Optimization of wheat blends for end use application. Ashok K. Sarkar Senior Advisor, Technology Can. Intl. Grains Institute Winnipeg, Canada

Transcription

1 Optimization of wheat blends for end use application Ashok K. Sarkar Senior Advisor, Technology Can. Intl. Grains Institute Winnipeg, Canada

2 Optimization of Wheat Blends for End Use Application 1. Wheat Evaluation Physical aspects 2. Quality Evaluation Functional properties Linear properties 3. Linear programming concepts and application Wheat/Flour blends formulation using linear programming 4. Multi blend optimization concepts Evaluate various scenarios where production of multiple blends need to be optimized that may use a specific wheat in limited supply

3 Optimization of Wheat Blends for End Use Application 1. Wheat Evaluation Physical aspects

4 Selection of wheat Wheat Type Wheat A Wheat B Wheat Cost per tonne, $ Foreign Material, %

5 Selection of wheat Wheat Type Wheat A Wheat B Wheat Cost per tonne, $ Foreign Material, % Natural Moisture, %

6 Selection of wheat Wheat Type Wheat A Wheat B Wheat Cost per tonne, $ Foreign Material, % Natural Moisture, % Flour Extraction, %

7 Selection of wheat Wheat Type Wheat A Wheat B Wheat Cost per tonne, $ Foreign Material, % Natural Moisture, % Flour Extraction, % Ash in Flour, %

8 Selection of wheat Wheat Type Wheat A Wheat B Wheat Cost per tonne, $ Foreign Material, % Natural Moisture, % Flour Extraction, % Ash in Flour, % Wheat Protein, % Falling number, sec

9 Selection of wheat Wheat Type Wheat A Wheat B Wheat C Wheat D Wheat E Wheat Cost per tonne, $ Foreign Material, % Natural Moisture, % Flour Extraction, % Ash in Flour, % Wheat Protein, % Falling number, sec

10 COST OF FLOUR DUE TO WHEAT COST COST OF A BAG OF FLOUR 40 Kg. FLOUR IS ~80 % DUE TO THE COST OF WHEAT

11 OPTIMIZATION OF WHEAT BLEND WHEAT EVALUATION QUALITY DATA EVALUATION USE OF LINEAR PROGRAMMING TO WORK OUT ECONOMIC SOLUTIONS

12 WHEAT EVALUATION 1. NATURAL MOISTURE CONTENT 2. FOREIGN MATERIAL 3. FLOUR EXTRACTION 4. FLOUR ASH CONTENT 5. OPTIMUM MILLING MOISTURE 6. MILLFEED PRICES

13 ASH CORRECTION + _ 0.01% ASH = 0.4% EXT. _ +

14 0.35 ASH % 0.50 Cumulative Ash Curve EXTRACTION 75

15 ASH % ASH % Cumulative Ash Curves EXTRACTION EXTRACTION 75

16 MOISTURE ADDITION WATER = WHEAT X (M2 M1) (100 M2)

17 Calculation of Cost of Flour Wheat Type Wheat A Wheat Cost per tonne, $ Foreign Material, % 0.75 Natural Moisture, % 12.9 Milling Moisture, % 16.0 Flour Extraction, % 74.8 Ash in Flour, % 0.5 Std. Ash Required, % 0.48 Ash Correction, % 0.4 Ash Corr. Extr., % 74.0

18 Calculation of Cost of Flour Raw Wheat, kg Less Foreign Mat., kg. 7.5 Clean Untemp. Wheat, kg Water to be Added, kg Clean Temp. Wheat, kg Flour Produced, kg Low Grade Flour % 0.00 Low Grade flour produced, kg 0.00 Milling Loss, % 1.75 Qty. of Milling Loss, kg Net Millfeed, kg Plus Foreign Mat., kg. 7.5 Gross Millfeed, kg

19 Calculation of Cost of Flour Market Val of Millfd / Tonne, $ 100 Value of Millfeed, $ Market Val of Low Grade Flour / Tonne, $ Value of Low Grade Flour, $ 0.00 Cost of Flour/ tonne of wheat gr., $ Cost of Flour/tonne, $

20 Wheat Evaluation Exercise Wheat Type Wheat A Wheat B Wheat C Wheat D Wheat E Wheat Cost per tonne, $ Foreign Material, % Natural Moisture, % Milling Moisture, % Flour Extraction, % Ash in Flour, % Std. Ash Required, % Ash Correction, % Ash Corr. Extr., % Raw Wheat, kg Less Foreign Mat., kg Clean Untemp. Wheat, kg Water to be Added, kg Clean Temp. Wheat, kg Flour Produced, kg Low Grade Flour % Low Grade flour produced, kg Milling Loss, % Qty. of Milling Loss, kg Net Millfeed, kg Plus Foreign Mat., kg Gross Millfeed, kg Market Val of Millfd / Tonne, $ Value of Millfeed, $

21 Market Val of Low Grade Flour / Tonne, $ Value of Low Grade Flour, $ Cost of Flour/ Wheat Evaluation Exercise tonne of wheat gr., $ Cost of Flour/tonne, $

22 Market Val of Low Grade Flour / Tonne, $ Value of Low Grade Flour, $ Cost of Flour/ Wheat Evaluation Exercise tonne of wheat gr., $ Cost of Flour/tonne, $ Using What-If Analysis Goal Seek Feature Gual Seek? X Set cell: C33 To Value: By Changing Cell $C$4

23 Market Val of Low Grade Flour / Tonne, $ Value of Low Grade Flour, $ Cost of Flour/ Wheat Evaluation Exercise tonne of wheat gr., $ Cost of Flour/tonne, $ Using What-If Analysis Goal Seek Feature Gual Seek? Set cell: C To Value: By Changing Cell $C$

24 Market Val of Low Grade Flour / Tonne, $ Value of Low Grade Flour, $ Cost of Flour/ Wheat Evaluation Exercise tonne of wheat gr., $ Cost of Flour/tonne, $ Wheat required for 1 tonne of flour, t Cost of wheat, $ Costof wheat after millfeed credit, $

25 QUALITY DATA EVALUATION EVALUATION OF DATA AFFECTING FUNCTIONAL PROPERTIES WHILE ALLTYPES OF QUALITY DATA SHOULD BE KEPT IN MIND, BUT ONLY THE DATA THAT ARE LINEAR SHOULD BE USED IN THE PROGRAM, SUCH AS ASH, PROTEIN AND LIQUEFACTION NUMBER

26 BLENDING FOR PROTEIN WHEAT A x 100 / ( ) = 80% WHEAT B x 100 / ( ) = 20%

27 BLENDING FOR PROTEIN WHEAT A x 100 /( ) = 60% WHEAT B x 100 / ( ) = 40%

28 LINEAR QUALITY DATA LINEAR NUMBERS ARE THOSE THAT FOLLOW MATHEMATICAL RULES FOR EXAMPLE, FALLING NO. IS NOT LINEAR BUT LIQUEFACTION NUMBER IS WHICH IS AS FOLLOWS: 6000 L.N. = F.N. - 50

29 LINEAR QUALITY DATA F.N. 250, 300, 450 L.N. 30, 24, 15

30 BLENDING FOR FALLING NO. WHEAT A x 100 / ( ) = 50% WHEAT B x 100 / ( ) = 50%

31 BLENDING FOR LIQUEFACTION NO. WHEAT A x 100 /(6 + 4) = 60% WHEAT B x 100 /(6 + 4) = 40%

32 Linear Properties & Farinograph Stability Flour 1 Stability 8.5 Flour 2 Stability 9.0 Blend Flour 1 70% Stability 13.9 Flour 2 30% Source: Kansas wheat commission Brabender HRW Study

33 USE OF LINEAR PROGRAMMING TO WORK OUT ECONOMIC SOLUTIONS

34 LINEAR PROGRAMMING CONCEPTS

35 USE OF LINEAR PROGRAMMING TO WORK OUT ECONOMIC SOLUTIONS

36 USE OF LINEAR PROGRAMMING TO WORK OUT ECONOMIC SOLUTIONS?

37 Bread Quality Gas Production Gas Retention

38 Development Development Development Balance between gas production and gas retention Optimum Gluten Gas Gluten Gas Gluten Gas Fermentation (hours) Fermentation (hours) Fermentation (hours)

39 LARGE BAKERS BLEND TARGETED SPECIFICATIONS Min. Max. Protein L.N W Total Prod 1.00

40 LARGE BAKERS BLEND WHEAT QUALITY DATA & COSTS Wheat A Wheat B Wheat C Wheat D Wheat 1t, $ Protein, % L.N W

41 LARGE BAKERS BLEND WHEAT QUALITY DATA & COSTS Wheat A Wheat B Wheat C Wheat D Wheat 1t, $ Protein, % L.N W Portion /tonne Cost of wheat, $

42 Solver Parameters

43 Incorporating Constraints

44 Solution Options

45 Solution Options

46 LARGE BAKERS BLEND TARGETED SPECIFICATIONS & WHEAT SELECTED PER TONNE BASIS Min. Max. Blend Wheat A 0.26 Protein Wheat B 0.26 L.N Wheat C 0.28 W Wheat D 0.20 Total Prod Opt. Cost $389.95

47 SPREADSHEET LARGE BAKERS BLEND Wheat A Wheat B Wheat C Wheat D Wheat 1t, $ Protein, % L.N W Portion /tonne Cost of wheat, $ Protein 0.13 L.N W 3.20 Total Prod 1.00 Min. Max. Blend Wheat A 0.26 Protein Wheat B 0.26 L.N Wheat C 0.28 W Wheat D 0.20 Total Prod Opt. Total Revenue

48 STRONG BAKERS BLEND TARGETED SPECIFICATIONS Min. Max. Protein L.N W Total Prod 1.00

49 STRONG BAKERS BLEND WHEAT QUALITY DAT & COSTS Wheat A Wheat B Wheat C Wheat D Wheat 1t, $ Protein, % L.N W Portion /tonne Cost of wheat, $

50 STRONG BAKERS BLEND TARGETED SPECIFICATIONS & WHEAT SELECTED PER TONNE BASIS Min. Max. Blend Wheat A 0.36 Protein Wheat B 0.00 L.N Wheat C 0.64 W Wheat D 0.00 Total Prod Opt. Cost $396.00

51 FANCY CLEARS BLEND TARGETED SPECIFICATIONS Min. Max. Protein L.N W Total Prod 1.00

52 FANCY CLEARS BLEND WHEAT QUALITY DAT & COSTS Wheat A Wheat B Wheat C Wheat D Wheat 1t, $ Protein, % L.N W Portion /tonne Cost of wheat, $

53 Min. Max. Blend Wheat A 0.20 Protein Wheat B 0.00 L.N Wheat C 0.80 W Wheat D 0.00 FANCY CLEARS BLEND TARGETED SPECIFICATIONS & WHEAT SELECTED PER TONNE BASIS Total Prod Opt. Cost

54 WHOLE WHEAT FLOUR BLEND TARGETED SPECIFICATIONS Min. Max. Protein L.N W Total Prod 1.00

55 WHOLE WHEAT FLOUR BLEND WHEAT QUALITY DAT & COSTS Wheat A Wheat B Wheat C Wheat D Wheat 1t, $ Protein, % L.N W Portion /tonne Cost of wheat, $

56 WHOLE WHEAT FLOUR BLEND TARGETED SPECIFICATIONS & WHEAT SELECTED PER TONNE BASIS Min. Max. Blend Wheat A 0.00 Protein Wheat B 0.33 L.N Wheat C 0.67 W Wheat D 0.00 Total Prod Opt. Cost

57 PRODUCTION PLANNING & WHEAT DATA FLOUR MARGINS Flour INVENTORY WHEAT INVENTORY & QUALITY W Cost Selling price Margin Order Available Production Wheat A Wheat B Wheat C Wheat D Family Flour Large Bakers Flour Small Bakers Flour Fancy Clears Flour Whole wheat Flour Wheat required Wheat available Wheat 1t, $ Protein, % L.N W

58 OPTIMIZATION OF MULTIPLE BLENDS Blend 1 Blend 2 Blend 3 Blend 4 Cost of blend per tonne, $ Wheat C, % Margins, $ Wheat C, tonnes Opt Rev. Production, tonnes Min Max Select Wheat C Blend Blend Blend Blend Production

59 OPTIMIZATION OF MULTIPLE BLENDS INFEASIBLE SOLUTION Blend 1 Blend 2 Blend 3 Blend 4 Cost of blend per tonne, $ Wheat C, % Margins, $ Quantity, tonnes Revenue, $ Wheat C, tonnes 500 Opt Rev Production, tonnes 714 Infeasible Min Max Select Wheat C Blend Blend Blend Blend Production

60 OPTIMIZATION OF MULTIPLE BLENDS FEASIBLE SOLUTION Blend 1 Blend 2 Blend 3 Blend 4 Cost of blend per tonne, $ Wheat C, % Margins, $ Quantity, tonnes Revenue, $ Wheat C, tonnes 500 Opt Rev Production, tonnes 800 Min Max Select Wheat C Blend Blend Blend Blend Production

61 OPTIMIZATION OF MULTIPLE BLENDS INFEASIBLE SOLUTION Blend 1 Blend 2 Blend 3 Blend 4 Cost of blend per tonne, $ Wheat C, % Margins, $ Quantity, tonnes Revenue, $ Wheat C, tonnes 499 Opt Rev Production, tonnes 800 Min Max Wheat C Blend Blend Blend Blend Production

62 OPTIMIZATION OF MULTIPLE BLENDS FEASIBLE SOLUTION Blend 1 Blend 2 Blend 3 Blend 4 Cost of blend per tonne, $ Wheat C, % Margins, $ Quantity, tonnes Revenue, $ Wheat C, tonnes 435 Opt Rev Production, tonnes 700 Min Max Select Wheat C Blend Blend Blend Blend Production