Annually, millions of tons of maize and wheat are grown and processed to create high-quality products like bio-ethanol, starch and sweetener products. During this process cereal is milled, after which the desired product is extracted. Bas: “A side stream result of these processes are what we call co-products, residual ingredients not utilized in the primary production chain. For example with maize processing, co-products can be fibres and corn syrup or corn steep liquor.” Usually, these ingredients are mixed, dried, pelletized and sold to the compound feed industry. “The drying step, however,” Bas continues, “is an energy intensive process with high costs and carbon emissions as a result. Especially when the compound industry consumes even more energy to grind down the pellet before creating their own pellets using the co-product.”

 

Low-carbon rations

By switching from dried to unprocessed, or ‘moist and liquid’, co-products, cereal processors can reduce their emissions and amount of energy required, thereby directly saving and stabilising costs.

According to Neil, other participants in the value chain also benefit from wet co-products. “With our co-products, farmers can utilize a low-carbon ration for their animals. This helps them meet requirements set by for example dairy or meat processors.” A transition in handling co-products has implications for both supplier and farmer though, Bas explains. “It is situation-specific of course, but producers are often not set up to handle wet co-products. In many cases this requires some changes in their existing infrastructure. That is where we come in.”

 

Full responsibility

Bas and Neil work together with European suppliers to set up a new process and supply chain for wet co-products, based on Duynie's experience throughout different European markets. “We take full responsibility for handling co-products,” Bas describes. “This means that we ensure production continuity, safety, registration and documentation, and an overall efficient logistical process.” Duynie also develops and manages a market to ensure reliable sales of the wet co-products. “Every new market has its own regulations, needs and requirements. We approach these markets successfully by building on our experience in business development, nutrition, health & safety, and regulations.”

 

Strong partnerships

Neil provides an example how they worked together with a supplier to enter a new market: “Last year we helped an international starch producer in Europe to switch completely from dried to wet co-products. The project took just three months. We explored their market, set up a supply chain and provided the supplier with the necessary equipment to adjust their logistics within the factory. We explored the local market demand for co-products. We spoke to influencers and nutritionists in the area, creating demand and anticipation for a new product. We supplied around 15 vehicles to the site, giving the opportunity for complete 24/7 site clearance as well as purchasing product mixing equipment and supplying a project team to ensure the product was produced in a stable, high quality, market friendly way. In just three months, we went from zero to 3000t a week!”

By building strong partnerships with their suppliers, Duynie can tackle issues that appear in various markets, such as mycotoxins in cereals. In some markets in Europe an increased risk of mycotoxins in cereals like maize can occur. Bas: “This has an impact on where the product can be sold. Regulations vary per country and whether it is fed to dairy or beef cows for example. Because we know the markets and regulations we can anticipate and solve issues before they become a problem for our suppliers. On top of that we are actively doing research and working on solutions to reduce the risk of mycotoxins in co-products.”

 

Part of the solution

Neil mentions another example of a switch from dry to wet co-products in Italy: “We helped a supplier transition from fully dried co-products to a 25 to 30% proportion of wet feed. We were able to develop a market from nothing in a relatively short time, due to our office being close to the factory. Our volume with this supplier is growing each month, giving them the confidence that there is a market for these kinds of products. Bas concludes: “Switching off the dryers is part of the solution for the future viability of grain processing factories. The more we can flick the switch, the more carbon emissions and costs we can save.”