Transcript Complete Toolkit - Food Fortification Initiative
Flour Millers Tool Kit
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Marketing
Definitions
Enrichment / Fortification
• Adding vitamins and minerals to flour during the milling process • May include nutrients naturally in the grain or additional nutrients • Addition may meet or exceed natural levels • Designed for mass populations
Supplementation
• Nutrients provided in liquid or pill form • Usually in doses higher than found in fortified food • Designed for specific target groups (i.e. women or children) ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Flour Millers Tool Kit for Fortification
► ► ► ► ► ► Table of Contents Section 1: Introduction to Flour Fortification Section 2: Procuring Premix Section 3: Mill Set-up Section 4: System Operation Section 5: Assuring Quality Control Section 6: Advocacy and Marketing
Click on the arrows above to go directly to the first page of each section.
In the rest of the Tool Kit, click on the text at the bottom of each page to go to the first page of that section.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Section 1:
Introduction
► Why Fortify?
► Overview of Fortification Process ► Fortification ’ s Public Health Impact ► Minerals and Vitamins Used in Flour Fortification ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Why Fortify?
Health and Economic Benefits • Prevent iron deficiency, neural tube birth defects, and other health concerns • Improve the national economy by increasing productivity and decreasing healthcare expenditures ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality FFI photo ► Advocacy
Why Fortify?
Leverage Existing Infrastructure to Reach Population Grain milling is a centralized business with broad distribution of products Foods made with wheat and maize are widely consumed Consequently, fortification has the potential to reach millions of people.
► Introduction ► Premix ► Mill Set-Up Siemer flour mill http://www.siemermilling.com/Locations/125/a/159 ► Operations ► Quality ► Advocacy
Overview: Wheat’s Natural Iron
Bran Endosperm • Bran contains 55% of wheat’s natural iron • Germ contains 5% of wheat’s natural iron
The bran and germ are primarily used for animal feed.
► Introduction Germ Percentages calculated from USDA Nutritional Database Image courtesy of the Wheat Foods Council ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Wheat ’s Mineral Loss in Milling
Mineral loss at 75-80% extraction ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Marketing
Overview: Wheat’s Natural Vitamins
Bran Endosperm
Vitamin
Folic Acid (B9) Niacin (B3) Thiamine (B1) Riboflavin (B2) Pyridoxine (B6) Pantothenic Acid (B5)
Found in Bran (%)
33 86 33 42 73 50
Found in Germ (%)
12 2 64 26 21 7 ► Introduction Germ Percentages calculated from USDA Nutritional Database Image courtesy of the Wheat Foods Council ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Wheat ’s Vitamin Loss in Milling
Vitamin loss at 75-80% extraction ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Marketing
Overview: Fortification Process
Powdered vitamins and minerals are added to flour during the milling process using equipment called feeders.
A large mill may use a “feeder bank” such as this set of four. One feeder is for fortification and three are for other flour improvers.
Photo courtesy of Research Products Company ► Introduction ► Premix ► Mill Set-Up
Smaller mills may use a single feeder for fortification.
Photo copyright: David Snyder / CDC Foundation ► Operations ► Quality ► Advocacy
Impact on Health: Iron
Burden of Deficiency
• Reduced productivity • Iron deficiency anemia • Undeveloped mental capacity • Maternal mortality • Pre-term births
Health Benefits
• Increased productivity • Fully developed mental skills • Improved maternal and child health “
Iron deficiency affects more people than any other condition, constituting a public health condition of epidemic proportions.
” -World Health Organization http://www.who.int/nutrition/topics/ida/en/ ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Success of Fortifying with Iron
Four studies of the effectiveness of fortifying with iron all showed improvement in iron status:
Country
China Iran Venezuela Fiji
Population studied
Women Women and men School-age children Women ► Introduction ► Premix ► Mill Set-Up FFI review December 2012. Photo from istockphoto.com
► Operations ► Quality ► Advocacy
Results of Insufficient Folic Acid
(vitamin B9)
• Children born with neural tube birth defects (NTDs) such as spina bifida • Permanently disabling or fatal • More than 300,000 NTDs occur every year globally* Photo of child with spina bifida from Google images * Global Report on Birth Defects, March of Dimes Birth Defects Foundation, 2006 ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Impact of Fortifying with Folic Acid
• Reduce risk of NTDs 31% to 78% • Healthcare savings from averted surgeries and therapy • Cost: benefit ratios reported: o o o 1:12 in Chile 1:30 in South Africa 1:48 in the United States Photo from istockphoto Risk reduction from Blencowe, H: Folic acid to reduce neonatal mortality form neural tube disorders.
International Journal of Epidemiology.
April 2010 (suppl_1):i110-i121 Cost benefit data from: Llanos, A., et. al., Cost-effectiveness of a Folic Acid Fortification Program in Chile.
Health Policy
83 2007:295-303.
Sayed, A., et.al., Decline in the Prevalence of Neural Tube Defects Following Folic Acid Fortifcation and Its Cost-Benefit in South Africa.
Birth Defects Research
82 2008:211-216.
Grosse, Scott, et. al., Reevaluating the Benefits of Folic Acid Fortification in the United States: Economic Analysis, Regulation, and Public Health.
American Journal of Public Health
95 2005:1917-1922.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Minerals and Vitamins Used in Flour Fortification
Minerals
• Iron • Zinc
Vitamins
• Folic Acid (B9) • Thiamine (B1) • Riboflavin (B2) • Niacin (B3) • B12 • Vitamin A • Vitamin D ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Types of Iron Used In Fortification
Elemental Iron (reduced iron or electrolytic iron) Ferrous Sulfate Ferrous Fumarate ► Introduction ► Premix ► Mill Set-Up Sodium Iron EDTA (NaFeEDTA) ► Operations ► Quality ► Marketing
• • • •
Factors for Choosing Iron Compound
Bioavailability
(absorption) – Water soluble compounds have the highest relative bioavailability because they are very soluble in gastric juices.
– The size, shape and surface area of the iron particle affects bioavailability, as does composition of food made with fortified flour.
Sensory changes
– High levels of some iron compounds could cause coloration or rancidity of the flour.
Cost:
– Highly bioavailable forms of iron are more expensive, but less is needed per metric ton of flour for fortification to have a health impact.
Magnets:
– Iron salts (ferrous sulfate, ferrous fumarate and iron EDTA) will not be attracted to magnets that may be used in milling process ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Other Minerals in Flour Fortification
Zinc
• Zinc oxide is most commonly used • Inexpensive • No sensory concerns • Use higher levels in high extraction flours due to higher phytic acid content
Calcium
• Calcium sulfate and calcium carbonate are both used • No sensory concerns • Not included in premix with other nutrients because levels are far higher than other nutrient additions • Not usually included in fortification standards ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
B Vitamins in Flour Fortification
Folic Acid (B9)
• Folic acid is preferred source • No sensory concerns • Relatively stable with some loss from exposure to light and food preparation • More bioavailable than B9 in natural food sources
Thiamine (B1)
• Thiamine mononitrate is preferred source • No sensory concerns • Susceptible to losses from exposure to light and heat and alkaline conditions (pH over 7) ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
B Vitamins in Flour Fortification
Riboflavin (B2)
• Orange crystalline powder • Use only food grade material exceeding 97% purity • Unstable in light
Niacin (B3)
• Commonly used source: nicotinic acid (commonly just called niacin) and nicotinamide.
• No sensory concerns • Nicotinic acid can cause reddening in the skin on exposure • Both niacin compounds are very stable in heat and light ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
B Vitamins in Flour Fortification
Pyrodoxine (B6)
• Pyrodoxine hydrochloride is preferred source • No sensory concerns • Stable to heat, but sensitive to UV light.
Cobalamin (B12)
• Cyanocobalamin is common source • No sensory concerns • Relatively stable in heat, but unstable in alkali and strong acidic environments • Difficult and expensive to test for the small amounts used in fortification • More bioavailable than B12 in natural food sources ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Other Vitamins in Flour Fortification
Vitamin A
• Retinyl acetate and retinyl palmitate are recommended.
• Beta-carotene’s yellow color makes it undesirable for flour.
• Available in encapsulated forms that do not cause sensory concerns • Significant losses can occur on storage if the encapsulation and antioxidant protection system is poor. A standard stability test at 45 ° C on the raw material should show losses no greater than 20% after 21 days.
• Countries often fortify edible oil or sugar rather than flour with vitamin A.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Other Vitamins in Flour Fortification
Vitamin D
• Form used in fortification: D3 Cholecalciferol • Countries often fortify dairy products with vitamin D in combination with vitamin A • Currently only a few countries fortify flour with vitamin D ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
More Information
• Health, productivity and economic benefits of flour fortification: http://www.ffinetwork.org/why_fortify/index.html
• World Health Organization recommendations for wheat and maize flour fortification: http://www.who.int/nutrition/publications/micronutrients/wheat_maize _fortification/en/ ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Section 2
Premix
► ► ► ► ► ► Premix Components Individual Nutrients or Premix?
Premix Formulation How to Procure Premix Costs for Premix Through the Supply Chain Premix Shelf Life and Storage ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Components
The most common flour fortification practice is to add multiple vitamins and minerals using a single ingredient called a
premix
.
Premix includes: • Fortificants (powdered vitamins and minerals) • Excipients (carriers, fillers) • Free-flow agent
Premix may have a yellow or green color. This does not affect the color of flour because premix is added in such small amounts.
Photo courtesy of Hexagon Nutrition ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Non-Fortificant Premix Components
Excipient
• Lowers premix bulk density to match flour • Improves feeding and blending • Also referred to as carrier or filler • Examples include starch or maltodextrin
Free-flow agent
• Keeps the premix from clumping and bridging in the hopper • Examples include tri calcium phosphate or precipitated silica (silicon dioxide) ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Limitations of Fortifying with Individual Nutrients
• Used in very small amounts • Tend to be excessively light or dense compared to flour • Tend to clump • Difficult to feed individually • Requires multiple feeders, checks and adjustments Folic acid, pictured here, is hard to add to flour individually due to the small amounts needed. Recommended addition rates are 1 to 5 parts per million based on the country’s consumption patterns. It is easier to add nutrients in a premix with other vitamins and minerals. Photo by Jeff Gwirtz ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Benefits
• Easier to test • Single feeder, check and adjustment • Easier to feed • Provides uniform nutrient distribution • Single ingredient tracer possible • Less expensive than buying individual nutrients
Individual nutrients, such as these pictured, are more difficult to add to flour than a single premix with a blend of the required nutrients.
Photo courtesy of WIN, World Initiative for Nutrition, a business unit of Fortitech ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Formulation
Manufacturers select ingredients and formulations based on: • Compound composition • Additive characteristics – Bioavailability – Storage stability – Cost • Targeted premix addition rate
Premix manufacturers create premix based on a variety of factors
.
Photo courtesy of Muehlenchemie GmbH & Co ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Manufacturer Overages
Premix manufacturers usually include nutrients at levels approximately 2% to 5% higher than listed on the label.
Premix photo courtesy of Muehlenchemie GmbH & Co This accounts for potential nutrient loss and ensures that the premix meets the label claims.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Flour Improvers
Flour improvers used in mills may include:
Enzymes
• Alpha Amylase • Proteas
Oxidants
• Azodicarbonamide • Benzoyl peroxide • Potassium bromate • Ascorbic acid
Do not add these materials to the fortification premix in a single feeder.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Risks of adding improvers to fortification premix:
• Quality is compromised as addition of fortificant should be constant but improver addition rates are adjusted to meet specifications.
• Shelf life of vitamins may be altered if combined with improvers in a highly concentrated mix in the feeder.
• Some fortificants can react with benzoyl peroxide and degrade the nutritional value of the premix.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
How to Procure Premix
• Establish premix specifications • Establish an economic order quantity • Establish internal re-order point considering: Lead time Inventory Production schedule • Develop list of alternate suppliers • Conduct annual review of: - Certificate of Analysis - Pre-mix performance - Delivery Time - Quality - Price ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Specifications
1. Definition – Describe the product, source, intended purpose, processing aids 2. Chemical Analysis – Moisture, vitamin activity, mineral content 3. Organoleptic qualities – Aroma, taste 4. Physical – Particle size, density, color, appearance 5. Bacteriological – Total plate count, salmonella, staph, aureus, e. coli, yeast, molds ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Specifications (continued)
• 6. Mycotoxin Status: none should be present • 7. Enzyme Activity: alpha-amylase if applicable • 8. Functional/Characterization: nutritional improver 9. Packaging and Storage Conditions • Package net weight, type and size, label declaration, storage conditions (temperature and RH), shelf stability, length of time in storage • 10. Dietary Law Status
Target, minimum, and maximum levels and test methods should be identified for each specification as appropriate.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Purchasing Department
The Mill Purchasing Department keeps the following information about the supplier on file: • Name and address of the supplier’s company or organization • Name and phone number of the principal contact to whom the order should be directed.
• Name or type of the premix to order (specification) • Standard amount of the premix ordered • Premix price history • Method and time of delivery ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Supplier Provides:
A Product Information Sheet or Fact Sheet including: • Name and intended use of premix • Name and contact information of manufacturer • Ingredient composition of premix – usually in descending order • Food grade status of ingredients (i.e. Food Chemicals Codex (FCC) grade) • Recommended addition rate of premix to flour and levels of micronutrients added at that rate • Certificate of analysis for each lot with: • Minimum assay standards for the premix • Maximum assay standards if any exist • Storage and handling instructions • Allowable storage periods or shelf life of premix
Keep this document on file at the mill.
Make it available to key operating and quality control personnel.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Procurement Options
• Order domestically if possible to avoid importing fees • Look for regional or global producers if needed • Purchase from direct private enterprise, representative, or broker • Centralized, cooperative purchasing group such as a local millers association may purchase in bulk for members • Some governments provide premix to all millers in country • Non-governmental agencies may provide premix for a limited time ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Procurement Alternatives
• GAIN Premix Facility: Competitive bids from approved suppliers for a specified premix through an internet bidding system. GAIN is the Global Alliance for Improved Nutrition. See http://gpf.gainhealth.org/ • Some countries, such as South Africa, have created approved premix supplier lists that must be used. See
http://www.grainmilling.org.za/
- click Vitamin Suppliers.
Please Note: No supplier is endorsed by this toolkit.
Potential suppliers should be thoroughly investigated prior to purchasing premix.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Estimated Premix Costs
Premix Iron + folic acid Iron, folic acid, other B vitamins Iron, folic acid, other B vitamins, vitamin A US $ per metric ton of flour $0.85 - $3.00 $1.60 - $3.90
$2.85 - $9.90
Note: Estimates do not including shipping, import duties and value added tax.
Actual costs may vary by as much as 30% and is dependent on manufacturer, location, amount ordered and should NOT be used as official market prices.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Cost Reduction Approaches
• • • Pursue government reduction and/or elimination of premix taxes and import fees Seek price quotes from two or more suppliers to ensure competitive bids.
Follow Economic Order Quantity principles: Order large quantities as determined by premix shelf life Commit to purchase premix from a single supplier for a longer contract period ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Cost in the Supply Chain
Fortification costs are minimal throughout the supply chain.
• Flour millers: US$1.00 - $4.00 metric ton • Bakers and re-processors: US $0.05 - $0.20 per 50 kilogram of flour • • • Consumers: < US $0.02 per 5 kilogram bag of four < US $0.003 per 1.5 kilogram loaf of bread, < US$0.001 for 250 grams pasta. ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Shelf Life
• • • • Minerals are particularly stable Vitamin effectiveness reduced over time Premixes without vitamin A may keep their nutritional value up to two years Premixes with vitamin A may only keep their nutritional value for 6 months
Special Notes:
Premix manufacturers or distributors do not accept return of premix that has exceeded its shelf life.
Shelf life may be further reduced if premix is stored incorrectly at the mill.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Storage
In the Warehouse:
• Readily accessible • Not Exposed to: - Sunlight - Excessive Heat - Moisture - Damage or Theft • First-In-First-Out (FIFO) Above: http://www.flourarranging.com/2010/10/14/wright-out-of nowhere Below: http://www.dnpint.com/email_newsletter/Ingredient_Times_No82.htm
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
On the Production Floor
Segregate premix and improvers by color coding or labeling .
Keep one or two working boxes of premix near the feeders for easy access.
► Introduction ► Premix ► Mill Set-Up
Multiple feeders installed in a row are known as a feeder bank. Identify each feeder clearly to prevent accidently mixing improvers and premix.
Photo courtesy of Research Products ► Operations ► Quality ► Advocacy
More information on Premix
• Recommended practices for premix manufacturers: http://www.ffinetwork.org/implement/documents/Premix_Best_Practi ce270408.pdf
• Answers to frequently asked questions about wheat flour milling: http://www.ffinetwork.org/about/faq/faq_wheat_industry.html
• Code of Practice for Food Premix Operations • Pan American Health Organization of the World Health Organization http://www.who.int/nutrition/publications/micronutrients/92_75_1258 9_9/en/index.html
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Section 3
Setting Up the Mill for Fortification
► ► ► ► ► ► Required Equipment Premix Addition Options Types of Premix Feeders Mechanical Principle and Size Delivery Mechanisms Equipment Suppliers Photo courtesy of Research Products
Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Required Equipment Premix Feeder
• Measures correct amount of premix • Position at appropriate place in production line
Mixing Mechanism
• Can be done during normal flour transport or with special equipment • Assures that premix is uniformly added to flour
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Addition
Premix is usually added to flour using one of two procedures: • Continuous • Batch
The gravity-based system such as the one pictured here is an example of premix being added to flour continuously as it is produced at the mill.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Addition: Continuous
• Premix is continuously added to the flour stream using a feeder • Premix addition is proportional to the rate of flour production • Validation of mixing uniformity is required ► Introduction ► Premix feeder conveyor
Premix can be continuously added into a collection conveyor such as the one shown here.
► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Addition: Batch
• Premix is generally added to a batch of flour via a gravity spout and blended in a mixer • Premix addition is based on flour batch size • Operation can be manual or automatic • Validation of mixing uniformity is required ► Introduction ► Premix ► Mill Set-Up
Batch mixer photo courtesy of Buhler Company
► Operations ► Quality ► Advocacy
All Feeders Require Anti-bridging
With
continuous or batch
, use feeders with anti-bridging devices to provide consistent premix flow.
Two product flow issues resulting in flow stoppage include: • Bridging occurs when product discharges above the outlet but no premix flows in to fill the void. Looking into the top of the feeder hopper, it appears to contain premix across the entire hopper.
• Tunneling is a form of bridging where the product falls directly through the outlet but premix remains on the sides of the hopper. Looking into the feeder hopper, the discharge point is visible but the sides of the hopper remain covered with a wall of premix.
See the troubleshooting pages of section 4, Operations, for more information.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Feeder Outlet Requirements
• Cover the feeder’s outlet spout for sanitation purposes • The cover can be part of the feeder design or it can be addressed in installation • Locate the outlet spout for easy opening for inspection and check weighing At left, a screw feeder discharge spout is covered. At right, the cover opens to allow for easy inspection and check weighing.
Photo by Jeff Gwirtz ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Control Systems for Premix Addition
• Control systems selected should match the technical capability of the plant operation and maintenance program.
• Systems range from manual systems, to those with basic and advanced interlocking to fully automated systems. • All systems presented achieve the basic needs of a fortification program.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Controlling the Feeder Manually
• In a manual system, the feeder is started and stopped manually by the mill operator. • Feeder settings are controlled and monitored by the mill operator.
• This is the least expensive approach to install requiring no sensors or electronic controls.
Flour Streams Premix Feeder In manual operation, the feeder control is near the premix feeder. This control model can be operated manually or automatically.
Photo by Jeff Gwirtz ► Introduction ► Premix ► Mill Set-Up ► Operations Flour Out ► Quality ► Advocacy
Controlling the Feeder Using Basic Sensors and Interlocking
Sensors: • Monitor for incoming flour • Switch the premix feeder on and off as needed • Monitor premix level and flow • Warn operator of problems • Reduce mill operator workload • Are inexpensive Flour Streams Flow Sensor Premix Feeder Flow or Level Sensor Mill/Control Room Warning Flour Out ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Controlling the Feeder Using Advanced Sensors and Interlocking
• Loss in weight feeder makes feeder setting and monitoring easier for the operator • An online flour scale more accurately starts and stops the feeder using a baseline flow rate • These system improvements are needed to develop an automated system Flour Streams Flow Sensor Premix Feeder Loss-In-Weight Flow or Level Sensor Mill/Control Room Warning Flour Out ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Controlling Feeder with Automation
• Programmable logic controller continuously matches the addition rate of premix to the Flour Streams measured flow rate of Flow Sensor flour Premix Feeder Loss-In-Weight Flow or Level Sensor • Requires appropriate human machine interface • Most accurate method of flour fortification and exceeds minimal requirements • Easily retrofitted into mills using existing automation Mill/Control Room Warning Programmable Logic Controller Flour Scale ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Controlling the Feeder-Summary
Control Point Control System Level Manual Basic Advanced Automation 1 Manual Feeder On/Off X X X X X X X 2 Automatic Feeder On/Off 3 Premix Hopper Level 4 Premix Flow Sensor X X X X X X X X X X X X X 5 Premix Rate Set Manual X X X X 6 Loss-In Weight X X X X X X X 7 System X X X X X X 8 Flour Flow Sensor 9 Flour Production Scale 10 Programable Controler or Computer X X X X X X X X X ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Mechanical Principles
Two ways feeders control amount of premix added to flour:
Gravimetric
• Also known as “loss in weight” • Continuously weighs premix • Requires greater volume of premix than generally used • More complex and expensive than required in most cereal milling
Volumetric
• Most commonly used by screw feeders • Similar to using a measuring cup • Minimum error of measurement is +2% ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Feeder Mechanical Information
Electrical interlock system prevents flow of premix when flour flow stops.
• The on/off switch, speed controller, and low- level indicator light can be located near the feeder or at a remote location. • Some installations may need a voltage regulator to ensure proper performance of the feeder and controller.
Controller Feeder
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Feeder Mechanical Information
• The electrical interlock system be installed between the feeder motor and the motor driving the flour collection conveyor. • In pneumatic delivery systems, an interlock should be made between the feeder and the blower to ensure that the feeder cannot be turned on without the blower operating. This prevents buildup of premix in pneumatic lines followed by over-treatment of flour once the blower is turned on.
• An alternative is an automatic shut-off switch on the feeder that is hooked up to a flour flow indicator or a pressure indicator in a pneumatic system. ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Feeders
Feeders are required for automated batch and continuous addition. Three main types of premix feeders are used to fortify flour.
2. Revolving Disk 1.Screw Feeder 3. Drum / Roller
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Feeders: Screw Feeders
• Dispense fixed volume of premix per revolution • Size of feed screw determines the feed rate volume of premix dispensed per revolution • Variable speed controls the number of revolutions per unit of time • Weight of premix dispensed is determined by product density
Size of the feed screw vary such as the small ones above and the larger one below.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Feeder: Revolving Disk
• Slide mechanism controls rate of premix addition • Powered by either an AC or DC motor • Small hopper must be refilled frequently • More mechanical components than the screw feeder Hopper Gate Adjustment Rotating Spring Rotating Disc ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Feeder: Drum or Roll Type
Premix passes between two closely set revolving cylinders. Floating Fill Container Flexible Hopper with Agitation Guide Veins Feed Rate Slide Bar Adjustment Roll Scraper Feed Rolls Motor ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Feeder: Drum or Roll Type
• Used for decades and many are still in use • Can be volumetric, gravimetric or loss of weight feeders • Either a DC or AC motor for power • Pulley system controls the rotation speed • Pulleys and wheels of differing diameters make gross adjustments in the feed rate. An adjustable gate is used to make fine adjustments • Require more parts and more maintenance • Shear pins in the drive mechanism break if large objects (bolts, plastic) get stuck between the rolls • In some newer models, a variable speed DC drive motor allows addition rate to be adjusted electronically rather than mechanically • Variable speed AC drive motors are also available ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Feeder Hopper Size
• Choose a feeder with a large enough hopper that it does not have to be filled frequently • Regardless of type of feeder used, the size and number of feeders needed will depend on: – Number of production lines – Hourly production of respective production line ► Introduction
This feeder bank has feeders with different size hoppers for different additives.
P hoto courtesy of Research Products Company ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Feeder Premix Discharge Rates
All types of premix feeders are available with different discharge rates • A small feeder may discharge premix at levels as low as 25 g per hour (0.4 g/min) • The largest can discharge up to 32 kg per hour (533 g/min)
Estimated premix discharge rate Mill Capacity (MT/day) 5 20 50 100 Flour flow rate* (kg/min) 2.5
10 25 50 Premix** Discharge rate (g/min) 0.4
1.5
3.8
7.5
200 100 15 400 200 30 * At 72% extraction rate ** At 150 grams premix per metric ton of flour
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Continuous Premix Delivery Systems
With continuous feeding, two types of premix delivery are possible. Location of the feeder depends on the type used.
Gravity
• Feeder is placed above the flour collection conveyor • Premix drops directly into flour as it flows through the conveyor
Pneumatic
• Can be located at several places in the mill • Premix drops into a venturi tube • Premix is blown into the flour collection conveyor ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Delivery System: Gravity Feed
Things to consider: – Feeder is installed above the flour collection conveyor – Premix is delivered via a nearly vertical gravity spout – Install spout away from general suction system Gravity Method of Premix Delivery Premix Feeder Flour In Mixing Conveyor Flour Out ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Delivery System: Pneumatic
Things to Consider: • Requires equipment such as blowers, valves and piping • Conveying lines should have minimal length and directional changes • Make the venturi tube accessible for monitoring Flour Pneumatic Method of Premix Delivery Feeder Venturi Tube Air Blower ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Delivery System: Pneumatic
1 2 1. Venturi tube with air flow restriction and product inlet 2. Attaching venturi tube to premix hopper transition 3. Completed assembly ► Introduction ► Premix ► Mill Set-Up 3 ► Operations ► Quality ► Advocacy
Ensuring Adequate Mixing in the Mill
Proper addition point for premix on the flour collection conveyor is essential for effective flour fortification.
• Locate the feeder at the front half of collection conveyor, above the blades of the mixing screw • At least 3 meters of conveyor length is normally needed to ensure adequate blending • Introduce premix away from general suction system
Poor
To Little Flour
Good
Mixing
Poor
To Little Mixing Flour Level ► Introduction Flour Flow ► Premix ► Mill Set-Up ► Operations ► Quality Flour Outlet ► Advocacy
Ensure Adequate Mixing In Packaging
If premix addition cannot be accomplished in mill, consider this option: • Install mixing conveyor between holding bin and packout bin • The premix is discharged into the start of this special conveyor • At least 3 meters of conveyor length is normally needed to ensure adequate blending • Introduce premix away from general suction system ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Equipment Recommendations
When considering equipment, look for these specifications: • Directions for installation and maintenance available in desired language or can be translated • All surfaces in contact with premix are food-grade and non-corrosive • Adjustable delivery control, calibrated from 0 to 100% of feeder capacity • 220 volt ± 10% 50/60 Hz single phase power • Anti-bridging design to prevent bridging or tunneling of premix in hopper • Capable of delivering from 0.04 to 8 L/hr with ± 5% accuracy over full range • Hopper capacity of 8 liter minimum • Easy accessibility for operator to check hopper and flow rate ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
System Recommendations
When considering equipment, look for these specifications: • Directions for installation, maintenance, and system operation available in desired language or can be translated • Automatic shut off / warning capability Feeder shuts off when flour flow stops Warning if feeder is empty or premix fails to discharge • Place feeder on load cells to aid in monitoring premix usage or use loss-in-weight feeder • If possible, use electronic control loop to balance feeder discharge to flour production scales ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Vendor Expectations
Millers should expect the following from equipment and system vendors: • At least two references from mills where equipment and systems have been in operation for at least one year • Installation and operating instruction manual that explains in words and diagrams the installation, calibration and maintenance of the equipment and system • Technical support for installation, training, calibration, and maintenance • Recommended spare parts inventory for items with life span of less than three years • Identified lead time for parts delivery and commitment to maintain parts inventory support ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Equipment Costs
• Cost of feeders varies with the capacity of the production line and optional equipment.
• Cost of blending equipment, if needed, varies with capacity of production line.
• Costs shown do not include shipping, import duties, value added tax or installation.
Equipment
Volumetric Feeder Gravimetric Feeder Loss-of-weight Feeder Powder Feeder
Cost Range (USD)
Feeders
$1,000 - $8,000 $5,000 - $20,000 $10,000 - $21,000 $1,000 - $25,000 Electronic Screw-Ribbon
Scales
$100 - $2,000
Blenders / Mixers
$10,000 - $25,000 /Paddle/Cut Flight Rotary Batch Blender Vertical Batch Mixer $35,000 - $170,000 $15,000 - $200,000 ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Marketing
More Information About Mill Set-up
Contact FFI at [email protected]
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
► ► ► ► ► ► ►
Section 4
Milling Operations for Fortification
Operation Guidelines Examples of Record Keeping Premix Receiving and Safety Maintaining Premix Supply Feeder Calibration and Premix Feed Rate Check-weighing Procedure Equipment Maintenance and Troubleshooting ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Fortification Operation Guidelines
1. Know actual production rate of mill 2. Calibrate feeders to production rate of mill 3. Ensure feeder hopper contains premix 4. Start mill and run for at least 15 minutes to reach normal production rate 5. Start feeder at required setting as determined by the feeder calibration process 6. Conduct
check weighing
at start of mill production run and every 2 hours to verify correct addition rate. Adjust if addition rate is greater than 10% above or below target, and recheck addition rate.
7. Check weights at the start of every shift or every 2 hours of operation ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Fortification Operation Guidelines
8. Maintain check weight within 5% of target 9. Ensure that the feeder does not run out of premix. This is the most important check on the production line. To do this: • • • Check the low-level signal Check each premix feeder routinely and fill hopper Record weight of material left in premix supply container • Compare actual premix use with the expected premix use based on flour production ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Fortification Operation Guidelines
10. At the end of a production run, turn off the premix feeder before shutting down the mill.
11. Production records need to record the following: • The lot number of the premix used • • • Check weights Feeder adjustments if made Times of check weighing ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Production Report
Example
► Introduction ► Premix ►
Flour Ingredient Usage Report First Shift Date: Mill: Beginning Lot # Flour Production
Time Grade
7:00 8:00 9:00 10:00 11:00 12:00 13:00 14:00 Shift Total
MT Flour 0.00
701 CCN Enrichment
% KG 0.00
Shift Total
MT Flour 0 KG 0.00
%
052 AGU Malt
KG KG 0 0
700 CCN
%
Bleach
KG KG 0 0
Begin Inventory Transfer to Mill Floor Total to account for Closing Inventory Disappearance
0 0 0 0 0 0 0 INGREDIENT Enrichment Malt Bleach NEW LOT # START TIME STOP TIME Mill Set-Up
SUPERVISOR (name): OPERATOR (name):
► Operations ► Quality ► Advocacy
Feeder Check Report Example
Flour Fortification Feeder Check First Shift Date: Mill:
5/31/2012 B Mill
Fortification - Feeder Test Enrichment Lot # Time 7:00 8:00 9:00 10:00 11:00 12:00 13:00 14:00 Flour Grade
MXE MXE MXE MXE MXE MXE MXE MXE
Flour Rate (Mt/hr)
9.4
9.4
9.4
9.4
9.4
9.4
9.4
9.4
Target (g/min)
24.6
24.6
24.6
24.6
24.6
24.6
24.6
24.6
701 CCN
* Required only if Test #1 is out of specification
Test #1 (g/min)
24.2
24.5
24.8
24.1
24.6
24.8
24.9
24.7
Test #2* (g/min) Test #3* (g/min) SUPERVISOR (name): OPERATOR (name):
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Receiving Procedures
1) Assess package condition 2) Ensure that you received what you ordered 3) Record Lot # and type of premix 4) Remove and file certificate of analysis
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Safety
Premixes are concentrated sources of vitamins and minerals and are too concentrated for direct consumption.
Mill workers must follow these safety instructions: 1. Label premix boxes with warning labels and handling precautions 2. Inform all workers handling the premix of the
material safety data sheet
(MSDS) or product information sheet with safety instructions
WARNING. COMBUSTIBLE DUST.
Avoid generation of dust to prevent dust explosions. Keep away form sources of heat and ignition. Prolonged and/or repeated contact may cause skin irritation. Gloves, dust mask, and protective clothing should be worn when handling. Wash thoroughly after using.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Premix Safety
3.
Wear long sleeves, gloves and dusk mask when filling the feeder hopper, even if it just takes a minute. The operator may also wear safety goggles, a hair net, safety helmet or other protective devices depending on mill policy.
4.
Wash hands and any skin exposed to the premix after filling hoppers.
5.
Clean any premix spill immediately by putting meal on the spill prior to sweeping.
Some people have allergic skin reactions to flour fortificants, in particular niacin.
This can be avoided by following the precautions outlined.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Maintaining Premix Supply
1. Keep Small Quantities on Mill Floor • Estimate amount of premix needed and have sufficient quantities in the mill for production 2. Stock Rotation • Record the production lot number(s) upon receipt • Develop a rotating first-in, first-out (FIFO) system ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Maintaining Premix Supply
3. Use of Active Containers • • Place a scoop inside the container for convenient use Keep paper, plastic, and other contaminates out of the container as they may get in the feeder cause its malfunction • After the hopper is filled, put the scoop back in the container or another designated location • • Seal container and close outer container if applicable Keep operating container away from damaging conditions including heat, light, and moisture ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Maintaining Premix Supply
4. Assign specific mill staff these responsibilities: • Stock control • • - Order new premix at intervals that take into account usage rates, time for processing the order and receiving a shipment.
Premix handling in the mill - Including storage, movement to the production line and addition to the feeder(s) Premix quality control - Inspect the premix when a shipment arrives, periodically check the storage conditions of unopened premix, and check the production line process ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Feeder Calibration Instructions
Confirm the flour flow rate (kilograms per hour) for the production line.
This is typically done at one of two points in a continuous system: 1.
2.
If fortifying in the mill, check the flour production scales and confirm with a weigh-off if possible If fortifying in packaging and load-out, check the scales of the flour transfer system in which the flour will be fortified and confirm with a weigh-off if possible In a batch system, check the weight of material delivered to the batch mixer by confirming scale reading accuracy.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Feeder Calibration Instructions
Next, determine the premix feed (discharge) rate at different speed settings on your feeder. 1.
Fill hopper half full with premix 2.
Set feeder to maximum discharge 3.
Run feeder for 2 minutes 4.
5.
Weigh the premix that has been discharged Operator at a feeder control panel.
Calculate maximum discharge per minute by dividing total weight by 2 6.
Repeat multiple times at different speeds or percent settings 7.
Make a chart that shows the premix discharge rate per minute at different speed settings from 0 to 100% of maximum discharge 8.
Display the chart near the feeder. See example on next slide.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Feeder Calibration Chart Example
20,0 17,5 15,0 12,5 10,0 7,5 5,0 2,5
y = 0,2024x - 1 R² = 0,996
0,0 0
► Introduction
10 20
► Premix
30 40 50 60 70 80 90 100 110
►
Feeder Setting (%)
Actual results from commercial premix feeder Mill Set-Up ► Operations ► Quality ► Advocacy
Determining Premix Feed Rate
1.
2.
Identify the premix addition rate recommended by the premix supplier Multiply by the flour production line flow rate to calculate the premix delivery required in grams per minute Premix Addition X Flour Flow Rate = Premix Required (grams / MT flour) (MT/minute) (grams/minute) 3.
4.
Adjust feeder control to calculate delivery rate (consult your mill’s calibration chart) Check the weigh-off and adjust accordingly ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Check-Weighing Procedure
1. Zero the scale or weigh the sample container 2. Position the container at feeder discharge 3. Collect premix for 2 minutes 4. If you zeroed the scale in step one, the weight shown is that of the premix. Otherwise, subtract the container weight from the total to determine premix weight ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Equipment Maintenance
• Follow the recommended maintenance schedule from the equipment supplier (request supplier to provide this information in local language) • Lubricate moving parts as required (use approved food grade lubricants) • Inspect for wear; adjust and/or replace parts as needed • Maintain inventory of spare parts that may need replacement ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Troubleshooting: Premix Flow
Compact and sticky premix may ball, bridge or tunnel in the feeder. This results in feed rate variability.
ACTIONS: 1. Frequently inspect the premix feeder, especially after it is newly installed 2. Specify and use premix feeders with mechanical agitation (see next two slides) 3. Empty feeders that will be unused for any length of time 4. Have premix supplier change the levels of excipients and free-flow agents ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Hopper Agitators Improve Flow
A mechanical agitator in the hopper prevents the premix from bridging, clumping and compacting. Some models come with an agitator device.
► Introduction ► Premix ► Mill Set-Up Photo by Jeff Gwirtz ► Operations ► Quality ► Marketing
Hopper Design Improves Flow
The hopper of the premix feeder at left is made of flexible material. A mechanical device such as the motor and paddle pictured at right causes the flexible wall to pulsate and prevents the premix from bridging.
Photos by Jeff Gwirtz ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Troubleshooting: Flour Flow
If the flour or premix flow is intermittent, fortification level will not be correct. ACTIONS: 1. Frequently inspect the feeder and flour flow 2. Install low-level alarm or indicator light on hopper 3. Install electrical interlock system between the mill and feeder controls (described in section three on the mill set-up) ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Troubleshooting: Magnets
If using elemental iron, the surface of rare earth magnets in the production process may collect iron powder. ACTIONS: 1. No change required. This will not affect the iron fortification level or the magnet’s performance regarding tramp metal.
2. Install magnets in a location so that the flour stream acts as a continuous cleaning mechanism as it passes over the magnet.
3. If the iron powder bridges between the magnet tubes, use a magnet system with a larger distance separating the tubes.
4. Use a non-magnetic iron source, such as iron salts.
5. Continue to inspect and clean magnets following good manufacturing practices (see photo) ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Troubleshooting: Power Supply
Variations in voltage can alter flour production and premix feed rates, which will cause the flour to be fortified incorrectly.
ACTIONS: 1. Install voltage regulators when working with single-phase voltage feeder motors 2. Use three-phase motors 3. Work with electric supplier to provide uniform, high-quality power into the plant 4. Negotiate with energy company to provide alerts before power outages ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Troubleshooting: Nutrient Loss
Quantitative testing may show that vitamins and mineral content is consistently lower than the expected value. Vitamin A and riboflavin are particularly vulnerable due to exposure to light.
ACTIONS: 1. Confirm that premix is appropriate for type of flour 2. Confirm that the correct addition rate is used 3. Put sample bags in opaque containers 4. Analyze flour sample as soon as possible 5. Make sure both the premix and fortified flour is not exposed to high heat (>40 ° C) or light during storage 6. If the dust collection stock is yellow, the collection system may be removing riboflavin near the premix addition point. In this case, • • Confirm and set suction to proper pick-up velocity Position suction system away from premix addition point ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
More Information on Operations
• Contact the Food Fortification Initiative at [email protected]
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Section 5
Quality Control / Assurance
►
Quality Control / Assurance
►
Internal Quality Overview
►
Qualitative Testing, including iron spot test procedures
►
Record Keeping and Quality Control Schedule
►
Quantitative Testing and Composite Samples
►
Government’s Role In Monitoring ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Quality Control / Assurance
Ramadan Deliu, Head of Laboratory at M & Sillosi Milling Company, prepares flour for an iron spot test.
Photo by Kate Wheeler.
► Introduction ► Premix An effective quality assurance and quality control program throughout a country’s flour fortification program: • Ensures adequate levels of vitamins and minerals to improve nutrition among the population • Prevents the cost of over-using premix • Gains customer satisfaction • Adheres to government regulations ► Mill Set-Up ► Operations ► Quality ► Advocacy
Quality Control / Assurance
Internal External Five parts of the program
Flour millers conduct process control and quality checks Food control authorities inspect flour mills and analyze flour samples Inspectors check fortified products at retail stores
Commercial Intake
Household surveys confirm consumption
Impact
Biological impact is verified
Source: Chapter eight of the Guidelines on Food Fortification with Micronutrients published by the World Health Organization and the Food and Agricultural Organization of the United Nations
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Quality Control / Assurance
Internal External Five parts of the program
Flour millers conduct process control and quality checks Food control authorities inspect flour mills and analyze flour samples
This tool kit focuses on the internal quality control with the assumption that the millers purchased high-quality wheat to meet the customers’ expectations.
The tool kit also highlights the quality assurance process at external laboratories.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Internal Quality: Overview
Use these five quality control methods in every mill: 1. Monitor the fortification system regularly 2. Conduct qualitative testing regularly 3. Monitor premix feed rate and flour flow rate 4. Keep records of premix usage and fortified flour production 5. Submit samples for quantitative testing ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Qualitative Flour Testing
Used to: • Determine if flour sample has been fortified • Provide visual estimate of fortification level A common qualitative test is the iron spot test. If iron is detected by this method, it is assumed that other nutrients in the premix are present.
The iron spot test is formally Method 40-40.01: Iron Qualitative Method as approved by the American Association of Cereal Chemists ( AACC ).
Photo by Kate Wheeler.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Iron Spot Test Procedure
1. Take a sample of fortified flour. Make an impression in the sample.
2. Add the reagents with a plastic, disposable dropper.
3. Wait for red spots to appear to indicate presence of iron.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Iron Spot Test Procedure
4.
Compare test with prepared samples or images such as the one below to estimate premix addition level 22 ppm ½ treatment 44 ppm Target Treatment 88 ppm Double Treatment ppm = parts per million 5.
Discard sample ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Test Responses
• Variability is expected (quantitative test show below)
Feeder Test Results- May 31, 2012 Running Average (N=3) 26,0 25,5 Upper Control Limit 25,0 Target 24,5 24,0 23,5 1
► Introduction
3 5
► Premix
7 9 11 13 Hour of Day 15
► Mill Set-Up
17
► Operations
19 21
► Quality
23 Lower Control Limit
► Advocacy
Iron Spot Test Response
• Make adjustments based on systematic trends over time established by multiple observations.
• Adjusting a premix addition system based on one or two spot test results could widen the system variability and complicate future measurements.
• If 2 out of 5 consecutive samples do not meet expectations, increase the sampling frequency as outlined on the next page.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Iron Spot Test Sample Frequency
• If 2 of 5 consecutive samples do not meet the requirements, increase sampling frequency. • If the next 2 of 5 samples fail to meet requirements, implement corrective actions. Verify that the feeder is operating properly then consider adjusting the: • premix feeder control • flour transport scales • mixing machinery • If the next 2 out of 5 consecutive sample fail to meet requirements, stop production until the error is found and corrected.
• Once production restarts, continue frequent sampling.
• Return to normal sampling schedule after 3 consecutive samples are correct.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Iron Spot Test
Advantages
• Simple, fast, inexpensive • Requires no sample pre treatment.
• Requires only two reagents: potassium thiocyanate (KSCN) or sodium thiocyanate (NaSCN) and hydrochloric acid (HCI) • Food grade NaSCN is available if desired • Easy: personnel with minimum training can perform this
Limitations
• Not quantitative: does not determine amount of iron in sample. • Iron spot test is not currently applicable for sodium iron EDTA. ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Iron Spot Test Alternatives
• If using sodium iron EDTA, include elemental iron in premix – The simplest solution is to order premix with a minimal amount of elemental iron (10 ppm) to respond to the iron spot test. This slightly increases the total iron content in quantitative measures.
• Ask premix provider for alternatives • If the premix has riboflavin, use a black light test – Riboflavin (vitamin B2) will fluoresce under ultraviolet light. Perform this test in a dark room or box using a wet Pekar slick to compare fortified with unfortified flour. • If the premix has vitamin A, use a color test – Must be done in a laboratory to compare the intensity of color when vitamin A mixes with copper sulfate.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Record Keeping
Maintaining accurate records is an essential part of internal monitoring. Develop a system to track:
Flour Ingredient Usage Report First Shift Date: Mill:
• Premix delivery and usage
Beginning Lot # Flour Production
Time Grade
7:00 8:00 9:00 10:00 11:00 12:00 13:00 14:00 Shift Total
MT Flour 0.00
701 CCN Enrichment
% KG 0.00
052 AGU
%
Malt
KG
700 CCN
%
Bleach
KG • • Flour production 0 0 Comparison of premix usage with target needs based on flour production
Shift Total
MT Flour 0 KG 0.00
KG KG 0 0 • Results of check weighing tests
Begin Inventory Transfer to Mill Floor Total to account for Closing Inventory Disappearance
0 0 0 0 0 0 0 • Internal and external quality control testing results.
INGREDIENT Enrichment Malt Bleach NEW LOT # START TIME STOP TIME
SUPERVISOR (name): OPERATOR (name):
These records help the mill assure quality and may be required during an external inspection.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Internal Quality Control Schedule
1. Check premix feeder hourly. Make sure the speed detector shows that it is running. Fill hopper if it is low.
2. Run feeder check weights at least every 8 hour shift. 3. Run iron spot tests at least every 8 hour shift. 4. Conduct inventory control of premix usage and fortified flour production at least quarterly.
Detail the quality control responsibility, frequency, protocol, and reporting activities in the mill’s quality assurance manual. Instruct all mill personnel in the procedures. Assign reporting to someone with authority to act on the information.
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Internal and External Testing
Types of laboratories testing fortified flour
Quantitative tests of all added nutrients - Checks results and procedures of other labs
Reference Laboratory
-Certificate of analysis on premix
Premix Suppliers
- Quantitative tests of all added nutrients Quantitative tests.
- Runs or manages biological testing.
- Audits mills.
Government Laboratory Central Milling Laboratory
-Runs quantitative tests on indicator nutrient and other tests -Audits mills within the company ► Introduction
Mills
► Premix ► Laboratory/Production Activities - Fortificant inventory control - Feeder checks - Iron spot tests (if applicable) - Flour sampling Mill Set-Up ► Operations ► Quality ► Advocacy
Quantitative Testing
• Send samples to laboratory using internationally recognized methods (AACC or ICC and AOAC) • Requires sophisticated equipment and careful adherence to protocols due to the small concentration of vitamins and minerals in a flour mixture.
• If results are suspect, the sample can be submitted to a certified, reference laboratory for further analysis.
Laboratories running quantitative tests should: • Make a sample of standardized flour fortified with a certified level of nutrients as a reference • Routinely conduct a blind analysis of the reference sample to verify laboratory procedures ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Indicator Nutrient Testing
• One premix ingredient (usually iron) is typically tested as “indicator” of others. This is valid for premix that has been properly designed, manufactured and mixed • Because the ratio is constant, measuring one nutrients can verify the delivery of the others.
• Assumes no destruction or separation of the indicator nutrient after the premix was added.
► Introduction ► Premix ► Mill Set-Up Spectrophotometric test for iron ► Operations ► Quality ► Advocacy
Creating Composite Samples
A composite sample may be used to estimate the weighted average nutrient value in a production run. For a composite sample: – Take 5 to 10 spot samples representative of a production lot, such as an 8-hour run – Collect the same sample size – Distribute sample collection evenly over the production time period ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Capability Study Guideline
Mills may seek external quantitative testing to determine their ability to produce a uniformly fortified flour, meeting specifications.
• Collect individual, not composite, flour samples • Take 7 or more samples over an 8-hour run.
• Calculate the coefficient of variation (CV). The CV is the standard deviation divided by the mean, expressed as a percent. • Identify the analytical error for that lab assay ► Introduction
Assay Error
4.9% or less 5 - 9.9% 10 - 15%
Acceptable CV
20% 35% 45%
Guidelines developed from FFI references
► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
26,0
Control Chart
Feeder Test Results- May 31, 2012 Running Average (N=3) 25,5 25,0 24,5 Upper Control Limit Target 24,0 23,5 1 3
► Introduction
5 7
► Premix
9
►
11 13 Hour of Day 15
Mill Set-Up
17
► Operations
19 21
► Quality
23 Lower Control Limit
► Advocacy
Government’s Role in Mill Monitoring
Government authorities conduct various roles in flour fortification monitoring, often including: • Confirming that technical specifications, process control and quality procedures and performance records are maintained at the mill, packaging sites, and points of entry into the country • Inspecting and verifying legal compliance with the country standard, based on a quantitative assay – Samples should contain the fortificant, and at least 80% of samples should present the legal minimum.
– Less then 20% of the samples should have a nutrient content above the maximum level, if one has been established. ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Plant Audits
• Off-site audit with government official reviewing information supplied by mills • On-site audit with government official visiting the mill to determine if the mill is properly fortifying flour and to validate data supplied in off-site audits ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
More Information on Quality Control / Assurance
• Chapter eight of the Guidelines on Food Fortification with Micronutrients published by the World Health Organization and the Food and Agricultural Organization of the United Nations • The Food Fortification Initiative at [email protected]
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Section 6
Advocacy and Marketing
► ► ► ► ► Fortification Regulations Marketing Mandatory Fortification Identify Audiences and Ensure Satisfaction Marketing Ideas Marketing, Logo, and Packaging Examples ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Marketing
Fortification Regulations
Ideally national leaders from public, private, and civic sectors work together to establish country standards for fortification. Among factors to consider are: • Existing regulations • Global and regional recommendations • Dietary needs in the population • Per capita flour consumption • Extraction rate of commonly consumed flour • Cost of premix combinations • Effect on sensory properties ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Fortification Regulations: Industry’s Role
• Understand and follow existing country regulations for food fortification • Follow best practices for quality control and quality assurance • Participate in national process to develop standards that reflect industry capability • Advocate for mandatory legislation ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Fortification Regulations: Benefits of Mandatory Legislation
• Population has equal access to health benefits from fortified flour, regardless of economic status • All millers in country have the same cost expectations • Quality assurance is easier to accomplish More than 70 countries have legislation for mandatory wheat flour fortification. See the current map and country list at: http://www.ffinetwork.org/global_ progress/index.php
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Marketing Mandatory Fortification
The role of marketing is to ensure acceptance of fortification.
Marketing is a joint effort of public, private and civic sector partners.
Civic Sector Private Sector Public Sector
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Marketing Audience
Potential audiences for fortification messages are: • Consumers, especially women and children who are most likely to benefit from fortification • Customers who purchase food for women and children • Government leaders who influence healthcare and economic policies • Health advocates who provide research, education, and outreach • Millers, bakers, and others involved in the supply chain • Media who influence consumer decisions ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Potential Concerns
Highlight fortification’s health benefits, but be prepared to address concerns such as: • Product uniformity • Market competition • Price increase • Change in flour ’ s taste, appearance, or smell • Change in flour’s baking qualities ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Meeting Customer Expectations
Properly fortified flour will not change: • Color and appearance • Shelf life • Sensory testing • Functional qualities ► Introduction ► Premix ► Mill Set-Up ► Operations Photo by Karen Codling ► Quality ► Advocacy
Ensuring Customer Satisfaction
– World Health Organization recommendations reflect organoleptic properties – Fortified foods accepted by consumers globally
Workshop participants in Kenya conducted taste tests of bread made with different iron compounds
. Photo by Sarah Zimmerman ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Marketing Ideas
• Billboards • Brochures • In-store banners • Community skits • T-shirts • Calendars • Cartoons • Coupons • Rebates • Text and phone messages • Radio and television advertisements or interviews • Messages on Facebook or other social media • Posters on trucks and buses • Coloring contests for children • Interactive packaging • Give-away items • Sponsorships of special events ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Marketing Examples
Billboards Signs on Trucks Posters ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Fortification Logo Examples
Logos can be used to enhance awareness Kosovo Uganda Regional logo used for fortified foods in West Africa ► Introduction ► Premix South Africa ► Mill Set-Up ► Operations Azerbaijan ► Quality ► Advocacy
Labeling Examples
Label fortified products with the additional vitamin and mineral content ► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
More Advocacy Information
• Contact FFI for a advocacy toolkit: [email protected]
• Topics to consider when setting fortification standards and writing legislation: http://www.ffinetwork.org/plan/index.html
• Sensory tests in Asia: http://www.ffinetwork.org/plan/documents/AsiaFoodImpact.pdf
• Sensory tests in Africa: http://www.ingentaconnect.com/content/nsinf/fnb/2012/00000033/A0 0304s3/art00011 • More marketing examples: http://www.ffinetwork.org/implement/documents/MarketingFlourFortif ication.pdf
• West Africa marketing experiences at: http://www.ffinetwork.org/implement/documents/SocialMarketing_HK I_Experience.pdf
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy
Thank You
For more information: www.FFInetwork.org
Contact FFI at [email protected]
► Introduction ► Premix ► Mill Set-Up ► Operations ► Quality ► Advocacy