Digital Re-print -
January | February 2014
Tech Focus - NIR
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
©Copyright 2014 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form
or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872
F 14 | January - February 2014 Grain &Feed millinG technoloGy
systems are small and
handy analytical instru-
ments which can be
directly mounted at the outlet of the press
and extraction installation for real-time meas-
urement of the oil and moisture content of
team at Bunge: Here, the industrial spectrom-
eters are used for continuous generation of
the reference values for rapeseed processing.”
rapeseed the press cake - 24 hours a day, seven days
a week. This is obtained by successive emis-
sion of light in the near infrared (NIR) region
Transparency in just two hours
The new analytical method allows Bunge
trough a vision panel. The light interacts with to control the complete production proc-
the press cake which is transported by chain ess for the first time - from the pressing of
conveyer and the reflected light is recorded the rapeseed to the extraction. This whole
using NIR technology by photo diode arrays. The important point is
that the composition of the reflected light is
subject to the oil and moisture content.
process lasts around two hours and after
this time span, Bunge can assess whether
the process is running under optimal condi-
These measurement values are further tions, i.e. whether the maximum amount of
processed by dedicated software which is oil is exploited from the press cake. In the
ne fact in rapeseed process- integrated into the industrial spectrometers. case where there is room for improvement,
ing is: the higher the exploita- The measuring curve is displayed in real-time the operator at the control room is able to
tion in oil, the higher the profit. to the operators at Bunge control room. counteract undesirable development which
Bunge Deutschland GmbH implements Furthermore, the measurement values are prevents financial losses.
and realises this basic principle through directly integrated into the process control “Traditional analytical methods provide
real-time process-control with NIR-Online system of Oil Mill Mannheim. the results after around one day and in the
industry spectrometers. “Assuming the press cake exceeds the past we were not able to tell whether the
accepted moisture level, the operator at individual sampling was prone to outlier or
Overall, 3,500 tonnes of rape seeds are the control room can directly intervene to whether the whole process was deficient,”
processed day by day at Bunge Oil Mill in ensure that the upstream rape seeds are said Moritz Lücke.
Mannheim, Germany with two identical subject to stronger drying during steps of “Throughout the whole time we were
production lines. Production yields are 2,000 conditioning,” said Roland Bauer, assistant virtually operating without knowledge of
tonnes of rapeseed meal which is further production manager for seed processing, real-time information about the process
used for feed processing and 1,500 tonnes Bunge Germany. parameters.”
of raw oil for further biodiesel and refined “This is because the higher the moisture Those responsible at Bunge now know
edible oil production after neutralization. content of the press cake, the more difficult about the true optimization potential of rape-
Rapeseeds pass through a press resulting it gets to exploit the oil in the subsequent seed processing, thanks to continuous real-
in press cake and press oil, representing extraction step.” time control of the pressing and extraction
two-thirds of the profitable oil output of the Direct indication about the final rate of oil process - purposefully increasing the profit.
oil seeds. In the next step, the oil from the exploitation is provided by the measurement
remaining press cake is further exploited via values of the second NIR-Online spectrom- The refinery should also benefit
extraction process. This process is energy eter, analysing the rapeseed meal at the end In order to also benefit from the advan-
and time demanding and, hence, Bunge has of the extraction step. tages of real time process control during
set a limit for the percentage of oil to be steps of refinery, the Oil Mill Mannheim plans
tolerated to remain in the press cake. Applicable in explosive the acquisition of additional NIR-Online
environments industrial spectrometers this year. These sys-
Deficits due to time-delayed Industrial spectrometers can also be used tems are meant to be used during steps of
sampling under potentially explosive environment. For de-sliming and neutralization of the pressed
But when exactly has this percentage example, during the extraction process using oil for determination of the concentration
been reached and when has the maximum Hexane as a solvent, constituting another of phosphorus and free fatty acids. The
exploitation of oil been realised? “Previously, important advantage for Bunge. potential for improving these processes are
this question could not be answered satisfy- “Other comparable analytical systems are significant: each day Bunge produces 1,500
ingly since for process control, the analytical not vibration-free and have no ATEX Gas- tonnes of raw oil from which 70 percent is
methods were restricted to nuclear magnet- Ex-certification. Instead, they are fitted into an further processed for generations of biodie-
ic resonance analysis and further laboratory explosion-proof cabinet making it necessary sel by an external company, 30 percent is
methods,” said Moritz Lücke, production to work with optical fibre in order to reach used for edible oil generation at their own
manager, Bunge Germany. “The results of the true measurement position,” said Klaus production site.
these time-delayed methods only reflect a Klawun, head of laboratory, Bunge Germany.
given moment in time and, hence, real-time “This is quite complex and results in far
intervention to the process was not possible weaker measuring impulse and inferior meas- More inforMation:
in the case that there was scope for increase uring results compared to an NIR-Online Website:
in exploitation. device. Furthermore, the integrated software www.bunge-deutschland.de
This situation changed after application of is characterized by high user friendliness and www.nir-online.de
NIR-Online industrial spectrometers. These this is especially important for the laboratory
Anatomy of Tapco Food Grade
Nylon Elevator Bucket
FDA-Compliant Resins Unequaled Strength
Nonmetallic resin will never oxidize or corrode. Style CC-XD is molded with 35-50% more resin
Will not leach into or affect the integrity of throughout the entire bucket – not just at critical
ingredients used for food products. * wear points – for superior strength and long life.
Minimal Cross Nutrients
Contamination • • Stay Intact
Precision molds create • • Straight sides, high end
smooth non-porous CC design and rounded
surfaces and seamless • front lip provide clean
construction. • discharge with less damage
to the commodity.
Ease of Maintenance Wears Better, Lasts Longer
Lighter weight aids in mounting STYLE CC-XD (XTREME DUTY) Highest grade prime virgin resins
buckets and reduces load on belt Impact-Modified Nylon Elevator Bucket for unequaled impact strength and
and running components. superior abrasion resistance.
Accurate Capacity Ratings Tough & Flexible
Equal or greater carrying capacity of equivalent Prime virgin resins “give” or “yield” to bypass
size steel buckets. Engineered design allows close obstructions in your elevator, allowing the bucket to
bucket spacing for more product delivery per hour. return to its original shape.
FDA-compliant Polyethylene and Urethane resin is standard. FDA-compliant Nylon resin available by special request.
Over 900,000 buckets in 93 sizes, 6 materials, 12 styles -- plus 15 million elevator bolts in stock.
ELEVATOR BUCKETS - ELEVATOR BOLTS
St. Louis, Missouri U.S.A.
Tel.: +1 314 739 9191 • +1 800 AT TAPCO (+1 800 288 2726) • Fax: +1 314 739 5880
*Statement based on our current level of knowledge and covers the above mentioned material produced by Tapco Inc. at the date of issue. Since conditions of use are outside of
Tapco’s control, Tapco makes no warranties, express or implied, and assumes no liability in connection with any use of this information. Tapco Nylon resin meets U.S. Food and Drug
Administration (FDA) Regulations Title 21 CFR177.1500, 21 CFR175.105, 21 CFR178.2010 and 21 CFR177.300. © 2013 Tapco Inc.® All rights reserved.
15 | January - February 2014 Grain &Feed millinG technoloGy F
ProFoss has been on trial at a B1, about 4000 tonnes of B2
Senwes facility in South Africa. and 4500 tons of B3 grade, and
The solution consists of an NIR lower amounts of lower grades.
analyser, a sample interface and The process analysis system
special software for graphical enables continuous monitoring of
display of the results. wheat protein levels, allowing in-
It has been used at a group line adjustment to regulate the
of silos next to a large mill. The blending and maintaining specific
How to get the mix different silos contain different minimum
protein levels: 9 percent, 10 percent, 12
protein levels during outloading. As indicated
by the B1–B3 columns, this resulted in all the
right with in-line NIR percent and so on. The sample interface is
installed in a pipe that delivers grain from
lower grades being blended with higher protein
grades, yielding B1 and B3 grades that were
by Richard Mills, FOSS, the different silos onto a conveyor belt that considerably higher than the initial stock level.
Denmark serves the mill. “We successfully managed the optimiza-
The sample interface is installed by cutting tion of all protein levels and the homogeneity
outh African grain suppliers Senwes a hole in the pipe of about 10 cm diameter. of quality in all wheat batches,” says Purnell.
have tried out a new way of using near It has a sapphire window that sits flush with “As far I am concerned the ProFoss works
infrared (NIR) analysis to optimize the sides of the pipe, allowing the NIR unit to very well for managing your grain quality as
the use of increasingly scarce high-protein take measurements on the grain as it flows by. it monitors 100 percent of the batch being
wheat in blends going into milling. The new Measurements are made every few sec- loaded and really keeps protein fluctuation
instrument will now become a permanent onds and the results are displayed on a within a narrow band.”
feature, helping to get the very best out of computer in the control room, where they She also points out that it is of course
both high- and low-protein material. can be viewed as a trend graph to make it important to have the right quantities avail-
easy to keep track of the protein content. If, able to maximize the usefulness of NIR
In the fairy tale ‘Rumpelstiltskin’, a miller for example, 11 percent protein is the target analysis.
boasts to a king that his daughter can spin and the level starts to fall below that, then a The trial completed, the plan is now to
straw into gold. little higher protein wheat can be added to put the system into use on a permanent
While nothing can make this enduring stabilize the overall protein content. basis. “We can see that the level of control
dream come true, modern process analyti- and management of the protein level being
cal technology in the form of an in-line NIR Lower grade to higher grade shipped out is far superior to when it is
analysis system is making a real difference Manager of special products Mariana controlled by a human being who does infre-
to what millers can get out of wheat grain Purnell describes how the ProFoss ana- quent sampling and testing,” says Purnell.
deliveries. It is not exactly turning straw into lyser was installed at the Senwes facility in “By gathering more precise data of pro-
gold, but is perhaps the next best thing given October 2012. tein units leaving the silo, one can be assured
the increasing scarcity of high quality wheat. When the analyser was brought into use, of a lower number of disputes related to
Corporate Banner process analysis solution called 1
The new (190x132mm)(outlines)_Layout there were just over 5000 tonnes of grade
23/12/2013 08:54 Page 1 protein levels and subsequent downgrading."
This digital Re-print is part of the January | February 2014 edition of Grain & Feed
Milling Technology magazine.
Content from the magazine is available to view free-of-charge, both as a full
online magazine on our website, and as an archive of individual features on
the docstoc website.
Please click here to view our other publications on www.docstoc.com.
January - February 2014
first published in 1891
• See the full issue
• Having no choice
is not reasonable
The quest for a healthier
• Visit the GFMT website
In this issue:
Production control in
• Contact the GFMT Team
Design of an rapeseed processing
efficient intake using NIR technology
system • Keep running
the state-of-the-art in costs down
technology operating en-masse
• Silos special: • Getting your
• Subscribe to GFMT
Bulk storage dies and rolls
locally to global
INCORPORATING PORTS, DISTRIBUTION AND FORMULATION
A subscription magazine for the global flour & feed milling industries - first published in 1891
To purchase a paper copy of the magazine, or to subscribe to the paper edi-
tion please contact our Circulation and Subscriptions Manager on the link
INFORMATION FOR ADVERTISERS - CLICK HERE
All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these
have been used as point of sale materials, promotional materials for shows and exhibitions etc).
If you are interested in getting this article re-printed please contact the GFMT team for more informa-
tion on - Tel: +44 1242 267707 - Email: email@example.com or visit www.gfmt.co.uk/reprints