IAOM 118th Annual Conference & Expo


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Grain milling professionals consistently find that the IAOM conference experience affords them an opportunity to enhance and advance their careers through comprehensive education programs, to connect with their industry peers at exciting networking events, and to develop relationships with vendors who offer the products and services they need to efficiently do their job.

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IAOM 118th Annual Conference & Expo

  1. 1. Digital Re-print - May | June 2014 IAOM 118th Annual Conference & Expo www.gfmt.co.uk Grain & Feed MillingTechnology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 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
  2. 2. 24 | May - June 2014 GRAIN&FEED MILLING TECHNOLOGY 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. Mideast & Africa District Organized by: Management Keynote Speaker Dr. Beau Lotto Neuroscientist & Founder, Lottolab (UK) Mike Krueger Founder & President, The Money Farm (USA) Top Notch Keynote SpeakersConference and Expo Highlights REGISTER NOW www.iaom-mea.com/IAOM-SOUTHAFRICA2014/ Email: info@iaom-mea.com or call 0096824711755 Milling Industry’s Largest Gathering in the Middle East & Africa • Largest gathering of flour & feed milling industry machine suppliers, grain millers and commodity traders from the Middle East, Africa and all over the world • Captivating and vibrant keynote speakers for Management, Technical and Trading sessions • Extensive networking opportunities • World renowned keynote speakers include Dr. Beau Lotto, Neuroscientist & Founder Lottolab (UK) and Daniel Basse, President & founder, AgResource Co. (USA) • Evening Functions in Cape Town’s most elite venues • English and Arabic simultaneous translation available • Full access to conference presentations and expo Trading Moderator & Keynote Speaker Daniel Basse President & Founder, AgResource Co. (USA) F
  3. 3. G rain milling professionals consistently find that the IAOM conference experience affords them an opportu- nity to enhance and advance their careers through comprehensive education programs, to connect with their industry peers at exciting networking events, and to develop relationships with vendors who offer the products and services they need to efficiently do their job. The IAOM Annual Conference & Expo is the premier educational event for grain milling and seed processing professionals. The annual event gathers milling and allied trade professionals from around the world for three days of education, networking and fellowship. Educational and technical programs presented at the conference assist millers in improving yields, productivity, customer satisfaction and safety. The programs are presented by seasoned professionals in the field who have experienced the issues affecting millers first-hand. In addition, the annual conference also includes the world’s largest Expo for milling professionals, typically featuring over 100 companies displaying milling and processing equipment and related services. Having spent five thrilling and educational days last October in Souse, Tunisia, for the regional conference for IAOM Africa & Middle East, it was an honour to have been invited to the 118th Annual IAOM Conference and Expo in Omaha, Nebraska, US. Whilst in Tunisia I had interviewed Melinda Farris for GFMT magazine, talking about her ninth year at IAOM and seventh year as Executive Vice President. Melinda pointed out the challenges ahead. Challenges for IAOM With 16 different regions, there was talk of restructure. Having visited some of the regional events, which were becoming very successful in their own right, it would appear that some millers and suppliers focus more on the regional meetings than the larger annual conference and expo. So six months on, I find myself in Omaha at the Hilton, at the top of the escalators registering for the 118th annual International Association of Operative Millers (IAOM) conference and expo. Check in and registration is smooth and efficient, I have my badge and deck of perforated tickets allowing me entrance to and participa- tion in, the many well thought out and planed receptions, dinners, meetings and conferences. As the exhibition was erected, it was clear from Melinda what the focus was for this year’s IAOM Annual Conference and Expo. Or course with such a well-structured organisation with committed committees, there are of course many foci, however what stood out for me was the need to entice new blood into the milling industry. Course at all levels The courses offered by IAOM are available at all levels, Melinda talked about the need for more qualified milling and science gradu- ates, the need for more qualified head and shift managers, the need to recognise professional millers who want to pursue a long term career path and of course the biggest of them all, and the need to attract a new generation of millers. With these challenges in place, the milling industry has already indicated the need for a robust career kit, which can be used to help attract high school and college graduates into the world of milling. During the conference there was a booth available for anyone in the milling industry that was attending the conference to go into and record a segment about how they got into milling, what they like and enjoy about a career in milling, etc. These testimonials will then appear on the IAOM website and will form 'art of the career' kits. Highlights Once again the IAOM Annual conference and expo has been a resounding success, with so much in the program it was impossible to capture every excit- ing and informative moment, however, I have put together a selection of the IAOM’s highlights in the following pages which covers the event, from the Buhler welcome reception, through to the IMEF Breakfast, the exciting Product Showcases and informative Educational sessions, through to the AGM and much more. If you could not make it, it is fair to say you missed out. If the following pages entice you to come along to the next conference and expo don’t leave it too late. It is being held on May 4-8, 2015 at the Renaissance Palm Springs Hotel and Palm Springs Convention Center, Palm Springs, California, US. Join hundreds of milling professionals from across North America and around the world when they convene in Palm Springs in 2015 for the next IAOM Annual Conference & Expo. See you there in 2015 Darren Parris Darren Parris is the head the GFMT International Marketing Team IAOM118th Annual Conference & Expo GRAIN&FEED MILLING TECHNOLOGY May - June 2014 | 25 F
  4. 4. Left: Andreas from Buhler with Jose, Eliseo from Fundiciones Balaguer, Enrique from Molinos Modernos S.A. and Mark from Mocasa. Right: Dave, Dan, Chris & Robert from Industrial Fumigant Company (IFC) Right: David, Bill, Mike and Tom from Corbion Caravan with Damon from Miller Milling Co. Left: Harrold, Keven & Mike from Essmueller Company and Doug from Safe Grain/Maxi Tronic Inc Left: Joe from Buhler with Deming from Satake, Steve from Sefar and Al from Hogg Packaging Corporation Right: Ken Hofstra, Head Miller with Howard, DAllas, Brad and Scott from Richardson MIlling Limited Right: Lindsay and Mike from Electro Sensors Right: Mike & Rich from C-Tec AG Right: Paul Walti from Buhler entertaining a guest Right: Ruifeng Li the team from Baixiang Food Group (Henan) in China Left: Steve & Barry from Design Corrugating with Howard from Conagra Mills Left: Tim, Randy, Matt & Franz from Buhler Left: Melinda Farris IAOM opening reception evening K 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 opening reception. With fabulous food and gratis liquid refreshments Buhler succeeded in bringing together all the right people to truly set the scene for what was a successful IOAM expo and conference. F
  5. 5. A fter two days of successful committee meeting and a fantastic welcome reception given by Buhler the focus moves to the formali- ties of the International Milling Educational Foundation (IMEF) Breakfast. Breakfast with donors, scholarship and award winners Bright and early Wednesday morning we all convened in the Hilton Ballroom for bacon and eggs. After a scrumptious morning snack, we sat back coffee in hand to enjoy the morn- ings presentations. Hosted by Damon Sidles, who wastes no time in highlighting the IMEF priorities for the year ahead. He says: 1)“We would like to offer more scholarships to those who would like to enhance their skills and to add to their knowledge of grain processing. 2)“We will be providing grants for professional management speakers who address conferences worldwide. 3)“We want to develop senior milling executive workshops. “These are all viable goals that can be reached as long as IMEF continue to have the support of the industry. IMEF would like to thank all who have given to the endowment fund,” he explained. 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 room. 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 IMEF and Friends, Contributors and Donors. Double Donor Districts honored on district donor plaque. Mr Sidles announced that two districts had reached “donor level of giving” these two districts will be added to the district donor plaque, which will be on display at the IMEF headquarters. Mr Sidles announced the IMEF Benefactors Award The IMEF Benefactors Award was won by Grain Millers Inc., Keith from Grain Millers, Inc came on stage to accept the award. The company had made a generous pledge at last year’s conference. Keith had announced his intention to give generously to the foundation and in doing so would create a scholarship in the name of Grain Millers Inc. co-founder Christian F. Kongsore. The scholarship would be given to one of the top grain science stu- dents at Kansas State University. So the Christian F Kongsore Scholarship Award was born. On addressing the audi- ence, Keith said Christian could not attend the conference but is very excited and honored to be able to lend his name to such an award. Keith went on to explain a little about Christian F Kongsore. He was Born in Oslo, Norway in 1927 and worked in the family mill as a second generation miller. He graduated from K - State in 1954 and then worked for Fisher Mills, Pillsbury and Continental Grain, culminating in building 17 flour mills in various countries. Keith announces the first recipient of the Christian F Kongsore Scholarship Award was Miss Jodi Roberts. In her application Miss Roberts noted that she was hooked on milling from the very first time she toured the Al Ross Flourmill. She has been selected to attend K-state study-abroad program at Swiss Milling School in the fall 2014 semester. Filling the bin Rounding up what was a well planned and excellent breakfast meeting, Damon Sidles announced the ‘Filling the bin for the future’ IMEF Scholarship program. A scholarship pro- gram for people already in the milling industry. Recipients include: • Ryan Legge: Used his scholarship to work on correspondence course • Steve Carpenter: Will be using his scholarship to participate in a resident milling program course later this year • Md Abu Zahid: Engineer, will be using his scholarship to improve his knowledge of milling operations Mr Sidles, closes off the awards section of the mornings event and hands the reins over to Jim McCarthy, President of the North American Millers Association (NAMA) to talk about the “Power of Flour.” International Milling Educational Foundation (IMEF) Breakfast GFMT's sister publication, The International Milling Directory was on hand at IAOM to offer a complimentary copy of the industries premier buyers guide and directory to as many millers as possible! 28 | May - June 2014 GRAIN&FEED MILLING TECHNOLOGYF
  6. 6. G rowing up in Washington DC Jim McCarthy started out working for a US Senator on Capitol Hill before moving on to work for five years at Hershey Food Corporation. During this time he earned an MBA and a Law Degree. He then went on to work at the Snack Food Association for 22 years, including 14 years as its President. Now President of North American Millers Association, (NAMA) which was created in 1998, McCarthy explained how NAMA was a combination of the National Miller Federation, American Corn Millers Federation, American Oat Association and Protein Grain Products International. Representing the wheat, corn and oat mill- ing industries and the international trade for milled flour. Mr McCarthy spoke about there being 45 members across 38 states and Canada, representing 170 mills which is around 90 percent of the total industry production in North America producing around 80,000 tonnes per day. There has been change and there needs to be more change as the growth in vol- ume produced is increasing, at the same time there has been a sea change with consolidations and mergers. For example, back in 1990 the top 10 millers were a little different to those today, he told delegates. Having explained his own background and a brief history of NAMA, Jim McCarthy gave a talk on the power of flour, in which he touched upon the politics surrounding flour today. Food safety, nutrition and the supply chain are ‘the three pillars’ that support NAMA’s success as an organization. These were his points of reference. Mr McCarthy grew up in Washington DC and understands just how important constituent power is and why the food industry needs a presence in Washington. His goal has always been ‘to bring business and government together’ and as the president of NAMA he does just that - working with many organisations to make sure that NAMA’s members are well represented before government, so that the needs of the milling industry are understood by the decision makers who really can make a difference to the future of milling. When discussing food safety Mr McCarthy explained how NAMA endeav- ors to promote the use of and safety of GMO, joining forces with Wheat Innovation Alliance who are active in educating public and media on the importance of GMO wheat. NAMA has also joined the coalition for a safe and affordable food supply to support legislation for ‘voluntary’ GMO labeling, as ‘mandatory’ GMO labeling will only cause confusion and suspicion of food products approved by the FDA. Mr McCarthy pointed out that with coeliac disease only effecting one per- cent of the American population and 93 percent having no dietary problems at all with wheat, NAMA feels the popularity of a gluten-free diet has really got out of hand, and he looks to set the record straight by working with Wheat Foods Council and Grain Foods Foundations. US Dietary Guidelines are being revised and NAMA wants to preserve the current recommended guidelines of six servings of grain a day. NAMA also urges lunch programs not to set any maximum on grain products. The American milling industry had some issues with rail supply last winter so NAMA is trying to make sure this does not happen again. NAMA is taking action by becoming a member of the Agriculture Transportation coalition, working with Canadian allies on legislation and commenting on US Surface Transportation Board. It is also pursuing a trucking strategy for the milling industry. Mr McCarthy finished his session by highlighting the key roles of NAMA: • Ensure the interests of our members are well represented before government • Promote the adequate supply of quality grains • Provide timely information to our members and allies • Increase public awareness of our products • Support the increase consumption of our products 1990 2014 Miller Capacity % of Industry Miller Capacity % of Industry Con Agra Inc. 226,900 19.8% Ardent Milling 513,600 34.4% Adm Milling Co. 169,700 14.8% Adm Millingco. 281,100 18.9% Cargill 148,700 13.0% Milner Milling 164,000 11.0% The Pillsbury Co. 119,700 10.4% General Mills 77,500 5.2% Cereal Food Processors 68,300 5.9% Miller Milling-Nisshin 76,100 5.1% General Mills Inc. 66,700 5.8% Bay State Milling 75,100 5.0% Dixie Portland Flour Mills 55,000 4.8% Mennel 40,900 2.7% Bay State Milling Co. 53,250 4.6% Bartlett Milling 40,500 2.7% Nabisco 28,000 2.4% Kraft Foods 31,000 2.1% Mennel 22,700 2.0% North Dakota Milling 30,000 2% Total 958,950 83.5% Total 1,329,800 89.1% 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 30 | May - June 2014 GRAIN&FEED MILLING TECHNOLOGYF
  7. 7. Bernd Kruse and Carl-Ludwig Bollweg from Schule, also representing Kahl Bernie Jansen and Quin Vincent from VAA Bibiana and Dayn from Omas Bob Warren and Tim Larsen from Rentokil Bryson Ramsey from LIftco LLC, specialising in Belt And CAge Manlifts Carl Swisher & Rick Fifer from 4B Components Ltd. Cimbria Clint Steele and Paul Sondgeroth from Todd & Sargent Craig and Steven from IntraSystems Deming Sun from Satake, rice and grain colour sorting machines. Harold Mauck and Mike Resner from Essmueller - Bulk Material Handling Equipment Henning and Thomas from Fawema Hidayet, Tuncay & Sibel from th to Seyit & Diwakar Melike Arikan from Alapala with Hidayet, Tuncay and Sibel from the Turkish Grain Board Regan Heaton and Daniel Wambeke from Scafco Grain Systems Robert Cook, Vice President of Biomist Richard and Nick from Vortomech Robert, Chris, Dan, Dave & James from IFC Service Rusty and Guenter from Static Binder Sou Yuzhong from the Kaifeng Maosheg Machinery Co IAOM EXPO F
  8. 8. Craig and Steven from IntraSystems he Turkish Grain Board next r from imas North AMerica Craig and Steven from IntraSystems Fabrizio, Marco, Gerald and Christopher from Ocrim Garip Cantemir from Urgur showing a customer the inside of an Urgur machine Gary and David from AMVT colour sorting Doug McCan from Maxi-Tronic Ertan Kaya from Erkaya Laboratory Instruments he Turkish Grain Board next r from imas North AMerica Jamie & Matt from Chantland John Hunter from Buhler Josh and John from Green Future structual Innovations Keith Robinson from Copesan Joe and MIke from SEFAR Kristen McCarty, Laboratory Manager from Brabender Michael Cowl and Terry Geraghty from Tapco Inc Steve and Wylie from BS&B - Explosion Protection Technologies Stephen Nenonen, Sales Director for Romer Labs Steven and Mike from BinMaster stood next to the Smart Bob Thorsten Muenker from Siwaco Tod and Israel from Sentry Todd Morey, Nathan Huning and Scott Hanson from Airlanco Tom and Nick from Blower Engineering
  9. 9. Millguard-Pro Protecting property, lives and businesses CMC Industrial Electronics Douglas Forrest, president and founder of the small, boutique electron- ics company based in British Columbia called CMC Industrial Electronics, explained the company’s main business in hazard monitoring. Protecting peoples property, human lives and grain elevators in the grain business. CMC Industrial Electronics were commissioned to solve a roll stand problem at large a company, and quite by chance when Douglas Forrest met the company’s maintenance manager there was a typical roll stand in an older mill from the 1920s-1930s to work on. “If you look at this machine you will see there are just a couple of very small sensors added which are used to measure characteristics of the machine,” he says pointing to a presentation slide. “We do it with red baring sensors, vibration and speed, connected 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- ple in your plant with no electricians, no screwdrivers or the need for waterproofs,” he adds. “You may not realise it but many of you reading this article have CMC’S hazard monitoring systems in your milling plants today: they have 150,000 points monitored in North America alone.” When creating a hazard perception device for use on roll stands the challenge for CMC was two fold: baring failure and roll fire. The first was easy to fix. The roll stand part was much more difficult. CMC adapted one of its infrared sensors so that it could be used on the stand. The challenge for infrared on a roll is coping with dust. CMC figured out how to do it. “The system is designed and certified for use in a class two-div-one environment. It has been tested by a certified testing agency and is suit- able and fully approved for use in,” he adds. Key benefits include protects milling operations prevents catastroph- ic failures and enables scheduling of proactive maintenance. MPAU S Sifter Azurit ‘S’ for food safety Bühler John Hunter from Buhler presented one of the best Showcases of the day. He starts his presentation by explaining why there is an ‘S’ after the prodcut name. "The MPAU S-Sifter is to show that it has been designed with a clear focus on food safety" says Mr Hunter. “We need to address the needs of the modern food industry and we are being directed by regional, national and global regula- tions as they are implemented. Safety is always a priority for our customers. “As with our other sifters this MPAU S features excellent sift perfor- mance and the number one thing we all need on a sifter is stainless steel lining with insulation for food safety. Insulation reduces condensation in machine, which is a risk at some times of the year.” In addition to this great design we have Novapure sieve boxes and frames, we have eliminated all wood from machine and replaced it with a hi-tech synthetic material. “A key requirement of this material is that it needs to deliver 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 clean. “You can move it 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 mesh 250 micron 14 tons per hour. Larger mesh sizes means you can increase capacity, he says. “At 58-inch, five foot deep, 90-inch wide and 94-inch high to the top of the frame will fit onto most mill floors. And its easy to get in for maintenance. To keep the space envelope the motor has been put at the back. Mounted directly behind the machine for easy accesses and mainte- nance. Counter weight is strung underneath machine instead of in the middle of the sifter. Nova Technology uses a single cleaner that cleans both sieve screen and box. This has been simplified. Novafit is also retrofitted into some older models. Features and options available include: safety ropes, probe that will detect motion of sifter to make sure that it is correct and not out of level. “The key benefits are that we are delivering excellent setting per- formance while delivering the food safety requirements we need in the modern food industry. “We are in the food industry and we have to make sure we meet its requirements,” he concludes. IAOM Technology on display 34 | May - June 2014 GRAIN&FEED MILLING TECHNOLOGYF
  10. 10. Pro-Tector Your best defense against metal Magnetic Process Equipment (MPE) As customers face increasingly stringent product safety standards, Material Process Equipment (MPE) has sought to provide a new and better way to prevent both ferrous and nonferrous metals from con- taminating final product. The result, the MPE Pro-Tector which efficiently combines the simplicity of a magnetic separator with the reliability of a metal detector in one compact unit. This innovative new system assures the quick, easy removal of metals from the product stream, while its size accommodates the tight spaces commonly found in production facilities. 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- ues through a gravity-feed metal detector. The Pro-Tector’s integrated drawer magnet employs twin layers of rare-earth magnetic tubes to provide maximum magnetic separation of metal contaminants, and its quick-clean feature allows the operator to clean the unit in less than 10 seconds. Extremely reliable and easy-to-use, the Pro-Tector’s integrated metal detector features a straightforward operating system the quickly guides the user through set-up and operation. Designed for intuitive use, the effectiveness and ease of use makes this metal detector the premier choice for manufacturers unwilling to compromise on product safety or quality. Recognised as the world standard for design, easy use and reliability, MPI drawer magnets deliver maximum capture of metal contaminants and assist food processors and others to keep product contaminant free and to protect processing equipment from damage. Valve Bag Packaging Highest capacity four-packer in the world Haver Filling Systems Rim Boltong, from Haver Filling Systems, started his Showcase presentation on Valve Bag Packaging by telling the audience that he definitely had some exciting things to show in filling flour into valve bags. “At Haver, we first look at your product to get an understanding of their properties. We look at bulk densities and how the product flows and how to best dose it into the bags. “We have a wide arsenal of techniques available to bring the prod- uct into the bag. “When it comes to bag valve technology we employ empowers that are either vertical or horizontal, depending on the bulk density of product. We can use air for coarse products or mixed products or oily or liquid containing products.” Mr Boltong mentioned other more traditional methods, which are much slower, explaining that they also use gravity when possible, which allows faster packaging of products. He then demonstrates what it looks like to bring product into a bag using the impeller method; this is the preferred method for flour because flour has such small particle sizes and it flows relatively easily. “The bag is applied to the spout; the impeller is turning the paddle wheels; the impeller is forcing product into the filling pipe where we are applying some air into the filling pipe to help aerate the product and get it into the bag. “You can imagine we have to remove around 50 liters of air and then when you remove air you also remove some of product - with this system it is bringing that back into your hopper and recycling it. It’s a closed system.” There is an inflatable sleeve that prevents the dust from exiting the bag. “It’s important as we are filling that we are inflating the sleeve of the spout meaning we are not releasing any dust into the atmosphere. All the product and dust is going into the bag.” “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- est densification possible using mechanical methods. “We can go anywhere from a one spout solution to a 10 spout solu- tions. What that means is per spout we are looking at approximately 200 bags per hour at 50lb weights so, we can go anywhere from 200lbs to 2000lbs and above when your talking smaller bags. “We have recently installed a 10-spout installation in the northeast for flour. It can do 2000 bags per hour at 50lb weights and whilst it leaves a very small footprint we are confident that this is the highest capacity flour-packer in the world. Some of the advantages of the roto seal is that one operator can run a whole packing plant - 2000 bags per hour. “In a 20 by 20 footprint we can produce 2000 bags per hour, which is pretty much unheard of. In addition to all this speed and efficiency we must also pay attention to the cleanliness, that’s an issue we are always addressing, not least in terms of food safety but because of explosions and protection. The magic happens here “We have installed a roto-packer in The Netherlands for potato starch, which is a more difficult product than flour. “As bags are singled out and picked up with suction cups, they are put into a sero-driven grip band and shot into the air and onto the spout. We find this to be an accurate and reliable way of bringing the bags onto the spout. “Then this is where the magic happens, which is when the bags land on the spout it automatically raises or lowers depending on bag size and product. The spout has the sleeve. The bag is firmly nested in a bag chair supported on all sides. The bag is filled rather slowly. The power of the system allows each bag to have time to be filled, release air then sealed and discharged. “High rates are achieved by having multiple spouts working at same time. “Each head has its own weighing electronics which constantly feeds back the weight of the bag to the weighing electronics so it can adjust itself. This allows bag weights not to drift much,” he adds. May - June 2014 | 35GRAIN&FEED MILLING TECHNOLOGY F
  11. 11. A problem solver is someone who examines problem, someone who considers relative perspectives and solution models. Listen, observe and use all your senses. Sharpen your skills and understanding. Everyday should be a learning opportunity in the flourmill. Become a lifelong learner. In preparation for this presentation I looked over at least 14 different textbooks on the section about problem solving. It was clearly the most limited volume of information you could ever imagine because it all has to do with four steps and the fact that in order for you to solve a problem you really have to have a base of knowledge of these four steps. This assumption is identified in almost every mathematics course presented at university, even in England! These four steps are: understanding the problem, devising a plan, carrying out the plan and looking back. The Deming Cycle The Deming Cycle: ‘plan, do, check, act, cycle’ considered statistical process control. The Deming Cycle has been revised about four or five different times to fit various disciplines. These techniques are essential to take you from where you are to where you want to be and of course you have to ask questions. In typical understanding of questioning and fact finding there are several entry ques- tions: who, what, when, where, why. I sup- pose to some of you engaged in magazine production you include these questions in your particular articles in order to bring that article to fruition. There are a few rhetorical constitutions or dispositions that you should think about as you’re in the process of solving a problem and developing an understanding about the problem. Some things sound very simple, but there is dispute about fact: What do you really know and what had really been just an assumption? There is also often a dispute about definition - how do you define things? Again I suggest that if you follow the thought processes of a lawyer you might get a little bit lost in that area! But the definitions and the differences between the definitions can be very subtle. I’ve had long discussions over several beers about the difference between a flow diagram a flow chart and flow sheet and I still don’t understand. The dispute about the nature of the act and what was done, who did it, was it inten- tional, was it not intentional and disputes about jurisdiction and procedure: These are very classic argument methods. Another opportunity to enhance your understanding of a problem is to use Ishikawa’s fish bone diagram. This includes six Ms and these Ms suggest any varia- tion in the outcome or change in process may be as a result of: manpower, mother nature, measurements, methods, material and manufacturing, Bloom’s taxonomy Bloom’s taxonomy: as flour millers we need to be ‘higher order’ thinkers, the people on the floor running your mill need to be ‘higher order’ thinkers, you need to be a ‘higher order’ thinker. You can’t live on things you have remembered but how you synthesise, analyse, apply, evaluate, create solutions or solve problems. What you need to understand about solving problems in a flourmill is that many of the answers have already been identified for you: the flow sheet is the dictionary of what’s happening. I trust the system but this trust is always verified. A system may tell you a bin is full but a good rap on the side of a bin will tell you if its full or empty too. I’ve learned some things about solving problems from different parts of the mill and that’s what I’d like to share with you today. In sizing stock I had a problem with open dry good ash and low yield, and when we closed ground we had a high ash and very good yield. These two things are a complex matrix of two points. How we addressed the problem: Read the flow sheet, pull samples of every stock. Stock appearance alone can be misleading. Read flow sheet, address the problem and not the symptoms. I questioned what was reasonable when it came to dust. You should have an idea of what are reasonable expectations for this process as the collection and disposition of dust filter stock has changed over time. It has moved from bucket elevator systems, where we had good suction and poor suction, to rolls with perspective quantities of bran in their systems. Flour and sock choke was evident around a roll stand. Overlooking obvious problems So often that happens to us. Sifting effi- ciency is what needs to be addressed. Often we forget basics and fundamentals. The choke is not always the source of the problem. Sifting, suction and grinding, these things are all interconnected. Screen splitting: what did I observe? Two identical sifter boxes making the same separation on identical stock produc- ing different qualities and quantities of scalp material. Roller bin mill adjustments could make or correct the problem. We observed that the scalp from one of several sifter boxes appeared to be rich as a result of that incomplete sifting. We studied the product guess what? We looked at the flow sheet! We screen tested the product under the rolls, we screen tested the product in the sifter, we attempted to rebalance the load but the problem was we couldn’t correct it. We still had scalp and we had just changed the loca- tion of the problem. The layout of the system would not permit equal distribution of that load for the different locations of the mill. How many times do we see things like this set up in order to split the stock-there is certainly nothing wrong with it but I would ensure that the product is homog- enous and most of our products in flour mills are not. The balance of those sifter boxes could not be controlled and as I thought about it I thought “what are my sifter loading expecta- tions?” Increasing or decreasing the loads of sifter boxes assuming that this is the same material in each sifter box we expect changes in the scalp as the load increases. We’d see an increase in potential through in that scalp. If we put that in terms of efficiency in sift- ing separation it would go down instead of making an increase in the perpetual through. Flour production would go up. Flour in the carryover would go up affecting downstream milling operations. You want low ash flour n one sifter box. You get a low ash flower but you get a lot of carry-over in the next grain system. You want to shift the particle size of the flour? You increase the load the particle size of the flour will go down. Quick release I did run into a problem where we couldn’t open a roll enough to achieve the target quick release. We couldn’t open up a “A problem is a disparity between where you are and where you want to be.” – Dr Jeff Gwirtz Problem solving in the milling industry by Dr Jeff Gwirtz, JAG 2003 and K-State JAG only from 2011, US 36 | May - June 2014 GRAIN&FEED MILLING TECHNOLOGYF
  12. 12. roll enough: that’s a strange problem. The stock that was coming down to the roller mill - it was already too fine to begin with. What happened? I read the flow sheet I checked the stock (the stock doesn’t lie). Flow sheets sometimes lie – Let’s blame the engineers who don’t take time to redraft the flow sheet! We have to have an up-to- date flow sheet. Grinding too close Grinding too close: all the bran whether its coarse. The product was sieved over a 21er that was 1041 microns approximately, it may have been broader but it was still slithering. I think that if you slither the bran the propensity to increase the ash in the flour goes up. The challenge of getting the endosperm off the bran hinges on getting the proper quick release. One of the last milling story problems where I learned a little bit about problem solving was in the process of adjusting a purifier 7. I observe large pieces of bran coming off the purifier at a significant rate. We observed this and it wasn’t consistent with what I had really expected. What we did was we got out the flow sheet! We identified what we expected to be there. We ran sieving tests. We took the sifter apart and we found a large hole. How did I know it was going to be there? I read the flow sheet. Sometime in life you will end up looking at a new machine or set of machines or processors and I offer you these things to think about: • Ask yourself about the material and processing objectives of the machine • What are the physical dimensions of the machine? • What are the materials of construction? • What are the drives, what do the drive systems look like? • What are the general equipment adjustments available to the operator? • What kind of material or stock is to be processed by the machine? • What are the sanitation issues associated with the machine? • What maintenance skills are needed? • External inputs? • Do you need a fan somewhere? • Do you need compressed air? • What is the dependency or relationship between the equipment and the system? • You can look at the incoming material, the expected uniformity quality quantity and rate • Look at the inputs - quality, quantity, and rate • Process objectives, whether it’s to reduce size or make some kind of separation Having knowledge is the key to critical thinking having flow sheets being able to determine what’s not there. Leverage every tool that you have to solve problems. GM’s naughty words list General Motors’ lawyers put together a list of words that could no longer use at GM. Instead of ‘having a problem’ there is an ‘issue,’ ‘condition’ or ‘matter’. “In addition, there were several hundred other words that came into play, that I will not take the time to share them with you today, but I do have a list of synonyms that I want to share,” says Dr Jeff Gwirtz of JAF 2003 and K-State JAG from 2011. “Through my career there have been many words I’ve heard to describe a problem. While I was with Ralston Purina Co you could not say you had a ‘problem’ you had an ‘opportunity’ so everything was an ‘opportunity’. “I’m sure in the world of supply chain management you too have a word that’s used in place of the world ‘problem’. “A problem is a disparity between where you are and where you want to be. “I’m not talking about physically I’m talking about the process, particu- larly within respect of operations in a flourmill,” says Dr Gwirtz. May - June 2014 | 37GRAIN&FEED MILLING TECHNOLOGY M lling International Directory twenty two 2013/14 international milling .com ONLINE | PRINT | MOBILE Get the IMD on your smart phone i i i i i i iiiiiiiii i iiiiiiiii iiiiiiiii i i i i i i i i i iiiiiiiii i iiiiiiiii iiiiiiiii i i i The premier resource for the global milling industry F
  13. 13. Educational Session NIR Shifting protein target closer to your specification O n a bright warm Thursday morning at IAOM in Omaha we sit down to listen to Jeff Boedigheimer enlighten us on utilising NIR technology for inline process control. Jeff starts by talking about goals: • How you can save time and money by improving your grain blending or flour production by utilizing in-line NIR technology. Reducing protein losses or moisture variation • The ability to eliminate sample ware from your process as well as reduce rework • Ensure you’re producing your product close to your specification “I’m certain that many of you use near infrared technology in your mills. It’s widely accepted technology that’s been used in the agricultural industry for many years primarily in the bench top mode where you take a sample from the process and you then present it to the instru- ment.” “What we’re trying to achieve with the next approach in the industry is move it in-line.” *When you take into consideration errors asso- ciated with the bench top analyser plus sampling error, you actually have to make a determination as your process variation is going to be wider than it should be. *So when you go continuous and analyse a sample and get results every 20 or 30 seconds you actually remove sampling errors. You’re able to reduce your standard deviation, change your process variation from an out-line approach to an in-line approach. *Really the concept with in-line standardisation is to see how much variation you have in your process. When you’re running with a bench-top analyser you typically have a wider variation than you’re running with to compensate for a safety margin.” He went on to say, that when you look at doing the genus analysis you have greater improve- ment and confidence in your analytical results and therefore can shift your target and reduce your standard deviation. You’re basically shifting your protein target closer to your specification. In-line can be used in grain receiving to segre- gate grains or grain blending for protein analysis further down stream. “So what we’re looking at is reducing that protein variation and that’s really where the economics come into play in flourmills.” From a moisture perspective, whether that is whole grain to ensure your tempering is correct or on the flour side to make sure moisture is at specification or to bring it up closer to your target of 14 percent, in-line can provide a solu- tion, he says. “Also on the flour side we measure ash with in-line analysis that’s to make sure that you’re not out of spec.” An example of one company’s experience showed in-line on protein blending in wheat saved approximately US$100,000 annually by targeting 13.1 protein from 13.4. Average saving are about US$0.04 per hundredweight (45Kgs). “One of the things we have focused on a lot with our in-line technology is the detection limit of the analyser. That’s the ability to detect a change in the process and what you will be able to see is those statistics. So with whole grain moisture our process detection had been down to 0.011 and protein 0.022. “These are very important statistics, it gives the analyser the ability to detect a change and gives him the confidence that the analyser is repeatable.” Another example of how an inline can be utilised effectively in a daily operation, where whole grain in this example the target spec was between 11% and 13% protein and here you can understand the product is above 13% so this type of technology can really be beneficial. React and make changes whether you have the ability to make a manual change or operators can make changes or implement the technology into a plc or a pid loop that automatically makes corrections for you. In-line allows you to take in the trending or the ability to see trends in real time. One of the things you’ve got to keep in mind when you’re doing lab analysis or bench top analysis is you have that time difference between results when you pull samples every half hour or two hours? That’s where the power of in- line comes in because you can take away that potential variation that could occur. The flour plant is a harsh environment. You’re dealing with dust, vibration and various tem- perature swings. It’s important to take into consideration, with an inline analyser, the things that have been done to the equipment so that it can withstand the test of time in that kind of environment. “Things we’ve implemented include: high rating, dust tight and watertight enclosure. We use USDA approved hygiene components and all our components are USDA certified. We also have the ability to put them in classified areas Class 1 or Class 2 where we can propose a solution. Also with an inline analyser as with any NIR there’s a light source, that’s what you need within the instrument. What we implement is a dual lamp in the actual analyser so if one burns out the other takes over automatically. This is critical when you’re running operation 24 hours a day seven days a week. In-line analysis: • It’s all about reducing standard deviation to ensure production of a consistent product. Do that and you will be closer to your target. If you’re closer to your target you’ll gain extra profit • Reduce the sampling and analysis time is also to consider. That’ll be done less frequently and you’ll be eliminating sampling error from the process • You can look at this as reducing rework as well • Typical payback is between 6-12 months Foss has 60 years of experience in analytics in the grain industry. With over11,000 Infratechs for protein analysis installed worldwide. In a quarter of a century of inline technology it has now installed 500 systems worldwide. Safety in the flour mill by design food safety aspects Randy Shmidt from Buhler speaking on food safety aspects of machine design and operation started his talk by showing steps which Buhler uses to ensure sanitary design of its equipment as well as the hygienic facility designs. There are two organisations that can help when it comes to designing food processing facilities that are specific to flour mills. The European Hygienic Engineering and Design Group, a consortium of equipment manufacturers, food industry companies, research institutes and public health authorities is an organisation that is much used throughout Europe. In the US there is the 3-A Sanitary Standards Inc (3ASSI), commonly consulted in for food industry North America non-profit organisa- tion representing the interests of regulatory, sanitarians, equipment fabricators and food processors. Both are non-profit organsations focused on the promotion of safe food and hygienic design. Both have common goals and exchange draft guidelines to stay in sync with each other. Even contents with all EHEDG guidelines have been cross-referenced with 3ASSI. Materials in construction The two organisations cite stainless steel as a logical option for material constructions give guidelines and specifications as to the quality that must be met as well as the finish of the steel. Two different types of stainless steel surface treatment: the product touching parts are pol- ished with a surface finish of 0.4 micrometers and the non-touching parts are electro-polished with a finish of 0.8 micrometers; both exceed the recommendations of both orginisations. Rubbers or soft materials guidelines, chemical temperature and steam stress crack resistant are MBR-type material closed cell that do not absorb cleaners. Lubricants Equipment needs to be designed to avoid product contact with lubricants. Secondly, lubricant needs to conform to FDA or NSF guidelines which are geared toward filter lubricants of treated drinking water. We put an additional seal in gear box to help protect the crucial interface between the gearbox and the product area. Wiring and cabling Routing of wiring and cabling through enclosed junction boxes and support brackets need to be designed in a way to eliminate the accumulation of material and designed to eliminate dead spots or areas that aren’t easily cleaned and where the growth of bacterial could occur. Most of the cable routing is inside the leg of the machine. Motor cables are routed by cable tray with grids in the control cabinets. GRAIN&FEED MILLING TECHNOLOGYF
  14. 14. Dust formation Equipment must be designed in a way that doesn’t generate dust. Tight access doors to eliminate leakage or cross contamination are critical. These access points need to be easy to remove to eliminate dead spots or accumulation of dust. Cleaning Needs to be easily cleaned. Easy access. All components easy to remove eliminate all gaps and crevices. Radius corner. Rather than have sharp 90-degree corners. Using NSDF micro feeder as the example for hygienic machine design. You can under- stand the detailed steps we take to ensure the most sanitary design of our equipment using both 3ASSI and EHEDG guidelines helps us meet these strict hygienic guidelines. The golden rule of zoning Move on to some of rules for designing complete food processing facilities. The golden rule for Buhler is to arrange the plant design into its different hygienic zones, labeling these zones as either a no- zone, low-, medium- or high-risk zone. No-zone pose almost no food safety risk at plant: Outside areas; separate administra- tion offices; were smoking, eating and drink- ing is permitted. Low-risk includes areas where direct contact with finished products is not likely. This may include grain receiving, loading bays or quarantine rooms for product. Medium-risk zone are closer to area where food contamination could occur. Stairways, elevators and areas typically where most processors have rules and guidelines like washing hands, etc. Wood should be eliminated as much as possible Zone 1, the high-risk zone where there is the highest chance of product contamina- tion, include mill grinding, finish product, storage, bagging and packing facilities. So following VRC’S hygienic design of food factories guidelines plants are encour- aged to divide the facility into these hygienic zones. No color-code for no-zone 4; zone 3 – green; zone 2 – orange; zone 1 - red. This helpselps processors. We try to enhance this by the location of the zones and clear divisions such as doors and walls. They enhance guidelines by having walls between places. Building design key factors Little things make big differences, such as type of flooring - ideally smooth surface floors that are easy to clean yet safe to walk junc- tion between equipment and building itself weather floor ceiling well pay special attention to how that junction will take place. Temporal water control system equip- ment should be designed so that it does not contribute to non-hygienic conditions, but also needs to be maintenance friendly. As with plant sifters, temporal water con- trol systems should have suspension points for are integrated into the ceiling structure. Bin design On the inside of product bins all corners should be rounded excluding discharge points. Surfaces need to be prepared to meet the specific requirements of the product that is to be stored. Two basic philoso- phies for bin top design - raised manhole covers may be less likely to have contami- nates inadvertently entered in from the top. Adds more hassle for cleaning. Flush manhole covers makes cleaning floor and area much easier but must have good seal to prevent contaminates from entering the bins. Summary In summary selecting the right building con- cept is key, ultimately determining the added value of your investment prerequisites. Obviously, hygienic concepts is part of the project concept phase and this needs to be talked about in great detail at the very beginning of a project phase and needs to be kept in mind throughout the entire project with building engineering according to hygienic concepts and high quality execution of the construction and instillation work. Hopefully, with all that kept in mind and everybody following those prerequisites, we would end up with a clean and appeal- ing processing facility that’s easy to clean, complies with food safety requirements and happy customers thank you. May - June 2014 | 39GRAIN&FEED MILLING TECHNOLOGY Grain cooling GRANIFRIGOR™ The most natural way of grain preservation: • Protection against insects and microbes • Without chemical treatment • Short amortisation period • Low energy costs • Independent of ambient weather conditions F r i g o r T e c G m b H • H u m m e l a u 1 • 8 8 2 7 9 A m t z e l l / G e r m a n y Phone: +49 7520/91482-0 • Fax: +49 7520/91482-22 • E-Mail: info@frigortec.de w w w. f r i g o r t e c . c o m www.summit2014.org REGISTER TODAY! 20% Early Bird Discount Ends 31 July For registration and more information, go to www.summit2014.org/registration F GRAIN&FEED MILLING TECHNOLOGY
  15. 15. F ollowing the official opening of the 2014 IAOM Annual General Meeting in Omaha, vice-president Damon Sidles moved a special motion of standing remembrance for members lost in the past year. They included: Jack Higginbotham, Alvin Albert Prinzine, Harry Myers III , John. E. Webster, Carl Bush and Richard Robertson. The Treasurer’s Report by Roy Lepp stated the cash asset position of IAOM stands “sol- idly at this point in time” with the organization functioning within budget. It was noted that conferences and correspondence courses had boosted revenues through 2013. Pre- registering expo exhibitors had also helped the organisation’s financial position. It was also noted that 42 percent of IAOM members are international and there is a move to internationalise the membership further. Key points Scott Ardem, Education Committee chair- person, reported that three meetings had been held since the Niagra Falls Conference and Expo. A new chairperson is being sought, following Lionel Holwa’s resignation from Mondelez International, and who will be appointed by the IAOM President Don Hoffer as soon as possible. Current board members include: Doug Stuckie - ADM Milling; Chris Capenter - Bunge Milling; Steve Matson - Horizon Milling; Jim Haggart - Star of the West Milling and Joe Woodward - ADM Milling. More individuals from within the membership are being sought to serve. Correspondence Courses units 1, 2 and 3 are being reviewed currently and are being translated into Spanish and Arabic. Mill Maintenance and Fundamentals This course is going well and more are being planned. Two short courses - Fundamentals of Milling 1 and 2 - received very good reviews by participants. The course was taught by Dr Jeff Works of OCRIM, Cremona, Italy and Dr Jeff Works lead the sessions. A new online system is being developed for students and instructors. A new Grain Milling Certification for community colleges and a programme in partnership with Kansas State University is in the pipeline. Food Protection Committee Ron Galley, Food Protection Committee (FPC) chairperson reports that his com- mittee met 3 times since the last Annual Conference and Expo. The committee heard an update on Food Safety and EPA’s proposal to remove fluo- ride and chloride tolerances in food and to remove the effects of fuming and profume. During this meeting, the committee finalised its work on the IAOM IPM manual for stored projects and risk management. Jim Bears of NAMA proposed this in early 2012 and this document is now complete and is published on the IAOM’s website. The FPC then met and held a conference, the committee briefly heard about the FDA regulations and inspections. Earlier this week, the committee met with four vendors to talk about allergens and cross- contamination. Technical Committee Jim Doyle, Technical Committee chairman reports that recent meetings have focused on education and training programmes such as IAOM to part- ner with community colleges. Challenges, new projects and packaging issues were all discussed. One universal challenge is hiring capable and competent employees. Damon Sidles, Treasurer and IAOM President Don Hoffer’s recent meeting with the Middle-East and African office of IAOM in Muscat, Oman was reported upon. Trade shows and educational programmes were held which meant good attendance levels. Craig Frayling from Cargill updated the group on NFPA changes and Roskin McClure gave regulatory updates to the committee. Rudy Wise from Buhler gave a presentation about the technological trends taking place in the industry around the world to the committee. Environmental, Health and Safety Committee Anthony Hunter, Environmental, Health and Safety Committee chairman says there is a variety of issues to be addressed, but the three most important ones are OCEA’s new requirements, NFPA combustable dust standards and the combustable dust inspec- tions from OCEA. The committee intends to share a document within the next three months on ‘our mission of promoting and sharing ideas with industry to give a vital function to the industry’. More individuals are invited to join. Employer Relations Committee David Pickett, Employer Relations Committee chairman is working to recruit more members to the committee. New appointments incoude: Troy Anderson, Horizon Milling; Kurt Wedsall, General Mills and John Schalz from Matson Milling. The committee is working on a new recruitment website, www.grainmillingcareers.com and more topics for the 2015 Conference. Elections Rory Lepp for the open Vice-President post, nominated and elected by the committee. Brad Allen for Treasurer, nominated by the committee and elected by an unanimous vote. IAOM ACE (Annual Conference and Expo application). IAOM is pleased to provide this and look forward to doing more in the future. Nominating Committee The Nominating Committee recognizes Rial Denny as a distinguished member. Safety awards ConAgra Mills, Puerto Rico and ConAgra Mills, Ohio, USA, won the awards. For 10 years in a row, these mills have been awarded safety awards, so this special award has been given in recognition of their achievements. The other three winners all come from Britian: ADM Seaforth, Liverpool; ADM, Corby, Northampton and King’s Flour Mill, West Yorkshire. The committees were then installed. IAOM AGM Hightlights 40 | May - June 2014 GRAIN&FEED MILLING TECHNOLOGYF
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  17. 17. www.gfmt.co.uk LINKS • See the full issue • Visit the GFMT website • Contact the GFMT Team • Subscribe to GFMT A subscription magazine for the global flour & feed milling industries - first published in 1891 INCORPORATING PORTS, DISTRIBUTION AND FORMULATION In this issue: • Role of extruders in Halal food production • Fortification Fortification in rice and flour • IAOM 118th Annual Conference & Expo May-June2014 • GM soybeans The on-farm facts • Harvest conditions: wheat quality and addressing issues • The Mills Archive GFMT becomes a patron first published in 1891 This digital Re-print is part of the May | June 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. 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 adove. INFORMATION FOR ADVERTISERS - CLICK HERE Article reprints 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: jamest@gfmt.co.uk or visit www.gfmt.co.uk/reprints