There has been an enormous level of investment by both the major groups and also by some of the smaller operators in the rural areas. This is at least partly as a result in the growth of poultry rearing since the majority of poultry feed is grain based. The current bird population is about 154 million which is 40 percent higher than 10 years ago. The average slaughter age for broilers at 1.85kg per bird has been brought down to only 35 days. Recent projects include a complete turnkey project for VKB in Vrede in Free State Province which is being built in partnership with Andritz Feed & Biofuel and Cimbria to be the most fully equipped ‘state of the art’ feed mill in the region. The Rand 52 million plant will produce 40 t/h of pelleted feed. Another major, (Rand 60 million), feed mill is also being built for De Heus, the Netherlands based company, in Pietermaritzburg in Kwazulu Natal in three phases of which the first is complete, the second being commissioned and the third in the planning stage. Pioneer Group’s Nova Feeds in Pretoria are adding a second pelleting line
&feed milling technology
Grain
FEATURE
THE POWER BEHIND YOUR TRANSPORT
In response to the requirement for more economical plants, mainly in rural areas, Techmach developed and introduced a Modular Maize Mill concept, incorporating the innovative Satake/ Techmach degerming system, in 2008 (World Grain, August 2009). Typically the four preassembled modules for cleaning, degerming, polishing
Seed processing Although seed processing has long been an important activity in the business, it has recently taken on new significance with the completion of the major turnkey project for Pioneer Hi-Bred International (PHI), a subsidiary of the Du Pont Corporation of America. This plant, outside Pretoria, which produces transgenic maize seeds to the highest international standards, was followed by another in northern Zambia, where Techmach have also built a system for Monsanto and now a further plant is to be built near Addis Ababa in Ethiopia. Other Company projects in sub-Saharan Africa are being executed in Nigeria, Namibia, Mozambique and Swaziland.
contact@vav.nl
Modular mills
and milling are supplied as a full set or individually for upgrading an existing plant. This has proved to be successful not only within South Africa with over 10 units sold but also further North in equatorial regions of Africa. Now this same concept has been applied to a PeriTec wheat flour milling system for OVK as described above and more recently to the new 10M animal feed mill. Deon Cronje, sales director, commented “It has been logical to extend the concept by initiating these new designs since many of our customers wish to apply the very latest plant and technology, get into production quickly and are understandably reluctant to make major investments in non-productive building structures and other non-essential infrastructure.”
Conveyor chains Elevator belting Elevator buckets
www.vav.nl
together with fat coating and new outloading bins and the Humansdorp Koop are also adding a second pelleting line, this time for high roughage feed. As a consequence of this high level of feed milling activity the sales of dies and rolls for the pellet presses is growing at over 30 percent per annum.
Screw segments
Process technology, machinery, and complete plants for the animal feed industry ■ New process lines and plants ■ Process equipment upgrades and replacements ■ Spare and wear parts ■ Service and maintenance programs ■ Optimization and support ■ Leading technologies ■ Global presence ■ Local service
Lifland, Iceland. A complete pro cessing line for animal feed production. With this greenfield plant (capacity 50,000 t/a), Lifland will cover nearly 60% of total animal feed production in Iceland. The turnkey feed plant started producing in October 2010.
Together, we make it work!
ANDRITZ FEED & BIOFUEL Europe, Asia, and South America: andritz-fb@andritz.com USA and Canada: andritz-fb.us@andritz.com
&feed milling technology
Grain
www.andritz.com
November - December 2011 | 9
FEATURE
CNC machine tool
Colour sorting
machine tools, are able to produce cost effective in-house components and equipment to complement the specialist machines that are sourced from its international partners. In this way they can also be more responsive to changing market needs. The CAD designs can be fed directly to the CNC cell for programming the plasma cutters and punch machines without the need for any hard copy drawings. Here plate can be accurately cut and punched before fabrication after which they are painted by a powder coating process for a durable finish. The precision punched replacement screens, as used in the degermManufacturing Although South Africa has a remarkably ers, after punching and forming are sent open economy, Techmach have found it to an outside specialist for wear resistant beneficial to be increasingly self sufficient in hardening. Izak van der Merwe, engineering director terms of manufacturing and, through their explained, “Manufacturing and scheduling of major investments in design equipment and 15:25:33 20111130 - GFMT December.pdf 1 2011/11/30 small batches of complex 625 Series Roller Stand machines or even simple Increase your Performance and Efficiency with the Durable and components cost effective 625 Series from Roff has been revolutionised by the technology I now have available.” The significant improvement in component accuracy achievable by CNC has enabled the company to add to its core product range with new machines such as the versatile in-process Specifications: and bagging • 600x250mm Adjustable Rollers • 11kW Motor scales, called www.roff.co.za TMS, which are proving competitive Maize Milling Plants in terms of Stockfeed, Cleaning and function, qualConveying Products ity and cost Cnr. Piet de Vries Drive & 7th Avenue P.O. Box 2439 | Kroonstad | 9500 | South Africa compared Kroonstad | 9499 | South Africa Tel: +27 56 212 2697 | Fax: +27 86 618 0651 with imported GPS: S27º39’45” E27º13’35” www.roff.co.za | sales@roff.co.za makes. The separation of contaminants from seeds, groundnuts and cereals by optical means has long been a core activity of the company through their longstanding relationship with ESM of Houston, Texas, now part of the Satake Group. The new Evolution RGB machine with its high resolution full colour detection and LED focused lighting has already had a rapid take up with five installations in under four months including one for peanut grading and it is also proving suitable for new applications such as plastics separation.
C
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Y
CM
MY
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CAD view of OVK modular wheat flour mill
®
10 | November - December 2011
New design and engineering facility As a result these scales are rapidly gaining market share across the industry.
Conclusions Techmach’s young and energetic management, investment in productive equipment and skilled personnel combined with the know-how of their industrial partners have demonstrated an encouraging ability to take the company forward under sometimes difficult trading conditions. They are carving out a niche as leaders in a broad range of activities in the fields of agri-engineering.
History of Techmach Technology: Techmach was established in 1979 to provide equipment and engineering services to the seed, cereal and groundnut processing industries. The business expanded in 1999 when we acquired skilled personnel and the intellectual property rights to the food and animal feed businesses of LTA which were in turn derived from its consolidated predecessors, Simon, Thomas Robinson and Macdonald- Forman over more than 50 years. Key Milestones: 1979 Private company founded by Greg Farinha and two partners. 1985
Greg Farinha takes full control
Acquisition of agency for Heid of Austria which later, on their merger, also encompassed Cimbria of Denmark
1999
Becomes agent for Satake Corporation for cereal milling equipment
Juan-Paul Farinha joins the business
2001
Deon Cronje joins the business
Company converts to (Pty) Ltd
2003
Acquisition of Andritz Sprout agency
2008
Modular maize mill launched
2010
Expansion of buildings, major investment in IT, machine tools and other manufacturing facilities.
120 employees.
2011
Modular wheat flour mill launched - appointment of Izak van der Merwe as engineering director
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Grain
FEATURE
Get in line
Process analysis solutions open new opportunities for improved profit and quality by Darren Robey, Foss, Denmark
T
he use of NIR technology as an analytical technique is far from new to the grain and feed milling industry.
In many parts of the world it has been a mainstay of grain quality analysis for more than 20 years and the benefits of the technology are well understood. So what is the next step for this technology? As with many aspects of food and agricultural quality control today, the answer lies in the field of in-line near infrared analysis. But even in-line NIR is not a new concept. The potential benefits of moving the instrument from the lab to the production line where it can take constant measurements hour after hour and day after day have been clear to quality controllers and production managers for years. Until recently however, the technology has failed to meet the challenge with filter-based near infrared technology unable to deliver the sort of savings hoped for. All that has changed with the advent of new Diode Array based solutions teamed with strong calibrations and the latest computing technology. One company already making good use of
12 | November - December 2011
the technology development is Spanish premium flour suppliers Emilio Esteban. With the help of an in-line, near infrared process monitoring solution called ProFoss from Foss, it is raising high quality standards to new levels while gaining more vision and insight into the milling process.
From laboratory to production A flour production facility like the one at the Emilio Esteban flour mill in Spain typically produces around 100 kilos of premium grade flour every minute. That’s not a huge output by industry standards, but plenty for the staff at the in-house laboratory to control as they strive to ensure that deliveries always match the high standards of discerning customers, including, amongst others, producers of baby food. Company director Emilio Esteban sets out the business strategy in the current competitive business landscape. “There are basically two options. Either you go for high capacity and compete on price or you invest in high quality.” With a high quality strategy in mind, Esteban
and his staff have acquired a helping hand - or ‘eye’ to be more precise - in the form of the ProFoss. Mounted directly in production at the final steps in the milling process, the ProFoss monitors the flour as it flows through pipes at up to 25 metres a second. This avoids the need for a bypass stream to collect samples. The instrument is housed in a practical and robust stainless steel cabinet (ATEX approved). While it may not win any design awards, the wealth of information the ProFoss provides is something for any quality controller to get excited about. The analyser automatically monitors moisture, protein and ash every few seconds and the regular results are fed back to a computer in the mill control room where they are displayed in a graphical form using Foss ISIscan software. The charts resemble a seismic graph. A nice straight line indicates that the flour composition is on target, but with a tremor indicated if something starts to go off track. This allows anyone working in production to see at a glance whether everything is running to plan. The new system does exactly the same job
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November - December 2011 | 13
FEATURE
Laboratory manager, Antonio Caballero conducted a study which indicates very similar performance for both instruments. And, of particular importance is the fact that even though the performances of the two solutions are very similar, the frequency of measurement with the ProFoss system allows trends and irregularities to be spotted more quickly.
as the previous analysis instrument in the laboratory, but now measurements are made several times a minute instead of every few hours. It is this frequency that helps to keep production right on target. It also reduces the risk of variations in content of products when a new batch is started. Esteban sums up the advantage of continuous measurement and the difference in comparison to the Infratec 1241 Grain Analyser located in the laboratory. “Infratec and ProFoss are completely different devices,” he says. “The reason for this is where they are situated. Infratec allows you to analyse samples
14 | November - December 2011
arriving at the lab, but these don’t represent the whole process. ProFoss is another concept – it is placed inline and provides constant and continuous information, so in case there is any problem, you can react immediately and that is the key.” According to laboratory manager Antonio Caballero, the accuracy of ProFoss is equal to the Infratec when measuring protein, moisture and ash. Besides this, with ProFoss, he believes that traceability has increased as the company now has a more comprehensive picture of quality. “I believe that improved control of the process will increase quality levels and give us a competitive edge,” says Caballero. “We will also improve traceability, as we know exactly how the process is working. And overall, we will increase the quality of our products.” An obvious consideration was whether the accuracy of measurements with the ProFoss would be comparable to the existing desktop Infratec 1241 grain analyser used in the laboratory.
Other applications? While the benefits for flour production are clearly demonstrated in the story above, it doesn’t take a great deal of lateral thinking to see the application of this technology in other parts of the grain and feed supply chain.
Thankfully the answer to this question is very much yes. A similar story to the one above can be told in protein meal production where the instrument has demonstrated similar levels of benefit. Likewise whole grain is an area where this technology can provide significant benefits to grain handlers. Whether it be at intake into the mill, on loading a bulk vessel or in the elevator conducting in stream segregation or blending, having real time inline analysis can have significant benefits over bench top techniques.
One novel use for in line analysis might well be fraud prevention. Anyone handling grain has heard a story of someone delivering a load of grain who has taken it upon themselves to mix some poor grain, perhaps high moisture or low protein, in areas of the load where they know the sample spear won’t reach, while putting the good grain on top. With inline analysis, such practices will soon be found as inline analysis takes samples from a much higher proportion of the load as it passes through the elevator. Sure, once the product is in the plant or silo it is too late, but such monitoring combined with appropriate penalties will soon see those wanting to beat the system either stop the practice or at least divert their attention to the receiver who isn’t so alert. The simple fact is that inline NIR is always alert and is constantly checking quality.
Grain
&feed milling technology
FEATURE
Database for animal diet formulation techniques: A glance to last decade
A
number of techniques have been in use for animal diet formulation for more than 100 years.
For an effective animal diet, different nutrient ingredients are combined in such a way that they provide all necessary nutrition at different stages of production. Different class of animal has different requirement of energy to maintain growth, metabolism, reproduction and lactation. While formulating animal diet, other factors are also considered; such as digestibility, acceptability of nutrient ingredients, cost factor and minimum presence of toxic elements. Objective of animal diet formulation is to produce an effective diet at minimum cost to provide appropriate energy to animal.
Fixed vs non-fixed formualtions A number of techniques have been formulated for the purpose of animal diet formulation. Fixed formulation techniques and non-fixed formulation techniques have been derived. Nutrient ingredients formulation cannot be altered arbitrarily in fixed formulation diet. Benefit of this kind of diets is; less amount of variation in dietary composition, controlled diet and less negative influence on well being of animals. But lower quality or lower price nutrient ingredients cannot be introduced time to time in this type of diet because of fixed formulation. While in non-fixed formulation diet, low price ingredients, non-assayed components and required concentration of components can be introduced. Initially, Linear-programming technique was used as main tool for non-fixed formulation. In the era of changing technology, a number of tools and software have been developed in this regard. The past decade has witnessed a great change in the field of animal diet formulation, as it is the high time when optimisation techniques other than linear programming were used very well for the purpose of diet formulation. Chance constrained programming, separable programming, multi-objective approach, sensitivity analysis and other methods used for this purpose have given a new dimension to feed formulation techniques. In this article, an attempt has been made to consider most of the work of last decade.
Linear programming A combination spreadsheet is represented for ration formulation using linear programming [VandeHaar M J, Black J R, 1991]. Chance-constrained programming is used to formulate commercial feeds for animals [William B Roush, Robert H Stock, Terri L Cravener and Thomas H D’Alfonso, 1994]. Two non-linear optimisation problems are formulated as an iterative sequence of linear programming problems 16 | November - December 2011
by Dr Pratiksha Saxena, School of Applied Sciences, Gautam Buddha University, Greater Noida, India
References and further reading may be available for this article. To view references and further reading you must purchase this article.Alan G Munford 1999]. The first is concerned with the problem of meeting the nutrient requirements of the dairy cow in the case when nutrient requirements are taken to be a function of the diet fed. The second problem is concerned with formulating batches of animal feed when raw material nutrient content is variable, and it is necessary to meet nutrient requirements with a given probability. A model is developed to achieve a final calving weight of 600kg for large breed replacement dairy heifers [P R Tozer, 2000]. A smallholder dairy project was undertaken by the Ministry of Livestock and Fisheries Development [MoLFD, the Kenya Agricultural Research Institute (KARI) and the International Livestock Research Institute (ILRI)]. The project is led by the Ministry with primary funding from the UK Department for International Development (DFID) [Muriuki H, Omare A, Hooton N, Waithaka M, Ouma R, Staal S J, and Odhiambo P 2003]. A base linear program is developed and then variability of crude protein content of ration ingredients is incorporated by three methods; right hand side adjustment, incorporation of a safety margin and stochastic programming. Cattle diet is formulated in an Argentinean farm [Jose M Cadenas, David A Pelta, Hector R Pelta, Jose L Verdegay, 2004] by applying fuzzy linear programming. This problem is solved by using decision support systems (DSS) named SACRA (a Spanish acronym for support system for the construction of diets) that is specifically developed for this problem. SACRA is based on PROBO, an already experimented DSS developed by the authors. The tests carried out with SACRA have shown a high level of satisfaction from the side of decision makers. An Excel solver non-linear programming technique was used to optimise performance response to energy density in broiler feed [Guevara V R 2004]. This period can be coded as resolution for optimisation model of animal diet formulation. In these period, linear assumptions of animal diet formulation is overcome by introducing nonlinear programming technique for animal diet formulation [Saxena Pratiksha, 2006]. This technique mainly uses three important nutrient ingredients; Total Digestible Nutrient (TDN), Crude Protein (CP) and Dry Matter (DM). Genetic algorithms are applied for the cost optimisation of the feed mixtures and a software is developed by using Delphi environment, which provides flexible, extensible and user-friendly framework for tuning the heuristic relevant parameters and improving the solution
quality [M Akif Şahman, Mehmet Çunkaş, Şeref İnal et al]. Dynamic programming technique is used to determine optimal marketing and feeding policies for beef cattle [Kennedy J O S 2008]. Open and closed formula laboratory animal diets and their importance in research was described by Dennis E Barnard, Sherry M Lewis, Beverly B Teter, and Julius E Thigpen, 2009. Extensions of the classical Markowitz meanvariance portfolio optimisation model was done by P Bonami, M A Lejeune, 2009. An exact solution approach was proposed in which the uncertainty in the estimate of the expected returns and the integer trading restrictions are simultaneously considered. The proposed algorithmic approach rests on a nonlinear branch-and-bound algorithm that features two new branching rules. A spreadsheet feed problem was set up with 11 ingredients and 11 constraints [W B Roush, J Purswell and S L Branton, 2009]. The LP and SP solutions were determined using the Excel Solver algorithm. Two problems compared LP and SP solutions at 50 and 69 percent probabilities for the protein constraint. Results for the 69 percent probability problem showed a difference in the formulated rations. The LP reduced cost was US$34.25 and the SP reduced cost was US$34.52, showing the respective amounts that the cost of wheat would have to be reduced to be included in the solution. The shadow price and the Lagrange multiplier were US$2.73 and US$2.71, respectively, for the amount of increase in diet cost that could be expected by a unit of change in the protein requirement.
Multi-agent modeling A multi-agent modeling approach [A Hamel, I Bouvarel, S Pinson, M Lessire, P Lescoat, 2009] is used for simulation of vegetal raw material in poultry production chains. This simulation method (Avisim) represents dynamics of raw materials as a feed compound, poultry markets and evolution of individual and collective decision-making process within pulty forms. The purpose of AviSim is to represent the dynamics of human activities and decision to establish the formulation matrix. It works on Java language and simulates the production process and provides the results. The details of the simulation run (exchanges between agents, external events, undertaken decisions, etc.) can also be viewed. This simulation program has four agents, Formulator, Integrator, Purchaser, Manufacturer and Manager. AviSim simulates the poultry production process following four firms functioning layers, which consist of the simulation of (i) the upstream
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Grain
FEATURE
247-1007 • Brabender • Anz. 90x270 mm • Stand 25.03.2011 • englisch
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Brabender® GmbH & Co. KG E-Mail: food-sales@brabender.com · www.brabender.com
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November - December 2011 | 17 25.03.2011 10:22:03 Uhr
PUB85x254-T5X
FEATURE
28/01/10
14:22
Page 1
There are other ways to bind mycotoxins…
T5X
much more than a Toxinbinder T5X has four major actions : T5X binding components have been selected in a sophisticated “in vivo” model. Mycotoxins do not pass through the intestinal wall. T5X stimulates the production of specific natural detoxication enzymes to catalyse the elimination of the mycotoxins. T5X powerful antioxidants inhibit free radicals and prevent cells' membrane from degradation. T5X stimulates the non specific immune system to strengthen animals
Additives & difference a brand of the group
B.P. 394 - 56 009 VANNES Cedex - FRANCE Neovia@evls.net
18 | November - December 2011
dynamics (raw materials market) and raw materials purchase processes (ii) feed formulation (iii) feed manufacturing and the management of raw materials storage (iv) and finally, poultry production planning evolutions. Each agent simulates the activities of corresponding functioning layer. To simulate the dynamics of firm environments (raw materials poultry markets) a conceptual agent is defined, called EMA (Event Manager Agent). EMA generates randomly external events), and firm agents react to these events. AviSim is based on a discrete simulation mode, where each simulation step represents one week of production. The simulation process evolves according to firm production objectives and domain agents behaviours. A multi-objective stochastic model is formulated confronting the cost of the ration with the probabilities of meeting the nutrient requirements of the animal can enhance the process of animal diet formulation [Peña T, Lara P, Castrodeza C 2009]. A method called Precision feeding is proposed to improve the utilisation of dietary nitrogen, phosphorus and other nutrients and thus reduce feeding costs and nutrient excretion [Pomar, Candido 2009]. After determining feed potentials, diet is improved by addition of enzymes or feed treatments.
Using this approach, it has been estimated that feeding costs can be reduced by more than 4.6 percent, and nitrogen and phosphorus excretion can both be reduced by more than 38 percent. A LP technique is derived to investigate, analyze and indicate how best the available local ingredients can be combined effectively and efficiently to formulate least-cost ration for broilers [Bassam Al-Deseit, 2009]. The result of this study showed that the least cost ration for starter broiler produced by linear programming model consists of 68.0 percent yellow corn, 25.07 percent soybean, four percent wheat bran, 0.5 percent fish meal, 0.5 percent Ca diphosphate, 0.1 percent lysine, 0.32 percent methoinine, 0.3 percent limestone, 0.3 percent NaCl, 0.5 percent ready premix, 0.4 percent soya oil and 0.01 percent vitamins and mineral mix. For the finisher ration the results showed that the ration consists of 67.5 percent yellow corn, 20.45 percent soybean, five percent wheat bran, 0.25 percent fish meal, 1.5 percent ca diphosphate, 0.25 percent lysine, 0.35 percent methoinine, 0.3 percent limestone, 0.5 percent NaCl, 3 percent ready premix, 0.75 percent soya oil and 0.15 percent vitamins and mineral mix.
Feed mill and farmer study Another study is conducted [S M Mutua, A Y Guliye, B O Bebe, A K Kahi, 2010] in Nakuru District-Kenya with 78 respondents: 19 feed millers, 37 smallholder dairy farmers, and 22 feed policy officials (10 from KEBS and 12 from NEMA) between September 2009 and April 2010. Data was collected by a pre-tested, structured questionnaire. Dependent variables were classified as: Least cost of ingredients (LCI) issue consisting of nine items, Maximum profit margins (MPM) issue consisting of nine items, Minimum P-levels (MPE) in manure issue consisting of nine items. Correlation between dependent variable items: (least cost of ingredients, maximum profit margins, and minimum nutrient excretion) within each feed industry stakeholder group (feed millers, dairy farmers, KEBS and NEMA) were determined using the spearman’s rank correlation coefficient (r) method. The statistical significance of differences in opinion responses between pairs of feed industry actors for the relative importance of economic, production and environmental goals; were determined using one way analysis of variance (ANOVA) at 95 percent confidence interval (CI) using SPSS for windows. Rank correlations coefficient within feed millers were significant between LCI and MPM (r = 0.54; p < 0.05) and between MPM and MPE (r = 0.46; p < 0.05). The dairy farmers showed significant correlations (0.61; p < 0.05) between MPM and MPE only. Correlation between LCI and MPM (r = 0.64; p< 0.05) within KEBS was significant. The correlations between MPM and MPE within KEBS and NEMA were not significant. The LCI and MPE were not significantly correlated for all the stakeholder groups. The NEMA did not show any significant relationship for any pair of the three formulation objectives. It was concluded that the current singular objective formulation approach is limited in dairy feed manufacturing.
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Grain
FEATURE Sustained feed manufacturing will depend upon finding solutions to such limitations. Solutions to this limitation will include innovations towards the development of broad-based multiple formulation approaches that attempt to collectively optimise stakeholder needs step by step. Application of Genetic Algorithm is proposed Rosshairy [Abd Rahman, Chooi-Leng Ang, and Razamin Ramli, 2010] to obtain minimum cost diet for farmed animal. GA is integrated with other Artificial intelligence techniques that come from bees’ family and is based on Artificial Bee Algorithm. In this algorithm, two types of Artificial Bee Algorithm are considered; Artificial Bee Colony (ABC) algorithm and Marriage in Honey Bee Optimisation (MBO) algorithm. ABC framework is chosen here to increase the exploration and exploitation in basic GA algorithm. By incorporating GA, ABC and MBO, this algorithm is expected to produce great solution for feed mix problem. A linear fuzzy model is developed [D. Darvishi SalooKolayi, A. Teimouri Yansari, S. H. Nasseri, 2010] in which composition based inference function works for single input and single output systems. It demonstrates differencing operation and with extensive limitations, there is collection of responses. Minimise cost 1476.9 and 1222.5 Rial/ kg is achieved at and respectively. The use of fuzzy model approaches allows nutritionists and dairy producers to manage better a heterogeneous population of cows in a herd via for-
mulating the ration. In addition, a nutrition fuzzy model is more mechanistically based and therefore permits a more robust application of scientific knowledge.
Energy density and preformance A non-linear programming Excel Workbook (Microsoft Corporation, Redmond, WA) was developed using the Excel Solver (Frontline Systems Inc., Incline Village, NV) to optimise energy density and bird performance [M Afrouziyeh, M Shivazad, M Chamani, G Dashti, S Amirdahri, 2011]. In this study, six dietary treatments (2.535, 2.635, 2.735, 2.835, 2.935, and 3.035 Mcal of ME/ kg) were fed to Hy-Line W-36 laying hens (n = 192) in phase two (from 32 to 44 weeks of age). Data were fitted to quadratic equations to express egg mass, feed consumption and the objective function return over feed cost in terms of energy density. To demonstrate the capabilities of the model, the prices for eggs, corn and soybean meal were increased and decreased by 25 percent and the program was solved for the maximum profit and optimised feed mix. A feed-formula optimizing system is successfully studied based on Windows 2000 Advanced Server, with SQL Server 2000 database and ASP Web-page language and Linear programming together [XiongBen-hai, LuoQing-yao and PangZhi-hong, 2011]. It has set up one whole calculating platform to design all kinds formulas based on web technique, which can share information of feed science and animal nutrition to help directly designing feed-formulas.
Feed product had been formulated both with linear and stochastic programming on different probability levels with nutrient averages and the standard deviation of a key nutrient in ingredient batches from two vendors [Csikai, A 2011]. Integration between supplier quality management and feed formulation brings the benefits of more consistent product quality, lower costs of rations, accuracy in planning, support in ingredient purchasing decisions, better traceability, improvement of supplier performance, and internal quality management processes.
Digestible amino acids A study was conducted to determine the effects of diets formulation based on digestible amino acids of feedstuffs and nitrogen correctedtrue metabolisable energy on egg characteristics and reproductive performance of Arian broiler breeder in 50 to 64 week of age [Javad Nasr¹+, Akbar Yaghobfar², Yahya EbrahimNezhad¹, Kambiz NazerAdl 2011]. This experiment suggested that diet formulation based on AMEn+DAA significantly increased egg weight, albumen height, Haugh unit, fertility, hatchability and chicken weight. A method is developed to stimulate interest in the generation and application of ileal digestibility as a method for estimating amino acid availability in poultry nutrition [I U Udo and U E Umoren, 2011].
References: Available on request
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November - December 2011 | 19
FEATURE
Mycotoxins
an overview
by Perstorp Performance Additives, The Netherlands
I
t has been estimated that 25 percent of the crops in the world are contaminated with mycotoxins. And this results in an annual loss of foodstuffs of over 1,000,000 tonnes according to the FAO (Food and Agriculture Organisation).
5 Fumonisins (FA1, FA2, Fb1, FB2, FB3 and FB) Most mycotoxins are region-specific. For example DON is mostly found in Europe and North America, while aflatoxins are mostly found in the Southern hemisphere.
Let’s have a look at what mycotoxins are, what sub-types there are, what they do and how a consistent mycotoxin policy can help minimise the damage.
The effects of mycotoxins
What are mycotoxins? Mycotoxins are toxic secondary metabolites produced by organisms of the fungus kingdom - commonly known as moulds such as Aspergillus, Fusarium and Penicillin. One mould species may produce many different mycotoxins and/or the same mycotoxin as another species. They infect crops in the field, can grow on feed or food as it is stored if the environmental conditions (such as temperature and humidity) are favorable. Although thousands of different myco-
“Depending on the mycotoxin and the quantity that has been found, a suitable adsorbent can be chosen to which the mycotoxines adhere and safely pass through the animal without causing harm” toxins have been identified, only 300 are detectable by regular analytical tests. The major mycotoxins are: 1. Aflatoxins (B1, B2, G1 and G2) 2. Ochratoxins (OTA) 3. Zearalenone (ZEA) 4. Trichothecenes (DON also known as Vomitoxin, T2) 20 | November - December 2011
Different mycotoxins have different harmful effects. The consumption of feed containing mycotoxins can lead to numerous problems including reduced immune response, infertility and liver and kidney damage. Aflatoxins are synthesized by Aspergillus spp. and can severely damage the health of animals. In poultry liver damage, inferior egg shell and carcass quality and increased susceptibility to disease are the major symptoms. In pigs the main symptoms after high doses of aflatoxins are feed refusal, reduced weight gain, liver and kidney lesions. Furthermore, aflatoxins can alter the immune response and animal performance. Ochratoxins (OTA) are produced by Aspergillus and Penicillium spp. and are toxic for the kidney where they cause necrosis of the tubules. Off all the mycotoxins OTA is the most toxic for domestic poultry. It is even more deadly for poultry than aflatoxin. In pigs OTA also causes kidney damage which can result in rejection of carcasses. It also affects boar fertility and can affect the unborn foetus. In newborn piglets tail necrosis is often a sign of OTA. Zearolenone is a mycotoxin produced by Fusarium moulds and has oestrogen-like activity in cattle, sheep and pigs. This mimicking of female hormones leads to problems with ovulation, conception and foetal development. Poultry seems to be able to tolerated ZEA well, however turkeys are very sensitive. Trichothecenes are also produced by Fusarium spp. In poultry T2 causes oral lesions which can be used as a field diagnosis.
Furthermore T2 toxin can cause nervous symptoms as well as abnormal feathering, decreased feed intake and egg production. Don and T2 are the most harmful to pigs. They can cause reduced productivity and even infertility in the sow. In addition DON can cause acute diarrhea of suckling piglets with a high mortality. Fumonisins cause impaired immune function, liver and kidney damage, decreased weight gain and increased mortality in most species. It would appear that poultry is less sensitive to the effect of the fumonisins than pigs. The toxin FB1 in swine leads to specific disease called porcine pulmonary oedema which affects heart and lungs. It is also important to note that if feed is contaminated by more than one mycotoxin the effects can not only be additive but even synergistic meaning a far greater toxicity than expected on the basis of each mycotoxin on its own.
Mycotoxin management Besides good farming practice to prevent mould growth and subsequent mycotoxin production it is essential that the producer knows the mycotoxin status of his feed. There is an almost bewildering array of testing possibilities available for mycotoxins but they all stand or fall with the method of sampling. At least 12-20 samples need to be taken from the feed taking care to include samples from the side where mould will more readily occur. These samples need then to be mixed thoroughly and a 500 gram sample can be taken and sent for testing. Depending on the mycotoxin and the quantity that has been found, a suitable adsorbent can be chosen to which the mycotoxines adhere and safely pass through the animal without causing harm. Depending on geographical and environmental factors an absorbent could be indicated all year round or at known critical times.
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Food and Feed Quality Control Reference and Fast-Screening Methods
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FEATURE
Optical sorting Optical sorting has come of age and should be considered as a serious option for inclusion in any modern wheat cleaning plant by Vanessa Emberson, Satake Europe, United Kingdom
O
ptical systems, known better as colour sorters, using visible and non-visible wave lengths and once considered as almost ‘exotic’ equipment, have rapidly advanced to become a mainstream means for separating and grading many industrial and food products including, importantly, cereal grains. The low cost, reliability and speed of modern components, as in so many consumer and industrial goods, has transformed the design and building of optical processing equipment. Consideration can now be given to include optical sorting machines in cereal cleaning plants, whereas they were formerly deemed too sophisticated, unreliable and of low capacity for such applications. In this feature the origins and products of one of the leading suppliers, Satake, are outlined to show how the technology has been developed and applied more widely for its cereal milling and other customers. Satake produced their first sorters in Japan in 1979 during a period when a limit on pesticide use imposed by the government had caused an increase in weed contamination of harvested rice and greater discolouration of kernels due to insect activity. After the successful application of optical sorting technology to the domestic Japanese rice market, and having identified its potential for wider exploitation, they acquired the leading US supplier, ESM International Inc of Houston, Texas during 1992. ESM, Established in 1931, were well known in North America and Europe for their versatile range of sorting equipment, not only for rice but also for grading nuts, beans, sesame 22 | November - December 2011
seeds and even tomatoes and other non-free flowing materials. Satake now have design and testing centres in Japan, the United States and Great Britain from which they offer their new sorting technology. In this report we will look at the area of most interest to our readers for which the new AlphaScan has been developed, while recognising that other sectors such as nuts, pulses, coffee beans and industrial applications provided the impetus for its development.
In the Cereal sectors: Rice as a white and polished finished product should have a pure and lustrous appearance which is easily marred if even small imperfections are visible to the consumer. For such applications, machines are available which have very sensitive charge coupled device (CCD) sensors to detect, with greater discrimination, these small imperfections to substantially reduce good kernels in the rejects. The RMGS type sorter which was designed specifically for such high quality rice applications is equipped with CCD sensors with a resolution of 0.14mm and 2048 pixels and can be also fitted with near infra-red (NIR) sensors to detect pieces of glass, stone or other inert contaminants not even visible to the human eye. Rye is often susceptible to ergot, a fungal infestation that could constitute a health hazard. A sensor operating in the visible light spectrum is effective for detecting ergot that can then be ejected for safe disposal. Satake have over 300 AlphaScan machines in Germany and Scandinavia operating on this application. The AlphaScan is a dedicated
grain and seed sorter that matches each individuals requirements to remove all discoloured contaminants. This affordable sorter will help you produce the cleanest possible product in a compact, small footprint, with high capacities & using high speed digital signal processing technology and with capacities up to 35TPH these machines are suitable for farms, mills and grain stores alike. Maize (corn) can suffer from fungal infestation, particularly as a result of damp harvest conditions. The affected kernels can be detected by optical means, and as a result sorting equipment using high-speed bichromatic sensors has been found to reduce aflotoxin and fumonisin levels in yellow and white maize. Maize destined for breakfast corn flakes benefits from monitoring at the finished ‘grit’ stage to reject particles that would produce discoloured flakes, marring the appearance of a wholesome food product. Seed corn is monitored by monochromatic sensors which also detect and remove broken kernels and thus improve germination levels. Durum wheat used for production of high quality pasta or cous cous needs to be free of discoloured kernels and black seeds which would spoil the appearance and lower the actual or perceived quality of the finished products. Since durum is of higher value than common wheats, colour sorting became well established in durum cleaning plants. However due to the low capacity and high capital and supervision costs of early generation equipment, the sorters were usually used for small scale recovery of good broken kernels from the rejected seed stream. Now it is practical to use sorters for more general rejection of both discoloureds and seeds from the main grain stream.
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November - December 2011 | 23
FEATURE
Brief history 1931: ESM (Electric Sorting Machines) began business in Lowell, Michigan where the first machines were designed to sort the Michigan navy bean. (known elsewhere as baked beans). 1951: new rice sorting equipment had been developed and the company was purchased by Mandrell Industries Inc and moved to Houston to be near the flourishing rice growing and processing region. 1959: Ampex Corporation purchased Mandrell allowing ESM to share development facilities with the Petty Company, a sister organisation. Soon after this ESM introduced bichromatic sorting for raw coffee beans and peanuts.
1992: Satake Corporation, soon after the purchase of the Robinson and Simon milling business acquire ESM, and with their combined know-how began development of further sorter equipment for this and other sectors. The ScanMaster was launched with its high-resolution cameras (CCD) followed in 1994 by the Infra-red version, offering the only true bichromatic and IR machine on the market. 2000s: the establishment of the Vision Systems division of Satake USA Inc., saw the introduction of touch screen controls, increased light intensity and contrast. Ultra violet versions were also introduced for sorting almonds and coffee beans.
1973: Geosource was formed from ESM and a number of oil related businesses. Rapid advances in optics and digital electronics were adopted for the new sorter designs.
2004: The AlphaScan was launched to bring a low cost, high capacity, digital sorting option to the cereals sector for use by farmers, grain elevators and flour mills.
1984: ODISTA created as a holding company with Geosource operating in the oil sector and ESM independently in colour sorting.
2008: The AlphaScan II was launched
Wheat of bread making types is now also being subjected to more stringent cleaning procedures. This is particularly true of wheats of organic origin, or destined for whole grain products where the subsequent milling process does not act to scalp off residual impurities. Organic cereals have often been found to be prone to contamination by seeds of an undergrown crop.
Optical Sorters for cereal cleaning Optical (colour) sorters of the new generation are intrinsically suited to playing a major role in the cleaning of most cereal grains. They are compact, robust, consume very little energy and do not need elaborate ancillary exhaust systems. They are suitable for a versatile role for not only removing foreign seeds and discoloured kernels but they can be considered for removing of stones, glass and other inert contaminants. The latest range from Satake also now includes a full colour machine (RGB) which is a revolution in optical sorting. Both the human eye and the Evolution detect colour through three wavelengths (Red, Green & Blue), allowing the sorter to match the human eye’s ability to see true colour. This full colour sorting machine uses 16 million colours, high resolution cameras & long lasting LED lighting to detect and remove defects. The smallest colour deviations are identified and rejected. The Evolution has the
24 | November - December 2011
2010: The Evolution RGB machine range was launched.
ability to see true colour, precisely sort a wide range of products, even those with small shade differences.
Operation Most manufacturers produce optical sorters that operate on similar principles, the differences essentially being in the detailed design and applications. The granular material to be sorted, in our case cereal grain, is fed by gravity and spread across multiple channels so that individual kernels follow each other in rapid succession down a series of parallel channels. The optical sensors are arranged to ‘look’ at each and every kernel. Once a defect has been detected, a subsequently placed compressed air ejector opens for as little as 0.5 milliseconds at an input pressure of 3 bar (45psi) to remove the substandard particle and blow it to the reject outlet. Sorting machines can be configured to make an initial coarse separation at very high capacities and then re-treat the rejects to give an overall separation with an optimum discrimination. Optical sensors are positioned such that the product is inspected on both sides of its trajectory in order to detect any defects on either side of the kernel.
Applications for wheat cleaning The AlphaScan can be used in a modern wheat cleaning plant & is a new generation of sorter developed especially
for milling applications. In this application it can form the core of the primary cleaning stage when it would follow directly after the Milling Separator and its Aspirator and often replace a series of conventional concentrating and seed separating machines prior to the first temper stage. It can be set to remove black seeds and other foreign grains, ergot, black tip, fusarium as well as burnt and other discoloured grains. Huge savings in space, energy, and air exhaust systems are possible. Alternatively, or additionally, it can form a very effective cleaner after the temper stages prior to first break where the flow rate of the wheat stream is often steadier and a little lower in capacity. Optical sorters with appropriate sensors can also be considered to replace conventional ‘air hungry’ dry de-stoners for removal of stones, glass and other mineral impurities.
Control Most current sorters benefit from the use of reliable and robust solid-state digital control technology. Touch screens, stored ‘preset’ programs and diagnostics all assist the operation of the equipment.
Maintenance Careful attention to the design hoppers, chutes and enclosures minimises build up of dust and consequent need for cleaning. Wipers keep the optical systems clean. Pneumatic ejector valves are robust and have lives of well over one billion cycles. The fluorescent and halogen light sources have a typical life exceeding 3,000 hours & the new LED light sources last for many years.
Food purity The retailer and his consumer public are acutely aware of contamination scares and the need for purity during and after processing of food products and ingredients. The application of leading edge technology to monitor and maintain the expected levels of purity is reassuring. Processors using such equipment demonstrate a commitment to quality and are thereby also better protected against liability claims.
Conclusion Optical sorting has come of age and should be considered as a serious option for inclusion in any modern wheat cleaning plant. Satake has introduced the AlphaScan as an easy to use and economical machine especially to meet the need for removal of foreign seeds and discoloured kernels from wheat, and it has been well received for this purpose. It has benefited from the technologies of their ‘family’ of other sorter types which includes the well known ScanMaster and RMGS products designed for sorting seeds, nuts, beans, industrial products and, of course, rice.
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FEATURE
FOOD SAFETY in the grain milling industry by Urs Dübendorfer, Bühler AG, Switzerland
T
he aim of the millers is to provide a healthy and pure staple food to the consumers. The focus lies on the purchasing and treatment of the raw materials, its processing, the training of the people and precautions in order to prevent a possible recontamination. Food becomes hazardous by contamination. Contamination is the unintended presence of harmful substances or microorganisms in food. Food can become contaminated from chemical, physical or biological sources. In an increasingly complex world, there is a higher risk of food borne diseases. Providing safe flour requires the effort of many partners and various skills within the company. With Bühler as a partner, in understanding the demands and verifying the most adequate solutions and technologies, the changing markets are not a thread but a huge opportunity to fulfil consumer expectations and add value to flour or other products out of the mill. Traditionally, the miller is used and experienced to operate processes, which are
designed to detect and remove foreign matters out of the raw material. Several techniques based on the physical differences in between the particles have been matured during the passed decades and centuries. A contemporary topic in the cereal processing industry is natural toxins metabolised by fungi. These so called mycotoxins are strictly monitored and their removal is a huge challenge for the miller. Since millers are processing a biological raw material, there is always the presence of natural contaminants such as microorganisms. By knowing about the risk and by conducting the processes carefully, the miller is able to minimize the risk of having pathogen germs in the finished products. 26 | November - December 2011
Food safety issues have not be considered as a cost driver or an option, but as a must for the food producing industry throughout the entire value chain from the farm to the fork. In regard of the “Don’t do harm”–approach in machine design, several guidelines are elaborated in order to set up checklists for equipment design. It is an established procedure in Bühler that all the equipment and technology developments are counterchecked to these standards. In the Buhler R&D process any newly designed equipment and processes are cross-checked carefully with regard to: • Clean-ability in- and outside of the equipment • Avoiding of any dead pockets or hidden angles in the process • Undertake all necessary actions to make a re-contamination within the process impossible • All eventual coatings need to be approved for food safety It is the common understanding throughout the industry that the efforts for food safety are not limited to machines and equipment. Modern mill buildings for example do not have windows or at least a quite reduced, screened surface; this is mainly explained by banning the possibility of emissions such as dust or insects. Another building related issue is the clean-ability of the production environment. It should be considered as a standard execution to cover floors with a smooth epoxy layer, likewise corners should be rounded and windowsills must not be horizontal. Having the engineering related topics done nicely, the control of the climate is another very important topic. At the same time it is possible to lift the pressure within the buildings above the atmospheric pressure, this results in higher efficiency of the entire aspiration system and hinders flying insects to get into the mill. Since consumer habits are changing quickly, there is a noticeable impact on flour production. Flours that are downstream processed to convenient foodstuff like frozen dough or semifinished baking goods are supposed to be very
low in microbiological charge. Depending on the sourcing of the wheat, it is not always possible to procure a pure raw material. So Bühler is providing solutions to treat the finished product thermically. The well-known process FHT (Flour Heat Treatment) is used for example to lower the charge of pathogen germs within the flour. For other usages of flour, to assure baking functionality is required a low contamination in microorganisms and an entirely functional gluten. Bühler strives for this reason to mature a new technology of flour pasteurisation. With the upcoming trend of enriching the diet with fibres and other precious constituents out of the wheat kernel, there are new chances for cereal processors to enlarge the portfolio of noble products. The demand for germ and hygienised bran is increasing worldwide, representing a possible niche market for millers. So in conclusion, one can resume to the following basic rules: • It starts with the purchase of the cereals only from crop assured sources. • Check every delivery of wheat for any
food safety hazards and reject wheat, which does not fit for purpose. • Apply HACCP (Hazard Analysis, Critical Control Points) systems through the milling process. • Define different risk zones and assign the people who may access. • Apply proven and certified equipment and technologies only. • Demarcate clearly “High Sanitation” zones like bagging and prevent access.
Conclusion Points to take influence for food safety in grain milling
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November - December 2011 | 27
FEATURE
Recent advances in rapid grain testing by Stefan Tordenmalm, Product Manager, Perten Instruments AB, Sweden
A
ccurate, rapid and reliable grain analyzers are important tools to the grain industry. Whether trading or processing grain, grain quality testing is at the heart of the business. Moisture, protein, oil and specific weight (Hectoliter Weight / Test Weight) are among the most commonly determined quality parameters.
Radio Frequency (RF) moisture meters and Near InfraRed (NIR) analyzers have been used for decades to determine these parameters. While moisture testing is ubiquitous, NIR instruments are used when parameters such as protein or oil must supplement the moisture measurement. This has long been the case for wheat in many countries, and for oilseeds in fewer countries. As more and more markets introduce grain pricing based on factors such as protein or oil content, the interest in NIR instruments increases. Currently there are as many as 10,000 NIR grain analyzers in use globally, and more than 15,000 RF moisture meters. Although previous models have been highly useful for grain grading, recent advances help grain companies become even more efficient.
Benefits of using modern IT Touch screen technology is everywhere today, and is now available in newer grain analyzers. Some of the most recent instruments incorporate large color-touch screens making them easier to operate than older models with often-complicated steps and menus. This helps operators avoid mistakes and costly errors. Modern instruments are built on standardized software platforms such as Microsoft Windows and have USB and Ethernet connections. Users can easily connect printers, barcode readers, wireless communication etc, without being locked in by vendor specific solutions. An obvious benefit is to the simplicity of access to analytical results and exchange of data with
28 | November - December 2011
other applications. Remote service and support is facilitated through internet communication and modern software tools. An example is the Inframatic 9500 from Perten Instruments where TeamViewer software is pre-installed on all instruments allowing support staff to connect securely to instruments regardless of location. More specific improvements to NIR instruments and RF moisture testers are reviewed in the following sections.
NIR grain analysis improvements For readers who are unfamiliar with the basics of NIR technology, we start with a short introduction. As implied, infrared light is used in Near InfraRed grain analyzers. The general principle is that substances such as moisture, protein and fat absorb specific wavelengths of infrared light. The higher the concentration, the more light is absorbed. A parallel is found in how juice of higher concentration is darker than those of lower concentrations (see picture). In the same way we can easily see which glass contains the strongest tasting juice, an NIR instrument can see the difference in protein content between different grain samples. NIR instruments use a lamp to illuminate the sample, and a detector measures how much of the light was absorbed by the sample. A mathematical formula (calibration) is used to derive the protein concentration from the amount of absorbed light. Modern NIR instruments implement the most up to date electronics and hardware meaning significant improvements in accuracy and system performance are achieved. While the general principle is easy enough to understand, designing and building accurate NIR grain analyzers is difficult. Getting good light absorption information from a grain sample is similar to taking photos in the dark without using a flash: you need high sensitivity, low noise detectors and electronics. Expensive, modern cameras produce much better pictures than cameras just a few years old as sensor and signal processing technologies have improved greatly. Older cameras produce noisier photos. The same is true for NIR grain analyzers where the most recent models offer better accuracy. A challenge when building NIR grain analyzers is to ensure that all instruments are identical (i.e. matched), robust,
unchanging over time, and traceable to a fixed reference. Matching instrument hardware allows users to get the same results from the same samples on different instruments. Often labeled transferability as it relates to using one calibration on multiple instruments, transferability makes possible networks of instruments used to analyze and grade entire commodities of grain across a wide geographical area. It ensures payments are made fairly and equitably based upon measureable quality attributes. Newer instruments incorporate several methods for hardware matching. The first is an optics bench made from a single piece of machined metal. Being a single piece, its dimensions and characteristics do not change over the life of the instrument. For the next improvement, itâ&#x20AC;&#x2122;s useful to employ the digital camera analogy. Those who have compared two photos of the same object taken with two different cameras will know that colors donâ&#x20AC;&#x2122;t always match. The photo from one camera might have slightly stronger blues while the photo from the other camera could be stronger in reds. To standardize digital cameras, reference color charts with defined hues of red, blue, yellow and other colors are used. For NIR grain analyzers the equivalent reference is a wavelength reference material, supplied by the US National Institute of Standards and Technology (NIST). The NIST standard consists of several components which each absorb light at a specific wavelength. These can be inserted in the NIR instrument at factory for standardization. This, - in combination with the single piece optics - results in identical individual instruments from a measurement point of view. They produce the same result when analyzing the same sample. As an extra benefit, this creates full traceability back to a fixed reference for ISO and other purposes.
RF moisture testing improvements RF moisture testing is based on the fact that radiowaves of certain frequencies interact with water molecules. In a moisture meter, the sample is dropped into a
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measurement cell containing a radio transmitter and receiver. As the radiowave is sent into the sample and it hits water molecules, it is changed and exits the sample looking a bit different. The moisture meter reads the radiowave as it exits the sample and detects the amount of change. The change correlates to the amount of water in the sample. A mathematical formula is applied to derive the correct moisture content. To present the moisture content in percent, the total sample is weighed, and the amount of water detected is divided by the sample weight. A few years ago, the US Department of Agriculture (USDA) introduced an improvement to RF moisture testing using a 150 MHz signal instead of the older 1-10 MHz. This brought about significant accuracy improvements in moisture testing. Approximately 1,000 instruments worldwide use the new technique. More recently the USDA presented an update to the 150 MHz technology where further improvements were made. Overall accuracy has further improved, and it’s now possible to test moisture with accuracy in frozen grain to -20C. The AM 5200 uses the updated 150 MHz technology and is officially approved in the USA by the National Type Evaluation Program (NTEP). Compared to its predecessor, the AM 5100, repeatability and agreement between
units has improved 50 percent thanks to updates in electronics and improvements in factory standardizations.
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Summary By employing the latest advances in instrumentation, grain handling organizations will be able to grade grain more accurately and confidently. They will also benefit from improved reliability and lower costs of ownership. Whether moisture is the only parameter that is tested, or a wider range of traits are determined, the most recent equipment offers significant benefits compared to the previous generations.
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November - December 2011 | 29
COMPANY PROFILES - 2011/12 Bühler
Perfection in grain milling – a highly demanding task. Antares sets new standards for round-the-clock milling. The self-contained roll pack and reliable product feed ensure precise and consistent flour. Maximum hygiene is guaranteed thanks to clever insulation, integrated product inlet aspiration and stainless steel lining. Experience a new level of ease of use and quality from ergonomic controls and operating reliability to the highly impressive design. Antares – The New Art of Milling.
Bühler AG, Grain Milling, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 66 11 milling@buhlergroup.com, www.buhlergroup.com
Antares MDDR-600. Small Roller Mill for High Requirements. Compact dimension. Four-roller mill with roll length of 600 mm Sanitation. Top hygienic standards for food safety. Outstanding precision. Ultra-precise settings, consistent flour. Perfect grinding. Powerful roll pack, highly consistent grinding. Ultimate design. The perfect combination of ergonomics and performance.
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From the local iron foundry founded in 1860 to the global corporation. Bühler delivers leading technology and solutions for processing grain into safe and healthy finished products. Bühler stands for straight forward and cutting-edge solutions. State-of-the-art process technology, innovative plant engineering and a deep knowledge of the related processes maximize both quality and product yields. But there is even more to it: Bühler know-how also enables customers to create the most cost - and energy-efficient process solutions from stand-alone machines to complete plants. Innovation. One of the key terms in this connection is innovation based on the art of engineering. Without an additional healthy dose of enthusiasm and persistence, the spirit of discovery so typical of Bühler would never have thrived. Time and again, this spirit has enabled the organization to roll out firsts in the global marketplace, for example in the field of roller mill development. Quality leadership. This attribute is manifested in quantifiable and transparent quality targets which are defined in an open dialog with our customers so that promised performance is achieved and the edge in confidence can be further increased. Focus on solutions. Focus on solutions means to center all efforts on our customers’ profitability. This requires an understanding of and a capability to improve their complete value chains and thus to offer our customers an edge in performance over pure equipment manufacturers. Global reach. Bühler has been a global player for many decades, with a multicultural team and a local presence extending across all the major markets of the world. This edge in availability, whose significance will further increase in the future, pays off in the results it allows to be achieved.
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Chief Industries UK Ltd Chief Industries UK Ltd, and Phénix Rousies Industries in France, are part of the Chief Industries Inc. Group based in Nebraska, USA. Together, the Chief companies manufacture and supply a comprehensive range of top quality grain storage silos, grain dryers, grain cleaners, conveyors and ventilation systems for worldwide distribution.
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If you need a partner with the expertise, technology and manufacturing methods to ensure that your storage plant is second-to-none in terms of quality and processes, then look no further.
Chief Industries has over 50 years experience in grain handling systems, incorporating stateof-the-art design and manufacturing, supplying flat floor silos with capacities ranging from 30 to 30,000 tons, hopper bins with capacities ranging from 2.5 to 1,400 tons, and grain dryers capable of drying up to 300 tons per hour. By designing complexes of a number of silos, the grain storage and drying possibilities are infinite. Manufactured from high quality galvanized steel, Chief’s storage installations last for many years. Chief UK has seen significant growth in 2011, particularly in sales of grain dryers, which are manufactured at its own factory in the UK for worldwide supply. The home market has also shown greater activity, which has been helped by taking over the representation of Marot cleaners in the UK, which are also represented by Chief in Ireland, Australia and New Zealand. With a good team of experienced personnel Chief UK can provide top quality solutions, whatever your requirements in grain storage and quality.
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30 | November - December 2011
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COMPANY PROFILES - 2011/12 Increase profitability with Hydronix Moisture Measurement Controlling moisture at the correct level throughout all stages of processing can be one of the biggest problems for feed and grain manufacturers. Too wet, and the raw material can become mouldy during storage or sticky during processing. Too dry and it will become brittle and turn to ‘flour’ or dust. Either circumstance leads to waste and therefore directly impacts on profit.
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Microwave moisture sensors are not affected by dust, colour or vapour arising from processing and have proved to be the most cost effective, reliable and easy to use method of controlling moisture in grain and feed manufacturing. Raw materials are passed across the ceramic faceplate of the sensor which radiates an extremely low powered electromagnetic microwave field. The resonant frequency of the material changes with variations in moisture content, and with 25 readings taken per second, the sensor detects changes in moisture levels almost instantaneously. This allows adjustments to the water addition process to be automatic and in real time. A perfect system would have sensors positioned throughout all of the various elements of the processing plant. Hydronix have a range of sensors that can be positioned in a variety of different locations depending upon specific requirements. The Hydro-Probe is designed to be located in the neck of a bin, underneath the gate, or in the material on a conveyor, and takes readings as the material flows around the sensor. For applications with a high ambient temperature, the Hydro-Probe Orbiter can be mounted above belt conveyors. Finally for applications that use a screw conveyor, chute or mixer, the Hydro-Mix is a flush mounted sensor that enables the material to pass across the faceplate. Hydronix has 30 years experience in moisture measurement, and is the original developer of the digital microwave moisture measurement method. Tel: +44 1483 468900
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Muyang Muyang is a leading global integrated solution provider in machine building and engineering service for feed and grain industries. The group delivers competent one-source solutions for feed mills, rice mills, grain storing silos and handling facilities with advanced technology, efficient equipment, professional installation, complete support and service including steel structure buildings and civil engineering, Innovation is the key term in keeping technology-leading. Committing to the sustainable development of customers and environment, Muyang keeps focus on developing cost- and energy-efficient solutions to create customers a leading ship operation with higher product quality and output.
Keeping technology-leading, getting nearer to customers, and a history of over 3,000 feed mill projects and about 2000 grain storage facilities implementation all over the world, will further enable Muyang to define the specific requirements and demands of each operation and to develop the value-created customized solutions.
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November - December 2011 | 31
COMPANY PROFILES - 2011/12
“Go to market and create value for customers”. Taking this as a guide, Muyang has set up a strong international sale & service network with 30 overseas offices, eight liaisons, eleven service centers and a presence over 80 countries in 2011. And over 200 professional salesmen and service personal are fostered and sent out with qualification, professional skills as well as social and linguistical knowledge to come closer to customers and offer them better and faster service. It is believed that through a solid international sales & service network and plus about 40 overseas agencies, the customers can find Muyang wherever they are and be served whenever they need.
COMPANY PROFILES - 2011/12 Project Organisation Alexander Torlach GmbH Project Organisation Alexander Torlach GmbH is based in Freilassing, Germany. We have a well-established reputation for providing professional, high quality solutions to our clients on an international level, serving the flour and bulk solids industry. Our company exports new and used machines, equipment and parts for flour and feed mills and bulk handling industry. We are experienced in plant erection and maintenance services since more than 20 years in many countries all over the world.
international
Our services are also covering the sales of complete and used milling plants, including disassembling, relocation and start up. We are acting as an EPC contractor, and in addition, we provide our clients with single services, which include engineering, handling and shipment as field installations. We also provide project logistics such as export and shipment. Our core business is high-grade equipment, especially from German and Swiss manufacturers. New, rebuilt or second hand, in our warehouse in Bavaria, Southern Germany. Our equipment ready for shipping covers more than 1.200 square meters. In the unlikely event that we do not have what you are looking for in stock, we will deliver this to you as quickly as possible and for the best price available. Your provider for the bulk solids and milling industry – True German quality!
True German Quality! Your provider for the bulk solids and milling industry. Breslauerstr. 41a DE - 83395 Freilassing Germany Tel +49-(0)8654/77669-0 info@torlach.com www.torlach.com
www.torlach.com
RETSCH – Solutions in Milling & Sieving RETSCH is a global company dedicated to providing novel technologies and high quality tools for the sample preparation and characterization of solids used in R&D and QA applications. Many decades of experience have made RETSCH the world’s leading supplier of crushers, grinders, sieve shakers and test sieves.
SAMPLE PREPARATION OF FOOD AND FEED
The product range includes laboratory mills for coarse, fine and ultra-fine size reduction as well as homogenization. They produce a perfectly homogeneous, unaltered and uncontaminated sample so that the subsequent analysis is always trustworthy and meaningful. The sieve shakers and test sieves are used for optimum quality control of solid materials. RETSCH is the only company to produce test sieves fully automatically; the manufacturing process, which is unique in the world, ensures highest product quality.
COMPANY PROFILES - 2011/12
Product range Milling
Sieving
Assisting
■ Jaw Crushers
■ Vibratory Sieve Shakers
■ Sample Dividers
■ Rotor Mills
■ Horizontal Sieve Shakers
■ Feeders
■ Cyclone Mills
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■ Dryers
■ Cutting Mills
■ Air Jet Sieving Machines
■ Cleaners
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■ Disc Mills ■ Mixer Mills ■ Planetary Ball Mills
If you require professional solutions that combine high performance, ease of use, a maximum of operational safety and a long lifetime, then RETSCH’s equipment is your only choice!
www.retsch.com 32 | November - December 2011
www.retsch.com &feed milling technology
Grain
COMPANY PROFILES - 2011/12 Cultura Technologies Bringing Agri-Food Solutions to Life Cultura Technologies provide specialist agri-food software solutions to some of the world’s leading agri-businesses. Utilising the latest technology, Cultura offer bespoke, scalable and flexible software solutions written in collaboration with leading agri-business experts from the industry for the industry. We offer a wide-ranging level of pre and post sales consultancy, project management, training and customer support in the following market verticals: Feed Manufacturing / Grains & Oilseeds / Commodity Trading / Seed Processors / Maltsters / Merchants / Speciality Crops – Fruits and Vegetables / Bio-fuels Cultura’s name has its roots in the Latin word “agricultura” -- which is Latin for agriculture -- and “cultivate” -- which is to foster growth or development. Our company culture is people-focused. We believe in strong customer relationships and that the strength of our people and their expertise can make the difference in delivering customer-centric solutions that enable Agri-Food businesses to efficiently produce, process, and deliver quality food and bio-products. Cultura is all about connecting people and processes across the broader Agri-Food supply chain, helping to nurture Agri-Food advancement through technology. With offices in the UK, USA and Corporate Headquarters in Canada, we welcome enquiries from Europe, Africa, Asia, Australia and The Americas. We are Cultura Technologies. We bring Agri-Food solutions to life. For further information, please contact the UK sales and marketing department on +44 (0) 1257 231011, alternatively you can email us at info@culturatech.com
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COMPANY PROFILES - 2011/12
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November - December 2011 | 33
COMPANY PROFILES - 2011/12 NUTREX Nutrex is a leading supplier of innovative, top quality additives for the flour milling & animal feed industries, with headquarters in Belgium and an expansive global distribution network. In it’s dedicated facility in Belgium, Nutrex produces an extensive range of enzyme solutions (Nutrase) and flour improvers (Nutrimco) for the flour milling industry. At its production sites in Belgium and the Netherlands, Nutrex manufactures a full range of feed additives including NSP enzymes, mycotoxin binders, immunonutrition products, watersoluble supplements and yeast derivates.
Milling & baking enzymes
Flour improvers
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Nutrase Xyla is a unique bacterial endo-xylanase with special properties that considerably improve digestibility of corn and wheat diets for poultry and swine. Free-Tox is a range of selected indigestible adsorbents that bind mycotoxins in the gastrointestinal tract and prevent their uptake into the blood Y-Mune and Nutracid Intestim are new, innovative products for poultry and pigs that support growth and improve feed conversion by modulating the immune system, stimulating villi growth and increasing absorption capacity Nuvisol products are range of water-soluble vitamin supplements, specifically formulated for administration through the drinking water Y-MOS & Y-Boost are derived from high quality bakery yeast used in feed to support the development of young animals Our food and feed products are developed in close cooperation with leading research institutes around the world and supported by solid independent research and top performance.
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Nutrex prides itself in providing the finishing touch for nutrition by consistently adding high value to its customers’ and users’ products, allowing them to save more costs and improve performance.
www.nutrex.be 20111128-GFMT-Milling.indd 1
2011/11/28 15:31:34
Sizer 2011 has been a great year for Sizer and we are hoping that 2012 will be even better! Despite a difficult start to the year with the worldwide economic downturn, we had an excellent response when exhibiting at Victam International, Cologne in May. Contacts made during the show have led to us securing agents/customers in new European markets, which have made a very welcome addition to our existing worldwide network. ®
pelleting solutions
COMPANY PROFILES - 2011/12
Sizer....The future of pelleting since 1899
In view of this success, we are excited to be exhibiting at Victam Asia 2012 in Bangkok. The last time we exhibited at Victam Asia was in 1991, so our long awaited return is drawing close and preparations are well underway. Our aim for Victam Asia 2012 is to secure new agents/distributors for our comprehensive range of pellet press spare parts in the Asian market areas not already covered. As well as spares for our own Orbit Pellet Press range, we also offer parts to suit many other manufacturers such as CPM, Buhler & Simon Barron. We even supply parts discontinued by other manufacturers, giving you peace of mind that you’ll have continuity of availability. Our pelleting knowledge and technical engineering expertise combine together allowing us to offer solutions that not only suit our customers’ needs but help them deal with their challenges and remain at the forefront of their industry.
Whether you are looking for a pelleting press, a full production line or just spare parts, Sizer Pelleting Solutions makes a positive difference financially and environmentally. Telephone: +44(0)1709 724279 or email us: Suzanne Birley: suzanne.birley@sizer-pelleting.co.uk
www.sizer-pelleting.co.uk The parent company of Richard Sizer Ltd. Established 1899
34 | November - December 2011
Our Commercial Manager, Suzanne Birley is leading the team for the Victam Asia 2012 exhibition. Suzanne has been with the Sizer Ltd for 8 years and manages the International Development of the company. She will be available on our stand for the full duration of the show. We look forward to a successful show and to seeing you there! Please come and visit us on stand no. D045 – Victam Asia, BITEC Bangkok | 15-17 February 2012.
www.sizer-pelleting.co.uk &feed milling technology
Grain
GLOBAL GRAIN & FEED MARKETS
Every issue GFMT’s market analyst John Buckley reviews world trading conditions which are impacting the full range of commodities used in food and feed production. His observations will influence your decision-making.
At this early stage, some pundits are looking for modest growth in next year’s US soyabean plantings and, given normal weather a possible larger crop. The outlook for EU 2012 rapeseed output is uncertain at this stage with good weather boosting winger sowings in much of western Europe but too much rain delaying and downsizing plantings in Germany, normally the top producer, and too little moisture threatening prospects for some southern/eastern member states.
36 | November - December 2011
Lowest grain costs in over a year
G
ROWING supplies and renewed fears of global economic recession cramping demand have slashed grain prices again in recent weeks. As we go to press, market leaders wheat and maize are a good 25% below their 2012 peak prices, trading in some markets at their cheapest levels in well over a year – and there may be more downside to come. Although the EU wheat market itself looks in fairly fine balance this season (i.e. a forecast marginal change in ending stocks), world wheat supplies have clearly been moving into a surplus position as 2011 crop estimates continued to grow, led mainly by the ‘Black Sea’ (CIS) countries. What reaction should wheat prices offer to this ever loosening supply? Are they now cheap enough to reflect the known ‘fundamentals?’ One might as well ask, did they ever really merit going as high as they did in February of this year (almost $9/bu, about $330/tonne) on the bellwether Chicago futures market. After all, while last year’s Russian crop failure and wet harvest/quality issues in Canada, Australia and Germany deservedly put a firework under the market, world wheat stocks fell by a mere 2.4% and remained at their fourth highest level of the past decade. This inevitably again begs the question, what role did speculators really play in driving up wheat and maize prices in 2008 and 2011? Did they overreact to fundamentals and are they now doing the same now on the downside amid the ‘risk aversion’ generated by the bleak global economic outlook. (some of the selling of grain futures by ‘managed money’ is also thought to be a cash raising exercise to margin recent huge losses on US and other global stock-markets). Many traders and analysts think wheat prices would even now be far lower than the recent $6/ bushel (about $220/tonne) recently trading in Chicago, were it not for the high price of maize
which has maintained its highly unusual premium to wheat into latter 2012. With wheat supplies far more abundant than maize and plenty of lower grade wheat from the milling quality problems mentioned above, feeding of wheat to livestock is already expected to rise by about 14m tonnes to 126.4m – almost a fifth of total world wheat consumption. If wheat prices dipped seriously on their own loose fundamentals, the rationale goes, feed demand would go even higher. Some of this feed gain for wheat is taking
place in the US, Europe and the former Soviet Union, some if it a straight switch from maize in importing countries in Asia and elsewhere. Looking to the medium/longer term for wheat, first indications for 2012 crops suggest higher planted acreage as farmers continue to respond to relatively high prices in Europe, the USA, probably other regions too – so even more wheat. Already some pundits are fretting about the price of wheat descending to levels that leave farmers little or no profit as it did two seasons ago (Chicago wheat collapsed to $4.50s/bushel - $165/ tonne - as soon as December 2008 from a peak of $13 - $478/tonne in February of that year!). We have consistently maintained in this column, ever since the Russian crop failure that prices this time were more likely to come halfway rather than all the way back to those lows. One reason is that costs of production have risen – inputs, land etc all saw an above-inflationary jump when the base prices for grains doubled. Another reason is the other factor behind
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Grain
COMMODITIES
the two grain price booms of recent years – bio-fuels. Is bio-ethanol - after a period of relatively flat growth – about to start mopping up any surpluses as grain costs fall? US corn ethanol production has already been looking with the slide in maize prices (although the scheduled ending of blending subsidies in 2012 might also be encouraging a ‘make hay while the sun shines’ push in this sector). It’s interesting to note that the main growth in US corn ethanol production now is in exports rather than domestic consumption – so US feed corn users, traditionally the main outlet for maize, are still paying relatively high prices, not just to wean US drivers off dependence on foreign oil but to help fill car vehicle fuel tanks in Brazil and Europe. Although the UK/European grain ethanol industry has had its well-publicised problems, one might expect lower grain costs to have an impact here too. The same applies to a host of countries who had been thinking about using more grain as a renewable fuel source before rising grain costs spoiled things Will broader feed demand in China and other emerging economies maintain the rapid pace of recent years in the current uncertain economic climate? China has been the biggest single factor driving up feedgrain demand in recent years, raising its consumption by 43% or 44m tonnes in the past decade to account for 56% of world growth in this sector. Recent Chinese official forecasts suggest 4-5%
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Grain
per annum growth will continue in its feed demand for the next five years. That will need 6/7m tonnes more grain fed in 2012/13
and each year after that to 2015/16 . Will China’s domestic crops keep pace? Official figures suggest they have so far but western
November - December 2011 | 37
analysts think this has been at the expense of running down reserve stocks and that imports, especially of maize, will play a far larger part from next year onwards. However, China has a habit of springing surprises on the market. While it has been buying far more foreign maize this year, it has not yet lived up to the bullish import forecasts of the US Grains Council and others. There is also the possibility that its own economy may slow, putting the brakes on its expanding meat consumption. Another question is whether US demand for feedgrains - running 10/12% lower for the past two seasons – will perk up next year under these economic conditions? Mixed messages have been coming from the livestock sectors, more encouraging for cattle and pigs than for poultry. European grain feeding is also down about 7% still from its 2008/9 level. Will that pick up in 2012? For oilmeals, led by soyabeans, the prospect is largely encouraging. The US did have a smaller than expected soya crop this year, considerably under last year’s, but lower crush and exports will keep stocks from getting too tight before season’s end. Latin American soya crops have meanwhile gone in quickly and are getting good weather, promising earlier than usual, possible record harvests next spring. US soya exports are already down amid Latin American competition from the region’s huge 2011 crops which left record stocks to dispose of this autumn at a time when the US usually has the market to itself. This, along with the drop in grain prices and the macro-economic gloom has brought soya costs down sharply too and, if all goes well with the Latin American crops in the next few months, further price cuts might not be ruled out.
Main commodity highlights since our last review Wheat – further price cuts possible European markets in recent weeks have taken much of their lead from the US markets, especially the Chicago futures, where nearby wheat deliveries during November were trading at some of their lowest levels since July 2010. The Paris futures market fell to a new low of €179/tonne on the front month
38 | November - December 2011
from its September highs of €209. It’s hard to believe that this market was trading €281 in February when ‘skies the limit’ pundits talked of an assault on €300. UK feed wheat has also dropped to about £143 from February highs of £214/tonne. Despite drought threats to the US hard red winter crop, expor t prices for this grade dropped to $284/tonne in mid-November compared with $310 at the time of oir last review. Quality spring wheats had been the firmest sector after the USDA revised down its US crop estimate in November, pushing fob value up from $390 to $409/tonne. However, these too appear to be easing on lack of domestic and export demand a these levels and reports of much better quality from this year’s Canadian crop. Most of the credit for cheaper wheat goes to the ‘Black Sea’ former Soviet producers who have raised their combined wheat output by 31.5m tonnes, 13m more than most pundits expected back in the summer. Relentless, aggressive sales by Russia and latterly both Ukraine and Kazakhstan have virtually dominated the world import markets, undercutting US and European grain by as much as $30/50 per tonne, depending on types and grades. Top importers like Egypt and other Middle Easterm/North African countries have been only too pleased to reap this bonanza, shunning the US, Europe and other countries that baled out FSU shortages during last season’s Russian export bans and Ukrainian quotas, duties etc. Along with gradually descending maize prices (to which wheat has pinned its fortunes this year), this intense export competition has been the biggest factor driving down Chicago and European grain futures markets. Wheat output is also up this year by more than expected in Europe and China (about 2m tonnes each), India (+5m), Canada (1m). Even a 5.7m tonne crop decline for the leading exporter, the USA, has been overwhelmed by the staggering 40m tonnes added to output elsewhere. As a result, world wheat output is currently expected to finish 2011/12 at about 683m tonnes but it would not be surprising to see that creep up over 685m when all the Black Sea crops have been fully counted. That’s about 20/25m more than predicted in July. Wheat consumption on the other hand is seen rising this season by about 23m tonnes. That’s above the long term trend, thanks to the boom in wheat feeding, but it will still lag production by enough to add at least 6m, maybe 10m or more (when all the CIS crops are in) to global ending stocks by mid-2012. These are already forecast at a 10-year high of around 203m tonnes, a stock/use ratio of 30% about 15.6 weeks supply. Early forecasts from the International
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Grain
COMMODITIES Grains Council suggest world plantings for 2012 will increase by 1.6% top 224.6m ha, the biggest rises in North America and the CIS. Although total US area could be as much as 7% higher, questions linger over the impact of dry planting conditions affecting about 30% of the key hard red winter crop, the biggest component in US expor ts and domestic breadwheat use. Recent rains have helped
considerably and current projections are for a bigger crop than last year’s. EU sowings are also seen up amid generally favourable weather in northern member states but some dryness issues in the south/east. Driven by this year’s good crops and successful exports (at still relatively high prices), Russia is expected to sow about 5% more. First tentative estimates for 2012 output have been around 690/695m
tonnes. However the global out-turn will, as usual, depend more on weather and yields than acreage changes. Yields, for example, fell 3.3% in 2010 but recovered by almost 7% this year, achieving a record average 3.1 tonnes/ ha. That’s all the more remarkable when one considers the challenges faced by late sowing in Canada, droughts and heatwaves in Western Europe and other weather issues.
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November - December 2011 | 39
FACTORS IN THE MONTHS AHEAD • Big Ukrainian and Kazakhstan crops are stepping up their 2011/12 exports, willing and able to fill the ‘cheap wheat’ vacuum once Russia starts to wind down its own aggressive 2011/12 campaign. • But can landlocked Kazakhstan get the grain out fast enough through Russia (clogged with its own record grain traffic) or Ukraine (heading the same way as it markets record maize versus wheat exports). And how much quality milling will Ukraine actually have as opposed to lower/feed grades?
• Will the Ukraine and the USA yet pull reasonable 2012 crops out of a challenging dry autumn/early winter period? • Will the US plant a lot more spring wheat in 2012 to make up for this year’s shortfalls?
Coarse grains – Unlike wheat, maize is still a fairly tight market on paper. The US crop has turned out smaller than expected, lower than last year’s by 3.5m tonnes and about 8m under estimated domestic and export needs. The tighter ending stocks resulting, their lowest for decades in terms of consumption, are keeping some of the speculative money on board in the Chicago futures market (although much of it jumped ship on the most recent price drop in November). Another restraint on maize prices is the relatively looser foreign supply. Thanks to record crops in the former Soviet Union and expected big harvests in South America next year (not to mention the EU’s own record
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crop), world output is up by 30m tonnes this season against a consumption rise of 22m. As in the USA, this will still leave world 2011/12 ending stocks (next September) about 7m-8m tonnes down and very low in relation to consumption needs. This is more encouraging for die-hard maize bulls and demands a larger world maize crop next year. Currently, pundits are predicting the US will sow more maize next spring but, as always, area will depend on relative corn prices versus soyabeans and on the weather, which can cause huge shifts in acreage to soyabeans if maize planting gets delayed. Until these uncer tainties are resolved, in second quarter 2012, there is always the possibility of another bull run on maize prices and where maize goes, wheat must follow. For the moment, however, the competition from South American and the former Soviet Union is setting a low world import price, considerably below US fob and Chicago futures levels. So is the abundance of feed wheat mentioned above. US maize exports are falling behind official forecasts amid the competition and while these only make up about 12% of US maize disposals (the rest split mainly between feed and ethanol), this has been weighing on prices. For the EU itself, maize supplies have been boosted by a record crop around 64.7 tonnes compared with last year’s 55.8m. Demand is expected to expand by about 2m tonnes, using up all the extra supplies but imports will drop away sharply from the past season’s unusually large 7m, probably to about half that level.
FACTORS IN THE MONTHS AHEAD • China’s maize ‘deficit’ remains a live issue. If maize prices fall further it may take a lot more imported maize after all – bullish for prices
• How much maize will the US sow next spring? Probably more than this year • Will Ukraine sow even more maize next spring on land vacated by failed/unplanted winter wheat and bartley crops? • Global economic problems continue to erode consumer confidence, negative for meat/feed demand and a continuing restraint on grain & oilseed prices
• Speculators’ interest in commodities – likely to be more evident in maize due to the tight forecast US/world ending stocks for 2011/12 – spring planting time could see them return as buyers if the weather plays up • Ethanol competition for maize supplies – could resurge if maize costs continue to fall – helping prices find a bottom
Oilmeals cheaper too Since our last review, soya meal prices have come down by about 15% on the US market, putting them about 26% below their August highs and at their cheapest level since June last year. Meal prices have fallen as soyabean supply prospects have improved – the lifting of a threat of tight US end-season stocks and a far better outlook than expected for the coming Latin American crops.
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COMMODITIES Although USDA is currently predicting world soyabean production about 5m tonnes lower for 2011/12, the gap may shrink if the South American crops exceed current forecasts for a mere 2m tonne increase in this region.
their meal production up amid the smaller 2012 crop. At this early stage, some pundits are looking for modest growth in next year’s US soyabean plantings and, given normal weather a possible larger crop. The outlook for EU 2012 rapeseed output is uncertain at this stage with good weather boosting winger sowings in much of western Europe but too much r a i n d e l ay i n g and downsizing plantings in Germany, normally the top producer, and too lit tle moisture threatening pr ospec t s for some southern/ eastern member states.
• Relative soya/maize prices & weather when the US plants next spring • EU winter rapeseed plantings - up or down for 2012?
Based on high bean prices and good weather at planting time – and plenty of moisture since – it would not be surprising to see more than this coming out of Latin America. Either way, world soyabean crush will still rise by about 10m tonnes, boosting meal supplies by about 8m or so. About half of that increase is expected to be consumed within China, 1m tonnes or so within the EU, 500,000 in Brazil, the rest spread over a number of smaller users. Higher EU soya meal usage is replacing • Latin American rapeseed meal after a smaller European canola soyabean crop weather crop cut domestic rapemeal production. The EU’s large 2011 sunflower crop will also • Chinese expand use of this meal by about 600,000 consumption and tonnes but soya will retain its usual dominant timing of imports 60 % mar ket sha r e of t he p r ote i n m e a l silos ships sector. Globally there is no shor tage THE UTMOST of meal supply, BULK RECLAIMER to which soya will contribute about 70% . This is thanks to a r ecor d wor ld simple, maintenance free, automatic, efficient on most bulk products*, unbeatable reclaim rates sunflower crop * cereals, oil seeds, sugar, flour, soya bean meal, wood pellets, wood chips, fly ash, cement, sulphur, charcoal, RDF etc… (Russian and Ukrainian output VIBRAFLOOR F-71680 Givry +33(0)385 440 678 +33(0)680 964 144 vibrafloor@vibrafloor.com also soa r e d ) , wagons domes a big leap in containers cottonseed/ meal production and r apeseed crushers drawing down carryover stocks to keep
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42 | November - December 2011
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• • • •
Flour improvers Enzymes Baking premixes Advice on applications
Kurt-Fischer-Strasse 55, D-22926 Ahrensburg Tel.: + 49 (0) 4102 / 202 001, Fax: -010 info@muehlenchemie.de A member of the Stern-Wywiol Gruppe
Ein Unternehmen der Stern-Wywiol Gruppe
&feed milling technology
Grain
Pag
Classified section Grinder hammers John Staniar & Co.
Packaging
Rolls
• Arodo BVBA
Other
• Andritz Feed & Biofuel BV • Kay Jay Chill Rolls Pvt Ltd
Grinder Screens A Clondalkin Company
FLEXIBLE PACKAGING
John Staniar & Co.
Level measurement CB Packaging is a market leader of multi-walled paper sacks. With over 50 years of experience, we offer solutions for a wide range of industries, including animal feeds, pet food, seeds, milk powder, flour and root crops.
• Millson Engineering Limited • Muench-Edelstahl GmbH
Silos
For more information, please call Tim Stallard: +44 (0) 7805 092067 www.cbpackaging.com
Yingchun Group
Process control • • • •
Grain Silo Manufacturing
Converteam UK Ltd Datastor Systems Ltd KSE Protech BV RED-BERG s.r.l.
Buhler AG CH – 9240 Uzwil, Switzerland T: +41 71 955 11 11 F: +41 71 955 66 11 E: milling@buhlergroup.com
Tel: +86 546 8313068 Email: ycgbc@silo86.com
www.silo86.com
Analysis & Control
Equipment for sale
Intake and Inline measurement of moisture, protein, temperature, structure, ash, fat, fibre, starch and colour. Recipe management and traceability records.
Shangdong_class.indd 1
Condex (UK) Ltd
29/03/2011 11:20
2011/12
Mill Design & Installation
www.buhlergroup.com ®
For maximum control and efficiency call:
Buhler Class ad_GFMT10.indd 1
11/12/2009 09:07 www.suffolk-automation.co.uk
01473 829188
Recruitment
HANDLING TECHNIQUES
“Turner” Flaking Rolls 30 ins complete with drive.
• TekPro Ltd • Wallace & Associates Inc. • Younglove Construction LLC
Large flaking roller by “Damman & Croes” Belgium
complete with two x 30kw motors,rollers 24 ins diameter x50 ins wide very heavy duty
For more information Tel: 01453 826016
FOR SALE
• AGRI-Associates • Agribusiness Recruiters
OUT NOW CL_Handling_techniques.indd 1
&feed milling technology
Grain
22/09/2011 13:54
November - December 2011 | 45
Events 2011
8th - 10th December 11
december 2nd - 3rd December 11
*
3rd National Conference - Sensible Grains Sector Policies for 12th Five Year Plan (2012-2017), New Delhi, India Contact: Raj Kapoor, Assocom-India Pvt. Ltd, Flat No. 601, DDA Building, District Center, Plot No.4, Laxmi Nagar, Delhi - 110 092, India Tel: +91 1147675218 Fax: +91 1147675201 Email: rajkapoor@assocom-india.com Web: www.assocom-india.com
* China Animal Health Products Approval and 2nd - 2nd December 11
Registration Seminar 2011 Kuntai Royal Hotel Bejing, China Contact: Jean Chen, 14F, 390 Panyu Road, Shanghai China, 200052 Tel: +86 21 5258 8005 Fax: +86 21 5258 8011 Email: jchen@duxes.cn Web: http://www.duxes-events.com/ahs/
*
Livestock Philippines 2011 Expo & Forum – 1st International Feed, Livestock & Meat Industry Show, SMX Convention Centre, Manila, Philippines Contact: Ms. Michelle Ha/ Ms.Miza, Suite 1701, 17th Floor, Plaza Permata, 6 Jalan Kampar, Off Jalan Tun Razak, 50400 Kuala Lumpur, Malaysia Tel: +603 40454993 Fax: +603 40454989 Email: support@ambexpo.com Web: www.livestockphilippines.com
2012 january 16th - 18th January 12
*
1st ICC India Grains Conference, in Partnership with ICRISAT New Delhi, India Contact: Anita Habershuber, Event Management, ICC- International Association for Cereal Science and Technology. General Secretariat. Marxergasse 2 1030 Vienna, Austria. Tel: +43170 772 027551 Fax: +4317 077204 Email: anita.habershuber@icc.or.at Web: http://india2012.icc.or.at
24th - 26th January 12
*
7th - 9th February 12
31st January 12 - 1st February 12
*
7th - 10th February 12
8th - 9th February 12
february
*
ISRMAX India 2012, Chandigarh, India Contact: Geetika Malhotra Asudani, Pixie Consulting Solutions Ltd, #923/9, Urban Estate, Karnal, Haryana, India Tel: +91 9991705003 Fax: +91 1842231050 Email: Isrmex@pixie.co.in Web: www.isrmexindia.com
New Delhi I Mexico City I Cape Town I Sao Paulo I Cairo I Warsaw I Atlanta I Bangkok
http://www.pix.org.au
*
Ildex Bangkok, BITEC, Bangkok International Trade & Exhibition Centre, Bangkok, Thailand Contact: Mr. Jobe Smithtun, N.C.C. Exhibition Organizer Co., Ltd. (NEO), 60 New Rachadapisek Rd, Klongtoey, Bangkok 10110 – Thailand Tel: +662 229 3000 Fax: +662 229 3001 Email: info@qsncc.com Web: www.ildex.com
Good Agricultural Practice
46 | November - December 2011
*
Cereals-Mixed Feed-Veterinary--2012, AllRussian Exhibition Centre, Moscow, Russia Contact: Tatiana Sokolova, P.O.Box 34, Moscow, 129223, Russia Tel: +7 495 7555035 Fax: +7 495 7556769 Email: ts@expokhleb.com Web: www.breadbusiness.ru
2nd Commercial Farm Africa, Dubai, UAE Contact: Ms Grace Oh, Centre for Management Technology, 80 Marine Parade Road, #13-02 Parkway Parade, Singapore, 449269 Singapore Tel: +65 6345 7322 / 6346 9132 Fax: +65 6345 5928 Email: grace@cmtsp.com.sg Web: http://www.cmtevents.com
2nd - 4th February 12
*
EuroKarma 2012, MTPolska Center Ul. Marsa 56, 04-242 Warszawa, Poland Contact: Agnieszka Niemczewska, PO Box, 73, 32-332 Bukowno, Poland Tel: +48 514 544 048 Email: info@eurokarma.eu Web: www.eurokarma.eu
2012 International Poultry Expo and International Feed Expo, Atlanta, GA, USA Contact: Pennie Stathes, 1530 Cooledge Road, Tucker, GA 30084, USA Tel: +1 678 5141977 Email: pstathes@poultryegg.org Web: www.ipeweek12.org
Coming Your Way
Everything you need to know about Good Agricultural Practice Certification at a place near you! Register now on www.tour2011.org
Meet us in one of the following cities: Would you like to know more about the GLOBALG.A.P TOUR 2011? Then please see www.tour2011.org or contact Nina Kretschmer: kretschmer@globalgap.org Follow us on Twitter@GLOBALGAP!
New Delhi – India, 1/2 March 2011 Mexico City – Mexico, 11/12 April 2011 Cape Town – South Africa, 11/12 May 2011 Sao Paulo – Brazil, 6/7 June 2011 Cairo – Egypt, 12/13 July 2011 Warsaw – Poland, 14/15 September 2011 Atlanta – USA, 17/18 October 2011 Bangkok – Thailand, 22/23 November 2011
&feed milling technology
Grain
GEAPS
Grain Elevator and Processing Society www.geaps.com
GEAPS EXCHANGE 2012 The Industry’s Largest Expo Over 300 grain-handling industry suppliers showcasing the latest in equipment and innovation
An Outstanding Educational Program • 3 days of educational sessions only found at GEAPS Exchange • 12 small group “pod” sessions focusing on safety in the workplace • 3-hour workshop on how companies can develop a culture of safety
PLUS... The Industry’s Best Networking Opportunities Connect with thousands of dedicated industry professionals, all in one place
EXCHANGE MINNEAPOLIS, MN
MARCH 3-6, 2012
March 3-6, 2012 Minneapolis Convention Center | Minneapolis, Minnesota, USA The 83rd Annual International Technical Conference and Exposition of the Grain Elevator and Processing Society For Details on Attending and Exhibiting: Visit www.geaps.com Or Contact Us: info@geaps.com or (952) 928-4640 The Knowledge Resource for the World of Grain Handling Industry Operations
48 | November - December 2011
&feed milling technology
Grain
AQUAFEED INGREDIENTS, ADDITIVES, FORMULATION
AQUAFEED PROCESSING TECHNOLOGY
1 5 – 1 7 F e b r u a r y 2 0 1 2 . B a n g k o k I n t e r n a t i o n a l Tr a d e a n d E x h i b i t i o n C e n t r e , B a n g k o k , T h a i l a n d
For everything you need for producing and packaging safe and cost-effective aquafeed No new hw in ome B
ITEC
The conferences Aquafeed Horizons Asia 2012, The FIAAP Conference 2012, Petfood Forum Asia 2012, The Thai Feed Conference 2012
Supported by Thailand Convention & Exhibition Bureau
Co-located with GRAPAS Asia 2012 The show for rice & flour milling, grain & noodle processing, breakfast cereal & extruded snack production
Further information For additional information and free visitor registration visit: www.fiaap.com or www.victam.com
‘
’
a partnership with synergy...your key to success
Events 10th - 11th February 12
*
6th International Seminar on Wheat & Wheat Products - Moving Towards Food & Nutrition Security, New Delhi, India Contact: Wheat Products Promotion Society., #601, 6th Floor, DDA Building, Laxmi Nagar District Centre, New Delhi - 110 092, India Tel: +911 122 457518 Email: seminar@wpps.org Web: wpps.org/iws/index.php
* FIAAP, Victam & GRAPAS Asia 2012, BITEC, 15th - 17th February 12
Bangkok, Thailand Contact: Andy West, Victam International, Po Box 411, Redhill, Rh1 6We, Uk Tel: + 44 1737 763501 Email: Andrew.west733@ntlworld.com Web: www.victam.com
* Gulfood 2012, Ingredients Middle EAST 2012 19th - 22nd February 12
and Resturant and Cafe 2012, Dubai International Convention and Exhibition Centre. Dubai, UAE Web: www.gulfod.com
21st - 23rd February 12 Middle East Grains Congress 2012, Dubai, UAE Contact: Ms THAM Ruoh Yi, 1 Grange Road, #08-02 Orchard Building, Singapore 239693 Tel: +65 6508 2463; +65 6508 2400 Fax: +65 6508 2408; +65 6508 2407 Email: Ruohyi.tham@ibcasia.com.sg Web: http://www.middleeastgrains.com
22nd - 24th February 12 VIV/ILDEX India 2012, BIEC centre, Bangalore, India Contact: Guus van Ham, P.O. Box 8800, 3503 RV Utrecht, The Netherland Tel: +31 30 295 2302 Fax: +31 30 295 2809 Email: viv.india@vnuexhibitions.com Web: www.viv.net
28th February 12 - 3rd March 12
*
*
*
*
29th March 12 - 1st April 12
*
Turkish Flour Industrialists Federation, TFIF 2012 International Congress: Wheat, Flour and Bread, Susesi Hotel, Belek Antalya Contact: Turkish Flour Industrialists Federation, TFIF, Konrad Adenauer Caddesi 523. Sokak No: 1/2 Yildiz Cankaya, Ankara, Turkey or Alp Reyal Tourism travel Agencey, Events Organisation Office. Ataturk Bulvari, No:160/6 Kavaklidere, Ankara Turkey Tel: +90 312 4 400454 Fax: +90 312 4 400364 Email: bilgi@tusaf.org Web: www.tusaf.org
*
Global Grains Asia 2012 Singapore Contact: Ms Grace Oh, Centre for Management Technology , 80 Marine Parade Road , #13-02 Parkway Parade, Singapore, 449269 Singapore Tel: +65 6345 7322 / 6346 9132 Fax: +65 6345 5928 Email: grace@cmtsp.com.sg Web: http://www.cmtevents.com
*
22nd - 24th March 12
March 3rd - 6th March 12
Europain & Intersuc 2012, International Bakery, Pastry, Ice-Cream, Chocolate, Confectionary Exhibition, Paris-Nord Villepinte Exhibition Center. Paris, France Web: www.europain.com
13th - 15th March 12
IPACK-IMA 2012, Fieramilano, Milan, Italy Contact: Cristina Bassan, Corso Sempione 4, 20154 Milan, Italy Tel: +39 02 3191091 Fax: +39 02 33619826 Email: ipackima@ipackima.it Web: www.ipack-ima.com
GEAPS Exchange 2012, Minneapolis, Minnesota, USA Contact: 4248 Park Glen Rd, St. Louis Park, MN USA Tel: +1 952-928-4640 Fax: +1 952-929-1318 Email: info@geaps.com Web: www.geaps.com
3rd - 7th March 12
Ildex Vietnam, The New Saigon Exhibition and Convention Center (SECC), Ho Chi Minh City, Vietnam Contact: Mr. Jobe Smithtun, N.C.C. Exhibition Organizer Co., Ltd. (NEO), 60 New Rachadapisek Rd, Klongtoey, Bangkok 10110 – Thailand Tel: +66 (0) 2 203 4241 Fax: +66 (0) 2 203 4250 Email: info@qsncc.com Web: www.ildex.com
In mid-December 2011 Perendale launches it’s new mobile app - IMD WEB APP. Free to download here, after December 16, 2011
middle east
GRaINS
The Most Comprehensive Event
For complete post harvest supply chain of Rice and Sugar i.e.
Leading Middle East Buyers
Al-Arabi Hamdi Advisor to the President for Economic Affairs, Arab Authority for Agricultural Investment and Development (AAAID), United Arab Emirates
Hakan Bahceci Group CEO & President, Hakan Agro DMCC, CICILS-IPTIC (World Pulses Organization), United Arab Emirates
Shahrokh Khazaei CEO, Mohsen Line General Trading LLC, United Arab Emirates
Antoun Betinjaneh Vice President, Betinjaneh EST
Strategies to manage
Agriculture supply shocks
12 20
Hisham El Atta Board Member, Egyptian Agriculture Council, Egypt
in
2-4 February 2012 Expo Centre, Sec-62, IARI Ground, Pusa, Noida (NCR)INDIA New Delhi,
Sudhakar Tomar Managing Director, Hakan Agro DMCC, United Arab Emirates
w Ne
›› Procurement ›› Warehousing/ Storage ›› Material Handling ›› Processing ›› Quality Control ›› Packaging ›› Logistics ›› Sale ›› Consumption
CONGRESS 21-23 February 2012 Sheraton Deira Hotel, Dubai, United Arab Emirates
Governments initiatives
on national Strategic Grain Reserves and impact on world markets
Agriculture investment –
what are the ME regions strategies, and where are the opportunities
Emerging grain supply markets for the region and trade opportunities
Brian Barriskill Supply Chain Director, Al Dahra Agricultural Company LLC, United Arab Emirates
Dubai’s new initiatives
to strengthen its position as a regional re export hub and resultant opportunities
Top Grains Exporters Steve Cachia Agri-Commodities Market Analyst and Director, Cerealpar, Brazil
Sumeth Laomoraphorn CEO, C.P. Trading Group Co.,Ltd., Thailand
Dian Donev CEO, Scanwel Commodities SA, Bulgaria
Vijay Setia President, All India Rice Exporters Association, Director, Chaman Lal Setia Exports Ltd., India
Dr. Turhane M Doerga President, Alesie Group of Companies, Western Hemisphere
Syed Najaf Hussain Shah Chief Executive, ATC Processing (PVT) Ltd, Pakistan
Changing freight market
dynamics and resultant economic viability of new trade routes
A Full Day Pre-Conference Workshop 21 February 2012
Hedging with Futures and Options
REPLY FORM q Yes! I/We Will attend Middle East Grains Congress, 21-23 February 2012, Sheraton Deira Hotel, Dubai, UAE q I am unable to attend this time but please put me on your mailing list Name:
Job Title:
Company:
Business Activities:
Address:
Geetika Malhotra Sr. Project Manager M: 09991705003 isrmax@pcsl.co.in
Sunil Dev Sr. Project Head M: 09971842099 pro@pcsl.co.in
Tel:
Fax:
Email:
For more information, please contact Ruohyi Tham, Tel: +65 6508 2463 Email: ruohyi.tham@ibcasia.com.sg
IBC Asia (S) Pte Ltd • 1 Grange Road, #08-02, Orchard Building, Singapore 239693 • Tel: +65 6508 2400 Fax: +65 6508 2408 • Email: enquiry@ibcasia.com.sg P51339 GFMT Dec 2011
Produced by:
Supported by:
All India Rice Exporters Association
an informa business
Thai Rice Exporters Association
Agricultural and Food Marketing Association for Asia and the Pacific (AFMA)
RegistRation Hotline: +65 6508 2401
www.ibc-asia.com
&feed milling technology
50 | November - December 2011
Grain MEGC (105X148-GFMT Dec11).indd 1
11/25/11 4:36:27 PM
Events
IPACK-IMA 2012. No better place to trade
VIV/ ILDEX India 2012 February 22 - 24, 2012
IPACK-IMA 2012, the benchmark event for Processing, Packaging and Material Handling, is the meeting place for nine Business Communities: Grain-Based Food, Dairy Products, Beverage, Confectionery, Vegetables & Fruit, Fresh and Convenience Food, Health and Personal Care, Chemicals – Industrial & Home, Industrial & Durable Goods CALEIDOS-NEXXUS.IT
If you are active in one of these industries, IPACK-IMA is your place to be. A unique collection of integrated, innovative and sustainable solutions due to the exhaustiveness of the product display. A valuable chance for business update and an extensive agenda of international events, including “Enhancing Food Safety and Food Security in Africa”, organized in partnership with the UN food agencies.
Visit our website n for more informatio
IPACK-IMA: an increasingly valuable and unique business opportunity.
www.viv.net www.ildex.com
Special themes
Eggs!
Your portal to India’s Feed to Meat trade Bangalore, India
adv-ildex-india-2012-90x132-V2.indd 1
&feed milling technology
Grain
Feedtech Croptech
The dedicated event for the Indian Milling industries
Fieramilano, Milan - Italy 28 February – 3 March 2012 Opening hours: 10.00 am – 6.00 pm Entrances: East, South and West gates Save time, preregister on www.ipack-ima.com Organized by: Ipack-Ima spa - corso Sempione 4 - 20154 Milano - Italy tel. +39 023191091 - fax +39 0233619826 e-mail: ipackima@ipackima.it - www.ipack-ima.com
06-07-11 13:03 Grain & Feed Milling Technology Magazine 90x132.indd 1
14/10/11 16:48
November - December 2011 | 51
WEBLINKS
2011 related links
In every issue of GFMT, we will be providing a list of companies and web links related to key stories and topics within each specific issue. If you would like information on how your company can get involved, please contact our Marketing Manager, Caroline Wearn. Email: carolinew@gfmt.co.uk Tel: +44 1242 267707
Adifo N.V. = www.adifo.com
NIR Online = www.nir-online.com
Agromatic AG = www.agromatic.com
Nutrex BV = http://nutrex.com
Almex b.v. = www.almex.nl
Obial = www.obial.com.tr
Andritz Feed & Biofuel = www.andritz.com
Ottevanger Milling Engineers B.V. = www.ottevanger.com
Bastak Gida Makine Medikal paz. Lth. Lhr. San. Tic. Ltd Sti = http://www.bastak.com.tr
Perstorp Performance Additives = www.perstorpfeed.com
Brabender GmbH & Co KG = www.brabender.com Buhler AG = www.buhlergroup.com Buhler AG = www.buhlergroup.com Chief Industries UK Ltd = www.chief.co.uk Chopin Technologies = www.chopin.fr Consergra s.l = www.consergra.com Cultura Technologies Limited = www.culturatech.com Daniit A/S = www.daniit.com
Petkus Wutha Sortier- und Aufbereitungstechnik GmbH = www.petkus.de Project Organisation Alexander Torlach GmbH = www.torlach.com R-Biopharm Rhone Ltd = www.r-biopharmrhone.com Retsch GmbH = www.retsch.com Satake Corporation = www.satake-japan.co.jp Satake Europe Ltd = www.satake-europe.com Satake Europe Ltd = www.satake-europe.com SCE nv, Silo Construction & Engineering = www.sce.be
Dinnissen BV = www.dinnissen.nl
School of Applied Science = http://www.gbu.ac.in/User_Pages/ SOA_Directory.aspx
Ehcolo A/S = www.ehcolo.com
SEA Srl ELECTRONIC SORTERS = www.seasort.com
Extru-Tech = www.extru-techinc.com Foretell Business Solutions Pvt Ltd = www.fbspl.com
Shanghai ZhengChang International Machinery and Engineering Co., Ltd = www.zhengchang.com
Format International = www.formatinternational.com
Silexport International = www.silexport.com
Foss = www.foss.dk
Silos Cordoba = www.siloscordoba.com
Hubei Yongxiang Food Processing Machinery Co Ltd = www.hbyxlj.com
Skov AS = www.dol-sensors.com
Hydronix Ltd = www.hydronix.com
STIF = www.stifnet.com
InVivo NSA = www.neovia-additives.com
Suffolk Automation Ltd = www.suffolk-automation.co.uk
JCB Consulting Ltd = www.jcb-consulting.com
Symaga SA = www.symaga.com
John Staniar & Co. = www.johnstaniar.co.uk
Tapco Inc = www.tapcoinc.com
JSConwell Ltd = www.buhlermillbank.co.nz
Tornum AB = www.tornum.se
Leonhard Breitenbach GmbH = www.breitenbach.de
TSC B.V. = www.tsc-silos.com
Mogensen Raw Materials Handling = www.mogensen.co.uk
UNORMAK DEG. MAK. SAN. ve TIC. LTD. Sti = www.unormak.com.tr
Muyang Group = www.muyang.com
V.A.V. Aandrijvingen b.v. = www.vav.nl
MYSILO DIS TICARET LTD. STI = www.mysilo.com
VEGA Controls Ltd = www.vegacontrols.co.uk
NABIM = www.nabim.org.uk
Vigan Engineering S.A. = www.vigan.com
Neuero Industrietechnik = www.neuero.de
Wynveen International B.V. = www.wynveen.com
We wish all of our readers and supporters a happy and properous 2012
Perfection in grain milling – a highly demanding task. Antares sets new standards for round-the-clock milling. The self-contained roll pack and reliable product feed ensure precise and consistent flour. Maximum hygiene is guaranteed thanks to clever insulation, integrated product inlet aspiration and stainless steel lining. Experience a new level of ease of use and quality from ergonomic controls and operating reliability to the highly impressive design. Antares – The New Art of Milling.
Bühler AG, Grain Milling, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 66 11 milling@buhlergroup.com, www.buhlergroup.com
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Innovations for a better world.