Lesson 1Blending and millstream recombination: blending logic to meet extraction/ash targets, use of midstreams and tailstreamsExplains blending millstreams for flour specs. Covers core/mid/tail streams, ash/colour profiles, extraction aims, auto scales/recipes for steady 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 labelingCovers packing, labelling, storing flour to keep quality. Moisture/oxygen control, pack materials, tracking systems, warehouse tips against bugs, clumping, dirt.
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 controlPost-milling flour conditioning/fortification. Tempering for even moisture, vitamin/mineral/improver adds, silo conditions, air flow, germ control for safe 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 airflowKey spots where bad settings hurt yield/quality. Temper moisture/time, break/reduction roll gaps/diffs, sifter mesh/air for ash, starch damage, specks.
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 sizeDesign/operation of sifters/plansackers. Sieve setups, purifier links, plans controlling ash, granulation, stream sorts.
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 settingsCleaning prep for tempering. Scalping, aspiration, destoning, magnets, scourers; settings remove dust/stones/metals/seeds, save good grain.
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 logisticsGrain intake from truck to silo. Sampling, quality/safety tests, grading, quality splits, blending for steady milling.
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 considerationsBreak system opens kernels low damage. Roll types, corrugations, gaps/diffs, feed control releases clean endosperm, limits bran.
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 sequencingReduction grinds middlings to flour. Smooth rolls, step size cuts, feed/stock, starch/heat control, passage sequence.
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 tuningPurifiers/scourers clean/grade middlings. Air/vibe/sieves remove bran, settings for purity/yield, scour cuts surface 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 timesPre-mill conditioning/tempering. Moisture calcs, targets per wheat, time/temp on bran/endosperm, soak times/controls.
Moisture addition and target calculationsTempering time and temperature effectsSingle versus multistage temperingMonitoring kernel hardness and friabilityTypical soaking times and adjustments
