AGM Challenges and opportunities of the milling industry
AGM Challenges and opportunities of the milling industry
AGM Challenges and opportunities of the milling industry
You also want an ePaper? Increase the reach of your titles
YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.
<strong>Challenges</strong> <strong>and</strong><br />
<strong>opportunities</strong> in<br />
<strong>the</strong> <strong>milling</strong><br />
<strong>industry</strong><br />
Martin Schlauri
Flour Milling is a Regional Business<br />
But, <strong>the</strong> world is one global market!<br />
2 | © Bühler | Title | Author | 2005
Topics<br />
Grain market WW<br />
Trends in grain based food<br />
<strong>Challenges</strong> for <strong>the</strong> Milling Industry<br />
Innovations in Flour Milling Technology<br />
3 | © Bühler | Title | Author | 2005
Grain market<br />
worldwide
Grain is a staple food<br />
Wheat is <strong>the</strong> most important<br />
food for over three billion people.<br />
2 billion people live on rice.<br />
1 billion people consume mainly corn (maize).<br />
5 | © Bühler | Title | Author | 2005
Grain supply challenges<br />
Global changes in wheat supply<br />
- new grain supply chain<br />
- climate changes<br />
- grain dem<strong>and</strong> for renewable energy<br />
Wheat is a natural product with<br />
quality variations<br />
Wheat contains impurities<br />
Wheat can be contaminated<br />
6 | © Bühler | Title | Author | 2005
Global wheat supply from established growing areas<br />
Canada<br />
USA<br />
Argentina<br />
Australia<br />
7 | © Bühler | Title | Author | 2005
Global wheat supply from new sources<br />
Pol<strong>and</strong><br />
Romania<br />
Russia<br />
Ukraine<br />
Kasachstan<br />
India<br />
8 | © Bühler | Title | Author | 2005
Possible contaminants in wheat<br />
Raw Wheat<br />
Cleaned Wheat<br />
Straw / strings<br />
S<strong>and</strong> / fines<br />
Stones<br />
Foreign grain /<br />
seeds<br />
husk / dust<br />
ferrous metal<br />
9 | © Bühler | Title | Author | 2005
Bug damaged wheat<br />
10 | © Bühler | Title | Author | 2005
Mycotoxin contaminated wheat kernels<br />
mainly surface contamination<br />
11 | © Bühler | Title | Author | 2005
Healthy Kernel<br />
DON affected<br />
12 | © Bühler | Title | Author | 2005
Healthy kernel<br />
DON affected<br />
13 | © Bühler | Title | Author | 2005
Jul 09<br />
Source: Indexmundi<br />
Jan 09<br />
Jul 08<br />
Grain Prices Development 2002 - 2009<br />
Food Prices<br />
1200.0<br />
Wheat Maize Rice<br />
1000.0<br />
800.0<br />
600.0<br />
400.0<br />
$/metric ton<br />
200.0<br />
0.0<br />
Jan 02<br />
Jul 02<br />
Jan 03<br />
Jul 03<br />
Jan 04<br />
Jul 04<br />
Jan 05<br />
Jul 05<br />
Jan 06<br />
Jul 06<br />
Jan 07<br />
Jul 07<br />
Jan 08<br />
14 | © Bühler |<br />
Title | Author | 2005
Stocks (2009/2010F) – Wheat<br />
World total 195.9 Mio. T<br />
Russia<br />
98.6 d<br />
Canada<br />
308.9 d<br />
EU-27<br />
49.0 d<br />
China<br />
217.5 d<br />
USA<br />
302.8 d<br />
Egypt<br />
106.7 d<br />
India<br />
86.4 d<br />
Iran<br />
93.7 d<br />
Turnover in days<br />
> 40 Mio. T<br />
20 - 40 Mio. T<br />
10 - 20 Mio. T<br />
1 - 10 Mio. T<br />
< 1 Mio. T<br />
World total wheat stocks could cover world wheat consumption<br />
over a period <strong>of</strong> 110.7 days (USDA estimate, 02/2010)<br />
Source: USDA, FAO<br />
15 | © Bühler | Title | Author | 2005
Stocks (2009/2010F) – Maize<br />
World total 134.0 Mio. T<br />
USA<br />
65.5 d<br />
EU-27<br />
17.3 d<br />
China<br />
91.3 d<br />
Mexico<br />
31.8 d<br />
South Korea<br />
65.2 d<br />
Turnover in days<br />
> 40 MT<br />
20 - 40 MT<br />
10 - 20 MT<br />
1 - 10 MT<br />
< 1 MT<br />
Brazil<br />
82.5 d<br />
Malawi<br />
297.0 d<br />
(Consumption 2005)<br />
South Africa<br />
107.6 d<br />
World total maize stocks could cover world maize consumption<br />
over a period <strong>of</strong> 60.4 days (USDA estimate, 02/2010)<br />
Source: USDA, FAO<br />
16 | © Bühler | Title | Author | 2005
Stocks (2009/2010F) – Rice<br />
World total 92.5 Mio. T<br />
India<br />
54.7 d<br />
China<br />
123.8 d<br />
USA<br />
111.2 d<br />
Japan<br />
117.3 d<br />
Philippines<br />
83.0 d<br />
Thail<strong>and</strong><br />
223.8 d<br />
Turnover in days<br />
> 40T<br />
20 - 40 MT<br />
10 - 20 MT<br />
1 - 10 MT<br />
< 1 MT<br />
Indonesia<br />
82.4 d<br />
World total rice stocks could cover world rice consumption over<br />
a period <strong>of</strong> 77.2 days (USDA estimate, 02/2010)<br />
Source: USDA<br />
Vietnam<br />
40.1 d<br />
17 | © Bühler | Title | Author | 2005
Trends in<br />
grain based food
Consumer trends in grain based food<br />
Increasing world population <strong>and</strong><br />
urbanization means: higher dem<strong>and</strong><br />
for staple food<br />
Changing eating habits, that means:<br />
more convenient food<br />
Dem<strong>and</strong> for health <strong>and</strong> safe food<br />
Luxury <strong>and</strong> live style products<br />
Our solution – health food!<br />
19 | © Bühler | Title | Author | 2005
Trends in Nutrition<br />
Efficient Nutrition<br />
Fast but nutritious <strong>and</strong> healthy<br />
The hypochondriac<br />
factor<br />
• More information<br />
• More evidence for claims<br />
• More control through ‚food<br />
plus‘, ‚food minus‘ <strong>and</strong><br />
‚natural‘ alternatives<br />
Guilt free indulgence<br />
Low & light – without<br />
compromises on taste <strong>and</strong> texture<br />
HEALTH<br />
PLEASURE<br />
CONVENIENCE<br />
The time factor<br />
• More individual<br />
(portion) control<br />
• More control over<br />
time <strong>and</strong> quality <strong>of</strong><br />
preparation<br />
Convenience plus<br />
Convenience with restaurant<br />
quality <strong>and</strong> entertainment<br />
value<br />
The sensory<br />
experience<br />
• More fund <strong>and</strong> entertaining<br />
• More ethnic <strong>and</strong> exotic tastes<br />
• More premium <strong>and</strong> indulgent<br />
20 | © Bühler | Title | Author | 2005
Health Issues 21 st Century<br />
Obesity is increasing<br />
21 | © Bühler | Title | Author | 2005
Why Grain based Fibres<br />
Natural Ingredients from Grain (Clean Labelling)<br />
Complex Corbohydrate (Arabinoxylans, Cellulose, Beta-Glucan)<br />
High in Satiety, Low digestibility (Less energy release)<br />
With bioactive components (Phenolic acids, Lignans, Folate, Betaine)<br />
Improvement <strong>of</strong> digestive health (e.g. prebiotics)<br />
Cholesterol Lowering effects for Heart Health<br />
22 | © Bühler | Title | Author | 2005
Wheat Aleurone Applications<br />
Digestive Health<br />
Excellent Source <strong>of</strong> Dietary Fiber<br />
for digestive Health<br />
With bioactive components<br />
High in Magnesia<br />
23 | © Bühler | Title | Author | 2005
<strong>Challenges</strong><br />
for <strong>the</strong><br />
Milling Industry
<strong>Challenges</strong> for <strong>the</strong> <strong>milling</strong> <strong>industry</strong><br />
<br />
<br />
<br />
<br />
Make <strong>the</strong> best out <strong>of</strong> your raw material<br />
High yield<br />
Efficient plant operation<br />
Low Production cost<br />
Top technology <strong>and</strong> equipment<br />
High quality products<br />
High sanitation, plant engineering<br />
Food Safety<br />
25 | © Bühler | Title | Author | 2005
Operation <strong>and</strong> production costs <strong>of</strong> a flour mill<br />
Capital costs<br />
/Pr<strong>of</strong>it: 7 - 8 %<br />
Amortization 4%<br />
Interest ?<br />
X %<br />
7 - 8 %<br />
7 - 8 %<br />
Distribution: 7 - 8 %<br />
Packing 2 %<br />
Transport 2 %<br />
Personnel 2 %<br />
Marketing 1 %<br />
Pr<strong>of</strong>it X %<br />
7 - 8 %<br />
Raw material<br />
Grain:<br />
76 - 82 %<br />
76 - 82 %<br />
Production: 7 - 8 %<br />
Energy 1 - 2 %<br />
Personnel 4 - 6 %<br />
Maintenance 1 %<br />
26 | © Bühler | Title | Author | 2005
Higher energy costs<br />
Development <strong>of</strong> energy cost is moving<br />
more <strong>and</strong> more into <strong>the</strong> focus <strong>of</strong> our<br />
customer<br />
Customers are seeking support for<br />
solutions to save energy<br />
150.0<br />
140.0<br />
130.0<br />
4.3. Erzeugerpreisindizes Strom bei Abgabe an gewerblichen Anlagen und an<br />
Sondervertragskunden, Verbraucherpreisindex Strom<br />
120.0<br />
110.0<br />
100.0<br />
90.0<br />
80.0<br />
Jan 00 Jul 00 Jan 01 Jul 01 Jan 02 Jul 02 Jan 03 Jul 03 Jan 04 Jul 04 Jan 05 Jul 05 Jan 06 Jul 06 Jan 07 Jul 07<br />
Erzeugerpreisindex Strom bei Abgabe an gewerbliche Anlagen<br />
Verbraucherpreisindex Strom<br />
Erzeugerpreisindex Strom bei Abgabe an Sondervertragskunden<br />
27 | © Bühler | Title | Author | 2005
Advanced plant concepts for energy savings<br />
1st & 2nd Break roller mills,<br />
installed above Plansifter<br />
(18-22% lower air volume)<br />
less pneumatic lifts<br />
saving up to 2 kWh / ton<br />
Flour control sifter <strong>and</strong><br />
weigher in direct flow<br />
no relift<br />
saving up to 1kWh / ton<br />
28 | © Bühler | Title | Author | 2005
The efficiency <strong>of</strong>....<br />
The Bulb<br />
Light ~ 10%<br />
Energy input = 100 %<br />
Loss (Heat) ~ 90%<br />
29 | © Bühler | Title | Author | 2005
The efficiency <strong>of</strong>….<br />
The mill<br />
(Example = 400t <strong>of</strong> wheat per day)<br />
60%<br />
570 kWh/h<br />
in Heat<br />
100%<br />
El. Power<br />
1000 kWh/h<br />
What if<br />
1. …we could recover some 2/3 <strong>of</strong> <strong>the</strong> heat loss?<br />
2. …we could generate „alternative Energy“?<br />
430 kwh/h for<br />
transformation<br />
40%<br />
30 | © Bühler | Title | Author | 2005
Molineria Futura<br />
Capacity: 1200t/ 24h<br />
Energy Reduction/Recovery: 25%<br />
CO 2 Reduction: 4060t/ year<br />
Wind turbine<br />
T- Engine<br />
(inside)<br />
Heat Collectors for<br />
T- Engine<br />
Photo voltaic<br />
31 | © Bühler | Title | Author | 2005
SWISSMILL, Zürich, Switzerl<strong>and</strong><br />
Solar panels at SWISSMILL (Switzerl<strong>and</strong>):<br />
- 1996 Grain silo side wall<br />
- 2001 Grain storage silo in Basel.<br />
- 2005 on <strong>the</strong> ro<strong>of</strong> <strong>of</strong> <strong>the</strong> warehouse<br />
32 | © Bühler | Title | Author | 2005
KÜNKELE Grainsilo, Germany<br />
- Height <strong>of</strong> grain silo: 116m<br />
- Photo voltaic display producing<br />
70.000 kWh/year<br />
- 50t/ year CO 2 reduction<br />
33 | © Bühler | Title | Author | 2005
Innovation in<br />
Flour Milling<br />
Technology
The value chain within <strong>the</strong> grain processing <strong>industry</strong><br />
The key position <strong>of</strong> <strong>the</strong> miller<br />
35 | © Bühler | Title | Author | 2005
Innovations in <strong>the</strong> process from wheat to flour<br />
Cleaning<br />
Flour <strong>milling</strong><br />
Value added processes<br />
Intake / Pre-Cleaning<br />
36 | © Bühler |<br />
Title | Author | 2005
High Capacity Pre-Cleaner<br />
Light impurities Separator (LS)<br />
- Circulating-air separator<br />
Sieve modul (SM)<br />
- 14 m2 sieve area<br />
- 2-4 different fractions<br />
37 | © Bühler | Title | Author | 2005
Optical Sorter SORTEX for accurate grain cleaning<br />
38 | © Bühler | Title | Author | 2005
Dark sort defects<br />
deceased grain<br />
immature grain<br />
foreign seeds<br />
spot coloured<br />
defects<br />
foreign grains<br />
(e.g. oats)<br />
39 | © Bühler | Title | Author | 2005
Light sort defects<br />
accept<br />
reject<br />
straw<br />
unthreshed<br />
grain<br />
40 | © Bühler | Title | Author | 2005
Wheat kernel<br />
Epidermis<br />
Cross Cells<br />
Tube Cells<br />
Seet Coat<br />
Nucellar Tissue<br />
Aleurone Cells<br />
Endosperm<br />
Empty Layer<br />
Suction Epi<strong>the</strong>l<br />
Scutellum<br />
Plumule<br />
Rudimentary<br />
Leaves<br />
Primary Root<br />
Root Cap<br />
Germ<br />
Hairs <strong>of</strong><br />
brush<br />
Bran<br />
41 | © Bühler | Title | Author | 2005
Flour quality in Premium Flour Flow<br />
42 | © Bühler | Title | Author | 2005
43 | © Bühler | Title | Author | 2005
We strive to exceed your expectations in terms <strong>of</strong>:<br />
<br />
<br />
<br />
Reliability<br />
by rugged components<br />
Sanitation<br />
by easy cleaning<br />
Product safety<br />
by using stainless materials<br />
44 | © Bühler | Title | Author | 2005
45 | © Bühler | Title | Author | 2005
NOVAPUR – The New Sieve Generation<br />
PUR sieve frame with stainless steel insert frames<br />
<br />
<br />
<br />
No wood in <strong>the</strong> process<br />
food safety<br />
Easy <strong>and</strong> quick cleaning<br />
less maintenance<br />
Sieve area: 0.404 m2<br />
(4.34 ft2) per sieve<br />
high performance<br />
46 | © Bühler | Title | Author | 2005
New Purifier Polaris – MQRG<br />
47 | © Bühler | Title | Author | 2005
New Purifier Polaris – MQRG.<br />
Ultimate purity, efficiency <strong>and</strong> product safety<br />
<br />
<br />
<br />
Fulfills International Food St<strong>and</strong>ards (IFS)<br />
Fully enclosed design<br />
Efficiency with patented pre-classifying<br />
<strong>and</strong> enlarged sieve surface<br />
48 | © Bühler | Title | Author | 2005
Finished <strong>and</strong><br />
value added<br />
products
Mixing plants gluten <strong>and</strong> gluten free products<br />
Gluten products<br />
Gluten free products<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Bread<br />
Biscuits, Cakes, Muffins<br />
Fruit <strong>and</strong> Nut fillings<br />
Pudding mixes<br />
Mixture for beverages<br />
Mixture for isotonic beverages<br />
Ice cream mixture<br />
Instant soup mixture<br />
<br />
<br />
<br />
Bread<br />
Biscuits, Cakes, Muffins<br />
Ice cream mixture<br />
50 | © Bühler | Title | Author | 2005
Mixing plant for pre-mix <strong>and</strong> ready mixes<br />
Block fat added by h<strong>and</strong><br />
Mixer with liquid injection <strong>and</strong><br />
chopper<br />
51 | © Bühler | Title | Author | 2005
Hygienized <strong>and</strong> treated flour<br />
Advantages <strong>of</strong> Buhler Process:<br />
Reduction <strong>of</strong> total plate count/germ<br />
Minimized impact on flour properties<br />
Suitable for:<br />
- Fresh dough<br />
- Cookies<br />
- Soup flours<br />
- …<br />
52 | © Bühler | Title | Author | 2005
Qualified staff assures “operational excellence”<br />
Swiss Milling School<br />
<br />
<br />
Training <strong>of</strong> technical management staff in<br />
grain <strong>milling</strong> <strong>and</strong> grain processing<br />
technology.<br />
The Swiss Milling School St.Gallen (SMS)<br />
was founded in 1957 by Dr. René Bühler.<br />
53 | © Bühler | Title | Author | 2005
54 | © Bühler | Title | Author | 2005
55 | © Bühler | Title | Author | 2005
56 | © Bühler | Title | Author | 2005
57 | © Bühler | Title | Author | 2005
58 | © Bühler | Title | Author | 2005
59 | © Bühler | Title | Author | 2005
60 | © Bühler | Title | Author | 2005
Process Innovation …<br />
Thank you for your<br />
attention!<br />
… Millers‘ success<br />
61 | © Bühler | Title | Author | 2005
Change language