Lesson 1Blending and millstream recombination: blending logic to meet extraction/ash targets, use of midstreams and tailstreamsThis section explains blending millstreams to meet flour specs. It covers core, mid, tail streams, ash and colour profiling, extraction goals, and automated scales and recipes for steady 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 labelingThis section covers packing, labelling, and storing finished flour to keep quality. It explains moisture and oxygen control, packaging, traceability, and warehouse practices against bugs, caking, and 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 controlThis section covers flour conditioning and fortification post-milling. It discusses tempering for even moisture, adding vitamins, minerals, improvers, silo conditions, aeration, and microbe controls 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 airflowThis section spots control points where bad settings hurt yield or quality. It focuses on tempering moisture and time, break and reduction roll gaps, differentials, and sifter mesh and airflow 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 sizeThis section describes sifting systems design and operation, plansifters and plansackers. It explains sieve arrangement, purifier integration, and sifting plans for ash, granulation, and stream 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 ops to prep wheat for tempering. It covers scalping, aspiration, destoning, magnetic separation, scourers, settings to remove dust, stones, metals, seeds while saving 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 logisticsThis section explains grain reception from truck to silo. It details sampling, quality and safety tests, grading, quality class separation, and 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 considerationsThis section examines break system opening kernels with low flour damage. It covers roll surfaces, corrugation, spiral, gap and differential settings, feed control for clean endosperm, less bran powder, 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 reduction system grinding middlings to flour. It covers smooth rolls, gradual sizing, feed distribution, starch damage and heat control, reduction sequencing.
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 cleaning middlings. It explains air flow, vibration, sieve selection for bran removal, settings for semolina purity, yield, surface clean, bran reduction.
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 before milling. It explains moisture addition, targets for wheats, time and temp effects on bran toughness and endosperm friability, soaking times and controls.
Moisture addition and target calculationsTempering time and temperature effectsSingle versus multistage temperingMonitoring kernel hardness and friabilityTypical soaking times and adjustments
