Let’s start a conversation
We’re here to share more details and answer any question you might have. Our manager will contact you to provide all necessary information
We’re here to share more details and answer any question you might have. Our manager will contact you to provide all necessary information
Science never stands still: what once seemed like a fantastical and unrealistic goal has become an achievable reality today. Biotechnology is rapidly advancing in the grain processing industry, and its most logical application is to clean grain of contaminated hulls even before the milling process begins.
The GRAIN IMPROVERS team has succeeded not only in enabling effective hydrolysis of cellulose hulls during the conditioning stage and removing 2–8% of them using dehulling machines before milling. We’ve also achieved direct and complete control over the key properties of flour.
The primary goal of grain processing is to achieve consistent milling results, minimizing variations in grain quality and producing a final product that meets market demands.
Across all regions worldwide, producers strive to source grain that satisfies specific consumer needs while maintaining a balance between cost and the quality of the final product.
However, during the milling stage, significant losses can occur in yield, nutrients, protein structure, and starch quality — especially when intensive milling methods are applied.
During this process, subaleurone layer — rich in proteins, vitamins, minerals, and enzymes — is often lost along with the bran.
Regardless of the area of specialization in grain processing (whether it’s flour milling, oilseed processing, or advanced grain refinement) this issue poses a significant challenge for every enterprise.
The patented formula of GRAIN IMPROVERS finally addresses one of the most critical problems in the industry.
There are no alternative solutions that can effectively separate the hull from the endosperm while increasing yields without compromising flour quality.
GRAIN IMPROVERS offer an exceptional solution for grain processors to maintain profitability, even if high-quality grain is in short supply.
Our experience has demonstrated that GRAIN IMPROVERS not only enhance the final product but also create financial opportunities for mills to expand and grow their operations.
By maximizing protein and nutrient extraction while maintaining a balanced particle size distribution, your mill can purchase more affordable grain without compromising quality of the final product.
Effective separation of hulls from the kernel allows mills to increase the proportion of premium-quality flour by up to 2%, leading to a majorly improved overall yield.
By extracting the maximum nutritional value from the grain and improving the properties of the final product, producers can deliver higher-quality outputs. For example, in bread production, this approach significantly reduces the need for flour additives, enabling the creation of high-quality, natural products.
When it comes to grain quality, protein content and quality are undeniably the most important factors.
However, even grain with a high protein potential may not always be the best one to use. Other quality parameters can render its processing challenging — or even outright impossible.
What can a mill do when wheat has both high protein potential (around 15%) and an extremely elevated enzymatic activity?
When the falling number (FN) of grain at the mill is critically low — just about 140 seconds — it presents a significant challenge.
The 2024 harvest has been particularly difficult for farmers and processors due to heavy rains during the harvest period. It heightened the activity of the grain's endogenous enzymes, leading to a sharp drop in Falling Number.
This year, GRAIN IMPROVERS has already helped several large and medium-sized milling mills achieve what was previously thought impossible: processing grain with catastrophically low FN into premium-quality bread flour.
Let’s take a closer look at one such case.
The GRAIN IMPROVERS team has extensive experience in helping mills process problematic grain. However, this case was unique. Our client purchased a batch that included grain with a falling number (FN) of 200 seconds, but a portion of this shipment had an extremely low FN of just 140 seconds.
The decisive factor — whether to ditch or keep keep and process this grain separately — was its high protein content (14.5–15%).
The client’s technologists saw this as a professional challenge, decided to go for a production experiment, and turned to our team for assistance.
We are grateful to the mill’s technologists for their courage and commitment to achieving results.
Processing grain with an extremely low FN is a rare opportunity, and it was as intriguing for our team as it was for the mill.
To provide context, neither our technologists nor the mill’s team had ever worked with such challenging grain before.
Under normal circumstances, the standard for milling grain falls within the sweet spot range, with a falling number (FN) between 200 and 400 seconds:
Given the unconventional nature of this challenge, we decided to experiment with processing this grain specifically into bread flour, without blending it with higher FN grain. Our approach focused on innovation at every stage of the process:
For this experiment, our team chose GRAIN IMPROVERS Smart. This innovative enzyme complex is, essentially, a natural technological aid, composed of only the highest-quality food-grade enzymes.
The product is free from toxic substances, GMOs, and antibiotics, and it leaves no residues in the flour.
Like all grain improvers in our lineup, GRAIN IMPROVERS Smart enhances grain quality during the pre-milling stage:
All of it — by allowing water to penetrate beneath the hull efficiently.
Low-FN grain is characterized by high autolytic activity of its endogenous enzymes. Preserving the integrity of starch granules within their protective lipoprotein layer is a critical objective to reduce starch degradation by the grain’s natural amylases.
We adjusted the conditioning time to optimize the process for this specific grain:
The usual conditioning time for this mill was 24 hours. Based on positive global experience, we recommended reducing it to 10 hours. The rationale is straightforward: the higher the activity of grain amylases, the greater their potential for starch hydrolysis during resting periods. Therefore, when working with moisture-damaged grain, the industry standard is to shorten conditioning time.
The mill’s specialists were concerned about potential losses in flour whiteness and yield, and we understood this was a significant adjustment for a facility with well-established production processes. To address this, our team adopted a phased approach, initially reducing the conditioning time to 17 hours and then further to 10 hours.
Throughout the process, the laboratory team meticulously monitored flour yields and quality parameters to ensure the milling remained on track.
Looking ahead, this decision led to some fascinating results, as demonstrated by the farinograph data.
To further refine the process, we needed to adjust the sieve configurations. In global milling practices, it is a standard approach to produce coarser flour when working with damaged grain to mitigate the effects of the damage.
Based on this principle, the following adjustments were made sequentially at the mill:
These adjustments ensured that the milling process could accommodate the unique properties of the damaged grain, improving separation and maintaining product quality.
To process such complex grain, we needed to adjust the settings on the reduction systems:
It is well-known that entoleters significantly increase starch damage, which is unacceptable for grain with a falling number below 250 seconds, as it reduces rheological properties. With GRAIN IMPROVERS, the main function of entoleters is already handled during the dehulling stage.
Based on the quantity of grain in the milling batch and the planned settings, the entire cycle, from the first grind to the final result, took three full working days.
Despite all initial concerns, the processing of grain with an extremely low falling number was a success. Both our team and the mill’s technologists were completely satisfied with the outcomes.
The mill is equipped with a well-resourced laboratory, which allowed us to thoroughly analyze the resulting flour using various instruments.
Here’s an overview of the results:
A gentle milling method was employed to preserve starch granules and reduce enzymatic activity. The result is — a major increase in falling number (FN):
The experiment results also revealed intriguing rheological data. The farinograph demonstrated significant improvements when the conditioning time was reduced from 17 hours (Figure 1) to 10 hours:
Below is the farinograph data illustrating these results:
The goal of increasing overall flour yield was successfully met, with a total increase of +1.35%, and further growth potential remains. The breakdown of results is as follows:
The standard protein loss from grain to premium-grade flour with an ash content of 0.55% at this mill typically ranges from 1.7% to 2%.
However, within 6 hours of milling the batch treated with GRAIN IMPROVERS, we observed a significant reduction in protein loss.
After 14 hours, we achieved the maximum reduction for this mill:
Additionally, when testing gluten extraction, the mill noted an additional improvement in protein retention.
Laboratory instruments alone cannot always fully evaluate the baking properties of flour. This is why conducting laboratory baking tests is crucial—they provide a more objective assessment of milling results.
Bread baked from flour with an ash content of 0.55% and an FN of 211 seconds delivered impressive results:
Bread made from flour with an ash content of 0.65% and an FN of 188 seconds also demonstrated high quality:
The difference between traditional methods of grain preparation for milling and the results achieved using GRAIN IMPROVERS was evident to the naked eye.
Thanks to the client mill’s well-equipped laboratory, we were able to thoroughly analyze the results and reach a clear conclusion: the processing of extremely challenging grain was a success.
This case illustrates how careful removal of grain hulls and gentle milling can enhance mill efficiency, improve flour quality, and increase the value of bread for consumers.
Even with a falling number as low as 140 seconds, GRAIN IMPROVERS enables mills to achieve remarkable results:
Using GRAIN IMPROVERS Smart at just one stage of the grain processing workflow delivers benefits to every link in the value chain, enhancing product quality and adding value across all levels.
It’s not a secret that separating a germ from a grain of c...
It’s not a secret that separating a germ from a grain of c...
Excellent grinding results with Grain Improvers Optimum hav...
Excellent grinding results with Grain Improvers Optimum hav...
2015-2024
