The use of peripheral machines in flour mills of today
Whilst there can be no disputing the fact that the rollermills and the sifters are the main, key machines within a flour mill, there are a host of other machines scattered around the mill, wheat cleaning, bulk storage and packing areas that have significant roles to play in maintaining or enhancing operational efficiency on a site and it is these machines I intend to look at in this article.
Digital Re-print - May | June 2010 Feature title: The use of peripheral machines in flour mills of today Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872 www.gfmt.co.uk NEXT PAGE Peripheral machines Feature Feature Peripheral machines Images courtesy of Satake Europe : http://www.satake-group.com condition of wheat to first break to such an 1950s when The use of extent as to allow the mill operative to set his mill up properly and optimize extraction mills often had two roller floors. Images courtesy of Satake Europe : http://www.satake-group.com peripheral rates. The fact that Calibration is required regularly and if a roll was set records of “as found” conditions should be to grind too kept to identify seasonal trends. For example hard then flakes machines if the local vegetable processing factory uses were produced high levels of water in the season then you which were will need to make adjustments to allow for scalped off and that. lost down the As we move on into the mill I would class coarse reduc- in flour mills of today the scales as peripheral machines, since they tion side of do not change the nature of the product as the mill was it passes through. apparent to Scales do however play an enormously most millers important part in the running of the mill and engineers since all our information about mill efficiency, and hence the by Jonathan Bradshaw extraction rates, throughput rates etc comes flake disrupter from the scales, more often than not these was introduced Bran Finisher days linked to a central processor that gives so that hard a continuous read out of the scale readings grinds could be and the calculations which we would other- achieved and any flakes could be very pungent and unique W hilst there can be no I don’t class the intake separator as a a separator and a colour sorter is all that is wise do long hand at the end of each shift. broken down before they reached the scalp- odour. So unique is the disputing the fact that peripheral machine but I do class the magnet required to provide a clean wheat stream to It goes really without saying that proper ing covers. Similar maintenance tasks should smell that many operatives do not recognize the rollermills and the in the silo as being peripheral to the process. first break. calibration is required on all scales and their be carried out periodically on disruptors it and it goes unattended to. It pays to train sifters are the main, key machines Magnets, wherever they may be, in the However, colour sorters come under my proximity to blowing lies should be checked and blades should be kept sharp by running all staff correctly to recognize this odour and within a flour mill, there are a host intake house, the wheat cleaning plant, scat- heading of peripheral devices and they do for any adverse effects on scale operations. an angle grinder over them to maintain the also in the accepted practices for dealing of other machines scattered around tered around the mill or in the bulk flour require regular servicing, bulb changes and The use of flake disruptors on the head leading edge. with insects. the mill, wheat cleaning, bulk storage silo should have the material they collect nozzle checks. The compressor which sup- reductions, detachers on the lower reduc- I also class sieve cleaners, throughs tray Pheromone traps can help identify insects and packing areas that have signifi- examined regularly and for me that means at plies air to these machines is definitely on my tions and other similar devices, either posi- cleaners and other devices on purifiers and on the wing and also give warning that a cant roles to play in maintaining or least once every eight hours unless there is a list of peripheral machines and needs good tioned in the basement, on the top floor in sifters as peripheral devices and I believe fumigation should be performed. Pheromone enhancing operational efficiency large quantity of product passing over them servicing if it is to work efficiently. or mounted directly in the pneumatic lift all that regular inspection of these and replace- traps should be logged and should not be on a site and it is these machines I in which case twice a shift would be more We have a great dependence on clean have an impact on extraction and ash. ment of worn ones will give you a handsome placed anywhere where they are likely to intend to look at in this article. acceptable. dry air for many functions in our mills and Keeping rotors in good order is of para- return for very little expenditure. be dislodged or fall off into the process. Looking at what has been collected on a I see many mills where the compressor is mount importance and I believe it pays to If you are not careful you could cause Let us start at the beginning in the wheat magnet can often give warning of a disaster stretched to its limit due to the air supply change pins once a year ideally just prior to Recognizing odours yourself more of a problem than you silos where we see an intake separator, often about to happen elsewhere. If a large quan- having ever increasing demands placed upon harvest. The number of rollermills in a mill Regular strip down of sifters will reveal bargained for. tity of sifter bolts starts it as additional machines are added. has now drastically reduced since the mid- the tell tale signs of bug urine which has a Several sifter sections are prone to to appear then further In my strongly advocated daily walk round examination is required the mill I recommend turning on the com- “It pays to know your at the sifter since one or more is clearly about to pressed air supply when the mill is not run- ning. It is much easier to hear air leaks and fall apart. track them down when plant is stopped and mill and screenroom but New items you would be surprised just how many traps and water separators jam open, costing you appearing we must not forget the money when it is unnecessary. In the wheat clean- The principle of colour sorting is to use ing house the principal the diffused light to make the wheat grains ancillary machines, they machine are all familiar to us but there are some “disappear” into the background which then allows impurities to be much more easily all have a role to play” new items appearing identified. If bulbs are not maintained then which need our attention. the wheat remains visible and the colour Colour sorters are sorter will reject it. A good maintenance common place now and contract will pay dividends … literally. often can be seen replac- much maligned and rarely maintained since it ing cylinders and disc separators in the older, The importance of calibration is such a simple piece of equipment which more established mills. In the new mills they Damping systems are important and rarely breaks down or goes wrong. are now the accepted norm and often just when operating accurately can improve the 24 | may - June 2010 Grain &feed millinG technoloGy Grain &feed millinG technoloGy PREVIOUS PAGE NEXT PAGE may - June 2010 | 25 Images courtesy of Satake Europe : http://www.satake-group.com Peripheral machines Feature M lling 2010/11 International will struggle all day trying to set a good sionally with very few, if any operatives at grind. all. Such highly efficient items of equipment Directory Screw conveyors collecting flour obviously require a sizeable investment and being used to mix in additives should have the additives feeders posi- tioned as far away from the discharge and a large volume is needed to justify the expense. Well worth it however in the larger mills around the world. 19th PRINT EDITION - OUT NOW! point as possible in order to attain a In these larger mills it is quite common • Industry Terminology good mix. to pellet the bran produced and in mills • Products & Services section > including thousands of products and services from across the industry Intake Separator SATAKE GFID Additive feeders should be equipped where there is a low demand for bran it • A-Z of milling suppliers > Over 25% of our information has been updated since last years edition, as well as over with level alarms so that flour cannot be is common to place the bran in the wheat 150 new companies that have joined the IMD. produced without the correct additives. It silos as they are emptied and then trans- • International Organisations > We have added more organisation data, that will help any company operating sweating if not exhausted properly and varies from country to country as to wheth- ship the bran back to the origin of the within the global industry careful attention should be paid to estab- er the miller or the baker adds the bakery wheat on the next available grain vessel. • Commodities data > Completely updated section, produced in association with IGC (International Grains Council) lish which sections are prone to this improvers but it is becoming the norm Occasionally larger mills will have their • Equipment guides section > now including: since when sweating or condensation does for the miller to do it, hence it is vitally own feed mill and will use the bran as - NEW! Elevator buckets guide occur the sifter cannot perform prop- important for there to be good indication part of the diet for local livestock. In such - Extruder & Expander guide > additional charts added! erly and flour covers will simply blind over of low levels in all the feeders. In the case cases they may bring in mixed cargoes of - Hammermills guide > additional charts added! gradually. of mills who have an automated mill control commodities such as wheat, maize, soy, - NEW! Pellet press guide What ever you Spouts should be checked regularly under sifters that sweat to ensure moth system the mill will be sent into suspend mode whenever low levels of additives are etc to make up a balanced diet often using local ingredients such a guinea corn where are looking for frasse and webbing does not build up. If reached rather than produce any flour that available. - ﬁnd it with IMD! it does then spouts should be cleaned by is not acceptable to the baker. And, finally, I include in peripheral “dragging”. Fortunately such evidence of Health and safety has precluded the machinery such items as generators, labo- insect activity is rarely seen these days. use of gas to bleach flour but several mills ratories and vehicles used for transporting Definitely classed as a peripheral machine in my book but with a very still maintain agitators through which dif- finished products locally. All of these www.internationalmilling.com important role to play is the bran finisher. need to be Now fully recognized by most engi- maintained, par- IMD_AD190x132.indd 1 25/05/2010 16:43 neers, Satake in particular, this machine ticularly genera- Shangdong Yingchun not only removes the last remnants tor sets. Where of flour from bran but is also they are installed Steel Silo Manufacturing marshalls coarse stocks into a to supply power as recognizable stream. Given an alternative to the the use of inclination main supply company in the new Satake it is done for reasons TRUTH - INNOVATION - PURSUIT OF EXCELLENCE - QUALITY - PEOPLE ORIENTED - PROFOUND KNOWLEDGE machine the bran of continuity of supply finisher can be and to maintain a constant used to great voltage, not often achiev- effect, espe- able from the local power “With over 50 years of experience in the industry, we have built a solid reputation for “Yingchun”. cially as far as company. Using fuel from the This reputation is based on our scientific management, advanced processing, strict quality control extraction levels are incoming grain vessel to power and excellent after sales service. concerned. the generators can show some We will stick to our tenet of “Quality first, credit uppermost, customer guided, common economies, but there is little need The last ‘policeman’ ferent flour streams may pass. Whilst to justify the expense of a generator development” and provide the best products and services for you” Redress sifters are all important since this is somewhat over the top for most set when the alternative is invariably no they are the last ‘policeman’ in the mill. operations, I see no reason not to maintain power supply at all. I am seeing more mills using level agitators to assist with blending of flour As a last comment, it is attention to probes under redress sifters to tell the additives. detail that keeps all these peripheral and mill operative when the bag is full of In the bulk flour silos and through to the ancillary machines performing satisfactorily excess overtails, indicative of a burst packing plant there is usually a liberal use and daily walks around the mill and other cover back up the mill somewhere. of magnets. My earlier notes about mag- processes will pay handsome returns come Drawing samples will quickly identify nets applies just as much here as earlier the days of reckoning. Shandong Yingchun Steel Silo Manufacturing Co., Ltd. where the burst cover lies. in the flow. A simple check list of functions that Address: No.101, Beiyi Road, Dongying City, Shandong Province As well as sieve cleaners being impor- should be examined daily is well worth Tel: +86 546 8313068 tant then so too are roll brushes and Making a large investment keeping especially of the operations that Email: firstname.lastname@example.org other roll cleaners, criterion cleaners and Packing houses have changed beyond are being monitored. It pays to know your similar These, when working correctly will all recognition since the mid 20th Century. mill and screenroom but we must not enable the miller to set a good grind but High speed packing using carousels has forget the ancillary machines, they all have if they are damaged or ill fitting the miller led to direct loading onto vehicles, occa- a role to play. 26 | may - June 2010 Grain &feed millinG technoloGy Grain &feed millinG technoloGy PREVIOUS PAGE NEXT PAGE may - June 2010 | 27 Your mill is our priority. No one knows our systems as well as we do. We built them, and we will do everything we can to ensure that they continue to improve your company’s productivity. With fully customized service plans we are able to provide everything from reliable troubleshooting and original replacement parts to technology upgrades, preventative maintenance, and consulting services. Are you satisfied? Then we are too. 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