Milling and Grain August 2015 - FULL EDITION

8/20/2019 Milling and Grain August 2015 - FULL EDITION

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Feedmill of

the future• Stabilising rice bran

through high shear

extrusion

• Why India’s agri-food

policies need a holistic

review

• Mycotoxins and

mycotoxicosis in

livestock production

• Preventing bread waste

millingandgrain.com

perendale.com Volume 126 Issue 8

A u g u s t 2 0 1 5

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52 Feedmill of the futureOur special feature on the feedmill of the

future - the Kalmar Lantmän feedmill inKalmar, Sweden

REGIONAL FOCUS Europe 4

Perendale Publishers Ltd7 St George’s TerraceSt James’ Square, Cheltenham,Glos, GL50 3PT, United Kingdom

PublisherRoger GilbertTel: +44 1242 [email protected]

International Marketing Team

Darren ParrisTel: +44 1242 [email protected] Tom Blacker

Tel: +44 1242 [email protected]

Mark CornwellTel: +1 913 [email protected]

Latin America Marketing TeamIván MarquettiTel: +54 2352 [email protected]

India Marketing TeamRitu [email protected]

Nigeria Marketing TeamNathan Nwosu

[email protected] Editorial TeamOlivia HoldenTel: +44 1242 [email protected]

Peter Parker [email protected]

Malachi [email protected]

International EditorProfessor Dr M Hikmet BoyacıoğluTel: +44 1242 [email protected]

Design Manager

James Taylor Tel: +44 1242 267707 [email protected]

Circulation & Events ManagerTuti TanTel: +44 1242 [email protected]

Australia CorrespondentRoy Palmer Tel: +61 419 [email protected]

VOLUME 126

ISSUE 8

NEWS 6-24

FEATURES

30 Stabilising rice branthrough high shearextrusion

34 Why India’s agri-foodpolicies need a holisticreview

38 Mycotoxins andmycotoxicosis in livestockproduction

44 Preventing bread waste

48 Pioneering UK wheattrials

52 Feedmill of the futureSpecial feature

STORAGE

66 Are ATEX powder storagesilos disasters waiting tohappen?

2 GUEST EDITORGraham Hartwell

76 MARKETS John Buckley

92 INTERVIEWGörkem Alapala

©Copyright 2015 Perendale Publishers Ltd. Allrights reserved. No part of this publication may bereproduced in any form or by any means withoutprior permission of the copyright owner. Moreinformation can be found at www.perendale.com

Perendale Publishers Ltd also publish ‘TheInternational Milling Directory’ and ‘The GlobalMiller’ news service

EVENTS82 Event listings, reviews

and previews

COLUMNS8 Mildred Cookson14 Tom Blacker

16 Christophe Pelletier

20 Chris Jackson

22 Els van der Boon

FACES94 People news from the

global milling industry

TRAINING27 IGP institute feed

manufacturing course

PRODUCT FOCUS 28

CASE STUDY 74

Grain & Feed MillingTechnology magazinewas rebranded to Millingand Grain in 2015

AUGUST 2015

COVER PICTURE: It was a privilege for Milling and Grainto be invited to Sweden immediately after Victam in

Germany to visit what must be the most advancedfeedmill in operation today - Kalmar Lantmän. In

recognition of the achievement this representsin terms of technology advances, efciency or

production and minimal environmental impact, wehave devoted over 10 editorial pages to its review.In short we are proud to make Kalmar Lantmän our

cover feature. - Roger Gilbert, The Publisher


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Economy, society andecology are key pillars

of sustainability withthe role of Innovationand Stewardshipcritical elements forstakeholders in thefood value chain toensure supplies of foodand raw materials forthe coming seasons.

Communication of innovation and thecommunication of stewardship are criticalareas in the knowledge transfer process and arevisible at the height of the technical ‘shows anddemonstrations’ season.

In the UK the past month or so farmers havebeen aware of these processes as they watchedtheir own cereal crops mature as ear emergenceand grain-ll began.

At the same time wheat variety selection for2016, the choice of current and future agronomytechniques, crop protection product choice andperformance are all reviewed. This seasonalityalso needs to be balanced with changes in worldmarkets and consequent market values, shifts ingovernment policy and changes in biodiversity.

As the requirement for biodiversity areasincreases, a balanced understanding of how

to manage sustainability processes becomesparamount for all those involved in the foodvalue chain.

Within BASF Plc, our strategy is based ona strong technical message, based on goodscience that delivers such technical messagesand development concepts to a wide range ofaudiences throughout the food value chain andalso to those who inuence the agriculturalindustry from grass roots to Government levels.

In a world that appears to gain its knowledgefrom online searches and uses web-basedinformation to inuence decisions, it is

particularly rewarding to be ableto encourage guests onto a farm to

see, hear and touch agriculture rst hand, andto allow them to ask questions regarding howagriculture works.

BASF is fortunate to collaborate with twofamily-owned private farms in the UK in thedelivery of technical and biodiversity messagesthrough a whole farm approach.

Protable crops are key but are grown alongsidewell-managed biodiversity areas. A best practicestewardship ethos for applications of fertilisersand pesticides is part and parcel of the farmmanagement so that precious resources of soil,water and wildlife are protected. Often simplechanges to farm practice make this possiblewithout detriment to the balance sheet anddeliver a more sustainable farm managementprocess - certainly with great levels ofbiodiversity and improved farm wildlife.

The two UK farms are part of a coordinatedpan-European Sustainability Farm Networkthat runs to some 15 privately owned farmsin six countries all designed to demonstratesustainability principles through rst handexperiences.

Developed with independent third-party expertsto deliver practical solutions and to monitor thefarms, we can share a balanced view of innovation

and sustainability for the food value chain.Signicant positive changes in the FarmlandBird Index are noted on both farms by managingeld margins and biodiversity areas to improvehabitat value for birds, bees and butteries.Delivery of well-managed biodiversity alongsidegreat agricultural crops uses farm managementskills to bring the best of both worlds onto thefarms.

I hope that you enjoy this month’s edition of

Milling and Grain.

Graham Hartwell Environmental Stewardship

Manager UK & Ireland BASF plc

Innovation and Stewardship

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

More Informationwww.millingandgrain.com

http://gfmt.blogspot.co.uk

ISSN No: 2058-5101

EditorGuest

Meet the Milling and Grain team

The team are travelling across the globe toindustry events.

16-21August - 17th Annual Practical

Short Course on “Food Extrusion:

Cereals, Protein & Other Ingredients


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EUROPE

REGIONAL FOCUS

1 865 000 - the total amount of

compound feed produced overallin 2014 (tonnes)

841 000 - the total amount ofcompound feed produced in 2014for Cattle in Sweden (tonnes)

572 000 - the total amount ofcompound feed produced in 2014for poultry in Sweden (tonnes)

1 436 000 - total livestock populationof cattle in Sweden in 2014

1 469 000 - total livestock populationof pigs in Sweden in 2014

45% - the total amount of compoundfeed produced for cattle in 2014

(Source: FEFAC)

SWEDEN STATS

Trends in ingredients

at IBA

People are increasingly complainingabout food intolerances and

allergies. In addition to that which isnecessary, personal desire to avoidcertain products e.g. animal productsis also playing an increasingly bigrole.See the full story on page 84

Feedmill of the future

How we feed the world’s ever growing population is the bigquestion for the milling industry. Milling and Grain magazinegoes in search of answers, on a behind the scenes tour of the VanAarsen-built, Kalmar Lantmän project - the most modern feedmillin the world - to nd out how the technology in this new mill setsa standard for the future.See the full story on page 53

European feed statistics

This month we look at Europeanstatistics – both feed and specicallyruminants. We are using two sourcesof statistics; our regular contributorAlltech and FEFAC, the European Feed

Manufacturer’s Federation.Europe produced 224.6 milliontonnes of compound feeds in2013, the latest year for compiledstatistics from the Federation.See the full story on page 25

INDUSTRY PROFILE

SPECIAL FEATURE

FEATURE

Mycotoxins and

mycotoxicosis in

livestock production

Cereal and cereal by-products, corngrains and corn silage are thought to bethe most exposed ingredients to mold andmycotoxin contamination.See the full story on page 38

EVENTS

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India’s pulses sector: trends,challenges and opportunities

India is the largest producer, consumer and importer of pulses in the world. Thisis due to India’s enormously diverse culinary traditions that use many pulses and

minor millets, says Raghavan Sampathkumar who comments on agribusiness from apolitical, socio-economic and cultural perspectives on the country’s food value chain.He will be contributing to our ‘Commodities’ section in MAG from time-to-time.

However, India imports nearly three-to-four million tonnes of pulses annually, hesays.

This is motivation “for India’s pulse and oilseed production to become self-reliant,with some aiming for this to be achieved by 2022.”

Based on current average yields, India would need nearly seven-to-eight millionadditional hectares of land to meet the gap in demand without imports. In order forIndia’s pulses sector to become self-reliant many obstacles have to be consideredsays Mr Sampathkumar, including:

Indian agricultural and price policies: In India, generally, food means only twocrops – rice and wheat. ‘Politics’ are always winning over ‘economics’, which

is evident from entrenched policies such as MSP (Minimum Support Prices) andprocurement systems that seem to favor only these two crops.

Issues around domestic marketing: There are no reliable marketing opportunitiesfor farmers to sell their crop, so why grow something that you cannot sell? Archaiclaws such as APMC (Agricultural Produce Marketing Committee) regulationsprevent farmers from entering into direct supply contracts with a processor orretailer. The safest crops to grow would be rice or wheat, which have minimumsupport prices that are increased annually and have established procurement systems.

Limited crucial statistical data within the sector: There is a lack of reliable dataon production, acreage and/or consumption. Estimates tend to vary greatly fromdifferent sources, not only for pulses but for all crops. It is obvious what will happenwhen policies are made without reliable data on these parameters.

What is clear is that if India is to achieve a self-reliant pulse and oilseed sector,it will require a holistic understanding of the food value chain and the agrariansituation in the country, a review of current ag-food policies and increasedinvestment in Research and Development and infrastructure for storage, foodprocessing and marketing, he says.

NewsMilling

A U G 1

5

The Global Miller blog is anonline offshoot of Millingand Grain magazine. Whilethe monthly magazine coversmilling technology issuesin-depth, the Global Millertakes a lighter approach.Our columnists have a keeneye for the most interesting,relevant and (let’s faceit) bizarre milling storiesfrom across the world.Each weekday we scour theinternet for top-notch newsand package it for yourperusal in one neat dailydigest.

An expanding Filipinomilling industry sends atrade team to the UShttp://bit.ly/1DpFJuQ

IAOM AnnualConference news: callfor proposalshttp://bit.ly/1SNuFyv

New FIAAP/VICTAM/GRAPAS event to beorganised in 2017http://bit.ly/1KQmBZo

Lallemand AnimalNutrition conrms itssilage expert positionat the XVII InternationalSilage Conference inBrazilhttp://bit.ly/1K3JrXX

gfmt.blogspot.com

GF

MT

A blog dedicatedto milling industry

professionals globally

6 | Milling and Grain


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Iam delighted to announcethat here at the MillsArchive, we have beensuccessful in gaining a grantfrom the UK’s Heritage LotteryFund (HLF) for an excitingproject that is about to get underway. Extending until 2018, wewill use the £68,200 grant to

preserve records of the history of our milling, from itsancient origins up to the present day, and to tell this story

to you and to people around the world.Participatory elements in the project, “From Quern to

Computer”, mean that individuals and milling rms willhave plenty of opportunities to get involved, not only inlearning about the story (even the most knowledgeablemill enthusiast may be surprised at what they discover)but also in actively shaping the story for future generationsand ensuring that key moments in history are recorded andnot forgotten.

The world’s rst roller our millarchive

For milling rms, the projectprovides the timely opportunity toensure that their history is recordedfor posterity. We invite suggestions ofcontent to include in the story. We areinterested not only in suggestions butthe raw material as well.

As we are building the rst specialistarchive for roller our mills andmilling, we welcome the donationof original historical images anddocuments, so that we can providea safe home for such items and

in time make them available tothe public. With over two millionhistorical records of traditional millsand milling, we have acknowledgedthe need to preserve the story of theadvances in milling technology overthe last 150 years. This expansion ofour original remit, means the MillsArchive Trust will now incorporate theworld’s rst roller our mill archive,allowing rms and milling families from

around the world to ensure their history

is respected and preserved for futuregenerations.The records of the different elements

of our milling – particularly morerecent roller our mill records are at

risk of being lostforever. In some cases thisis due in part to a lack of understanding of their historicalimportance, but more often than not it is because untilnow there has not been a suitable place to deposit suchmaterial. To truly understand the different our milling“eras” one needs to have an awareness of what has comebefore and what has since developed.

Connecting modern milling developments withwhat has come before

Humans have used milling methods over thousands ofyears to make bread and other food products, at rst forsurvival and over time for enjoyment such as biscuitsand cakes. While the methods may have changed, it isimportant to see all the events and developments as part ofan evolving story about our milling, and how this story isrelevant to everyone.

We will capture the story of our milling from 6000 BC

by Mildred Cookson, The Mills Archive, UK

Milling Journals of the past at the Mills Archive

From Quern to Computer

Foundry drawing of waterwheel detail, 1895

Great Barton Post MillSuffolk, 1910

Post mill DiderotEncyclopedia, 1763

Horizontal windmill,Islam Qala, Herat,Afghanistan, 1973



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and hand-operated quern stones right up until the presentday. The story will therefore capture traditional windmillsand watermills as well as large roller mill plants such asthose whom this magazine reaches. Related industriessuch as the rms that furnish these plants with roller millmachinery will also have an opportunity to feature in thestory.

Bennett and Elton, attempted to tell the complete storyin their seminal 4-volume History of Corn Milling writtenat the end of the 19th century. However, since then therehas been nothing of the same scope and scale. Their booksalso reach only a limited audience. Things have movedon over the last century, not only in terms of our millingtechnology but also the methods by which we can tell thestory and make it available to the public.

Modern website technology will allow this projectto record and display a detailed interactive timelinecovering eight millennia and enable the public and thosewith involvement or interest in the milling industry toparticipate in its telling.

Opportunities onlineOur website at millsarchive.org has a large global

audience that primarily uses our online resources toaccess our existing archive. Our online catalogue alreadyfeatures some 40,000 digitised images and documents in180 collections. We have invested a lot in improving thewebsite to incorporate the new roller our mill archive aswell as the planned timeline. We already offer a numberof interesting features and articles as well as a vast MillsIndex, which will shortly be expanded to include rollerour mills as the donations come in.

In addition to developing our timeline as an online

resource, we will be running competitions to encouragethe public to participate in a Flour Mill Survey, which willuse submitted data about mills and mill sites to enhanceour Mills Index. So the list will expand as people start totell us about mills we are not aware of, and we hope theywill help in the important task of adding roller mills to theIndex too.

The past shapes the futureIn its essence, this is what an archive is really all about.

While historical records are preserved, this is so thatfuture generations can understand and learn from the pastwhen creating the future. These give us the opportunity to

document and appreciate the work of the milling industryin serving humanity and enabling us to ourish.

Flour milling is not a disjointed story, and shouldnot be alienated from wider events that encompass theeconomy and societal changes as well as advances intechnology. By relating our milling to these concepts,our hope is to engage different groups with a varietyof interests and inspire an interest in milling in a widerange of people.

One of the goals of “From Quern to Computer” is tocatalogue an additional 20,000 images and documents (nosmall feat) and link some of the best examples to the online

timeline to illustrate and amplify the story of our milling.Out of the two million or so images and documents that wecare for in our archive, we have so far only catalogued afraction of what we have. With this project, we will be ableto direct more resources towards better understanding thatmaterial and presenting it to a wider public.

Milling & Grain’s own history needs tellingThis timeline will be freely available to explore and will

link not only to items on our catalogue but also externalresources and the websites of participating mills and rms.

The public, as well as those involved in the project, willbe able to suggest items, mills and historical events to beadded to the timeline. Our goal is to work with mills, rmsand individuals to tell the story of our milling and toprovide participants with the tools to tell the story to theirown visitors, staff and volunteers.

We are grateful to Milling & Grain’s publisher, Perendale,for recognising the importance of the story of our millingand for supporting us by getting involved in our work as anArchive Patron. We will involve this magazine – and, wehope, you, in the project by featuring the magazine’s longhistory from 1891 on the timeline.

Our project needs youTo make our project a success, we need you. We will

be looking for contributions, suggestions and commentsover the coming two years, and we would like you tohelp shape the story of our milling and inuence whatfuture generations learn about the past and current millsand milling. You will be able to suggest events, topics,links and other interesting snippets to feature on the onlineinteractive timeline.

Similarly we will welcome your help in taking part in theFlour Mill Survey – an exciting new initiative where youcan put mills on their rightful place on the map.

You will hear more about this and other ways you canget involved over the next few months and throughout theduration of the project.

If you would like to nd out more, please email me [email protected] and I would be happy to tell youmore.

Primitive milling as anadvertisement, 1908

“More than Pleased”, 1908

The Cornwell Roller Flour Mill Collection

August 2015 | 9

Milling News


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David Sugden sadly died at the

age of 77 at home in Suffolk,UK on July 8, 2015. He was15th and last in the family line of pre-eminent our millers, the Sugdens.The family business - Thomas Sugden& Son Ltd’s mill was located inBrighouse, Yorkshire, UK.

David was born on 22nd September1937 in Yorkshire. He was the son ofRichard Sugden CBE TD – formernabim President from 1955-56. Hetrained mostly at Henry Simon Ltd.

Before his milling career, David

served 10 years in the military,where, like his father he wascommissioned in the Duke ofWellington’s regiment. From 1957to 1959, David trained in mills in theUK, Norway and the Netherlands. Hequalied with a City & Guilds FirstClass Final Technological Certicate(Milling). David then spent whatwould become 31 continuous yearsof service working for AssociatedBritish Foods (ABF). It was during

these years that Thomas Sugden &Son Ltd was sold to Allied Mills/ABF.

David ran various mills around theUK, becoming product director of

main subsidiary at Allied Bakeries,

as well as technical and projectdirector at Allied Mills. He becamea successful miller inventing theworld’s rst commercial wheatleast cost grist (wheat mix)computerised programme to savecosts, implementing reinvestmentinitiatives, installing new plants, andmuch more.

During this time, David wasan independent grain industriesconsultant for twelve years from1980 to 1992. He was well attuned to

working internationally in the millingtrade, and attended many conferencesoverseas.

In 1989, David was the recipient ofthe Thaddeus B. Bownik OutstandingService Award from the NorthAmerican Association of OperativeMillers (AOM), which is now knownas the IAOM. Furthermore, he thenbecame an honorary member of theAssociation.

David moved to work for Satake

as the Business DevelopmentDirector from 1992 to 1996. Whilstat Satake, David was instrumentalwith a special remit for establishingthe Satake Centre for Grain Process

Engineering between the University

of Manchester’s Department ofChemical Engineering and SatakeCorporation, Japan and Satake in theUK. This was a specialist centre forpost-graduate learning and research.Following this, David then spenteight years there from 1994 to 2002as a visiting Senior Lecturer.

Beyond his professional life,David was also active in the affairsof his community and church. Inretirement he was Vice Chairmanof Res-Care, the nationwide charity

which supports those with learningdisabilities and mental handicaps, aswell as their families; an AssociateGovernor of Otley College, Suffolk,and a Church Warden at All SaintsChurch, Chelsworth. From 2001to 2006 he was a member of theDepartment of Health LearningDisability Task Force monitoring“Valuing People”. With each of thesefour entities, he contributed greatlyto society and the wider community

in a volunteer capacity.David’s leisure interests were insporting events, boating and fellwalking. His family, friends and themilling industry will miss him dearly.

David Sugden 1937-2015


Milling News


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Norwood and Company

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flour milling and wood industries our family would be

more than happy to help you design, build, repair orexpand any new or existing grain facilities

Futurist Mike Walsh: Food producers mustembrace innovation to succeed with nextgeneration

T

he most successful foodproducers and manufacturersin the next decade will be

the ones who harness the rapidadvancements in science andtechnology to meet the demands ofthe rst fully digital generation asthey become adults, according to aJuly 13 keynote address by futuristMike Walsh at IFT15: Where ScienceFeeds Innovation hosted by theInstitute of Food Technologists (IFT)in Chicago.

“If you really want to understandthe future, you have to start with the

people who are going to live in it,”said Walsh, author of The Dictionaryof Dangerous Ideas and CEO of theconsultancy rm Tomorrow.

“And the most disruptive group offuture food consumers, I believe, arepeople who are currently celebratingtheir eighth birthday. If you canunderstand how an eight year oldthinks, you’re a long way towardreally understanding a transformative

change in consumer behavior. ”Walsh said that age group is of

particular interest because they wereborn in 2007 - the same year theiPhone was introduced. They arethe rst generation to be connectedfrom birth, so they are growing upwith a much different outlook onshopping, cooking and eating thanother generations. They will expectproducts that are customised, readilyavailable and - as already apparentlyon Instagram - look good enough tobe photographed and shared on socialmedia.

“When you think about an eightyear old, how they will be making judgments about food, about foodbrands, eating and dining, it’s allgoing to be very connected to theirexperience on that smartphone,” hesaid.

“Look at the way the nextgeneration forms their views on foodtoday. Look at Instagram - thereis some extent to which the next

generation doesn’t want to eat ameal unless they are going to take apicture of it.”

Walsh said the challenge for theentire food industry is to be preparedto meet the demands of thesetech-savvy, on-demand consumerswhile still producing enough foodfor a population expected to growto about nine billion by 2050. Hesaid that will elevate the discussionalready taking place about whetherto genetically modify plants andlivestock to meet the population’sfood needs.

“As a futurist, one of the thingsreally that fascinates me is thatintersection point where science andtechnology head-butts the realitiesof everyday human experience,”Walsh said. “As food scientists andtechnologists, this is something youencounter every day, because for allof the developments that you comeup with, at the end you’re still talkingabout food.”

August 2015 | 13

Milling News


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Hello! With many topical subjects this month to get

through in this column I will begin immediately! TheNorthern Hemisphere’s harvest is now taking place.It has been enlightening to see wheat harvests in myregion come to fruition during long evenings and drydays. Farmers, storage co-operatives and the wholelogistics chain are working together to provide thewheat for millers. Feed and our millers are expectantof good quality and quantity. Perhaps this harvest will

see both coming together.It is so impressive to see other harvests from around the world via the Internet.You only have to search online social media sites for ‘#harvest2015’ to see manyphotos and accounts of wheat farmers harvesting their crop. Some impressive

videos taken from drones ying above the elds also feature. It is worth lookingthis up to see the huge range and scale of coverage on social media. In myopinion, it is a great thing that wheat harvesters do this to encourage greaterawareness for consumers to the origin of so much of the food in their diet.We also report on some very sad news about David Sugden, formerly of AlliedMills is covered in this issue. Those who knew him in the milling communityaround the world will sorely miss him. Key individuals from milling families arealways greatly admired and rightly respected. He leaves behind a long legacy.Coming up soon, I am due to visit Holme Mills, best known as Jordan’s cerealmill in the UK. There has been a site at this mill for nearly 1000 years. Thecounty of its location, Bedfordshire, had 400 functioning mills at its peak andwas a critical industry. However, that is not the case today. This particular millwas milling our up until the year 2000 and became the mill of a family of well-known breakfast cereal brands. Despite the mill no longer functioning, the cerealproducts are still well known today. The legacy of the mill lives on as a visitorcentre that provides leisure attraction where the story of milling can be retold.My next column will report back from the visit. Look for this in the Septemberissue!

Tom Blacker

Directory Coordinator

PS: Don’t miss out on being included in our upcoming International Milling

Directory for 2015/16. There is still time to place your advertisement, banner,

product profle, logos, etc. Just contact me on: [email protected] and I will

help you through the ordering process.

International events VICTAM and GRAPAS

boost the International Milling Directory

Tom Blacker, International Milling Directory

A Flour World

Museum story

No. 1

www.muehlenchemie.de

King-sizeking cake

You can get it as a dry cake, with

cream, truffle chocolate, or in world-

record size – king cake, eaten in

Mexico since the 16th century at

Epiphany. To celebrate 200 years

of Mexican independence, Mexico

City bakers made a truly king-size

"Rosca de Reyes" weighing ten tons

and measuring 2360 feet long. The

massive cake took 16,684 pounds of

flour, 56,880 eggs and 8157 pounds

of butter, and cut nicely into 254,000

pieces. But no one knows who

found the porcelain figurine that is

hidden in every Rosca de Reyes. This

will no doubt remain a mystery, for

whoever finds it must make tamales

for all the guests, later at the

"Fiesta de la Candelaria". With this

gargantuan cake that would be an

impossible task.

The Mühlenchemie FlourWorld Museum

in Wittenburg is an expression of our

company culture and the responsibility

we feel towards the miller and his flour,

as one of the most important staple

foods. The museum is a journey through

the millennia, illuminating the devel-

opment and importance of flour. It is

the only one of its kind in the world.

www.flourworld.de


Milling News


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Lallemand Animal Nutrition conrms its silageexpert position

Lallemand AnimalNutrition waspleased totake part in the XVIIInternational SilageConference organised byESALQ (Luiz de QueirozCollege of Agriculture,University of São Paulo)in Piracicaba, São Paulo,Brazil, from July 1st to3rd, as platinum sponsorof the event, industryexhibitor and scienticcontributor. This event gathered morethan 300 attendees from 32 countries,

among them some of the mostimportant scientists and researcherson silage and many industryrepresentatives. Moreover, it was therst time that the International Silage

Conference was held in the SouthernHemisphere.

Lallemand Animal Nutritionconrmed its position as globalsilage expert during this key event.Two lectures were presented by theLallemand silage team: Dr Pascal

Drouin, Forage ResearchManager, and BernardAndrieu, Lalsil BrandManager. More than 15posters presented concernedLallemand strains or products.

Julien Sindou, GlobalSilage Product Manager,commented: “We areparticularly pleased that therst International SilageConference to be organisedin the Southern Hemisphereis hosted by ESALQ at

the University of São Paulo, whohas been a privileged partner for

Lallemand Animal Nutrition for somefteen years; a fruitful relationshipthat has led to major achievementssuch as the patent for L. buchneri40788 application in sugar cane.”

European Investment Bankand FAO bolster investment inagriculture

The European InvestmentBank (EIB) is expandingits collaboration with FAO,

a move aimed at broadening anddeepening investment in agriculturein countries outside of the EuropeanUnion.

The two institutions have signeda ve-year Memorandum ofUnderstanding (MoU) that seeks tofoster investment operations in theeld of agriculture, private sector

development and value chains thatpromote both EIB’s priorities andFAO’s strategic objectives.

The agreement, announced duringthe Third International Conference onFinancing for Development, furthermarks the engagement of the EIB inthe agribusiness sector and, for FAO,a partnership with the world’s largestmultilateral nancial institution that

was signed in Addis Ababa in mid-July.

FAO’s expertise in investment-related policies and projectformulation for investment, togetherwith EIB’s access to internationalcapital markets and prowess indevising robust investment operations,

are natural complements to oneanother.

Looking to neighbours and

beyond

The cooperation will initially looktowards the Eastern and Southernneighbour countries of the EuropeanUnion and the member states ofthe African Caribbean and Pacic

Group of States (ACP), with therst initiatives likely to focus on

investment support in Georgia andUkraine, leveraging the EIB’s existingcredit lines.

Many of the ACP’s 79 memberstates are particularly vulnerable toclimate change, a priority for bothinstitutions. The articulation of thetwo institutions’ interventions in theregion’s agricultural and food sector

will build on these common priorities.EIB’s four priority areas for

investment include boostinginnovation and skills, climate action,strategic infrastructure and improving

access to nance for smallerbusinesses. It recently agreed also tofocus support towards young farmersand local initiatives favouring supplychains to boost rural incomes.

Supporting EU policy goalsThe European Investment Bank

(EIB) is the long-term lendinginstitution of the European Unionowned by its Member States. It makeslong-term nance available for sound

investment in order to contribute

towards EU policy goals.An intergovernmental organisation,

FAO has 194 member nations, twoassociate members and one memberorganisation, the European Union.It works to meet the demands posedby major global trends in agriculturaldevelopment and challenges faced bymember nations.

Send us your newsSend your news items [email protected]

August 2015 | 15

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The growing population is oftenperceived as a threat for thefuture. The challenges are there,indeed. Yet, looking at the glasshalf empty is not necessarily thebest approach. The future needs

to be looked at with a differentperspective than the past and thepresent. Many things have to

change and evolve. It is true, but it was true a century ago,too.We should celebrate much more loudly than we currentlydo the fact that, although there are still close to onebillion people hungry, an unprecedented number of sixbillion people can eat enough every day. We also mustkeep in mind that we achieve this performance in spite ofsubstantial food waste and inefciencies in both productionand supply chains in many regions. If we need to change

how we operate in these two areas, it is also crucial to bealert to adapt to a changing consumer market.The growing world population is not so much about howmany people there will be in 2050 as it is about whatthey will eat. The diets of the future will determine thesustainability of food supply. Proper nutrition educationis an absolute necessity to get on the path of a sustainableagriculture. The exciting part of feeding the future liesin the dynamics of future food markets. The populationis growing but not everywhere in the same way or at thesame pace. Next to the growing number of people, theireconomic situation also evolves at different paces betweenthe regions.As the number of people joining the world middle classincreases, they will look at food differently... and so mustfood producers. There are useful lessons to learn fromthe evolution of food markets in Western countries afterWorld War II. Today’s emerging countries show a similarpattern. Food is not anymore a matter of daily survivalfor their populations. Food is not just for the stomachanymore but the psychology of food consumption evolves,too. That is exactly what Maslow described with hispyramid of needs. Once the physical need is covered, inthis case food security, other needs appear. The social andemotional functions of food start to prevail. As they go up

in the pyramid, consumers become more demanding andchallenging. It is quite normal. It is how human natureworks. It also has the amazing ability of disrupting thedesire of the industry for well-standardized and cost-efcient processes; hence the frustration and the difculty

to get on the same wave length.

With increasing absolute numbers of wealthier and morecritical consumers, it is only normal to expect a stronggrowth of niche specialties. Such a trend started severaldecades ago in Europe and has been in full bloom in theUS for some time, too. A similar trend is already growingin the leading emerging countries such as China and India,

and it will only grow further and stronger. The future offersan amazing number of possibilities for niche markets. Thereasons and possibilities for differentiation are and willbe many. They range from physical quality to productionmethods to social, philosophical, political, ethnic andethical issues as well as provenance, transparency andtrust. Feel free to dene subgroups in these categories and

you will map a myriad of possibilities.Such trends will be true for all food categories. Somefood groups will keep showing very strong growth inthe coming decade. That is the case for protein, and inparticular animal protein. Protein crops will be in demand

for animal feed production. Carbohydrate crops willincreasingly be used for animal feed both in volume as inshare of total consumption. Oil seeds and oil crops willalso show a strong demand because of their many usesin industrial processes, not only as human food. It willalso be the case of fruits and vegetables and of “pleasure”commodities such as nuts, cocoa and coffee.Beverages, in particular wine and beer will also drivestrong demand for grapes and barley. For these foodcategories, the growth will be on both volume and thenumber of niche specialties, which will create even morelevels of opportunities. Other food groups will reinventthemselves mostly through quality schemes. Expect thisto be the case for the food groups with a bad reputationsuch as edible fats and grain. The trend towards a changeof heart regarding fats is already in motion and manyprejudices are now being corrected. The same will happenwith carbohydrates in the future. When that happens,consumption will not return towards undiscerning useof fats and carbohydrates in large amounts, but it will beabout nutritional, sensory and health qualities.The world is changing and opportunities will come upin different places than by the past. Anticipate, adapt andthrive!

Adjusting strategies to changing consumption habits

by Christophe Pelletier

Christophe Pelletier is a food and agriculture strategistand futurist from Canada. He works internationally. He

has published two books on feeding the world’s growingpopulation. His blog is called “The Food Futurist”.

The Pelletier Column


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GLOBALG.A.P. AQUACULTURE

STANDARD VERSION 5

NOW ONLINE

GLOBALG.A.P. COMPOUND FEED

MANUFACTURING STANDARD

Safe Feed - Safe Food

Check out our website for events happening near you! www.globalgap.org/events

2015 Alltech mycotoxin storage analysis:

Mycotoxins a growing concern for European ruminants

Mycotoxins are increasinglycausing a negative impacton farms in terms ofhigher costs and lower productivity.Due to continuous development ofmoulds in storage, corn silage is nowtrending at high risk for mycotoxincontamination which contributes toa higher risk for total mixed rations(TMR), according to Alltech’s recentmycotoxin storage analysis for 2015.Alltech has analysed more than 800samples of European ruminant feedfrom September 2014 to July 2015.

Mycotoxicosis in ruminants is oftenthe result of exposure to multipletoxins, due to preharvest infestationof feed materials by Fusarium

species as well as from postharvestcontamination of stored materials.Due to multiple mycotoxins at lowerlevels, the damaging effects onruminants may not always be evidentby solely observing the animals.

“All mycotoxins are produced bymoulds. Moulds are highly inuenced byweather conditions and environmentalfactors. Factors that affect mycotoxin

production in fermented foragesinclude plant stress prior to harvest,packing density, moisture [and] oxygenexposure,” said Dr Max Hawkins, anutritionist with Alltech’s MycotoxinManagement Team.

Through Alltech’s AnalyticalServices Laboratory, the company’s37+® mycotoxin analysis programevaluates the change in mycotoxinnumbers and levels over time fromharvest through storage. By analysingthe number and levels of mycotoxinspresent, the program can provide aRisk Equivalent Quantity (REQ) ofthe increase in risk from harvest tofeed out.

The most prevalent mycotoxins

found in corn silage include TypeB Trichothecenes and Fusaric Acid.According to Dr Hawkins, corn silagein Europe is more contaminatedthan grass silage and appears to berepresenting a greater risk; thereforeit is a more problematic ingredient.However, this does not indicate thatgrass silage is risk-free. In terms ofrisk for dairy and beef, both are at

high risk due to presence of Type BTrichothecenes and Fusaric Acid.

REQ levels for dairy illustrate 60percent high risk, 26 percent mediumrisk and almost 16 percent low risk.The average REQ for beef cattle isat moderate to high-risk level. Morethan 83 percent of the corn silagesamples are at moderate to high riskfor dairy cattle. Total mixed rations(TMR) samples illustrate more than60 percent contain at least threemycotoxins. Type B Trichothecenes,Fusaric Acid and Penicillium showsignicant prominence and inuencedry matter intake, rumen function,milk/ meat production, gut health,low immune response and growthrate, which can affect the life timeperformance of dairy and beef cattle.One-third of TMR samples from

European dairy and beef cattle are athigh-risk level.

“The TMR monthly average shows adenite increase over time originatingfrom a low risk to well above ahigh risk. This is prevalent fromthe samples coming from Europe.The trend since February 2015 hasdemonstrated a much higher REQlevel to cow health and performance.

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COMPANY

UPDATES

AB Vista opens rst ofce in India

to serve growing customer base.

On July 31, 2015 AB Vista hasopened its rst ofce in India,following extensive growth in theregion during the past eight years.The new ofce, located in Pune, willserve as a base for sales, technical,nance and supply chain functions,and is the rst such headquarters inthe region.

Alltech sponsors rst mineral

symposium at PSA annual

meeting. For the rst time in its 104-year history, the Poultry ScienceAssociation (PSA) annual meeting,held in Louisville, Kentucky,July 27-30, included a mineralsymposium. “Changing Insight intothe Role of Trace Minerals” waspresented and sponsored by Alltech.This symposium reected on the

broad range of new informationabout trace elements and suggestedseveral ways of putting this scienceto good use.

Anpario awarded the Queens

Award for Enterprise. Anpario

plc, Meriden Animal Health’s parent

company, is delighted to announcethat they have won The Queen’sAward for Enterprise for outstandingacheivement in International Trade.The Queen’s Award for Enterprise isthe UK’s most prestigious accolade,designed to recognise and rewardthe achievements of UK businessesthat have shown outstanding andsustained growth. The awards aremade each year by Her MajestyThe Queen on the advice of thePrime Minister, who is assisted byan Advisory Committee includingrepresentatives of Government,industry and commerce and trade

unions.

This month Iam writing mycolumn fromIndonesia havingled a group of UKcompanies to theIndo Livestockexhibition heldthis year in

Surabaya, the second biggest Indonesiancity. Surabaya is located in the EastJava region, one of the most importantagricultural regions in the country.Demonstrating the importance of agriculturehere, the exhibition was opened by theirDirector General of Livestock and AnimalHealth Services, Dr Ir Muladno. Ourexhibiters were kept very busy throughoutthe show, hopefully good business willfollow beneting both countries.This is a country where the Government

wants to see serious improvement to theagricultural sector for three reasons:• To cut their reliance on imported

products• Establish a signicant export trade using

their abundant natural resources• Signicantly improve rural incomesThis week in East Java I have been shownfarms that are already improving theirincomes by making use of cooperativemarketing. Government help has enabledthem to create a tiered system for marketingdairy products, whereby a group of village

cooperatives supply a central cooperative.The central cooperative then, in turn,manufactures the milk with UHT treatment,adding avours before proceeding to send tothe supermarkets of Jakarta.In addition to marketing, at village levelthe cooperative takes back the cows fromthe farmers when their lactations nish andreturn them to the dairy farmers once theyhave calved down again. This way they onlykeep cows that are producing an income.In return for this service, the cooperative

keep the calves, they sell on bullcalves whilst retaining heifers for herdreplacements and expansion.An insemination service is also providedfor the farms. Sexed semen of the Holsteinbreed seems to be the animal of choice,

likely because it has a short production lifeand there can be difculty in maintainingherd numbers.East Java alone has about 500 000 milkingcows, they want to double this number ascurrently there is market demand whichcannot be met.Milk production per cow is not high, butattention to stockman ship is good. We were

constantly asked for information on feedingto improve milk yields.Genetics also plays a key role; perhapslooking at some different breedingprogrammes to gain production in therst instance would be advantageous.Additionally, using hardier breeds willprobably, given the conditions, give asmuch milk as the Holstein but have otheradvantages in regards to replacement,longevity and health.The animals are kept in herds of mostly up

to ve cows being the norm. Forage is cutdaily from forested areas and taken to thecows. The grass is course and in its rawstate is acknowledged to be difcult for therumens to cope with. They do try choppingthe grass to make it more palatable but thatdoes not break the cellulose chain to makemore carbohydrate available in the rumen.For the larger herds imported lucerne isavailable. In the dry season grass shortagecan be problematic as there are no facilitiesto dry or ensile the product when it is inabundance.

Locally bred bull calves are frequentlyused in the feeding lots with importsfrom Australia, again quality of feed is areoccurring issue.In addition to the farming we saw rst handthe efciency of cooperation. Small biogas plants were utilising manure to supplyseveral families who would then use thenal dried waste to produce owers andvegetables for Surabaya.I have to say that if I were a young manI would really like to come to Indonesia

to farm the opportunities here I think arefantastic.Next month I will take a group of UKcompanies to China, I look forward toreporting on this event.

@AgrictecExports

Cooperatives supply a central cooperative

by Chris Jackson, Export Manager UK TAG


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Supplementaryfeeding oflive insectsas a sourceof protein for

broilers

ForFarmers and

WUR start joint trial

ForFarmers has launched a trialtogether with the Departmentof Entomology at WageningenUniversity in The Netherlands, toexplore the impacts of live insects as a

source of protein in the broilers’ diet.Leon Marchal, Nutrition and

Innovation Director at ForFarmerssays, “The most important researchquestion is whether the chicks aregrowing healthily and at a sufcientrate in comparison to a traditionaldiet.

“We also want to look at whetherthe broilers’ natural behaviour willimprove as a result of the addition oflive insects. If this project proves to

be a success, it will be an importantstep towards further sustainabilitywithin the industry.”

ForFarmers have commented thatearly observations have clearly shownmore lively foraging behavioursamongst the broiler chicks, and thatit is known that more active Broilerchickens have less leg disorders.

The trial is being conducted atForFarmers’ experimental farm inNijkerk, The Netherlands, where atotal of 1000 chicks are being fed

in four different groups. A controlgroup will be given a traditionaldiet, while the remaining three willbe given 5 percent, 10 percent or 15percent respectively of black soldiery larvae. The high protein content ofthese larvae replaces up to 75 percentof a protein like soya.

“The larvae from this species aretruly omnivorous and are relativelyeasy to grow,” according to AlbertDijkslag, Poultry Innovation Manager

at ForFarmers.“This will also result in prot for thefarmer and increased sustainability.These larvae are grown on residualows from the food industry. Theseresidual ows and the protein within

these would otherwise end up inbiomass (fuel), however now they areavailable as feed.”

“And if the trial proves successful,we will have found an alternativesource of protein,” he added

Natural nutrition and behaviour

The initial results are expectedin September. “The application iscurrently quite expensive. But it’sdenitely a good rst step and mind-set. If we see positive results, we willcontinue with the further optimisationand development of the trial,” MrDijkslag explained.

Elaborating on the high costs ofthe application, and if possible,how this price might reduce, MrMarchal responded with, “Thecost of production of insects will

reduce in the future. The two majorcontributors are automation and betterfeed efciency/growth performance.Currently the nutritional knowhow ofhow to best feed insects is still in itsinfancy if you compare it to the levelwe are at with for example pigs andpoultry. The few small producers thatexist generally protect their own wayof operating and exactly what theyare feeding. What is needed to reallyboast the rearing of insects is the

development of publically availablefeed tables and nutrient requirementsof the insects. This will create acommon foundation on which otherscan build and compete again witheach other as individual companies.”

Mr Marchal added, “The nice thinghere is that chickens in the wild arenaturally omnivorous and insectswould feature as part of their diet, theoutcome of the project therefore couldbe to help birds further express theirnatural behavior.”

ForFarmers wants to be a leader insustainability, given its position in thefood chain. ForFarmers is providing acontribution to an economically viableand sustainable food production byefciently producing animal feedsand developing products and conceptswhich allow the animals to utilise thefood in a healthier and better way -improved feeding efciency. This trialwith live insects indicates ForFarmersis really giving substance to itssustainability ambition.

The various different partiesinvolved think it will be some timebefore the large scale supplementingof diets with live insects can beintroduced in practice. When I askedForFarmers about this, they predictedthat realistically speaking they expectthe rst steps to be taken in 2016or 2017, but this greatly dependson whether they are able to createa market pull by implementationin a premium segment. Noting that

currently there are several premiumsegments (besides organic) withattention to animal welfare orsustainability, and see live insect feedas possibly improving such premiumsegments further.

Leon Marchal and AlbertDijkslag, ForFarmers

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Safe feed and foodstarts with secure riskmanagement. For this,GMP+ International offers theirknowledge and informationthrough the Feed SupportProducts (FSP). The FeedSupport Products are intended tosupport all future GMP+ certied

companies with setting up their company-specic HACCPsystem. The responsibility for use and implementationremains with the GMP+ certied companies, the Feed

Support Products can offer support in this process. TheFSP is also intended as a reference for the auditors withinthe framework of GMP+ certication.

The following products are a part of FSP:

Fact Sheets - The fact sheets show background detailsregarding the hazards and the (explanation of the)severity of the risk to animals and humans. The contentof the fact sheets is as follows: Nature, history andprevalence; Transmission to the environment, plants,

animals and humans; Diagnose of poisoning; Potentialhazards and adverse effects; Severity of the hazard;Standards; Analysis methods and Control measures. Thecompany when undergoing a specic risk analyses canuse the information. Fact sheets are available for severalmycotoxins and other undesirable substances (hazards) inthe Risk Assessments and for processing aids.

Generic Risk Assessments - This section of FSP containsabout 200 risk assessments of feed materials for Food-producing animals (including goats, poultry, cattle, sheepand pigs, but also horses and rabbits). Farmed sh willbe included. The risk assessments in the FSP database are

of a generic nature and represent a worst-case scenario.The risk assessment gives information about a productionprocess and the resulting possible hazards.

Product list - This list gives a short summary of allproducts available. There are about 600 products on thelist that may be used as a feed material in the GMP+ FeedCertication scheme.

Product standards - Standards with maximum permittedlevels have been issued by legislation and by GMP+International for many hazards in order to be able todetermine if a feed material is safe. All the standards area part of the GMP+ FC scheme, GMP+ BA1 Product

Standards. Also the standards for mycotoxins areincluded.

GMP+ Monitoring database - A service from GMP+International is the GMP+ Monitoring database.Companies can put their analyses into the database andcan share these results with a group of companies or

with the GMP+ community. Sharing is an option, not arequirement. Monitoring results can be used to assess thelikely occurrence of a hazard. In the Database there arefor mycotoxins analyses results available. It is possible tomake overviews per product for a dened period.

The GMP+ monitoring database is an easy tool for storingand sharing analysis results, you can easily check if theproducts meet the standards.

Guidance’s - At the beginning of 2014 the rst GMP+

guidance about implementation of a Feed Safety Systemin accordance with the GMP+ Feed Certication schemehad been launched. The D1.2 GMP+ guidance containsall needed information and steps and can be ordered viathe webshop of GMP+ International.

Your benetsFSP provides ease of use, a uniform source of relevant

data, linking of relevant les and efcient searching. Thebenets of use are:• up to date knowledge of risks of feed materials• up to date knowledge of undesirable substances;

• assessment from independent experts;• a uniform source of knowledge;• automatic linking of all relevant les.

Core valuesThe Feed Support Products operates from four core

values:Practical information - The information in FSP about

processing, possible hazards, risk assessments andmonitoring data is received from GMP+ companies.

Science based - The (generic) risk assessments of feedmaterials fully comply with the requirements referred toin the HACCP manual for the animal feed sector (2008).

To substantiate potential adverse effects of a hazard,the information is published in fact sheets for bothundesirable substances and technical processing aids.The severity of hazards indicated in fact sheets and riskassessments have been evaluated by scientists of RIKILT.

Independency - The policy and technical aspects ofFSP are reviewed by independent committees, theInternational Expert Committee Animal Feed (IECAnimal Feed) and the Technical Committee FSP (TCFSP), the latter acts as a HACCP team for the FSP.The TC FSP has members who are representatives ofdifferent subsectors and knowledge areas (chemical andmicrobiological)

The meeting of TC FSP will at least take place two timesa year. Besides the regular members of the TC FSP,‘advisors’ can be invited to TC meetings. These advisorsare either laboratory representatives, representatives of

by Els van der Boon, Program Manager Feed Support Products, GMP+

Mycotoxins and other hazards controlled by the use of FSP


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the Food and Consumer Product Safety Authority,or scientists (eg. Rikilt). Also independent advisorsfrom certication bodies or consultancy agencies canbe invited to (parts of) the TC.

Transparency - GMP+ uses a transparentcommunication to all stakeholders as well astransparent working methods. Procedures for changesare described. Every change is communicated to theGMP+ community via the FSP newsletters.

How do we keep the FSP up to date?The content of the different products continuously

changes due to new feed legislation, regulations,emerging risks and new scientic information.Changes include new feed materials/products,hazards, new “product-hazard combinations” and newstandards (legislation). These changes are periodicallyprocessed by GMP+ International within FSP by amaintenance procedure.

Changes in a hazards severity or effect are processedin factsheets and/or risk assessments. If needed,

changes in risk assessments, factsheets, GMP+standards or monitoring program, are discussed withinthe TC FSP. Reasons for changes can be (amongothers):

In general:• New feed legislation• Early Warning System (EWS) from GMP+• Rapid Alert System for Food and Feed (RASFF)• Feed Crises• New scientic information/new hazards (eg. from

TNO, Rikilt, EFSA)• Practical experiences from companies

Information must be evaluated on the necessity for

taking immediate action. In some cases, immediateaction is needed, for instance in case of a newlyemerging risk. Other types of information, for instancescientic information, can be processed in a later stageand will be led for planned maintenance of FSPinformation annually.

If new non-conformities related to food and feedsafety occur there must be a short-term evaluationabout the consequence for feed (if it is a non-conformity from food) and the consequences for FSP.New hazards can be communicated in a short term tothe feed sector.

GMP+ certied companies are being informed ofchanges in risk assessments and/or fact-sheets bymeans of newsletters. All newsletters can be foundon the GMP+ portal www.gmpplus.org (under “In theSpotlight”).

Die and roll re-working machines

O&J Højtryk A/S

Ørnevej 1, DK-6705

Esbjerg Ø

CVR.: 73 66 86 11

Phone: +45 75 14 22 55

Fax: +45 82 28 91 41

mail: [email protected]

www.oj-hojtryk.dk

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This month we look at European statistics –both feed and specically ruminants. We areusing two sources of statistics; our regular

contributor Alltech and FEFAC, the European FeedManufacturer’s Federation.

Europe produced 224.6million tonnes of compoundfeeds in 2013, the latest yearfor compiled statistics fromthe Federation.

Ruminants, includingcattle, dairy cows, sheep

and goats, and the focusof our ruminant reviewthis month is also basedon FEFAC statistics from2013, showing some 32.5million tonnes of compoundfeeds (or 27.5 percent)were produced by the EU28. To this must be addedFEFAC’s ‘others’ category,which is mostly made upof sheep and goat feeds and

accounting for a further 10million tonnes in 2013.

European statistics

The industry’s most

authoritative resource

on feed production


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Twenty-nine participants from eight countries learnt the

nuances of large-scale industrial feed and much more, when

they attended the feed manufacturing course held on July

7-10, 2015 at IGP-KSU. Feed mill supervisors and managers,

plant operators, quality assurance managers, nutritionists

and supplement manufacturers were some of the individuals

who attended the training.

“Taking this course, participants were able to learn thenew trends in feed manufacturing and to strengthen theirknowledge on the crucial concepts that make the feedproduction process more effective,” says Carlos Campabadal,Feed Manufacturing and Grain Management CurriculumManager and course manager.

The four-day course focused on grain storage, particle sizereduction, batching and mixing, extrusion, animal nutrition,pelleting, quality control and advances in feed technology. Thecourse encompassed lectures, workshops and tours of the O.H.Kruse Feed Mill and Kansas State’s dairy facilities.

Course participant Peter Dehn, feed mill manager fromKJMM Pork & Grain, appreciates the networking opportunitieshe will gain by attending an IGP Institute course. New to theindustry, Dehn decided to attend the course to understand what

his employees’ jobs entail. “The fact that we can communicate back with IGP Institute

after the course, that’s fantastic. This has been a top-notch,professional and classy course, top to bottom,” says Dehn.

Fellow course participant Ayoola Oduntan, group managingdirector of three companies, national president of the PoultryAssociation of Nigeria adds, “I’m now better equipped tomanage the feed complex. I’m denitely going to get some of

our managers to attend this course.”In addition to feed manufacturing and grain quality

management, the IGP Institute offers courses in the areas ofour milling and grain processing, and grain marketing and

risk management.

IGP-KSU FeedManufacturing Training

TrainingMill

Turnkey Feed Mil l

Sys tems

www.yemtar .com600 Evler Mah. Balikesir Asfaltı Sol Taraf Cad.No:65 BANDIRMA / BALIKESİR / TURKEY

P(+90)266 733 85 50 | F(+90)266 733 85 54

G e a r D r i v e n P e l l e t M i l l

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PRODUCT FOCUSAUGUST 2015In every edition of Milling and Grain,we take a look at the products that willbe saving you time and money in themilling process.

Processing equipment Thismonth we look at the latestproducts available forprocessing lines

www.dinnissen.nl

www.buhlergroup.com

Pellet cooler Coolex™Bühler has launched the new pellet cooler Coolex™. Coolex™provides efcient cooling of the hot pellets discharged fromthe pelleting process, this is the only way to obtain high-qualityend products with optimal hygiene. With its integral productionprocesses, using Coolex™ as an integrated cooling systemcomponent, Bühler supports feed manufacturers in increasingtheir product quality and hygiene while reducing their costs.

The innovative design of

this system is based on thecountercurrent coolingprinciple. Coolex™ offersregulation of the dischargegap, ensured continuousproduct discharge, uniformcooling, an optimalmoisture content, and aconsistently high pelletquality.

Perry belt drierPerry launch brand new belt drier - The most signicantproduct release in a decade Perry’s brand new belt drier iscapable of drying everything from woodchip to cereals andgranular products to recycled waste.

When drying wheat you can expect capacities of up to 60tphwith a 5 percent moisture reduction. As standard it has fullygalvanised, modular design (2.1m length increments) with 3different widths available (1.5m, 2.2m and 3m). A full stainlesssteel assembly and a fully insulated model are additionaloptions available.

It is available with either axial orcentrifugal fans; axial

fans allow for lower airspeeds and pressure incomparison tothe centrifugalfans and havea lower powerconsumption.

Density Control SystemWenger has integrated three successful, existing process

components together to create a new Automatic DensityControl (ADC) system for the control of wet bulk density duringproduction of pet foods.

The Wenger ADC system incorporates a sampling and bulkdensity measuring device (Source Technology’s BDS) intoa system that includes the Wenger back pressure valve(BPV) on the extruder barrel and Wenger’s integrated APM(automated process management) extrusion control system toautomatically measure product density and adjust the processto maintain the desired density specications.

Wenger’s ADC can be installed as partof a new system or retrotted intoa system that already has oneor more of the three basiccomponents.

Semiautomatic screen changerDinnissen Process Technology is introducing its newest HamexHammer Mill tted with a semiautomatic screen changingsystem. This latest model was developed to provide users whoregularly switch from one product to another with increasedspeed, convenience and energy savings.

The semiautomatic screen changer allows the user to quicklychange screens without stopping the grinding rotor. Thisminimises downtime during the grindingprocess and maximises productioncapacity. In addition, as thegrinding rotor and the motor nolonger have to be repeatedlyswitched on and off, it alsosaves a great deal ofenergy.

www.wenger.com

www.perryofoakley.co.uk



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SPECIAL FOCUSAs an essential part of Famsun’s extruder machinery, the single-screw extruder (for aquafeed, raw materials) is widely used infeed plants. The removal of screws has always been a problemin the operation of extruder machinery. Every manufacturer mayhave its own removal tool kit, yet few can offer satisfactory

solutions.To develop new efcient removal tool kits, the following threefactors should be taken into consideration:To begin with, during peak production season, the machines haveto stay operational as long as possible to cut the costs incurred bydowntime. For instance, without an efcient method, removingthe screw head can take anywhere between 30 minutes and one ortwo days with nothing but temporary tools at hand. Consideringthe time consumed, it is of signicant necessity to makeimprovements in the removal process to meet the productionagenda.Second, to lengthen the service life of the screw head, it isnecessary to minimise the damage done to the screw head when it

is being taken off.Third, a high degree of automation isnecessary. So far, some of Famsun’s rawmaterial extruders have been automatisedand these machines are more operation-friendly than they used to be. But simpler,faster removal tools are still needed toimprove the competitiveness of Famsun’smachinery.Currently, the removal tool kits availableare for raw material extruders. ForTPH/PHY200, TPH260/PHY260 seriesextruder, the removal tool kit in use doesnot deliver satisfactory results. Becauseof its structure, the tool can only removethe rst section of the screw. Besides,current removal tools also require specicscrew leads. It also takes a lot of effortand time to manually turn the screw lever,especially when some screws haven’tbeen removed for years. For single screwextruders for aquafeed, however, theaforementioned method does not work.Compared with earlier versions, theup-to-date removal tool kit can removesingle screws of all types (TPH200/260;PHY200/260; SJPS135/165/215/265), not

just the rst section of certain types of screws.The time needed to remove one section is less than 20 minutes.Its structure and operating principles are as follows:

Performance:

• Time spent in removing one section of screw: ≤20min

• Maximum thrust: 30TX2• Ability to remove each section of the screw: yes• Number of operators: two

Structure:

• Double jack: to balance the force• Hand pump: easy to handle• Anti-deviation design: to ensure precision• Extension rod: to make it easier to drive the whole screw out

• Mounting plate: waist-shaped holes in the plate make it easierto readjust the hold hoops in different positions

• Spindle position-limit mechanism: prevents the spindle fromshifting position when it is being knocked out by the ejectionmechanism (Patent No. 201320370871.3)

• Screw ejection mechanism:

The pair of jacks can be operated with the hand pump, theirstroke synchronised by hand with less effortThe mounting plate facilitates the xation of the pair of jacks

The waist-shaped holes make it easier to adjust the phase of thehold hoops in different positionsThe split locking sleeves are easier to installThe anti-deviation design prevents the unsynchronised jack fromgetting stuck with the main spindleThere are 20 extension rods included, to help remove the lastscrews.

Position-limiting mechanism:

• The position-limiting mechanism is used to prevent thespindle from being damaged by friction caused by thespindle in the block and the main spindle (the currentstructure of the extruder only has a limit screw to bearbackward thrust; without a limit screw to counter forwardforce, the spindle can only take a little forward-pullingforce)

• The front bezel is composed of two half-type panels xed inthe inner wall of the spindle

• The backplate is composed of two quartered pieces xed inthe inner ring of the rear spindle

• The front bezel and the backplate are connected by a stopperbolt

• There are two M30 lock screws; each of them can bear anaxial force of more than 30 tonnes.

Famsun’s single-screw removal tool kit

FOCUS #8

www.muyang.com

Screw

Main spindle

Spiltlockingsleeve

Pull rod set

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Rice is considered one of the world’smost important crops and is a majorpart of the food culture in Asia, LatinAmerica, Africa and other parts of theworld.

Global rice production is steadilyincreasing to meet the growingdemand for food from a rapidlyrising global population. The Food

and Agriculture Organisation (FAO) – United Nations estimatedthat 2015 production of rice is around 500 million metricton. Production of grains including rice is currently meetingand exceeding consumption. As more rice is being producedand processed, another part of the paddy, rice bran, is beinggenerated.

Rough rice or paddy (see diagram) consists of the white starchyrice kernel, surrounded by a tightly adhering brown coating ofbran and enclosed within a loose outer hull. During the ricemilling process, the hull and the bran along with the rice germ areremoved mechanically to access and polish the white rice, whichis the principle sustenance for the majority of world’s population.Due to the lack of a proper method for rice bran stabilisation inunder developed and developing countries, rice bran was under-utilised until low cost extruders were introduced in the market.

General steps in the production and utilisation of

stabilised rice bran

The separation of the hulls and the bran can be through one,or more stages. If the dehulling took place in one stage whereboth the hulls and the bran are mixed, the oil content will below (below 10 percent), an economical separation of the oil isnot possible. However, the use of two stage rice mills, in whichthe bran and the hulls are recovered separately, allows for aneconomical extraction of oil.

The hulls (about 20 percent of the rice paddy by weight)have no signicant nutritional value as they consist mainly of

cellulose, lignin and select minerals. On the other hand, rice bran(approximately 5-10 percent of the rice paddy by weight) is richin protein (14-18 percent) and energy; mainly in the form of theoil it contains (10-20 percent). The percentage of oil in the brandepends on the milling process, the contamination of the branwith hulls and broken kernels and whether the bran is obtained

from raw or parboiled paddy.Besides the protein and energy, stabilised rice bran is an

excellent source of vitamins B and E and some antioxidants. Ithas been used as an ingredient in poultry, pet food, and ruminantanimal diets.

The urgency for stabilisation of rice bran

Rice bran has a powerful enzyme system which is activatedduring the milling process and causes rapid deterioration of theoil by exposure to the enzyme lipase and, to a certain extent,oxidase. Enzymatic hydrolysis of the oil into free fatty acidsand glycerol will start and the acidity increases (reduced PH)resulting in the development of a soapy off avor.

The oil in the un-milled rice paddy is stable, as the Lipolyticenzymes are located primarily in the seed coat. Whereas mostof the oil in the un-milled paddy or brown rice is stored in thegerm and the Aleurone cells (the protein rich outmost layer ofthe endosperm), upon milling, the oil is subject to the activity ofthe powerful lipase enzyme causing the accelerated break downof the oil into free fatty acids and glycerol. The free fatty acidsbecome susceptible to further decomposition through oxidativerancidity that will produce free radicals, cause soapy avour and

Stabilising rice bran

through high shear

extrusion

by Dr Nabil W. Said, VP Nutrition & Extrusion Technologies,Insta-pro International

Figure 1

Figure 2


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a reduction in the nutritional value. For this reason, it is of utmost

importance to immediately stabilise the bran to prevent thedeterioration and the rancidity of the oil.

Inactivation of enzymes through extrusion

High shear dry extrusion was developed by Insta-ProInternational in the late 1960’s to inactivate the anti-nutritionalfactors present in soybeans. Those anti-nutritional factors areenzymes such as the trypsin Inhibitors, hemagglutinins, lipase,lipoxygenases, urease and other anti-nutritional factors. If

ingested in their intact state, the anti-nutritional factors willadversely affect the digestion of nutrients through their inhibitoryeffects on the pancreatic enzymes responsible for digesting theprotein and carbohydrates. The high dry shear extruder generatesheat through friction (mechanical energy) along with pressure.The barrel of the extruder consists of segmented chambers with ashaft that rotates at constant speed.

Screws are tted on the shaft separated by steam locks or shear

locks designed to disrupt the conveying of the material and force

some of it to revert back through channels in the wall of the barrelthus generating shear and friction that raises the temperature ofthe extrudate in a controlled manner (see the following gures).

Upon exiting the extruder, a sudden drop in the pressuretakes place that results in rupturing cell walls, releasing naturalanti-oxidants (tocopherols), partially dehydrating the product assome of the moisture will be ashed off in the form of steam.

This sudden drop in pressure also results into sterilisation of theproduct. As concluded from numerous scientic studies, viruses,

bacteria, coccidia, mold and yeast cannot survive the extrusionconditions.

The inactivation of the enzymes takes place through altering the

tertiary structure by breaking the disulde bonds holding the aminoacids strands together. The proper optimisation of the extrusionparameters allows for the denaturing of those enzymes without theadverse effect on the primary structure of the amino acids.

The cooking time takes only a few seconds and under theproper conditions of operation, the digestibility of nutrients inthe extrudate would be at its highest level. The extruder hasbeen used as one of the most effective tools to stabilise productsthrough enzymes inactivation thus in the case of rice bran,

Figure 3

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stabilising it immediately after milling.Fresh milled rice bran oil normally contains 1.5-2.0 percent

free fatty acids. Free fatty acids level of less than 5 percentis desirable. If not stabilised within few hours after milling,the free fatty acids in the oil will exceed the 5 percent level.Exceeding 10 percent free fatty acids in the oil would indicateless recoverable edible oil.

Utilisation and benets of stabilised rice bran

Stabilised and extracted rice bran oil is very popular as acooking vegetable oil in China, Japan, Taiwan and other Asiancountries. In the late 1800’s, it was discovered that East Indiessailors suffered from what thought to be toxins or infectiongenerated from the white rice that they consumed. The diseaseis called Beriberi. It was later discovered that when the sailorswere fed meat, vegetables and dry milk, the symptoms subsidedand disappeared. It was then recognised that it was a nutritionaldeciency in the polished rice that lead to the discovery of

vitamin B1, thiamin. This vitamin stays in the bran uponpolishing the rice. By adding rice polishing to the Beriberiinicted chicken’s diet, the fowl were cured of the disease.

Because of its content of decent protein level, oil, bre andantioxidants, stabilised rice bran can be used as an excellentsource of energy, protein and bre in animal feeds, human food

and as a functional food or nutraceutical ingredient. Many claimshave been made as to its benet in lowering the cholesterol

through its content of tocotrienols tocopherols, ß-sitosterol andγ-oryzanol. It is also been used as a stool-bulking agent.

In the feed industry, stabilised rice bran is being used as apalatable ingredient and excellent source of protein in pet food;energy and bre in equine feed, poultry and ruminant animals.

References available upon request

Figure 4

Figure 5

Figure 6

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Brock Grain Systems

Storage | Handling | Conditioning | Structures

BROCK GRAIN SYSTEMSA Division of CTB, Inc.

A Berkshire Hathaway Company

+1 574.658.4191 www.brockgrain.com [email protected]


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The term ‘food basket’ here in Indiaactually means a real basket that anaverage Indian homemaker takes toshop for groceries and food. Somedecades ago, her basket (nowadays,‘his’ too), will contain plenty ofvegetables, small millets and a richvariety of leafy greens in addition tostaple grains, such as rice and wheat.

However, many of the above items had been vanishing, albeitslowly from the food basket, and most of these are not evenknown to the millennials and Gen X.

Even the older generation, that is popularly called as the

baby boomers, and who used to consume these diversefoodstuffs everyday had, to a large extent, forgotten them. Thetransformation of diet in India over the past few decades is mind-blowing in the extreme and disturbing to boot.

In this article I would like to discus the key macro trends in theconsumption of select food crops in India; possible causes of thetransformation of diets; potential impacts on health and wellbeingand, nally, the importance of enabling policies that can augment

not only food but the nutritional security of a country.Although this analysis is primarily related to India, the

recommendations and implications can be applied to any countrythat shares a similar agrarian, demographic and socio-economic

prole.

Is shrinking diet diversity a serious concern?

If one might think how relevant or important diversity in dietsis - that is, the different types of commodities and foods thatsupply nutrients - then they should consider this. In a recent study

on how and from where population in different countries derivetheir calories revealed that in the past 50 years, more and morecountries became dependent on fewer crops.

In other words, diets of majority of people in several countriesacross the globe are becoming homogeneous and the dependenceon few key crops such as wheat, maize (corn) and soybean.

If harvests in any of the major regions that produce these cropsface adverse weather, the ramications go deeper and wider

across the globe. Prices tend to soar, and producing countries maytake knee-jerk reactive measures to curb trade which will furtherstrangle global availability.

Any increas

Milling and Grain August 2015 - FULL EDITION

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