Grain Forum - Technologies to reduce contaminations in grain by Stefan Schneider Mycotoxinereduction @ GRAPAS 2010 March 2010
The risks within the value chain. Possible sources and critical points of contamination Raw Material Recontamination Solids Organisms Solids Organisms 2 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
What are mycotoxins? Metabolism of molds Extremely heat and acid resistant Spread worldwide 3 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Mycotoxins generated by fungi. - Aflatoxins - Tenuazon acid - Alternariol Ochratoxin A (OTA) Ergot alkaloids - Zearaleon (ZEA) - Fumonisins - Deoxynivalenol (DON) 4 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Mycotoxin contaminated Wheat kernels. mainly surface contamination 5 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Healthy Kernel DON affected 6 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Healthy kernel DON affected 7 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Possible contaminants found in wheat. Raw Wheat Cleaned Wheat Straw / strings Sand / fines Stones Foreign grain / seeds husk / dust ferrous metal 8 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
The value chain within the grain processing industry. The key position of the miller 9 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Steps to reduce contamination in grain. Gravity classification Colour sorting intensive scouring Intake / Cleaning 10 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Efficiency starts in the Pre-cleaning. Every time Grain gets moved dust develops from grain to grain friction A good performing Aspirationsystem allows efficient dust removal. Grain dust has an extremely high contamination degree With an efficient separator a noteworthy part of fine impurities can be removed, implementing a large sand sieve surface In certain countries (among them also most of the european states) legislation exists already that offals from the Silo which have a very high contamination degree must not be mixed into the bran for feed 11 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Efficient grain cleaning Separator Classifier. High performance in pre-cleaning up to 100 t/h Maximal sparation degree in cleaning up to 24 t / h Sturdy construction for a long life cycle Built in easy to exchange wear parts 12 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Efficient grain cleaning - Air-recycling aspirator. For the separation of low density products from the wheat stream after the separator classifier 13 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Efficient grain cleaning - Air-recycling aspirator. Needs by far less aspiration air than a freshair aspiration channel Less air resistance because of small aspiration ducts (power saving) Easy installation and space management (small ducts) Has constant pressure and air volume (independent from other machines) 14 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Efficient grain cleaning - Destoner MTSC. Working principle Specific weight gravity separation For the removal of Stones and Heavy particles (metal / glass) 15 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
A quantum step in grain cleaning Optical Sorter MSOC. Concept Optical Sorter SORTEX M High precision efficient cleaning Ease of use High up time Top reliability constant performance Maximum profitability Higher yield of raw material MSOC SORTEX M3 16 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
MSOC Integrated into cleaning section 17 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
MSOC Functional principle Available Camera Settings: Buffer Double Sided Dark Single Sided Light / Dark Vibro standard dark sort camera Chute Camera reject accept Productlighting Ejectors Camera standard dark or light sort camera 18 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Separation of impurities in the first Cleaning section. SORTEX: Typical screenings Raw material Discoloured germ Dark seeds Diseased kernels Clean wheat Final reject Ergot 19 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
MSOC Defects separated by dark sorting Discoloured grain Unripe grains Foreign seeds Discoloured germ Foreign grain (e.g. oats, barley ) 20 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
MSOC Features High resolution camera: - Two sided 2048 pixel cameras - offering the widest range of sorting possibilities - simultaneous color and transparency sort as well as dual sort (light/dark) Long-life serviceable ejectors: - Designed to provide high speed and accuracy with reduced wear - extended service interval cycles and therefore reduced cost of ownership High capacity in a small footprint: - Application for wheat, durum, rye, oats, etc. - Capacity for wheat: up to 27 tones/hour (<1% contamination) - choice between two models M2 + M3 with different capacity 21 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Reduction of Bacteria. 100 % AMB 80 60 40 20 0 raw wheat after 1 st cleaning after tempering after 2 nd cleaning flour 22 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Efficient grain cleaning Scourer. Applied in 1 st and 2 nd cleaning to for the surface treatment of the wheat to remove impurities such as dust and sand To reduce contamination by reducing microbe count and filth 23 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Intensive scouring ensures Surface treatment for bacteria count reduction is achieved through friction rotor warts and screen jacket Fixed and moving wart plates rotating and stationary conveying channels 24 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Effective grain cleaning LiteCoS, your control system. LiteCoS reliable base automation system with intuitive operation Integrated process control - high plant uptime Intuitive operation user friendly Proven components high reliability Modular system easy upgrade 25 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
LiteCoS grows with customer needs. Add-on modules for expansion - Quality monitoring, - Trend curves - Corrective intervention in process Application for process control of entire mill plant or individual process steps (like cleaning, mill.) - Data records allowing reproducibility - Subsequent analysis of data whenever required - Integration of roller mills, scales etc. - Display of up-to-the-minute process values - Production transparency 26 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
Effective cleaning Solutions for the milling industry. Conclusion We want to: - make the best out of the raw material - avoid expensive and complex recall actions - avoid negative impacts on reputation and image - make sure that the traceability is always ensured and transparent - avoiding unplanned down time of production installations - be suppliers of Safe Food and Safe Feed! 27 Mycotoxinereduction @ GRAPAS 2010 March 2010 Bühler
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Leading technology Local solutions. For 150 years Buhler has delivered technology and solutions for processing grain into safe and healthy finished products. Today, Buhler stands for straight forward and cutting-edge solutions. State-of-the-art process technology, innovative plant engineering and a deep knowledge of the related processes maximize both quality and product yields. But there is even more to it: Buhler know-how also enables customers to create the most cost- and energy-efficient process solution from stand-alone machines to complete plants: www.buhlergroup.com The solution behind the solution.