CROSS-REFERENCE TO RELATED PATENT APPLICATIONS [0001] This International patent application claims priority to U.S. Provisional Patent Application No. 63/212,165, filed on June 18, 2021 and U.S. Provisional Patent Application No. 63/212,168, filed on June 18, 2021, the disclosure of each of which are incorporated herein in its entirety.

BACKGROUND

Field

[0002] The present disclosure relates to exemplary methods and systems for in-line measurement and control of the moisture content of grain products.

Description of Related Art

[0003] Conventional moisture control equipment in the cattle industry lacks remote access and accurate control parameters, hindering feed suppliers from providing consistent moisture and/or flake density in animal feed products. A lack of effective moisture control systems can cause a variety of health issues in cattle reducing performance. Moisture control technology adapted from poultry feed mills has been ineffective. Inconsistent moisture control leads to reduced Feed Conversion Ratio (FCR) and Average Daily Gain (ADG) in livestock reducing the Return on Investment (ROI).

[0004] Accordingly, there is a need in the agriculture industry for improved systems and methods for determination and control of the moisture content of grain products.

SUMMARY

[0005] The present disclosure provides exemplary systems and methods for measuring and controlling the moisture content of grain products. For example, the system and methods described herein can be used to measure the moisture content of a grain product before, during, and/or after steam flaking in real-time and adjust the moisture, as necessary, to optimize flake moisture content. Also, the system and methods described herein can be used to measure the moisture content of a grain product before, during, and/or after processing in real-time and adjust the moisture, as necessary, to optimize processed grain product moisture content.

[0006] The systems and methods can comprise passing a grain product through the detection region of at least one sensor; this can be a sample of a portion of a flowing stream of grain product. In one instance, the detection region is placed downstream from a unit operation to modify the grain products in a flowing stream, for example a mill, for flaking the grain. Optionally, the detection region is placed downstream from a unit operation which is designed to modify the grain products in a flowing stream, for example a mill, for processing (e.g. , flaking) the grain.

[0007] In one aspect, the grain product, including but not limited to whole grain, flaked grain, and combinations thereof, can be delivered at a speed between 0.1 and 3.0 m/s. When a plurality of sensors is used, the sensors can be coupled in a line along the flowing stream of grain products, such as a first sensor that measures moisture content of a whole grain product, a second sensor that measures the moisture content of tempered whole grain product, and/or a third sensor that measures the moisture content of flaked grain product. The sensors can measure one or more additional physical parameters, including but not limited to grain product size, protein content, fat content, starch content, or combinations thereof. Each of these sensors can be located adjacent to the same mill or at a separate mill. Further, the sensors can be electronically coupled, either physically or wireless.

[0008] The aforementioned sensors, including a detection region, illumination source, and detector can be used at a variety of points within a mill and/or a variety of points within separate mills. The system and method can illuminate the sample in the detection region with infrared light from at least one infrared light source and detect the near infrared light that is reflected by the sample or transmitted past the sample. The infrared light can include a near infrared light. Once the near infrared light reflection or transmission spectral information is detected, the near infrared light reflection or transmission spectral information is converted into at least one physical parameter value, for example, moisture content. The conversion of spectral information into a physical parameter value can take place using, for example, a computer system associated with the system. Moreover, this conversion can be based on near infrared light detected at multiple wavelengths and/or a calibration constant based on a previously determined correlation between previously detected near infrared light at the same wavelength and previously measure parameters.

[0009] A computer processor can be used to perform an optimization analysis on converted physical parameter values and provide feedback on the physical parameter based on the optimization analysis. The system and method can also include storing data, including but not limited to parameter data, conversion data, optimization analysis data, or combinations thereof, in memory electronically coupled to a processor and displaying data via a display interface. [0010] In one aspect, a method for measuring moisture content of a whole grain can comprise:

(a) measuring the moisture content of a whole grain to produce a first data set; (b) communicating the first data set to a computer system; (c) processing the first data set using a computer system executing an analysis program to produce a first condition settings for tempering the whole grain; (d) sending the first condition settings to adjust tempering conditions to reach a target moisture content for a flaked grain product; (e) optionally, adding water to the whole grain to reach a target moisture content for the whole grain; (f) tempering the whole grain to form a tempered whole grain; (g) processing the tempered whole grain to form a flaked grain product; (h) measuring the moisture content of the flaked grain product to produce a second data set; (i) communicating the second data set to the computer system; (j) processing the second data set using the computer system executing an analysis program to produce second condition settings for tempering the whole grain; (k) optionally sending the second condition settings to adjust tempering setting conditions to reach a target moisture content for the flaked grain product; and (1) optionally, adding water to the whole grain to reach a target moisture content for the flaked grain product. The moisture content can be measured by infrared spectroscopy. The moisture content can be measured by an oven dry test, an electrical conductance impedance method, a microwave technique, or a combination thereof.

[0011] In another aspect, a method for measuring moisture content of a whole grain can comprise: (a) measuring the moisture content of a whole grain by infrared spectroscopy to produce a first data set; (b) communicating the first data set to a computer system; (c) processing the first data set using a computer system executing an analysis program to produce a first condition settings for tempering the whole grain; (d) sending the first condition settings to adjust, as necessary, tempering conditions to reach a target moisture content for a flaked grain product;

€ optionally, adding water to the whole grain to reach a target moisture content for the whole grain; (f) tempering the whole grain; (g) processing the tempered whole grain; (h) measuring the moisture content of the processed grain product by infrared spectroscopy to produce a second data set; (i) communicating the second data set to a computer system; (j) processing the second data set using a computer system executing an analysis program to produce second condition settings for tempering the whole grain; (k) sending the second condition settings to adjust, as necessary, tempering setting conditions to reach a target moisture content for the flaked grain; and (1) optionally, adding water to the whole grain to reach a target moisture content for the flaked grain.

[0012] In another aspect, a method for measuring moisture content of a grain product can comprise: (a) measuring the moisture content of a whole grain by infrared spectroscopy to produce a first data set; (b) communicating the first data set to a computer system; (c) processing the first data set using a computer system executing an analysis program to produce a first condition settings for tempering the whole grain product; (d) sending the first condition settings to adjust, as necessary, tempering conditions to reach a target moisture content for the processed grain product; (e) optionally, adding water to the whole grain to reach a target moisture content for the whole grain; (f) tempering the whole grain; (g) processing the tempered whole grain; (h) measuring the moisture content of the processed grain product by infrared spectroscopy to produce a second data set; (i) communicating the second data set to a computer system; (j) processing the second data set using a computer system executing an analysis program to produce second condition settings for tempering the whole grain product; (k) sending the second condition settings to adjust, as necessary, tempering setting conditions to reach a target moisture content for the processed grain product; and (1) optionally, adding water to the whole grain to reach a target moisture content for the whole grain.

[0013] In a further aspect, the measurement of moisture content can comprise (a) passing a sample through a detection region; (b) illuminating the sample with infrared light from at least one infrared light source; (c) detecting the near infrared light that is reflected by the sample or transmitted past the sample; (d) converting, using at least one processor, the detected infrared light reflection or transmission spectral information into a moisture content value; and (e) communicating the moisture content value to the computer system.

[0014] In one aspect, a method for measuring moisture content of a grain can comprise: (a) measuring the moisture content of a whole grain to produce a first data set; (b) communicating the first data set to a computer system; (c) processing the first data set using a computer system executing an analysis program to produce a first condition settings for tempering the whole grain; (d) sending the first condition settings to adjust tempering conditions to reach a target moisture content for a flaked grain product; (e) optionally, adding water to the whole grain to reach a target moisture content for the whole grain; (f) tempering the whole grain to form a tempered whole grain; (g) processing the tempered whole grain to form a flaked grain product; (h) measuring the moisture content of the flaked grain product to produce a second data set; (i) communicating the second data set to the computer system; (j) processing the second data set using the computer system executing an analysis program to produce second condition settings for tempering the whole grain; (k) optionally sending the second condition settings to adjust tempering setting conditions to reach a target moisture content for the flaked grain product; and (1) optionally, adding water to the whole grain to reach a target moisture content for the flaked grain product.

[0015] In an aspect, the moisture content can measured by infrared spectroscopy. The moisture content can be measured by oven dry test, electrical conductance impedance method, microwave technique, infrared spectroscopy, optionally in-line infrared spectroscopy (NIR), or a combination thereof.

[0016] In an aspect, the processing of the tempered whole grain can comprise steam treatment, milling, or a combination thereof. [0017] In an aspect, the whole grain can be tempered in a vessel to form a tempered whole grain. The vessel can be a steam chest.

[0018] In an aspect, the steam can added to the vessel, optionally a steam chest, to add moisture to the whole grain. The steam can be wet steam, saturated steam, superheated steam, or a combination thereof.

[0019] In an aspect, the tempering can comprise treating the whole grain in a vessel, optionally a steam chest, for between about 1 minute to 60 minutes at a temperature between about 50°F and 212°F.

[0020] In an aspect, the tempering can comprise treating the whole grain in a vessel, optionally a steam chest, for between about 1 minute to 60 minutes.

[0021] In an aspect, the whole grain can be processed in the steam chest for about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or 60 minutes.

[0022] In an aspect, the tempering can comprise treating (e.g. , incubating) the whole grain in a vessel, optionally a steam chest, at a temperature between about 50°F and 212°F.

[0023] In an aspect, the tempering can comprise treating (e.g., incubating) the whole grain in a vessel, optionally a steam chest, at a temperature between about 50°F and 212°F, 60°F and 212°F, 100°F and 212°F, 60°F and 212°F, 120°F and 212°F, or 90°F and 212°F.

[0024] In an aspect, the tempering can comprise treating (e.g., incubating) the whole grain in a vessel, optionally a steam chest, at a temperature of about 50°F, 51°F, 52°F, 53°F, 54°F, 55°F, 56°F, 57°F, 58°F, 59°F, 60°F, 61°F, 62°F, 63°F, 64°F, 65°F, 66°F, 67°F, 68°F, 69°F, 70°F, 71°F, 72°F, 73°F, 74°F, 75°F, 76°F, 77°F, 78°F, 79°F, 80°F, 81°F, 82°F, 83°F, 84°F, 85°F, 86°F, 87°F, 88°F, 89°F, 90°F, 91°F, 92°F, 93°F, 94°F, 95°F, 96°F, 97°F, 98°F, 99°F, 100°F, 101°F, 102°F, 103°F, 104°F, 105°F, 106°F, 107°F, 108°F, 109°F, 111°F, 112°F, 113°F, 114°F, 115°F, 116°F,

117°F, 118°F, 119°F, 120°F, 121°F, 122°F, 123°F, 124°F, 125°F, 126°F, 127°F, 128°F, 129°F,

130°F, 131°F, 132°F, 133°F, 134°F, 135°F, 136°F, 137°F, 138°F, 139°F, 140°F, 141°F, 142°F,

143°F, 144°F, 145°F, 146°F, 147°F, 148°F, 149°F, 150°F, 151°F, 152°F, 153°F, 154°F, 155°F,

156°F, 157°F, 158°F, 159°F, 160°F, 161°F, 162°F, 163°F, 164°F, 165°F, 166°F, 167°F, 168°F,

169°F, 170°F, 171°F, 172°F, 173°F, 174°F, 175°F, 176°F, 177°F, 178°F, 179°F, 180°F, 181°F,

182°F, 183°F, 184°F, 185°F, 186°F, 187°F, 188°F, 189°F, 190°F, 191°F, 192°F, 193°F, 194°F,

195°F, 196°F, 197°F, 198°F, 199°F, 200°F, 201°F, 202°F, 203°F, 204°F, 205°F, 206°F, 207°F,

208°F, 209°F, 211°F, or 212°F. [0025] In an aspect, the condition setting can comprise the temperature setting of the steam, the temperature setting in the tempering process, the length of time of tempering, the length of time of steam treatment, milling parameters, or a combination thereof.

[0026] In an aspect, the optimization analysis program can comprise a steam efficiency algorithm. The steam efficiency algorithm can be: wherein steam efficiency is measured as °F/1% moisture gain, and: m _t = moisture of the tempered grain m _s = moisture added through steam t _s = vessel (steam chest) temperature t _g = whole grain temperature.

[0027] In an aspect, the processing of the tempered whole grain may comprise tempered, rolled, milled, ground, roasted, pelleted, or a combination thereof.

[0028] In an aspect, the condition setting may comprise the temperature setting in the tempering process, the length of time of tempering, the length of time of processing, processing parameters, or a combination thereof.

[0029] In an aspect, the analysis program may comprise Unified grain Moisture Algorithm (UGMA) [promulgated by the U.S. Department of Agriculture]. See, also FIG. 3; Design Criteria for Unified Grain Moisture Algorithm (UGMA) (usda.gov); Directive 9180.61 OFFICIAL MOISTURE CALIBRATIONS FOR UGMA METERS (usda.gov). The analysis program may comprise calculating the additional moisture required based on the whole grain moisture level and the desired moisture content of the processed grain product. The analysis program may comprise calculating the additional moisture required based on the whole grain moisture level, the tempered grain moisture content, the process grain product moisture content, and the desired moisture content of the processed grain product.

[0030] In an aspect, the sample can comprise a flowing stream of whole grain. The sample can comprise a flowing stream of flaked grain product. The grain can be millet, fonio, com (maize), sorghum, barley, oats, rice, rye, tefif, triticale, wheat, chickpeas, soybeans, safflower seed, canola seed, flax seed, hemp seed, poppy seed, or a combination thereof. The grain can be com, wheat, barley, or a combination thereof.

[0031] In an aspect, the target moisture content can be between about 5% and 35% water by weight (w/w). The target moisture content can be between about 8% and 30% water by weight (w/w). The target moisture content can be between about 10% and 30% water by weight (w/w), 15% and 25% water by weight (w/w), 20% and 30% water by weight (w/w), 20% and 25% water by weight (w/w), 15% and 30% water by weight (w/w), or 21% and 23% water by weight (w/w). The target moisture content can be about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or 35% water by weight (w/w).

[0032] hi an aspect, the method can further comprise measuring a physical parameter value of grain product. The physical parameter can be particle size, protein content, grain temperature, starch extract content, b-glucan content, beta-amylase content, and mycotoxin content, or a combination thereof.

[0033] In an aspect, the infrared red light can be near infrared light. The wavelength of the near infrared light can be about 800-2,500 nm.

[0034] In an aspect, the detecting can be performed at a plurality of predetermined points during processing of the grain product.

[0035] In an aspect, the grain can be delivered at a speed of between about 0.1 and 3.0 m/s. The grain can be delivered at a speed of about 0.1, 0.25, 0.5, 0.75, 1.0, 1.25, 1.50, 1.75, 2.0, 2.5, or 3.0 m/s.

[0036] In an aspect, the conversion can be based on near infrared light detected at multiple wavelengths and at least one calibration constant. The at least one calibration constant can be based on a previously determined correlation between previously detected near infrared light at the same wavelengths and previously measured parameters.

[0037] In an aspect, the method can further comprise outputting the data to a display.

[0038] In an aspect, the infrared sensors, computer system, tempering equipment, steam chest, or a combination thereof, can be electronically coupled via a wireless network.

[0039] In an aspect, the data can be collected, stored, and/or accessed in a remote database. [0040] In an aspect, a system for measuring moisture content of a grain product can comprise an apparatus for providing a grain product; a first infrared sensor can comprise a detection region, an illumination source, and a detector configured to measure moisture content of a grain product; a computer system can be configured receive data from infrared sensors to produce condition settings to reach a target moisture content of a flaked grain product using a steam efficiency algorithm and send condition settings to the grain tempering equipment and/or steam chest can comprise a mill, optionally, add water to the grain and/or increase the amount of steam provided; grain tempering equipment; and steam treatment equipment can comprise steam equipment and a mill; a second infrared sensor can comprise a detection region, an illumination source, and a detector configured to measure moisture content of a grain product, wherein components are coupled in line. The mill can be a roller mill.

[0041] In an aspect, the system can further comprise a third infrared sensor comprising a detection region, an illumination source, and a detector configured to measure moisture content of the tempered grain product coupled the grain tempering equipment. The sensors can further be configured to measure protein particle size, protein content, grain temperature, starch extract content, b-glucan content, beta-amylase content, mycotoxin content, or a combination thereof. [0042] In an aspect, the infrared light can be near infrared light (NIR). The wavelength of the near infrared light can be about 800-2,500 nm.

[0043] In an aspect, the computer system can comprise at least one processor coupled to a memory and, optionally a display.

[0044] In an aspect, the infrared sensors, computer system, tempering equipment, processing equipment configured to add moisture to the grain product, or a combination thereof, may be electronically coupled via a wireless network.

[0045] In an aspect, a system for measuring moisture content of a grain product may comprise an apparatus for providing a grain product; a first infrared sensor may comprise a detection region, an illumination source, and a detector configured to measure moisture content of a grain product; a computer system may be configured receive data from infrared sensors to produce condition settings to reach a target moisture content of a flaked grain product using a Unified Grain Moisture Algorithm (UGMA) and send condition settings to the grain tempering equipment and/or processing equipment configured to add moisture to the grain product; grain tempering equipment; and processing equipment may comprise a mill; a second infrared sensor may comprise a detection region, an illumination source, and a detector configured to measure moisture content of a grain product, wherein components are coupled in line. The mill may be a roller mill.

[0046] In an aspect, the grain tempering equipment can comprise a steam chest.

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figures 1A-B depict flow-charts showing method steps of an NIR in-line moisture analysis and control method;

[0048] Figures 2A-B depict flow-charts showing method steps of an NIR in-line moisture analysis and control method; and

[0049] Figure 3 depicts the Unified Grain Moisture Algorithm promulgated by the U.S. Department of Agriculture.

DETAILED DESCRIPTION ASPECT

[0050] Various aspects are described in detail herein and can be further illustrated by the provided examples. Additional viable variations of the aspects can easily be envisioned.

Definitions [0051] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as those commonly understood by one of ordinary skill in the art to which this invention belongs.

[0052] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise.

[0053] “Diffuse reflectance,” as used herein, refers broadly to the reflection of light from a surface such that the incident ray (source) is reflected at many angles.

[0054] “Diffuse transmission,” as used herein, refers broadly to the transmission of light through a medium such that the incident ray (source) is deflected at many angles (also known as scattering).

[0055] “Dispersed light,” as used herein, refers broadly to light that has been converted from light of mixed wavelengths into light with the component wavelengths separated.

[0056] “Dispersing,” as used herein, refers broadly to either reflected or transmitted light, and a device for separating light of mixed wavelengths into light with the component wavelengths separated.

[0057] “Forming or producing reflected or transmitted light,” or similar phrases as used herein, refers broadly to directing light from a light source to a sample so that reflected light and/or transmitted light is thereby generated.

[0058] “Passing through a spectrograph,” or similar phrases as used herein, refers broadly to either the reflected or transmitted light, and a device for receiving the reflected or transmitted light at an entrance aperture such as a slit such that the light travels through the optics of the spectrograph, is dispersed, and is emitted from an exit aperture.

[0059] “Spectacular reflectance,” as used herein, refers broadly to the reflection of light from a surface such that the incident ray (source) is reflected at one angle.

Moisture Control Equipment Technology

Grain Flaking

[0060] The moisture content of flaked grain products is important in the livestock feed industry because the processing of animal feed involves rolling a grain product to produce a product with greater surface area. Untreated whole grain can have a moisture content at about 12% water w/w and the target moisture content of flaked grain products can be about 22% water w/w. To increase and maintain the target moisture content of flaked grain products, the whole grain may be treated with increase the moisture content and rolled out to produce flakes. For example, to increase and maintain the target moisture content of flaked grain products, the whole grain can be treated with steam and rolled out to produce flakes. [0061] The grain product with a greater surface area increases the digestibility of the grain products for livestock (e.g., more surface area for the digestive enzymes and acids to work on the grain product).

[0062] Flaking, in particular steam flaking, is a process where whole grain is heated over time to soften the grain (“tempering”), allowing for the uptake of moisture via steaming (“steam treatment”), and passed through a mill (“rollers”) to increase the surface area of the grain, thereby improving starch digestibility. Generally, steam flaking requires time, temperature, and moisture.

[0063] To improve the efficiency of the steam chest, the whole grain can be pretreated. For example, the whole grain can be admixed with water comprising a surfactant or wetting agent prior to incubation in the steam chamber. For example, the whole grain can be pretreated “tempered,” and then moved to grain processing equipment to add moisture and grind to a desired size and/or shape, e.g., steam treated and flaked using rollers (e.g., steam flaked). Additionally, for example, the whole grain may be admixed with water comprising a surfactant or wetting agent prior to processing by equipment configured to add moisture to the grain product. For example, the whole grain may be pretreated “tempered,” and then moved to grain processing equipment to add moisture and grind to a desired size and/or shape.

[0064] The whole grain can be allowed to “temper” for about 1 to 24 hours prior to steaming (incubation in a steam chamber) and flaking (pressing through a roller). The tempering step can permit moisture to penetrate each kernel of grain. The tempering step may, optionally, permit grain moisture reach an equilibrium before the whole grain is moved to a steam chamber. Tempering, providing a higher and/or equilibrated moisture level, and/or the action of an added surfactant can improve the ability of the whole grain absorb moisture during steam flaking and/or can increase the thermal conductivity of the kernels of whole grain. Further, following the tempering step, the tempered whole grain can be processed to produce a final grain product. For example, the tempered grain can be milled to produce a final grain product. The tempered grain can be steam flaked to produce a final grain product.

[0065] Additionally, for example, the whole grain may be allowed to “temper” for about 1 to 24 hours prior to processing, optionally by equipment configured to add moisture to the grain product. The tempering step may permit moisture to penetrate each kernel of grain. The tempering step may, optionally, permit grain moisture reach an equilibrium before the whole grain is moved to processing equipment configured to add moisture to the grain product. Tempering, providing a higher and/or equilibrated moisture level, and/or the action of an added surfactant may improve the ability of the whole grain absorb moisture during processing and/or may increase the thermal conductivity of the kernels of whole grain. Further, following the tempering step, the tempered whole grain may be processed to produce a final grain product. For example, the tempered grain may be milled to produce a final grain product.

[0066] The whole grain can be incubated in a large vessel commonly referred to as a steam chamber, steam chest, or steamer. The retention time in the steam chest can vary for any suitable time, for example from 12 to 15 minutes, up to 60 minutes. The whole grain can be treated (e.g. , heated and moisture added) in the steam chest at a temperature between about 50°F and 225°F. For example, the steam chest can be heated to about 212°F. One or more types of steam can be used in a steam chest: wet, saturated, or superheated. Wet steam can have saturation at around 212°F at 1 ATM and consist of both liquid and vapor phases. Saturated steam can have saturation at around 212°F at 1 ATM and only consist of vapor phase. Superheated steam can be supersaturated at above 212°F at 1 ATM and consist of a vapor phase only.

[0067] Conventional tempering systems only measure the moisture of the whole grain using impedance, and/or microwave technology (an unreliable technology). Once the moisture is measured in such systems, a set amount of water is added to the whole grain. However, the control of moisture in conventional systems does not extend to the finished flake, providing inconsistent results, increasing costs, and decreasing the value of the flaked grain product for animal feed. Further, conventional steam flaking process control systems control the steam added to the flake by temperature alone. There is no measurement or automated control of the moisture adsorbed by the whole grain while it is being steamed. Additionally, a common measure of the flaked grain product is flake weight, (or density). The data is poor and inconsistent because operators record the value that the nutritionist wants to see in the daily log book. However, wide variation exists between and within roll stands on a daily and hourly basis. Therefore, control of the moisture of the flaked grain product is not possible using conventional methods.

In-line Real Time Monitoring and Control of Grain and Flake Moisture

[0068] The system and methods described herein provide in-line, real time monitoring and control of flaked grain product moisture content. The system and methods described herein show an unexpected improvement in controlling the moisture content of flaked grain products, leading to a surprising improvement in Feed Conversion Ratio (FCR), Average Daily Gain (ADG), and health in animals fed the flaked grain products made using the system and methods described herein.

[0069] The system and methods described herein comprise a moisture control system that utilizes infrared (IR) probes, optionally near-IR probes (NIR) to monitor input whole grain moisture content, tempered grain moisture content, and/or flaked grain product moisture content. The whole grain tempering systems and/or steam treating system can be coupled to a computer system configured to process one or more moisture content values, other physical properties, data collected by the one or more infrared probes of the whole grain, tempered grain, flaked grain product, or combinations thereof. Based on the data received by the computer system, the computer system can process the data using a steam efficiency algorithm to produce condition suggestions to be executed by the whole grain tempering systems. The computer system can process the data using a steam efficiency algorithm to change the method parameters of the moisture control system to better achieve a target final moisture content of the flaked grain product. In various aspects, the target final moisture content of the flaked grain product can be about 22% water w/w.

[0070] In various aspects, the data collected by the probes, IR probes and/or NIR probes, is communicated to a computer system. The computer system can process the data in real time and/or can use a steam efficiency algorithm to produce condition settings. The condition settings can be communicated to the steam flaking equipment comprising, optionally, pretreatment, tempering, steam chest, mill functionality, or combinations thereof, that adjust the conditions at which the whole grain is pretreated, tempered, and/or steam flaked. Such condition settings can include, without limitation, adjusting time, temperature, moisture content, additives, flow rate of whole grains, tempered (pretreated) grains, or flaked grains, or combinations thereof, to better reach the target moisture content of the flaked grain product. The data collected by the probes,

IR probes and/or NIR probes, is communicated to a computer system. For example, after the tempering step, the tempered whole grain can be processed to produce a final grain product and this process can be monitored and/or the conditions modified in real time as described herein to optimize moisture content of the final grain product. For example, the tempered grain can be milled to produce a final grain product. The tempered grain can be steam flaked to produce a final grain product. These processed can be monitored and/or the conditions modified in real time as described herein to optimize moisture content of the final grain product [0071] In various aspects, the computer system processes the data using a steam efficiency algorithm to produce condition settings. The condition settings can be communicated to a steam chest that adjusts the conditions at which the tempered grain is steamed. Such conditions can include, without limitation, time, temperature, moisture content, additives, type of steam, flow rate of whole grains, tempered (pretreated) grains, or flaked grains, or combinations thereof, to better reach the target moisture content of the flaked grain product. For example, data collected by infrared probes of the moisture content, and/or other physical properties, of whole grain, tempered whole grain, steamed whole grain, flaked grain product, or combinations thereof, can be used to adjust the conditions in which the whole grain is tempered, steam treated, or both. [0072] In an aspect, the system and methods described herein may comprise a moisture control system that utilizes infrared (IR) probes, optionally near-IR probes (NIR) to monitor input whole grain moisture content, tempered grain moisture content, and/or flaked grain product moisture content. The whole grain tempering systems and/or processing equipment may be configured to add moisture to the grain product and may be coupled to a computer system configured to process one or more moisture content values, other physical properties, data collected by the one or more infrared probes of the whole grain, tempered grain, flaked grain product, or combinations thereof. Based on the data received by the computer system, the computer system may process the data using a Unified Grain Moisture Algorithm (UGMA) to produce condition suggestions to be executed by the whole grain tempering systems. The computer system may process the data using a Unified Grain Moisture Algorithm (UGMA) to change the method parameters of the moisture control system to better achieve a target final moisture content of the flaked grain product. In various aspects, the target final moisture content of the flaked grain product may be about 22% water w/w.

[0073] In various aspects, the data collected by the probes, IR probes and/or NIR probes, is communicated to a computer system. The computer system may process the data in real time and/or may use a Unified Grain Moisture Algorithm (UGMA) to produce condition settings. The condition settings may be communicated to the processing equipment configured to add moisture to the grain product comprising, optionally, pretreatment, tempering, processing equipment configured to add moisture to the grain product, mill functionality, or combinations thereof, that adjust the conditions at which the whole grain is pretreated, tempered, and/or flaked. Such conditions may include, without limitation, time, temperature, moisture content, additives, flow rate of whole grains, tempered (pretreated) grains, or flaked grains, or combinations thereof, to better reach the target moisture content of the flaked grain product. The data collected by the probes, IR probes and/or NIR probes, is communicated to a computer system. For example, after the tempering step, the tempered whole grain may be processed to produce a final grain product and this process may be monitored and/or the conditions modified in real time as described herein to optimize moisture content of the final grain product. For example, the tempered grain may be milled to produce a final grain product. The tempered grain may be flaked to produce a final grain product. These processed may be monitored and/or the conditions modified in real time as described herein to optimize moisture content of the final grain product [0074] In various aspects, the computer system processes the data using a Unified Grain Moisture Algorithm (UGMA) to produce condition settings. The condition settings may be communicated to a processing equipment configured to add moisture to the grain product that adjusts the conditions at which moisture is added to the grain. Such conditions may include, without limitation, time, temperature, moisture content, additives, flow rate of whole grains, tempered (pretreated) grains, or flaked grains, or combinations thereof, to better reach the target moisture content of the flaked grain product. For example, data collected by infrared probes of the moisture content, and/or other physical properties, of whole grain, tempered whole grain, flaked grain product, or combinations thereof, may be used to adjust the conditions in which the whole grain is tempered, processed, or both.

[0075] In place of in-line NIR techniques, the moisture content of the grain, including but not limited to whole grain and flaked grain product, can be determined by microwave resonator technique, oven dry tests, electrical conductance impedance method, or a combination thereof. Kocsis et al. “On-Line Microwave Measurement of the Moisture Content of Wheat” 17 ^th IF AC World Congress Proceedings (2008); Jones et al. “Electrical Characteristics of Com, Wheat, and Soya in the 1 - 200 MHz Range” NBSIR Publication (October 1978), hereby incorporated by reference in its entirety. In this aspect, in-line NIR techniques and components can be replaced by, for example, by moisture determination methods, including but not limited to Karl Fischer Moisture Meter Method, Loss on Drying Moisture Meter Method (LOD), electrical moisture meter method, microwave moisture meter method (MW), nuclear moisture meter method (NUC), or a combination thereof.

[0076] In reference to FIG. 1A, a method for measuring moisture content of a grain product is illustrated. In various aspects, a target moisture content, e.g., about 22% water w/w of the flaked grain product, is provided to the computer system. A whole grain product is provided to the system 100. The moisture content of the whole grain and/or other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or combinations thereof) can be determined by a first near-infrared probe Step 101. The data collected by the NIR probe can be communicated Step 101a to a computer system 108 that processes the data using an analysis program to produce and send condition settings Step 108a for the tempering equipment Step 102, so as to achieve the target final moisture content. In an aspect, the conditions for other steps of grain processing can be monitoring and/or adjusted to optimize the moisture content of the finished product. For example, the analysis program can produce condition settings including but not limited to time, pressure, temperature, steam type, moisture levels, or combinations thereof, to the tempering equipment, steam treatment equipment, or both. Upon receipt of the condition settings, the tempering process Step 102, steam treatment Step 104, or both, can adjust the conditions to optimize the moisture content of the whole grain product.

[0077] During the tempering process Step 102, the whole grain product can be heated with moisture added for between about 1 and 24 hours at a temperature of between about 50°F and 100°F. The whole grain product can optionally be pre-treated with water, optionally comprising surfactants, wetting agents, or combinations thereof. The whole grain product can be tempered at conditions sufficient to achieve a target moisture content. For example, the whole grain product can be tempered at conditions sufficient to achieve a grain moisture content of between about 12% and 18% water w/w. In an aspect, the whole grain product can be tempered at conditions sufficient to achieve a grain moisture content of about 20% water w/w.

[0078] After the whole grain product is tempered Step 102, optionally during the tempering process, or both, the moisture content of the whole grain and/or other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or a combination thereof) can be determined by a second near-infrared probe Step 103. The data collected by the NIR probe can be communicated Step 103a to a computer system 108 that processes the data using an analysis program to produce and send condition settings Step 108a for the tempering process Step 102, condition settings for the steam flaking equipment, or both, so as to achieve the target final moisture content. For example, the analysis program can produce condition settings including but not limited to time, pressure, temperature, steam type, moisture level, or combinations thereof, to the tempering equipment, steam treatment equipment, or both. Upon receipt of the condition settings, the tempering process Step 102, steam treatment process Step 104, or both, can adjust the conditions to optimize the moisture content of the whole grain product, and, ultimately, the flaked grain product.

[0079] After tempering Step 102, the whole grain product can be steam treated to achieve a target moisture content Step 104. In the steam treatment, the tempered whole grain product can be treated with steam for a period of time and/or at a set or variable temperature to achieve a target moisture content. The whole grain can be treated with steam in a large vessel commonly referred to as a steam chamber, steam chest, or steamer. The retention time in the steam chest can vary from about 12 to 15 minutes, up to 60 minutes or more. The whole grain can be treated (e.g. , heated and moisture added) in the steam chest at a temperature between about 50°F and 225°F. For example, the steam chest can be heated to about 212°F. One or more types of steam can be used in a steam chest, for example, wet, saturated, or superheated (“dry”).

[0080] In various aspects, the steam treated whole grain product is then processed by a roller mill 105 to produce a flaked grain product. The moisture content of the whole grain, and/or other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or a combination thereof) can be determined by a third near- infrared probe Step 106. The data collected by the NIR probe can be communicated Step 106a to a computer system 108 that processes the data using an analysis program to produce and send condition settings Step 108a for the tempering process Step 102, condition settings can also be adjusted for the steam treatment, so as to achieve the target final moisture content. For example, the analysis program can produce condition settings including but not limited to time, pressure, temperature, steam type, moisture level, or combinations thereof, to the tempering equipment, steam treatment equipment, or both. Upon receipt of the condition settings, the tempering process Step 102, steam treatment process Step 104, or both, can adjust the conditions to optimize the moisture content of the whole grain product, and, ultimately, the flaked grain product.

[0081] In reference to FIG. 2A, a target moisture content is provided to the computer system, e.g., about 22% water w/w of the flaked grain product. A whole grain product is provided to the system 200. The moisture content of the whole grain, optionally other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or a combination thereof) can be determined by a first near-infrared probe Step 201. The data collected by the NIR probe can be communicated Step 201a to a computer system 207 that processes the data using an analysis program to produce and send condition settings Step 207a, in an aspect, the conditions for steam treatment can also be continuously monitoring and/or adjusted so as to achieve the target final moisture content. For example, the analysis program can produce condition settings including but not limited to time, pressure, temperature, steam type, moisture levels, or combinations thereof, to the tempering equipment, steam flaking equipment, or a combination thereof. Upon receipt of the condition settings, the tempering process Step 202, steam treatment process Step 203, or both, adjust the conditions to optimize the moisture content of the whole grain product.

[0082] During the tempering process Step 202, the whole grain product can be heated with moisture added for between about 1 and 24 hours at a temperature of between about 50°F and 100°F. The whole grain product can optionally be pre-treated with water, optionally comprising surfactants, wetting agents, or combinations thereof. The whole grain product can be tempered at conditions sufficient to achieve a target moisture content. For example, the whole grain product can be tempered at conditions sufficient to achieve a grain moisture content of between about 12% and 18% water w/w. Again, the whole grain product can be tempered at conditions sufficient to achieve a grain moisture content of about 20% water w/w.

[0083] After the tempering process Step 202, the whole grain product is steam treated to achieve a target moisture content using steam treatment process(es) Step 203. In the steam treatment, the tempered whole grain product is treated with steam over a period of time at a set temperature to achieve a target moisture content. The whole grain can treated with steam in a large vessel commonly referred to as a steam chamber, steam chest, or steamer. The retention time it the steam chest can vary from 12 to 15 minutes, up to 60 minutes. The whole grain can be treated (e.g. , heated and moisture added) in the steam equipment at a temperature between about 50°F and 225°F. For example, the steam equipment can be heated to about 212°F. One or more types of steam can be used in a steam chest, wet, saturated, or superheated.

[0084] The steam treated whole grain product is then milled Step 204 (e.g., processed by roller mill) to produce a flaked grain product. The moisture content of the whole grain, optionally other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or a combination thereof) can be determined by a second near-infrared probe Step 205. The data collected by the NIR probe can be communicated Step 205a to a computer system 207 that processes the data using an analysis program to produce and send condition settings Step 207a for the tempering process Step 202, in an aspect, the steam flaking conditions can be continuously monitored and/or adjusted, so as to achieve the target final moisture content. For example, the analysis program can produce condition settings including but not limited to time, pressure, temperature, steam type, moisture levels, or combinations thereof, to the tempering equipment, steam chest, or both. Upon receipt of the condition settings, the tempering process Step 202, steam flaking process Step 203-204 or both, adjust the conditions to optimize the moisture content of the whole grain product, and, ultimately, the flaked grain product.

[0085] The inventors surprisingly discovered that by using near-infrared or other optical measurements in connection with the systems and methods described herein, they could accurately measure and control moisture of whole grain and flaked grain products. Indeed, the inventors found that systems and methods utilizing two NIR probes were capable of achieving optimal moisture content, e.g., an NIR probe to evaluate whole grain prior to tempering and a NIR probe to evaluate flaked grain product after steam flaking. Using information from these probes, the inventors developed a steam efficiency algorithm to determine how much water should be added to the whole grain for tempering and/or during steam treatment. Further, time and temperature parameters can be varied to optimize moisture content. Additionally, the final flaked grain product moisture level can be measured using NIR. The final flake moisture data can be fed back into a programmable logic controller (PLC) and the steam temperature controlled using the equation for steam efficiency. The process of controlling steam temperature using final flake moisture in a feedback loop led to a surprising improvement in the control of flaked grain moisture levels. Using the systems and methods described herein, an operator can precisely and accurately control final flaked grain moisture content, which has a direct impact on flake apparent density. Both parameters (moisture content and density) can impact starch release in the digestive tract of the animal, improving FCR, Health, and ADG, which, in turn, improves ROI. [0086] In reference to FIG. IB, a method for measuring moisture content of a grain product is illustrated. In various aspects, a target moisture content, e.g., about 22% water w/w of the flaked grain product, is provided to the computer system. A whole grain product is provided to the system 100. The moisture content of the whole grain and/or other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or combinations thereof) may be determined by a first near-infrared probe Step 101.

The data collected by the NIR probe may be communicated Step 101a to a computer system 107 that processes the data using an analysis program (e.g., Unified Grain Moisture Algorithm) to produce and send condition settings Step 107a for the tempering equipment Step 102, so as to achieve the target final moisture content. In an aspect, the conditions for other steps of grain processing may be monitoring and/or adjusted to optimize the moisture content of the finished product. For example, the analysis program may produce condition settings including but not limited to time, pressure, temperature, moisture levels, or combinations thereof, to the tempering equipment, processing equipment configured to add moisture to the grain product, or both. Upon receipt of the condition settings, the tempering process Step 102, treatment Step 104, or both, may adjust the conditions to optimize the moisture content of the whole grain product.

[0087] During the tempering process Step 102, the whole grain product may be heated with moisture added for between about 1 and 24 hours at a temperature of between about 50°F and 100°F. The whole grain product may optionally be pre-treated with water, optionally comprising surfactants, wetting agents, or combinations thereof. The whole grain product may be tempered at conditions sufficient to achieve a target moisture content. For example, the whole grain product may be tempered at conditions sufficient to achieve a grain moisture content of between about 12% and 18% water w/w. In an aspect, the whole grain product may be tempered at conditions sufficient to achieve a grain moisture content of about 20% water w/w.

[0088] After the whole grain product is tempered Step 102, optionally during the tempering process, or both, the moisture content of the whole grain and/or other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or a combination thereof) may be determined by a second near-infrared probe Step 103. The data collected by the NIR probe may be communicated Step 103a to a computer system 107 that processes the data using an analysis program to produce and send condition settings Step 107a for the tempering process Step 102, condition settings for the processing equipment configured to add moisture to the grain product, or both, so as to achieve the target final moisture content. For example, the analysis program may produce condition settings including but not limited to time, pressure, temperature, moisture level, or combinations thereof, to the tempering equipment, processing equipment configured to add moisture to the grain product, or both. Upon receipt of the condition settings, the tempering process Step 102, treatment process Step 104, or both, may adjust the conditions to optimize the moisture content of the whole grain product, and, ultimately, the flaked grain product.

[0089] After tempering Step 102, the whole grain product may be processed by equipment configured to add moisture to the grain product to achieve a target moisture content Step 104. [0090] In various aspects, the treated whole grain product is then processed by a roller mill to produce a flaked grain product. The moisture content of the whole grain, and/or other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or a combination thereof) may be determined by a third near-infrared probe Step 105. The data collected by the NIR probe may be communicated Step 105a to a computer system 107 that processes the data using an analysis program to produce and send condition settings Step 107a for the tempering process Step 102, condition settings may also be adjusted for the treatment, so as to achieve the target final moisture content. For example, the analysis program may produce condition settings including but not limited to time, pressure, temperature, moisture level, or combinations thereof, to the tempering equipment, equipment configured to add moisture to the grain product, or both. Upon receipt of the condition settings, the tempering process Step 102, treatment process Step 104, or both, may adjust the conditions to optimize the moisture content of the whole grain product, and, ultimately, the flaked grain product.

[0091] In reference to FIG. 2B, a target moisture content is provided to the computer system, e.g., about 22% water w/w of the flaked grain product. A whole grain product is provided to the system 200. The moisture content of the whole grain, optionally other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or a combination thereof) may be determined by a first near-infrared probe Step 201. The data collected by the NIR probe may be communicated Step 201a to a computer system 206 that processes the data using an analysis program to produce and send condition settings Step 206a, in an aspect, the conditions for treatment may also be continuously monitoring and/or adjusted so as to achieve the target final moisture content. For example, the analysis program may produce condition settings including but not limited to time, pressure, temperature, moisture levels, or combinations thereof, to the tempering equipment, equipment configured to add moisture to the grain product, or a combination thereof. Upon receipt of the condition settings, the tempering process Step 202, treatment process Step 203, or both, adjust the conditions to optimize the moisture content of the whole grain product.

[0092] During the tempering process Step 202, the whole grain product may be heated with moisture added for between about 1 and 24 hours at a temperature of between about 50°F and 100°F. The whole grain product may optionally be pre-treated with water, optionally comprising surfactants, wetting agents, or combinations thereof. The whole grain product may be tempered at conditions sufficient to achieve a target moisture content. For example, the whole grain product may be tempered at conditions sufficient to achieve a grain moisture content of between about 12% and 18% water w/w. Again, the whole grain product may be tempered at conditions sufficient to achieve a grain moisture content of about 20% water w/w.

[0093] After the tempering process Step 202, the whole grain product is processed by equipment configured to add moisture to the grain product to achieve a target moisture content (optionally milled) Step 203.

[0094] The treated whole grain product may be milled Step 203 ( e.g ., processed by roller mill) to produce a flaked grain product. The moisture content of the whole grain, optionally other physical parameters (e.g., average particle size, particle size distribution, density, protein content, fat content, starch content, or a combination thereof) may be determined by a second near-infrared probe Step 204. The data collected by the NIR probe may be communicated Step 204a to a computer system 206 that processes the data using an analysis program to produce and send condition settings Step 206a for the tempering process Step 202, in an aspect, the processing conditions may be continuously monitored and/or adjusted, so as to achieve the target final moisture content. For example, the analysis program may produce condition settings including but not limited to time, pressure, temperature, moisture levels, or combinations thereof, to the tempering equipment, equipment configured to add moisture to the grain product, or both. Upon receipt of the condition settings, the tempering process Step 202, processing Step 203 or both, adjust the conditions to optimize the moisture content of the whole grain product, and, ultimately, the flaked grain product.

[0095] The inventors surprisingly discovered that by using near-infrared or other optical measurements in connection with the systems and methods described herein, they could accurately measure and control moisture of whole grain and flaked grain products. Indeed, the inventors found that systems and methods utilizing two NIR probes were capable of achieving optimal moisture content, e.g., an NIR probe to evaluate whole grain prior to tempering and a NIR probe to evaluate flaked grain product after processing. A plurality of probes may also be used, for example, 2, 3, 4, 5, or 6 NIR probes. Using information from these probes, the Unified Grain Moisture Algorithm (UGMA) may be used to determine how much water should be added to the whole grain for tempering and/or processing. Further, time and temperature parameters may be varied to optimize moisture content. Additionally, the final flaked grain product moisture level may be measured using NIR. The final flake moisture data may be fed back into a programmable logic controller (PLC) and the processing conditions controlled using the Unified Grain Moisture Algorithm (UGMA). The process of controlling temperature using final flake moisture in a feedback loop led to a surprising improvement in the control of flaked grain moisture levels. Using the systems and methods described herein, an operator can precisely and accurately control final flaked grain moisture content, which has a direct impact on flake apparent density. Both parameters (moisture content and density) are can impact starch release in the digestive tract of the animal, improving FCR, Health, and ADG, which, in turn, improves ROI. The tempering and/or processing conditions may be set by a computer system executing an analysis program. The analysis program may comprise calculating the additional moisture required based on the whole grain moisture level and the desired moisture content of the processed grain product. The analysis program may comprise calculating the additional moisture required based on the whole grain moisture level, the tempered grain moisture content, the process grain product moisture content, and the desired moisture content of the processed grain product.

Grain

[0096] Whole grain products can include, but are not limited to millet, fonio, com (maize), sorghum, barley, oats, rice, rye, teff, triticale, wheat, chickpeas, beans, lentils, peanuts, soybeans, safflower seed, canola seed, flax seed, hemp seed, poppy seed, or mixtures thereof. A preferred whole grain product is com, wheat, barely, or a mixture thereof. The whole grain product can be com. The whole grain product can be wheat. The whole grain product can be barley.

Tempering

[0097] Whole grain can be allowed to “temper” for about 1 to 24 hours prior to steam flaking (incubation in a steam chamber and pressing through a roller). The tempering step can permit moisture to penetrate each kernel of grain and/or to reach an equilibrium before the whole grain is moved to a steam chamber. The higher moisture and/or the action of an added surfactant can improve the ability of the whole grain to absorb moisture and/or increase the thermal conductivity of the kernels of whole grain.

[0098] The whole grain can be tempered for between about 1-24 hours. For example, the whole grain can be tempered for about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, or 24 hours.

[0099] The whole grain can be tempered at a temperature between about 70°F to 85°F. For example, the grain can be tempered at a temperature at about 70°F, 71°F, 72°F, 73°F, 74°F, 75°F, 76°F, 77°F, 78°F, 79°F, 80°F, 71°F, 82°F, 83°F, 84°F, or 85°F.

[0100] The whole grain can be tempered for sufficient time and temperature to reach a moisture content of between about 10% and 20% water w/w. For example, the whole grain can be tempered for sufficient time and temperature to reach a moisture content of about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, or 20% water w/w.

[0101] To improve the efficiency of the steam chest, the whole grain can be pretreated. For example, the whole grain can be admixed with water comprising a surfactant or wetting agent prior to incubation in the steam chamber.

[0102] In an aspect, the whole grain may be allowed to “temper” for about 1 to 24 hours prior to processing. The tempering step may permit moisture to penetrate each kernel of grain and/or to reach an equilibrium before the whole grain is moved to a equipment configured to add moisture to the grain, optionally comprising a mill (e.g. , roller mill). The higher moisture and/or the action of an added surfactant may improve the ability of the whole grain to absorb moisture and/or increase the thermal conductivity of the kernels of whole grain. To improve the efficiency moisture uptake, the whole grain may be pretreated. For example, the whole grain may be admixed with water comprising a surfactant or wetting agent prior to processing. The whole grain may be milled to produce flaked grain product. Milling the whole grain may increase surface area and/or improve starch availability, thereby improving the digestibility of the grain product for livestock. Mills that may be used include but are not limited to roller presses, roller mills, cracking rollers, flaking rollers/presses or assemblages thereof.

Steam Flaking

[0103] For steam flaking, the whole grain can be incubated in a large vessel (e.g., a steam chest) for between about 1 minute to 60 minutes or more at a temperature between about 50°F and 225°F. Steam can be added to the steam chest to add moisture to the whole grain. The steam can be wet steam, saturated steam, and/or superheated steam.

[0104] The whole grain can be incubated in the steam chest for about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36,

37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or 60 minutes.

[0105] The whole grain can be incubated in the steam chest at a temperature of about 50°F, 51°F, 52°F, 53°F, 54°F, 55°F, 56°F, 57°F, 58°F, 59°F, 60°F, 61°F, 62°F, 63°F, 64°F, 65°F, 66°F, 67°F,

68°F, 69°F, 70°F, 71°F, 72°F, 73°F, 74°F, 75°F, 76°F, 77°F, 78°F, 79°F, 80°F, 81°F, 82°F, 83°F,

84°F, 85°F, 86°F, 87°F, 88°F, 89°F, 90°F, 91°F, 92°F, 93°F, 94°F, 95°F, 96°F, 97°F, 98°F, 99°F,

100°F, 101°F, 102°F, 103°F, 104°F, 105°F, 106°F, 107°F, 108°F, 109°F, 111°F, 112°F, 113°F,

114°F, 115°F, 116°F, 117°F, 118°F, 119°F, 120°F, 121°F, 122°F, 123°F, 124°F, 125°F, 126°F,

127°F, 128°F, 129°F, 130°F, 131°F, 132°F, 133°F, 134°F, 135°F, 136°F, 137°F, 138°F, 139°F,

140°F, 141°F, 142°F, 143°F, 144°F, 145°F, 146°F, 147°F, 148°F, 149°F, 150°F, 151°F, 152°F,

153°F, 154°F, 155°F, 156°F, 157°F, 158°F, 159°F, 160°F, 161°F, 162°F, 163°F, 164°F, 165°F, 166°F, 167°F, 168°F, 169°F, 170°F, 171°F, 172°F, 173°F, 174°F, 175°F, 176°F, 177°F, 178°F,

179°F, 180°F, 181°F, 182°F, 183°F, 184°F, 185°F, 186°F, 187°F, 188°F, 189°F, 190°F, 191°F,

192°F, 193°F, 194°F, 195°F, 196°F, 197°F, 198°F, 199°F, 200°F, 201°F, 202°F, 203°F, 204°F,

205°F, 206°F, 207°F, 208°F, 209°F, 211°F, 212°F, 213°F, 214°F, 215°F, 216°F, 217°F, 218°F,

219°F, or 220°F.

[0106] The whole grain can be incubated in the steam chest at a temperature of between about 50°F and 220°F, 60°F and 215°F, 100°F and 215°F, 60°F and 212°F, 120°F and 220°F, or 90°F and 212°F.

[0107] Following steam treatment in the steam chest, the whole grain can be milled to produce flaked grain product. Milling the whole grain can increase surface area and/or improve starch availability, thereby improving the digestibility of the grain product for livestock. Mills that can be used include but are not limited to roller presses, roller mills, cracking rollers, flaking rollers/presses or assemblages thereof.

Computer System

[0108] One or more probes can collect moisture content data and/or other data, in real time, as the whole grain or flaked grain product passes through a detection zone. The data can be collected and processed by a computer system. The one or more probes, can be electronically coupled to the computer system by physical connections, wireless connections, or both. Optionally, the probes, can be electronically coupled with a virtual computer system, for example operating remotely (e.g. , “the cloud”).

[0109] A computer system can comprise a processor (Central Processing Unit, CPU) and supporting data storage. A computer system can comprise a programmable logic controller (PLC), microcontroller, distributed control system (DCS), or a combination thereof. Further, the data analysis can be implemented across multiple devices and/or other components local or remote to one another. The data analysis can be implemented in a centralized system, or as a distributed system for additional scalability. Moreover, any reference to software can include non-transitory computer readable media that when executed on a computer, causes the computer to perform a series of steps, such as the methods according to exemplary aspects.

[0110] The computer systems described herein can include data storage such as network accessible storage, local storage, remote storage, or a combination thereof. Data storage can utilize a redundant array of inexpensive disks (“RAID”), tape, disk, a storage area network (“SAN”), an internet small computer systems interface (“iSCSI”) SAN, a Fibre Channel SAN, a common Internet File System (“CIFS”), network attached storage (“NAS”), a network file system (“NFS”), or other computer accessible storage. The data storage can be a database, such as an Oracle database, a Microsoft SQL Server database, a DB2 database, a MySQL database, a Sybase database, an object oriented database, a hierarchical database, or other database. Data storage can utilize flat file structures for storage of data.

[0111] For example, the computer system can include various components and/or different computer systems, including components that are physically separated or remote from one another. A first computer can be used to access a remotely located server on which the method according to exemplary aspects is executed. The first computer can access the server through an interface, such as a web-based interface. The output of the method can be provided through the web-based interface. The method can be carried out over a computer-based network, such as the Internet. The data collected by the infrared probes can be stored and/or accessed on a local database, remote database (“cloud based database”), or a combination thereof. Further, the computer system can access additional databases for condition settings, infrared spectroscopy data, including standards, algorithms, or combinations thereof.

[0112] The systems described herein can include one or more network-enabled computers connected to the detectors and/or NIR spectrograph. As referred to herein, a network-enabled computer can include, but is not limited to: e.g., any computer device, or communications device including, e.g., a server, a network appliance, a personal computer (PC), workstation, a mobile device, a smartphone, a handheld PC, a personal digital assistant (PDA), a router, a thin client, a fat client, an Internet browser, or other device.

[0113] The network-enabled computers can execute one or more software applications to, for example, receive data as input from an entity accessing the network-enabled computer system, process received data, transmit data over a network, and receive data over a network. The one or more network-enabled computers can also include one or more software applications to configured to determine physical parameters of grain samples, as described herein.

[0114] The method and systems described herein can be fully automated.

[0115] The description below describes servers, devices, and network elements that can include one or more modules, some of which are explicitly shown, others are not. As used herein, the term “module” can be understood to refer to computing software, firmware, hardware, or various combinations thereof. It is noted that the modules are exemplary. The modules can be combined, integrated, separated, and/or duplicated to support various applications. Also, a function described herein as being performed at a particular module can be performed at one or more other modules and/or by one or more other devices instead of or in addition to the function performed at the particular module. Further, the modules can be implemented across multiple devices and/or other components local or remote to one another. Additionally, the modules can be moved from one device and added to another device, and/or can be included in both devices. [0116] It is further noted that the software described herein can be tangibly embodied in one or more physical media, such as, but not limited to, a compact disc (CD), a digital versatile disc (DVD), a floppy disk, a hard drive, read only memory (ROM), random access memory (RAM), as well as other physical media capable of storing software, or combinations thereof. Moreover, the figures illustrate various components (e.g. , servers, network elements, processors) separately. The functions described as being performed at various components can be performed at other components, and the various components can be combined and/or separated. Other modifications also can be made.

[0117] The network that electronically couples the probes (e.g., NIR probes), computer system, tempering equipment, and/or steam flaking equipment can be a wireless network, a wired network or any combination of wireless network and wired network. For example, the network can include one or more of a fiber optics network, a passive optical network, a cable network, a telephony network, an Internet network, a satellite network (e.g., operating in Band C, Band Ku or Band Ka), a wireless LAN, a Global System for Mobile Communication (“GSM”), a Personal Communication Service (“PCS”), a Personal Area Network (“PAN”), D-AMPS, Wi-Fi, Fixed Wireless Data, IEEE 802.1 la, 802.1 lb, 802.15.1, 802.1 1h and 802.1 lg or any other wired or wireless network for transmitting and/or receiving a data signal. In addition, the network can include, without limitation, telephone line, fiber optics, IEEE Ethernet 802.3, a wide area network (“WAN”), a local area network (“LAN”), or a global network such as the Internet. Also, the network can support an Internet network, a wireless communication network, a cellular network, or the like, or any combination thereof. The network can further include one, or any number of the exemplary types of networks mentioned above operating as a standalone network or in cooperation with each other. The network can utilize one or more protocols of one or more network elements to which it is communicatively coupled. The network can translate to or from other protocols to one or more protocols of network devices. Although the network can be depicted or described herein as one network, it should be appreciated that according to one or more aspects, the network can comprise a plurality of interconnected networks, such as, for example, a service provider network, the Internet, a broadcaster’s network, a cable television network, corporate networks, and home networks.

[0118] In an aspect, the network that electronically couples the probes (e.g., NIR probes), computer system, tempering equipment, and/or equipment configured to add moisture to the grain may be a wireless network, a wired network or any combination of wireless network and wired network. For example, the network may include one or more of a fiber optics network, a passive optical network, a cable network, a telephony network, an Internet network, a satellite network (e.g., operating in Band C, Band Ku or Band Ka), a wireless LAN, a Global System for Mobile Communication (“GSM”), a Personal Communication Service (“PCS”), a Personal Area Network (“PAN”), D-AMPS, Wi-Fi, Fixed Wireless Data, IEEE 802.1 la, 802.1 lb, 802.15.1, 802.1 1h and 802.1 lg or any other wired or wireless network for transmitting and/or receiving a data signal. In addition, the network may include, without limitation, telephone line, fiber optics, IEEE Ethernet 802.3, a wide area network (“WAN”), a local area network (“LAN”), or a global network such as the Internet. Also, the network may support an Internet network, a wireless communication network, a cellular network, or the like, or any combination thereof. The network may further include one, or any number of the exemplary types of networks mentioned above operating as a standalone network or in cooperation with each other. The network may utilize one or more protocols of one or more network elements to which it is communicatively coupled. The network may translate to or from other protocols to one or more protocols of network devices. Although the network may be depicted or described herein as one network, it should be appreciated that according to one or more aspects, the network may comprise a plurality of interconnected networks, such as, for example, a service provider network, the Internet, a broadcaster’s network, a cable television network, corporate networks, and home networks.

Steam Efficiency Formula

[0119] In various aspects of the systems and methods described herein, the moisture content of the incoming whole grain is measured using NIR. Water can be added to the incoming whole grain according to the set point target selected by a nutritionist and/or operator. The incoming whole grain can be allowed to temper for any suitable amount of time and at any suitable temperature.

[0120] In various aspects, the tempered whole grain is added to the steam flaking equipment (e.g. , a steam chest coupled to a roller mill). Process control software can open one or more steam valves of the steam chest and/or set an initial temperature, the steam chest temperature, using the known value of steam efficiency to achieve the target final flake moisture using the following steam efficiency algorithm:

Where steam efficiency is measured as °F/1% moisture gain And: m _t = moisture of the tempered grain m _s = moisture added through steam t _s = vessel (steam chest) temperature t _g = whole grain temperature

[0121] Following steam treatment, the grain can be milled. For example, the grain can be “flaked” using a roller mill. [0122] In various aspects, the moisture of the flaked grain is measured using NIR, and the data is fed back into the computer system. The temperature of the steam chest can be controlled by the computer system based on the target moisture of the finished flake. The inventors found that use of this algorithm in the systems and methods described herein resulted in a surprising improvement in efficiency of achieving the target moisture content of flaked grain product.

[0123] Additionally, the computer system can be electronically coupled to at least one mill or operating module to provide feedback on a physical parameter of the processed grain. In order to provide feedback on a physical parameter of the processed grain, a computer and/or data storage can utilize various optimization techniques, such as, for example, convex programming, such as linear programming, second order cone programming, semi-indefinite programming, conic programming, and geometric programming; integer programming; quadratic programing; fractional programming; nonlinear programming; stochastic programming; robust programming; stochastic optimization; infinite-dimensional optimization; heuristics; machine learning (artificial intelligence); calculus of variations; optimal control; and/or dynamic programming. A computer and/or data storage can also use various statistical analysis tools to determine, for example, probability distributions, sample mean, sample variance, sample covariance, mean squared error, type I errors, type II errors, standard deviations, standard errors, statistical errors, root mean square error, residual sum of squares, linear regression, nonlinear regression, significance, or an ensemble thereof.

[0124] The moisture content of whole and/or flaked grain can be monitored by the computer system. For example, if the grain product, either whole or flaked, falls below a predetermined moisture content level, the computer can send a signal to perform a predetermined function. For example, the predetermined function can include, stopping a mill or production flow, transmitting an alert for recalibration, increasing the steam input, changing temperature, changing the time for a process step, and/or other appropriate measures to optimize moisture content. This allows for improved performance and efficiencies by ensuring that a mill is not running off-specification and/or avoiding having to reprocess a product. These increased efficiencies were unexpected in comparison to the standard methods of producing flaked grain products in the industry. In standard methods, samples are taken from the production and analyzed. This led to, at best, an analysis of individual batches of product. If a batch was found to be undesirable, the entire batch had to be reprocessed contributing to waste (e.g., loss of time, lack of efficiency). In contrast, the claimed method allows for an in-line real time monitoring of the process to reduce and/or eliminate waste of time and resources due to off-specification products. Also, the computer can send an alert signal to inform an operator of the need to stop a mill or product flow is a moisture content falls below a predetermined threshold, allowing a user to stop a mill or product flow to prevent the processing of a product at an off-target moisture content level.

[0125] Measured values can be determined with great accuracy using the systems and methods described herein. This is surprising because the conventional method requires discrete sampling and separate processing of the samples. In contrast, the described system and method utilizes a compact stream, and thereby a reproducible condition of the sample surface. The sample need only be moved relative to the measurement detector, optionally forwards in the sense of the product flow direction. This stream-lined system allows for a large number of individual measurements to be performed on constantly replaced sample material. Thus, discreet measurement values are obtained to create a population of values which can be used to generate moisture content values.

[0126] A large number of individual measurements can be made with measuring times below 50 milliseconds so that one or, if necessary, several physical parameters corresponding to the selected wavelength range or ranges can be calculated by statistical averaging.

[0127] Surprisingly, despite the movement of the grain and the very short exposure times, measured values of acceptable quality were obtained in a shorter period of time as compared with conventional techniques. Reflectance samples can be measured every about 1-50 milliseconds, while transmittance samples can be measured every about 1-60 milliseconds. The average time it takes to calculate moisture content based on reflectance measurements ranges from about 3-15 seconds, optionally about 1-3 seconds. The average time it takes to calculate moisture content based on transmittance measurements ranges from about 1-60 seconds. For example, the NIR probe can only require about 1-3 seconds of reflectance to collect sufficient data for an accurate reading.

[0128] The surprising discovery of the present aspects includes the discovery that in-line NIR spectroscopy can be used to determine the moisture content of grain products. Further, the surprising discovery also can include that the in-line NIR spectroscopy yields consistent moisture content results regardless of the temperature and/or humidity of the environment, the type of grain, the protein content or size, and/or the fat content of the grain. This was unexpected because it was expected that environmental conditions (e.g., temperature, humidity) and grain properties (for example, protein content, size, or fat content) would adversely affect the consistency of in-line NIR spectroscopy measurement of particle size.

Unified Grain Moisture Algorithm (UGMA)

[0129] In various aspects of the systems and methods described herein, the moisture content of the incoming whole grain is measured using NIR. Water may be added to the incoming whole grain according to the set point target selected by a nutritionist and/or operator. The incoming whole grain may be allowed to temper for any suitable amount of time and at any suitable temperature.

[0130] hi various aspects, the tempered whole grain is added to the processing equipment (e.g., mills). Process control software may modify the processing conditions using the Unified Grain Moisture Algorithm (UGMA) promulgated by the U.S. Department of Agriculture shown in FIG. 3. “Unified Grain Moisture Algorithm Recipe Book” Funk & Gillay (2012) U.S. Department of Agriculture; Funk et al. Measurement Science and Technology 18(4): 1004.

[0131] Processing may comprise milling the grain. For example, the grain may be “flaked” using a roller mill.

[0132] In various aspects, the moisture of the flaked grain is measured using NIR, and the data is fed back into the computer system. The temperature of the processing equipment may be controlled by the computer system based on the target moisture of the finished flake. The inventors found that use of the Unified Grain Moisture Algorithm in the systems and methods described herein results in a surprising improvement in efficiency of achieving the target moisture content of flaked grain product.

[0133] Additionally, the computer system may be electronically coupled to at least one mill or operating module to provide feedback on a physical parameter of the processed grain. In order to provide feedback on a physical parameter of the processed grain, a computer and/or data storage may utilize various optimization techniques, such as, for example, convex programming, such as linear programming, second order cone programming, semi-indefinite programming, conic programming, and geometric programming; integer programming; quadratic programing; fractional programming; nonlinear programming; stochastic programming; robust programming; stochastic optimization; infinite-dimensional optimization; heuristics; machine learning (artificial intelligence); calculus of variations; optimal control; and/or dynamic programming. A computer and/or data storage may also use various statistical analysis tools to determine, for example, probability distributions, sample mean, sample variance, sample covariance, mean squared error, type I errors, type II errors, standard deviations, standard errors, statistical errors, root mean square error, residual sum of squares, linear regression, nonlinear regression, significance, or an ensemble thereof.

[0134] The moisture content of whole and/or flaked grain may be monitored by the computer system. For example, if the grain product, either whole or flaked, falls below a predetermined moisture content level, the computer may send a signal to perform a predetermined function. For example, the predetermined function may include, stopping a mill or production flow, transmitting an alert for recalibration, increasing the moisture input, changing temperature, changing the time for a process step, and/or other appropriate measures to optimize moisture content. This allows for improved performance and efficiencies by ensuring that a mill is not running off-specification and/or avoiding having to reprocess a product. These increased efficiencies were unexpected in comparison to the standard methods of producing flaked grain products in the industry. See, e.g., Bogart “Learn the Six Methods for Determining Moisture” Kett US (2022); “Grain Moisture- guidelines for measurement.” HGCA (2008). In standard methods, samples are taken from the production and analyzed. This led to, at best, an analysis of individual batches of product. If a batch was found to be undesirable, the entire batch had to be reprocessed contributing to waste (e.g., loss of time, lack of efficiency). In contrast, the claimed method allows for an in-line real time monitoring of the process to reduce and/or eliminate waste of time and resources due to off-specification products. Also, the computer may send an alert signal to inform an operator of the need to stop a mill or product flow is a moisture content falls below a predetermined threshold, allowing a user to stop a mill or product flow to prevent the processing of a product at an off-target moisture content level.

[0135] Measured values may be determined with great accuracy using the systems and methods described herein. This is surprising because the conventional method requires discrete sampling and separate processing of the samples. In contrast, the described system and method utilizes a compact stream, and thereby a reproducible condition of the sample surface. The sample need only be moved relative to the measurement detector, optionally forwards in the sense of the product flow direction. This stream-lined system allows for a large number of individual measurements to be performed on constantly replaced sample material. Thus, discreet measurement values are obtained to create a population of values which may be used to generate moisture content values.

[0136] Surprisingly, despite the movement of the grain and the very short exposure times, measured values of acceptable quality were obtained in a shorter period of time as compared with conventional techniques. Reflectance samples may be measured every about 1-50 milliseconds, while transmittance samples may be measured every about 1-60 milliseconds. The average time it takes to calculate moisture content based on reflectance measurements ranges from about 3-15 seconds, optionally about 1-3 seconds. The average time it takes to calculate moisture content based on transmittance measurements ranges from about 1-60 seconds. For example, the NIR probe may only require about 1-3 seconds of reflectance to collect sufficient data for an accurate reading.

Infrared Probe Settings

[0137] In the analysis zone, near-infrared light can be impinged onto the grain product and information concerning the resultant near-infrared light pattern of scattering and/or transmission can be collected by at least one detector. The detector can collect the near-infrared light pattern of scattering and/or transmission spectral information and relay it to a processing machine, optionally a computer comprising a processor coupled to a memory. The computer can apply a pre-determined correlation between the near-infrared light scattering and/or transmission spectral information and/or a calibration curve to generate an average physical parameter of the comminuted product. The physical parameter can be moisture content, average particle size, particle size distribution, protein content, fat content, starch content, or a combination thereof. Preferably, the physical parameter is moisture content.

[0138] The near-infrared (NIR) light can be impinged upon the grain at any length along the processing line of the grain. The near-infrared (NIR) light can be impinged on the grain along a conveyor and/or as the grain falls through a shaft or pipe. The grain can be poured off a ledge past the NIR light source. For example, the processed grain can be moved along a conveyor belt that ends, allowing the processed grain to fall through the NIR light in the analysis region.

[0139] The light source can be directed to a product to produce reflected light and/or transmitted light. Reflected light can be any light that strikes and can be emitted from the sample but that does not pass through the sample. To measure reflected light, the detector can be oriented at any angle to the sample relative to the light source. Using reflected light, the detector can be oriented at an angle of less than 180 degrees relative to the light source. For example, for a flat sampling device positioned horizontally, the light source can be positioned at an angle of 20 degrees from an imaginary line perpendicular to the plane of the sampling device with the intersection of the line and the sample as the vertex, and a detector can be positioned at an angle of 20 degrees from the imaginary line opposite the light source and 40 degrees from the light source with the same vertex. At this orientation, light from the light source will be reflected from the sample to the detector.

[0140] Transmitted light can be light that passes through the sample and can be emitted from the sample on the side opposite the light source. In this mode, the light source and the detector are positioned on opposite sides of the sample, all three are positioned substantially colinearly, and a product can be passed between a light source and a detector. The light from the light source can strike the sample, and some of the light can be transmitted through the sample to the detector. [0141] Either reflected light or transmitted light or both can be passed through a spectrograph. A spectrograph refers broadly to a device having optical components that are capable of receiving light of mixed wavelengths, dispersing the mixed wavelength light into its component wavelengths, and emitting the dispersed wavelengths. For example, a spectrograph can comprise an entrance slit for receiving light and a prism-grating-prism for dispersing the light. [0142] This spectrograph can be a reflective grating spectrograph having either a holographic grating or a fixed groove grating. The entrance slit can be positioned so as to receive light from the sample, and a detector is affixed to the exit aperture.

[0143] The light can be emitted continuously onto the optically dense flowing stream of a product. The reflectance and/or transmittance information of the NIR spectrum can then collected by a detector that is operably connected to a computer comprising a processor and a memory. The detector can be coupled to a computer by a fiber optic cable, wireless connection, network, wiring, or the detector and computer can be an integrated unit. The system can comprise multiple detectors and/or multiple computer systems. The NIR light reflectance, transmittance, or both, spectral information can then be applied to a known correlation to determine a physical parameter of the processed grain. The physical parameter can be average particle size, particle size distribution, moisture percentage, protein content, fat content, starch content, or any combination thereof.

[0144] The particulate product can then be conveyed to an analysis zone. In the analysis zone, near-infrared light can be impinged onto the grain product and information concerning the resultant near-infrared light pattern of scattering and/or transmission can be collected by at least one detector. The detector can collect the near-infrared light pattern of scattering and/or transmission spectral information and can relay it to a processing machine, optionally a computer comprising a processor coupled to a memory. The computer can apply a pre-determined correlation between the near-infrared light scattering and/or transmission spectral information and/or a calibration curve to generate an average physical parameter of the particulate product. The physical parameter can be average particle size, coating, shape, particle size distribution, moisture percentage, protein content, fat content, or starch content. See, e.g., Ros et al. (1997) Journal of Chemometrics 11 : 469-482; Optics in Agriculture. Forestry, and Biological Processing (Proceedings of Spie— The International Society for Optical Engineering, V. 2345.) (1994) Meyer & DeShazer (Eds).

[0145] The infrared probes can collect moisture content data, and/or optionally other data, multiple times per hour, for example every 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,

18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43,

44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or 60 minutes. The infrared probes can collect moisture content data, and/or optionally other data, multiple times per minute, for example 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52,

53, 54, 55, 56, 57, 58, 59, or 60 times an minute. The NIR meters are capable of (100) readings per second, capturing each and averaging these readings for a single output once per second. (1 output/second, or 60 outputs per minute).

Infrared Sensors

[0146] Light in the infrared spectrum has wavelengths between about 800-2,500 nm. The near infrared spectrum has wavelengths from about 750-1400 nm. The light can be emitted at a wavelength range of between 200-2000 nm. The light can be emitted at wavelengths between 780-2000 nm. The light can be emitted at wavelengths of between 900-1500 nm. For reflectance measurements, light can be emitted at a wavelength range of between 1100-1650 nm. For transmittance measurements, light can be emitted at wavelengths between 850-1050 nm.

[0147] Any suitable light source can be used that can provide the broad band illumination for the range of wavelengths used for any particular sample studied and light measuring device used. Suitable light sources are those that can provide light throughout the spectral response range for the light measuring device used. Examples of such light sources include, but are not limited to, halogen, tungsten halogen, long filament halogen, xenon, xenon flash, fluorescent, neon, and mercury. A light source producing light over at least the near infrared spectral range can be used. [0148] The optically dense grain layer can be delivered through the analysis region at a speed of between 0.5 and 2.5 m/s. aspect. The optically dense grain layer can be delivered at a speed of between 1 and 2 m/s. In other aspects, optically dense grain can be delivered through the analysis region in a “gravity flow” (free fall) condition. For example, the grain can be followed at a rate of about <0.5-2.0 m/s.

[0149] The light can be detected from the quantity of grain in a time of between 15-70 milliseconds. The light can be detected from the quantity of grain in a time of between 30-50 milliseconds. Thus as the light can be rapidly detected, this also accelerates the process for analyzing the grain. This allows for an unexpected improvement in the evaluation of moisture content.

[0150] The grain can be fed through one or more NIR spectroscopes, such as NIR spectroscope 110. The one or more NIR spectroscopes can include an analysis region where processed product sample can be irradiated with NIR light. The one or more NIR spectroscopes can comprise one or more light sources, one or more monochromators, and one or more detectors. Other aspects can include three, less than three, or more than three detectors, depending on the configuration of the spectroscope.

[0151] A light source can generate light to provide broad band illumination for the range of wavelengths used for any particular processed product sample studied and light measuring device used. The light source can be one or more of halogen, tungsten halogen, long filament halogen, xenon, xenon flash, fluorescent, neon, and mercury. The light source can be one or more light emitting diodes (LEDs).

[0152] Monochromator can be an optical device that transmits a mechanically selectable narrow band of wavelengths of light or other radiation chosen from a wider range of wavelengths received from light source. Light source and monochromator can be used in conjunction to produce light at wavelengths within the NIR spectrum.

[0153] Monochromator can use one or more prisms and/or diffraction gratings to physically separate light from the light source into different wavelengths that can then exit through one or more slits. In other aspects, light source and monochromator can be combined into one device. [0154] As the grain product, whole grain or flaked grain, passes through an analysis region, light from light source can be directed to the processed product sample via monochromator. As the NIR light impinges on the processed product sample, at least some of the light can reflect off the sample to produce reflected light (such as diffuse reflectance or spectacular reflectance), while some of the light can pass through the sample as transmitted light (such as diffuse transmittance). The reflected and/or transmitted light can be detected by one or more detectors. The material chosen for each detector can depend on the range of wavelengths to be measured. Examples of detectors include Silicon-based charge-coupled-devices (CCDs), Indium gallium arsenide (InGaAs)-based devices, and Lead(II) sulfide (PbS)-based devices. However, any suitable detector can be employed based on the range of wavelengths to be measured in the reflected and transmitted light. For example, CCD devices can be used to measure wavelengths below 1000 nm.

[0155] Detectors can be oriented to detect transmitted light. Other detectors can be oriented to detect reflected light. Detectors can each be oriented at an angle of less than 180 degrees relative to the light source and monochromator. Detector can be oriented on a side opposite light source and monochromator. The light source and the detector can be positioned on opposite sides of the sample being measured, and all three are positioned colinearly.

[0156] Detectors can include a spectrograph. Reflected and/or transmitted light from processed sample can initially pass through the spectrograph. A spectrograph can refer broadly to a device having optical components that are capable of receiving light of mixed wavelengths, dispersing the mixed wavelength light into its component wavelengths, and emitting the dispersed wavelengths. A spectrograph can comprise an entrance slit for receiving light and a prism- grating-prism for dispersing the light. The spectrograph can be a reflective grating spectrograph having either a holographic grating or a fixed groove grating. The entrance slit can be positioned so as to receive light from the sample, and a detector is affixed to the exit aperture. [0157] Reflected and transmitted light detected by detectors can be converted into reflectance and/or transmittance spectral information by detectors. Detectors can be diode arrays positioned to collect spectral data from many wavelengths simultaneously. The detector module can include spectral analysis software within the same housing. The reflectance and/or transmittance information can be transmitted to calibration module. NIR spectroscope can be operably connected to calibration module. Calibration module can comprise one or more network-enabled computers. NIR spectroscope can be connected to calibration module via one or more fiber optic cables, wired network, wireless network. In other aspects, some or all of the hardware and software of calibration module can be integrated into NIR spectroscope. NIR spectroscope can transmit the reflectance and/or transmittance information to calibration module.

[0158] Calibration module can store one or more correlation values. Each correlation value can correlate light reflectance and/or transmittance spectral information to a physical parameter of processed product sample. The physical parameter can be average particle size, particle size distribution, moisture percentage, protein content, fat content, starch content, or combinations thereof. For example, calibration module can store one or more moisture content correlation values. Each moisture content correlation value can correlate measured transmittance and/or reflectance spectral information with the moisture content of a grain sample. The moisture content correlation value can have been previously determined by measuring transmittance and/or reflectance information for multiple samples of a product, then measuring moisture content for each sample in a lab using filters and screens. The moisture content correlation value can then be determined by regression analysis of the lab-measured grind size against the transmittance and/or reflectance spectral information for corresponding samples. By way of example, calibration module can determine an R squared value for the correlation of lab measurements of moisture content and the transmittance and/or reflectance measurements of moisture content. It can be desirable for the R squared value to be within the range of .67 to 1 , indicating a strong correlation. By way of example, calibration module can determine a standard error for the transmittance and/or reflectance measurements of moisture content. It can be desirable for the standard error to be within the range of 0.1% to 0.5%, in an aspect, the range can be about 0.5% to 1%. The moisture content correlation value can then be provided to calibration module for use in the in-line processing system. For each processed product sample that passes through NIR spectroscope, the calibration module can use stored moisture content correlation values to determine moisture content for the grain product based on measured reflectance and/or transmittance spectral information.

[0159] Calibration module can be coupled to one or more control modules of tempering equipment and/or steam chest including the mill to provide feedback on the physical parameter of the processed grain. While the example shown above measured moisture content of the grain, other physical parameters can be measured, such as particle size distribution, protein content, fat content, or starch content. Calibration module can store correlation values for each of these physical properties. Control module can store one or more predetermined values for each parameter and type of product.

[0160] In another aspect, the calibration module may be coupled to one or more control modules of tempering equipment and/or equipment configured to add moisture to the grain comprising a mill to provide feedback on the physical parameter of the processed grain. While the example shown above measured moisture content of the grain, other physical parameters may be measured, such as particle size distribution, protein content, fat content, or starch content. Calibration module may store correlation values for each of these physical properties. Control module may store one or more predetermined values for each parameter and type of product. [0161] Although the invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it should be understood that certain changes and modifications can be practiced within the scope of the appended claims. Modifications of the above-described modes for carrying out the invention that would be understood in view of the foregoing disclosure or made apparent with routine practice or implementation of the invention to persons of skill in food chemistry, food processing, mechanical engineering, and/or related fields are intended to be within the scope of the following claims.

[0162] All publications (e.g., Non-Patent Literature), patents, patent application publications, and patent applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All such publications (e.g., Non-Patent Literature), patents, patent application publications, and patent applications are herein incorporated by reference to the same extent as if each individual publication, patent, patent application publication, or patent application was specifically and individually indicated to be incorporated by reference.

[0163] While the foregoing invention has been described in connection with this preferred aspect, it is not to be limited thereby but is to be limited solely by the scope of the claims which follow.

EXAMPLES EXAMPLE 1

Calculation of Steam Efficiency

[0164] The goal was to increase the control over the moisture in the final flaked grain product. The system was designed to monitor flake quality through apparent density and moisture. Flake weights can be collected multiple times an hour and data automatically recorded and uploaded a database for storage and/or analysis. Control chart equations were created for select date ranges. [0165] For example, the whole grain initial moisture can be about 12% w/w and the whole grain initial temperature can be about 75°F. If 6% water w/w is added to the grain, and moisture content can be increased to about 18% water w/w. The steam efficiency can be at about 25°F/1% moisture. The target finished moisture is 22%; therefore, 4% moisture needs to be added to the grain during steaming. To calculate the temperature of the steam equipment:

22%-18% = 4%

4%*25°F/1% moisture = 100°F temperature rise in the steam equipment Therefore:

75°F + 100°F = 175°F steam equipment temperature

[0166] It is estimated that better control of the moisture in the final grain product can result in a potential savings of $.05/h/d through reduced metabolics and the ability to increase com by 3% in the finish ration.

EXAMPLE 2

Unified Grain Moisture Algorithm

[0167] The goal was to increase the control over the moisture in the final flaked grain product. The system was designed to monitor flake quality through apparent density and moisture. Flake weights can be collected multiple times an hour and data automatically recorded and uploaded a database for storage and/or analysis. Control chart equations were created for select date ranges. [0168] For example, the whole grain initial moisture may be about 12% w/w and the whole grain initial temperature may be about 75°F. If 6% water w/w is added to the grain, and moisture content may be increased to about 18% water w/w. The target finished moisture is 22%; therefore, 4% moisture needs to be added to the grain processing. To calculate the processing parameters to reach the desired moisture content, the moisture may be monitored, the data processed by a computer system executing the Unified Grain Moisture Algorithm, parameters suggestions produced and executed to reach the desired moisture content. See, e.g., FIG. 3.

[0169] It is estimated that better control of the moisture in the final grain product may result in a potential savings of $.05/h/d through reduced metabolics and the ability to increase com by 3% in the finish ration.