Bharti Teotia
Product Manager
Silos and Storage Systems
Bühler AG
Stefan Pienkny
Product Manager
Chain Conveyors and Elevators
Bühler AG
In an era marked by significant climatic shifts and growing food security concerns, the principle “every single grain counts” has never been more relevant. At Bühler, we recognize the value of every grain for our customers. For millers and stakeholders across the entire grain value chain, ensuring crop safety and quality is paramount, and sustainability cannot be overlooked. Let’s delve into the challenges and opportunities in grain safety and how synergies in harvesting, grain handling, and storage can mitigate the threats faced.
THE INVISIBLE THREATS LURKING IN OUR GRAINS
Grains, humble as they may seem, can host a multitude of contaminants if not managed correctly. Being a staple for billions worldwide, the safety of grain is of paramount importance for public health. To safeguard consumers from foodborne illnesses, it is important to address both climate change, which impacts grain production, and food safety measures throughout the supply chain. Chemical residues from pesticides and fumigants can linger, heavy metals from polluted soils can accumulate, and under improper storage conditions, harmful mycotoxins can infiltrate. Even physical contaminants like insects and stones can slip through during harvesting or transportation, making vigilance at every stage essential.
Imagine enjoying your favorite dish made from grains, only to suffer from diarrhea, vomiting, or hospitalization. This is the grim reality for many when foodborne illnesses strike. Some contaminants, particularly chemical residue, mycotoxins, heavy metal residue and physical contaminations can pose severe long-term health risks, including foodborne illnesses and long-term adverse health effects. Ensuring grain safety is not just a matter of quality but of public health. Moreover, reducing waste maintains food security and prevents food shortages.
The Economic Ripple Effect: Food safety breaches can cause financial repercussions far beyond the farm and processing plants. Disposing of contaminated grains leads to financial losses for farmers, processors, and retailers alike. Contamination incidents and ensuing recalls can tarnish even the most trusted brands. The correlation is clear: safeguarding grains delivers substantial savings, protects livelihoods, and preserves brand integrity.
Integral to Food Safety and Security: Sustainability is no longer optional—it is imperative. Integrating food safety with sustainability is essential for securing the future of our food systems. This extends beyond the field. The entire grain value chain, from harvesting to storage, must embrace sustainable practices. This includes adopting energy-efficient storage solutions, reducing post-harvest losses through improved grain handling and finally adding effective cleaning equipment such as TAS and a SORTEX Optical sorter, acting as a final quality gate to ensure optimal food safety. By ensuring that every grain is safe, nutritious, and sustainably produced, we address immediate health concerns and contribute to long-term food security and economic stability.
MACHINE SOLUTIONS AND DESIGN
At Bühler, our approach to safeguarding grain involves multifaceted solutions at every stage from harvest to storage. These solutions rest on several crucial pillars designed to uphold food safety, quality, and sustainability.
Hygienic Design: Implementing equipment with an emphasis on hygienic design significantly reduces contamination risks. By designing equipment that is easy to clean, maintain, and inspect, we prevent microbial growth and ensure product purity. This involves creating machinery with smooth surfaces, minimal joints, and accessible components for thorough cleaning and maintenance. Moreover, using materials that are safe for food processing ensures the highest standards of hygiene and safety.
Proper Grain-Cleaning and Mycotoxin Reduction: Effective grain-cleaning processes remove dust, husks, and other impurities, maintaining quality. Advanced technologies handle large volumes efficiently, delivering a premium product meeting the highest standards of food safety. Our holistic approach to mycotoxin reduction includes early detection, optical sorting, and specific gravity separation, ensuring safe levels of mycotoxins.
Removal of Foreign Bodies: Sophisticated sorting and detection systems meticulously remove all foreign grains and foreign materials like glass, stones and metals. Using mechanical and optical methods—such as optical sorting, magnetic separation, and density-based classifiers—we ensure only the highest quality grains progress to the next stages.
Gentle Conveying: The way grains are transported throughout their processing journey significantly affects their quality. Gentle conveying systems are integral to preventing damage and preserving the delicate structure of the grains. By minimizing physical stress, we maintain the nutritional value and appearance of the crops, delivering the least amount of broken grains possible.
Optimal Storage Solutions: Efficient and optimal grain storage solutions are of critical importance. Bühler’s integrated storage systems (silos) with controlled environments monitor temperature, inventory, and moisture. Aeration and ventilation prevent spoilage and pest infestations, while advanced technologies like grain chilling optimize conditions in difficult climates. State-of-the-art storage facilities, supported by digital solutions, facilitate easy monitoring and ensure the quality of the grain until it reaches the processing plant or consumer. With Bühler Solutions, your silos are not just standing tall but speak loud with data.
PLANT AND PROCESS ENGINEERING
Designing and operating a plant to ensure the safety and quality of grains requires careful consideration of various technological aspects like:
Different Grains and Tailored Approaches
Each type of grain—wheat, corn, rice, barley—has unique characteristics influencing cleaning, conveying, and storage processes. For instance, rice may require precise sorting mechanisms to remove husks, while wheat may need specific conditioning before milling. Tailored approaches ensure that the quality and safety of each grain type are upheld throughout the processing chain.
Choosing the Right Machines and Configurations
Selecting the right machines and configurations is crucial. Equipment must be chosen based on its ability to handle the specific needs of the grains processed. This involves selecting the right cleaning systems, precise sorting mechanisms, gentle conveying solutions, and optimal storage facilities. Each machine must be configured precisely to perform its role efficiently and effectively, ensuring the overall process runs smoothly.
Considering Regional Differences
Regional differences in climate, farming practices, and regulations significantly influence plant design and operations. For example, a plant in a humid climate might need advanced humidity control systems to prevent spoilage, while a plant in a region with stringent food safety regulations would require compliance with additional standards. By understanding and incorporating these regional differences, plants can operate more effectively and sustainably.
Customized Services You Can Trust
At Bühler Services, we foster reliable partnerships throughout the asset lifecycle to maximize customer outcomes. Our services blend classic offerings with cutting-edge automation and digital solutions. With service stations worldwide, we ensure comprehensive support, streamlined maintenance, and easy access to spare parts.
Training and ongoing support of operators are pivotal to maintaining high standards of grain safety and quality. At Bühler, we emphasize comprehensive training programs and continuous support to ensure optimal plant operation. Fine-tuning machines to accommodate variations in grain quality, seasonal changes, or specific production goals is essential. Operators must be knowledgeable about the machinery and understand the processes involved in maintaining grain safety and quality. Training programs equip workers with the skills needed to operate and adjust machines correctly, troubleshoot problems, and adhere to best practices in hygiene and safety.
Field to Fork – A Unified Bühler Approach
The journey of grains from the field to your table is complex and demands stringent safety measures at every turn. On the farm, Good Agricultural Practices (GAPs) manage chemical residues and heavy metals. During transportation, safe practices prevent cross-contamination. In storage, proper conditioning and monitoring (temperature, moisture, CO2, and inventory) mitigate mycotoxins and pests. Processing steps like cleaning and optical sorting eliminate physical contaminants, while good hygiene practices ensure grains remain safe up to the point of purchase.
By weaving a safety net of integrated solutions from cultivation to consumption, we ensure that every grain delivered to our plates is safe and nourishing. Protecting our grains means protecting our health, profits, and food security. The next time you enjoy a bowl of rice or a slice of bread, remember the meticulous journey it undertook and the collective efforts to ensure its safety.