Digital Re-print May | June 2014

IAOM 118th Annual Conference & Expo

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&FEED MILLING TECHNOLOGY

24 | May - June 2014

GRAIN

Milling Industrys Largest Gathering

in the
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
Largest gathering of our & 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

Top Notch Keynote Speakers

World renowned keynote
speakers include Dr. Beau Lotto,
Neuroscientist & Founder Lottolab
(UK) and Daniel Basse, President
& founder, AgResource Co. (USA)
Evening Functions in Cape
Towns most elite venues
English and Arabic simultaneous
translation available
Full access to conference
presentations and expo

Management
Keynote Speaker
Dr. Beau Lotto

Neuroscientist & Founder,

Lottolab (UK)

Trading Moderator
& Keynote Speaker
Daniel Basse

Mike Krueger

Founder & President,

The Money Farm (USA)

President & Founder,

AgResource Co. (USA)

REGISTER NOW

Organized by:

Mideast & Africa District

www.iaom-mea.com/IAOM-SOUTHAFRICA2014/
Email: [email protected] or call 0096824711755

&FEED MILLING TECHNOLOGY

GRAIN

IAOM

May - June 2014 | 25

118th Annual Conference & Expo

rain 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.
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 worlds 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 participation 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 years 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 graduates, 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 exciting and informative moment, however, I have put
together a selection of the IAOMs 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 dont
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

IAOM opening
reception
evening
Left: Harrold, Keven &
Mike from Essmueller
Company and Doug
from Safe Grain/Maxi
Tronic Inc

Right: Dave,
Dan, Chris &
Robert from
Industrial
Fumigant
Company (IFC)

Right: Mike
& Rich from
C-Tec AG

Left: Melinda
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 Buhlers
opening reception.

Right:
Lindsay and
Mike from
Electro
Sensors

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.

Left: Steve
& Barry
from Design
Corrugating
with Howard
from Conagra
Mills

Left: Andreas
from Buhler
with Jose, Eliseo
from Fundiciones
Balaguer, Enrique
from Molinos
Modernos S.A.
and Mark from
Mocasa.

Left: Tim,
Randy, Matt
& Franz from
Buhler
Right: Paul
Walti from
Buhler
entertaining a
guest
Left: Joe from Buhler
with Deming from
Satake, Steve from
Sefar and Al from
Hogg Packaging
Corporation
Right: Ruifeng Li the
team from Baixiang
Food Group
(Henan) in China

Right: Ken Hofstra,

Head Miller with
Howard, DAllas,
Brad and Scott
from Richardson
MIlling Limited

Right: David,
Bill, Mike
and Tom
from Corbion
Caravan with
Damon from
Miller Milling
Co.

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28 | May - June 2014

GRAIN

International Milling
Educational Foundation
(IMEF) Breakfast

fter two days of successful

committee meeting and a fantastic
welcome reception given by
Buhler the focus moves to the formalities of the International Milling Educational
Foundation
(IMEF)
Breakfast.

Double Donor Districts honored

on district donor plaque.

Breakfast with donors, scholarship

and award winners

Mr Sidles announced the IMEF

Benefactors Award

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 mornings 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 donations, Mr Sidles introduced the Friends of
IMEF award. Unfortunately, none were in
attendance. However, the three people highlighted 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.

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.

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
years 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 students at Kansas State University.
So the Christian F Kongsore Scholarship
Award was born. On addressing the audience, 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 program 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.

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!

&FEED MILLING TECHNOLOGY

30 | May - June 2014

GRAIN

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 IMEFs breakfast meeting

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

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
NAMAs success as an organization. These
were his points of reference.

1990
Miller

2014

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

Total 958,950

83.5%

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 milling 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 volume produced is increasing, at the same

Total 1,329,800

2%
89.1%

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 NAMAs 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 endeavors 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 percent 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

IAOM EXPO

Robert, Chris, Dan, Dave & James

from IFC Service

Rusty and Guenter from

Static Binder

Melike Arikan from Alapala with

Hidayet, Tuncay and Sibel from the
Turkish Grain Board

Deming Sun
from Satake,
rice and grain
colour sorting
machines.

Bernd Kruse and Carl-Ludwig

Bollweg from Schule, also
representing Kahl

Bibiana and Dayn

from Omas

Regan Heaton and Daniel Wambeke

from Scafco Grain Systems

Bernie Jansen and Quin

Vincent from VAA

Bob Warren and Tim

Larsen from Rentokil

Bryson Ramsey from LIftco LLC, specialising in

Belt And CAge Manlifts

Cimbria

Robert Cook, Vice President

of Biomist

Sou Yuzhong from the Kaifeng

Maosheg Machinery Co

Richard and Nick from

Vortomech

Carl Swisher & Rick Fifer from 4B

Components Ltd.

Clint Steele and Paul Sondgeroth from

Todd & Sargent

Harold Mauck and Mike Resner from

Essmueller - Bulk Material Handling Equipment

Craig and Steven from

IntraSystems

Henning and Thomas from

Fawema

Hidayet, Tuncay & Sibel from th

to Seyit & Diwakar

Stephen Nenonen, Sales

Director for Romer Labs

Doug McCan from

Maxi-Tronic

he Turkish Grain Board next

r from imas North AMerica

Joe and MIke from

SEFAR

Ertan Kaya from Erkaya

Laboratory Instruments

John Hunter from

Buhler

Fabrizio, Marco, Gerald and

Christopher from Ocrim

Craig and Steven from

IntraSystems

Tom and Nick from Blower

Engineering

Steve and Wylie from BS&B - Explosion

Protection Technologies

Garip Cantemir from Urgur showing a

customer the inside of an Urgur machine

Steven and Mike from BinMaster

stood next to the Smart Bob

Josh and John from Green Future

structual Innovations

Keith Robinson from

Copesan

Gary and David from AMVT

colour sorting

Jamie & Matt from

Chantland

Michael Cowl and Terry

Geraghty from Tapco Inc

Kristen McCarty, Laboratory Manager

from Brabender

Thorsten Muenker
from Siwaco

Tod and Israel from

Sentry

Todd Morey, Nathan Huning and Scott

Hanson from Airlanco

&FEED MILLING TECHNOLOGY

34 | May - June 2014

GRAIN

IAOM
MPAU S Sifter Azurit
S for food safety
Bhler

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 regulations as they are implemented. Safety is always a priority for our
customers.
As with our other sifters this MPAU S features excellent sift performance 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

Millguard-Pro

Protecting property, lives and businesses

CMC Industrial Electronics
Douglas Forrest, president and founder of the small, boutique electronics company based in British Columbia called CMC Industrial Electronics,
explained the companys 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 companys 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 network which means you
can use low cost cable to
wire the system with us to
32 sensors on one devices.
Its a very low cost
systems and neat thing is
that its serviceable by peo-

Technology
on display

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 maintenance. 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 performance 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.

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
CMCS 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 suitable and fully approved for use in, he adds.
Key benefits include protects milling operations prevents catastrophic failures and enables scheduling of proactive maintenance.

&FEED MILLING TECHNOLOGY

GRAIN

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 contaminating 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 contaminants in continuous-flowing granules or
powders such as sugar, flour, corn meal or
spices, the Pro-Tectors integrated drawer
magnet provides maximum magnetic separation 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

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 product 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. Its a closed system.
There is an inflatable sleeve that prevents the dust from exiting the bag.
Its 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-

May - June 2014 | 35

ues through a gravity-feed metal detector.

The Pro-Tectors 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-Tectors 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.

est densification possible using mechanical methods.

We can go anywhere from a one spout solution to a 10 spout solutions. 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, thats 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.

&FEED MILLING TECHNOLOGY

36 | May - June 2014

GRAIN

Problem solving in the

milling industry
by Dr Jeff Gwirtz, JAG 2003 and K-State JAG only from 2011, US

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.

A problem is a disparity
between where you are
and where you want to
be. Dr Jeff Gwirtz

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 questions: who, what, when, where, why. I suppose 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 youre 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.
Ive had long discussions over several
beers about the difference between a flow
diagram a flow chart and flow sheet and I still
dont understand.
The dispute about the nature of the act
and what was done, who did it, was it intentional, 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
Ishikawas fish bone diagram. This includes
six Ms and these Ms suggest any variation in the outcome or change in process
may be as a result of: manpower, mother
nature, measurements, methods, material
and manufacturing,

Blooms taxonomy

Blooms 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 cant 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
whats 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.
Ive learned some things about solving
problems from different parts of the mill and
thats what Id 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 efficiency 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 producing 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 couldnt correct it. We still
had scalp and we had just changed the location 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 homogenous 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 expectations?
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.
Wed see an increase in potential through
in that scalp.
If we put that in terms of efficiency in sifting 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

couldnt open a roll enough to achieve the
target quick release. We couldnt open up a

&FEED MILLING TECHNOLOGY

GRAIN

GMs 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 Ive 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.
Im sure in the world of supply
chain management you too have
a word thats used in place of the
world problem.
A problem is a disparity between
where you are and where you want
to be.
Im not talking about physically Im
talking about the process, particularly within respect of operations in
a flourmill, says Dr Gwirtz.

May - June 2014 | 37

roll enough: thats 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 doesnt lie).
Flow sheets sometimes lie Lets blame
the engineers who dont take time to redraft
the flow sheet! We have to have an up-todate 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 wasnt 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

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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 its to
reduce size or make some kind of
separation
Having knowledge is the key to critical
thinking having flow sheets being able to
determine whats not there.
Leverage every tool that you have to
solve problems.

&FEED MILLING TECHNOLOGY

GRAIN

Educational Session

NIR

Shifting protein target closer

to your specification

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 youre producing your product close
to your specification
Im certain that many of you use near infrared
technology in your mills. Its widely accepted
technology thats 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 instrument.
What were trying to achieve with the next
approach in the industry is move it in-line.
*When you take into consideration errors associated 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. Youre 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 youre running with a bench-top
analyser you typically have a wider variation than
youre 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 improvement and confidence in your analytical results
and therefore can shift your target and reduce
your standard deviation. Youre basically shifting
your protein target closer to your specification.
In-line can be used in grain receiving to segregate grains or grain blending for protein analysis
further down stream.
So what were looking at is reducing that
protein variation and thats 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 solution, he says.
Also on the flour side we measure ash with
in-line analysis thats to make sure that youre
not out of spec.
An example of one companys 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.
Thats 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 youve got to keep in mind
when youre 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? Thats where the power of inline comes in because you can take away that
potential variation that could occur.
The flour plant is a harsh environment. Youre
dealing with dust, vibration and various temperature swings. Its 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 weve 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
theres a light source, thats 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 youre running operation 24 hours
a day seven days a week.
In-line analysis:
Its all about reducing standard deviation to
ensure production of a consistent product.
Do that and you will be closer to your
target. If youre closer to your target youll
gain extra profit
Reduce the sampling and analysis time
is also to consider. Thatll be done less
frequently and youll 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 organisation 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 polished 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 arent 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.

&FEED MILLING TECHNOLOGY

GRAIN

Dust formation

Equipment must be designed in a way that

doesnt 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 understand 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 nozone, low-, medium- or high-risk zone.
No-zone pose almost no food safety risk
at plant: Outside areas; separate administration offices; were smoking, eating and drinking 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.

May - June 2014 | 39

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 contamination, include mill grinding, finish product,
storage, bagging and packing facilities.
So following VRCS hygienic design of
food factories guidelines plants are encouraged 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 junction between equipment and building itself
weather floor ceiling well pay special attention
to how that junction will take place.
Temporal water control system equipment 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 control systems should have suspension points
for are integrated into the ceiling structure.

&FEED MILLING TECHNOLOGY

GRAIN

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 philosophies for bin top design - raised manhole
covers may be less likely to have contaminates 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 concept 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 appealing processing facility thats easy to clean,
complies with food safety requirements and
happy customers thank you.

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w w w. f r i g o r t e c . c o m

&FEED MILLING TECHNOLOGY

40 | May - June 2014

GRAIN

IAOM

AGM

Hightlights

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 Treasurers Report by Roy Lepp stated
the cash asset position of IAOM stands solidly at this point in time with the organization
functioning within budget. It was noted that
conferences and correspondence courses
had boosted revenues through 2013. Preregistering expo exhibitors had also helped
the organisations 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 chairperson, reported that three meetings had
been held since the Niagra Falls Conference
and Expo.
A new chairperson is being sought, following
Lionel Holwas 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 committee met 3 times since the last Annual
Conference and Expo.
The committee heard an update on Food
Safety and EPAs proposal to remove fluoride 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 IAOMs 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 crosscontamination.

new requirements, NFPA combustable dust

standards and the combustable dust inspections 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.

Technical
Committee

Jim Doyle, Technical

Committee chairman reports that recent
meetings have focused on education and
training programmes such as IAOM to partner 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 Hoffers 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 OCEAs

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 Kings Flour Mill,
West Yorkshire.
The committees were then installed.

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If you are interested in getting this article re-printed please contact the GFMT team for more information on - Tel: +44 1242 267707 - Email: [email protected] or visit www.gfmt.co.uk/reprints

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