'What's New?'in flour milling equipment
July 01, 1999
by Teresa Acklin
The annual A.O.M. trade show offers flour millers the opportunity to view the latest technical advances in flour milling equipment. Following is a summary of the “What's New?” products featured at the A.O.M.'s 103rd technical conference in Fort Worth.
BUHLER NEWTRONIC ROLLERMILL
The Newtronic roller mill from Buhler Ltd., Uzwil, Switzerland, offers reliable feeding, perfect and consistent grinding, non-compromising sanitation, high isolation degree, noise control and an integrated control system.
Stock is gravimetrically measured in an entirely novel way across the wide inlet. The feed rolls are automatically controlled and monitored by an electronic system, with infinite variation of the product feed rate. In roller stands processing the same product on both sides, a higher- and lower-ranking control system ensures the necessary load compensation. With break rolls, larger feed rolls ensure the uniform discharge of difficult products.
The compact roll pack offers precision adjustment, perfect and consistent grinding action, and extremely fast roll changes. The swing-out feed module allows complete cleaning of the feed section, and the inlet aspiration system incorporated inside the machine ensures controlled air flow to prevent condensation and dust accumulation. Each roller stand incorporates its own independent local control system, maximizing operational reliability and ensuring a consistent production process.
The new GMP 65-65 purifier from Golfetto S.p.A., Padova, Italy, is designed for today's highly automated flour milling applications. Some features of the GMP purifier include:
Enhanced efficiency: A 50% increase in sieving area.
High capacity: Triple deck with 24 extra large sieves
Modern design: Extensive use of stainless steel and sanitary manufacturing techniques.
Simplified maintenance: Vibratory motor drive and quick release sieve removal.
Accurate adjustment: Full width feedgate for excellent stock stratification and 18 exhaust valves for optimum control.
Easy production inspection: Large windows and convenient sampling points.
Power efficiency: Reduced air requirement.
Flexibility: Available in two sizes.
OCRIM ROTARY GRAIN SEPARATOR
The new SPR rotary grain separator from Ocrim S.p.A., Cremona, Italy, is a compact, reliable machine designed for optimum results in the pre-cleaning and cleaning process of cereals. Cleaning capacity ranges from 294 to 882 bus per hour while pre-cleaning capacity ranges from 1,286 to 3,675 bus per hour.
The SPR rotary grain separator features an original “serial type” sieve configuration instead of the traditional “parallel” configuration, allowing the fine screenings to run over the full surface of the perforated screen. The machine has two distinct oscillating sieves, with the upper one converging in a diverging lower one.
To save space, Ocrim recommends ceiling installation using fiberglass reeds, similar to plansifter installation. An alternative floor installation utilizes eight flexible joints, mounted on a base, to guarantee a nearly 100% reduction of the induced vibration.
A new sieve locking device allows the sieves to be removed quickly while the screen is kept clean by rubber balls.
SATAKE MULTI SORTER
The new Satake Multi Sorter simultaneously and successfully removes damaged and discolored grains, mud, glass and other foreign materials from cereal grains at high capacities. This new technology has also effectively removed aflatoxin-containing kernels from corn.
Unlike conventional mechanical separators, which cannot remove impurities of the same color, size and specific gravity as sound grain, the Multi Sorter uses newly developed, high-sensitivity CCD sensors to remove even slightly contaminated grains that can pass undetected by conventional sorters.
Other features include a liquid crystal touch panel for operator interface and fault diagnosis; lower air consumption through an enhanced ejector system; models with up to 160 channels to process the full grain stream at commercial capacity; and built-in secondary sorting for re-treatment of rejected material.
NON-CONTACT INFRARED TEMPERATURE CONTROLS
The non-contact infrared temperature measurement system ITM-1 from Vibronet, Graf, Gmbh & Co., Lahnau, Germany, can be easily installed outside the roller mills.
The surface temperature of fast rolls is measured on-line and automatically from approximately 25 to 30 centimeters from both ends. In this manner, the roller mills are constantly surveyed. If the temperature drops below or exceeds an optimum value, an alarm will be activated and the entire milling system will shut down.
Installation options include a battery supply system, a power supply and data transmission to a PLC control system and data transmissions to a PLC control system with fully automatic roll gap adjustment.
The non-contact infrared temperature control protects mill operators and guarantees observation of machine safety regulations. Measurements are precise, easy to handle and, most important, harmless for the miller.
Kice Industries, Inc., Wichita, Kansas, U.S., recently introduced its Automated Process Control Systems for use in flour and spice milling, food processing, baking, plastics and foundries.
As an authorized Rockwell software strategic provider, Kice Automation can integrate electrical and mechanical systems and components into one complete system for maximum efficiency.
Combining 50 years of process equipment systems experience with the highest quality hardware and software available, Kice can now provide a single source for automation control, equipment and components.
Kice said its automated systems can increase productivity, ensure accuracy of operation, eliminate human error and extend the life of the equipment. In addition, Kice offers 24-hour emergency support, diagnostic support via modem and a one-year HMI and PLC program warranty.
CODEMA C&P CLEANERS
The new cloth and pan cleaner from Codema, Inc., Minneapolis, Minnesota, U.S., is a highly economical and efficient way to simultaneously clean sieves and pans in sifter frames that do not use a backwire inset.
The triangular body and two-part design allows for maximum cleaning of nearly any type of sifting application.
In this configuration, a sieve cleaner with a longer glide stem is inserted into a second cleaner with a center hole. This second cleaner has its cleaning surface positioned against the pan, 180° from the sieve cleaner surface.
The relatively large size of each cleaner provides up to a 30% increase in efficient cleaning area, and does especially well cleaning hard-to-reach corners of sieve compartments.
RECEIVING PIT DUST CONTROL
The Dustmaster from ABC Industries, Mendota, Illinois, U.S., uses a simple, patented design concept that keeps the dust with the grain, eliminating the need for receiving pit aspiration.
Powered by a small air compressor, rows of heavy steel louvers, installed six to eight inches below the pit grate, cover and seal the entire pit. When a rail car or truck is unloaded, pneumatically operated cylinders open only those louvers directly beneath the unloading area. The remaining louvers stay closed.
The result is that the louvers blanket the pit during unloading, physically keeping grain dust in the pit. The Dustmaster controls up to 96% of receiving pit dust emissions.
The Dustmaster also is much quieter than vacuum-operated dust control systems and 50% less expensive. The machine also meets all state and federal E.P.A. standards for controlling receiving pit dust emissions.
The Chrono-Fill K 1000 from Chronos Richardson, Nottingham, U.K., with a new multi-spout bagging carousel, is designed for high-speed bagging of flour or other powder products into open-mouth bags of 10 kg to 50 kg.
Depending on the bag and the product, up to 20 bags per minute can be filled. Possing or setting time up to five seconds per bag is achieved without any loss in throughput.
Three vertical possers compact the flour in the bag. Optional motorized or hank crank adjustments facilitate quick bag changes.
For gusseted bags, the lateral gusset is maintained from bag placing to bag closure. When handling heat-sealed “pinch bags,” the total bag top control system assures that bags are properly aligned, straight and level for precise closure at high speeds.
HULLING AND SCOURING
The hulling and scouring machine, Type MMSC, from Spomasz S.A., Torun, Poland, is used to separate dust, sand, small seeds and other impurities from cereal grains, to reduce bacterial microflora and to reduce insect infestation by separation.
The hulling and scouring machine features intensive scouring and can be used in the first and second stage of grain cleaning. The machine can be connected to the pneumatic channel or pneumatic channel with inertial chamber. The sieve jacket can be quickly and easily replaced.
Grain is fed to the horizontal rotor, which catches it and throws it against the sieve jacket. By whirling the grain in the working area, impurities are separated from the grain and partially pass through the sieve jacket, then are carried outside the machine by an air jet.
BRANSCAN IMAGE ANALYSIS
After five years in development, Branscan Ltd., Redditch, U.K., has introduced the Branscan 4000, an on-line image analysis system that automatically adjusts mill settings in response to measured flour or semolina purity. The system enables processors to optimize production yield while maintaining product specification at all times.
Branscan 4000 systems may be used to control field devices in a mill, such as diverter valves and screw feeders, and to establish feedback control loops to automatically include additional mill streams into the final product blend. This loop concept may be engineered to add additional product when the measured values dip below a target level.
Automatic printouts produced by the Branscan 4000 system have shown greater consistency of bran content and a 1% increase in yield. A payback period of just four weeks is realistic, Branscan said.
The Multi-Cleaner Type MCS-20 from Sangati Berga, Padova, Italy, combines cleaning, grading and dry stoning cereals in a single system, reducing installation, maintenance and capital costs.
Several elements, each with independent settings, are mounted on a bearing structure. The first element is a vibroseparator, which removes coarse impurities such as straw, strings and foreign material as well as fines such as sand, dust and broken kernels.
Product from the vibro-separator is fed into the stoner/grader gravity selector and distributed along the entire surface of the top sieve. The oscillating motion, combined with countercurrent air flow, provides product stratification and fluidization so it can be graded into two fractions.
The heavy fraction passes through the de-stoning operation while the clean product is forwarded to the outlet. The light fraction is separated by the countercurrent air and forwarded to the air separator, which removes all low density impurities as such dust, hull and shriveled grains. A closed circuit air separator is optional.