“Diagramming requires meeting expectations and needs during installation and post-installation production phases and having the technical knowledge to rapidly adapt to the technology with a new industrial approach to changing circumstances and demands in the milling sector. Diagrammers should always create new solutions and renew themselves according to new expectations in a dynamic environment of wheat processing.”
The wheat is a global crop and demand for wheat flour has been increasing each year. This cements the position of the milling sector as being the main global food industry. Milling, the first industry branch of the history, has seen fundamental technological changes because of changing needs.
Grinding technology consists of different processes from taking the grain to the first silo intake to having outputs like flour, semolina, bran and foreign materials. Diagram shows all those steps in a schematic way and Diagramming is realizing those theoretical information into real life with a full knowledge of the grinding process.
Diagramming requires meeting expectations and needs during installation and post-installation production phases and having the technical knowledge to rapidly adapt to the technology with a new industrial approach to changing circumstances and demands in the milling sector.
The milling sector, has taken its fair share from technological developments and it has been rapidly adapting to the digitalization process after developments of industrialization and automation. Like all sectors, the flour industry should be renew itself during competition environment, adapt to advancing technology and explain its ability for stable production.
The Process Diagram for Wheat Processing is shown below:
The main working principle for grinding is conditioning the grain, processing between two rollers and separating flour and bran with sifting systems. Today, wheat processing technology enables us to utilize innovative technologies including controlled production system thanks to its adaptation with the digitalization.
Process Automation System Integration provides us the opportunity to use digitalization. We can list benefits of digitalization as follows:
• Setting up a cost-effective system that can monitor and improve itself
• Ensuring the permanent quality
• Ensuring continuous data exchange for production process
• Real-time feedback
• Hygiene safety
• Faster, easier and more simple analysis in comparison with the conventional analysing system
As diagrammers, we are the implementer of these innovations. As technology advances, some machinery and equipment lose their functionality and some others become more important. For example:
In order to prevent peeling, a detacher (drum detacher - 1000rpm) between Liso Roller Mill and plansifter was being used. But new liso roller system minimizes peeling and flaky structure with semolina. As a result, this machine has lost its function.
Semolina detacher (300rpm) is being used between Liso Roller Mill and plansifter to crush the semolina and because of its peeling prevention effects. As rate per minute values increase, adaptation of differential rates, increasing ability of semolina crushing and increase of roller sizes; the need for semolina detacher machines has decreased.
Dry Peeling Machine causes broken kernels as the humidity goes under 10% because its efficiency for wheat peeling is low. Therefore it may be harmful for wheat processing.
These are the developments that contribute grinding performance and efficiency;
• New design for intensive dampener conditioning machine
• Double Roller Mill and roller sizes
• Size of plansifters,
• Vibro bran finishers’ new functionality.
As the structure of the process dynamically changes, the diagram should also be configured. Performing the same task in a shorter time and smaller space with a more cost-effective approach is significant for installation costs and saving energy during production.
Double decker intensive dampener conditioning machine has a new design which the wheat has a substantial contact with water during the first intake. In mono-block upper housing, the wheat scab is impacted in rotor to have a more dense wheat-water mixture. Peeling becomes easier when the wet wheat throws away the dust-like structure from the shutter on the rotor.
Double roller mill has enabled increased grinding surface since the size of the roller is larger (250x1250, 300x1500). Thus, we have a bigger grinding power with less rollers now. Therefore, it is vital to change the diagram accordingly.
If double roller mill is being used in the first crushing, we have to take double-phase cutting-scraping principle as the criteria. To do that, semolina like particles should not go into the third crushing and bran-like semi-product should not mix with the semolina-like semi-product going to the next reduction passage. If this process fails, it will affect all other passages.
If double roller mill will be used in liso passage, damaged starch rate will increase because of high thinning rate stemming from double crushing-flattening. This will contribute for low-ash bright flour intake but damage for the flour will be higher.
Increasing the sieve frame sizes (740x740), sieve passage and heights (10x30) enables to process more products in a smaller area.
As size of vibro bran brushes increases and vibration goes up, the capacity also increases. Vibro bran brushes that are formerly put out of 4th or 5th crushing ends are now put on 2nd or 3rd crushing ends in order to decrease the load of crushing passage and enable them to process more materials.
The harmony between sieve, roller and vibro bran brushes makes it possible to increase the amount of processed materials.
As a result, diagrammers should always create new solutions and renew themselves according to new expectations in a dynamic environment of wheat processing.