Lesson 1Blending and millstream recombination: blending logic to meet extraction/ash targets, use of midstreams and tailstreamsThis section explains how millstreams are blended to meet flour specifications. It covers classification of core, mid, and tail streams, ash and colour profiling, extraction targets, and the use of automated scales and recipes to maintain consistent flour quality.
Classification of millstreams by qualityAsh, color, and protein profilingBlending logic for extraction targetsUse of midstreams and tailstreamsAutomated scales and recipe controlLesson 2Finished flour packing and storage: protecting against moisture uptake and oxidation, traceability and labellingThis section covers how finished flour is packed, labelled, and stored to preserve quality. It explains moisture and oxygen control, packaging materials, traceability systems, and warehouse practices that prevent infestation, caking, and contamination.
Bagging lines and bulk loading systemsPackaging materials and barrier propertiesMoisture and oxygen control in storageLabeling, coding, and traceability recordsWarehouse hygiene, pests, and stock rotationLesson 3Flour conditioning and fortification: tempering, emulsifier or improver additions, storage in silos and microbial controlThis section covers flour conditioning and fortification after milling. It discusses tempering for moisture uniformity, addition of vitamins, minerals, and improvers, silo storage conditions, aeration, and microbial control measures that ensure safe, stable flour.
Post-milling flour tempering objectivesVitamin and mineral premix handlingEmulsifiers and functional improversFlour silo design and aeration controlMicrobial risks and mitigation stepsLesson 4Critical control points where poor settings harm quality: conditioning moisture/time, roll gaps and differential, sifter mesh/openings and airflowThis section identifies critical control points where poor settings damage yield or quality. It focuses on tempering moisture and time, break and reduction roll gaps and differentials, and sifter mesh and airflow settings that govern ash, starch damage, and speck count.
Tempering moisture targets and timingRoll gap setting and differential controlFeed rate, roll wear, and temperatureSifter mesh selection and maintenanceAirflow balance and tailing managementLesson 5Sifting plans and plansacker operation: plans, purifier passages, and how sieving fractions are arranged to control ash and particle sizeThis section describes the design and operation of sifting systems, including plansifters and plansackers. It explains how sieves are arranged, how purifier passages are integrated, and how sifting plans control ash distribution, granulation, and millstream classification.
Plansifter layout and flow diagramsSieve cloth selection and maintenancePlansacker operation and bag changeoverPurifier passages within the sifting planGranulation and ash control by streamsLesson 6Cleaning: equipment (scourers, aspirators, destoners, magnetic separators, sieves), objectives and typical operational settingsThis section reviews cleaning operations that prepare wheat for tempering. It covers scalping, aspiration, destoning, magnetic separation, and scourers, along with settings that remove dust, stones, metals, and foreign seeds while minimising sound grain loss.
Cleaning flow sheet and line layoutScalpers, sieves, and aspiration unitsDestoners and gravity separationMagnetic separators and metal controlScourers and surface dust removalLesson 7Grain reception and intake: sampling protocols, official tests to run on arrival, storage segregation and blending logisticsThis section explains grain reception procedures, from lorry arrival to silo allocation. It details sampling plans, official quality and safety tests, grading, segregation by quality class, and blending strategies that support consistent milling performance.
Truck inspection and unloading safetyRepresentative sampling and sample handlingOfficial quality and food safety testsGrading, rejection, and acceptance criteriaSegregation and blending in silo managementLesson 8Breaking system (break rollers): function, roll configuration, crack sizing, and typical roll gap/speed considerationsThis section examines the break system, where kernels are opened with minimal flour damage. It covers roll surface types, corrugation and spiral, gap and differential settings, feed control, and how break releases clean endosperm while limiting bran powder and specks.
Objectives of the break systemRoll surface, corrugation, and spiralBreak roll gap and differential settingsBreak release, sizing, and tailingsMonitoring bran powder and speck levelsLesson 9Reduction system (reduction rolls): gradual size reduction, control of starch damage, and reduction sequencingThis section analyses the reduction system, where middlings are ground to flour. It covers smooth roll configuration, gradual size reduction, feed and stock distribution, control of starch damage and heat, and sequencing of reduction and sizing passages.
Role of reduction versus break systemSmooth roll surface and feed distributionGradual reduction and stock recyclingStarch damage and temperature controlReduction and sizing passage sequencingLesson 10Purifiers and scourers: role in bran removal and semolina quality for high extraction; particle size and airflow tuningThis section focuses on purifiers and scourers used to clean and grade middlings. It explains how air flow, vibration, and sieve selection remove bran, how settings affect semolina purity and yield, and how scourers reduce surface contamination and adhering bran.
Purifier construction and working principleAirflow, deck load, and vibration tuningMiddlings sizing and sieve selectionSemolina purity versus yield tradeoffsScourer types and operating parametersLesson 11Conditioning/tempering: hydration targets, time/temperature effects on bran toughness and endosperm friability, typical moisture adjustments (1.5–3% increase) and soaking timesThis section details wheat conditioning and tempering before milling. It explains moisture addition calculations, target levels for different wheats, time and temperature effects on bran toughness and endosperm friability, and typical soaking times and controls.
Moisture addition and target calculationsTempering time and temperature effectsSingle versus multistage temperingMonitoring kernel hardness and friabilityTypical soaking times and adjustments
