SOW_Mill_Repairs_Phase_1.pdf

Statement of Work (SOW) Project: MIAG Multomat Remediation - Preliminary Engineering Support.

GENERAL INFORMATION

1.0 Background and Purpose: The Hard Spring & Durum Wheat Quality Laboratory (WQL), part of the Potato, Pulse and Small Grain Quality Research Unit, owns a MIAG Multomat mill purchased in 1962-1965 for $51,964. The mill supports annual hard red spring (HRS) wheat quality evaluations. In 2024, it was relocated from NDSU Harris Hall to the NDSU Peltier Complex. Post-relocation, operational issues have prevented reliable and repeatable results. A July 2024 review by JAG Services Inc. identified concerns with building configuration, equipment installation, and modifications to the mill flow and pneumatic systems. Startup attempts in 2025 confirmed the mill cannot be safely operated or achieve acceptable sample recovery for crop quality analysis. JAG Sevices Inc. reports provided below (Attachment1).

2.0 Definitions:

ARS: Agricultural Research Service HRS: Hard red spring NDSU: North Dakota State University P&ID: Piping and instrumentation diagram WQL: Hard Spring & Durum Wheat Quality Laboratory

CONTRACTOR REQUIREMENTS

3.0 Technical Requirements/Tasks:

Contractor will come to NDSU Peltier Complex Pilot Mill room facility where the MIAG mill is located. Contractor will:

1. Conduct a site visit for a detailed review and documentation of the existing infrastructure and process flow for the MIAG mill.

2. Perform safety evaluation of the equipment and facility against relevant regulatory (OSHA) standards.

3. Develop preliminary engineering documentation: piping and instrumentation diagrams (P&ID), layout drawings, parts and equipment lists, piping schematics, and detailed remediation punchlist.

4. Assess installation options and infrastructure compatibility, including tie-in locations, pipe routing, utility access, and control integration (if deemed applicable).

5. Solicit budgetary pricing from vendors to inform the purchasing strategy and budgetary planning for Phase II (Detailed engineering, procurement, installation, and recommissioning).

4.0 Deliverable / Schedule:

• USDA-ARS will contact contractor and schedule the site visit at a mutually agreed upon date, generally within 7 days of issuing the service contract.

• Contractor will perform site visit and all tasks listed in Section 3.0. At the end of the review, contractor will provide:

o 80% design package (P&ID, layout drawings, and parts and equipment lists);

o Budgetary cost estimate for parts, equipment, and installation;

o Asset remediation plan outlining priorities, rationale, assumptions, and additional requirements;

o Timeline with detailed assumptions;

o Final readout and report.

5.0 Government Furnished:

• ARS will provide the contractor access to the Pilot Mill room located at NDSU Peltier Complex (1300 18th Street North, Fargo, ND) in cooperation with WQL director or ARS-technicians. Access can generally be gained from 6:00 a.m. to 6:00 p.m., Monday through Friday, excepting federal holidays.

• MIAG mill system.

6.0 Travel:

All travel costs are billed to ARS by the contractor.

7.0 Contractor’s Key Personnel:

Contractor must have expertise on milling system remediation, particularly the MIAG-Multomat mill, which is a very unique mill that is utilized for experimental milling.

8.0 Security Requirements: Not applicable.

9.0 Data Rights: Not applicable.

10.0 Section 508 – Electronic and Information Technology Standards: Not applicable

11.0 Performance Requirement Measures: Not applicable

Date: July 24, 2024

To: Linda Dykes

From: Jeff Gwirtz, Ph.D. JAG Services Inc.

Subject: Site Visit USDA Fargo, ND July 10-13, 2024

Background:

JAG Services Inc. accepted the opportunity to provide service according to USDA Purchase Request 1134510. The RFQ (Request for Quotation) specifically asked for: “Evaluation of the condition and installation of the MIAG mill located at the North Dakota State University Peltier Complex. The goal is to obtain a MIAG mill expert's second opinion as to the condition of the mill and its installation and to determine whether the mill is operational as-is.”

Discussion:

The attached report is provided in response to the requested evaluation. It may be shared in part or in its entirety as needed to serve the interest of USDA. Resources identified or mentioned in the report are being shared directly with you and your team. Please feel free to ask any questions you might have regarding my observations and assessment.

In general, the mill is not operational as-is due in part to the sifter bearing replacement and sifter box repairs and remounting required. Once the USDA Miag sifting unit is repaired as identified in the report, the next concern is the failure of the current installation to replicate the flow of the original system Dust Collector (DC) stock returned to 4Bk and unsuitability of the spouting and pneumatic conveying system design and installation.

The working relationship between NCI, its contracted services for engineering design and installation are not transparent and appear to conflict with USDA Miag installation expectations. The Executive Summary contained within this report exposes in greater detail the nature of the NCI/USDA relationship and concerns regarding the contractual expectations or more likely the lack of contractual expectations with NCI’s and its Engineering and its sub-contractor(s).

The engineer’s (EAPC) insistence on a test run is unwarranted and pre-mature. At this point, one must ask, why test run the current USDA Miag installation knowing it doesn’t match the original flow and its spouting, suction and pneumatic conveying system design and installation do not follow milling conventions? Doing so is likely to result in additional project delays beyond that currently experienced. System corrections should be made concurrent with USDA Miag sifter repair.

Attachment 1

The technical issues are all solvable provided with proper leadership and understanding of existing agreements between NCI, its contractors and sub-contractors, and USDA. It is difficult to imagine how or why USDA and NCI with milling operation background were not engaged with design, construction and execution.

Thank you for the opportunity to be of service to the USDA. Please feel free to ask any questions you might have regarding my observations and assessment.

Table of Contents

Executive Summary

Previous Review Confirmation

NCI/USDA Project Leadership

Engineering Design and Installation

Performance Expectations-Engineering Design and Installation

Test Run

Moving Forward

Site Activity-Observation and Issues

Design and Installation Issues Separation of Pneumatic and Gravity Spouting Valve Issues Product and By-Product Collection Pneumatic Access Under the USDA Miag Pneumatic Access Above the USDA Miag P1 and P2 Suction USDA Miag Flow Changes

Opportunities Missed Splitter from 1Bk to 2Bk I and 2Bk II P1 and P2 Suction P1 and P2 Liftings Install Bran and Shorts Duster Grain Cleaning

Safety Issues Electrical Compressed Air Freight Elevator Toe Plate Dump Stations-3rd Floor Structural Dust Control Dust Control Spouting

Sanitation Issues Insects Rodent Bait Stations Central Vacuum Building Issues

General Spouting, Pneumatic, and Suction System Issues Elbow Construction Pipe Joints New and Revised Piping Various Piping Sizes

USDA Miag Sifter Box Repair

Addendum

Additional Images

Table of Figures

Figure 1 Examples of wrinkled or deformed elbows or bends in pneumatic piping

Figure 2 Break dust line to purifier P5

Figure 3 Indicating the "C" channel that makes it difficult to loosen the wing nut on the other side. See Figure 4 for a view of the wing nut

Figure 4 Wing nut needed to loosen the back of the platform clamp to release the line in addition to removing the hose clamp

Figure 5 Long line with multiple unnecessary curves. Project requires better planning than demonstrated by the existing installation

Figure 6 Centerline of one pipe needs to flow together at the centerline of the adjoining pipe. Introduction of stock at the mid-point of the elbow is not correct. Pneumatic conveying lines should be brought together on center and with minimal angle difference as shown on the right-hand picture

Figure 7 Current P1& P2 installation the lifting should be directed to 4Bk. The existing system may not be functional due to excessive air pull of the pneumatic system. Suction line should be revised like the other purifies with modification of manifold at the top of the purifier and reinstallation of false are inlet on the purifier

Figure 8 The pipes coming from P1 & P2 should be gravity lines joining together behind the back side of the North Miag unit then conveyed pneumatically

Figure 9 Product collection is directly under access needed to service USDA Miag spouting.

The picture to the left is very poor transition for collection of low bulk density materials such as bran and shorts

Figure 10 Overdesigned, poorly positioned valves

Figure 11 Too many bends, no access to clear product lines to sample collection. Piping into the USDA Miag has edges which will hold product creating a cross contamination as well as infestation issue. Sample collection has not been well thought out

Figure 12 The "T" junction shown on the right is a horrible design for introducing or blending stock into a pneumatic conveying line. The curved entrances on the left are okay although the angle could be even more shallow. The configuration shown however, is confusing

Executive Summary

Previous Review Confirmation Can easily confirm and extend Peter Lloyd’s comments of concern relative to the installation of the USDA Miag Mills and Purifier in the NCI facility. The modifications made to the USDA Miag mill to facilitate swing mill operation to Durum wheat are poorly designed and executed and failed to deliver the same capabilities as provided for in its previous location.

NCI/USDA Project Leadership The most significant challenge to getting the Miag unit up and running for either HRS or Durum milling is Project Management Leadership. No one person(s) representing the interest of both USDA and NCI with a knowledge of milling and laboratory milling operation can make decisions, interact, and direct outside contractors and sub-contractors to resolve issues, make changes and deliver the completed project in satisfactory operating condition.

Engineering Design and Installation It is not clear what performance expectations or outcomes are expected from the contractors and sub-contractors engaged in the USDA Miag move and modifications necessary to mill both HRS and Durum wheat. Many feasible solutions were offered by Peter and me in addition to USDA staff only to be stifled or dismissed because NCI had or would have an issue and was not involved in the conversation and decision. As a result, the project is stalled. It is clear project leadership and decision-making requires a functional leader or leadership team to complete the project. Immediate attention to this point is critical as the wheat crop harvest is nearing and milling and grain industry constituents are demanding results.

The engineer (EAPC) has taken the approach that installing a fan capable of generating and arbitrarily picking sufficient static pressure will make the mill pneumatic system work. The engineer ignored variations in product size, density and flow properties as well as dilute phase pneumatic conveying conventions adapted by the milling industry including long radius curves, curved pick-up rather than "T" entrance points and the inclusion of gravity lines into the pneumatic conveying system. While the pneumatic system as designed is flawed, the installation work is of very poor-quality including lack of conveying line entrance points, poor pipe alignment, and connection of pipes of different diameter without proper connection. The design and installation of gravity spouting, suction and pneumatic conveying lines are sub-par.

Performance Expectations-Engineering Design and Installation Engineering and design projects typically include a performance clause. The NCI or NDSU Facilities contract with the engineering firm should be immediately reviewed and enforced with respect to a performance clause if it exists. The contract should first indicate the original flow is to be maintained for HRS and that spouting, suction and conveying system design should follow milling conventions for material handling between unit operations while allowing for the insertion of a Durum milling flow. Secondly, the contract should state that the engineering firm is responsible for system design, installation and start up to the satisfaction of the customer. Based on my observations either the NCI or NDSU Facilities made a poor agreement and/or the engineering firm has failed the customer. Project management leadership will have to make that assessment immediately.

While NCI controls the designated space and has established agreements with the Engineering Firm, USDA owns the Miag mill and purifier for HRS and should have control over its modification including design and installation. No changes should have been made to the USDA Miag flow without USDA consent. Final approval on both the design and installation plan as well as final inspection and performance rests with both NCI and

USDA.

Test Run EAPC’s trial run request should not be scheduled until the USDA Miag sifter repair is complete and USDA concerns identified herein and in cooperation with NCI are satisfactorily addressed. When a test run is scheduled, NCI/USDA should provide tempered wheat at the target flow rate to the USDA Miag mill with NCI/USDA operating the Rolls, Sifters and Purifiers while the EAPC engineer balances the pneumatic conveying system and P1& P2 suction to NCI/USDA operator satisfaction. The cost of NCI/USDA labor and materials for operation and clean-up in addition to any required modifications during the initial start-up should be borne by EAPC.

Moving Forward Even if a pre-mature test run is successful, the suggestions herein should be addressed as the existing conveying and spouting design is an embarrassment that site visitors such as scientists, trade teams and associates of the wheat industry should not endure. The USDA Miag flow must be restored completely including pneumatic conveying of dust collector stock to 4Bk consistent with its pre-move set-up in addition to directing P1& P2 liftings to 4Bk.

USDA and NCI must establish uniform effective Integrated Pest Management, Safety, Food Safety and Miag Mill Operation protocols and programs and adhere to them religiously to the benefit of both.

Site Activity-Observation and Issues

During the visit discussions were held with Jesse Sandry a Senior Mechanical Engineer from the firm EAPC and Chris Hamre, NDSU Maintenance and Projects Coordinator, Facilities Management. Both acknowledged the poor installation of the design but not concerned about the design itself. Nothing shared suggested the engineer had experience in grain milling operations but focused on having provided adequate static pressure in fan and dust collector design. Jesse remained focused on getting the USDA Miag sifter fixed and having a test run before making any changes. Chris was agreeable to fixing some things based on a punch list to be developed.

USDA staff and I agreed to work on a list of correction items addressing the most critical items first prior to any test run. The addendum section provides a detailed list discussed with me and written out by Amy Stolt, USDA. During our discussion it was agreed that following the sifter repair corrections for splitting stock from 1Bk to 2Bk I and 2Bk II, from 1Bk to Bk Dust and from 2Bk I & II to 3Bk must be addressed. This list may be extended to include several other key pipe breaks identified in the addendum.

It is clear from the layout and design integrating the purifiers from NCI that gravity spouts should not be integrated into a pneumatic conveying system specifically those picking up from the purifiers. The use of these gravity spouts as part of the pneumatic lift system increases static pressure requirement and provide suction to a vertical opening allowing for entry of non-food grade material to be more easily picked up. The gravity lines from P1 and P2 should be collected behind the Miag equipped with a proper pick up into the designated pneumatic conveying system for delivery to their respective destination.

Design and Installation Issues Separation of Pneumatic and Gravity Spouting The pneumatic conveying design and installation fail to follow basic design principles observed in the industry resulting in excessive air and energy loss as designed and executed. The coupling of what are typically gravity spouts from P1 and P2 to the pneumatic conveying system lengthens pneumatic line distance and pressure drop beyond that which is necessary to connect the grinding, sifting and purification operations of the USDA Miag. Entrance to a gravity spout positioned upward and combined with suction increases the potential for mill stream contamination. This should be corrected by using gravity fall to a properly designed pick up point behind the North USDA Miag which can deliver stock to the appropriate destination(s).

Valve Issues Of the12 over-designed diverters placed in pneumatic conveying lines, 11 of them are set to direct the HRS mill stream 90° in a straight “T” configuration rather a diverter branching off at something less than a 30-45° angle. Each of these valves cost more than $409-$875 each with additional cost associated with extra pipe fittings for their installation. The valves are stainless steel and rated for 1000 psi of Water, Oil or Gas (valve specifications have been provided to USDA). These valves are not typical of a dilute phase pneumatic conveying system indicating the designer had little understanding of the types of conveying system used for mill stock. These valves are over-designed for the existing application (i.e.

1000 psi vs 25 psi max) and fail to accommodate both design and operational principles and typical practices employed in a grain milling/processing pneumatic conveying system.

The material to be conveyed is a mixture of gas (air) and solid product of various size, density and material property ranges as typically exhibited by mill stocks. Typical conveying velocities are approximately 4,000-5,000 feet per minute (FPM). In the existing 1- 1/4” valve application the pipe diameter increased from 1" to 1.25" at the valve inlet transition increasing the line’s cross-sectional area thereby reducing conveying velocity from 4,000 FPM to 2,560 FPM given constant air volume. Maintaining material entrapment and velocity is essential for pneumatic conveying of solid in a dilute phase. The right angle turns within the valve, basically a “T” arrangement, violates dilute phase conveying norms which utilize curves with a radius of 6-8 times the pipe diameter for turns exceeding 45° (especially 90° turns).

A low-cost solution is to use a 6-8" lone flexible hose and clamp connecting from the terminal end of the original pick-up pipe to the desired destination pipe of the same diameter. The angle created will be less than 30° offering much less resistance. Should air flow need to be cut off for the unused alternative pathway, a simple rubber stopper should be used. Changeover time between using the USDA Miag for milling either Hard Red Spring or Durum wheat is not believed to be a significant issue.

Product and By-Product Collection Changing product pick up points from the original USDA Miag design collection under the sifter to collection of stock in over-sized containers or tubs placed on carts on the first floor below the mill was not well thought out. Collection of products on the second floor with the USDA Miag keeps the mill operator in front of USDA Miag cyclones and sight glasses. In this location the operator can confirm continued mill operation and have advanced warning of potential chokes while collecting and weighing finished product and by-product streams.

The risk of product or by-product contamination or cross-contamination is greatly enhanced with open or insecurely sample container covering. The potential for contamination is significant with USDA Miag pneumatic pick-ups from under the sifters just above sample collection area.

Product and by-product collection on the first floor makes operating the mill extremely difficult due to floor height requiring a ladder and direct spouting access impossible.

Alternative suggestions were provided including installation of a platform, relocating product collection points and dropping the lifts to a height of 6-6.5 feet but nothing could be decided because NCI was not available, and it was their designated space.

Pneumatic Access Under the USDA Miag The area directly under the USDA Miag Mill sifters must be clear to prevent contamination and provide safe access to the USDA Mill pneumatic conveying system to clear pneumatic conveying system chokes. The 6’ or 8’ ladder needed to reach the bottom of the USDA Miag mill spouting will require a foot space of 54” X 27” positioned under the USDA Miag sifter discharge spouting which interferes with current product and by-product collection design.

Consideration of revising sample collection location or returning to the original USDA Miag sample collection design must be considered. USDA Miag spouting must be lowered to approximately 6.5 feet high to provide safe spouting access while standing safely on the floor as was reasonably possible in its prior installation.

Pneumatic Access Above the USDA Miag Pneumatic conveying lines on the 2nd floor are positioned out of reach of the operator and should be lowered and hung in smaller sections for quick removal to clear chokes. Given the floor to ceiling height a 10-12’ step ladder is required with a base footprint of up to 33.84” X 78.25”. Handling the ladder and piping as currently installed will be a challenge for any operator. Consider running the lines under the USDA Miag on the first floor as suggested under Product and By-product Collection.

P1 and P2 Suction Processing air source for P1 and P2 may not be able to be adequately reduced to allow proper operation of the purifier. The current installation has a cyclone attached to the pneumatic conveying system providing a drop point for P1 and P2 liftings collection. It remains to be determined if the damper adjustment on the pneumatic side of the cyclone and false air inlet adjustment on the suction line from the purifier can be balanced to allow correct purifier setting and performance. Control failure will lift an excessive amount of good quality material to a cyclone and into a sample container which will have to be handled manually effecting yield and flour quality. P1 and P2 liftings should be introduced into to the 4Bk system for proper recovery as identified in “Opportunities Missed”.

As pointed out by Peter Lloyd, given the limited amount of processing air required for purifier operation, the increase in line size after the purifier run leading into the main pneumatic line may result in product collection due to slow air speed in the cross-section of the larger conveying line. This will have to be monitored carefully as such accumulation is a yield loss, insect contamination risk and potential safety risk due to cumulated stock weight and support design.

USDA Miag Flow Changes Material from the mill pneumatic and suction systems Dust Collector should be returned to system 4 Bk as originally designed and implemented in the USDA Miag mill previous location. This practice is consistent with commercial practice and should be maintained.

Currently, materials from the dust collector will be collected in a large drum. Should a cyclone choke occur pulling stock into the dust collector and collection drum, it will be too heavy to handle safely with equipment in place. Monitoring stock return from dust collection is a common and simple way to monitor mill operation. No bin level control devices were observed on the drum or dust collector hopper which could provide a safety warning. Failure to correct this flow change has safety implications and will impact mill recovery and yield.

Opportunities Missed Splitter from 1Bk to 2Bk I and 2Bk II Revise splitting of 2Bk stock from 1Bk by utilizing or developing a simple two-way stream splitter like that described in the Kice Speed Spouting Manual.

P1 and P2 Suction Change purifier suction pick up from P1 and P2 to match remaining purifiers with damper located at floor level on the top of the purifier.

Remove old suction line and replace with false air inlet at the head end of the purifier to provide purifier adjustment capability at floor level.

P1 and P2 Liftings Delivering P1 and P2 liftings to 4Bk to eliminate unnecessary record keeping and material handling making the milling unit flow more consistent with commercial practice.

Install Bran and Shorts Duster Install a Bran and Shorts Duster on bran and shorts stock from 5Bk delivering duster tails to feed and duster through stock to B&S sifter section for removal of bran/short, middlings and flour. This will increase yield and likely produce cleaner stock from B&S sifter section to later parts of the mill. Currently, there is no Bran and Shorts Duster only a Bran and Shorts Duster sifter section which is being underutilized because there is no Bran and Shorts Duster.

Grain Cleaning It is highly recommended that both NCI and USDA use the current NCI cleaning system (Milling Separator and Aspirator) followed by the USDA Carter Bull Dog Cleaning system to optimize grain cleaning and protect both the mill and the color sorter to be used on Durum wheat. Utilizing the cleaning systems sequentially in this manner will better protect the NCI/USDA cleaning equipment including the color sorter and provide for an optimally cleaned wheat thereby protecting the USDA Miag and ensuring a clean quality finished product.

Safety Issues

Electrical Does the mill meet local, state and federal electric codes as common 110 electrical outlets are in place in the mill room. Understanding NEC and NEMA for Locations with Combustible Dust and IAOM will be provided to USDA.

Compressed Air Compressed air is currently available at the southwest corner of the mill on each floor. It must be repositioned to the center of the south wall or alternatively, a second outlet placed in the northeast corner of the room on each floor. Compressed air is needed to assist in cleaning and blow down for dust and insect control. The single current position requires a very long compressed air hose to address the furthest reaches of each room near the ceiling. As such, the hose will be out of operator line of sight creating a tripping hazard for others in addition to a heavy load burden to handle while working on a very tall ladder especially on the 2nd and 3rd floors.

Freight Elevator The freight elevator door should be modified to extend the door full height from top to bottom thus preventing items from protruding out and catching on the building floors during operation. The existing modification does not provide satisfactory protection.

Toe Plate The toe plate behind both USDA Miag units must be made easily removable to enable access to piping and clamps under the units. Easy access is required to facilitate operation and clearing of chokes in the system.

Dump Stations-3rd Floor Dump Station Suction The dump station for wheat being cleaned on the Bull Dog Unit (USDA) is poorly designed.

The suction placement is well above the dust source which is in the pit. The side walls and hood structure are grossly over designed using thicker plate steel than necessary. Hanging clear poly strips as a curtain terminating above the working level may provide some dust control but would not be optimal. The remaining three dump locations have a dust collection piping and slide gate control at head height near the dump stations. These piping and slide gates create a safety issue as they are head height with no marking or protection.

See Peter Lloyd’s red tape marking behind the north Miag along the north wall. Besides being a safety issue, the suction lines are not able to provide dust collection at the point of dust generation. The design is incomplete and should be addressed.

Dump Station and Ferrous Metal Protection The grates installed on each of the four hand dump stations are not bar magnets. Bar magnets remove ferrous tramp metal protecting machinery and product. The current system for dirty wheat being delivered to the Bull Dog unit (USDA) does not have a magnet on the incoming stock. A magnetic grate or a spout magnet should be designed into the Bull Dog (USDA) dirty wheat system prior to cleaning as well as the NCI Milling Separator and Aspirator system. Consideration must be made for magnet inspection and cleaning ease as the entrance to the NCI Color Sorter is located near the ceiling on the second floor.

Fortunately, there is a magnet in the tempered wheat spout entering the Miag Mill.

Dump Station Grate Size Not only are the grates installed on each of the four hand dump stations non-magnetic, also their spacing is too large as designed for a grain elevator dump pit. The spacing is very large considering the low flow of the hand dump station. A smaller grate design opening of ¾-1” round or square should be placed in the system to prevent non-wheat materials from entering the system. Modified grates or screen overlay will protect both USDA and NCI equipment and building assets as well as product.

Dump Station Doors The dump station doors for wheat being cleaned on the NCI Milling Separator and Aspirator system is too large to be lifted by the center positioned handles. Handles should be installed close to the end of each door panel for lifting purposes as two people may be required to lift the doors safely. Each door should be fitted with a chain, cable or a block to hold the door open without straining hinges or landing on operators’ feet.

The dump station for tempered wheat to the USDA Miag should be further modified to keep the handle from being a tripping hazard as it does not readily rest flat on the lid at floor level. Additionally, the door should be fitted with a chain, cable or block to hold the door open without straining hinges or landing on the operator’s feet. Most importantly, the grate and door should be removed and installed 180° from the current position so that the operator can bring and dump wheat without having to work around the purifier installation.

Structural Dust Control The floor wall junctures should be coved to facilitate cleaning and eliminate cracks and crevasses.

The column base and horizontal beam runs should be beveled to aid in controlling dust build-up.

The floor cut out for the USDA Miag units as well as those for the purifiers are not appropriated for a grain processing facility. The metal framework for the poured concrete floor has been left sharp in many locations. Voids created by the concrete are filled with dust and stones which may get into the mill due to vibration falling freely into the rolls during operation and inspection. The materials will damage rolls and contaminate finished product. Also, the voids will hold grain dust providing harborage for insects. The cut outs must be cleaned, filled and smoothy finished for safety and sanitation concerns.

Dust Control Spouting Termination of multiple dust control spouts with slide gates are positioned head high creating a safety hazard. An outside contractor was observed to have hit his head on one of these fixtures. These need to be positioned where required for dust control or terminated at a height of at least 7’ from the floor.

Sanitation Issues

Insects Open cross box type beams should be sealed at the top or cleaned monthly to prevent insect growth and development. These openings are also pathways for rodents.

Insect trails and a mouse was observed during the visit. It will be necessary to upgrade sanitation design and protocol to accommodate poor design.

Rodent Bait Stations Improvements should include bait stations on the building interior and exterior.

Building should be properly sealed to prevent rodent entry as indicated in the following Building Issues section.

Central Vacuum Blowing down with compressed air is the least preferred method of dust clean up. It is better to brush down overheads to reduce working in suspended dust and waiting for it to settle before sweeping up. An even better solution is to vacuum overheads and surfaces where possible so that the dust is collected without ever being suspended in the air. A central vacuum system is recommended and should have multiple outlets on each floor with dust collection positioned on the first floor. A Central vacuum is essential for maintaining a safe, clean sanitary milling environment.

Building Issues Structural openings in the brick masonry work on the building exterior encompassing the NCI designated space must be completed to properly seal the openings. Rodents and insects may enter the building and contaminate the building, raw materials, finished goods, and other materials including the USDA Miag Mill.

There is a gap underneath the exit door. Cold air will come through that opening, making it difficult to maintain the desired temperature during wintertime. The door will end up with ice accumulating at the bottom due to condensation and heat and cooling cycles. The exit may be blocked or sealed shut at a time of emergency egress.

Is the building insulated adequately to allow for 60-65% R.H. without condensation forming on the walls? The mill room may need to be heated in advance of milling to warm the outside walls prior to and increasing the relative humidity to a proper milling condition of 60-65% R.H. The protocol for USDA Miag Mill operation should spell this out clearly to prevent working floor slippage and mold on wall and floor surfaces resulting from condensation

General Spouting, Pneumatic, and Suction System Issues

Elbow Construction Pipes bent to 90° curves of long radius are deformed. Many 1” pipes were pressed into an oval cross section for example, 1.18” pipe before and after bend was deformed into an oval with height of 0.97” and width of 1.3” which will impair flow. Replace all deformed 90° pipes.

Pipe Joints Both gravity and pneumatic pipes should be squarely butted together and clamped rather than spaced apart. The connections are not to be used as a sight glass. A sight glass is a clear Plexiglas material which has the same outside and inside dimension as the conveying pipe. It is held in place at the top and bottom forming a connection between the two solid conveying pipes. The sight glass installation allows the operator to confirm vertical flow during mill operation.

New and Revised Piping For product safety, all piping especially the white newly painted pipes should be cleared of paint on the inside of pipes as well as burrs on the inside of the pipes for product safety.

The burrs will damage roll corrugations and along with paint contamination of the finished product.

Various Piping Sizes As with the prior installation, there are several pipe sizes employed within reason however, the new installation has too many pipe connections requiring a plastic insert or sleeve to facilitate clamping. Pipe sizes (diameter/length) and/or coupling material must be modified to achieve a square fit.

USDA Miag Sifter Box Repair Discussed sifter drive and box issues. Suggested thrust bearing for replacement and repair of the sifter box utilizing carpentry talent available. The box should be shimmed in the framework and the framework level left to right, front to back vertically and diagonally across each box located on either side of the counterweight. It is suggested that four corners of each sifter box be supported during the repair process and bearing replacement to prevent torquing of the sifters metal frame holding the boxes and the counterweight drive mechanism. Sifter reeds should be replaced if possible and torqued as per Great Western and Norvell installation procedures to ensure the sifter is properly supported. JAG will provide a copy of these instructions.

Addendum MIAG mill notes made during Dr. Jeff Gwirtz visit on 07/11/2024-07/12/2024

1. Split product load coming off 1Bk going to 2Bk I and 2 Bk II more appropriately. The current funnel splitting the load has 4 dampers in there that need to be adjusted with precision which make it very difficult to split the load properly to avoid over-loading one section over the other. It was suggested to put a mechanical divider (Kice valve) to split the load going to 2Bk I and 2Bk II. It will be important to be able to adjust it and to be able to see in there while making the fine adjustments.

2. Repair the outlet from 1Bk to Break Dust. Currently we are not able to adjust air flow because it has been damaged. Repair on this one as well as any other outlet funnels that are damaged will provide opportunity to adjust air flow in the pneumatic conveying system.

3. The line going from 2Bk to 3Bk has been known to cause chokes and the way the pipe curves and where the connections clamps are located make it difficult to remove the pipe to clear the choke. It was suggested to cut the line where the red tape is (just a suggested spot on the pipe to make it easier to clear the choke) or turn the elbow on 2Bk I to the outside near the toe kick and turn the elbow on the 3Bk pick-up to then connect this line on the back side of the mill rather than underneath.

4. There are many pipes that were bent that caused the pipe to become deformed. The 90⁰ sweeps were flattened when they were bent and are now more oval shaped on the bend. They should all be round.

5. In addition to number 4, some of the lines were also wrinkled when they were bent.

A good example is on the line coming from Break Dust going to Grader I or even from Break Dust to Purifier 5 for the durum flow. Please see Figures 1 and 2 below. Aside from the line being wrinkled, the line from Break Dust to Purifier 5 provides segway into number 6.

6. Make sure to put elbows to disconnect the horizontal or vertical runs more easily or to access the funnel under the mill to clear the choke, if necessary, instead of disconnecting the entire line.

a. For example, the line identified in number 5 is one solid pipe with no disconnects in the line. In the case of a choke, it will need to be disconnected from the funnel under the mill, disconnected from where it is secured onto a piece of flat iron attached to the mill on the back side, and then disconnected from a hose clamp that is over 7’ off the floor on the second floor. The “wiggle worm” of a line is just over 9’ long. This line is like a hook that will need to be finagled out from under the mill to clear the product out of the line (Figures 3 and 4).

b. Another situation that must be addressed is the need to disconnect a line that is clamped onto the back of the platform where all the pick-up lines are secured. The wingnut will need to be released, but you will also need to get a wrench to hold the nut to unscrew the screw which is in a ‘C’ channel (Figure 5), and then the hose clamps can be released. This situation can be found on the durum flow coming from Grader I going to Sizing I (Figure 6). It would be best if there was a separation point in the line before it goes up the back side of the mill to be fed into the cyclone. There are other instances where this occurs as well, but they are not as bad because there is shorter line and a disconnect point close (Figure 7)

c. Another example where an elbow should be used on the line from Break Dust to Grader I. Under MIAG 1, the line comes out of the Break Dust that has a 90⁰ bend in it and then goes over to MIAG 2. There should be an elbow at the 90⁰ bend to be able to disconnect the line more easily instead of having to disconnect the line at the funnel under the mill and then all the way to the horizontal run before it goes over to MIAG 2. Please see Figure 2.

7. The product coming from Purifier 1 and 2 going to Sizing I is using pneumatic conveying on a gravity line. There were a couple of suggestions to remedy this problem. First suggestion is to use gravity to drop product down to the first floor, then use an elbow to sweep it across to the original MIAG line and use another elbow to connect it to go up the back side of the mill like it was at Harris Hall. The second suggestion was to drop it down to a good height (a. good height to be able to access without a ladder and b. more importantly to be below the cyclone for proper product pick-up) and then over to Sizing I to the pick-up line.

8. The line going from 3Bk to 4Bk needs to be shorter so that it is closer to the mill or have it come out on the side near the toe kick and have the line sit on the concrete ledge. Similar proposal as number 3.

9. To remove the diverters that were put in place, some of the lines may need to be physically removed and replaced with another section to make the change over when switching between HRS and Durum. For instance, in the HRS system product is going from Sizing II to 1M. The diverter should be removed so that the product does not come up the back side of MIAG 1 to then go back down to the first floor to be conveyed over to MIAG 2 and then up to the 1M. Can we drop it down under MIAG 1 on first floor and then over to MIAG 2 like it was at Harris Hall? Then to address the durum flow coming from Sizing II to P4, can we change out the pipe so that the product will flow up the north wall behind MIAG 1 up to P4? This approach may be utilized in other situations on the mill as well. Such as Sizing I to 1M in the HRS flow and Sizing I to P4 in durum flow.

10. The green cyclone contains liftings from the purifier and the product can be returned into the mill 4Bk.

11. Lines going into a cyclone should have center lines aligned. For example, the line going into the 4Bk cyclone has a gravity line that is coming from P1 and P2 that is fed into a pick-up line from behind the mill. The center line of each line coming in is not aligned with one another. It would be better suited like the line coming together on the 3Bk cyclone (Figure 6).

Figure 1 Examples of wrinkled or deformed elbows or bends in pneumatic piping.

Figure 2 Break dust line to purifier P5

Figure 3 Indicating the "C" channel that makes it difficult to loosen the wing nut on the other side. See Figure 4 for a view of the wing nut.

Figure 4 Wing nut needed to loosen the back of the platform clamp to release the line in addition to removing the hose clamp.

Figure 5 Long line with multiple unnecessary curves. Project requires better planning than demonstrated by the existing installation.

Figure 6 Centerline of one pipe needs to flow together at the centerline of the adjoining pipe. Introduction of stock at the mid-point of the elbow is not correct. Pneumatic conveying lines should be brought together on center and with minimal angle difference as shown on the right-hand picture.

Additional Images

Figure 7 Current P1& P2 installation the lifting should be directed to 4Bk. The existing system may not be functional due to excessive air pull of the pneumatic system. Suction line should be revised like the other purifies with modification of manifold at the top of the purifier and reinstallation of false are inlet on the purifier.

Figure 8 The pipes coming from P1 & P2 should be gravity lines joining together behind the back side of the North Miag unit then conveyed pneumatically.

Figure 9 Product collection is directly under access needed to service USDA Miag spouting. The picture to the left is very poor transition for collection of low bulk density materials such as bran and shorts.

Figure 10 Overdesigned, poorly positioned valves.

Figure 11 Too many bends, no access to clear product lines to sample collection. Piping into the USDA Miag has edges which will hold product creating a cross contamination as well as infestation issue. Sample collection has not been well thought out.

Figure 12 The "T" junction shown on the right is a horrible design for introducing or blending stock into a pneumatic conveying line. The curved entrances on the left are okay although the angle could be even more shallow. The configuration shown however, is confusing.

Date: July 25, 2025

To: Linda Dykes, Ph.D. USDA Fargo, ND

From: Jeff Gwirtz, Ph.D. JAG Services Inc.

Subject: Site Visit USDA Fargo, ND July 14-17, 2025

Background

In September 2023 training was provided by JAG Services Inc. for USDA staff on the USDA Miag Mill in Harris Hall at which time, it was operational with minor issues. In July 2024 JAG Services made a site visit to review the installation of the USDA Miag Mill following its move from Harris Hall to the Peltier Complex. At that time, the USDA Miag Mill sifter drive was being repaired not allowing for mill operation. Technical support was provided for the sifter repair, and a review of the new installation was made. The JAG Services July 2024 report expressed numerous concerns regarding the mill building, mill installation and modifications made to the mill flow and pneumatic conveying and general suction system.

In March 2025 a group of people including USDA staff, U.S. Wheat Associates staff as well as representatives from the design and/or engineering group attempted to conduct startup tests. Based on conversations with some participants the start-up was not successful due to various chokes, material loss and mill imbalance. JAG Services was provided an opportunity to run the USDA Miag Mill in July 2025. This report is a summary of observations made during the July 14-17, 2025, USDA Fargo, ND visit.

Conclusion

As a result of moving and modification of the USDA Miag Mill from Harris Hall to the Peltier Complex at North Dakota State University (NDSU) in Fargo, North Dakota, it is no longer suited for its intended purpose. The current installation cannot be operated safely even with two staff members. Moreover, as a matter of milling HRS wheat for crop or breeding line evaluation, neither the USDA Miag Mill yield, nor recovery can be adequately maintained without further modification and testing. Having commitment to providing meaningful milling results in support of wheat crop or breeding performance, JAG Services Inc. would not engage as USDA Miag Mill operator for upcoming HRS harvest.

Accomplishments

The dust collector for milling was examined. The collector holds a lot of product due to internal edges as part of the design. The dust collector and filters will require cleaning prior to any down time over one month in length. Consider bagging and freezing filters when not in use. Additional amounts of warm up wheat will be required to “load” the system before a control sample can be run. Material loss will make milling data useless.

1. Air flow from the mill was adjusted using damper valve that had been moved from the Harris Hall installation. This adjustment reduced lifting of product into the filter while providing adequate air for conveying within the mill with proper adjustment.

The new fan installation has greater capacity than the previous fan and must be properly balanced across the mill and purifier suction to be effective. Adjustments were made at the cyclones to obtain better air balance and reduce material lifted into the filter while reducing choke frequency.

2. A stream splitter was installed from 1BK to 2 BK I and 2BK II. While functional, appearance and handling must be improved.

3. Two loops including linear runs, water piping transitions, multiple short radius 90º turns and overdesigned valves were eliminated for stock going to 1M.

4. Many open lines entering active conveying lines were disconnected and sealed to prevent open lines from short circuiting systems where one or more conveying lines with stock were being controlled by a cyclone valve adjustment.

5. Additional modifications were made to facilitate continuous flow to both third and fourth break cyclones.

6. Three cyclones on the third floor for P1, P2 and Purifiers suction were more closely adjusted to processing need. Additional adjustment for the cyclone associated with purifier processing air may need some additional work involving opening of the false air inlet associated with the cyclone.

7. Flour associated with being lifted to one of the purifiers is believed to have resulted due to flour not being able to discharge from the sifter box and or backing up from the collection bucket and carrying over the flour cloth to the purifiers. This appears to have been eliminated.

8. Concerns about shifts in flour production were addressed as flow became less interrupted. Specifically, a greater quantity of flour of proper appearance (cleanliness) is being produced at the head end of the reduction system and less flour with a more appropriate appearance (less clean, darker) at the tail end of the reductions system.

Recommendations

1. Revise the pneumatic conveying lines necessary to mill HRS and cap off all other unnecessary lines to prevent air loss and contamination.

2. Update all pipe connectors and clamps making them uniform in size and style where possible to facilitate ability to quickly and safely clear system chokes with material recovery for processing.

3. Eliminate unnecessary loops and valves to shorten stock pathways where possible.

The valves installed were designed for liquids and gases not dilute phase conveying of milled product. As a result, small particles (think several microns in size) have filled voids and perhaps swollen (as biologic materials such as starch a cellulose

do) locking the vales into position making them extremally difficult to move.

4. Utilize long radius 90º elbows, 60º, 45º, 30º, and 15º elbows and similarly designed y–branches along with shorter manageable straight runs to eliminate difficult to handle pipes and clear pipes with multiple bends and curves.

5. Install flour and by-product collection buckets under the Miag sifter as…