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Sunil MaheshwariSiemer Milling Company
West Harrison, Indiana USA
Building the USA’s New Flour Mill Innovative Milling Solutions
1906: Joseph & Clemens J. Siemerbuy out other interests & establish Siemer Milling Company
1950’s: Business commits to flour milling exclusively
1979: New mill opens in Teutopolis, Illinois to meet demand
… and expands by another 80% in the next 20 years. va
More than 135 years of food ingredient history …
SMC Mission Statement Core Purpose:
Through personal professionalism, we deliver best-value food products to improve the quality of life.
Core Values:o We work with exceptional people to create satisfying
relationships through respect, trust and responsibility (RTR). o We strengthen these relationships through continuous
improvement and a commitment to excellence.
• One of the most dramatic changes took place in 2000, when an Employee Stock Ownership Plan was established.
• A significant percentage of company stock is now held in trust with all eligible employees as beneficiaries, so that company success will be translated into greater financial security for the participants.
Family/Employee Owned
Siemer Milling Company Locations …in America’s Heartland
Hopkinsville, KY
Teutopolis, IL West Harrison, IN
o 1,000,000 lbs of flour per dayo 210,000 Tons of wheat used per yearo 78,000 Tons On-site wheat storageo 21,000 Tons Off-site wheat elevator
Siemer Milling CompanyTeutopolis, IL
Built 1979
Siemer Specialty IngredientsHeat Treatment Facility
Teutopolis, ILPlant 1: Built 2003Plant 2: Built 2015
o 110 Million lbs per year
o Bulk, Super-Sack, Bag
o Food Safe and Functional Flour
o 1,600,000 lbs of flour per day
o 300,000 Tons of wheat used per year
o 90,000 Tons On-site wheat storage
Siemer Milling CompanyHopkinsville, KY A Mill: Built 1995B Mill: Built 1998C Mill: Built 2009
Siemer Milling CompanyCorporate Office
Teutopolis, ILBuilt 2014
Siemer Milling CompanyResearch Center
Teutopolis, ILBuilt 2017
Strategies for the Selection of the New Location
• Access to the Highway• Access to the Railroad• Closeness to the Wheat Supply• Closeness to the Customers• Other Considerations
Siemer Milling CompanyWest Harrison, Indiana
From Start to Finish
o 1,000,000 lbs of flour per day
o 210,000 Tons of wheat per year used
o 28,800 Tons On-site wheat storage
o 4,370,000 lbs Flour Storage
Siemer Milling CompanyWest Harrison, Indiana
Built 2015
Key Points
Newest Technology Automated/Easy Operation Sanitary Design Energy Efficient Food Safety
Planning for Mill Design
• Simpler Housekeeping• Improved Food Safety• Improved Industrial Safety and Security• Steps taken to eliminate product recalls.• EPA and OSHA Compliance Considerations• Fumigation friendly design
Site Layout
Floor Layout
• Intake and Storage• Allocation of Wheat Storage• Effective Pre-Cleaning• Appropriate Sampling for Quality
• Availability of Appropriate Quality Testing• Visual, TW, Protein, Moisture, FN, Vomitoxin
Planning for Wheat Intake
F C
WT
CLCL
P S
S C
F C
F C
S C
CL
F C
Wheat Intake
Planning for Cleaning and Tempering
• Cleaning and Tempering• Contingencies for Future
Expansion of Capacities• Selection of Cleaning Equipment
to Help Raising the Standards of Food Safety
WT
SC
PS
CL
SCFC
S
FC
WTWTWTWT
CL
TSVS
SCSC
CL
FC FCFC
WT
SC
PSPS
SC
WT
WT
SS
FCFC
CL CLCL
FC
S
S
CL
CL
CL
FC
S
SC
S
S
Cleaning Flowsheet
• Milling• Mill With or Without Purifiers• Any specific design measures to improve cleaning of bran and thereby
increase flour extraction.• Grades of Flour and Treatment (Chlorination)• Specific Safety Measures Related to Chlorination
Planning for Milling-Blending and Treatment
• Flour Blending and Treatment• Any specific design measures to improve flour blending and
treatment, if applicable.
Planning for Milling-Blending and Treatment
• Product Handling and Disposal• Bulk and Bagged Delivery
• Allocation of Finished Products Storage Space• Incorporation of Advanced Warehousing Practices
Planning for Product Handling
• Overall Efficiency in all Areas of Planning Included the Following Considerations:
• Low Energy• Low Maintenance and reduced downtime• Equipment Design to Support High Sanitation Standards – Leading
to Enhanced Food Safety• Equipment Reliability for High Level of Performance
Planning for Milling Efficiency
Equipment Selection and Supplier
• These selections were made on the basis of requirements.• The automation and On-line monitoring system was also
selected to meet those requirements.• Report generation for performance evaluations and audit.
Newest Technology
• Mill was the first of its kind in the USA.• Most advanced milling equipment (lights-out).• Ability to operate mill remotely.• Wi-Fi in mill to allow remote operation of equipment.• Utilized cable trays instead of conduit.
Automated/Easy Operation
• PLC utilizing Buhler Wincos R2 Program.• The automation allowed us to start and operate the mill with
a group that had never worked in a flour mill before. Group of experienced millers guiding the new millers.
• Programming minimizes chance of operator error.• Online NIR monitors quality and consistency.
Sanitary Design• Antares Roller Mill
• Stainless steel housing around roller mill. • Unit is sealed. • Aspiration is recycled air from pneumatic
line below.• Easy access to area behind feeder rolls for
quick sanitation.• Low noise level.
Sanitary Design
• Sirius Plansifter• No wood in process.• All sieves are molded Novapur frames.• No seams or joints• No fasteners• Tight sieve stack• No under wire, which lowers height of sieve.
Which in turn, allows more sieves and sifting surface.
Energy Efficient Equipment
• Aspirators• All of the aspirators used in 1st and 2nd cleaning are recycled air
aspirators. This gives us up to 50% energy savings.
• Blower motors and exhaust fan motors• Are all on Variable Frequency Drive (VFD) controllers. Programmed
soft starts use less energy.• Filter Exhaust Fans are programmed to a Pascal setting and use less
energy after new filter sleeves are installed.
Evaluation of the Project upon Completion
• Completed on Time• Completed on Budget• Startup Hiccups
Major and Minor Challenges Involving the Project• Hiring qualified people and training them.• Educate with Global Food Safety Initiatives and FSMA.• Plant was installed according to time schedule intended.
Coordination of work done with daily meetings and intense communication level during construction.
• 2nd transfer system installed soon after new construction was completed. Challenging to keep up with 1 transfer system delivering to Bulk load out, Packing Storage, with 1 System in the beginning.
Lessons Learned and Recommendations
• Temperature and Humidity control.• New plant allowing high production efficiency in regards to
$/Tons produced.• High extraction rate due to streamlined and tailored flow
sheet for products the plant is designed to produce.• Tailored Automation solution allowing operators to manage
production schedule flexibly and with minimal human interaction.
• Minimize Risk by working with your preferred suppliers.
West Harrison, Indiana(October, 2013)
West Harrison, Indiana(November, 2013)
West Harrison, Indiana(February, 2014)
West Harrison, Indiana(March, 2014)
West Harrison, Indiana(June, 2014)
West Harrison Mill1st Floor
West Harrison Mill2nd Floor
West Harrison Mill3rd Floor
West Harrison Mill3rd Floor
West Harrison Mill4th Floor
West Harrison Mill5th Floor
West Harrison Mill6th Floor
West Harrison Mill7th Floor
Products using Flour from the Teutopolis, Illinois Mill
Products using Flour from the Hopkinsville, Kentucky Mill
Products using Flour from the West Harrison, Indiana Mill
Products using Heat Treated Flour from the Teutopolis, Illinois
Heat Treatment Facility
Brands using Siemer Milling Flour
Thank You for Your Attention.
Sunil MaheshwariVice President SSISiemer Milling Co.
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