Single machinery introduction on +86 13722890692 [email protected]

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Single Machine Introduction of Maize Flour Mill Machine

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CAPACITY:5-500T/24H PROCESSING MAIZE

TEL:0086-311-85528086

FAX:0086-311-87910068

CELL:0086-13722890692

(viber/whatapp/imo)

EMAIL:[email protected]

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HONGDEFAFACTORY PHOTOS

www.mscandymill.com [email protected] Mobile:0086-13722890692


Plansifter Workshop

Roller Mill Workshop


Project Photos:

Six floor building maize mill for 500Tons/24h

Four floor building for maize mill line

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Stainless Steel Pipe in Milling section

PLC Control System

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CLIENT PHOTOS


SHIJIAZHUANG HONGDEFAMACHINERY :China and Australia Wheat Flour Mill Technology

China and South Africa Maize Mill Technology

Australia office;Brazil agent;South Africa office,Zambia office,Rd Congo office

Shijiazhuang Hongdefa Machinery Co.,LTd is a professional manufacture of wheatflour mill and maize mill,we provide high quality machine from 500kg/h to 50ton/h withdifferent design according to our client needs,with European technology,South Africa maizeprocess,China wheat process, roll out unique and innovative wheat flour mill and maize millplant.

The head office of Shijiazhuang Hongdefa Machinery Co.,Ltd is located 4hoursdriving From Beijing,where we have approximately 100employees, a manufacturing facility of3000square meters and 500 square meters of office space

Shijiazhuang Hongdefa Machinery have more than 30years experience in milling market.

The core technologies of our group are in the filed of wheat flour mill and maize

mill process engineering, with European technology, South Africa maize process,

China wheat process, roll out unique and innovative wheat flour and maize meal

processing line . It has the following features:

1.Roller Mills

NO.1 IN CHINA FOR ROLLER MILL

1)The partitioned paneling and swing-out feed module guarantee idealaccess to the feeding and grinding rolls. This makes residue-freecleaning possible.2) a pulse generator automatically adjust the feed material at the entrance door3) bearing SKF4) temperature monitor (option)


2.Plansifter

NO.1 IN CHINA FOR PLANSIFTER

1) Material: High-strength alloy steel

2)up and down sifter circles with steel plate overall by bending

3)Transmission system using spring force component institutions

4)Sieve frames of wood coated with synthetic resin,without backwire

5)All the inside walls as well as the doors are provided with high-grade

insulation

6)Vertical and horizontal clamping system


3.Dampener:Stainless steel.

4.Bucket elevator and conveyor with reducer

5.PIPE:stainless steel in milling section

6.Plant Control System :

PLC control system with CCTV surveillance system realize Seamless

integration

7.Electronic parts: Siemens/Schneider

8.Bearing:SKF/TWB

9.Reducer:flender/sumitomo /sew

10.Proportioning & Mixing,automatic computer control (wheat)


Introduction of each function of cleaning machineBucket elevator: Bucket elevator is the vertical machine for lifting the raw material, and

the worm conveyor is the horizontal machine for carrying the material. As have too muchmachines, we designed use vertical technical flow and horizontal flow in the factory to savearea and hight of the building.

High-performance belt:Reinforcing materialmade of syntheticgumming canvas,warp islow shrinkage polyesterfilament , nylon filament

weft ; between the belt and the head wheeladd one layer durable base fabric; very goodfor grain and good processing

The body bend withone plate,no welding ，

long life

High-speed vibratory sieve: Vibrating sieve is a sifting machine with high speed.The principle is when the sieve body are droved by two sides vibrating motors, maize flow intothe first sieve surface through feeding entrance, large impurity on the upper sieve is dischargedto the hopper. Another material come into the second sieve surface for continual sift. On thissurface, the maize and small impurity are separated eachother. Finally lighter impurity is discharged by thesuction pipes. This machine has much speciality such ashigh capacity, without jaming and so on. The function isthe sieve remove all impurities from maize to reduce dustand impurity to pollute workshop as much as it can. Andensure rear working line with good running. Meanwhileto avoid jaming into the slip of screw conveyor and exitof damper bin.

Main Area No welding Quality sheet

Vibration smooth uniform feeding

Special Drawer design,easily to maintain Galvanized Bolt Tight


Magnetic separator: Avoiding the metal material running a high speed into the machine tomake a spark under beating and friction situation.

Gravity classifier destoner: According to different gravity between maize and same sizestones, and air dynamics, adopt destone and sieve performance and movement parameter, andair current speed, the destoner to classificate the raw material. The maize and stones moving onthe sieve with different direction, made the stones are separated from wheat.

■ Higher efficiency destoner,shutter sieve structure■ Easy operation, compact structure.■ For different materials,destoner sieve can adjust between 10-14 degree■ External fan, whole machine sealing , no dust outside, to achieve the desired environmentalrequirements. Reciprocating swing,splices using rubber bearings, vibration low, low noise.■ Adopt self-aligning bearing with locking device, so that the mechanical character morestable


Damper: Specially for maize

Computer control moistureBi-Direction screw,prevent free waterIntensive intermixingStainless steel screw leaf and outsideNo Leaking

Degerminator:Degerminator is designed to scrub the maize skin from the maizekernel,and to dislodge the maize germ from its cavity,with the minimum reduction in sizeof the broke fragments.

American Technology minimum reduction in the size of the broke fragments


Roller Mill: The mill the most important one machine of whole processing line, is mainly forgrinding. To break maize and bran’s structure, and spearate the maize husk and the embryofrom endosperm by grinding.

The partitioned paneling and swing-outfeed module guarantee ideal access tothe feeding and grinding rolls. This makesresidue-free

A pulse generator automatically adjustthe feed material at the entrance door

Bearing SKFSensor Omron


Plansifter can classify the material that from break, reduction and scratch systems and siftingthe flour.

Material: High-strength alloy steelUp and down sifter circles with steel plate overall by bendingTransmission system using spring force component institutionsSieve frames of wood coated with synthetic resin，shape no changeAll the inside walls as well as the doors are provided with high-grade insulationVertical and horizontal clamping system


Gravity Table: which use the gravity is select the granual which is same size with thegrits,to improve final products extraction

This machine is the use of germ and corn granulesspecific gravity and different suspension velocity airstream by means of physical action up through the corngrits and corn germ gap prompted particle sizing, asdirected in the inclination to mention the role of theembryo reciprocating sieve, corn granules to thedischarge end of the movement. Floating on top of thegerm under its own weight, to the embryo populationmovements, thereby germ separated from corn residue

Turbo sifter is a perfect sifting equipment,combined vibrating shifting and centrifugalsifting,the screen hole not block,and more suitable for sticky material,widely using siftingthe bran and flour


PLC Control system


Scale:Online scale and packing scale

1.Online auto cumulative weight;2.High-precision on-line flow control;3.Frequency (batch) weight control;4.With MODBUS communication interface with computer networking, computer centralized

management control;5.According to customer needs, can have the print function.6.Feeding and support is stainless ste


PIPE:in milling section is stainless steel

AIR SYSTEM

Screw air compressor

Belt tensioning convenient, simple replacement of the belt structure,

completely eliminate mechanical resonance

According to acoustic principles, enclosures closed, eliminating noise


MAIZE MILLING DESIGN INSTRUCTION

COMPOSITION OF MAIZE PRODUCTS

CLASS OFMAIZE

PRODUCT

FAT CONTENTBYMASS %

FIBRECONTENT BY

MASS %FINENESS BYMASS

MIN MAX MIN MAX

1. Samp - 1.5 - 0.8Not more than 5% shall be whole grain and notmore than 5% shall pass through a 2.36mm sieve.

2. Maize Rice - 1.5 - 0.8At least 90% shall pass through a 4.0mm and notmore than 5% shall pass through a 1.18mm sieve.

3. Maize Grit - 1.5 - 0.8At least 90% shall pass through a 1.4mm sieve andless than 90% shall pass through a 300 micrometersieve.

4. Maize Flour -Less

than 2.0- 0.8

At least 90% shall pass through a 300 micrometersieve.

5. Super MaizeMeal

-Less

than 2.0- 0.8

At least 90% shall pass through a 1.4mm sieve andless than 90% shall pass through a 300 micrometersieve.

6. SpecialMaize Meal

2.0Less

than 4.0- 1.2 At least 90% shall pass through a 1.14mm sieve.

7. Sifted MaizeMeal

3.0Less

than 4.0- 1.2 At least 90% shall pass through a 1.14mm sieve.

8. UnsiftedMaize Meal

3.5Less

than 4.5

Morethan1.2

2.5 At least 90% shall pass through a 1.14mm sieve.

9. No.1 StraightRun MaizeMeal

3.7 - 1.8 2.5 At least 90% shall pass through a 2.36mm sieve.


10.No.2Straight RunMaize Meal

3.7 -Morethan2.5

6.5 At least 90% shall pass through a 2.36 mm sieve.

11. UnsiftedCrushed Maize

3.2 1 1 2.5Not more than 5% shall be whole grain,and notmore than 40% shall pass through a 2.36mm sieve

12. SiftedCrushed Maize

1.5 - - 2.0Not more than 5% shall be whole grain,and notmore than 5% shall pass through a 1.18mm sieve

13. FineCrushed Maize

1.5 - - 2.0At least 90% shall pass through a 2.36mm sieveand not more than 10% shall pass through a 1.0micrometer sieve.

14. MaizeGerm Meal

10.0 - - - -

15.Fine MaizeBran

-Lessthan10.0

Morethan6.5

17.0At least 90% shall pass through a 2.0mm sieve andat least 50% shall pass through a 1.4 micrometersieve.

16. CoarseMaize Bran

-Lessthan10.0

Morethan6.5

17.0 -

17. IndustrialGrade MaizeProduct

- - - - -

Though not strictly applicabe to products many of the above fat and fibre contents are stillrecommend in most company based quality matrix.

OUTLINE OFTHE MAIZE MILLING PROCESS

1. PREPARATION OFTHE MAIZE FOR THE MILLING PROCESS

Before the milling process proper can commence the maize must be suitably prepared. During thisoperation all impurities and foreign matter are removed, and finally the maize is conditioned by allowing acontrolled quantity of water to penetrate the bran before the grain is ready for milling.

2. THE MILLING PROCESS

The process of manufacturing the products involves three fundamental sub-processes. The firstof these, physically detaches the three components of the maize kernel from each other. with as little dilutionor mixing as possible.second, sorts and classifies the detached particles into specific groups and the last, sizesand reduces the particles to the required granularity. The three components are then recombined as


necessary depending on the type of finished productRequired The aim of the process then, is to detach the bran and germ from the maizekernels with a minimum disintegration of either the endosperm or the bran/germ casing. The pure endospermis then gradually reduced in size to form products of different granularity, ranging from the relatively largepieces of camp to the very Fine maize flour. Some of the bran and germ are also ground down in theprocess and a certain amount combined with the ground endosperm to meet thespecifications of the coarser meals such as sifted and unsifted maize meal.

2.1 Detaching the bran and germ from the endospermThis part of the process is carried out 6y treating the conditioned maize on either a degerminator or a rollermill.

2.1.1 The degerming processThe action of the degerminator is designed to 'scrub' the bran skin from the maize kernel and to dislodge

the germ from its cavity, with the minimum reduction in size of the broken fragments.in the machine themaize is subjected to a rubbing, tumbling action by a revolving cone with a very coarse surface whichpeels the bran from the endosperm and frees the germ. At the same time the machine effects a roughSeparation of the broken endospem pieces from the fragments of bran and Germ by means of a perforatedscreen. Because of varying maize characteristics,And imperfections in machine design, a certain amount ofbreakage and Imperfect separation is unavoidable and much be rectified later in the process.

2.1.2The roller mill processFor the purpose of detaching the bran from the endosperm, very coarsely fluted rolls are used, The shearingaction provided by the flute spiral and roller speed Differential breaks open the whole maize kernels anddetaches much of the endosperm from the bran and germ.

However, this does not provide as much clean endosperm as the degerminator and a good deal of workremains to he done later in the process, but the roller mill does have an advantage in that the action does notpulverise the germ and bran to the same extent as the degerminator.

2.2 Sorting and classifying the broken particlesThis is the second part of the milling process and involves the use of several different types of sievingmachines as well as aspirators.

2.2.1The drum type sifter or Le Coq sifterBecause of its sturdy construction and high capacity, this type of sieving machine is often used to separate thegerm meal fraction from the broken endosperm particles produced by the degerminators. The separationeffected is only a rough one but it greatly facilitates the later sieving operations on the plansifters.

2.2.2 PlansifterThe modern plansifter has been developed into a highly efficient machine capable of sorting a single feedinto six or seen different ranges of particle size. This is done by using several different mesh aperture sizeswhich effect the separations mainly as a result of difference in particle size as wail as variance in density andshape. The action of the plansifter causes endosperm particles, with


their inherently higher density and comparatively spherical shape, to work their way down to the lower layers,while the germ and bran particles remain in the upper layers. The size of the particle In relation to that ofthe aperture of the sieve, then ultimately determines whether the particle will pass through the aperture or not.Using these principles the plansifter classifies the broken particles of maize so that they may he processedmore efficiently on the Machinery which follows.

2.2.3 The Concentrator or gravity tableThis machine continues the classification of the particles by utilising a combination of air currents and anoscillating deck to sort out particles according to differences in density. Since endosperm is appreciablydenser than germ, which in turn is denser than bran, a single stream, consisting of a mixture of these particles,can be classified into as many as four groups of varying purity Prom pure endosperm at the one extreme topure bran at the other, with varying combinations of Composite particles in between.

2.2.4 The AspiratorThroughout the milling process one of the Chief aims is to Isolate bran and germ Particles from cleanendosperm in order to prevent contamination of the finished products.

The aspirator is particularly useful in this regard as it sorts out the particles by Using theirdisparity in air resistance. The shape of a particle plays a significant Part in determining itsbehaviour in an air current and since bran (and, to a lesser extent, germ) in addition to having alower density, tends to be flake-shape,it is ideal for separation by aspiration.

2.3 Reducing the particle size and sifting out the productsFinal reduction in size of the cleaned and graded maize particles is always carried out by rollermills. Finely fluted rolls are used and the accuracy with which the Severity of the grind can beset makes the roller mill ideal for this purpose. The plansifter is also ideally suited for thepurpose of sizing the ground particles according to the required granulation. Particle sizes in thefinished products range from 4000 microns in the case of maize rice down to 300 microns formaize flour and all of these can be accommodated by the range of sieves available in themodern plansifter.

2.4 Summary of the processThe entire milling process in constituted by combining the sub-processes referred to above intogroups of series and parallel operations. A simple example is shown in Diagram 1. Eachgroup performs basically the same operation, the only difference being that the particle sizegradually diminishes as the process proceeds step by step from raw material to finished product.

In general terms the machinery flow sequence is: degerminators and roller mills- plansifters一 aspirators 一 concentrators 一 rollermills. The reason for this sequence can be readilyappreciated by considering the nature of the particles before and after each treatment.To begin with, a wide range of different sized particles is created during treatment by thedegerminators and roller mills. To facilitate separation and subsequent processing, the particlesmust first be classified into groups, each having a narrow range of particle size. This is why theplansifters always follow the roller mills.


Once the particles have been classified into size groups, advantage can be taken in differencesin nature of the particles which make up the kernel components. The bran,being significantlydifferent from either germ or endosperm in air resistance, is readily separated first by meansof aspirators. With the bran removed, germ can be separated from the endosperm on theconcentrators or gravity tables, according to density differences.Endosperm particles,now comparatively free from Both bran and germ and the unavoidablefragments cut up during the roller mill process,can then be suitably sized on another roller millIn order to meet granularity specifications.

3.THE DEGERMING PROCESS3.1 The degerming process originated in America where it was developed as the quickest andeasiest way to remove the germ and outer bran covering from the maize kernel. In the USA,maize is seen as a valuable source of vegetable oil and the farmers are encouraged to cultivatevarieties of yellow maize with large germ components and high oil content. In this millingprocess, the main objective is to recover as much of this valuable portion of the maize kernel aspossible, and so, in effect, the germ fraction is considered to be the prime product, whilethe endosperm and bran are treated as the by-product and disposed of mainly as cattle feed.Some of the endosperm is recovered in the form of samp or grits and used in the production ofbreakfast cereals or snack foods。But of prime importance is the germ oil from which then, somany types of food are obtained. In the American process,the emphasis is on the production ofas much good quality germ as possible and the incidental breaking up of the endosperm isconsidered to be of minor importance.Perhaps because of this, the design of the degerminator is robust,with few refinements and itsaction in separating the bran from the endosperm and dislodging the germ is extremely rough.

In our country on the other hand, the aim of the degerming process is to remove the bran fromthe maize kernel and dislodge the germ from its cavity with the minimum damage to theendosperm, bran and germ. This facilitates the sorting process which follows degerming andis designed to separate the endosperm, bran and germ from each other and to minimisepossible contamination of the clean endosperm fraction with the oil from the germ. Furtherprocessing on the mill converts the endosperm into various finished products such as samp,grits or meal which, in this case, are the prime products, while the combined germ andbran fraction, which remains a valuable source of oil, constitute the by-product.

The type of degerming used in the South African milling process varies to some extent andmay take the form of1. a full degerming of the maize to produce clean samp (damp degerming);2. a type of skinning procedure where only a partial removal of the germ andbran takes place;3 or 'partial damp' degerming which differs considerably from the other two.

3.2. DAMPDEGERMING PROCESS FOR SAMPWITH HORIZITALTYPE DEGERMERS


This is a 'damp' degerming process which involves the use of steam or water to rise the moisture content ofthe outer bran layers of the maize kernels before they enter the degerminator. A 'HORIZITAL type'degerminator is used, based on concept, and the purpose is to produce a high proportion of largeendosperm pieces or samp, from which all the bran and germ has been removed, with a minimum amount ofdamage to any of the three components.

3.2.1 Condition of the maizeIn order to achieve the best results, it is vitally important that the maize feeding the samp degerminator

should be in optimum condition. The type of maize will affect results and it is best to use a hard, dent typeif a good yield of samp is to be obtained. Soft local varieties are unsuitable as they break up tooeasily and produce large quantities of fine endosperm particles which mix irretrievably withthe bran and germfragments. This problem was experienced in recent years by mills throughout the country when droughtconditions forced the millers to rely on soft, yellow maize imported from America and Argentina.

Most of the white dent varieties of maize produced under normal conditions in South Africa aresuitable for use in the samping process but, in addition to cultivar,

the following points should also be noted in selecting the maize:1. The endosperm must be free of cracks or stress lines which are usually

caused by negligent drying techniques on the part of the producer;2. the kernels must be whole and preferably as evenly sized as possible;3. The maize must be clean and free from loose impurities; and4. The natural moisture content should be low enough so that it is possible to

Add the required amount of water in the conditioning process.

If the maize selected conforms as nearly as possible to the above requirements, it should be possible todeliver the maize to the degerminators in the best possible condition for samping.

In order to produce the best results, the final condition of the maize should be such that:1. The endosperm remains as hard as possible and has the maximum resistance to attrition;2. the bran is as tough as possible. This includes the black tip cap which must be removed intact, with

the bran;3. the germ is firm and pliable; and4. the adhesion between the bran and endosperm is at its lowest.

The methods used to achieve correct conditioning have been covered in Module 2but, in general, they involvecontrolled moisture addition in the form of water or steam and carefully set lying times, in order to allowlimited penetration of the maize kernel. There is a divergence of opinion on moisture addition limits as wellas optimum penetration times but these will vary depending on local conditions and the type of maize used.

A moisture addition of 6% to 8% and lying time of 20 minutes should result in clean separationof the maize components by the degerminator under normal condition.


3.2.2 Other factors affecting degerming

3. 2.2.1 The feedThe capability of a degerminator to deliver good samp is directly affected by the

consistency of the feed rate. The maize should enter the machine at the rate recommended by themanufacturer, which is generally between two and four tons per hour, and should not be allowed to vary.The rate is normally controlled by volumetric feeders but these must be checked regularly as foreign materialvery often accumulates inside the compartments and so volume flow is reduced over a period even though thesetting has not altered.

When a degerminator is underfed, not only is the power being wasted but also the breakage willincrease because the particles remain inside the degerminator for longer than necessary. Conversely,if the machine is over-fed, the maize will not be properly degermed and the quality of the samp will bepoor. Electronically controlled variable speed measurers are now being used in the modern maize mill,their function is to reduce feed automatically in the event of an overload condition on the main motorcaused by a build-up of feed in the degerminator. The feed rate does not vary under normal conditions.The regular flow of maize to the machine may also be disrupted by a build-up of metal fragments on themagnet which is usually installed in the feed spout. Besides obstructing the feed, this also reduces theeffectiveness of the magnetic protection and could result in damage to the rotor or casing.

3.2.2.2 The rotor cone adjustmentThe pertormance of the degerminator may be controlled to a certain extent by altering the severity

of the treatment while the machine is in operation.'The main adjustment is effected by a leer, which movesthe position of the rotor cone in relation to the stationary casing. The correct setting is determined inassociation with the tension on the discharge gate and is a matter of establishing the correctbalance between the side and end clearances in order to avid under- or over degerming. Once theoptimum position has been determined, farther adjustments should not be necessary exce the rotor orcasing.

3.2.2.3 The discharge gate adjustmentAny adjustment to the tension on the discharge gate (or tailsgate) has an immediate effect on

performance as this virtually controls the duration, and hence, the severity of the treatment. The tensionmust provide just sufficient resistance to the maize flowing through the degerminator to enable degermingto take place without undue damage to the particles.

3.2.2.4 Condition of the degerminator partsWorn working surfaces inside the degerminator are bound to result in sub-standard results

and efficient operation depends on a regular maintenanceprogramme.a. Worn scroll sections at the feed end will retard the maize at this point and

upset the flow of product through the machine.b. Worn nodules will not be able to detach the germ and bran and will

produce a high proportion of finely ground germ meal.c. Worn perforations will upset the balance between throughs and overtails

while holed screens will allow undegermed particles to fall through.


3.2.2.5 Germ mealThe germ meal referred to here and elsewhere in the chapter consists of a mixture of finely

ground germ, bran and endosperm fragments created by the abrasive action of the degerminator. Thisfraction passes through the holes in the perforated plates and constitutes the degerminatar 'throughs'. Itcontains most of the germ and bran and nearly all of the water added in the conditioningprocess. Themoisture content must he reduced as quickly as possible by means of artificial drying to prevent deteriorationof the meal.

When a degerminator is operating efficiently, the fragmented endosperm content of the germmeal is reduced to a minimum. this is indicated by a low percentage germ meal figure showing that mostof the endosperm is overtailing the degerminator in the of large pieces of samp.Too much tine endosperm inthe germ meal is a sing of inefficiency and may be the result of soft maize, poor conditioning, incorrectmachine setting or worn working surfaces.

3.2.3 Advantang of the damp degerming processthe principal advantage of the process is that it yields a high percentage of large. fully degermed samp fromwhich a variety of other grade prodcts such as maize rice and brewers grits can be produced. Supe maizemeal and other meals produced from the samp are also of excellent colour and quality.

4.Break and reduction roll systemsThis chapter deals with the further treatment of the relatively pure endosperm pieces whichwere produced by the degerming system as described in the previous item.This is the last partof the actual milling process where most of the finished products are finally produced.The function is to reduce the endosperm to intermediate size particles which are divided intoseveral different grades which facilitates more accurate grinding on te reduction rolls.In settingthese rolls it should be borne in mind that the aim is to size the particles for further processingand while a small amount of meal will inevitably be produced, this is not the main objective.theseverity of the grind at this stage should never be sufficient to produce maize flour

5.Sifting system

6.Balance system

7.Packing Machine

Single machinery introduction on +86 13722890692 [email protected]

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Transcript of Single machinery introduction on +86 13722890692 [email protected]