Professional Documents
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MO3 - Preparing Raw Material
MO3 - Preparing Raw Material
January, 2023
Addis Ababa, Ethiopia
I
Table of Contents
Instruction sheet
This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:
Identifying hazards in the work area
Preparing bulk material storage to OHS standards.
Selecting, using and maintains suitable personal protective equipment.
Cleaning bulk material storage.
Checking bulk material storage for structural safety, damage or deterioration.
Preparing temporary storage to organization OHS standards.
Selecting, checking and maintain tools and equipment
Identifying environmental implications in the bulk material storage area
This guide will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
Identify hazards in the work area
Prepare bulk material storage to OHS standards.
Select, use and maintain suitable personal protective equipment.
Clean bulk material storage.
Check bulk material storage for structural safety, damage or deterioration.
Prepare temporary storage to organization OHS standards.
Select, check and maintain tools and equipment
Identify environmental implications in the bulk material
Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below.
3. Read the information written in the information Sheets
4. Accomplish the Self-checks
5. Perform Operation Sheets
6. Do the “LAP test”
Information Sheet 1-
C, Electrical
Shocks from live wires and malfunctioning equipment can happen with no warning and can easily be fatal. The
urgency and danger of electrical hazards underlines the importance of taking the appropriate preventive
measures.
Tips on how to prevent electrical injuries:
Maintain electrical installations, replacing damaged cables and appliances immediately.
Have electrical appliances inspected and recertified according to legislation and manufacturer
instructions.
D, Fire
Poorly maintained electrical equipment can lead to fire, which can cause burns at varying degrees and even
death. Fire is a hazard that can happen in almost any workplace so fire extinguishers should be accessible and
regularly maintained at all times.
Tips on how to prevent fire injuries:
Have fire extinguishers at various accessible locations. Fire-resistant workwear should be ready and
flammable materials should be handled with care.
F, Physical
This includes slips, trips, cuts, and other physical injuries from uneven surfaces and cluttered work
environments. These are the most common work-related hazards, and usually the least dangerous. Nevertheless,
the possibility for more serious injuries is ever-present and puts older and disabled members of your team at
greater risk.
G, Ergonomic
Sprains, body fatigue, and wear can accumulate over time due to repetitive tasks and awkward postures. This can
result in chronic conditions that require physical therapy to correct. They can also have a drastic adverse effect
on employee morale, as those who suffer from these ailments will associate work with the pain.
J. Noise
Machinery in food processing plants is noisy. The loud noise can inhibit clear communication among workers,
increasing the risk of injury. It can also cause long-term hearing loss. Hearing damage or loss can occur from
progressive and ongoing exposure to loud noises, such as from heavy machinery or other loud sounds.
13
A. Bulk Storage
Grains can be stored and preserved as bulk in both vertical and horizontal warehouses. In this
method, the surface of bulk stack cereals (wheat, barley, rye, oat, corn, chickpea and lentil) is levelled
properly. It is possible to store more grain on unit area. It also facilitates the control of grain samples
easily, has less labour cost and provides the time-saving.
B. Storage Underground
Underground pits are claimed to keep grain without damage for many years. The pits keep grain cool,
and some of them are relatively airtight. Grain on top and around the sides can however often be
mouldy. In this method, hay, stalk, polyethylene, apron, etc., are placed both under and also on the
cereal before covering with soil. This technique provides the grain not to contact with air, i.e., oxygen
(O2) during storage period. However, the weather conditions and the position of ground should be
considered carefully not to be exposed to any damage on cereals. Nowadays, the storage underground
is not preferred in the cereal industry.
C. Storage in Bag.
For long-term storage period, some types of cereals (rice, flour, legume, etc.) are unfavourable for
bulk storage, so they are put into bags (sacks) for keeping quality. The moisture content of cereal is
the critical factor on this technique. If the moisture content in cereal is increased, the number of sacks
in cereal stock is decreased. In this method, it is easy to number the sacks and to take sample from
each sack, but it is difficult to control the products as they are in bags. Besides, less amount of cereals
are stored on unit area when compared to the bulk storage technique. This method is also more
expensive due to high labour cost and more time-consuming causing to easier rodent damages
E. Storage in Silo
The most preferred storage technique in plants is to store the grain in silos. It has many advantages
due to less labour cost and less time-consuming depending on easy discharge and conveying of
cereals and keeping hygienic conditions during these processes. As the silos are vertical, more
products are stored on the unit area. There are three types of silos made of wood, concrete and steel.
Wood silos are not suitable for preservation, as they are susceptible to fire and favourable for the
insect surviving. Concrete silos are ideal to store cereals, as they are required less labor cost and less
time for storage. Steel silos (Fig. 1.8) and galvanized silos are the most common used stores, because
they are more resistant and easier controlled when compared with the others. Wheat, barley, rye, oat,
etc., could be stored conveniently both in concrete and steel silos.
Where exposure to machinery and equipment hazards cannot be eliminated or substituted for
machinery and equipment of improved design, risk controls must be applied to the hazards to Prevent
or reduce the risk (chance) of injury or harm. Workplace health and safety laws require the highest
order control be applied. Higher order machinery and equipment risk controls are preventative by
nature, are effective and durable for the environment it is used in, and deal directly with the hazard at
its source.
Lower order machinery and equipment risk controls, such as personal protective equipment. The
action of moving parts may have sufficient force in motion to cause injury to people. Must be
provided with safe access that is suitable for the work they perform in, on and around machinery and
equipment. A stable work platform, suited to the nature of the work that allows for good posture
relative to the work performed, sure footing, safe environment and fall prevention (if a fall may
occur), is a basic requirement
Glove
Rubber boots
Whichever kind of storage method a farmer uses, there are certain principles upon which every
method is based. Every storage container, no matter what it looks like or what it is made of,
should:
Keep grain cool and dry
Protect grain from insects
Protect grain from rodents
Cleaning machinery before and after harvest prevents the breeding of insects. Headers are
especially important in maintaining the hygiene of grain stored on farm, as they are known to be
the most common source of infestation in on-farm storage. The time and effort involved in
cleaning a header is well spent, because it will minimize insect infestation. Some growers clean
the header by flushing it out with the first batch of grain. This is inadequate as there are always
some insects which remain and the flushing grain may contaminate other grain. After cleaning
out and disinfesting the header, treat it with dry acid powder as per label rate and directions.
After cleaning out augers treat with Dry acid powder or Alarcon as per label rate and directions.
Grain insects will hide in dark crevices, under grass and leaves surrounding storage areas,
between steel sheeting joints in silos and sheds, around inlets and outlets, inside conveyors and
headers or wherever grain is stored. Sheds and bulk stores usually have areas which retain
significant amounts of grain and dust and require careful cleaning. Older silos too often have
poor 'grain shedding' joins and ledges. Bags should also be kept clean of grain residues or else
thrown out. Grain spilt during loading and unloading should be cleaned up and destroyed straight
away. Areas around storage structures and equipment should be kept clean and weed free, to
assist in removing grain spills. It is essential to plan a cleaning program and to have specific
cleaning equipment. Equipment, which need not be expensive, would include an air compressor
and fittings, air guns, vacuum cleaner, firefighting pump and hose and brooms.
Effective machinery and equipment risk controls reflect some or all of the following
characteristics:
The hazard is controlled at its source
Contact or access to the hazard is prevented
Sturdy construction (correct materials with few points of potential failure)
Fail-safe (failure of the control system to be effective will result in machinery shut-down)
Tamper-proof design (as difficult as possible to bypass)
presents minimum impediment to machinery and equipment operator
Easy to inspect and maintain
To put preventive maintenance into practice, the following actions are needed:
Identify priority machinery which have components that wear out more frequently
Make a clear description of the procedures and standards for the work of machine
operators and maintenance workers (such as lubricating, tightening bolts,
adjustmentsetc.) In daily, weekly and monthly routine maintenance plans
Organize a schedule and train staff to implement maintenance plans.
Prepare a maintenance budget
Record inspection results, analyses the records and evaluate the success of maintenance
Continuously update procedures and standards.
Name…………………………….. ……………………….ID………………………….Date……
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 1 hour. The project is expected from each student to do it.
Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below.
3. Read the information written in the information Sheets
4. Accomplish the Self-checks
Information Sheet 2-
Cleaning bulk material storage is a process to maximize the efficiency of storage silos that hold
bulk powders or granules. In silos, material is fed through the top and removed from the bottom.
Typical silo applications include animal feed, industrial powders, cement, and pharmaceuticals.
Free movement of stored materials, on a first-in, first-out basis, is essential in maximizing silo
efficiency. The goal of silo efficiency is to ensure that the oldest material is used first and does
not contaminate newer, fresher material. There are two major complications in silo efficiency
that are holing and bridging. Rat holing occurs when powders adhere to the sides of silos.
Bridging occurs when material blocks at the silo base.
Manual cleaning is the simplest way to clean silos. This entails lowering a worker on a rope to
free material inside the silo. Manual cleaning is dangerous due to the release of material and the
possible presence of gases. In cases of bridging, an additional danger exists as the exit hole needs
to be robbed from underneath, exposing the worker to falling powder
There are many reasons to choose our cleaning process, including:
Maintains longevity and structural integrity of bin
Utilizes and increases storage and inventory capacity
Less down time, resulting in larger profit margins
Increased efficiencies of associated mechanical components
Reclamation of material in bins
2.1.2 Factors controlling the cleaning operation-size, shape, specific gravity and
surface characteristics
The differences between crop material and the contaminants in physico-mechanical properties
are used to clean rand grade grains. These properties include;
1. Grains size (length, width, thickness)
2. Mass of grain (bulk density, difference in weight)
3. Nature and properties of surface
4. Shape
5. Aerodynamic properties
6. Surface texture
7. Colour
8. Electromagnetic properties
9. Affinity for liquid Seed Conductivity
One common type of bulk material handling system is the system that handles materials for
manufacturing. For instance, saw mills and paper mills often use bulk material handling systems
to pick up sawdust, logs and woodchips for further manufacturing. This type of bulk handling
system is also used to feed coal-fired utility boilers and in flour mills. Similarly, other bulk
material handling systems are designed to transport materials for processing. This is the case
systems that process ore for concentrating and smelting. Still other systems are designed simply
to transport bulk materials from a source location to a final location. This is quite common when
the goal of an application is inventory control or when the goal of an application is inventory
storage.
Whichever kind of storage method a farmer uses, there are certain principles upon which every
method is based. Every storage container, no matter what it looks like or what it is made of,
should:
• Keep grain cool and dry.
• Protect grain from insects.
• Protect grain from rodents.
Materials storage equipment from huge storage silos to small bins or hoppers, a bulk material
handling system should have a location where materials are stored until they are needed for
processing. Harvesting equipment are the machines which are used for cutting and harvesting the
crop to separate the grain from straw. Harvesting is the process of cutting and collecting the
mature crop from the field. The goal of good harvesting methods is to maximize grain yield, and
to minimize grain damage and quality deterioration. Bulk material handling machinery is cleaned
free of contamination and residues according to organization requirements.
Maintaining cleanliness and organization in the workplace is not easy. But it‟s something you
may not be giving enough thought. The fact is, the cleanliness and organization of your
workplace have a substantial impact on business and the well-being of your workforce. One
thing is certain: workplace safety should be a top priority at all times. Slips and falls are the
leading cause of workers‟ compensation claims. Illness is the No. 1 reason why employees call
off work. Employees can‟t be productive if your environment is grimy and in disarray.
All available information regarding characteristics that could result in potential health risks are
included in this process. After this, the raw materials are tested in vitro if required, using all
relevant test procedures (e.g. cell cultures to obtain additional findings about interactions with
living systems). This phase of the assessment process also allows us to dispense entirely with
animal experiments for our cosmetic products. Once raw materials have been classified as safe
according to these assessments, their skin compatibility in product applications is tested using
volunteers. In the subsequent manufacture of our products, continuous optimization of
occupational safety is of as much importance as compliance with the most stringent hygiene
standards. We also take steps to ensure that our manufacturing processes are as environmentally
friendly as possible.
To ensure we always keep abreast of the latest research, we maintain an in-depth dialog with the
scientific community, government authorities and public organizations. Our relationships with
product safety and environmental interest groups are just as important.
We analyze new findings and pointers from scientific literature, the media and interest groups for
the irrelevance to our safety assessment. If such data leads to a reassessment of a material, the
necessary measures are implemented within an appropriate time frame.
Material scheduled for rework shall be identified as such equipment, containers, and utensils
used to convey, hold, or store raw materials, work-in-process, rework, or food shall be
constructed, handled, and maintained during manufacturing or storage in a manner that protects
against contamination. Effective measures shall be taken to protect against the inclusion of metal
or other extraneous material in food. Compliance with this requirement may be accomplished by
using sieves, traps, magnets, electronic metal detectors, or other suitable effective means.
i. Moisture content.
ii. Hectolitre mass.
iii. Foreign matter.
iv. Percentage of coloured, broken and damaged grains.
v. Milling quality.
vi. Protein and oil content.
vii. Vigour.
viii. Mycotoxins.
ix. Presence of insects and fungi.
A.Purity Test
The objective of a purity test is to determine the percentage of pure seed in a sample and
quantifying the presence of contaminants such as weed seed, other crop seed, and inert matter, if
they are present. Purity test also includes the „All States‟ noxious weed exam. The minimum
sample size for purity test and noxious weed exam for cereals is 2 lbs.
B. Determination of Moisture
Weigh accurately about 5 gm of sample in a previously dried and tared dish and place the dish
with its lid underneath in the oven maintained at 130 – 133°C for 2 hours.
The time should be reckoned from the moment the oven attains 130°C after the dishes have been
placed. Remove the dish after 2 hours, cool in the desiccators and weigh.
C. Hectolitre mass
Hectolitre mass (HLM), also known as volumetric weight, is regarded as the most common and
easiest way of quantifying wheat. It measures the grain mass density and is expressed as mass
per volume. It is an important quality property because it provides an estimate of meal yield. The
HLM of grain is influenced by many factors, including climatic conditions during the growth
period of the grain, frost damage,climatic conditions during harvest and foreign matter in the
grain. The basic factors affecting the HLM are grain size and shape, grain density, maturity of
wheat, diseases and cultivar.
D.Determination of Gluten
Procedure
Weigh 25 gm sample into a dish and add about 15 mL of water to it and make it into a dough
taking care that all the material is taken into the dough. Keep the dough gently in a beaker filled
with water and let it stand for 1 hour. Remove the dough and place it in a piece of bolting silk
cloth with an aperture of 0.16 mm ( and wash it with a gentle stream of water till water passing
through the silk does not give a blue colour with a drop of iodine solution. Spread the silk tight
Conditioning of grain before milling is important to ensure the proper separation of the
component parts of the grain and give a good yield of flour (or in the case of rice, a good
separation of the hulls). A quality control check on moisture content should be made moisture
content measurement, grains). Grain that is too moist should be redried. If it is too dry a small
amount of water is mixed in and the grain is stored for 1224 hours and tested again for moisture
content. Parboiling of rice and subsequent drying has beneficial effects on both the efficiency of
dehulling and the quality of rice after storage. It helps to prevent rice grains cracking and also
increases their resistance to insect attack. The main quality control points are the time of
parboiling and the rate of drying.
Starting materials should only be purchased from approved suppliers named in the relevant
specification and, where possible, directly from the producer. It is recommended that the
specifications established by the manufacturer for the starting materials be discussed with the
suppliers. It is of benefit that all aspects of the production and control of the starting material in
question, including handling, labelling and packaging requirements, as well as complaints and
rejection procedures are discussed with the manufacturer and the supplier.
The main aim of inspection is to prevent the production of non-standard items. The inspection of
materials is today of utmost importance and both quality and quantity must thoroughly be
checked and inspected. It is important upon receiving a shipment to make sure that the material
meets quality specifications. If it is of great importance that no defects in quality exist, you will
probably want to run a quality check on each item of the entire shipment. In manufacturing
In general, sampling is conducted in such a way that the sample represents the population, but in
the same case a sample is taken from an especially good or bad section. Without understanding
the sampling method of the test sample, one cannot evaluate correctly about the quality of the
material being inspected. By the result of some sort of a test of a portion of the material with its
The invention relates to a method for preparing edible cereal grain including, consecutively: a
soaking step, during which the moisture of the cereal grain is increased to at least 20%; a step of
cooking the cereal grain; a step of drying the cereal grain, during which the moisture of said
cereal grain is reduced to less than 30%; a step of flattening the cereal grain; and a step of
expanding the cereal grain, characterized in that the method includes a step of heating the cereal
grain, during which the temperature of said cereal grain is increased so as to modify the plasticity
properties of said grain in order to facilitate the flattening thereof. The invention can be used in
the industrial preparation of food products, in particular of cereal grains.
The present invention relates to the general technical field of the industrial preparation of food
products within a production line, in particular the preparation of cereal grains intended for
human and / or animal consumption, for example grains of rice .The present invention relates in
particular to the general technical field of processes for preparing a cereal grain in a production
line intended, for example, to pre-cook said cereal grain, in particular by causing at least partial
gelatinization of the cereal grain. Starch it contains. The present invention relates more
particularly to a process for preparing a cereal grain intended for human and / or animal
consumption, comprising successively a soaking step during which the moisture of the cereal
grain is increased to at least 20%,a storing step during which the cereal grain is subjected to a
steam treatment, in order to gelatinize, at least in part, the starch contained in said cereal grain, a
step of drying the cereal grain during which the moisture of said cereal grain is reduced to less
than 30,a step of flattening the cereal grain during which the dimensions of said cereal grain are
modified.
Important of seed test for storage
To specify the standardized products
To prepare export commodity standards
To control exporters, surveyors and inspectors
To provide inspection service
Rotate stock and store according to FIFO (first in, first out) method assumes that products are
withdrawn from inventory in the order in which they are received and entered into storage.
Therefore, the products that remain in storage are judged to be the most recently purchased
items. The value of inventory becomes the cost of the most recently purchased products.
LIFO (last in, first out) method assumes the reverse of the FIFO method. The products most
recently purchased are used first. The value of inventory is represented by the unit cost of items
in inventory the longest.
Learning Instructions:
1) Read the specific objectives of this Learning Guide.
2) Follow the instructions described below.
3) Read the information written in the information Sheets
4) Accomplish the Self-checks
There are four sets of records that should be kept by the owner of a small cereal processing unit.
Keeping records is an investment of time and money and this must be related to the scale and
profitability of the business (the benefits must outweigh the costs.
This means that the processor must understand why the information is collected and what it can
be used for. Processors should also put in place a system of checks to ensure that one person
does not have responsibility for a whole area of record keeping. For example the person who
keeps records of ingredient purchases should be different to the person who records levels of
stocks and manages the storeroom.
Collecting Waste
Collection is a part of the process of waste management. It is the transfer of solid waste from the
point of use and disposal to the point of treatment or landfill. Waste collection also includes the
curbside collection of recyclable materials that technically are not waste, as part of a municipal
landfill diversion program. Waste is collected and disposed of or recycled to minimize damage to
the external environment. Collecting and disposing waste
A. Recycling waste
Recycling of waste is defined as any recovery operation by which waste materials is reprocessed
into products, materials or substances whether for the original or other purposes.
It includes the reprocessing of organic material but does not include energy recovery and the
reprocessing into materials that are to be used as fuels or for backfilling operations.
B. Disposing Wastes
Waste is collected and disposed of or recycled to minimize damage to the external environment.
Tools and equipment are cleaned and store according to organization work procedures. Disposal
includes burning, burial at land fill site orates, and recycling the collection, processing, and
recycling or deposition of the waste materials of human society. Waste is classified by source
and composition. Broadly speaking, waste materials are either liquid or solid in form, and their
components may be either hazardous or inert in their effects on health and the environment.
Cereals generate huge agriculture as well as agri-industrial wastes across the globe. If not
managed judiciously then in long run, that may lead to the environmental pollution and global
warming. Open burning of agricultural wastes is detrimental to both environment and human
health. Poisonous gases like carbon dioxide (CO2), carbon monoxide (CO), sulfur oxides (SOx),
C. Composting
Composting is the method of aerobic or anaerobic decomposition of organic solid wastes. It is
not new; rather, it has been the oldest practice of recycling the plant nutrients in the soil. Small
scale backyard composting is a usual practice in many developing and underdeveloped countries.
Up till now, composting had not gained the status of agriculture industry. But with the gaining
popularity of organic farming or eco-farming, its demand has increased these days. Its bulkiness,
low nutrient content and high labour requirement are the major challenges in undertaking such
organic waste composting projects. However, on-site composting without transportation of crop
residues could be the befitting answer for maintaining soil fertility and sustaining crop
production in long run. Compost improves bio-physiochemical properties of the soil while the
need for synthetic fertilizers and plant protection measures could be eliminated completely. Its
application improves nutrient uptake and cycling, soil microbial activity and biodiversity, and
deficit moisture stress conditions as it regulates soil pH, improves soil texture, structure and
aggregates, increases water holding capacity, caution ion exchange capacity and soil biodiversity
It reduces soil erosion, protects crop against soil borne diseases, increase carbon sequestration
and reduce compaction. Composting releases heat during thermophyllic stage that kills most of
the pathogens, insect larvae and eggs, and weed seeds
1. Which of the following are important time for cleaning of tools and equipment
A/ before work activity is carried out B. After a work activity is finished
C/ between work activities if needed D all E none
Reference Materials
Books
1) Bucklin, R., Thompson, S., Montross, M., and Abdel-Hadi, A. 2013. “Grain Storage
Systems Designs. “In Handbook of Farm, Dairy, Food Machinery Engineering. New
York, USA: Elsevier, 123-75.
2) Miller Magazine. 2016. “Grain Storage and Healthy Storage Conditions.” Accessed
August5, 2016.http://www.millermagazine.com/english/grain-storage-and-healthy-
storage-conditions/.
3) Said, P. P., and Pradhan, R. C. 2014. “Grain Storage Practices: A Review.” J. Grain
Process. Stor. 1 (1): 1-5.
4) Zelinger, J., Heidingsfed, V., Kotlík, P. & Šimúnková, E., Chemie v práci konzervátora a
restaurátora, 2nd edn, Academia: Prague, 1987
Webes adders
1) https://pdf.usaid.gov/pdf_docs/PNABM939.pdf (acces 15/1/2023(access 18/1/2023
2) https://www.osha.gov/shpguidelines/hazard-Identification.html#ai3( Access 18/12032
3) https://keesafety.sg/news/10-top-workplace-hazards-and-how-to-prevent-them (access
19/1/2023
Ministry of Labor and Skills wish to extend thanks and appreciation to the many
representatives of TVET instructors and respective industry experts who donated their time and
expertise to the development of this Teaching, Training and Learning Materials (TTLM).