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Issue 1 November 2012
IN THIS ISSUE
Hardy Process
Hardy Process Solutions increases flour mill productivity with improved flow and feed rate
Bin Measurement Basics for Millers BinMaster Level Controls
Sumak Milling
Introduce their range of products
AND MUCH MORE...
When Silos Need Cleaning
We talk to Hardy Process Solutions about flow and feed rate systems
Need to Know info on Bucket Elevator Sensors
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 andy@farm-smart.co.uk. 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 Ltd 14 Clarke Way Cheltenham GL50 4AX UK Editorial Manager Nicky Barnes Tel: +44 117 2306494 Email: nbarnes@globalmilling.com International Marketing Manager Sabby Major Tel: +44 117 2306493 Email: smajor@globalmilling.com News Editor Martin Little Email: mlittle@globalmilling.com Web: www.globalmilling.com
Contents Bird Silos & Shelters
4
Action Duct
5
Binmaster
8
Hardy Process
10
Sumak
12
4B
15
2013 Events List
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For more information: Bird Silos & Shelters PO Box 32, Popanyinning WA 6309 Australia Tel. +64 08 9887 5005 Web: www.birdssilos.com.au
Bird’s Silos and Shelters
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ird’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.
// Phosphinetray
// Phosphine Chamber
Pg 4 | November 2012
// Spent Phosine
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
When Silos Need Cleaning Dan Stradford Chief Executive Officer Action Duct Cleaning Co., Inc. Altadena, California www.actionduct.com
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n 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 28day 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. November 2012 | Pg 5
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.
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 eightyfoot 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.
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 Pg 6 | November 2012
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.
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
Bin Measurement Basics for Millers By Jenny Nielson Christensen, Marketing Director, BinMaster Level Controls
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illing 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.
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For more information: BinMaster Level Controls 7201 N 98th St Lincoln, Nebraska 68507 USA Tel: +1 402 434 9102 Web: www.binmaster.com
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
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, centerdischarge 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.
// 3D Scanner Bin Software
3D Scanners
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.
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For more information: Hardy Process Solutions 9440 Carroll Park Dr, San Diego, CA 92121 USA Tel: +1 858 278 2900 Web: www.hardysolutions.com
Hardy Process Solutions increases flour mill productivity with improved flow and feed rate How 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
SAP system is brought on-line globally, the data in the Excel spreadsheet utility can be viewed in real-time at a central location.
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
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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
• 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 generalpurpose 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 World Milling 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 (mlittle@globalmilling.com) with your latest news! November 2012 | Pg 11
For more information: Sumak Milling Machines Fevzi Çakmak Mahallesi Ayyıldız Caddesi No: 69 Karatay, Konya Turkey Tel: +90 332 345 42 70 Web: 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 those conveying machines are related to automatic of Conveying, Storage and Transportation in the world; this is why, SUMAK Milling Machines has an different SUMAK Milling Machines weighing bagging machines, extraction rate control Conveying Systemspecialised when SUMAK make an turn key milling plants allAlso, around the world. way All to ofused the factories has highly sytem as well. there is another which the is blower systemare which an conveying system is based on for Flour, Semolina, and conveying Bran, etc;system therefore, machines based on Today, SUMAK Milling Machines has highly means that pressure of the Wheat, Flour,Semolina, Elevators, Chain Conveyors, Spiral screw, Tube screw, and Electronic Bagging Scale System. So this is why, specialised in the design, manufacturing and and Bran, etc all of the factories. assembly of machinesare based on Conveying, those conveying machines related to automatic weighing bagging machines, extraction rate control sytem as Storage and Transportation. Most people are using Machines have been completed well. Also, there is another way to used conveying systemSUMAK which Milling is blower system which means that pressure of many different ways of Conveying, Storage and 250 different projects, and without any fault since the Wheat, Flour,Semolina, andthis Bran, etcSUMAK all of the factories. Transportation in the world; is why, 1986. The attached a flow diagram shows how the Milling Machines has an different Conveying System
Wheat, Flour, Semolina, and Bran Conveying System
SUMAK completed 250 different projects, and without any fault since when they Milling make turnMachines key millinghave plantsbeen all over the works on bottom of side What is showing is the flow world. All attached of the factories have an conveying system 1986. We have a flow diagram one of those howdiagram the Wheat, Flour, Building, Semolina, Bran Conveying 60TPD/24hr andand the machines which is based on for Flour, Semolina, and Bran, such as Elevators, Chain conveyors, Spiral screw, System works on bottom of side. This is what showing of the flow diagram 60TPD/24hr Building, and the etc; therefore, the machines are based on Elevators, Tube screw, and Electronic Bagging Scale, and machinesChain suchConveyors, as Elevators, conveyors, Spiral screw, Tube and Electronic Bagging Scale, and Spiral Chain screw, Tube screw, and Blower asscrew, well. Electronic Bagging Scale System. So this is why, also Blower as well.
SUMAK Milling Machines would like to give some the application purpose details of the explanation SUMAK Milling Machines would like to give some the application purpose details Conveying System machines which are:
Conveying System machines which are:
Pg 12 | November 2012
of the explanation
Elevators Elevators 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.
Spiral Screws It 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.
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.
Blower Used 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.
November 2012 | Pg 13
Chain Conveyors Chain 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.
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.
Pg 14 | November 2012
For more information: 4B Braime Elevator Components Hunslet Road Leeds LS10 1JZ United Kingdom Tel: +44 113 246 1800 Web: www.go4b.co.uk
Choosing the right hazard monitoring system for your bucket elevator
W
hen 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?
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.
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?
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.
4B 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.
Pg 16 | November 2012
T500 Elite
Watchdog Elite
Bearing temperature
ü (continuous) max. 256 sensors*
ü (continuous) max. 6 sensors*
Belt speed
ü (continuous) max. 256 sensors*
ü (continuous) max. 1 sensors*
Belt Alignment
ü max. 256 sensors*
Plugged condition
ü
ü
Communication interfaces
RS485 API
RS485 API
Test function
ü
ü
ü max. 4 sensors* (Touchswitch)
Alarm & shutdown
ü
ü
Logging & trending
ü
ü
Applications
Multiple elevators & conveyors; remote monitoring across site
Several elevators & conveyors
Certifications
ATEX CSA IECEx
ATEX CSA IECEx
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 nbarnes@globalmilling.com.
IDMA 2013 TOUR PACKAGES 5***** Contracted Hotels
Price Per Person in a Double Room Price Per Person in a Single Room
03 - 07 April 2013 / 4 Nights accomodation 04 - 08 April 2013 / 4 Nights accomodation
512 € 949 €
Package Includes:
WOW ISTANBUL HOTEL
TITANIC PORT HOTEL
4**** Contracted Hotels
Price Per Person in a Double Room Price Per Person in a Single Room
COURTYARD MARRIOT HOTEL
4 Nights accomodation & breakfast Airport - Hotel Transfer Hotel - Fair Area Transfer Fair Entrance Card Fair Brochure Bosphorus Boat Tour (Evening) Half Day Historical Peninsula Tour
03 - 07 April 2013 / 4 Nights accomodation 04 - 08 April 2013 / 4 Nights accomodation
512 € 827 €
Package Includes:
WOW ISTANBUL HOTEL
TITANIC PORT HOTEL
4 Nights accomodation & breakfast Airport - Hotel Transfer Hotel - Fair Area Transfer Fair Entrance Card Fair Brochure Bosphorus Boat Tour (Evening) Half Day Historical Peninsula Tour
Since January 01, 2013, price of tour packages will increase by 10%
2013 EVENT LIST Pg 18 | November 2012
January 2013
June 2013
29th-31st January International Production & Processing Expo (IPPE), Atlanta, GA, USA
10th June International Grains Council, London, UK
February 2013 23rd-26th February GEAPS 2013, Louisville, Kentucky, USA
March 2013 11th-15th March Purchasing & Ingredient Suppliers Conference, Texas, USA 13th-15th March VIV Asia, Bangkok, Thailand 26th-28th March AGRA Middle East, Dubai
April 2013 4th-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 2013 22nd-24th May VIV Russia, Moscow, Russia 29th-31st May CIMAE 2013, Beijing, China 30th May – 2nd June Surabaya Agri Expo, Surabaya, Indonesia
12th-13th June Cereals 2013, Lincolnshire, UK 27th-28th June The Nottingham Feed Conference, Nottingham, UK
July 2013 13th-16th July IFT Food Expo 2013, Chicago, USA
August 2013 7th-9th August Livestock Philippines 2013, Manila, Philippines 25th-28th August ICC Conference 2013, Perth, Australia
September 2013 10th-12th September Liquid Feed Symposium, St Louis, MO, USA 24th-26th September Livestock Asia 2013, Kuala Lumpur, Malaysia
October 2013 6th-9th October International Baking Industry Exposition, IBIE 2013, Las Vegas, USA
November 2013 10th-16th November Agritechnica, Hannover, Germany
December 2013 8th-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
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