flour milling: yesterday, today and tomorrow · 2018-12-06 · milling company. • 1950’s: under...
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FLOUR MILLING:YESTERDAY, TODAY AND TOMORROW
Sunil Maheshwari
Siemer Milling Company
Teutopolis, Illinois, USA
IAOM Inaugural South Asia Region Meetings
Delhi, India: December 3-4 2018
Bangalore, India: December 6-7, 2018
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• 1882: Hope Roller Mills, Uptmor & Siemer, Proprietors, opens
for business on November 6.
• 1906: Clemens J. Siemer changed company name to Siemer
Milling Company.
• 1950’s: Under Quintin A. Siemer as President, business
commits to flour milling exclusively.
• 1979: New mill opens in Teutopolis to meet demand.
Capacity is twice that of predecessor, and doubles again in the
next 20 years.
• 1995: New mill opens in Hopkinsville. Capacity doubles in the
next 20 years.
• 2001: Siemer becomes Family / Employee Owned - ESOP
• 2015: New mill opens in West Harrison. Company production
capacity increases by 40%.
136 Years of Food Ingredient History …
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Siemer Milling Company
Teutopolis, IL
Built in 1979
Siemer Milling Company
Hopkinsville, KY
Built in 1995
Whitewater Mill LLC
West Harrison, IN
Built in 2015
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PRESENTATION OBJECTIVES
Advancements in Grain Cleaning Technology
Overview of Machine Design Changes to Improve Food Safety, Sanitation and
Finished Product Quality
Internal and External Auditing of Complete Process
Process of Transferring Finished Product from Mill to Customer
How automation plays a key role in overall operation and traceability.
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PLANNING FOR MILL DESIGN
Simpler Housekeeping
Improved Food Safety
Improved Industrial Safety and Security
Steps taken to eliminate product recalls.
EPA Compliance Considerations
Design should be fumigation friendly.
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PLANNING FOR MILL DESIGN
Overall Efficiency in all Areas of Planning Included the Following
Considerations:
Low Energy
Low Maintenance
Equipment Design to Support High Sanitation Standards – Leading to
Enhanced Food Safety
Equipment Reliability for High Level of Performance
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Galvanized or Stainless supports and equipment to minimize
paint contamination at outer areas (Flour Loadout).
Flour storage bins have rounded corners.
Large Wall Openings to provide greater access for
maintenance and housekeeping around equipment.
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Metal and Brick FacilitySiemer Milling Facility
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What do we mean by Food Safety?
Product Protection
Allergen Management
Dust Control - Hygiene
Avoiding Cross Contamination
Managing Condensation
Traceability
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Ingredient management
GMP
Key Safety Records
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25 % of Food Crops are Contaminated with Mycotoxins
Aflatoxin:
DON (Vomitoxin)
Storage Mycotoxin (Poor Post-Harvest Handling)
Distributed in Hot Spots
DON (Vomitoxin)
Aflatoxin
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MYCOTOXIN CONTAMINATED WHEAT KERNELS
Contamination in Advanced Stage
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OPTICAL COLOR SORTER
Siemer Facility
Reduces Toxins in Grain
Delivers Maximum Product Purity for the Best Value
Empowering Sorting Performance
Ensuring Consistent Operation
Optimizing Productivity
-- Lowering Cost of Ownership
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Scourer
Working Principle
Friction of:
1.Grain Against Screen
2.Grain Against Rotor Segments
3.Grain Against Grain
Aspiration Channel after Scourer
for Removal of Remaining Dust
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Light Peeling Process
Peeling with DC-Peeler by “Friction”
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ASPIRATION / PNEUMATICS
Application
For Keeping Machines and Systems Dust-free
To enable machines to work properly that are using air
as a machines like Destoner / Aspiration Channel.
To provide cooling effect to the product and / or
machines.
Pneumatics Use Air as Transportation Medium
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SINGLE FILTER ASPIRATION
Every bin has its own aspiration filter.
Advantages:
Simple Layout (less ducts)
Better Sanitation
Separation of Flour Quality
Each aspirated flour will be kept at the
destination bin.
No Product Cross-Contamination
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PNEUMATIC CONVEYING SYSTEMS: FEATURES
Long Conveying Distances
Flexible Layout of Conveying Pipe
Less Space Requirement
Dust-free Operation
No Product Residues in the Conveying
Lines
High Sanitation
Simple Automation
Less MaintenanceSiemer Facility
Closed-loop system for the handling of
explosive materials of for the aroma
protection or by using nitrogen or other
inert gases.
Lower Investment Costs for Many
Applications
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HYGIENIC DESIGN FOR ULTIMATE SANITATION
Stainless Steel
Easy Swing-up Cover
Swing-out Feed Module for Residue Free
Discharge of the Feed Device
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Flour Milling MachinesRoll Stand Floors
1940’S
1970’s
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Siemer Facility
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SANITATION/DESIGN IMPROVEMENTS IN SIFTERS
Completely Insulated Compartments
Housing of Stainless Steel
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NOVAPUR – GENERATION
Wooden Sieves
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PLANSIFTER All Product Touching Parts in Stainless Steel or Food Grade Plastic – Replacing
Traditional Wood Sifter
2-10 Compartments with Modular Design
Optimum Sifting Efficiency
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FLOUR STERILATOR - 99.9% KILL RATE
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QUALITY ASSURANCE – CONTROL SIFTERS
Recommended Positions:
Directly After the Mill
Before Bulk Loading
Before Packing
Benefits:
Removal of Foreign Particles to Avoid Product Liability Claims
Indication for Broken Sieves in the Milling Process (Overtailing Product)
Siemer Facility
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Inline Magnetic Monitor
Magnet Strength Monitor
Can be Used on Inline Magnets
Existing Magnets can be Refitted
Monitor will signal when to clean a magnet.
Inline Magnetic
Separator w/
Monitor
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NOVABLUE - BRISTLELESS AND DETECTABLE SIEVE CLEANER
The new sieve cleaner is our answer to increasing food
safety requirements. This sifter comes without bristles
and is detectable.
For our customers who prefer cleaners for flour sieves
without bristles or for those who are not allowed to use sieve
cleaners with bristles, the new NOVABLUE is the perfect
solution.
NOVABLUE is suitable for use in the production of hard
and soft wheat as well as durum.
No more Bristles → Highest Sanitation
Benefits
Bristleless Sieve Cleaner
Detectable: Optically and by Metal Detectors
Temperature-; Fat- and Enzyme-Resistant
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NIR MULTI ONLINE ANALYZER
The measurement system guarantees precise monitoring in real time thanks to NIR spectroscopy.
Product data is available in real time.
Immediate corrective measures can be undertaken during the ongoing production process.
Online testing of moisture, protein, and ash contents of raw material and final products.
Reliable and Reproducible Measurement Results
Benefits
Precise Monitoring in Real Time
Reduced Costs and Lower Maintenance
Flexible Installation and Absolute Product Safety
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NIR Multi Online AnalyzerSiemer Facility
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FLEXIBLE INSTALLATION AND ABSOLUTE PRODUCT SAFETY
Compact measurement probes.
Hardware is not affected by dust, temperature, vibrations.
Compact, flexible installation – for example directly on the gravity spouting.
The compact sensors are excellently suited for the retrofitting of existing plant.
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TRACEABILITY WITH ONLINE-SENSORS
Problem: Color and specks are important quality parameters
in fresh dough.
Measurement: Color
Measurement: Specks (black, brown, colorless >80µ)
Benefit: Real-time Intake Control
Quick Reaction Time
Consistent, High End Product Quality
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ASPIRATION SYSTEMS ENSURE DUST-FREE OPERATION
Siemer Facility
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PRODUCTION TRACEABILITY – INTEGRATED IN CONTROL SYSTEM
Trending Manager
Statistic
Manager
Traceability
Report Manager
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PRODUCT AND PRODUCTION SECURITY
Recipe Management Production Security
Product Identification
Management
Product Security
Product Parameter Regulation
Contamination Control
Online Quality Monitoring
Temperature Control
Standby Concept
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TOP SANITATION ON FINAL TRANSFER SIFTERS
NOVAPUR sieve stacks made of polyurethane with stainless
steel frame inserts guarantee maximum sanitation: wood, nuts
and brackets are things of the past.
In addition, product build-up is prevented by the smooth
profiles.
Fully insulated, stainless steel compartment: all interior walls and
doors are effectively insulated, thereby reducing the formation
of condensation significantly.
Each component in contact with the product is made of stainless
steel or high-quality PUR.
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THE FUTURE?CONFIRMING QA DEVICE IS OPERATING CORRECTLY
Using Online Particle Size Analyzer to confirm final
sifter is operating correctly.
Machine Assembled Correctly
No holes in sieves, that mean final screening not
operating correctly.
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1960’S MILL CONTROL TECHNOLOGY
Today’s State of the Art Milling Technology
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KPI Bin Usage
KPI OEE
KPI Yield#
KPI Down Time
Energy Monitoring
Motor Running Hour
Roller Floor Cockpit KPI via SMS and E-mail
Management Information
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Plant Control System
Avoids an unintentional mixing of various products in the receiver bins.
The system is checking the receiver bins prior to starting the conveying process.
Avoids cross-contamination in the production process.
To Increase Product and Production Security
Prevents Production Losses
Make sure, that your clients have no reasons for complaints.
Automatic lock or cleaning request for silos or production lines.
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Plant Control System
Identification of raw material supply by the use of Barcode or RFID-Scanner.
A communication interface allows a smooth data transfer.
Allows to Compare Target Values
Scanned data will be registered and stored.
Reduce operating faults and improve product safety.
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Summary
Product Protection
Allergen Management
Dust Control - Hygiene
Avoiding Cross Contamination
Managing Condensation
Traceability
Ingredient Management
GMP
Key Safety Records
Management of Operator Risk
Errors
Hygiene
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THANK YOU!
Sunil Maheshwari
Siemer Milling Company
Teutopolis, Illinois, USA