Digital Re-print September | October 2013

Managing mill maintenance: Flour mill training

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FEATURE

Managing mill maintenance

by Richard Sillett Grain and Feed Milling Technology, United Kingdom

Flour mill training

ost mill maintenance is a question of inspecting equipment for signs of wear, replacing parts and identifying problems before they turn into failures. Equally important is the investment you make into the mills human components. So how do you ensure your technicians and managers arent having their sharp edges ground down by years of habit? Where can you source the highest quality of new employee? And how can these new appointments be fitted into your work processes in the most effective way? To quote former UK Prime Minister Tony Blair, the answer is Education, education, education. Wheat and flour behave according to complex physical and chemical processes, so anyone who wants to change aspects of their recipes or milling needs some understanding of the science behind them. And the various kinds of equipment involved provide challenges both in terms of process control and safety again, these are elements that with education millers can master. There are a few providers of training and qualifications for millers, but this column is going to focus on four organizations with a global reach: The National Association of British and Irish Millers (Nabim); the International Association of Operative Millers (IAOM); Bhler; and Kansas State University.

millers to have the opportunity to learn using similar machinery to that found in their day job: industry partnerships like these are popular for this reason. The courses emphasis on projects carried out within the candidates own company is another area where the practical meets the theoretical. Technological or operational research to benefit the milling industry is undertaken by analysing and experimenting inside the mill, exemplifying the kind of continuous improvement that all modern industries have to be comfortable with. Expert tutors are also provided (with strict confidentiality) to ensure that the research is carried out is of high quality. Nabim is particularly proud of this aspect of its assessment process, its tutors also being used for the distance learning component of the diploma. The Advanced Milling Diploma currently only provides places for 10 candidates every three years, so its the correspondence courses that are the obvious starting point for millers seeking professional training. The courses themselves consist of seven modules covering the range of flour milling procedures and activities, and complementing the textbooks are individually-assigned tutors who assess submitted coursework and assist their preparation for yearly exams, which, inevitably, take place in May.

Internationalism
As Nabim can testify, the rapidly industrializing developing countries of the modern world are driving demand for internationalized milling education. Major growth markets right now include Southeast Asia and Latin America, and milling schools work hard to develop courses that tap into that thirst for knowledge. In the USA, Kansas State University is well placed to take advantage of the demand for milling education in the Spanish-speaking parts of the Americas. Its International Grains Program (IGP) is partnered with Latin America-focused associations like the United

States Soybean Export Council (USSEC) and CANIMOLT (Cmara Nacional de la Industria Molinera de Trigo) and through these organizations holds several training programmes at its Manhattan, Kansas base every year. A similar on-site training course is provided every July for Nigerian flour millers, proving the viability of such educational programmes in Africa too. For Latin American millers unable to attend the course in person, the IGP currently offers one correspondence course in Spanish, with more in the pipeline. Mark Fowler, associate director of the International Grains Program, believes the two philosophies complement each other: The preference is always on-site training which allows a better personal attention to the training education with a hands-on component is always optimum. But we do understand not everyone has the time and resources to come to Manhattan, which is why we are developing courses that combine both. Its this reason that makes Bhlers own training courses stand out in the global market. The company (from multilingual Switzerland) is proud of its capacity to deliver courses in various languages, ranging from German, English and Spanish to Italian, Russian and Japanese. Indeed, their expertise in this area has been crucial to Kansas States efforts to bring milling education to Latin America.

Nabim
Having been at the forefront of the milling industry in Britain and the Commonwealth, Nabim has a great deal of experience in delivering training courses and assessments to millers. The jewel in its crown is undoubtedly the Advanced Milling Diploma, a threepart course which includes distance learning, on-site training and on-the-job projects. On-site training takes place with Nabims partners, namely the British research institute Campden BRI and the Bhler Training Centre in Uzwil, Switzerland. Its crucial for
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Networking opportunities
Though it offers a similar mix of residential and correspondence courses, the IAOM brings something unique to millers developing their knowledge and abilities. The week-long residential courses take place at Kansas State University in conjunction with its Grain Science and Industry department, and the whole course syllabus was revised after a complete overhaul in 2012. What really makes the IAOMs offering stand out are the opportunities presented by its famous collection of meetings and
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FEATURE conferences. Annual regional expos in the Middle East and Africa, Southeast Asia and Latin America regions, as well as the Annual Conference & Expo held in the United States, provide significant networking opportunities for millers at all stages of their careers. The IAOM is doing a bit of networking of its own to connect these two services, developing a programme where millers can log professional development hours for attending or giving presentations at their conferences. In one sense, education never stops, and this system will allow those seeking development to teach conference attendees from their experiences at the cutting edge. Although the IAOM has become famous for its global credentials, its unique characteristics make it even more wedded to the English language than other educational providers. Executive Vice President Melinda Farris sees the drawbacks alongside the obvious positives of their associations approach. Europe has been a tough nut to crack. We have this formula that has worked around the world, but they already have their national milling associations. Theres also a language issue. One of the great advantages of IAOM is the networking if theres no common language other than milling, it can be difficult. us to get closer to our customers. We are interested to know the needs of our customer, and offer training courses so they can optimize the running of their plants. Its in our own interest to support the milling education around the world and also support the best schools. Milling managers get an opportunity to receive as much input as possible in a defined, short time, and we offer them the chance to discover our newest machines and technology. And the benefits for Bhler, the company? Its always very interesting and very efficient to speak with good educated milling personnel. Well-educated milling personnel understand things better, they see and explain their needs. And on the other hand, we also strengthen our relationship with the customer and show him how they can profit from employing well-educated personnel. A feeling of responsibility for the direction of the milling industry was common among all the training providers, corporate or otherwise. Mills in the developing world need well-trained personnel, and mills in Europe, North America and Japan are faced with the necessity of replacing an ageing but highly knowledgeable workforce. Faced with these challenges, one thing is for certain: educators and training providers around the world are competing to make sure you have a solution thats right for your mill and your employees.

Industry partnerships

One of the most visible aspects of the milling industrys training providers is the level of technical partnership with major players. Nabims courses are tied to the UKs Campden BRI, and like many in the sector the Bhler training centre in Uzwil. The IAOM partners with the Italian machinery manufacturer Ocrim, and there is a consensus among providers that the ability to work with similar Interview: equipment to that found in Nigel Bennett, Secretary, Nabim a modern mill is a big draw for students. Nabim is a British-based association but Equipment suppliers a look at your course enrolment shows also benefit from these an international dimension. Where in the partnerships, as Bhler world are you looking to expand? marketing manager Isabel "Over the last few years, around two-thirds to threeMaganto explains: quarters of all enrolments in our distance learning proThese partnerships enable gramme have been from outside the UK. Traditionally, our overseas customers have been in the Commonwealth but Southeast Asia has been a growth area outside that base."

Can the course compete with the likes of KSU and IAOM?
"We believe our courses suit training needs throughout the world, the only limiting factor currently is that they are delivered in English only. We believe we have a unique product. "Whilst there may be other distance learning courses available, no other programme, so far as we are aware, provides the same tutor support, keeps its textbooks so up-to-date through a rolling review process or uses a rigorous assessment process (of written examination) to test whether students have retained knowledge and understanding. "Where the UK cannot compete is in the provision of practical mil training facilities such as those available in Switzerland, Germany, Canada and the USA, to name just four. The UK never set up a milling school and the numbers employed here now would not justify it."

What can your courses offer to millers?

"Nabims distance learning programme has been running for decades but is kept fresh, not least through updating each of the seven module textbooks every five or six years. The programme provides an overview of the industry and process for all involved in flour milling. It provides the underpinning knowledge and understanding for all who wish to progress in the industry, from wheat buyer to flour salesman, from miller to management trainee. The seven modules each tackle a specific subject area and the programme allows the flexibility for their study in any order and combination to suit the individual and their mill."
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September - October 2013

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Sieving technology in feed pellet production Mixed integer optimization:
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The holistic approach to avoid losses in the feed mill

Traceability
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Weighbridges
the workhorses of industrial weighing

High-precision sensors:
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