Global Milling Advances November 2012 -
-
Upload
global-milling-advances -
Category
Documents
-
view
213 -
download
1
description
Transcript of Global Milling Advances November 2012 -
Issue 1 November 2012
Sumak MillingIntroduce their range of products
Bin Measurement Basics for MillersBinMaster Level Controls
Hardy ProcessHardy Process Solutions increases flour mill productivity with improved flow and feed rate
ISSUE 1
of Global Milling’s New
quarterly magazine
When Silos Need Cleaning
We talk to Hardy Process Solutions about flow and feed rate systems
Need to Know info onBucket Elevator Sensors
IN THIS ISSUE
AND MUCH MORE...
Issue 1 November 2012
Welcome to the first issue of Global Milling Advances, a new online supplement to complement our Global Milling Annual for the grain, feed, and flour and cereal industry. Global Milling Advances (GMA) will be publishing four issues per year focusing on technology.
We start our first issue with a focus on storage and conveying featuring articles from industry professionals covering a variety of topics from maintenance and cleaning of silos to the level measurements and equipment needed.
Global Milling visited the UK Grain event this November, where some 60 exhibitors involved in every aspect of grain storage, monitoring, drying and marketing gathered at the Peterborough Arena, East of England Showground. This event is held annually and you can get involved with next years meeting by contacting Andy Newbold on [email protected]. Keep up to date with other industry events by visiting www.globalmilling.com/global-milling-events/
If you have a topic that you would like to see covered, why not get in touch with us.
Published by:
NISA Media Ltd14 Clarke WayCheltenhamGL50 4AXUK
Editorial ManagerNicky BarnesTel: +44 117 2306494Email: [email protected]
International Marketing ManagerSabby MajorTel: +44 117 2306493Email: [email protected]
News EditorMartin LittleEmail: [email protected]
Web: www.globalmilling.com
Contents
Bird Silos & Shelters 4
Action Duct 5
Binmaster 8
Hardy Process 10
Sumak 12
4B 15
2013 Events List 18
Pg 4 | November 2012
Bird’s Silos and Shelters
Bird’s silos and shelters are a family company and
have been making grain silos for over thirty-five years.
Although only a small factory they have always been at the
leading edge of sealed silo technology. Even before the
advent of sealed storage the founder, Don Bird conducted
a lot of experiments in conjunction with a Department of
Agriculture person who was concerned about the damage
that weevils were doing to the local stored grain. It was the
knowledge he gained there that was the basis for the present
fumigation system which they use today. It also leads him
to think that a lot of the explosions which are thought to be
caused by grain dust may actually be caused by phosphine.
The silos that Bird’s make all have a thermo siphon
fumigation system which has a container with all the
phosphine tablets in it which not only gives a quick
fumigation but prevents a dangerous build up of gas which
could cause a explosion. Also there is no residue left in any
of the grain, it is all retained in the chamber. The design of the
silo makes it easy to use nitrogen or any other gas to
do the job.
They appeal to people who want organic grain with no
chemicals and no insects. They are also equipped with a
spear which enables the owner to take five samples of
grain and also see if there are any weevils in it. Everything is
operated from the ground, there is no need to climb
on the silo.
Don still has hand on the pulse but the day to day running of
it is done by his son Wayne and granddaughter Courtney.
For more information:
Bird Silos & Shelters
PO Box 32, Popanyinning WA 6309
Australia
Tel. +64 08 9887 5005
Web: www.birdssilos.com.au
// Spent Phosine
// Phosphinetray
// Phosphine Chamber
In industry, silos have become the guardians at the gates of
many manufacturing plants, the first thing you see looming
above the roof line as you approach the facility.
Rising as much as sixty feet and higher, silos are used to store
bulk quantities of manufacturing materials. In the snack food
and baking industry, the most common items stored in silos are
grains, various flours, and sugar.
Silos offer a lot of advantages:
• No pallets of bagged material to unload and store
at the warehouse.
• No need to tear open one 50-100 lb. bag after another
and dump the contents into a hopper – and then clean
up the overspray and deal with the empty bags.
• By simply opening a valve, the rate and amount of
material can be regulated as it flows continuously
from the silo into the manufacturing process.
However, as it is with most solutions, silos require a little
maintenance of their own or they become problems, too. At the
top of the list of concerns is food safety and quality.
Wherever flour and sugar congregate, various members of the
animal and plant kingdom like to capitalize on the opportunity
for a quick, and often abundant, meal. This includes rodents,
insects, bacteria, and mold.
The chief insect invaders of flour silos are the Red Flour Beetle
and the Confused Flour Beetle. These bugs, each about 1/8-inch
long, look so similar that it is believed that is how the Confused
Beetle got its name - it is so easy to confuse it with a Red Beetle.
One difference is the Red Beetle can fly. Both breed heavily in
the warmer months.
The Confused Beetle is the number one insect pest in American
flour mills. And it's an old pest. It's been found in a jar that likely
contained flour in a tomb of the pharaohs from around 2500
B.C.
When present in large numbers, they can turn the flour grayish
and cause it to mold more quickly. They also give
the flour an unpalatable taste and odor from secretions of their
scent glands.
One client told us, "The Confused Flour Beetle has a 28-
day cycle from egg to adult. If our silo isn't regularly cleaned
approximately monthly and if there's infestation they might nest
in something like a gasket. Then they get very prolific in that
area."
Mold is another major concern. When silos are not cleaned
regularly, there is a high likelihood of mold buildup. This is
commonly visible as shades of green and black in the flour,
particularly on the inside walls. It can get as bad as an inch-thick
(or more) layer of greenish flour clinging to the walls.
Mold growth is facilitated by the presence of moisture, which
can precipitate when warm flour is pumped into a silo and cools
down. Dehumidifiers can help guard against this problem.
To avoid many of these issues, silos are usually put on a
routine cleaning schedule. The frequency of cleaning can vary
tremendously from every month to yearly,
depending on local weather conditions, what’s being stored,
how often the silo empties, and simple common
sense and experience.
When Silos Need CleaningDan Stradford Chief Executive OfficerAction Duct Cleaning Co., Inc. Altadena, Californiawww.actionduct.com
November 2012 | Pg 5
For more information:
Action Duct Cleaning Company Inc.
787 W. Woodbury Road Unit 2
Altadena, California 91001
USA
Tel: +1 800 371 2284
Web: www.actionduct.com
A Quality Maintenance Program
Doug Nakamura is the director of operations for Upper Crust
Enterprises of Los Angeles, America’s first manufacturer of
“panko” or Japanese breadcrumbs. He outlined the steps his
company routinely takes to keep their flour silos in top shape.
“We clean our silos twice a year and fumigate after each
cleaning,” Nakamura said. “We also change our filters monthly.
Plus we have our own self-audit, through our HACCP system
(Hazard Analysis and Critical Control Points). Lastly, we hire a
third party auditor to perform a routine review.”
This is in addition, of course, to standard inspections by the
FDA and health department.
Finally, Nakamura ensures that a system of precautionary
measures are in place, including:
• Buying from a reputable flour manufacturer.
• Getting a certificate of analysis for every load.
• Ensuring that the flour delivery trucks are inspected weekly.
• Inspecting the hoses and unloading mechanism on each truck.
•Ensuring the piping is kept locked.
The Cleaning Process
Silos can be cleaned by a number of methods, but in most
cases, the process involves brushing down the sides of the
interior and/or scraping them as needed. To avoid scratching
the surface and to prevent sparking, plastic scrapers may be
needed.
Although simple in principle, the work takes some practice and
preparation.
Safety has to come first because multiple hazards exist,
including falls, explosions, lack of oxygen, and “drowning” in
liquid or finely-milled products like flour and sugar. A silo is an
OSHA-defined “confined space,” meaning that workers in it
have to follow standard safety procedures for enclosed areas
with inherent hazards.
Proper breathing precautions must be considered where dust,
volatile chemicals or oxygen scarcity can occur. Sometimes
this is learned the hard way. Our firm was caught off guard
once when we had a worker steam cleaning a massive vat that
had held cooking oil. Steam vapor replaced the breathable
air and literally lifted the available oxygen above his head.
Fortunately, the matter resolved quickly, but it was a lesson in
the importance of trying to anticipate the unexpected.
Food storage silos typically have platforms or “cages” built in
at the top so workers have access for cleaning and servicing.
These have to be treated with respect. Although it happens
rarely, these cages can have breaks in them that can be hidden
by a coating of flour or sugar. A worker should fully inspect
these and ensure he’s wearing a harness and lifeline before
stepping onto such an apparatus.
Sometimes you find no cage at all. It’s simply open space at the
top. In this case, a worker will need to drop down from the top in
a "bosun's chair," a chair on a rope that is lowered down. It may
have a motor or be controlled by hand at the chair. Even eighty-
foot silos may need to be cleaned this way. Any time a bosun's
chair is used, it is secured on the outside of the silo and OSHA
safety standards are adhered to.
Such specialized equipment, preparations and OSHA
requirements prompt many companies to hire outside firms to
clean their silos. It saves a lot of headaches. But some plants
still prefer in-house cleaning. Whatever method is used to
clean, an opening at the top of the silo is vital for access and,
sometimes, ventilation. An opening at the bottom is equally
critical for draining out product which has been cleaned from the
silo. In some instances, there are no access doors at either end
and they have to be installed.
Vacuuming is a common method of cleaning debris from
the bottom. However, this can stir up a lot of static electricity
around certain materials such as flour. Visible sparks can occur.
A way to reduce this risk is to attach wooden poles to vacuum
hoses to ground them.
Silos are normally cleaned without water. When the stored
product is easily dissolved, such as sugar or syrup, wet washing
may be the method of choice. This approach may take longer
(sometimes it’s faster) because it requires more prep work and
attention to water drain-off. It also means the silo must dry out
and this can cost production time. Moisture attracts mold so
that is another consideration. Needless to say, the silo needs to
dry thoroughly before it is refilled.
In some instances wet cleaning is the only method available.
As an example, if a flour silo needs welding, all combustible
material must be removed and this may only be achievable
through wet washing.
Additional Issues
Food product storage silos are lined with a coating that can
deteriorate over time. Flaking or rusting can contaminate the
food product. This is commonly first noticed when particles
show up in sifters. Some manufacturers re-coat their silo
interiors every few years as a
precautionary measure.
Pg 6 | November 2012
Breather bags at the top of the silo are another sensitive area.
They permit filtered air in and out. Beetles can congregate in
them. Small holes can permit
insects to enter.
Leaks in a silo are, of course, a potential nightmare. A typical
full capacity of about 130,000 pounds can be wasted from rain
or dirt getting in. Water or air seepage should be looked for
during any visual inspection.
Routine physical inspections can help spot such leaks. Another
client, a tortilla manufacturer, regularly looks at gaskets, silo
doors, and even under the silo on the conveyor line for flour
leaks, insects, or rotten flour.
Summary
The checklist for any director of operations or sanitation should
include a periodic inspection and cleaning
of the silos.
Are you losing storage capacity because of buildup on the silo
interior walls? This literally reduces the available diameter of
the silo. It causes a silo to empty too quickly and costs more
frequent visits from suppliers.
Are you in compliance with hygiene regulations? Could a lack
of maintenance result in a food hazard, contamination problem,
or God forbid, a production shutdown?
Are your silos being inspected periodically for issues like rain
leaks, mold, or residue buildup? Routine visual checks can
keep small problems from becoming big ones.
Ben Franklin wrote, “An ounce of prevention is worth a pound
of cure.” A little attention to those quiet giants in your plant’s
“back yard” can keep them working smoothly for you for years
to come.
November 2012 | Pg 7
Milling operations have many challenges at hand when
it comes to measuring the level in bins. It’s likely that
a single operation is home to bins of various construction
(concrete or steel), an assortment of sizes, and a variety of
materials to measure – some granular, some powder, some
free-flowing and some prone to dust and buildup. To select the
device that is best for a particular bin, it is helpful to consider
the material being measured, whether the material surface
tends to be even or irregular, the regulatory environment (such
as with food), the size of the tank, and whether you need to
know when inventory has reached a certain level in the bin –
which calls for a point level device – or you need continuous
level measurement.
What can you expect from a bin level detection device?
• It will help you manage your inventory.
• It will eliminate the need to climb tanks to check levels.
• It will enhance safety for employees.
• It will alert you when material reaches a particular
level in the bin.
• It will provide a single measurement that is repeatable when
there hasn’t been any activity in the bin.
• It will provide an accurate distance to product
within a few inches.
• It will measure headroom in the tank or the distance to the
material, so you know how much space is left in the tank.
What can’t you expect?
It’s a common fallacy that a bin levels will convert to mass or
volume and then to pounds accurately. The nature of powders,
granular materials or pellets is that they will settle, shift and
compact in the tank. It’s true that some advanced devices can
and do incorporate compaction calculations into their software,
which will compensate somewhat for the behavior of the
material. However, a level measurement device is not a scale.
Let’s explore some of the best level sensor options for millers
and considerations when selecting a device, starting with
simple, economical sensors building toward the more complex,
accurate continuous level technologies.
Rotary Level Indicators
Rotaries are a familiar and common device used for high or
low level point level indication in bins, tanks, and silos. A rotary
sends an alert via a horn, light or to an alarm panel when
material reaches (for high level detection) or falls away
from (for low level detection) the rotary paddle. The principle of
operation for rotaries is quite simple. When the rotary is used
to alert that material has reached a high level while the bin is
filling, the paddle rotates continually until material reaches the
paddle. When the paddle meets resistance due to the presence
of material, it stops rotating and sends an alert. Conversely,
as a low level indicator, the paddle will begin turning when
material drops below the level of the paddle and will send an
alert or can be wired to start up a process system.
Capacitance Probes
Capacitance sensors are designed for a wide array of
applications and materials and may be used in powders,
granulars, pellets and other solid or slurry materials. The
sensors may be used for high, mid and low level detection in
bins, silos, tanks, hoppers, chutes and other types of vessels
where material is stored, processed, flowing or discharged.
Capacitance sensors operate by detecting the presence or
absence of material in contact with the probe by sensing a
change in capacitance caused by the difference between the
dielectric constant of the material in the tank and the air. These
sensors are able to detect very small changes in capacitance,
typically one picofarad.
Vibrating Level Sensors
The vibrating level sensor or vibrating rod is a piezoelectric
driven vibration type level switch can be used for level detection
in bins, silos, and hoppers filled with powders or dry solid
materials. A vibrating level sensor can detect extremely light,
fluffy materials as light as 1.25 lb./cu. ft.3, such as powders and
flakes or can be used for heavy materials such as grains or
pellets. These are rugged sensors that are often constructed of
durable stainless steel and are virtually wear and maintenance
free. A vibrating level sensor can be utilized as a high, mid or
Bin Measurement Basics for MillersBy Jenny Nielson Christensen, Marketing Director, BinMaster Level Controls
For more information:
BinMaster Level Controls
7201 N 98th St
Lincoln, Nebraska 68507
USA
Tel: +1 402 434 9102
Web: www.binmaster.com
Pg 8 | November 2012
low level alert and can be mounted on the top of the bin as a
high level detector or in the bottom cone of a bin to sense when
the tank is nearly empty.
A weight and cable-based sensor is a very economical and
accurate continuous level measurement choice. Weight and
cable-based or bob-style sensors can be ideal for diverse
applications in powdered and granular materials as these
sensors are not affected by dust, humidity, temperature,
dielectric constant, or fumes that may be present in the bin. Plus,
as a stainless steel probe at the end of the cable makes minimal
contact with the material, there is minimal risk of contamination.
This type of sensor works in virtually any material regardless
of particle size or bulk density including very fine powders to
heavy, dense materials. If there are multiple tanks containing
different types of materials that need to be monitored, “bobs”
are a proven technology that have been in existence for over
20 years and are trouble-free, long-lasting and require no
calibration.
Bob-style Sensors
A bob-style sensor can be used in bins up to 180 feet tall, but
are also often used in smaller, active process bins under 40 feet
tall. For the best accuracy, the sensor should be mounted on
the roof about 1/6 of the way in from the outer perimeter of the
bin, which places it ideally to account for the angle of repose
on a center-fill bin. Properly mounted on a center-fill, center-
discharge bin, bob-style sensors will consistently provide 5%
to 7% accuracy. They work by releasing a cable with a weighted
sensor probe that stops and retracts when the probe comes into
contact with material. Redundant measurements are taken when
the sensor probe is both descending and retracting to guarantee
every measurement is precise.
Bob-style sensor networks can be integrated utilizing a wide
variety of communication options. Most cost effective and
popular is a control console mounted at ground level that can
report the data from one up to over 100 bins and provides
information such as distance to product (headroom), height of
product, and percentage full. If the preference is to have bin data
sent to a personal computer, there is software to report detailed
data for multiple bins simultaneously and display a visual report
of bin levels. Other communications include the ability to send
automated email alerts when bins reach a predetermined level.
A 3D scanner is a non-contact, dust-penetrating bin volume
measurement system that uses acoustics-based technology
to measure bin contents at multiple points within the bin. What
makes a 3D scanner different is that unlike ultrasonic or radar
devices that are measuring one point and determining a single
distance, the 3D Scanner takes measurements from multiple
points within the bin and uses these points to help estimate
the volume of material in the bin. Sampling measurements
from multiple points when the material surface of the bin is
uneven enables the 3DLevelScanner to calculate bin volume for
powders and solids with greater precision than any single point
measurement device.
A 3D scanner is unique because it is able to map the topography
of the bin and create a computerized profile of the bin contents.
This allows for greater accuracy as it detects cone up, cone
down, bridging and sidewall buildup and then accounts for
these variations when it provides the volume estimate. The 3D
scanner comes equipped with software that displays the tank
data in an easy-to-read format. The measurements are sent to
a main display screen which includes data such as average,
minimum and maximum distances, level, temperature inside
the tank, and volume percentage. The 3D mapping software
depicts surface irregularities in a visual representation of the bin
contents.
Food for Thought
When it comes to managing inventory in any bin in your
operation, the first consideration is what type of information you
need. Are you seeking level, volume, or are you really looking
for weight? If you simply need to know if a bin is empty or full,
choose a point level device. If you need to know the level of the
bin, such as percentage full, headroom or distance to product
on an ongoing basic – a continuous inventory management
system such as a bob-style or 3D device is the right choice. A
non-contact device may be desired if the regulatory environment
demands it. Keep in mind that some non-contact devices such
as ultrasonic or radar perform inconsistently or unreliably in
dusty environments.
Bin size, the number of bins, and whether they need to be
networked will also influence the type of system you select.
If you are seeking convenience, look for a system that offers
wireless installation, plus software or consoles that centralize
the location of your data and can generate the types of reports
you need. The need for inventory accuracy can vary from one
operation or even one bin to the next. Getting an accurate
measurement for a single point in the bin can be accomplished
easily, but it might not give you the overall volume accuracy you
need. For uneven material surfaces, bins with multiple fill and
discharge points, or very large bins, expect for the solution to be
more complex and more expensive.
And remember, when it comes to bin level controls there is a
robust selection of technologies at prices ranging from a few
hundred to a few thousand dollars. Bin level measurement is
not a one-size-fits-all solution … it’s a puzzle with many pieces
that when put together right will give you a better picture of your
inventory.3D S
can
ner
s
// 3
D S
can
ner
Bin
So
ftw
are
November 2012 | Pg 9
Hardy Process Solutions increases flour mill productivity with improved flow and feed rateHow Hardy’s HI 4050 weigh controllers improve
process efficiency
A large global processor and exporter of grains and oilseeds
was experiencing inconsistencies in timing for discharging
wheat from a scale hopper, which resulted in an inconsistent
flow rate. If the scale hopper was filled prior to the period set in
the flow rate, the dump gate was delayed until a timer ran out.
If the feed rate to the scale hopper was slow and the timer ran
out prior to the draft load being satisfied, the dump gate would
open only after the set point had been reached and the actual
weight of the draft recorded. These inconsistencies in material
flow and feed rate were slowing production, creating waste, and
causing variations in actual weight.
The Solution
Hardy Process Solutions recommended utilizing five HI 4050
weight controllers in the flour mill. The variables recorded by
the HI 4050s include time start, total weight accumulated, and
actual flow rate in tons per hour. These variables are monitored
on a PC via the HI 4050’s embedded web server and on a
Microsoft Excel spreadsheet utilizing a utility provided by Hardy.
The first scale weighs dirty wheat at a set flow rate. This is
achieved by timing the discharge of the hopper. The dirty wheat
is cleaned and processed, then held in a silo that feeds the
second scale. The same variables are recorded. However, the
flow rate on this scale is important since it sets up the flow rate
to the flour mill. If the mill is fed too fast the line backs up; if too
slow, the mill will scorch flour. The remaining three scales are
used to receive the flour from the mill. On the three flour scales,
the flow rate measured is the actual rate of flour from the mill
(in other words, we take the flour as fast or as slow as the
mill will give it).
With the data from all five scales, the customer is able to
calculate the yield from stage to stage. The change in flow rates
alerts the millers to possible mill problems, which they can
immediately investigate.
The MS Excel utility proved crucial for the system. Once the
SAP system is brought on-line globally, the data in the Excel
spreadsheet utility can be viewed in real-time at
a central location.
Installation of the five HI 4050 weight controllers provided this
mill the following benefits:
• Consistent flow and feed rates
• Improved production
• Minimized waste
• Accurate weight readings
The HI 4050 weight controller includes Hardy’s
core technologies:
• WAVERSAVER® - eliminates the effects of unwanted vibration
on or around the scale by permitting the instrument to “see”
through the unwanted vibration signals – as low as 0.25hz –
while yielding a fast and stable actual reading.
• Electronic Calibration without the need for test weights - C2®
enables a fast, accurate, electronic calibration of the scale. This
saves system start-up costs and aggravation.
• Secure Memory Module with Secure Digital (SD) card (SMM®-
SD), which allows manual transfer of configuration data to
another instrument or PC using SD technology
For more information:
Hardy Process Solutions
9440 Carroll Park Dr,
San Diego, CA 92121
USA
Tel: +1 858 278 2900
Web: www.hardysolutions.com
Pg 10 | November 2012
• INTEGRATED TECHNICIAN® (IT) for system diagnostics and
troubleshooting - In conjunction with an IT® Junction Box, the
controller provides built-in system diagnostics that let you
troubleshoot and diagnose your weighing system right from its
front panel, your intranet, or the Internet. Read individual load
sensor voltages and weights, make comparisons, verify the
scale zero and isolate individual system components for quick
and easy troubleshooting.
The HI 4050 weigh controller can act as a front end to a PLC, PC
or DCS system, or as a stand-alone for simple control or weight
monitoring. Only three inches deep, the HI 4050 general-
purpose weight controller is used in tank farm, batching/
blending, filling/dispensing, check weighing, level by weight,
and force measurement applications.
To meet your specific installation needs, the HI 4050 is
available with AC or DC power and in panel, remote or blind
DIN rail mounting packaging configurations. Installations are
simplified with no special tools required to cut rectangular holes.
Just use the included template to drill standard holes and install.
The controller includes a standard Ethernet 10/100 Base T with
an embedded web server and an RS 232 printer or scoreboard
display port. Optional network communications over Ethernet/
IP, DeviceNet, Modbus TCP or Analog are also available.
Ease of Setup - With its embedded web server, all the
instrument’s parameters can be set up from anywhere on the
Ethernet network. Front panel keys and graphic display with
simple menus provide quick, easy setup with process weight
and parameter display.
Accessibility – The embedded Ethernet communications
port in the HI 4050 Series weight controller enables users
to easily share data across a production facility, eliminating
the time and costs associated with new network wiring. The
embedded Ethernet Web server also gives users remote access
to control information, instrument parameters and diagnose
problems, further optimizing production efficiency by sharing
real-time data on the plant floor with OEM partners or off-site
maintenance personnel.
Expandable Secure Memory Module (SMM®-SD) - rear panel
accessible SMM is more than just a memory card. It’s a network
media that connects SD enabled products. The SMM now uses
a standard Secure Digital (SD) memory card, which allows easy
expansion, transfers of data from one instrument to another
and is readable by your PC.
100 Updates per Second – Provides more data for faster
applications but not too much data that is of no use
to the system.
Hardy Process Solutions has been a leader in weighing
solutions for over 85 years and is best known for its innovative
approaches to precision weighing solutions and vibration
monitoring equipment. An ISO 9001-certified manufacturer,
Hardy Process Solutions is based in San Diego, California. For
more information about Hardy Instruments, please visit,
Milling WorldMilling World, a new blog from NISA Media
Ltd, bringing together agriculture news stories from around the world.
As well as looking at events and shows we look at companies involved in agriculture, food production and animal production as
well as the feed industry and veterinary aspects of farming and agriculture.
The blog runs side by side with our online resource Global Milling Annual. Publishing press releases from key companies and key figures in the agriculture world, books releases and information
from global sources. As well as looking at the ever-changing face of agriculture, through GMO’s, research and other innovative
approaches to agriculture.
Another aspect of the agriculture world is the ever-changing effect of climate change on the industry, and as natural disasters occur,
such as droughts, floods, hurricanes we keep you updated.
Contact Martin ([email protected]) with your latest news!
November 2012 | Pg 11
SUMAK Milling Machines highly specialised
Today, SUMAK Milling Machines has highly
specialised in the design, manufacturing and
assembly of machines based on Conveying,
Storage and Transportation. Most people are using
many different ways of Conveying, Storage and
Transportation in the world; this is why, SUMAK
Milling Machines has an different Conveying System
when they make turn key milling plants all over the
world. All of the factories have an conveying system
which is based on for Flour, Semolina, and Bran,
etc; therefore, the machines are based on Elevators,
Chain Conveyors, Spiral screw, Tube screw, and
Electronic Bagging Scale System. So this is why,
those conveying machines are related to automatic
weighing bagging machines, extraction rate control
sytem as well. Also, there is another way to used
conveying system which is blower system which
means that pressure of the Wheat, Flour,Semolina,
and Bran, etc all of the factories.
SUMAK Milling Machines have been completed
250 different projects, and without any fault since
1986. The attached a flow diagram shows how the
Wheat, Flour, Semolina, and Bran Conveying System
works on bottom of side What is showing is the flow
diagram 60TPD/24hr Building, and the machines
such as Elevators, Chain conveyors, Spiral screw,
Tube screw, and Electronic Bagging Scale, and
Blower as well.
1 Fevzi Çakmak Mahallesi Ayyıldız Caddesi No: 69 KARATAY – KONYA – TURKEY
TEL: +90 332 345 42 70- 71 FAX: +90 332 345 42 61 [email protected] www.sumakdegirmen.com
Today, SUMAK Milling Machines has highly specialized in the design, manufacturing and assembly of machines based on Conveying, Storage and Transportation. Most of the people are using many different ways of Conveying, Storage and Transportation in the world; this is why, SUMAK Milling Machines has an different Conveying System when SUMAK make an turn key milling plants all around the world. All of the factories has an conveying system is based on for Flour, Semolina, and Bran, etc; therefore, the machines are based on Elevators, Chain Conveyors, Spiral screw, Tube screw, and Electronic Bagging Scale System. So this is why, those conveying machines are related to automatic weighing bagging machines, extraction rate control sytem as well. Also, there is another way to used conveying system which is blower system which means that pressure of the Wheat, Flour,Semolina, and Bran, etc all of the factories.
SUMAK Milling Machines have been completed 250 different projects, and without any fault since 1986. We have attached a flow diagram one of those how the Wheat, Flour, Semolina, and Bran Conveying System works on bottom of side. This is what showing of the flow diagram 60TPD/24hr Building, and the machines such as Elevators, Chain conveyors, Spiral screw, Tube screw, and Electronic Bagging Scale, and also Blower as well.
SUMAK Milling Machines would like to give some the application purpose details of the explanation Conveying System machines which are:
SUMAK Milling Machines would like to give some the application purpose details of the explanation
Conveying System machines which are:
For more information:Sumak Milling MachinesFevzi Çakmak Mahallesi
Ayyıldız Caddesi No: 69
Karatay, Konya
Turkey
Tel: +90 332 345 42 70
Web: www.sumakdegirmen.com
Pg 12 | November 2012
ElevatorsElevators are used for vertical transporting the products in the flour mills. Buckets, which
are fixed regularly on the belt, ladle the products, which are transferred from the bottom
head inlet to inside by the means of reductor. It transfers products to cross outlet with
centrifugal force by passing the top head pulley. It is transferred to required place by the
means of pipe which is mounted at this. Products dust is transferred out of system by
the means of pipe and valves are mounted on the head. Two of discharge bolts are taken
their places for discharging the materials, that are choked up with products because of
probable lameness, elevator occurs bottom top head with reductor, pipe,belt, pulley and
buckets. Excepting the bucket fixing belt, all other parts of the machine are made of steel
construction. Bottom head has stretching mechanism for bottom top head belt – pulley
adjustment. The elevator pipes are made of 1,5mm or 2mm metal sheet as unique parts
and pressed. One of the pipes are designed could be seperated in order to change the
buckets. The reducer motors are choosen according to the capacity and height of elevator.
Reductor table on the top head is active, so there is nothing any problem about centering.
Tube Screws:Tube Screw are placed the bottom of Rotoflow, it is generally used for transporting the flour
and bran. It is mounted under the rotoflow which is set up outlet of the flour and bran silos.
It could be manufactured in different specifications.
BlowerUsed for hoizantal or vertical carrying of all kinds of grain and pulses and cleaning filter
bags. Direct coupled and belt pulleys operation are both available. Covering a small area,
easy maintenance and assembly have made the blower pump a highly prefered machine in
milling sector in recent years.
The pump in front of flour, wheat and so on. Systematically separated from each other fort
he transport of products, products with the air of a working machine type. Blower is made
with the transport systems. Minimum maintenance requirement Minimum leakage rate
was casting the main body and the inner palettes .
Collected in a silo or a cyclone allows goods to be shipped in two separate road. Can be
controlled manually or pneumatically. Teflon sealing elements to distinguish it from the
materials provided to each other. On which side flaps that can be understood with the help
of limit switches. Is demountable all parts of valves in terms of maintenance and repair of
major benefit.
Silos and cyclones are used to block the flow of material subdialects. Cover the desired
sizes of circular, rectangular or elliptical cross section can be produced. Can be controlled
manually or pneumatically. Manual of the unit square miles are driven by a gear. Automatic
sliding valve neumatic cylinder and solenoid valves are provided in the drive. Position
pointer is also the limit switches.
Spiral ScrewsIt is used for horizontal transporting the products in the flour mills. It is manufactured in
different diameter and lenght. It is manufactured as right or left direction according to
application fields. It is used for distributing, collecting, mixing and annealing
wheat process.
November 2012 | Pg 13
Electronic Bagging Scale:. Full PLC controlled. Suitable for bagging of materials in open mounth bags. Weighing range options of 10-25 kg. Accurate and quick weighing with load cells.. Programmable set values with 10gr. İntervals.. Programmable desired number of bags.. Seperately programmable high and low tolerance values. Alarm functions for out of tolerance weighment. Level control in the regulation bin 12-20 ton/ hour bagging capacity depending on the product. Display of total number of bagged and total weighed materials.. Easy and practical calibration.. Alarm function fort he faults. Display of the fault messags at the operatör terminal. Pneumatic bag clamp. Vibrator. Take- away belt conveyor. Adjusttable bag guiding plates. Sewing machine support and sewing machine motor. Sewing machine (optional) Various feeders for materials with different chacterestics. Double screw driven by seperate. Single Screw driven by two speed motor. Conveyor belt driven by two speed motor. Pneumatically operated gate.
CAPATICY: Changeable according to the bagged product and required tolerance and capacity is
between 12tons/ hour to 20 tons/hour. (Declared capacity is 12 tons/hour with a tolerance of+-
50/sack for flour and the products having same characteristic)
SETTING VALUE: Could be programmed 25-50 kgs. According to the user’s requirement.
WEİGHT DISPLAY: Weight display screen is 4digit
FAST-SLOW ADJUSTMENT: There is two programmable setting value in the system. and possible
to program the filling volumes of these values seperatelly. High and low tolerance values made
automatically according to the type of the flour and silo level.
TOLERANCE: High and low tolerance values can be programmable seperatelyç If the weighning
results are out of the tolerances, the products did not get out without on operator’s intervention.
BAG DIMENSIONS: Recommended sizes are 65x95 cm.
REQUIRED BAGGING: Programmable desired number of bags. The number og bags can be
changed during the bagging. System stops by itself when the rewuired bagging finished.
TOTAL BAG NUMBER and WEIGHT: Possible to display of total number of bagged and total
weighed materials.
TOTAL BAGGING TIME: Possible to display to display of the total time of bagging.
LEVEL CONTROL: By the help of level sensors in the regulation bin, the level controlled by the
system automatically.
ALARM FUNCTION FOR THE FAULT MESSAGES: Display of messages at the operatör terminal.
Chain ConveyorsChain conveyors are used for the horizontal ways of grain, feed, flour and bran.
Therefore, chain conveyors can be carried 300tons/hour of the capacity, and the
elimination of metal to metal contact conveying section leads to smooth operation
and also it makes less noise with a longer life as well. The chain conveying system
based on high volüme of the grain movement, and there are plastic rollers are
support the chain for returning.
Pg 14 | November 2012
Choosing the right hazard monitoring system for your bucket elevator
When 4B introduced their Watchdog Elite bucket elevator
monitoring system in the early 1980’s, they were the first
on the market to offer a system that could monitor a complete
bucket elevator or conveyor system. No more need to monitor
different hazards separately. -Taking the hassle out of hazard
monitoring, the Watchdog Elite has quickly established itself as
the industry reference in hazard monitoring.
Today, there are a number of systems on the market, and
customers may find it more difficult to establish which system
is best for them. When you add up all the additional costs of
adding sensors and servicing the system, then this decision
becomes even more complicated. And when you consider the
cost of the potential downtime and even damage, then it is
absolutely crucial to get this decision right!
So what should customers look out for when selecting a system
to monitor their bucket elevators and conveyors?
Firstly, scalability:
Make sure that the system is able to grow with your operations.
You might just want to monitor one elevator, for a start, but
what happens if you want to monitor an additional elevator, or if
you want to add more sensors to the monitoring system?
Secondly, sensor options and interfaces:
What hazards is the system able to monitor? Belt and pulley
misalignment? Underspeed & Overspeed? Belt slippage?
Blocked chute condition? Bearing temperature? – And what
is the choice of compatible sensors? Do you have to use the
supplier’s range of sensors, and are they up for the job?
Does it have a communication interface, to be connected
to a PLC or PC?
Thirdly, user friendliness and support:
How easy is the system to use for the people who have to
operate it? Is there an in-built test and diagnostic function?
And how are potential hazards displayed and identified? Is
there a well-documented instruction manual available? Does
the supplier offer a commissioning service? And what level of
support can you expect, if there is a problem?
Fourthly, compliance:
Does the system have the necessary hazardous area approvals
for the region where it is to be used: ATEX for Europe, CSA for
North America & Canada and IECEx for the rest of the world?
At 4B, 25 years of experience have shown that there is no
“one size fits all” hazard monitoring system. The company’s
approach to product development is very much bottom-up
through discussions with the end-user upwards, rather than
sales-driven. -And it is this industry driven approach to product
development that has led the engineering team to develop 2
distinctive multi-function hazard monitoring systems, each
of them well researched and tested and using the same high
quality components, but different in the variety of sensor
options and the scope of the applications they can cover.
For more information:4B Braime Elevator Components
Hunslet Road
Leeds
LS10 1JZ
United Kingdom
Tel: +44 113 246 1800
Web: www.go4b.co.uk
November 2012 | Pg 15
The T500 Elite Hotbus System
This is 4B’s top of the range system, able to monitor entire plants where the
bucket elevators and conveyors being monitored are spread out across large
distances.
A multi-function hazard monitor, it can monitor belt speed/alignment, bearing
temperature, pulley alignment and plug condition. It has been designed as a
serial communication system, to monitor up to 256 sensors, with a scan time
of only 4 seconds! With automatic machine shutdown capability and PLC /
PC compatibility, this advanced microprocessor based system offers low cost
installation, versatility and easy system expansion.
Logging and trending software is also available for historic data analysis and
preventative and predictive machine maintenance.
It is ATEX, CSA and IECEx certified.
The Watchdog Elite System
A well proven multi-functional hazard monitor for bucket elevators and conveyors,
the Watchdog Elite has recently been relaunched with continuous bearing
temperature monitoring.
The Watchdog Elite allows complete monitoring of multiple hazards in a bucket
elevator or conveyor, including belt and pulley alignment (top and bottom), bearing
temperature, belt speed and blocked chute conditions.
The Watchdog Elite system uses a range of compatible sensors to monitor
different hazards, such as the belt misalignment sensors “Touchswitch”, BAP2”
and WDA3”, the WDB bearing temperature sensors and the “Binswitch” capacitive
sensor.
An LCD screen displays elevator status messages (available in four different
languages) and a super-bright LED screen displays belt speed. RS485
communication is also available for connection to plant computers / PLCs.
Calibration and parameter adjustment are all menu-driven and kept simple.
The system is ATEX, CSA and IECEx certified.
T500 Elite
ü (continuous)
max. 256 sensors*
ü (continuous)
max. 256 sensors*
ü max. 256 sensors*
ü
RS485 API
ü
ü
ü
Multiple elevators & conveyors;
remote monitoring across site
ATEX CSA
IECEx
Watchdog Elite4B has an extensive range of CSA / ATEX / IECEx approved
sensors that work with these control units, including bearing
temperature sensors, speed sensors, misalignment switches,
level indicators and choke switches. The range is constantly
evolving to offer customers the best technical standard.
4B’s technical team can recommend the ideal combination
of sensors and monitoring systems to suit their customers’
requirements and budget. They can also offer a scalable
solution starting with carefully chosen equipment and systems
that can be expanded at a later date to encompass other
machines in the plant.
4B also offers a commissioning service as well as a competent
after-sales technical service to help customers overcome any
technical problems with their monitoring equipment.
ü (continuous)
max. 6 sensors*
ü (continuous)
max. 1 sensors*
ü max. 4 sensors*(Touchswitch)
ü
RS485 API
ü
ü
ü
Several elevators & conveyors
ATEX CSA
IECEx
Bearing temperature
Belt speed
Belt Alignment
Plugged condition
Communication interfaces
Test function
Alarm & shutdown
Logging & trending
Applications
Certifications
Pg 16 | November 2012
IDMA 2013 TOUR PACKAGES
5***** Contracted Hotels 03 - 07 April 2013 / 4 Nights accomodation04 - 08 April 2013 / 4 Nights accomodation
IDMA 5th International Flour, Semolina, Rice, Corn, Bulghur, Feed Milling Machinery & Pulse, Pasta, Biscuit Technologies Exhibition
IDMA 5th International Flour, Semolina, Rice, Corn, Bulghur, Feed Milling Machinery & Pulse, Pasta, Biscuit Technologies
Exhibition which takes place 4-7th April 2013 organised by Parantez Group
IDMA – is an event aimed to enable the directors and managers of companies to exhibit their products, directly communicate with
their customers, find new sales markets and partners for conclusions of agreements.
There has been a significant increase in the number of expected delegates and exhibitors 2013 compared to compared to 2011.
Now more than 10,000 thousand local and international visitors are expected from 120 countries. The exhibition allows it to be the
major negotiating point for international and Turkish milling and grain processing companies. This exhibition is helping to attract
and gather such manufacturers to share their experiences in the industrial and scientific field.
The Exhibition also offers a good experience and a chance for students who are studying in this field to declare themselves or to
find a good job.
If you are interested in visiting IDMA, please see our special visitor tour packages below and email [email protected].
WOWISTANBUL HOTEL
TITANICPORT HOTEL
COURTYARDMARRIOT HOTEL
Package Includes:4 Nights accomodation & breakfastAirport - Hotel TransferHotel - Fair Area TransferFair Entrance CardFair BrochureBosphorus Boat Tour (Evening)Half Day Historical Peninsula Tour
4**** Contracted Hotels 03 - 07 April 2013 / 4 Nights accomodation04 - 08 April 2013 / 4 Nights accomodation
WOWISTANBUL HOTEL
TITANICPORT HOTEL
Package Includes:4 Nights accomodation & breakfastAirport - Hotel TransferHotel - Fair Area TransferFair Entrance CardFair BrochureBosphorus Boat Tour (Evening)Half Day Historical Peninsula Tour
Price Per Person in a Double Room 512 €Price Per Person in a Single Room 949 €
Price Per Person in a Double Room 512 €Price Per Person in a Single Room 827 €
Since January 01, 2013, price of tour packages will increase by 10%
2013
EV
ENT
LIS
T January 201329th-31st January
International Production &
Processing Expo (IPPE),
Atlanta, GA, USA
February 201323rd-26th February
GEAPS 2013, Louisville,
Kentucky, USA
March 201311th-15th March
Purchasing & Ingredient
Suppliers Conference,
Texas, USA
13th-15th March
VIV Asia,
Bangkok, Thailand
26th-28th March
AGRA Middle East,
Dubai
April 20134th-7th April
IDMA 2013,
Istanbul, Turkey
8th-12th April
The 4th Global Feed and
Food Congress (GFFC),
Sun City, South Africa
29th April-3rd May
117th Annual IAOM, International
Association of Operative Millers,
Ontario, Canada
May 201322nd-24th May
VIV Russia,
Moscow, Russia
29th-31st May
CIMAE 2013,
Beijing, China
30th May – 2nd June
Surabaya Agri Expo,
Surabaya, Indonesia
June 201310th June
International Grains Council,
London, UK
12th-13th June
Cereals 2013,
Lincolnshire, UK
27th-28th June
The Nottingham Feed Conference,
Nottingham, UK
July 201313th-16th July
IFT Food Expo 2013,
Chicago, USA
August 20137th-9th August
Livestock Philippines 2013,
Manila, Philippines
25th-28th August
ICC Conference 2013,
Perth, Australia
September 201310th-12th September
Liquid Feed Symposium,
St Louis, MO, USA
24th-26th September
Livestock Asia 2013,
Kuala Lumpur, Malaysia
October 20136th-9th October
International Baking Industry
Exposition, IBIE 2013,
Las Vegas, USA
November 201310th-16th November
Agritechnica,
Hannover, Germany
December 20138th-10th December
NGFA Country Elevator
Conference & Tradeshow,
St Louis, Missouri, USA
Please visit www.globalmilling.com/global-milling-events/ for more information on these events
Pg 18 | November 2012
June 201310th June
International Grains Council,
London, UK
12th-13th June
Cereals 2013,
Lincolnshire, UK
27th-28th June
The Nottingham Feed Conference,
Nottingham, UK
July 201313th-16th July
IFT Food Expo 2013,
Chicago, USA
August 20137th-9th August
Livestock Philippines 2013,
Manila, Philippines
25th-28th August
ICC Conference 2013,
Perth, Australia
September 201310th-12th September
Liquid Feed Symposium,
St Louis, MO, USA
24th-26th September
Livestock Asia 2013,
Kuala Lumpur, Malaysia
October 20136th-9th October
International Baking Industry
Exposition, IBIE 2013,
Las Vegas, USA
November 201310th-16th November
Agritechnica,
Hannover, Germany
December 20138th-10th December
NGFA Country Elevator
Conference & Tradeshow,
St Louis, Missouri, USA
back cover
Global Milling DirectoryGlobal Milling Directory a new online directory
Global Milling has become a brand new reference source for the Grain, Feed, Flour, Cereals, Rice, and Pasta
industries. Covering all aspects from equipment to raw materials and including all suppliers and manufacturers
working within the industry.
Bringing you the latest up-to-date relevant news, upcoming industry events, Universities and worldwide company contact information – Everything you need in
one place!
Keep up-to-date with Global Milling!
www.globalmilling.com