Master of Science / Department of Grain Science and Industry / D.L. Wetzel / Chemical imaging enables displaying the distribution of different substances within a field of view based on their fundamental vibrational frequencies. Mid-IR bands are generally strong and feature direct correlation to chemical structure, while near IR spectra consist of overtones and combinations of mid-IR bands. Recently, mid-IR microspectroscopy has enabled determination of the relative substitution of hydroxyl groups with the modifying agent for individual waxy maize starch granules by using synchrotron source. The brightness and non-divergence of the synchrotron source and confocal masking enabled obtaining individual spectra with 5 [mu]m[superscript]2 masking and 1 [mu]m raster scanned steps. Each 1 [mu]m step results from the coaddition of hundreds of scans and lengthy data collection is required to produce data. The recent breakthrough at the Synchrotron Research Center uses a multi-beam synchrotron source combined with a focal plane array microspectrometer. This major improvement in localized detection of the modifying agent within single waxy maize starch granules is the increased efficiency of focal plane array detection and an effective spatial resolution of 0.54 [mu]m. Mixtures of granular solids represent an analytical challenge due to the range of heterogeneity and homogeneity within samples. Near IR imaging provides deeper sample penetration allowing for solid mixture analysis. However, the broad, overlapping bands present in the near IR necessitates statistical data treatment. This requires imaging specimens representative of the individual components to create spectral libraries for classification of each component. Partial least squares analysis then allows characterization and subsequent pixel analysis provides quantitative results. The primary break system for wheat milling was studied as it is key in releasing endosperm to be further ground into fine flour in subsequent processes. The mass balance of endosperm throughout individual unit processes was determined by obtaining flow rates of incoming and outgoing millstreams and calculating endosperm content through pixel identification. The feed milling industry requires the use of a tracer to determine adequate mixing and mix uniformity to limit the time and energy in processing. Near IR imaging allows individual components of a formula feed to serve as a self-tracer, eliminating the need of an inorganic tracer.

Master of Agribusiness / Department of Agricultural Economics / Bryan Schurle / The milling of wheat into white flour is a high volume, low margin business. Flour is a commodity. Competition is fierce. Over the past several years, there have been several mergers and acquisitions leading to fewer, but larger flour mills. The number of companies in the flour milling business has diminished as well. Flour sold in small packages on the grocery store shelf is but a small part of the business these days. Most flour is sold to commercial bakers in large bags or bulk trucks. The process of milling wheat into white flour consists of numerous variables within an extensive collection of equipment. It is the job of the miller to minimize the negative impact of these variables or at least hold constant as many of these variables as possible while achieving the best efficiency possible. To lessen the effect of these numerous variables on a large extensive system makes for a well running operation. When efficiency is achieved, a flour milling operation can be a profitable venture. A number of the variables that influence efficiency are affected by the amount of flour storage that a flour mill has. This thesis examines the benefits of flour storage as related to flour process efficiencies in milling. With flour mills operating at large output capacities, it is necessary for a flour mill to have adequate bulk flour storage bins as well as the right amount of warehouse space. Changes from one type flour to another in a flour mill require some time and an abundance of intervention by a skilled operator or miller. Having the proper amount of storage space makes it possible to minimize changes as well as the opportunity to optimize production of each specific flour type that is processed on the mill. To justify capital project money to invest in the proper amount of storage can be a challenge. Warehouse space and bulk flour storage can be expensive, and it is difficult to quantify how theoretical improvements will increase production and quality in the end product of flour. Using regression methods, production data obtained from an average sized commercial flour mill was used to estimate the increase in extraction due to a longer length of run allowed by the addition of storage space. By increasing the time a mill stays on a specific wheat mix to a minimum of twenty hours, there is a theoretical increase in extraction of 1.02 percentage points, resulting in wheat savings of over $500,000 per year. This resulting savings on the raw input material showed that capital expenditures on storage can be justified. A positive net present value and good internal rate of return show that the increased efficiency due to longer lengths of run justified the additional expense of the additional storage capacity. As volatility and the price per bushel of grain continue to increase, having the proper plant infrastructure with regard to storage space is of the utmost importance. Other benefits of storage will be realized as well in the area of flour quality and customer service.

Master of Agribusiness / Department of Agricultural Economics / John A. Fox / The cost of wheat is the largest input cost for a flour mill, and as a result, profitability in wheat flour milling is determined in large part by milling efficiency – i.e., the amount of flour extracted per unit of wheat milled. In this project the objective was to quantify the influence of several measurable variables on flour mill efficiency. Data was collected from two commercial milling units of similar size. Linear regression was then used to estimate the relationship between flour yield and variables measuring grain characteristics and environmental factors. The analysis suggests that increasing ambient temperature and the occurrence of downtime both have a significant negative effect on flour yield. A significant difference in flour yield efficiency was also found between the two mills.

Master of Agribusiness / Department of Agricultural Economics / Arlo Biere / The purpose of the research reported in the thesis, here, is to quantify new value added possible in flour milling with the use of the SDmatic monitor, produced and sold by Chopin Technologies SAS. As an employee of Chopin, part of my responsibility is to market the SDmatic. The SDmatic was designed and is marketed to improve flour quality by providing automatic monitoring of starch damage in flour—damaged starch affects dough characteristics, which affects baking quality and the ideal damaged starch differs by type of bakery product. While the SDmatic is so marketed, Chopin, now, realizes that SDmatic might also benefit a flour miller by increasing operational efficiency of the mill, specifically by reducing the electrical energy used in milling. If that can be done, it would improve mill profitability, reduce energy demand and, thus, reduce the pressure on the climate and environment from energy production. To address that possibility, the thesis research studied the relationship between energy usage and damaged starch in the flour and, then, estimated the cost savings possible by using the SDmatic to mill flour to specifications most efficiently. Finally, those results were used to estimate the return on investment in the SDmatic from improved mill efficiency, alone. The research shows improvement in energy efficiency is definitely possible with better management and targeting of the level of starch damage in flour production. Such improved management is possible, today, because SDmatic dramatically reduces the difficulty and time required to measure damaged starch. Such monitoring has not been done in the past because of the cost and time involved with prior methods. SDmatic makes that possible and cost effective, now.

<p>U radu je proučavana mogućnost racionalizacije tehnolo&scaron;kog postupka<br />mlevenja p&scaron;enice primenom osmovaljne stolice u fazi mlevenja griza i<br />osevaka. Na svim ispitivanim prolazi&scaron;tima mlevenja griza i osevaka, pri istom<br />razmaku između valjaka i istoj veličini otvora sejnog tkiva za odsejavanje<br />bra&scaron;na, ukupan prinos bra&scaron;na u postupku sa osmovaljnom stolicom manji je<br />nego u klasičnom postupku. Pomenuta razlika varira u zavisnosti od uzorka i<br />prolazi&scaron;ta mlevenja, ali je uvek statistički značajna. Nižim vođenjem valjaka u<br />postupku sa osmovaljnom stolicom, u poređenju sa razmacima između valjaka<br />u klasičnom postupku, u zavisnosti od uzorka i prolazi&scaron;ta mlevenja se<br />smanjuje razlika, dostiže ili prevazilazi prinos bra&scaron;na u odnosu na klasični<br />postupak. Povećanjem veličine otvora sejnog tkiva za odsejavanje bra&scaron;na<br />značajno se povećava prinos bra&scaron;na u postupku sa osmovaljnom stolicom, pri<br />čemu se pri odabiru sejnog tkiva u obzir mora uzeti i veličina svetlog otvora.<br />Odabirom odgovarajuće veličine otvora sejnog tkiva može se i prevazići<br />prinos bra&scaron;na u klasičnom postupku. Niže vođenje valjaka i/ili povećanje<br />veličine otvora sejnog tkiva za odsejavanje bra&scaron;na, pri primeni osmovaljne<br />stolice, nema za posledicu pogor&scaron;anje kvaliteta bra&scaron;na (po pitanju sadržaja<br />pepela) u odnosu na klasični postupak. Specifični utro&scaron;ak energije za<br />usitnjavanje po jedinici mase bra&scaron;na, pri istom vođenju valjaka i istoj veličini<br />otvora sejnog tkiva za odsejavanje bra&scaron;na, veći je u postupku sa osmovaljnom<br />stolicom nego u klasičnom postupku. Povećanjem izvoda bra&scaron;na u postupku sa<br />osmovaljnom stolicom, značajno se smanjuje specifični utro&scaron;ak energije za<br />usitnjavanje. Mogućnost ostvarenja bliskih efekata usitnjavanja u fazi<br />mlevenja griza i osevaka, u klasičnom i postupku sa osmovaljnom stolicom,<br />ukazuje da je za dalju racionalizaciju savremenog tehnolo&scaron;kog postupka<br />mlevenja p&scaron;enice neophodno uključivanje osmovaljne stolice.</p> / <p>Rationalization of the wheat flour milling process using the eight-roller mill in<br />the reduction system has been investigated. At the same roll gaps and same<br />sieving conditions, a lower flour yield has been obtained using an eight-roller<br />mill compared to a conventional one. The difference is statistically significant<br />regardless the passage. By decreasing the roll gap in the process with the<br />eight-roller mill, compared to the roll gap in the conventional process, it is<br />possible to decrease the difference, obtain a similar or even exceed the flour<br />release in the conventional system. Increasing the size of the screen aperture<br />for sifting flour, while percent open area of the screen also needs to be<br />observed, results in significant increase of flour yield (in some cases<br />exceeding the flour yield in the conventional system). Adjustments of the roll<br />gap and sieving conditions in the process with the eight-roller mill are not<br />followed by deterioration of flour quality. At the same roll gaps and same<br />sieving conditions, energy requirements for grinding are higher in the process<br />with the eight-roller mill compared to a conventional system. With the<br />increase of the flour release in process using the eight-roller mill, these energy<br />requirements can be significantly reduced. The possibility of achieving similar<br />milling results to those obtained in the conventional system, while the<br />investment costs and overall energy requirements are significantly lower,<br />justifies the use of the eight-roller mill in the reduction system of the wheat<br />flour milling process.</p>

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