Digital Re-print -
May | June 2014
IAOM 118th Annual Conference & Expo
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F 24 | May - June 2014 GRAIN &FEED MILLING TECHNOLOGY
Milling Industry’s Largest Gathering
Middle East & Africa
The 25th Annual IAOM MEA District Conference & Expo will be held
at the Cape Town International Convention Centre (CTICC), Halls 4A & 4B on 3-6 December 2014.
Conference and Expo Highlights Top Notch Keynote Speakers
• Largest gathering of ﬂour & feed • World renowned keynote
milling industry machine speakers include Dr. Beau Lotto,
suppliers, grain millers and Neuroscientist & Founder Lottolab
commodity traders from the (UK) and Daniel Basse, President
Middle East, Africa and all over & founder, AgResource Co. (USA)
the world • Evening Functions in Cape
• Captivating and vibrant keynote Town’s most elite venues
speakers for Management, • English and Arabic simultaneous
Technical and Trading sessions Management Trading Moderator Mike Krueger
translation available Keynote Speaker & Keynote Speaker Founder & President,
• Extensive networking • Full access to conference Dr. Beau Lotto Daniel Basse The Money Farm (USA)
opportunities presentations and expo Neuroscientist & Founder, President & Founder,
Lottolab (UK) AgResource Co. (USA)
Mideast & Africa District Email: firstname.lastname@example.org or call 0096824711755
&FEED MILLING TECHNOLOGY F
GRAIN May - June 2014 | 25
118th Annual Conference & Expo
rain milling professionals consistently find that the Or course with such a well-structured organisation with committed
IAOM conference experience affords them an opportu- committees, there are of course many foci, however what stood out
nity to enhance and advance their careers through for me was the need to entice new blood into the milling industry.
comprehensive education programs, to connect with
their industry peers at exciting networking events, and to Course at all levels
develop relationships with vendors who offer the products The courses offered by IAOM are available at all levels, Melinda
and services they need to efficiently do their job. talked about the need for more qualified milling and science gradu-
ates, the need for more qualified head and shift managers, the need
The IAOM Annual Conference & Expo is the premier educational to recognise professional millers who want to pursue a long term
event for grain milling and seed processing professionals. The annual career path and of course the biggest of them all, and the need to
event gathers milling and allied trade professionals from around the attract a new generation of millers.
world for three days of education, networking and fellowship. With these challenges in place, the milling industry has already
Educational and technical programs presented at the conference indicated the need for a robust career kit, which can be used to help
assist millers in improving yields, productivity, customer satisfaction attract high school and college graduates into the world of milling.
and safety. The programs are presented by seasoned professionals in During the conference there was a booth available for anyone in
the field who have experienced the issues affecting millers first-hand. the milling industry that was attending the conference to go into and
In addition, the annual conference also includes the world’s largest record a segment about how they got into milling, what they like
Expo for milling professionals, typically featuring over 100 companies and enjoy about a career in milling, etc. These testimonials will then
displaying milling and processing equipment and related services. appear on the IAOM website and will form 'art of the career' kits.
Having spent five thrilling and educational days last October in
Souse, Tunisia, for the regional conference for IAOM Africa & Middle Highlights
East, it was an honour to have been invited to the 118th Annual Once again the IAOM Annual conference and expo
IAOM Conference and Expo in Omaha, Nebraska, US. Whilst in has been a resounding success, with so much in the
Tunisia I had interviewed Melinda Farris for GFMT magazine, talking program it was impossible to capture every excit-
about her ninth year at IAOM and seventh year as Executive Vice ing and informative moment, however, I have put
President. Melinda pointed out the challenges ahead. together a selection of the IAOM’s highlights in the
following pages which covers the event, from the
Challenges for IAOM Buhler welcome reception, through to the IMEF
With 16 different regions, there was talk of restructure. Having visited Breakfast, the exciting Product Showcases and
some of the regional events, which were becoming very successful in their informative Educational sessions, through to the
own right, it would appear that some millers and suppliers focus more on AGM and much more. If you could not make it,
the regional meetings than the larger annual conference and expo. it is fair to say you missed out.
So six months on, I find myself in Omaha at the Hilton, at the If the following pages entice you to come
top of the escalators registering for the 118th annual International along to the next conference and expo don’t
Association of Operative Millers (IAOM) conference and expo. leave it too late. It is being held on May 4-8,
Check in and registration is smooth and efficient, I have my badge 2015 at the Renaissance Palm Springs Hotel
and deck of perforated tickets allowing me entrance to and participa- and Palm Springs Convention Center, Palm
tion in, the many well thought out and planed receptions, dinners, Springs, California, US.
meetings and conferences. Join hundreds of milling professionals from
As the exhibition was erected, it was clear from Melinda what across North America and around the world
the focus was for this year’s IAOM Annual Conference and Expo. when they convene in Palm Springs in 2015 for
the next IAOM Annual Conference & Expo.
See you there in 2015
Darren Parris is the head the GFMT
International Marketing Team
Left: Harrold, Keven & Right: Dave,
Mike from Essmueller Dan, Chris &
Company and Doug Robert from
from Safe Grain/Maxi Industrial
Tronic Inc Fumigant
& Rich from
Farris icking off a superb start to the IAOM Annual Conference
and Expo being held at the Holiday Inn Omaha was the
Buhler reception. As many hundred milling professional
s from all over the world came together at Buhler’s
Lindsay and With fabulous food and gratis liquid refreshments Buhler succeeded
Mike from in bringing together all the right people to truly set the scene for
Electro what was a successful IOAM expo and conference.
Left: Steve Left: Andreas
& Barry from Buhler
from Design with Jose, Eliseo
Corrugating from Fundiciones
with Howard Balaguer, Enrique
from Conagra from Molinos
Mills Modernos S.A.
and Mark from
Left: Tim, Right: Ken Hofstra,
Randy, Matt Head Miller with
& Franz from Howard, DAllas,
Buhler Brad and Scott
Left: Joe from Buhler Right: David,
with Deming from Bill, Mike
Satake, Steve from and Tom
Sefar and Al from from Corbion
Hogg Packaging Caravan with
Corporation Damon from
Right: Ruifeng Li the Co.
team from Baixiang
(Henan) in China
F 28 | May - June 2014 GRAIN &FEED MILLING TECHNOLOGY
fter two days of successful Double Donor Districts honored culminating in building 17 flour mills in various
committee meeting and a fantastic on district donor plaque. countries.
welcome reception given by Mr Sidles announced that two districts had Keith announces the first recipient of the
Buhler the focus moves to the formali- reached “donor level of giving” these two Christian F Kongsore Scholarship Award was
ties of the International Milling Educational districts will be added to the district donor Miss Jodi Roberts.
Foundation (IMEF) Breakfast. plaque, which will be on display at the IMEF In her application Miss Roberts noted that
headquarters. she was hooked on milling from the very first
time she toured the Al Ross Flourmill. She has
Breakfast with donors, scholarship Mr Sidles announced the IMEF been selected to attend K-state study-abroad
and award winners Benefactors Award program at Swiss Milling School in the fall
Bright and early Wednesday morning we all The IMEF Benefactors Award was won 2014 semester.
convened in the Hilton Ballroom for bacon by Grain Millers Inc., Keith from Grain Millers,
and eggs. After a scrumptious morning snack, Inc came on stage to accept the award. The Filling the bin
we sat back coffee in hand to enjoy the morn- company had made a generous pledge at last Rounding up what was a well planned and
ings presentations. year’s conference. Keith had announced his excellent breakfast meeting, Damon Sidles
Hosted by Damon Sidles, who wastes no intention to give generously to the foundation announced the ‘Filling the bin for the future’
time in highlighting the IMEF priorities for the and in doing so would create a scholarship IMEF Scholarship program. A scholarship pro-
year ahead. He says: in the name of Grain Millers Inc. co-founder gram for people already in the milling industry.
1) “We would like to offer more Christian F. Kongsore. The scholarship would Recipients include:
scholarships to those who would like to be given to one of the top grain science stu- • Ryan Legge: Used his scholarship to work
enhance their skills and to add to their dents at Kansas State University. on correspondence course
knowledge of grain processing. So the Christian F Kongsore Scholarship • Steve Carpenter: Will be using his
2) “We will be providing grants for Award was born. On addressing the audi- scholarship to participate in a resident
professional management speakers who ence, Keith said Christian could not attend the milling program course later this year
address conferences worldwide. conference but is very excited and honored • Md Abu Zahid: Engineer, will be using his
3) “We want to develop senior milling to be able to lend his name to such an award. scholarship to improve his knowledge of
executive workshops. Keith went on to explain a little about milling operations
“These are all viable goals that can be Christian F Kongsore. He was Born in Oslo, Mr Sidles, closes off the awards section
reached as long as IMEF continue to have the Norway in 1927 and worked in the family mill of the mornings event and hands the reins
support of the industry. IMEF would like to as a second generation miller. He graduated over to Jim McCarthy, President of the North
thank all who have given to the endowment from K - State in 1954 and then worked for American Millers Association (NAMA) to talk
fund,” he explained. Fisher Mills, Pillsbury and Continental Grain, about the “Power of Flour.”
On that note, Mr Sidles on behalf of the
IMEF invited anyone who would like to make
a contribution to come to the front of the
After collecting in the very generous dona-
tions, Mr Sidles introduced the Friends of
IMEF award. Unfortunately, none were in
attendance. However, the three people high-
lighted were: Masayuki Kawahasi, Thomas
Sliffe nad Ernest Van Vleet.
Mr Sidles, continued to host a number
of awards and highlighted key supporters of GFMT's sister publication, The International Milling Directory was on
hand at IAOM to offer a complimentary copy of the industries premier
IMEF and Friends, Contributors and Donors. buyers guide and directory to as many millers as possible!
F 30 | May - June 2014 GRAIN &FEED MILLING TECHNOLOGY
The Power of Flour
NAMA sees more change ahead
The floor was given over to Jim McCarthy, president of the North American
Millers’ Association and guest speaker at IMEF’s breakfast meeting
rowing up in Washington DC time there has been a sea change with GMO, joining forces with Wheat Innovation
Jim McCarthy started out consolidations and mergers. For example, Alliance who are active in educating public
working for a US Senator back in 1990 the top 10 millers were a little and media on the importance of GMO
on Capitol Hill before moving on to different to those today, he told delegates. wheat.
work for five years at Hershey Food Having explained his own background NAMA has also joined the coalition
Corporation. During this time he earned and a brief history of NAMA, Jim McCarthy for a safe and affordable food supply to
an MBA and a Law Degree. gave a talk on the power of flour, in which support legislation for ‘voluntary’ GMO
he touched upon the politics surrounding labeling, as ‘mandatory’ GMO labeling
He then went on to work at the Snack flour today. will only cause confusion and suspicion
Food Association for 22 years, including 14 Food safety, nutrition and the supply of food products approved by the FDA.
years as its President. chain are ‘the three pillars’ that support Mr McCarthy pointed out that with
Now President of North American NAMA’s success as an organization. These coeliac disease only effecting one per-
Millers Association, (NAMA) which was were his points of reference. cent of the American population and 93
percent having no dietary problems at all
1990 2014 with wheat, NAMA feels the popularity
Miller Capacity % of Miller Capacity % of of a gluten-free diet has really got out
Industry Industry of hand, and he looks to set the record
straight by working with Wheat Foods
Council and Grain Foods Foundations.
Con Agra Inc. 226,900 19.8% Ardent Milling 513,600 34.4%
US Dietary Guidelines are being revised
Adm Milling Co. 169,700 14.8% Adm Millingco. 281,100 18.9% and NAMA wants to preserve the current
Cargill 148,700 13.0% Milner Milling 164,000 11.0% recommended guidelines of six servings
The Pillsbury Co. 119,700 10.4% General Mills 77,500 5.2% of grain a day. NAMA also urges lunch
Cereal Food Processors 68,300 5.9% Miller Milling-Nisshin 76,100 5.1% programs not to set any maximum on
General Mills Inc. 66,700 5.8% Bay State Milling 75,100 5.0% grain products.
Dixie Portland Flour Mills 55,000 4.8% Mennel 40,900 2.7% The American milling industry had some
Bay State Milling Co. 53,250 4.6% Bartlett Milling 40,500 2.7%
issues with rail supply last winter so NAMA
is trying to make sure this does not happen
Nabisco 28,000 2.4% Kraft Foods 31,000 2.1%
Mennel 22,700 2.0% North Dakota Milling 30,000 2%
NAMA is taking action by becoming a
Total 958,950 83.5% Total 1,329,800 89.1% member of the Agriculture Transportation
coalition, working with Canadian allies
created in 1998, McCarthy explained how Mr McCarthy grew up in Washington on legislation and commenting on US
NAMA was a combination of the National DC and understands just how important Surface Transportation Board. It is also
Miller Federation, American Corn Millers constituent power is and why the food pursuing a trucking strategy for the milling
Federation, American Oat Association industry needs a presence in Washington. industry.
and Protein Grain Products International. His goal has always been ‘to bring Mr McCarthy finished his session by
Representing the wheat, corn and oat mill- business and government together’ and highlighting the key roles of NAMA:
ing industries and the international trade for as the president of NAMA he does just • Ensure the interests of our members
milled flour. that - working with many organisations are well represented before
Mr McCarthy spoke about there being to make sure that NAMA’s members are government
45 members across 38 states and Canada, well represented before government, so • Promote the adequate supply of
representing 170 mills which is around 90 that the needs of the milling industry are quality grains
percent of the total industry production in understood by the decision makers who • Provide timely information to our
North America producing around 80,000 really can make a difference to the future members and allies
tonnes per day. of milling. • Increase public awareness of our
There has been change and there needs When discussing food safety Mr products
to be more change as the growth in vol- McCarthy explained how NAMA endeav- • Support the increase consumption of
ume produced is increasing, at the same ors to promote the use of and safety of our products
Robert, Chris, Dan, Dave & James Rusty and Guenter from Sou Yuzhong from the Kaifeng
from IFC Service Static Binder Maosheg Machinery Co
Melike Arikan from Alapala with Bernd Kruse and Carl-Ludwig
Hidayet, Tuncay and Sibel from the Bollweg from Schule, also Bernie Jansen and Quin
Turkish Grain Board representing Kahl Vincent from VAA
rice and grain
colour sorting Bibiana and Dayn Bob Warren and Tim Richard and Nick from
machines. from Omas Larsen from Rentokil Vortomech
Regan Heaton and Daniel Wambeke Bryson Ramsey from LIftco LLC, specialising in Carl Swisher & Rick Fifer from 4B
from Scafco Grain Systems Belt And CAge Manlifts Components Ltd.
Clint Steele and Paul Sondgeroth from Craig and Steven from
Cimbria Todd & Sargent IntraSystems
Robert Cook, Vice President Harold Mauck and Mike Resner from Henning and Thomas from Hidayet, Tuncay & Sibel from th
of Biomist Essmueller - Bulk Material Handling Equipment Fawema to Seyit & Diwakar
Stephen Nenonen, Sales Steve and Wylie from BS&B - Explosion Tom and Nick from Blower
Director for Romer Labs Protection Technologies Engineering
Doug McCan from Ertan Kaya from Erkaya Joe and MIke from Michael Cowl and Terry
Maxi-Tronic Laboratory Instruments SEFAR Geraghty from Tapco Inc
Fabrizio, Marco, Gerald and John Hunter from Steven and Mike from BinMaster
Christopher from Ocrim Buhler stood next to the Smart Bob
Craig and Steven from Garip Cantemir from Urgur showing a Josh and John from Green Future Thorsten Muenker
IntraSystems customer the inside of an Urgur machine structual Innovations from Siwaco
Gary and David from AMVT Keith Robinson from Tod and Israel from
colour sorting Copesan Sentry
he Turkish Grain Board next Jamie & Matt from Kristen McCarty, Laboratory Manager Todd Morey, Nathan Huning and Scott
r from imas North AMerica Chantland from Brabender Hanson from Airlanco
F 34 | May - June 2014 GRAIN &FEED MILLING TECHNOLOGY
MPAU S Sifter Azurit closer to a wall to make use of space available at your mill,” he adds.
The sifter area is 9.6m2. The approximate capacity of machine five
‘S’ for food safety mesh 250 micron 14 tons per hour. Larger mesh sizes means you can
Bühler increase capacity, he says.
“At 58-inch, five foot deep, 90-inch wide and 94-inch high to the
John Hunter from Buhler presented one of the best Showcases of the top of the frame will fit onto most mill floors. And its easy to get in for
day. He starts his presentation by explaining why there is an ‘S’ after the maintenance.
prodcut name. "The MPAU S-Sifter is to show that it has been designed To keep the space envelope the motor has been put at the back.
with a clear focus on food safety" says Mr Hunter. Mounted directly behind the machine for easy accesses and mainte-
“We need to address the needs of the modern food industry nance. Counter weight is strung underneath machine instead of in the
and we are being directed by regional, national and global regula- middle of the sifter.
tions as they are implemented. Safety is always a priority for our Nova Technology uses a single cleaner that cleans both sieve screen
customers. and box. This has been simplified. Novafit is also retrofitted into some
“As with our other sifters this MPAU S features excellent sift perfor- older models.
mance and the number one thing we all need on a sifter is stainless steel Features and options available include: safety ropes, probe that will
lining with insulation for food safety. Insulation reduces condensation in detect motion of sifter to make sure that it is correct and not out of level.
machine, which is a risk at some times of the year.” “The key benefits are that we are delivering excellent setting per-
In addition to this great design we have Novapure sieve boxes and formance while delivering the food safety requirements we need in the
frames, we have eliminated all wood from machine and replaced it with modern food industry.
a hi-tech synthetic material. “We are in the food industry and we have to make sure we meet
“A key requirement of this material is that it needs to deliver its requirements,” he concludes.
the ware performance
including stainless steel
sieve inserts where
sieve clothing is glued
onto the frame. It has
one side access and is
therefore very easy to
“You can move it
Millguard-Pro ple in your plant with no electricians, no screwdrivers or the need for
waterproofs,” he adds.
Protecting property, lives and businesses
“You may not realise it but many of you reading this article have
CMC Industrial Electronics CMC’S hazard monitoring systems in your milling plants today: they
Douglas Forrest, president and founder of the small, boutique electron- have 150,000 points monitored in North America alone.”
ics company based in British Columbia called CMC Industrial Electronics, When creating a hazard perception device for use on roll stands the
explained the company’s main business in hazard monitoring. Protecting challenge for CMC was two fold: baring failure and roll fire. The first was
peoples property, human lives and grain elevators in the grain business. easy to fix. The roll stand part was much more difficult. CMC adapted
CMC Industrial Electronics were commissioned to solve a roll stand one of its infrared sensors so that it could be used on the stand. The
problem at large a company, and quite by chance when Douglas Forrest challenge for infrared on a roll is coping with dust. CMC figured out
met the company’s maintenance manager there was a typical roll stand how to do it.
in an older mill from the 1920s-1930s to work on. “The system is designed and certified for use in a class two-div-one
“If you look at this machine you will see there are just a couple of environment. It has been tested by a certified testing agency and is suit-
very small sensors added which are used to measure characteristics of able and fully approved for use in,” he adds.
the machine,” he says pointing to a presentation slide. Key benefits include protects milling operations prevents catastroph-
“We do it with red baring sensors, vibration and speed, connected ic failures and enables scheduling of proactive maintenance.
to a special network called
an ‘intrinsically safe net-
work’ which means you
can use low cost cable to
wire the system with us to
32 sensors on one devices.
“It’s a very low cost
systems and neat thing is
that it’s serviceable by peo-
GRAIN &FEED MILLING TECHNOLOGY May - June 2014 | 35 F
Pro-Tector ues through a gravity-feed metal detector.
The Pro-Tector’s integrated drawer magnet employs twin layers of
Your best defense against metal rare-earth magnetic tubes to provide maximum magnetic separation of
Magnetic Process Equipment (MPE) metal contaminants, and its quick-clean feature allows the operator to
clean the unit in less than 10 seconds.
As customers face increasingly stringent product safety standards, Extremely reliable and easy-to-use, the Pro-Tector’s integrated metal
Material Process Equipment (MPE) has sought to provide a new and detector features a straightforward operating system the quickly guides
better way to prevent both ferrous and nonferrous metals from con- the user through set-up and operation. Designed for intuitive use, the
taminating final product. effectiveness and ease of use makes this metal detector the premier
The result, the MPE Pro-Tector which efficiently combines the choice for manufacturers unwilling to compromise on product safety
simplicity of a magnetic separator with the reliability of a metal detector or quality.
in one compact unit. Recognised as the world standard for design, easy use and reliability,
This innovative new system assures the quick, easy removal of metals MPI drawer magnets deliver maximum capture of metal contaminants
from the product stream, while its size accommodates the tight spaces and assist food processors and others to keep product contaminant free
commonly found in production facilities. and to protect processing equipment from damage.
Designed for use in gravity-feed pipes to monitor for metal con-
taminants in continuous-flowing granules or
powders such as sugar, flour, corn meal or
spices, the Pro-Tector’s integrated drawer
magnet provides maximum magnetic sepa-
ration of contaminants.
Product first flows through the drawer
magnet, which is located at the top of the
unit, and then ferrous-free product contin-
Valve Bag Packaging est densification possible using mechanical methods.
“We can go anywhere from a one spout solution to a 10 spout solu-
Highest capacity four-packer in the world tions. What that means is per spout we are looking at approximately
Haver Filling Systems 200 bags per hour at 50lb weights so, we can go anywhere from 200lbs
to 2000lbs and above when your talking smaller bags.
Rim Boltong, from Haver Filling Systems, started his Showcase “We have recently installed a 10-spout installation in the northeast
presentation on Valve Bag Packaging by telling the audience that he for flour. It can do 2000 bags per hour at 50lb weights and whilst it
definitely had some exciting things to show in filling flour into valve bags. leaves a very small footprint we are confident that this is the highest
“At Haver, we first look at your product to get an understanding of capacity flour-packer in the world.
their properties. We look at bulk densities and how the product flows Some of the advantages of the roto seal is that one operator can run
and how to best dose it into the bags. a whole packing plant - 2000 bags per hour.
“We have a wide arsenal of techniques available to bring the prod- “In a 20 by 20 footprint we can produce 2000 bags per hour, which is
uct into the bag. pretty much unheard of. In addition to all this speed and efficiency we must
“When it comes to bag valve technology we employ empowers also pay attention to the cleanliness, that’s an issue we are always addressing,
that are either vertical or horizontal, depending on the bulk density of not least in terms of food safety but because of explosions and protection.
product. We can use air for coarse products or mixed products or oily
or liquid containing products.” The magic happens here
Mr Boltong mentioned other more traditional methods, which are “We have installed a roto-packer in The Netherlands for potato
much slower, explaining that they also use gravity when possible, which starch, which is a more difficult product than flour.
allows faster packaging of products. “As bags are singled out and picked up with suction cups, they are
He then demonstrates what it looks like to bring product into a put into a sero-driven grip band and shot into the air and onto the
bag using the impeller method; this is the preferred method for flour spout. We find this to be an accurate and reliable way of bringing the
because flour has such small particle sizes and it flows relatively easily. bags onto the spout.
“The bag is applied to the spout; the impeller is turning the paddle “Then this is where the magic happens, which is when the bags land
wheels; the impeller is forcing product into the filling pipe where we are on the spout it automatically raises or lowers depending on bag size
applying some air into the filling pipe to help aerate the product and and product. The spout has the sleeve. The bag is firmly nested in a bag
get it into the bag. chair supported on all sides. The bag is filled rather slowly. The power
“You can imagine we have to remove around 50 liters of air and then of the system allows each bag to have time to be filled, release air then
when you remove air you also remove some of product - with this system sealed and discharged.
it is bringing that back into your hopper and recycling it. It’s a closed system.” “High rates are achieved by having multiple spouts working at same
There is an inflatable sleeve that prevents the dust from exiting the bag. time.
“It’s important as we are filling that we are inflating the sleeve of the “Each head has its own weighing electronics which constantly feeds
spout meaning we are not releasing any dust into the atmosphere. All back the weight of the bag to the weighing electronics so it can adjust
the product and dust is going into the bag.” itself. This allows bag weights not to drift much,” he adds.
“We have an aeration
pad, to bring fluidization to
the product to help it flow.
The impeller is turning and
compacting the product.
What is excellent about
using the impeller process
is we get up to 80 percent
density, which is the high-
F 36 | May - June 2014 GRAIN &FEED MILLING TECHNOLOGY
reasonable expectations for this process as
the collection and disposition of dust filter
stock has changed over time.
Problem solving in the It has moved from bucket elevator
systems, where we had good suction and
milling industry poor suction, to rolls with perspective
quantities of bran in their systems. Flour
by Dr Jeff Gwirtz, JAG 2003 and K-State JAG only from 2011, US and sock choke was evident around a roll
Overlooking obvious problems
problem solver is someone who an assumption? There is also often a dispute So often that happens to us. Sifting effi-
examines problem, someone who about definition - how do you define things? ciency is what needs to be addressed.
considers relative perspectives Again I suggest that if you follow the thought Often we forget basics and fundamentals.
and solution models. Listen, observe and processes of a lawyer you might get a little The choke is not always the source of the
use all your senses. Sharpen your skills bit lost in that area! problem. Sifting, suction and grinding, these
and understanding. Everyday should be But the definitions and the differences things are all interconnected.
a learning opportunity in the flourmill. between the definitions can be very subtle. Screen splitting: what did I observe?
Become a lifelong learner. I’ve had long discussions over several Two identical sifter boxes making the
beers about the difference between a flow same separation on identical stock produc-
In preparation for this presentation I diagram a flow chart and flow sheet and I still ing different qualities and quantities of scalp
looked over at least 14 different textbooks don’t understand. material.
on the section about problem solving. The dispute about the nature of the act Roller bin mill adjustments could make or
It was clearly the most limited volume of and what was done, who did it, was it inten- correct the problem.
information you could ever imagine because tional, was it not intentional and disputes We observed that the scalp from one of
it all has to do with four steps and the fact about jurisdiction and procedure: These are several sifter boxes appeared to be rich as a
that in order for you to solve a problem you very classic argument methods. result of that incomplete sifting. We studied
really have to have a base of knowledge of Another opportunity to enhance your the product guess what?
these four steps. understanding of a problem is to use We looked at the flow sheet! We screen
This assumption is identified in almost Ishikawa’s fish bone diagram. This includes tested the product under the rolls, we
every mathematics course presented at six Ms and these Ms suggest any varia- screen tested the product in the sifter, we
university, even in England! These four steps tion in the outcome or change in process attempted to rebalance the load but the
are: understanding the problem, devising a may be as a result of: manpower, mother problem was we couldn’t correct it. We still
plan, carrying out the plan and looking back. nature, measurements, methods, material had scalp and we had just changed the loca-
and manufacturing, tion of the problem.
The layout of the system would not
Bloom’s taxonomy permit equal distribution of that load for the
“A problem is a disparity Bloom’s taxonomy: as flour millers we different locations of the mill.
need to be ‘higher order’ thinkers, the How many times do we see things like
between where you are people on the floor running your mill need this set up in order to split the stock-there
to be ‘higher order’ thinkers, you need to is certainly nothing wrong with it but I
and where you want to be a ‘higher order’ thinker. You can’t live on would ensure that the product is homog-
things you have remembered but how you enous and most of our products in flour
be.” – Dr Jeff Gwirtz synthesise, analyse, apply, evaluate, create mills are not.
solutions or solve problems. The balance of those sifter boxes could
What you need to understand about not be controlled and as I thought about it I
solving problems in a flourmill is that many thought “what are my sifter loading expecta-
The Deming Cycle of the answers have already been identified tions?”
The Deming Cycle: ‘plan, do, check, act, for you: the flow sheet is the dictionary of Increasing or decreasing the loads of sifter
cycle’ considered statistical process control. what’s happening. boxes assuming that this is the same material
The Deming Cycle has been revised I trust the system but this trust is always in each sifter box we expect changes in the
about four or five different times to fit verified. scalp as the load increases.
various disciplines. These techniques are A system may tell you a bin is full but a We’d see an increase in potential through
essential to take you from where you are good rap on the side of a bin will tell you if in that scalp.
to where you want to be and of course you its full or empty too. If we put that in terms of efficiency in sift-
have to ask questions. I’ve learned some things about solving ing separation it would go down instead of
In typical understanding of questioning problems from different parts of the mill and making an increase in the perpetual through.
and fact finding there are several entry ques- that’s what I’d like to share with you today. Flour production would go up. Flour in the
tions: who, what, when, where, why. I sup- In sizing stock I had a problem with open carryover would go up affecting downstream
pose to some of you engaged in magazine dry good ash and low yield, and when we milling operations.
production you include these questions in closed ground we had a high ash and very You want low ash flour n one sifter box.
your particular articles in order to bring that good yield. These two things are a complex You get a low ash flower but you get a lot
article to fruition. matrix of two points. of carry-over in the next grain system. You
There are a few rhetorical constitutions How we addressed the problem: Read want to shift the particle size of the flour?
or dispositions that you should think about the flow sheet, pull samples of every stock. You increase the load the particle size of the
as you’re in the process of solving a problem Stock appearance alone can be misleading. flour will go down.
and developing an understanding about the Read flow sheet, address the problem and
problem. not the symptoms. Quick release
Some things sound very simple, but I questioned what was reasonable when I did run into a problem where we
there is dispute about fact: What do you it came to dust. couldn’t open a roll enough to achieve the
really know and what had really been just You should have an idea of what are target quick release. We couldn’t open up a
GRAIN&FEED MILLING TECHNOLOGY May - June 2014 | 37 F
roll enough: that’s a strange problem. at a new machine or set of machines or
The stock that was coming down to the processors and I offer you these things to
GM’s naughty words list roller mill - it was already too fine to begin think about:
General Motors’ lawyers put with. What happened? I read the flow sheet • Ask yourself about the material and
together a list of words that could I checked the stock (the stock doesn’t lie). processing objectives of the machine
no longer use at GM. Instead of Flow sheets sometimes lie – Let’s blame • What are the physical dimensions of the
‘having a problem’ there is an the engineers who don’t take time to redraft machine?
‘issue,’ ‘condition’ or ‘matter’. the flow sheet! We have to have an up-to- • What are the materials of construction?
“In addition, there were several date flow sheet. • What are the drives, what do the drive
hundred other words that came systems look like?
into play, that I will not take the Grinding too close • What are the general equipment
time to share them with you today, Grinding too close: all the bran whether adjustments available to the operator?
but I do have a list of synonyms its coarse. The product was sieved over a • What kind of material or stock is to be
that I want to share,” says Dr Jeff 21er that was 1041 microns approximately, processed by the machine?
Gwirtz of JAF 2003 and K-State JAG it may have been broader but it was still • What are the sanitation issues
from 2011. slithering. I think that if you slither the bran associated with the machine?
“Through my career there have the propensity to increase the ash in the • What maintenance skills are needed?
been many words I’ve heard to flour goes up. The challenge of getting the • External inputs?
describe a problem. While I was endosperm off the bran hinges on getting • Do you need a fan somewhere?
with Ralston Purina Co you could the proper quick release. • Do you need compressed air?
not say you had a ‘problem’ you had One of the last milling story problems • What is the dependency or relationship
an ‘opportunity’ so everything was where I learned a little bit about problem between the equipment and the system?
an ‘opportunity’. solving was in the process of adjusting a • You can look at the incoming material,
“I’m sure in the world of supply purifier 7. the expected uniformity quality quantity
chain management you too have I observe large pieces of bran coming off and rate
a word that’s used in place of the the purifier at a significant rate. • Look at the inputs - quality, quantity,
world ‘problem’. We observed this and it wasn’t consistent and rate
“A problem is a disparity between with what I had really expected. What we • Process objectives, whether it’s to
where you are and where you want did was we got out the flow sheet! reduce size or make some kind of
to be. We identified what we expected to be separation
“I’m not talking about physically I’m there. We ran sieving tests. We took the Having knowledge is the key to critical
talking about the process, particu- sifter apart and we found a large hole. How thinking having flow sheets being able to
larly within respect of operations in did I know it was going to be there? I read determine what’s not there.
a flourmill,” says Dr Gwirtz. the flow sheet. Leverage every tool that you have to
Sometime in life you will end up looking solve problems.
milling ONLINE | PRINT | MOBILE
.com i i
i i i i i i
i i i i i i
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F GRAIN &FEED MILLING TECHNOLOGY
Educational Session saved approximately US$100,000 annually by
targeting 13.1 protein from 13.4. Average saving Safety
NIR are about US$0.04 per hundredweight (45Kgs).
“One of the things we have focused on a lot with our in the flour mill
Shifting protein target closer in-line technology is the detection limit of the analyser.
to your specification That’s the ability to detect a change in the process
and what you will be able to see is those statistics. So
food safety aspects
with whole grain moisture our process detection had
n a bright warm Thursday morning at been down to 0.011 and protein 0.022.
IAOM in Omaha we sit down to listen “These are very important statistics, it gives Randy Shmidt from Buhler speaking on food
to Jeff Boedigheimer enlighten us on the analyser the ability to detect a change and safety aspects of machine design and operation
utilising NIR technology for inline process gives him the confidence that the analyser is started his talk by showing steps which Buhler
control. Jeff starts by talking about goals: repeatable.” uses to ensure sanitary design of its equipment
Another example of how an inline can be as well as the hygienic facility designs.
• How you can save time and money utilised effectively in a daily operation, where There are two organisations that can help
by improving your grain blending or whole grain in this example the target spec was when it comes to designing food processing
flour production by utilizing in-line NIR between 11% and 13% protein and here you facilities that are specific to flour mills.
technology. Reducing protein losses or can understand the product is above 13% so The European Hygienic Engineering and
moisture variation this type of technology can really be beneficial. Design Group, a consortium of equipment
• The ability to eliminate sample ware from React and make changes whether you have the manufacturers, food industry companies,
your process as well as reduce rework ability to make a manual change or operators research institutes and public health authorities
• Ensure you’re producing your product close can make changes or implement the technology is an organisation that is much used throughout
to your specification into a plc or a pid loop that automatically makes Europe.
“I’m certain that many of you use near infrared corrections for you. In the US there is the 3-A Sanitary Standards
technology in your mills. It’s widely accepted In-line allows you to take in the trending or the Inc (3ASSI), commonly consulted in for food
technology that’s been used in the agricultural ability to see trends in real time. industry North America non-profit organisa-
industry for many years primarily in the bench One of the things you’ve got to keep in mind tion representing the interests of regulatory,
top mode where you take a sample from the when you’re doing lab analysis or bench top sanitarians, equipment fabricators and food
process and you then present it to the instru- analysis is you have that time difference between processors.
ment.” results when you pull samples every half hour Both are non-profit organsations focused on
“What we’re trying to achieve with the next or two hours? That’s where the power of in- the promotion of safe food and hygienic design.
approach in the industry is move it in-line.” line comes in because you can take away that Both have common goals and exchange draft
*When you take into consideration errors asso- potential variation that could occur. guidelines to stay in sync with each other. Even
ciated with the bench top analyser plus sampling The flour plant is a harsh environment. You’re contents with all EHEDG guidelines have been
error, you actually have to make a determination dealing with dust, vibration and various tem- cross-referenced with 3ASSI.
as your process variation is going to be wider perature swings. It’s important to take into
than it should be. consideration, with an inline analyser, the things Materials in construction
*So when you go continuous and analyse a that have been done to the equipment so that The two organisations cite stainless steel as a
sample and get results every 20 or 30 seconds it can withstand the test of time in that kind of logical option for material constructions give
you actually remove sampling errors. You’re able environment. guidelines and specifications as to the quality that
to reduce your standard deviation, change your “Things we’ve implemented include: high rating, must be met as well as the finish of the steel.
process variation from an out-line approach to dust tight and watertight enclosure. We use Two different types of stainless steel surface
an in-line approach. USDA approved hygiene components and all treatment: the product touching parts are pol-
*Really the concept with in-line standardisation our components are USDA certified. We also ished with a surface finish of 0.4 micrometers
is to see how much variation you have in your have the ability to put them in classified areas and the non-touching parts are electro-polished
process. When you’re running with a bench-top Class 1 or Class 2 where we can propose a with a finish of 0.8 micrometers; both exceed the
analyser you typically have a wider variation than solution. recommendations of both orginisations.
you’re running with to compensate for a safety Also with an inline analyser as with any NIR Rubbers or soft materials guidelines, chemical
margin.” there’s a light source, that’s what you need temperature and steam stress crack resistant are
He went on to say, that when you look at doing within the instrument. What we implement is a MBR-type material closed cell that do not absorb
the genus analysis you have greater improve- dual lamp in the actual analyser so if one burns cleaners.
ment and confidence in your analytical results out the other takes over automatically. This is
and therefore can shift your target and reduce critical when you’re running operation 24 hours Lubricants
your standard deviation. You’re basically shifting a day seven days a week. Equipment needs to be designed to avoid
your protein target closer to your specification. In-line analysis: product contact with lubricants.
In-line can be used in grain receiving to segre- • It’s all about reducing standard deviation to Secondly, lubricant needs to conform to FDA
gate grains or grain blending for protein analysis ensure production of a consistent product. or NSF guidelines which are geared toward filter
further down stream. Do that and you will be closer to your lubricants of treated drinking water.
“So what we’re looking at is reducing that target. If you’re closer to your target you’ll We put an additional seal in gear box to help
protein variation and that’s really where the gain extra profit protect the crucial interface between the gearbox
economics come into play in flourmills.” • Reduce the sampling and analysis time and the product area.
From a moisture perspective, whether that is is also to consider. That’ll be done less
whole grain to ensure your tempering is correct frequently and you’ll be eliminating sampling Wiring and cabling
or on the flour side to make sure moisture is error from the process Routing of wiring and cabling through enclosed
at specification or to bring it up closer to your • You can look at this as reducing rework as junction boxes and support brackets need to be
target of 14 percent, in-line can provide a solu- well designed in a way to eliminate the accumulation
tion, he says. • Typical payback is between 6-12 months of material and designed to eliminate dead spots
“Also on the flour side we measure ash with Foss has 60 years of experience in analytics in or areas that aren’t easily cleaned and where the
in-line analysis that’s to make sure that you’re the grain industry. With over11,000 Infratechs growth of bacterial could occur. Most of the cable
not out of spec.” for protein analysis installed worldwide. routing is inside the leg of the machine. Motor
An example of one company’s experience In a quarter of a century of inline technology it cables are routed by cable tray with grids in the
showed in-line on protein blending in wheat has now installed 500 systems worldwide. control cabinets.
GRAIN &FEED MILLING TECHNOLOGY May - June 2014 | 39 F
Dust formation Medium-risk zone are closer to area Bin design
Equipment must be designed in a way that where food contamination could occur. On the inside of product bins all corners
doesn’t generate dust. Tight access doors Stairways, elevators and areas typically where should be rounded excluding discharge
to eliminate leakage or cross contamination most processors have rules and guidelines points.
are critical. These access points need to be like washing hands, etc. Wood should be Surfaces need to be prepared to meet
easy to remove to eliminate dead spots or eliminated as much as possible the specific requirements of the product
accumulation of dust. Zone 1, the high-risk zone where there that is to be stored. Two basic philoso-
is the highest chance of product contamina- phies for bin top design - raised manhole
Cleaning tion, include mill grinding, finish product, covers may be less likely to have contami-
Needs to be easily cleaned. Easy access. All storage, bagging and packing facilities. nates inadvertently entered in from the
components easy to remove eliminate all So following VRC’S hygienic design of top. Adds more hassle for cleaning. Flush
gaps and crevices. Radius corner. Rather than food factories guidelines plants are encour- manhole covers makes cleaning floor and
have sharp 90-degree corners. aged to divide the facility into these hygienic area much easier but must have good seal
Using NSDF micro feeder as the example zones. No color-code for no-zone 4; zone to prevent contaminates from entering
for hygienic machine design. You can under- 3 – green; zone 2 – orange; zone 1 - the bins.
stand the detailed steps we take to ensure red. This helpselps processors. We try to
the most sanitary design of our equipment enhance this by the location of the zones Summary
using both 3ASSI and EHEDG guidelines and clear divisions such as doors and walls. In summary selecting the right building con-
helps us meet these strict hygienic guidelines. They enhance guidelines by having walls cept is key, ultimately determining the added
between places. value of your investment prerequisites.
The golden rule of zoning Obviously, hygienic concepts is part of
Move on to some of rules for designing Building design key factors the project concept phase and this needs
complete food processing facilities. Little things make big differences, such as to be talked about in great detail at the
The golden rule for Buhler is to arrange type of flooring - ideally smooth surface floors very beginning of a project phase and
the plant design into its different hygienic that are easy to clean yet safe to walk junc- needs to be kept in mind throughout the
zones, labeling these zones as either a no- tion between equipment and building itself entire project with building engineering
zone, low-, medium- or high-risk zone. weather floor ceiling well pay special attention according to hygienic concepts and high
No-zone pose almost no food safety risk to how that junction will take place. quality execution of the construction and
at plant: Outside areas; separate administra- Temporal water control system equip- instillation work.
tion offices; were smoking, eating and drink- ment should be designed so that it does not Hopefully, with all that kept in mind and
ing is permitted. contribute to non-hygienic conditions, but everybody following those prerequisites,
Low-risk includes areas where direct also needs to be maintenance friendly. we would end up with a clean and appeal-
contact with finished products is not likely. As with plant sifters, temporal water con- ing processing facility that’s easy to clean,
This may include grain receiving, loading bays trol systems should have suspension points complies with food safety requirements and
or quarantine rooms for product. for are integrated into the ceiling structure. happy customers thank you.
GRAIN &FEED MILLING TECHNOLOGY
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F 40 | May - June 2014 GRAIN &FEED MILLING TECHNOLOGY
ollowing the official opening of programme in partnership with Kansas State new requirements, NFPA combustable dust
the 2014 IAOM Annual General University is in the pipeline. standards and the combustable dust inspec-
Meeting in Omaha, vice-president tions from OCEA. The committee intends
Damon Sidles moved a special motion Food Protection Committee to share a document within the next three
of standing remembrance for members Ron Galley, Food Protection Committee months on ‘our mission of promoting and
lost in the past year. They included: Jack (FPC) chairperson reports that his com- sharing ideas with industry to give a vital
Higginbotham, Alvin Albert Prinzine, mittee met 3 times since the last Annual function to the industry’. More individuals are
Harry Myers III , John. E. Webster, Carl Conference and Expo. invited to join.
Bush and Richard Robertson. The committee heard an update on Food
Safety and EPA’s proposal to remove fluo- Employer Relations Committee
The Treasurer’s Report by Roy Lepp stated ride and chloride tolerances in food and to David Pickett, Employer Relations
the cash asset position of IAOM stands “sol- remove the effects of fuming and profume. Committee chairman is working to recruit
idly at this point in time” with the organization During this meeting, the committee finalised more members to the committee. New
functioning within budget. It was noted that its work on the IAOM IPM manual for appointments incoude: Troy Anderson,
conferences and correspondence courses stored projects and risk management. Jim Horizon Milling; Kurt Wedsall, General Mills
had boosted revenues through 2013. Pre- Bears of NAMA proposed this in early 2012 and John Schalz from Matson Milling. The
registering expo exhibitors had also helped and this document is now complete and committee is working on a new recruitment
the organisation’s financial position. is published on the IAOM’s website. The website, www.grainmillingcareers.com and
It was also noted that 42 percent of IAOM FPC then met and held a conference, the more topics for the 2015 Conference.
members are international and there is a committee briefly heard
move to internationalise the membership about the FDA regulations
further. and inspections. Earlier this
week, the committee met
Key points with four vendors to talk
Scott Ardem, Education Committee chair- about allergens and cross-
person, reported that three meetings had contamination.
been held since the Niagra Falls Conference
and Expo. Technical
A new chairperson is being sought, following Committee
Lionel Holwa’s resignation from Mondelez Jim Doyle, Technical
International, and who will be appointed by Committee chairman reports that recent Elections
the IAOM President Don Hoffer as soon as meetings have focused on education and Rory Lepp for the open Vice-President post,
possible. training programmes such as IAOM to part- nominated and elected by the committee.
Current board members include: Doug ner with community colleges. Brad Allen for Treasurer, nominated by the
Stuckie - ADM Milling; Chris Capenter Challenges, new projects and packaging committee and elected by an unanimous
- Bunge Milling; Steve Matson - Horizon issues were all discussed. vote.
Milling; Jim Haggart - Star of the West Milling One universal challenge is hiring capable and IAOM ACE (Annual Conference and Expo
and Joe Woodward - ADM Milling. More competent employees. application). IAOM is pleased to provide this
individuals from within the membership are Damon Sidles, Treasurer and IAOM and look forward to doing more in the future.
being sought to serve. President Don Hoffer’s recent meeting with
Correspondence Courses units 1, 2 and 3 the Middle-East and African office of IAOM Nominating Committee
are being reviewed currently and are being in Muscat, Oman was reported upon. Trade The Nominating Committee recognizes Rial
translated into Spanish and Arabic. shows and educational programmes were Denny as a distinguished member.
held which meant good attendance levels.
Mill Maintenance and Craig Frayling from Cargill updated the group Safety awards
Fundamentals on NFPA changes and Roskin McClure gave ConAgra Mills, Puerto Rico and ConAgra
This course is going well and more are being regulatory updates to the committee. Mills, Ohio, USA, won the awards.
planned. Two short courses - Fundamentals Rudy Wise from Buhler gave a presentation For 10 years in a row, these mills have
of Milling 1 and 2 - received very good about the technological trends taking place been awarded safety awards, so this special
reviews by participants. The course was in the industry around the world to the award has been given in recognition of their
taught by Dr Jeff Works of OCRIM, committee. achievements.
Cremona, Italy and Dr Jeff Works lead the Environmental, Health and Safety Committee The other three winners all come from
sessions. Anthony Hunter, Environmental, Health and Britian: ADM Seaforth, Liverpool; ADM,
A new online system is being developed for Safety Committee chairman says there is a Corby, Northampton and King’s Flour Mill,
students and instructors. A new Grain Milling variety of issues to be addressed, but the West Yorkshire.
Certification for community colleges and a three most important ones are OCEA’s The committees were then installed.
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