Economic Impact: The Cost of Insects in Milling Operations

Insect infestation is a measurable cost driver in milling operations. As wheat storage pests like the lesser grain borer (LGB) compromise grain quality, their presence directly impacts processing efficiency, raw material usage, and profit margins. Our Technical Services expert, Johnny Wilson, was instrumental in developing a recent USDA-backed study that sheds light on just how steep those costs can be without proactive control measures.

The full study, linked here, was conducted by Dr. Jeff Gwirtz and the USDA Center for Grain and Animal Health Research in Manhattan, KS, regarding the importance and value of insect control in the milling process. In our first blogs exploring the study, we discussed why insect control matters in milling and how to quantify loss.

Now, let’s take a deeper look at the larger economic impact of infestation in milling operations.

Infestation Shrinks Yield and Profit

The controlled study examined hard red winter wheat, a variety expected to lead U.S. wheat production this season, under varying levels of LGB infestation. Across a 9-week storage period, samples were later processed to mirror real-world milling operations. The findings were clear: even minor infestations result in measurable losses.

• Flour yield declined progressively from the uninfested control group to those with low and moderate LGB populations.
• Dry matter loss increased with infestation severity: 0.22% for low-infestation samples; up to 0.5% for highly infested wheat.
• Cleaning systems failed to remove all insect debris, rendering some material unsuitable for food-grade milling.
• Removing contaminated fractions improved quality, but at the cost of further raw material loss.

A Compounding Economic Effect

Every metric of efficiency was impacted: flour yield, raw material throughput, cleaning costs, and product integrity. And while each percentage point may seem small, the effect is magnified at scale:

• More grain must be used to meet flour targets.
• Increased processing time and cleaning are required.
• Unusable material must be discarded.
• Brand integrity and regulatory compliance may be jeopardized.

What starts as a few insects in storage quickly becomes a widespread operational issue that impacts the bottom line. The study quantifies what many mill operators have long suspected: the economic impact of infestation isn’t theoretical. It’s daily, cumulative, and costly.

Prevention Is More Cost-Effective Than Correction

With commodity costs rising and profit margins tightening, prevention is no longer optional. A proactive insect control strategy protects not just stored wheat, but every step of the milling process that follows.

Stay tuned for the final blog in this series, where we’ll explore integrated solutions for long-term protection and cost savings.

Have questions or ready to get started with preventative protection measures? Visit our product page for information to help you implement a proactive solution, or contact a representative in your area to talk through the solution that’s right for you.

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