Building the USA s New Flour Mill Innovative Milling Solutions Sunil Maheshwari. Siemer Milling Company West Harrison, Indiana USA

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1 Building the USA s New Flour Mill Innovative Milling Solutions Sunil Maheshwari Siemer Milling Company West Harrison, Indiana USA

2 More than 135 years of food ingredient history 1906: Joseph & Clemens J. Siemer buy out other interests & establish Siemer Milling Company 1950 s: Business commits to flour milling exclusively 1979: New mill opens in Teutopolis, Illinois to meet demand and expands by another 80% in the next 20 years. va

3 SMC Mission Statement Core Purpose: Through personal professionalism, we deliver best-value food products to improve the quality of life. Core Values: o We work with exceptional people to create satisfying relationships through respect, trust and responsibility (RTR). o We strengthen these relationships through continuous improvement and a commitment to excellence.

A significant percentage of company stock is now held in trust with all eligible

4 Family/Employee Owned One of the most dramatic changes took place in 2000, when an Employee Stock Ownership Plan was established. A significant percentage of company stock is now held in trust with all eligible employees as beneficiaries, so that company success will be translated into greater financial security for the participants.

5 Teutopolis, IL West Harrison, IN Hopkinsville, KY Siemer Milling Company Locations in America s Heartland

6 Siemer Milling Company Teutopolis, IL Built 1979 o 1,000,000 lbs of flour per day o 210,000 Tons of wheat used per year o 78,000 Tons On-site wheat storage o 21,000 Tons Off-site wheat elevator

7 Siemer Specialty Ingredients Heat Treatment Facility Teutopolis, IL Plant 1: Built 2003 Plant 2: Built 2015 o 110 Million lbs per year o Bulk, Super-Sack, Bag o Food Safe and Functional Flour

8 Siemer Milling Company Hopkinsville, KY A Mill: Built 1995 B Mill: Built 1998 C Mill: Built 2009 o 1,600,000 lbs of flour per day o 300,000 Tons of wheat used per year o 90,000 Tons On-site wheat storage

9 Siemer Milling Company Corporate Office Teutopolis, IL Built 2014 Siemer Milling Company Research Center Teutopolis, IL Built 2017

10 Strategies for the Selection of the New Location Access to the Highway Access to the Railroad Closeness to the Wheat Supply Closeness to the Customers Other Considerations

11 Siemer Milling Company West Harrison, Indiana

12 From Start to Finish

13 Siemer Milling Company West Harrison, Indiana Built 2015 o 1,000,000 lbs of flour per day o 210,000 Tons of wheat per year used o 28,800 Tons On-site wheat storage o 4,370,000 lbs Flour Storage

14 Key Points Newest Technology Automated/Easy Operation Sanitary Design Energy Efficient Food Safety

15 Planning for Mill Design Simpler Housekeeping Improved Food Safety Improved Industrial Safety and Security Steps taken to eliminate product recalls. EPA and OSHA Compliance Considerations Fumigation friendly design

16 Site Layout

17 Floor Layout

18 Planning for Wheat Intake Intake and Storage Allocation of Wheat Storage Effective Pre-Cleaning Appropriate Sampling for Quality Availability of Appropriate Quality Testing Visual, TW, Protein, Moisture, FN, Vomitoxin

19 FC Wheat Intake FC CL FC WT SC SC FC CL CL PS

20 Planning for Cleaning and Tempering Cleaning and Tempering Contingencies for Future Expansion of Capacities Selection of Cleaning Equipment to Help Raising the Standards of Food Safety

21 WT FC Cleaning Flowsheet FC SC S SC SC FC FC FC S S FC FC S S FC FC CL SC SC S S WT WT WT WT WT TS CL CL CL CL CL CL VS S CL WT WT SC SC PS PS CL PS

22 Planning for Milling-Blending and Treatment Milling Mill With or Without Purifiers Any specific design measures to improve cleaning of bran and thereby increase flour extraction. Grades of Flour and Treatment (Chlorination) Specific Safety Measures Related to Chlorination

23 Planning for Milling-Blending and Treatment Flour Blending and Treatment Any specific design measures to improve flour blending and treatment, if applicable.

24 Planning for Product Handling Product Handling and Disposal Bulk and Bagged Delivery Allocation of Finished Products Storage Space Incorporation of Advanced Warehousing Practices

25 Planning for Milling Efficiency Overall Efficiency in all Areas of Planning Included the Following Considerations: Low Energy Low Maintenance and reduced downtime Equipment Design to Support High Sanitation Standards Leading to Enhanced Food Safety Equipment Reliability for High Level of Performance

26 Equipment Selection and Supplier These selections were made on the basis of requirements. The automation and On-line monitoring system was also selected to meet those requirements. Report generation for performance evaluations and audit.

27 Newest Technology Mill was the first of its kind in the USA. Most advanced milling equipment (lights-out). Ability to operate mill remotely. Wi-Fi in mill to allow remote operation of equipment. Utilized cable trays instead of conduit.

28 Automated/Easy Operation PLC utilizing Buhler Wincos R2 Program. The automation allowed us to start and operate the mill with a group that had never worked in a flour mill before. Group of experienced millers guiding the new millers. Programming minimizes chance of operator error. Online NIR monitors quality and consistency.

29 Sanitary Design Antares Roller Mill Stainless steel housing around roller mill. Unit is sealed. Aspiration is recycled air from pneumatic line below. Easy access to area behind feeder rolls for quick sanitation. Low noise level.

No seams or joints No fasteners Tight sieve stack No under

30 Sanitary Design Sirius Plansifter No wood in process. All sieves are molded Novapur frames. No seams or joints No fasteners Tight sieve stack No under wire, which lowers height of sieve. Which in turn, allows more sieves and sifting surface.

31 Energy Efficient Equipment Aspirators All of the aspirators used in 1 st and 2 nd cleaning are recycled air aspirators. This gives us up to 50% energy savings. Blower motors and exhaust fan motors Are all on Variable Frequency Drive (VFD) controllers. Programmed soft starts use less energy. Filter Exhaust Fans are programmed to a Pascal setting and use less energy after new filter sleeves are installed.

32 Evaluation of the Project upon Completion Completed on Time Completed on Budget Startup Hiccups

33 Major and Minor Challenges Involving the Project Hiring qualified people and training them. Educate with Global Food Safety Initiatives and FSMA. Plant was installed according to time schedule intended. Coordination of work done with daily meetings and intense communication level during construction. 2nd transfer system installed soon after new construction was completed. Challenging to keep up with 1 transfer system delivering to Bulk load out, Packing Storage, with 1 System in the beginning.

34 Lessons Learned and Recommendations Temperature and Humidity control. New plant allowing high production efficiency in regards to $/Tons produced. High extraction rate due to streamlined and tailored flow sheet for products the plant is designed to produce. Tailored Automation solution allowing operators to manage production schedule flexibly and with minimal human interaction. Minimize Risk by working with your preferred suppliers.