2 ton/hour maize flour milling machine, corn flour production line
2 Ton/HourMaize flour Milling Machine, Corn Flour Production Line2T/hour Maize Flour Milling machine is very popular for the medium maize flour mill business.This set machine use steel structure,no need concrete structureThe flour milling section
Wheat processing equipment flour milling plant1. factory manufacturer for 10-500t per day complete plant.2. low power consumption with low cost3. CE SGS ISO BV certificates for all the wheat flour milling machines.Shijiazhuang Hongdefa Machinery Co.,
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uTwin screw extruder provides fine plasticizing, compounding, evenly dispersion and extrusion effect, and forming disintegrated particles by following connected tablet crusher. The compounding effect will directly determine the general quality of the final carbon powder product.
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milling process - definition , milling manufacturing processes
Milling is a process performed with a machine in which the cutters rotate to remove the material from the work piece present in the direction of the angle with the tool axis. With the help of the milling machines one can perform many operations and functions starting from small objects to large ones.
Milling machine is one of the important machining operations. In this operation the workpiece is fed against a rotating cylindrical tool. The rotating tool consists of multiple cutting edges (multipoint cutting tool). Normally axis of rotation of feed given to the workpiece. Milling operation is distinguished from other machining operations on the basis of orientation between the tool axis and the feed direction, however, in other operations like drilling, turning, etc. the tool is fed in the direction parallel to axis of rotation.
The cutting tool used in milling operation is called milling cutter, which consists of multiple edges called teeth. The machine tool that performs the milling operations by producing required relative motion between workpiece and tool is called milling machine. It provides the required relative motion under very controlled conditions. These conditions will be discussed later in this unit as milling speed, feed rate and depth of cut.
Normally, the milling operation creates plane surfaces. Other geometries can also be created by milling machine. Milling operation is considered an interrupted cutting operation teeth of milling cutter enter and exit the work during each revolution. This interrupted cutting action subjects the teeth to a cycle of impact force and thermal shock on every rotation. The tool material and cutter geometry must be designed to bear the above stated conditions. Depending upon the positioning of the tool and workpiece the milling operation can be classified into different types.
Milling Cutters There are a lot of cutting tools used in the milling process. The milling cutters named end mills have special cutting surfaces on their end surfaces so that they can be placed onto the work piece by drilling. These also have extended cutting surfaces on each side for the purpose of peripheral milling. The milling cutters have small cutters at the end corners. The cutters are made from highly resistant materials that are durable and produce less friction.
Surface Finish Any material put through the cutting area of the milling machine gets regular intervals. The side cutters have got regular ridges on them. The distance between the ridges depends on the feed rate, the diameter of the cutter and the quantity of cutting surfaces. These can be the significant variations in the height of the surfaces.
Gang Milling This means that more than two milling cutters are involved in a setup like the horizontal milling. All the cutters perform a uniform operation or it may also be possible that the cutter may perform distinct operations. This is an important operation for producing duplicate parts.
Milling is a metal removal process by means of using a rotating cutter having one or more cutting teeth as illustrated in figure Cutting action is carried out by feeding the workpiece against the rotating cutter. Thus, the spindle speed, the table feed, the depth of cut, and the rotating direction of the cutter become the main parameters of the process. Good results can only be achieved with a well balanced settings of these parameters.
Feed Rate It is the rate with which the workpiece under process advances under the revolving milling cutter. It is known that revolving cutter remains stationary and feed is given to the workpiece through worktable. Generally feed is expressed in three ways.
Depth of Cut Depth of cut in milling operation is the measure of penetration of cutter into the workpiece. It is thickness of the material removed in one pairs of cutter under process. One pairs of cutter means when cutter completes the milling operation from one end of the workpiece to another end. In other words, it is the perpendicular distance measured between the original and final surface of workpiece. It is measured in mm.
Owing to the variety of shapes possible and its high production rates, milling is one of the most versatile and widely used machining operations. The geometric form created by milling fall into three major groups:
Sachin is a B-TECH graduate in Mechanical Engineering from a reputed Engineering college. Currently, he is working in the sheet metal industry as a designer. Additionally, he has interested in Product Design, Animation, and Project design. He also likes to write articles related to the mechanical engineering field and tries to motivate other mechanical engineering students by his innovative project ideas, design, models and videos.
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increasing performance of the milling operation | | miller magazine
The increasing performance of the mills can be classified into two groups. One of them is increasing performance by organization and the other is increasing performance by milling technique. Both are important and different from each other. If both are supplied, maximum performance can be obtained.
Abstract Milling is used by different industries such as food, chemistry, mining, pharmacology, construction and materials etc. About 60-70% of the food industry is related to solid processing. The solid processing industry is also used the milling operation. Milling is known as size reduction or comminution, which is made by using different principles such as compression, impact, attrition/rubbing and cutting. During milling, as depend on the principles, the different forces are used like shear and compression etc. In this article, the milling principles and milling performance were evaluated and the increasing performance of milling was analyzed.
1. Introduction The main objective in the milling operation is the decreasing size of materials by creating new surface. Therefore, the creation of a new surface means that the requirement of energy. The ideal size reduction, milling or comminution should have a high capacity, small power requirement, high yield and producing uniform size distribution. The optimum values for each requirement can be determined theoretically, however actual values may be different due to processing conditions, design, parameters, raw materials, operators and handling.
The main difficulty for the milling operation is to the lack of the perfect scale-up procedure. The scale-up procedure means transferring laboratory or bench-type study results to industrial application. The scale-up is very useful method to make good optimization. In scientific studies, distillation, evaporation, agitation and reaction systems are easily scaled-up. However, in the literature, the scale-up methodology for the solid system or milling has still been completed. Due to the lack of perfect scale-up methodology in the milling industry, research and development, industrial application, monitoring and diagnosis are problem. Therefore, the measurement of performance of the milling operation is not perfectly parallel to the studies in the industrial scale.
The increasing performance of the mills can be classified into two groups. One of them is increasing performance by organization and the other is increasing performance by milling technique. Both are important and different from each other. If both are supplied, maximum performance can be obtained.
1.1. Increasing performance by organization Today, we are talking about Industry 4.0. The start of industry (Industry 1.0) is also accepted as the discovering of the steam engine. But, this is not true. The mills are the start of the industry by water and/over wind mills. Because there were available before steam engines and they were the first mechanical industry. During developments in the milling techniques, it revolved to a business or industry. Today, the milling industry especially in the food sector is one of the biggest industry such as wheat flour, semolina, pulses, rice, bulgur, ready-to-eat-soup, etc. In industry, size reduction or milling are widely used processing steps. The major milling industry or locomotive of this branch is flour, semolina, corn and starch industries.
By the growing industry and capacities, the milling industry is also turning to a big business and organization. However, the development of organization in the milling industry is weaker than the other food industry. Therefore, the increasing performance of the milling industry should be starting with the development of organization and structure of this sector.
In a regular mill, the organization depends on a family structure. Additionally, the main departments in these companies are accounting, buying-selling, security and process. However, in the developing sectors, these departments are only a part of the main structure. When the structures and organizations are analyzed, it can be seen that 90% of the mills do not have the following departments such as research and development, finance, process control, quality control, logistic, import-export, ERP and IT etc. If these departments cannot be adapted to the main organization and also not activated or supported, the mill cannot be developed and it will lose its sustainability.
Firstly, the milling companies should start to new organization and restoration. Especially, these new departments would be established in the organization. According to the knowledge obtained from the experience and other industries, these departments are key-factor for the future, value-added product obtaining, economics, performance and sustainability.
1.1.a. Research, Development and Innovation The growing every time depends on the innovation. Especially, in the food industry due to the changing of the living-style, the consumer prefers new products. Therefore, product-developments with innovation is critical issue for the future of the milling industry. Additionally, research is a key to generate new gate. Either product development or technology-process development can be achieved by this department and the result every time will be value-added production.
1.1.b. Finance, Import-Export, Logistic The economic management and power of the milling industry depend on the management of the finance. In general, the companies confuse the accounting department with finance. However, both are exactly different from each other. In general, milling plants use international raw materials and their products are almost not domestic i.e. international. Therefore, the management of goods, money, cash position, revenue, asset and risk, the finance will be critical. Most of the milling companies lost due to lack of the not enough finance knowledge. Similarly, the milling industry is not a domestic industry, it is a part of the international/global economy. Therefore, export-import and logistics are other required depts.
1.1.c. Process Control By Industry 4.0, all industries started to change. Today, instead of classical or manual processing; artificial neural networks, simulation, internet of things and data management are preferred for the industry. The studies show that there is no chance of manual systems against to process control system.
When classical or manual milling control analyzed, it can be obtained that there is a big fluctuation in quality and capacity in the production (Figure 1a). Additionally, due to the limitation of manual control, the production is significantly under the maximum limit or available/possible capacity (Figure 1b). When the ideal process control systems are preferred (Figure 2), process fluctuation will be lower and production capacity will be higher than the manual systems.
1.1.d. Quality Control By increasing the consumer demands, quality standards are increased day-by-day by the authorities and consumers. In old times, some basic quality parameters related with the process (physical, chemical, rheological properties) were measured and monitored. However, today and in the future, the most important quality parameters will be related to food safety. Therefore, microbiological, toxicological and other safety parameters should be supplied by the producers. A new powered dept. will be quality-control depts.
1.1.e. ERP and IT Growing industries and companies needs a new management system such as ERP. The big companies completed their transfer to ERP and IT systems. Therefore, the milling industry by growing to increase their performances, ERP and IT will be their new big steps to the future.
1.2. Increasing performance by technology Increasing performance by the technology of the milling system basically depends on raw materials, processing conditions, process control, processing parameters, monitoring and diagnosis, energy management, correct equipment, trained person, operator, engineering, quality control, correct design, technology level and yield (Figure 2).
There are important factors to obtain maximum milling performance. If all reach to the optimum level, the maximum performance can be achieved in the milling operation. Analyzing each one needs a long explanation.
Grain milling can be divided into two sections. One is cleaning and the other is size reduction or milling line. Technically, the cleaning section can affect the performance and yield of the milling by adjusting the equipment and good design practice (GDP). The cleaning section directly affects the yield and performance. Depends on the cleaning ratio and dirtiness of raw material, the operational conditions and equipment design and parameters also affect the further milling performance.
In the cleaning section; pre-cleaning sieve, magnet, destoner, light particle gravity table, trior (intendent cylinder) were some of the basic machines. First to all, their engineering design and their design parameters directly affect the performance and yield of milling. In the industry, )0% of the machines are copied and there is no engineering design. They may run however their performances are very bad due to the lack of design works. Due to this main problem in the design of the cleaning machine and conveyors, a lot of capacity, quality, performance and energy losses occur. In the cleaning section, there are mechanical, air, pressure, flow rate, capacity, angle, solid handling problems. Each parameter/variable for each equipment should be analyzed and engineering should be applied. For example, table area, angle of table, air pressure and air flow rate in the destoner are critical. However, when these parameters/variables are measured and analyzed, a lot of mistakes can be obtained due to the lack of engineering design principles and studies.
Additionally, the same mistakes related to table area, table angle, air flow rate and pressure can be seen in the gravity table. Trior (intendent cylinder) is another critical step in the cleaning section. Due to wrong whole, whole shape and angle, revolution, centrifugal force, sorting area etc. the loss of product of insufficient cleaning can be obtained. At each cleaning step, the milling performance decreases due to these kinds of problems.
In the milling section, physical and chemical properties and events should be followed to obtain good performance. The milling section in the wheat milling starts with tempering operation. Before the dehulling, grain is tempered. A new technological approaches also started to change the dehulling operation, especially in flour and semolina milling. Recently, vertical emery stone dehullers are started used in the processing. Tempering conditions (moisture content, time, RH%, temperature and raw material properties) are mainly important for milling performance. They should be under control. Especially, tempering will determine the yield and quality of the finished product.
In the milling operation, another step is the mill. Design of mill, corrugation, revolution, temperature, teeth size and shape, diameter of roll, gap, distribution and hardness of roll are the main parameter to get high performance from the mill.
After the mill, the next important equipment is sieve. Its diagram and positioning, vibration ratio or rotational ratio, sieve aperture, sieve material, surface sieving area, the opening of holes, passage between each plate sieve, centrifugal force and gravitational force balance over the sieve are the most important parameters to control the performance of the milling operation.
During the milling operation particle size distribution and energy calculation should be made. Unless they are smoothed by abrasion after milling, comminuted particles resemble polyhedrons with nearly plane faces and sharp edges and corners. The particles may be compact with length, breadth and thickness nearly equal or they may be platelike or needlelike. For compact grains, the largest dimension or apparent diameter is generally taken as the particle size. For particles that are plakelike or needlelike, two dimensions should be given to characterize their sizes.
Energy is an important expense in milling. During milling, the particles of feed material are first distorted and strained. The work necessary to strain them is stored temporarily in the material like mechanical energy of stress. Then, as additional stress added, they are distorted beyond their ultimate strength and suddenly rupture into fragments, and a new surface is generated. So, a unit area of material has a definite amount of surface energy, the creation of a new surface requires work that is supplied by the release of energy, the creation of new surface requires work that is supplied by the release of energy of stress when particle breaks. By conservation of energy, all energy of stress in excess of the new surface energy created must appear as heat. Therefore, the temperature of the mill surface during comminution should be cooled or controlled to prevent overheating. Also, the ratio of the surface energy created by milling to the energy absorbed by the solid is the crushing efficiency. The surface energy created by fracture is small in comparison with the total mechanical energy stored in the material at the time of rupture and most of the latter is converted into heat. Milling efficiencies are therefore low. They should continuously be measured and controlled. The energy absorbed by solid is less than that fed to the machine. Part of the total energy is used to overcome friction in the bearings and other parts of the machine, and the rest is available for milling. The ratio of the energy absorbed to the energy input is mechanical efficiency. In size reduction or milling, Rittinger, Kick and Bond equation can be used to make the calculation.
As a result, the milling performance depends on a lot of parameters. Therefore, a high knowledge is required to fix all parameters to the maximum level. In general, milling systems do not use high knowledge therefore a lot of loss in performance can occur.
milling process project optimisation through strategic design | miller magazine
The new approach to process design is the interaction amongst all systems, their interface and the streamline of functions and processes that take place from A to Z. By new design, an industrial process may need less equipment, or better graded and selected equipment, consume less energy, be more efficient and work in a straight operational line fully integratedThree objectives paramount to the food industry today: economic results, quality of product, environment and working conditions.
More than ever before applied design has played a fundamental role in the thinking of a new process line, a new facility, a sea, rail or land transport terminaland more than ever applied to a complete interface and inter functionality of all systems. Likewise, analysis of existing facilities under design reprocess may show a cost-cutting margin of relevant importance when adequately implemented.
This study enhances the main aspects of this subject by considering the advantages of a correctly thought of the project, by planning in advance the whole integrated systems that will complete the production steps, and by rethinking the existing process facilities.
Seeing high-quality process facilities, magnificent milling machinery, high quality conveying systems, best of class hoppers, silos, mills, plansifters and the whole range of process components is certainly a pleasure for the eye, but not always a pleasure for the mind, as in many cases, and more often than not, these systems are not adequately interfaced or not adequately designed from input of raw material to output of finished product.
Industry has learned from the past: individual systems cannot have a successful output if not interfaced and coordinated with the rest of the process line, and even the best-coordinated system will face productivity shortsteps if not designed together with the previous step, i.e. the port terminal that will feed the grain to the mill for example
At the other end, even with all coordinated lines, the system will again find a pace stopping situation if there is no sufficient space for the storing of finished products or for the adequate capacity and speed of re delivering to the market.
Design today looks at the actual drawing of systems that will be strategically thought of in speeds, capacities, volumes and all other parameters to the needs of the line, from A to Z. In other words, mathematics first, algorithms applied then, and design to follow by value engineering.
A correctly calculated input of raw material will ensure the needed feedinto the production line, but this is not enough. Production lines may need unexpected stops, feeding conveying lines may also have occasional breakdowns and maintenance, inbound vessels, trains or trucks may have delays, and even all going well the grist may need to be changed or altered due to quality requirements to be fine-tuned
In the same way, the feeding of the final product to the bagging lines and from these to the delivery point or loading bay may have its own time schedule and time programming of deliveries on to the receiver of the goods.
It is here where the strategic design comes in, programming and planning together with the end-user, the industrial facility, the correct speeds, capacities, quantities and volumes to be fed, stored, the buffer volumes, the adequate spaces to be designed and the delivery program together with the input of raw material program.
The first question to be asked is where does it all start? The answer would be to define the final product that will be consumed or fed to the market but it is more ahead than what the designer will need to look into. The first question in a more elaborated project manner will be where from, how and when and in what quantities my industrial process needs the input of wheat or raw material? The first parameter a project designer will have to look at is the input of raw material, and where they originate, how they arrive and how they are handled previously to be fed into the production line.
From the industrial revolution onwards the progress made would be difficult to quantify, but the last 20 years have seen more applied design development than ever, not as much related to new machinery or new processes, but the design thinking approach to industrial processes and their interface and intercoordinated pace.
The algorithm to follow the path of the goods from raw material to final product evaluates every single step of the ongoing path, studying and analyzing each step in itself and designing the next one and the one after considering quantities, capacities volumes speeds and all other to be perfectly coordinated in the most efficient chain of process.
Where does industrial planning start? Certainly with the buying ahead of the raw materials needed to produce our product, meaning with our commercial position, as it may be either long or short, most clearly if we are a flour mill and we produce an X amount of flour per year and we have not covered our needs in advance, our industry is short of the equivalent raw material to produce, i.e. We are at risk that prices may go higher and we may have to pay more for the wheat needed, or go down and hence we will sell our flour at a lower priceThis is the first step of process designThe supply chain program, the shipping program that will satisfy the needs of our industry
Following the shipping program, it will need to be defined the sizes and types of vessels to receive and to establish the break-even point between lower freight rates in larger vessels or financial costs to pay for smaller vessels to be received in more smaller shipments than one big shipment for various weeks or monthsto be our financial planning programand from this to the receiving, berthing, unloading, conveying, storing, conditioning and finally into the milling processbut all of these will have to be consciously designed well before and well defined in order to have the highest possible efficiency to then proceed to the next step.
Once the buying in of raw materials is completed, the logistics and the physical transport of goods will start to supply the industrial facility, and it is at this point that functional efficiency comes in.
Discharge: Applied design will calculate the amount of goods that will be received in each shipment, its volume, specific weight and from there the best way to discharge them, delicate goods as rice or durum wheat will be handled better by grab rather than with a CSU, and even less with pneumatic systems that will increase the breakage of the grains, other products may have less vulnerability and will be better discharged with a CSU system or with pneumatic equipment. Having this in mind the designer will calculate the correct power and capacity of the discharging equipment and then the receiving hoppers and conveyors belts to transport the goods to the initial storage.
Initial receiving storage: The calculation to follow is the conditioning of the goods and the capacity of the initial storage that may be coordinated with the conditioning equipment to clean the wheat from impurities, stones, other cereals, and inert material to send it, once cleaned, to the medium and long term storage.
Speeds: The calculation of coordinated speeds between the discharging equipment, the conveying equipment, the receiving pit, elevators and cleaning, and conditioning systems will play an important role, as all of them will work in an orchestra combination to discharge the vessel without delays, and to deliver the goods to the process line in the best possible condition and without interruption of the feeding lines.
Process: A special eye that designers will dedicate to this step together with the engineering of the process lines is to match speeds, capacities, volumes and output with the required quality, meaning better to mill less wheat per day obtaining a better quality of flour and not increasing the flux of process but creating a post problem of quality control and intrinsic quality itself.
Calculation of the buffer capacity to feed the bagging and packaging lines, calculation of the spaces needed to store the pre-delivery finished products, calculations of how to load and the volumes and speeds needed to load on a day to day basis will give the line the necessary parameters to be respected in order to:
Maintain the production lines in running rhythm without stoppages, Keep the goods stored for a short period of time before delivery Have enough space to store and deliver without short quantities mishaps Keep the bagging and packaging plants fed without interruption
A path to be followed to enhance efficiency, cost minimization and process functionality, a path that designers and engineers will keep building up to obtain value engineering, applicable to both the actual production units operative, and ideally when projecting and planning new facilities.
Designers will feed the engineers database with the knowledge of speeds, capacities, yields, volumes, and coordinated process lines in order to enable them to project and program the needed equipment to be installed and the spaces needed for the civil buildings, not only for the production lines but also for the accessory services, that are a sine qua non-condition to have an industry running, Administration blocks, services areas, parking availability, analysis, and laboratory spaces, maintenance workshops, amenities sectors and all related to human labor well being, that will make efficiency still higher and functionality optimized.
The analysis and redesign of existing facilities has proven that up to a 35% of direct and indirect costs have been saved in various process plants by bringing in specialized designers to study and analyze the actual situation and ask themselves how to improve the distances from storage to process, the speeds of discharging and storing, the distance from process to bagging, the speeds and capacities of each step of process coordinated with other process steps, the isolation of the Administration block and analysis laboratories to avoid vibration and noise from process lines, the rescaling of all conveying paths, elevation systems and land transport of final goodsIn other words to rethink the whole line on a more competitive, efficient and functional coordinated order that will save costs, time and surely improve working conditions.
On new facilities, the first thing to do nowadays is the feasibility study of the project, with a strong vision of the strategy of process coordination behind it, designers and engineers will layout the final project only after the strategic calculation described above has been done and tested mathematically till there are no mishaps found.
In both cases, may it be a new facility or the refurbishing of an existing facility, the strategic design, and engineering applied by commonly shared information of process and the full chain from supply to final delivery of final product, will play a significant role both in the economic result, as well as in the quality of product and working conditions of the industry.
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