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MILLING TECHNOLOGIES AND INNOVATION

15 January 201615 min reading

Many products-technologies have been launched as innovation in milling industry in the last 4 years. Some of them present small developments in available models; some present agricultural innovations and some present revolutionary technologies. Novitious of Selis Machinery, Antares Plus of Bühler, Similago II of Alapala, Superior Time of Ocrim, Multimilla of İmaş, Cleanmax-4 of Uğur and Leonardo 02 of Omas are just some of these remarkable technologies. The common characteristic of these new machineries except for Cleanmax-4 is that they are all roller mills. Of course it does not mean that innovation is realized only in roller mills. There are innovations in the other product groups too as in Cleanmax-4. However, rollers continue to be the focal point of milling. 

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Meaning both a process (renovation/renewal) and a result (innovation), Innovation is the method to overcome the complications and find a solution for the problems annoying us; it is not an invention. It means taking an available product or service, adding new and effective features to the product and presenting it to the service of humanity again. It is important that the new feature is effective and it should add a unique quality to the product.

Innovation presents competitive advantage and it increases profitability. Companies which develop innovative products can proceed more rapidly both in local and international markets if they can apply the innovation in products and service areas. When the well-known leading companies considered it is seen that they spare a significant source and time for R&D. It proves that any success is coincidence.

THE MOST INNOVATIVE TECHNOLOGIES OF MILLING Many products-technologies have been launched as innovation in milling industry in the last 4 years. Some of them present small developments in available models; some present agricultural innovations and some present revolutionary technologies. One of them is NOVITIOUS roll machine which Selis Machinery developed and launched in IDMA 2015 Exhibition.  Having a quite innovative technology named as Dynamic Angular Positioning System (DAPS), Novitious managed to be approved by the whole sector including the competing leader technology producers in the industry. You can find the detailed information about Novitious in the following pages.

BÜHLER & ANTARES PLUS Innovative Sensor Technology, High Yield and Quality As market leader of the milling industry, Bühler has a strong commitment to research and development. This results into innovative products such as the new Antares Plus roller mill. One of the most successful products of the company is the Antares roller mill which the company introduced to the milling industry in 2008. The Antares Plus roller mill optimizes yield and flour quality thanks to innovative sensor technology. Nicholas Trounce, Product Manager in Grain Milling, says about the Antares Plus roller mill which has won an innovation award: “Bühler AG has been manufacturing rolls since 1860. From that beginning, company founder, Adolf Bühler,  took  the  then  revolutionary  principle  of  the  roller  mill  and  began industrial production. 155 years later the roller mill still forms the core element of any flour mill. By applying latest sensor technology, the new Antares Plus roller mill increases yield, maximized flour quality and reduces energy consumption." Antares success story The Antares roller mill is the flagship of the extensive Bühler roller mill portfolio. It combines 155 years of Bühler experience with the latest knowledge in terms of grinding and hygiene, serving as the worldwide reference for modern roller mills in the milling industry. Since the launch in 2008, more than 3,000 Antares top line roller mills have been sold. The market success of Antares is due to its robustness, even feed and grinding and the highest standards of sanitation thanks to the use of stainless steel and sophisticated insulation. A “plus” thanks to sensor technology With the “Plus” version, Bühler opens a new chapter in the success story of Antares. The new Antares Plus roller mill ensures ideally coordinated grinding with minimal pneumatic conveying. Energy consumption and flour quality are in the optimal range. Standard on the Antares Plus are automatic grinding gap adjustment and the online MYTA particle size measuring sensor. Temperature monitoring of the rollers and bearings also ensure maximum operating safety and high production uptime. The Online MYTA sensor continuously measures the particle size distribution in the ground product and compares the measured actual value with the target value. The Antares Plus control system records the deviations and automatically adjusts the milling gap to the target value. The result is a consistent product quality with minimized energy consumption. The sensor-controlled milling gap adjustment automates this former manual procedure and enables millers to invest more time in their core tasks. Temperature monitoring In the new Antares Plus roller mill, the modern sensor technology not only checks the particle size but also the temperatures of the rolls and roll bearings. When contact pressure is too high, there is winding or dry running, causing the rolls to increasingly heat up. This can be prevented by constant temperature monitoring of the roller surfaces. Continuous measurement of the roll temperature ensures consistent product quality, particularly where there are few operators. Thanks to the temperature sensors in the roll bearings, wear and tear or lack of grease is recognized early. Preventive temperature monitoring of the rolls and roll bearings thereby ensures maximum operational safety and high finished product quality. ALAPALA & SIMILAGO II Speed, Easy Use, Safety and Precision Another innovation which has aroused interest recently was developed by Alapala Machine which is one of the technology leaders of the industry. Similago II roller mill which is described as new generation by Alapala Machine is an award-winning machine in innovation category. The new Similago II which is the result of Alapala’s 60-year of experience in technology and roller mill engineering is defined as the symbol of the power. Sturdy frame, high grinding capacity Similago II which is designed for high, continuous and consistent grinding of cereals such as wheat, maize (corn), rye, spelt, barley and sorghum ensures a consistent grind thanks to the a uniform feed rate across the grinding rolls. The steel used in the machine is a special quality high carbon steel. The bearings and the grinding rolls are directly mounted on to the frame. The sturdy construction gives the Similago II the ability to perform high capacity grinding. The internal product contact parts are made from stainless steel which also stops the adhering and accumulation of the product and condensation. Easy use and precision With new generation Similago II, easy and fast change of the rolls can be performed in 20 minutes. No special tools or lifting devices are required as the standard tools can perform easily. The grinding rolls are mounted on self-aligning double row roller bearings which are housed in 25 mm thickness housing. Roll temperature is kept low by the air circulation provided by the aero dynamic design of chamber structure. The universal frame of the Similago II allows the use of grinding rolls with either a diameter of 250 mm or 300 mm. The feed roll speed is controlled automatically by the capacitance sensor in the feed box which sends a signal to feed roll drive motor invertor via a PLC according to the product level in the feed box. No calibration is required. This ensures a perfect and uniform product feed to the grinding rolls. The polycarbonate inspection glass on the feed box can be easily removed from the outside without the need to dismantle the feed spouts and related parts, for cleaning. For inspection purposes, double walled inspection door which can be opened and closed easily due to a weight system avoiding the use of latches. This enables the doors to be dismounted / mounted to from the machine without the use of fasteners. A user friendly touch screen operator interface panel between the operator and microprocessor which is mounted on both sides allows the continuous and changing and monitoring of all the operating parameters together with alarms and graphical system visualization. New Generation Similago II which was developed after all the details were revised meticulously promises speed, easy use, safety, hygiene and precision in addition to its stainless steel structure and innovative design.  The main features of Similago II which combines the advantages of an excellent performance and efficiency with aesthetic are as follows: stainless steel technology, innovative design, door which can be opened easily to upward and sideways, parts that can be demounted easily, models with single or double floor, precise roll positioning, optional ball adjustment automation, special software solutions, graphical and touch screen. OCRIM & SUPERIOR TIME Unique Design, Accurateness and Knowledge One of the most outstanding innovations in the recent time is Ocrim’s Superior Time roller. OCRIM presented the Superior Time line for the first time at IPACK-IMA 2015 during the event “GRANO, FARINA E” (“Wheat, Flour and…”) held on the 21st of May. This new line represents the actualization of the experimentation and employment of different materials. The representatives of Ocrim say about the machine as follows: “It is the outcome of a productive path, which has brought to the development of a machine line studied item by item. This important goal represents the synthesis of the genius and professional wisdom of each Ocrim team member who has taken part into this project, a project carried out paying attention to the design, technic and mechanic. Innovation and tradition The name of the new OCRIM machine line, Superior Time, represents the actualization of an important example that comes from the past. The graphic of the two logos, the present and the previous one, identifies the will to confirm the way of working that is still the same since passion, competence and attention in producing is always the same. In fact, Superior is the name used by Ocrim in the 50s to indicate the single structure mills installed inside low buildings and sold all over the world. The technological advancement of these decades has strengthened and helped the work of the technicians, engineers and of the ones who have driven this project. Technical and engineering expertise has actualized a work that is done with head and hands through a futuristic approach in line with the times. Innovative design The sinuous design of Ocrim Superior Time machines has the aim to describe the experience and research that have given life and shape to them. The quality of a product is the result of the intelligence, knowledge and competence of the ones who realize it. Its shape, design and chromatic harmony are indispensable elements for a long coexistence between man and machine. Centrifugal impactor The new Superior Time DCI-S breaks down medium and fine durum wheat and regrinding passage plates. The breaking down action, obtained through knocking, increases productivity and at the same time improves yield and the degree of water absorption in the flour. Internally manufactured in stainless steel, it is characterized by a flat rotor, with 3 series of screwed in pins to break up the plates. The rotor is dynamically balanced and fitted on the motor shaft. It can be assembled on the floor or suspended from the ceiling.” İMAŞ & MULTIMILLA Easy Roll Adjustment, Less Waiting Time, Easy Use Another innovation about rollers is Multimilla Roller of İmaş Makine. Aluminum front covers in Multimilla roller which was launched with a special show in İDMA 2015 Exhibition have aesthetic and smooth surface; therefore they are easy to clean. It is possible to make roll gap & paralleship adjustment easily with the accurate gravity indicators. Roll cleaning brushes and knives can be adjusted easily and high-degree roll cleaning can be obtained. With central greasing system, it is possible to grease roll housings without stopping the roller mill which decreases the idle time. While the electric cabinet provides Easy access to high quality electric and electronic components isolated aluminum product control gate provides light weight and easy to use, noise-free and heat-free product control gate. Easy roller adjustment and long life Control panel with high isolation in Multimilla enables easy access and control of all parameters to control the roller mill. Touch-screen panel is also available on request. Safety locks prevent unauthorized access to dangerous places the gates designed with safety locks to secure working environment. The cycle of feeding rolls are regulated automatically by invertor controlled gear motor. Along with automatic inverter control, the feeder rolls cycle is regulated manually by digital setting device. Single time belt system with long life provides easy montage and dismantling. Belt sizes for all roller mill types and cycle are standard. Pneumatıc control system of Multimilla consists of strong and durable component. As it is maintenance free it is easy to montage and dismantle. Strong disc sprigs enables optimum roll grinding pressure for a constant roll space and provides high milling quality. Taper bush pulleys provide easy montage and dismantling and longer lifespan. Sphero-cast roll housıngs have enduring and durable housings. Aluminum housing covers prevents high temperature due to their special structure. Eccentrıc belt tensioning system is easy to adjust belt tensioning system. The main chassis is made of gray cast iron, increasing resistance and durability as well as absorbing the vibration and shocks. Maximum hygiene, minimum maintenance Feeding rolls housing and roll covers are made of high-resistant aluminum extrusion profiles with bolt-connection method. Thanks to the feedıng roll packs wıth lınear ball bearıngs, it is possible to obtain easy cleaning for the back of feeding rolls which enables maximum hygiene at minimum time. Feeding roll cycles are adjusted automatically by means of special level probes. Easy access and fast cleaning and maintenance with the completely-openable front cover. Adjustable pneumatic system in the machine creates negative pressure around the rolls and provides dust absorption. In addition, dusty air is evacuated from the inlet hopper to the outlet hopper by using pneumatic system. Changing grinding rolls in the machine takes only 20 minutes, thanks to completely dismantle grinding group which minimizes the idle & stop time of mill and creates time for an efficient production. UĞUR & CLEANMAX-4 High capacity, performance and sensitivity Uğur Makina is one of the milling technology producers which have the most developed distribution and marketing infrastructure in the world. The latest technology of Uğur Makina which managed to establish a factory or to install machinery in nearly every part of the world is Cleanmax-4 grain separator. Clean raw material is essential for a good final product. Uğur Makine launches Cleanmax-4 as the most efficient and successful pre-cleaning system in the world. Effective cleaning Cleanmax-4 which is a challenging technology in terms of high quality, capacity, performance and sensitivity provides an effective cleaning capability. Having a multi-layer sifting system, the sieves of machine are easy and quick to clean and change. Providing maximum safety and ease of use to the user, Cleanmax-4 has high capacity air canal and high efficient aspiration system. Having screw conveyor system for glume in air cabinet, the machine has also an aesthetic view. Providing minimum maintenance costs, Cleanmax is a grain separator which enables easy classification in cleaning. OMAS & LEONARDO 02 Maximum energy saving, high performance Omas is another leader technology producer which has presented its new roller mill recently. The machine which Omas named as LEONARDO 02 was designed to achieve the best possible milling performance with the highest energy efficiency. To achieve this goal, research and tests of 2 years was conducted with the R&D department which is having extensive knowledge on energy consumption improvement on mechanical machinery. OMAS Leonardo roller mill will have new drives arrangement with different speed to produce a better extraction of flours compared with conventional which utilized fixed speed in grain milling. Optimum grinding process Their main task is to optimize the milling process of different intermediate passages where the grains, middling, semolina and fractional parts have different size, texture and specific weight and are therefore in need of unindividual setting of the rolls ratio to perform the milling operation at its best. With the new LEONARDO 02, the mechanical project begins with uninnovative roll drive unit. Each roll will be driven by mean of a coaxial directly coupled electric motor. This drive will have modular and variable speed; will be belt free, therefore with highest energy efficiency. The motor stator will fitted on the machine frame while the rotor will be coupled with the rolls shaft. This arrangement will provide a unique saving ensuring both the highest milling performance and the highest power saving. 30 percent less energy The power consumption of the Leonardo 02 roller mill will be 30 % compared with the conventional roller mill belt drive mechanism. It is thought that the 30 % power saving will create a high impact on the flour production costs reduction and will allow to get access to government funds for improving the energetic efficiency of the milling plant. The newly developed drive arrangement will avoid the need of V and toothed belts , pulleys , motor chairs and machines floor fixtures such us Bauer rails od Single Shaft motor suspension. This will cause not only a saving on the material and cost of the machine itself, but also on the required installation time. The absence of belts will definitely kill the need of wearing spares and the maintenance costs as well. Although the overall dimension of the machinery is equal to the conventional one both the additional saving on the number of building floors and Sensible noise reduction is reached.
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