The use of peripheral machines in flour mills of today

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					            Digital Re-print - May | June 2010
Feature title: The use of peripheral machines in flour mills of today

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                                                                                            Peripheral machines                     Feature                                                                            Feature                 Peripheral machines

                                                                                                                                                      Images courtesy of Satake Europe :
                                                                                                                                                                                                                       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 :
                                                                                                                                                                                                                       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

                                                                                                                                                                                                                       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

             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
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 :

                                                                                                                                                          Peripheral machines                     Feature

                                                                                                                                                                                                                                    M lling 2010/11

                                                                                                                  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
                                                                 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:

                                                                 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
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provide everything from reliable troubleshooting and original replacement parts
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Description: 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.