Transcript Grain storage and management in a difficult harvest

IGQI Advisory Committee
Meeting
July 13, 2012
Charles Hurburgh, Professor, Agricultural and
Biosystems Engineering
AGENDA
9:30 AM Welcome and introductions
College of Agriculture, Extension update plans: John Lawrence
10:00 AM Bioprocessing projects:
RFS, E15 and pathways for plants to expand
Current projects – corn sourcing and frac
Discussion of future direction and opportunity
11:00 AM QMS/Food Safety projects
FSMA and grain handling – update
FDA grant update, results
12:00Noon
Lunch Break
12:30PM Storage and Grain Management projects
Storage Team
Potential mold toxin and other drought impacts
2:00 PM Update; International Center for Grain Operations and Processing
2:30 PM Next meeting plans then adjourn.
Suggested date: Friday, January 4, 2013
Program Update
Agriculture and Natural Resources
Extension
College of Agriculture and Life
Sciences
GQI Projects 2013
Bioprocessing
QMS/FSQMS Food Safety
Grain Management
Processing inventory
FDA Food safety project
Grain storage team
Fractionation
Training (FSMA)- industry component
Update materials
Feed balance
QMS templates, etc.
Current events
Soybean marketing
30%
Traceability
40%
30%
Expectation: Each project will create at least 2-3x its allocation in proposals
~ $150,000 Extension Allocation FY2013
104
Corn Grind for Ethanol
102
Million bushels
100
98
96
94
92
90
88
86
Sep- Nov- Jan- Mar- May- Jul10
10
11
11
11
11
Sep- Nov- Jan- Mar- May11
11
12
12
12
Source: DOE-EIA
Extension and Outreach/Department of Economics
1000
Ethanol Stocks
950
Million gallons
900
850
800
750
700
650
Sep- Nov- Jan- Mar- May- Jul- Sep- Nov- Jan- Mar- May10
10
11
11
11
11
11
11
12
12
12
Source: DOE-EIA
Extension and Outreach/Department of Economics
U.S. Blended Gasoline Consumption
7.6 bil. gal.
7.4 bil. gal.
Source: DOE-EIA, via USDA-ERS
Extension and Outreach/Department of Economics
05
Ju
l-0
Ja 5
n06
Ju
l-0
Ja 6
n07
Ju
l-0
Ja 7
n08
Ju
l-0
Ja 8
n09
Ju
l-0
Ja 9
n10
Ju
l-1
Ja 0
n11
Ju
l-1
Ja 1
n12
Ja
n-
$ per gallon
$2.50
Ethanol Margins
$2.00
$1.50
$1.00
$0.50
$0.00
-$0.50
Extension and Outreach/Department of Economics
Prices
Ethanol
Extension and Outreach/Department of Economics
Corn
Jan-12
Jul-11
Jan-11
Jul-10
Jan-10
Jul-09
$1.50
Jan-09
$1.00
Jul-08
$2.75
Jan-08
$1.50
Jul-07
$4.00
Jan-07
$2.00
Jul-06
$5.25
Jan-06
$2.50
Jul-05
$6.50
$ per bushel
$7.75
$3.00
Jan-05
$ per gallon
$3.50
Extension and Outreach/Department of Economics
Ethanol
Gasoline
5/3/12
1/3/12
9/3/11
5/3/11
1/3/11
9/3/10
5/3/10
1/3/10
9/3/09
5/3/09
1/3/09
9/3/08
5/3/08
1/3/08
9/3/07
5/3/07
1/3/07
$ per gallon
4.00
Fuel Prices
3.50
3.00
2.50
2.00
1.50
1.00
0.50
Relative Prices
1.25
1.20
1.15
1.10
1.05
1.00
0.95
0.90
0.85
Corn
Ethanol
Extension and Outreach/Department of Economics
Gasoline
7/3/12
6/19/12
6/5/12
5/22/12
5/8/12
4/24/12
4/10/12
3/27/12
3/13/12
2/28/12
2/14/12
1/31/12
1/17/12
1/3/12
0.80
Extension and Outreach/Department of Economics
1/3/15
7/3/14
1/3/14
7/3/13
1/3/13
7/3/12
1/3/12
7/3/11
1/3/11
7/3/10
1/3/10
7/3/09
1/3/09
7/3/08
1/3/08
7/3/07
1/3/07
$ per gallon
0.16
Blending Margins
0.14
0.12
0.10
0.08
0.06
0.04
0.02
0.00
-0.02
-0.04
RFS
40
35
Billion gallons
30
25
20
15
10
5
0
2009
2012
2015
2018
2021
Conventional Biofuels
Cellulosic Biofuels
Biodiesel
Additional Advanced Biofuels
Extension and Outreach/Department of Economics
RFS Detail 2010-12
16
Billion gallons
15
14
13
12
11
10
2010
2011
2012
Conventional Biofuels
Cellulosic Biofuels
Biodiesel
Additional Advanced Biofuels
Extension and Outreach/Department of Economics
16
RFS Implementation 2010-12
Billion gallons
15
14
13
12
11
10
2010
2011
2012
Conventional Biofuels
Cellulosic Biofuels
Biodiesel
Additional Advanced Biofuels
Extension and Outreach/Department of Economics
Value Added Agriculture Program
Current Projects within the
IGQI Bioprocessing Group
July 2012
- Development of Iowa Grain Flow Survey 2013
- Validation of Ethanol Yield Equation
- Plant test with new corn genetics
- United BioEnergy survey
- Discussions with fractionation companies
www.iavaap.org
Extension and Outreach/Department of Economics
Grain Storage and Handling Team
• First issue team under new plan
• Grain science well understood. Challenge is
volume and value of grain
• Delivery team of field specialists
Shaun Shouse, Greg Brenneman: ABE
Kelvin Leibold, Steve Johnson: Farm Mgt
Mark Licht: Agronomy
• Collect regional info; short multi media on key
topics, annual technology review and updates,
early warning.
Harvest conditions and projected needs
The first condition (heat at silk) for aflatoxin has been met. We will review
and update our aflatoxin/mycotoxin materials
(Hurburgh, Robertson, Shepherd)
New concern- FSMA, the reportable food registry and crop insurance.
(Hurburgh, Laury)
If severe drought; nitrate levels in silage
(Loy et al.)
High alpha amylase corn. Bad in corn dry milling and alkaline cook. One
plant plans to take all.
List of training topics that might be useful.
Aeration management: Brenneman
Dryeration: Shouse
Ventilation – fan sizes and performance: Brenneman
Energy bulletins: Hanna –format to use for all the handouts.
Mycotoxins: Robertson, Hurburgh and Licht
Food safety act and grain farms: Laury and Hardy
Bin drying:
Drying systems - how should I spend my money:
Economics of drying and storage: Leibold and Johnson
Grain testing – grading: Hurburgh
FDA - Food Safety Modernization Act
Update registration every two years
A written food safety plan is required
Carrier certification and examination (BSE)!!!!!
Surveillance inspection every 5-7 years
Accuracy guidelines for enhanced traceability
FDA now can force a recall
Self reporting website apply to mycotoxins???
Inspect records and audit without prior cause
First Actions
• Train new inspectors, visit facilities
• Emphasis on food safety plans – FEED!
• Specific audits and checks in familiar areas;
eg sanitation, BSE/meat products
• Traceability/recall – ask state of the art
• Wild card: Moldy grain and mycotoxins
• Third party audits – fading reputation
Food Safety Training for
Bulk Agricultural
Product Handling and
Processing
Charles R. Hurburgh, Jr.,
Professor,
Agricultural and Biosystems Engineering
Principal Investigator
Project Team-ISU
•
Dr. Charles R. Hurburgh, PI
•
Dr. Jim Roth, DVM, CoPI;
– Center for Food Security and Public Health
Educational Resources, College of Vet. Med.
– Feed Safety and Animal Health tracking
•
Dr. Gretchen Mosher, Industrial Technology;
–
risk, mapping
•
Howard Shepherd, IGQI Coordinator
•
Connie Hardy, Extension; current practice survey
ISU Responsibilities:
Process map of grains supply chain and food safety risk points
Survey of current food safety regulatory practice, jurisdictions.
Templates and procedure for creating a food safety plan/recordkeeping plan
Course unit in animal production from the food safety viewpoint
Course unit on traceability and recordkeeping
Risk analysis of the grain supply chain
ISO22000 coded to FSMA; PAS220, 222; AAFCO; FDA job analysis
Scientific publications and list of publications in the FSQMS area.
KSU Responsibilities:
Feed short course taught at KSU (VM101)
Process for ANSI accreditation of training materials
Course unit on mycotoxins
Addition of Food Safety Plan development to the GEAPS QMS course
Farm Grain – Field and Storage Risks
AFLATOXIN – case study
Action
Level
(ppb)
Reference
Corn and peanut products intended for
finishing (i.e., feedlot) beef cattle
300
CPG
683.100
Cottonseed meal intended for beef, cattle,
swine, or poultry (regardless of age or
breeding status)
300
CPG
683.100
Corn and peanut products intended for
finishing swine of 100 pounds or greater
200
CPG
683.100
Corn and peanut products intended for
breeding beef cattle, breeding swine, or
mature poultry
100
CPG
683.100
Corn, peanut products, and other animal
feeds and feed ingredients but excluding
cottonseed meal, intended for immature
animals
20
CPG
683.100
Corn, peanut products, cottonseed meal,
20
and other animal feed ingredients intended
CPG
683.100
Commodity
Animal Feeds
Mycotoxins
• Aflatoxin
• Fumonisin
• Vomitoxin
• Zearalenone
• Ochratoxin
Mycotoxins are an example of a food safety
issue that covers the entire supply chain.
VM101: Grain and Feed Mill Operations June 25-29, 2012
Date
Time
Presentation Title
Speaker
Organization
June 25th
8:00 AM
Importance of Feed and Food Safety and this course
Hull
FDA
Monday
8:30 AM
Course Orientation
McKinney
KSU
9:00
Evolution and Current Structure of the U.S. Feed & Animal Industry
Fairfield
NGFA
10:00
Grain Production and Handling
Hurburgh
ISU
10:45
Break
McKinney
KSU
11:00
Feed Mill Tour
12:00 PM
Lunch
1:00
Grain and Ingredient Quality and Storage
Hurburgh
ISU
1:30
Molds & Mycotoxins
Channaiah
KSU
3:00
Break
3:30
Problem Exercise
4:30
Recap
5:00
Adjurn
June 26th
8:00 AM
Milling
Miller
KSU
Tuesday
9:00
Oilseed Processing & Biodiesel
McKinney
KSU
10:00
Break
10:15
Corn Processing: Wet Milling, Dry Miling, Dry Grind Ethanol
Hurburgh
ISU
11:00
Rendering
Hamilton/Meeker
Darling/Natl. Renderers
12:00 PM
Lunch
1:00
Bakery and Dairy Products
McKinney
KSU
1:30
Ingredient Receiving & Logistics
Stark
NCSU
3:00
Break
3:15
Problem Exercise
4:00
Recap
4:30
Adjourn
VM101: Grain and Feed Mill Operations June 25-29, 2012 (cont'd)
June 27th
8:00 AM
Medicated Feed Additives
Fairfield
NGFA
Wednesday
9:00
Animal Nutrition & Diet Formulation
Megan Smith
ISU
10:00
Break
10:15
Vitamins & Minerals
Stark
NCSU
11:30
Problem Exercise
12:00 PM
Lunch
1:00
Particle Size Reduction & Steam Flaking
Fahrenholz
NCSU
2:00
Batching & Mixing
McKinney
KSU
3:00
Break
3:15
Pelleting
Fahrenholz
NCSU
4:45
Recap
5:00
Adjourn
June 28th
8:00 AM
Pellet Cooling & PPLA
Stark
NCSU
Thursday
9:30
Load Out and Warehouse
10:00
10:15
Break
Hazard Analysis of the Feed Industry
12:00PM
Lunch
1:00
2:30
2:45
4:30
5:00
June 29th
Friday
Stark
NCSU
McKinney
KSU
Feed Mill Workshops
Break
Feed Mill Workshops
Recap
Adjourn
McKinney/Stark/Fahrenholz
KSU/NCSU
McKinney/Stark/Fahrenholz
KSU/NCSU
8:00 AM
PPE & Conducting a Safe Inspection
Epperson
AFIA
9:00
Course Assessment & Course Evaluation
10:00
Adjourn
1.
2.
3.
4.
5.
6.
7.
The second year project will continue the sector specific training approach
Make the basic feed course (FFM) will be made more accessible in an on-demand
format as well as in a physical classroom format. This will be done by condensing
individual course units into 20-30 minute webinars, each with a 5-10 question self test
at the end.
The FFM course repeated at North Carolina State, but in a shorter format assuming that
participants have seen selected key elements by webinar, in advance. Classroom time
can be redirected to problem solving exercises.
The structure and materials for the Advanced Feed Manufacturing will be created.
The wheat supply chain training( always connecting feed components to the feed
course) –production, milling, flour distribution to the baker, feed by products – will be
done. Kansas
The corn and soybean supply chain training- wet milling, ethanol, dry milling, soy
crush, soy expeller plus production and product distribution to second stage will
be done in the webinar followed by shorter on-site training format. owa.
The basic animal husbandry and nutrition will be expanded to other species
beyond cattle and swine, for inclusion in the AFM training.
The identification of risk points and priority with industry will be published.
Food Safety Plan
Dr. Angela Laury
Department of Food Science and Human Nutrition
Extension and Outreach
Food Safety Plan
• All companies must have plan by June 2012
• More detailed than a traditional HACCP Plan
• New concept of proof of compliance
– More than prevention
• Companies must evaluate known and reasonably
foreseeable hazards
• Science (validation) and Risk-based (traditional
contamination) prevention strategies (interventions),
monitoring (written), and record keeping (traceability)
• Each program requires a separate hazard analysis
Food Safety Checklist
Part 1: Food Safety Program
Questions
Yes
Food Safety Program
1
A documented food safety program that incorporates Quality
Management Program has been implemented
2
The operation has designated someone to implement and
oversee the food safety program
Name______________________________________
3
All food safety documentation is located in one central location.
Where:_____________________________________
4
Records are kept for two years in an orderly manner.
5
A map of the facility and grounds is available.
No
N/A
Documents,
filenames
Aflatoxin Years
• 1983
• 1988 About the same as 1983
• 2005 SE IA 5-10 counties
Summary from 2005
1. Accurate testing
2. Accurate sampling
3. Need for flexibility in testing and sampling
4. Costs incurred by producers for the aflatoxin testing
5. Role of elevator in the sampling and testing process
6. Insurance coverage in bins.
7. Why can't corn go in the bin and still be covered in Iowa?
8. Timely visit by adjuster
9. Consistency among insurance companies
10. Inconsistency in information
11. Consistency in the field testing process
12. Extreme variability within fields
13. International implications for grain < 20 ppb aflatoxin
14. Use of grain > 20 ppb aflatoxin in livestock feed
15. What to do with truck loads of rejected corn
16. Marketing high testing grain
17. Variance for > 300 ppb grain by FDA
18. Co-mingling grain
19. Regulations after grain is at the elevator
20. How to measure the yield for APH if the field is zeroed out because of aflatoxin
21. Can corn be destroyed by leaving it in the field?
22. Can processing destroy aflatoxin?
23. This is beyond the control of producers
24. Worker safety issues in working with this corn
The primary education and applied research partner to the
global grain handling and commodity utilization industry.
INTERNATIONAL CENTER FOR GRAIN OPERATIONS AND PROCESSING
INTERNATIONAL CENTER FOR
GRAIN INDUSTRY OPERATIONS AND
PROCESSING
ICGOP Organization – Current Draft
$500K over 5 years = Board
In kind counts.
Companies by themselves or
Organizations pool funds
Scientific Societies ex Officio
Incorporators: ISU, KSU, AAI,
KGFA, GEAPS
KSU: Lead, Distance Ed.
ISU: Issue solving, Ed.
February 3, 2012: Kansas City
ICGOP Organization – Status
• Articles of Incorporation:
– Filed in KS
– KGFA Official Agent
• Tax Exempt Application:
–
–
–
–
Information under review
Submit to Legal Counsel by Aug 1, 2012
GEAPS has offered to pay attorney fees
KEY!!: Affiliation Agreements:AKA who does what
Attachment A: Sample Affiliation Agreement
AFFILIATION AGREEMENT
BETWEEN
AGENCY 1, AGENCY 2, AGENCY 3……..
THIS AGREEMENT (“Agreement”) is made and entered into as of ________, 20__ by and between Agency
1, hereinafter referred to “AGENCY 1”, and Agency 2, hereinafter referred to as “Agency 2.”
WHEREAS, AGENCY 1 is (State Name) not-for-profit corporation that receives funds pursuant to
________________ and provides _________________________________
______________________________________________________________________
WHEREAS, Agency 2 is (State Name) not-for-profit organization that receives funds pursuant to
________________ and provides _________________________________
______________________________________________________________________
WHEREAS, AGENCY 1 and Agency 2 recognize the need for and desire to aid in the development of
_________________________________________________________
______________________________________________________________________
NOW, THEREFORE, in consideration of the mutual promises and covenants contained herein and for good
and valuable consideration, the receipt and sufficiency of which are hereby acknowledged and intending
to be legally bound hereto, the parties hereby agree as follows:
I. SCOPE
A.
AGENCY 1 RESPONSIBILITIES:
AGENCY 1 agrees to undertake the following responsibilities with respect to the Affiliation
Agreement:
1.
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