global milling advances november 2012 -

Issue 1 November 2012

Sumak MillingIntroduce their range of products

Bin Measurement Basics for MillersBinMaster Level Controls

Hardy ProcessHardy Process Solutions increases flour mill productivity with improved flow and feed rate

ISSUE 1

of Global Milling’s New

quarterly magazine

When Silos Need Cleaning

We talk to Hardy Process Solutions about flow and feed rate systems

Need to Know info onBucket Elevator Sensors

IN THIS ISSUE

AND MUCH MORE...

Issue 1 November 2012

Welcome to the first issue of Global Milling Advances, a new online supplement to complement our Global Milling Annual for the grain, feed, and flour and cereal industry. Global Milling Advances (GMA) will be publishing four issues per year focusing on technology.

We start our first issue with a focus on storage and conveying featuring articles from industry professionals covering a variety of topics from maintenance and cleaning of silos to the level measurements and equipment needed.

Global Milling visited the UK Grain event this November, where some 60 exhibitors involved in every aspect of grain storage, monitoring, drying and marketing gathered at the Peterborough Arena, East of England Showground. This event is held annually and you can get involved with next years meeting by contacting Andy Newbold on [email protected]. Keep up to date with other industry events by visiting www.globalmilling.com/global-milling-events/

If you have a topic that you would like to see covered, why not get in touch with us.

Published by:

NISA Media Ltd14 Clarke WayCheltenhamGL50 4AXUK

Editorial ManagerNicky BarnesTel: +44 117 2306494Email: [email protected]

International Marketing ManagerSabby MajorTel: +44 117 2306493Email: [email protected]

News EditorMartin LittleEmail: [email protected]

Web: www.globalmilling.com

Contents

Bird Silos & Shelters 4

Action Duct 5

Binmaster 8

Hardy Process 10

Sumak 12

4B 15

2013 Events List 18

Pg 4 | November 2012

Bird’s Silos and Shelters

Bird’s silos and shelters are a family company and

have been making grain silos for over thirty-five years.

Although only a small factory they have always been at the

leading edge of sealed silo technology. Even before the

advent of sealed storage the founder, Don Bird conducted

a lot of experiments in conjunction with a Department of

Agriculture person who was concerned about the damage

that weevils were doing to the local stored grain. It was the

knowledge he gained there that was the basis for the present

fumigation system which they use today. It also leads him

to think that a lot of the explosions which are thought to be

caused by grain dust may actually be caused by phosphine.

The silos that Bird’s make all have a thermo siphon

fumigation system which has a container with all the

phosphine tablets in it which not only gives a quick

fumigation but prevents a dangerous build up of gas which

could cause a explosion. Also there is no residue left in any

of the grain, it is all retained in the chamber. The design of the

silo makes it easy to use nitrogen or any other gas to

do the job.

They appeal to people who want organic grain with no

chemicals and no insects. They are also equipped with a

spear which enables the owner to take five samples of

grain and also see if there are any weevils in it. Everything is

operated from the ground, there is no need to climb

on the silo.

Don still has hand on the pulse but the day to day running of

it is done by his son Wayne and granddaughter Courtney.

For more information:

Bird Silos & Shelters

PO Box 32, Popanyinning WA 6309

Australia

Tel. +64 08 9887 5005

Web: www.birdssilos.com.au

// Spent Phosine

// Phosphinetray

// Phosphine Chamber

In industry, silos have become the guardians at the gates of

many manufacturing plants, the first thing you see looming

above the roof line as you approach the facility.

Rising as much as sixty feet and higher, silos are used to store

bulk quantities of manufacturing materials. In the snack food

and baking industry, the most common items stored in silos are

grains, various flours, and sugar.

Silos offer a lot of advantages:

• No pallets of bagged material to unload and store

at the warehouse.

• No need to tear open one 50-100 lb. bag after another

and dump the contents into a hopper – and then clean

up the overspray and deal with the empty bags.

• By simply opening a valve, the rate and amount of

material can be regulated as it flows continuously

from the silo into the manufacturing process.

However, as it is with most solutions, silos require a little

maintenance of their own or they become problems, too. At the

top of the list of concerns is food safety and quality.

Wherever flour and sugar congregate, various members of the

animal and plant kingdom like to capitalize on the opportunity

for a quick, and often abundant, meal. This includes rodents,

insects, bacteria, and mold.

The chief insect invaders of flour silos are the Red Flour Beetle

and the Confused Flour Beetle. These bugs, each about 1/8-inch

long, look so similar that it is believed that is how the Confused

Beetle got its name - it is so easy to confuse it with a Red Beetle.

One difference is the Red Beetle can fly. Both breed heavily in

the warmer months.

The Confused Beetle is the number one insect pest in American

flour mills. And it's an old pest. It's been found in a jar that likely

contained flour in a tomb of the pharaohs from around 2500

B.C.

When present in large numbers, they can turn the flour grayish

and cause it to mold more quickly. They also give

the flour an unpalatable taste and odor from secretions of their

scent glands.

One client told us, "The Confused Flour Beetle has a 28-

day cycle from egg to adult. If our silo isn't regularly cleaned

approximately monthly and if there's infestation they might nest

in something like a gasket. Then they get very prolific in that

area."

Mold is another major concern. When silos are not cleaned

regularly, there is a high likelihood of mold buildup. This is

commonly visible as shades of green and black in the flour,

particularly on the inside walls. It can get as bad as an inch-thick

(or more) layer of greenish flour clinging to the walls.

Mold growth is facilitated by the presence of moisture, which

can precipitate when warm flour is pumped into a silo and cools

down. Dehumidifiers can help guard against this problem.

To avoid many of these issues, silos are usually put on a

routine cleaning schedule. The frequency of cleaning can vary

tremendously from every month to yearly,

depending on local weather conditions, what’s being stored,

how often the silo empties, and simple common

sense and experience.

When Silos Need CleaningDan Stradford Chief Executive OfficerAction Duct Cleaning Co., Inc. Altadena, Californiawww.actionduct.com

November 2012 | Pg 5


Action Duct Cleaning Company Inc.

787 W. Woodbury Road Unit 2

Altadena, California 91001

USA

Tel: +1 800 371 2284

Web: www.actionduct.com

A Quality Maintenance Program

Doug Nakamura is the director of operations for Upper Crust

Enterprises of Los Angeles, America’s first manufacturer of

“panko” or Japanese breadcrumbs. He outlined the steps his

company routinely takes to keep their flour silos in top shape.

“We clean our silos twice a year and fumigate after each

cleaning,” Nakamura said. “We also change our filters monthly.

Plus we have our own self-audit, through our HACCP system

(Hazard Analysis and Critical Control Points). Lastly, we hire a

third party auditor to perform a routine review.”

This is in addition, of course, to standard inspections by the

FDA and health department.

Finally, Nakamura ensures that a system of precautionary

measures are in place, including:

• Buying from a reputable flour manufacturer.

• Getting a certificate of analysis for every load.

• Ensuring that the flour delivery trucks are inspected weekly.

• Inspecting the hoses and unloading mechanism on each truck.

•Ensuring the piping is kept locked.

The Cleaning Process

Silos can be cleaned by a number of methods, but in most

cases, the process involves brushing down the sides of the

interior and/or scraping them as needed. To avoid scratching

the surface and to prevent sparking, plastic scrapers may be

needed.

Although simple in principle, the work takes some practice and

preparation.

Safety has to come first because multiple hazards exist,

including falls, explosions, lack of oxygen, and “drowning” in

liquid or finely-milled products like flour and sugar. A silo is an

OSHA-defined “confined space,” meaning that workers in it

have to follow standard safety procedures for enclosed areas

with inherent hazards.

Proper breathing precautions must be considered where dust,

volatile chemicals or oxygen scarcity can occur. Sometimes

this is learned the hard way. Our firm was caught off guard

once when we had a worker steam cleaning a massive vat that

had held cooking oil. Steam vapor replaced the breathable

air and literally lifted the available oxygen above his head.

Fortunately, the matter resolved quickly, but it was a lesson in

the importance of trying to anticipate the unexpected.

Food storage silos typically have platforms or “cages” built in

at the top so workers have access for cleaning and servicing.

These have to be treated with respect. Although it happens

rarely, these cages can have breaks in them that can be hidden

by a coating of flour or sugar. A worker should fully inspect

these and ensure he’s wearing a harness and lifeline before

stepping onto such an apparatus.

Sometimes you find no cage at all. It’s simply open space at the

top. In this case, a worker will need to drop down from the top in

a "bosun's chair," a chair on a rope that is lowered down. It may

have a motor or be controlled by hand at the chair. Even eighty-

foot silos may need to be cleaned this way. Any time a bosun's

chair is used, it is secured on the outside of the silo and OSHA

safety standards are adhered to.

Such specialized equipment, preparations and OSHA

requirements prompt many companies to hire outside firms to

clean their silos. It saves a lot of headaches. But some plants

still prefer in-house cleaning. Whatever method is used to

clean, an opening at the top of the silo is vital for access and,

sometimes, ventilation. An opening at the bottom is equally

critical for draining out product which has been cleaned from the

silo. In some instances, there are no access doors at either end

and they have to be installed.

Vacuuming is a common method of cleaning debris from

the bottom. However, this can stir up a lot of static electricity

around certain materials such as flour. Visible sparks can occur.

A way to reduce this risk is to attach wooden poles to vacuum

hoses to ground them.

Silos are normally cleaned without water. When the stored

product is easily dissolved, such as sugar or syrup, wet washing

may be the method of choice. This approach may take longer

(sometimes it’s faster) because it requires more prep work and

attention to water drain-off. It also means the silo must dry out

and this can cost production time. Moisture attracts mold so

that is another consideration. Needless to say, the silo needs to

dry thoroughly before it is refilled.

In some instances wet cleaning is the only method available.

As an example, if a flour silo needs welding, all combustible

material must be removed and this may only be achievable

through wet washing.

Additional Issues

Food product storage silos are lined with a coating that can

deteriorate over time. Flaking or rusting can contaminate the

food product. This is commonly first noticed when particles

show up in sifters. Some manufacturers re-coat their silo

interiors every few years as a

precautionary measure.


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.


Milling operations have many challenges at hand when

it comes to measuring the level in bins. It’s likely that

a single operation is home to bins of various construction

(concrete or steel), an assortment of sizes, and a variety of

materials to measure – some granular, some powder, some

free-flowing and some prone to dust and buildup. To select the

device that is best for a particular bin, it is helpful to consider

the material being measured, whether the material surface

tends to be even or irregular, the regulatory environment (such

as with food), the size of the tank, and whether you need to

know when inventory has reached a certain level in the bin –

which calls for a point level device – or you need continuous

level measurement.

What can you expect from a bin level detection device?

• It will help you manage your inventory.

• It will eliminate the need to climb tanks to check levels.

• It will enhance safety for employees.

• It will alert you when material reaches a particular

level in the bin.

• It will provide a single measurement that is repeatable when

there hasn’t been any activity in the bin.

• It will provide an accurate distance to product

within a few inches.

• It will measure headroom in the tank or the distance to the

material, so you know how much space is left in the tank.

What can’t you expect?

It’s a common fallacy that a bin levels will convert to mass or

volume and then to pounds accurately. The nature of powders,

granular materials or pellets is that they will settle, shift and

compact in the tank. It’s true that some advanced devices can

and do incorporate compaction calculations into their software,

which will compensate somewhat for the behavior of the

material. However, a level measurement device is not a scale.

Let’s explore some of the best level sensor options for millers

and considerations when selecting a device, starting with

simple, economical sensors building toward the more complex,

accurate continuous level technologies.

Rotary Level Indicators

Rotaries are a familiar and common device used for high or

low level point level indication in bins, tanks, and silos. A rotary

sends an alert via a horn, light or to an alarm panel when

material reaches (for high level detection) or falls away

from (for low level detection) the rotary paddle. The principle of

operation for rotaries is quite simple. When the rotary is used

to alert that material has reached a high level while the bin is

filling, the paddle rotates continually until material reaches the

paddle. When the paddle meets resistance due to the presence

of material, it stops rotating and sends an alert. Conversely,

as a low level indicator, the paddle will begin turning when

material drops below the level of the paddle and will send an

alert or can be wired to start up a process system.

Capacitance Probes

Capacitance sensors are designed for a wide array of

applications and materials and may be used in powders,

granulars, pellets and other solid or slurry materials. The

sensors may be used for high, mid and low level detection in

bins, silos, tanks, hoppers, chutes and other types of vessels

where material is stored, processed, flowing or discharged.

Capacitance sensors operate by detecting the presence or

absence of material in contact with the probe by sensing a

change in capacitance caused by the difference between the

dielectric constant of the material in the tank and the air. These

sensors are able to detect very small changes in capacitance,

typically one picofarad.

Vibrating Level Sensors

The vibrating level sensor or vibrating rod is a piezoelectric

driven vibration type level switch can be used for level detection

in bins, silos, and hoppers filled with powders or dry solid

materials. A vibrating level sensor can detect extremely light,

fluffy materials as light as 1.25 lb./cu. ft.3, such as powders and

flakes or can be used for heavy materials such as grains or

pellets. These are rugged sensors that are often constructed of

durable stainless steel and are virtually wear and maintenance

free. A vibrating level sensor can be utilized as a high, mid or

Bin Measurement Basics for MillersBy Jenny Nielson Christensen, Marketing Director, BinMaster Level Controls


BinMaster Level Controls

7201 N 98th St

Lincoln, Nebraska 68507

USA

Tel: +1 402 434 9102

Web: www.binmaster.com


low level alert and can be mounted on the top of the bin as a

high level detector or in the bottom cone of a bin to sense when

the tank is nearly empty.

A weight and cable-based sensor is a very economical and

accurate continuous level measurement choice. Weight and

cable-based or bob-style sensors can be ideal for diverse

applications in powdered and granular materials as these

sensors are not affected by dust, humidity, temperature,

dielectric constant, or fumes that may be present in the bin. Plus,

as a stainless steel probe at the end of the cable makes minimal

contact with the material, there is minimal risk of contamination.

This type of sensor works in virtually any material regardless

of particle size or bulk density including very fine powders to

heavy, dense materials. If there are multiple tanks containing

different types of materials that need to be monitored, “bobs”

are a proven technology that have been in existence for over

20 years and are trouble-free, long-lasting and require no

calibration.

Bob-style Sensors

A bob-style sensor can be used in bins up to 180 feet tall, but

are also often used in smaller, active process bins under 40 feet

tall. For the best accuracy, the sensor should be mounted on

the roof about 1/6 of the way in from the outer perimeter of the

bin, which places it ideally to account for the angle of repose

on a center-fill bin. Properly mounted on a center-fill, center-

discharge bin, bob-style sensors will consistently provide 5%

to 7% accuracy. They work by releasing a cable with a weighted

sensor probe that stops and retracts when the probe comes into

contact with material. Redundant measurements are taken when

the sensor probe is both descending and retracting to guarantee

every measurement is precise.

Bob-style sensor networks can be integrated utilizing a wide

variety of communication options. Most cost effective and

popular is a control console mounted at ground level that can

report the data from one up to over 100 bins and provides

information such as distance to product (headroom), height of

product, and percentage full. If the preference is to have bin data

sent to a personal computer, there is software to report detailed

data for multiple bins simultaneously and display a visual report

of bin levels. Other communications include the ability to send

automated email alerts when bins reach a predetermined level.

A 3D scanner is a non-contact, dust-penetrating bin volume

measurement system that uses acoustics-based technology

to measure bin contents at multiple points within the bin. What

makes a 3D scanner different is that unlike ultrasonic or radar

devices that are measuring one point and determining a single

distance, the 3D Scanner takes measurements from multiple

points within the bin and uses these points to help estimate

the volume of material in the bin. Sampling measurements

from multiple points when the material surface of the bin is

uneven enables the 3DLevelScanner to calculate bin volume for

powders and solids with greater precision than any single point

measurement device.

A 3D scanner is unique because it is able to map the topography

of the bin and create a computerized profile of the bin contents.

This allows for greater accuracy as it detects cone up, cone

down, bridging and sidewall buildup and then accounts for

these variations when it provides the volume estimate. The 3D

scanner comes equipped with software that displays the tank

data in an easy-to-read format. The measurements are sent to

a main display screen which includes data such as average,

minimum and maximum distances, level, temperature inside

the tank, and volume percentage. The 3D mapping software

depicts surface irregularities in a visual representation of the bin

contents.

Food for Thought

When it comes to managing inventory in any bin in your

operation, the first consideration is what type of information you

need. Are you seeking level, volume, or are you really looking

for weight? If you simply need to know if a bin is empty or full,

choose a point level device. If you need to know the level of the

bin, such as percentage full, headroom or distance to product

on an ongoing basic – a continuous inventory management

system such as a bob-style or 3D device is the right choice. A

non-contact device may be desired if the regulatory environment

demands it. Keep in mind that some non-contact devices such

as ultrasonic or radar perform inconsistently or unreliably in

dusty environments.

Bin size, the number of bins, and whether they need to be

networked will also influence the type of system you select.

If you are seeking convenience, look for a system that offers

wireless installation, plus software or consoles that centralize

the location of your data and can generate the types of reports

you need. The need for inventory accuracy can vary from one

operation or even one bin to the next. Getting an accurate

measurement for a single point in the bin can be accomplished

easily, but it might not give you the overall volume accuracy you

need. For uneven material surfaces, bins with multiple fill and

discharge points, or very large bins, expect for the solution to be

more complex and more expensive.

And remember, when it comes to bin level controls there is a

robust selection of technologies at prices ranging from a few

hundred to a few thousand dollars. Bin level measurement is

not a one-size-fits-all solution … it’s a puzzle with many pieces

that when put together right will give you a better picture of your

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Hardy Process Solutions increases flour mill productivity with improved flow and feed rateHow Hardy’s HI 4050 weigh controllers improve

process efficiency

A large global processor and exporter of grains and oilseeds

was experiencing inconsistencies in timing for discharging

wheat from a scale hopper, which resulted in an inconsistent

flow rate. If the scale hopper was filled prior to the period set in

the flow rate, the dump gate was delayed until a timer ran out.

If the feed rate to the scale hopper was slow and the timer ran

out prior to the draft load being satisfied, the dump gate would

open only after the set point had been reached and the actual

weight of the draft recorded. These inconsistencies in material

flow and feed rate were slowing production, creating waste, and

causing variations in actual weight.

The Solution

Hardy Process Solutions recommended utilizing five HI 4050

weight controllers in the flour mill. The variables recorded by

the HI 4050s include time start, total weight accumulated, and

actual flow rate in tons per hour. These variables are monitored

on a PC via the HI 4050’s embedded web server and on a

Microsoft Excel spreadsheet utilizing a utility provided by Hardy.

The first scale weighs dirty wheat at a set flow rate. This is

achieved by timing the discharge of the hopper. The dirty wheat

is cleaned and processed, then held in a silo that feeds the

second scale. The same variables are recorded. However, the

flow rate on this scale is important since it sets up the flow rate

to the flour mill. If the mill is fed too fast the line backs up; if too

slow, the mill will scorch flour. The remaining three scales are

used to receive the flour from the mill. On the three flour scales,

the flow rate measured is the actual rate of flour from the mill

(in other words, we take the flour as fast or as slow as the

mill will give it).

With the data from all five scales, the customer is able to

calculate the yield from stage to stage. The change in flow rates

alerts the millers to possible mill problems, which they can

immediately investigate.

The MS Excel utility proved crucial for the system. Once the

SAP system is brought on-line globally, the data in the Excel

spreadsheet utility can be viewed in real-time at

a central location.

Installation of the five HI 4050 weight controllers provided this

mill the following benefits:

• Consistent flow and feed rates

• Improved production

• Minimized waste

• Accurate weight readings

The HI 4050 weight controller includes Hardy’s

core technologies:

• WAVERSAVER® - eliminates the effects of unwanted vibration

on or around the scale by permitting the instrument to “see”

through the unwanted vibration signals – as low as 0.25hz –

while yielding a fast and stable actual reading.

• Electronic Calibration without the need for test weights - C2®

enables a fast, accurate, electronic calibration of the scale. This

saves system start-up costs and aggravation.

• Secure Memory Module with Secure Digital (SD) card (SMM®-

SD), which allows manual transfer of configuration data to

another instrument or PC using SD technology


Hardy Process Solutions

9440 Carroll Park Dr,

San Diego, CA 92121

USA

Tel: +1 858 278 2900

Web: www.hardysolutions.com


• INTEGRATED TECHNICIAN® (IT) for system diagnostics and

troubleshooting - In conjunction with an IT® Junction Box, the

controller provides built-in system diagnostics that let you

troubleshoot and diagnose your weighing system right from its

front panel, your intranet, or the Internet. Read individual load

sensor voltages and weights, make comparisons, verify the

scale zero and isolate individual system components for quick

and easy troubleshooting.

The HI 4050 weigh controller can act as a front end to a PLC, PC

or DCS system, or as a stand-alone for simple control or weight

monitoring. Only three inches deep, the HI 4050 general-

purpose weight controller is used in tank farm, batching/

blending, filling/dispensing, check weighing, level by weight,

and force measurement applications.

To meet your specific installation needs, the HI 4050 is

available with AC or DC power and in panel, remote or blind

DIN rail mounting packaging configurations. Installations are

simplified with no special tools required to cut rectangular holes.

Just use the included template to drill standard holes and install.

The controller includes a standard Ethernet 10/100 Base T with

an embedded web server and an RS 232 printer or scoreboard

display port. Optional network communications over Ethernet/

IP, DeviceNet, Modbus TCP or Analog are also available.

Ease of Setup - With its embedded web server, all the

instrument’s parameters can be set up from anywhere on the

Ethernet network. Front panel keys and graphic display with

simple menus provide quick, easy setup with process weight

and parameter display.

Accessibility – The embedded Ethernet communications

port in the HI 4050 Series weight controller enables users

to easily share data across a production facility, eliminating

the time and costs associated with new network wiring. The

embedded Ethernet Web server also gives users remote access

to control information, instrument parameters and diagnose

problems, further optimizing production efficiency by sharing

real-time data on the plant floor with OEM partners or off-site

maintenance personnel.

Expandable Secure Memory Module (SMM®-SD) - rear panel

accessible SMM is more than just a memory card. It’s a network

media that connects SD enabled products. The SMM now uses

a standard Secure Digital (SD) memory card, which allows easy

expansion, transfers of data from one instrument to another

and is readable by your PC.

100 Updates per Second – Provides more data for faster

applications but not too much data that is of no use

to the system.

Hardy Process Solutions has been a leader in weighing

solutions for over 85 years and is best known for its innovative

approaches to precision weighing solutions and vibration

monitoring equipment. An ISO 9001-certified manufacturer,

Hardy Process Solutions is based in San Diego, California. For

more information about Hardy Instruments, please visit,

Milling WorldMilling World, a new blog from NISA Media

Ltd, bringing together agriculture news stories from around the world.

As well as looking at events and shows we look at companies involved in agriculture, food production and animal production as

well as the feed industry and veterinary aspects of farming and agriculture.

The blog runs side by side with our online resource Global Milling Annual. Publishing press releases from key companies and key figures in the agriculture world, books releases and information

from global sources. As well as looking at the ever-changing face of agriculture, through GMO’s, research and other innovative

approaches to agriculture.

Another aspect of the agriculture world is the ever-changing effect of climate change on the industry, and as natural disasters occur,

such as droughts, floods, hurricanes we keep you updated.

Contact Martin ([email protected]) with your latest news!


SUMAK Milling Machines highly specialised

Today, SUMAK Milling Machines has highly

specialised in the design, manufacturing and

assembly of machines based on Conveying,

Storage and Transportation. Most people are using

many different ways of Conveying, Storage and

Transportation in the world; this is why, SUMAK

Milling Machines has an different Conveying System

when they make turn key milling plants all over the

world. All of the factories have an conveying system

which is based on for Flour, Semolina, and Bran,

etc; therefore, the machines are based on Elevators,

Chain Conveyors, Spiral screw, Tube screw, and

Electronic Bagging Scale System. So this is why,

those conveying machines are related to automatic

weighing bagging machines, extraction rate control

sytem as well. Also, there is another way to used

conveying system which is blower system which

means that pressure of the Wheat, Flour,Semolina,

and Bran, etc all of the factories.

SUMAK Milling Machines have been completed

250 different projects, and without any fault since

1986. The attached a flow diagram shows how the

Wheat, Flour, Semolina, and Bran Conveying System

works on bottom of side What is showing is the flow

diagram 60TPD/24hr Building, and the machines

such as Elevators, Chain conveyors, Spiral screw,

Tube screw, and Electronic Bagging Scale, and

Blower as well.

1 Fevzi Çakmak Mahallesi Ayyıldız Caddesi No: 69 KARATAY – KONYA – TURKEY

TEL: +90 332 345 42 70- 71 FAX: +90 332 345 42 61 [email protected] www.sumakdegirmen.com

Today, SUMAK Milling Machines has highly specialized in the design, manufacturing and assembly of machines based on Conveying, Storage and Transportation. Most of the people are using many different ways of Conveying, Storage and Transportation in the world; this is why, SUMAK Milling Machines has an different Conveying System when SUMAK make an turn key milling plants all around the world. All of the factories has an conveying system is based on for Flour, Semolina, and Bran, etc; therefore, the machines are based on Elevators, Chain Conveyors, Spiral screw, Tube screw, and Electronic Bagging Scale System. So this is why, those conveying machines are related to automatic weighing bagging machines, extraction rate control sytem as well. Also, there is another way to used conveying system which is blower system which means that pressure of the Wheat, Flour,Semolina, and Bran, etc all of the factories.

SUMAK Milling Machines have been completed 250 different projects, and without any fault since 1986. We have attached a flow diagram one of those how the Wheat, Flour, Semolina, and Bran Conveying System works on bottom of side. This is what showing of the flow diagram 60TPD/24hr Building, and the machines such as Elevators, Chain conveyors, Spiral screw, Tube screw, and Electronic Bagging Scale, and also Blower as well.

SUMAK Milling Machines would like to give some the application purpose details of the explanation Conveying System machines which are:

SUMAK Milling Machines would like to give some the application purpose details of the explanation

Conveying System machines which are:

For more information:Sumak Milling MachinesFevzi Çakmak Mahallesi

Ayyıldız Caddesi No: 69

Karatay, Konya

Turkey

Tel: +90 332 345 42 70

Web: www.sumakdegirmen.com


ElevatorsElevators are used for vertical transporting the products in the flour mills. Buckets, which

are fixed regularly on the belt, ladle the products, which are transferred from the bottom

head inlet to inside by the means of reductor. It transfers products to cross outlet with

centrifugal force by passing the top head pulley. It is transferred to required place by the

means of pipe which is mounted at this. Products dust is transferred out of system by

the means of pipe and valves are mounted on the head. Two of discharge bolts are taken

their places for discharging the materials, that are choked up with products because of

probable lameness, elevator occurs bottom top head with reductor, pipe,belt, pulley and

buckets. Excepting the bucket fixing belt, all other parts of the machine are made of steel

construction. Bottom head has stretching mechanism for bottom top head belt – pulley

adjustment. The elevator pipes are made of 1,5mm or 2mm metal sheet as unique parts

and pressed. One of the pipes are designed could be seperated in order to change the

buckets. The reducer motors are choosen according to the capacity and height of elevator.

Reductor table on the top head is active, so there is nothing any problem about centering.

Tube Screws:Tube Screw are placed the bottom of Rotoflow, it is generally used for transporting the flour

and bran. It is mounted under the rotoflow which is set up outlet of the flour and bran silos.

It could be manufactured in different specifications.

BlowerUsed for hoizantal or vertical carrying of all kinds of grain and pulses and cleaning filter

bags. Direct coupled and belt pulleys operation are both available. Covering a small area,

easy maintenance and assembly have made the blower pump a highly prefered machine in

milling sector in recent years.

The pump in front of flour, wheat and so on. Systematically separated from each other fort

he transport of products, products with the air of a working machine type. Blower is made

with the transport systems. Minimum maintenance requirement Minimum leakage rate

was casting the main body and the inner palettes .

Collected in a silo or a cyclone allows goods to be shipped in two separate road. Can be

controlled manually or pneumatically. Teflon sealing elements to distinguish it from the

materials provided to each other. On which side flaps that can be understood with the help

of limit switches. Is demountable all parts of valves in terms of maintenance and repair of

major benefit.

Silos and cyclones are used to block the flow of material subdialects. Cover the desired

sizes of circular, rectangular or elliptical cross section can be produced. Can be controlled

manually or pneumatically. Manual of the unit square miles are driven by a gear. Automatic

sliding valve neumatic cylinder and solenoid valves are provided in the drive. Position

pointer is also the limit switches.

Spiral ScrewsIt is used for horizontal transporting the products in the flour mills. It is manufactured in

different diameter and lenght. It is manufactured as right or left direction according to

application fields. It is used for distributing, collecting, mixing and annealing

wheat process.


Electronic Bagging Scale:. Full PLC controlled. Suitable for bagging of materials in open mounth bags. Weighing range options of 10-25 kg. Accurate and quick weighing with load cells.. Programmable set values with 10gr. İntervals.. Programmable desired number of bags.. Seperately programmable high and low tolerance values. Alarm functions for out of tolerance weighment. Level control in the regulation bin 12-20 ton/ hour bagging capacity depending on the product. Display of total number of bagged and total weighed materials.. Easy and practical calibration.. Alarm function fort he faults. Display of the fault messags at the operatör terminal. Pneumatic bag clamp. Vibrator. Take- away belt conveyor. Adjusttable bag guiding plates. Sewing machine support and sewing machine motor. Sewing machine (optional) Various feeders for materials with different chacterestics. Double screw driven by seperate. Single Screw driven by two speed motor. Conveyor belt driven by two speed motor. Pneumatically operated gate.

CAPATICY: Changeable according to the bagged product and required tolerance and capacity is

between 12tons/ hour to 20 tons/hour. (Declared capacity is 12 tons/hour with a tolerance of+-

50/sack for flour and the products having same characteristic)

SETTING VALUE: Could be programmed 25-50 kgs. According to the user’s requirement.

WEİGHT DISPLAY: Weight display screen is 4digit

FAST-SLOW ADJUSTMENT: There is two programmable setting value in the system. and possible

to program the filling volumes of these values seperatelly. High and low tolerance values made

automatically according to the type of the flour and silo level.

TOLERANCE: High and low tolerance values can be programmable seperatelyç If the weighning

results are out of the tolerances, the products did not get out without on operator’s intervention.

BAG DIMENSIONS: Recommended sizes are 65x95 cm.

REQUIRED BAGGING: Programmable desired number of bags. The number og bags can be

changed during the bagging. System stops by itself when the rewuired bagging finished.

TOTAL BAG NUMBER and WEIGHT: Possible to display of total number of bagged and total

weighed materials.

TOTAL BAGGING TIME: Possible to display to display of the total time of bagging.

LEVEL CONTROL: By the help of level sensors in the regulation bin, the level controlled by the

system automatically.

ALARM FUNCTION FOR THE FAULT MESSAGES: Display of messages at the operatör terminal.

Chain ConveyorsChain conveyors are used for the horizontal ways of grain, feed, flour and bran.

Therefore, chain conveyors can be carried 300tons/hour of the capacity, and the

elimination of metal to metal contact conveying section leads to smooth operation

and also it makes less noise with a longer life as well. The chain conveying system

based on high volüme of the grain movement, and there are plastic rollers are

support the chain for returning.


Choosing the right hazard monitoring system for your bucket elevator

When 4B introduced their Watchdog Elite bucket elevator

monitoring system in the early 1980’s, they were the first

on the market to offer a system that could monitor a complete

bucket elevator or conveyor system. No more need to monitor

different hazards separately. -Taking the hassle out of hazard

monitoring, the Watchdog Elite has quickly established itself as

the industry reference in hazard monitoring.

Today, there are a number of systems on the market, and

customers may find it more difficult to establish which system

is best for them. When you add up all the additional costs of

adding sensors and servicing the system, then this decision

becomes even more complicated. And when you consider the

cost of the potential downtime and even damage, then it is

absolutely crucial to get this decision right!

So what should customers look out for when selecting a system

to monitor their bucket elevators and conveyors?

Firstly, scalability:

Make sure that the system is able to grow with your operations.

You might just want to monitor one elevator, for a start, but

what happens if you want to monitor an additional elevator, or if

you want to add more sensors to the monitoring system?

Secondly, sensor options and interfaces:

What hazards is the system able to monitor? Belt and pulley

misalignment? Underspeed & Overspeed? Belt slippage?

Blocked chute condition? Bearing temperature? – And what

is the choice of compatible sensors? Do you have to use the

supplier’s range of sensors, and are they up for the job?

Does it have a communication interface, to be connected

to a PLC or PC?

Thirdly, user friendliness and support:

How easy is the system to use for the people who have to

operate it? Is there an in-built test and diagnostic function?

And how are potential hazards displayed and identified? Is

there a well-documented instruction manual available? Does

the supplier offer a commissioning service? And what level of

support can you expect, if there is a problem?

Fourthly, compliance:

Does the system have the necessary hazardous area approvals

for the region where it is to be used: ATEX for Europe, CSA for

North America & Canada and IECEx for the rest of the world?

At 4B, 25 years of experience have shown that there is no

“one size fits all” hazard monitoring system. The company’s

approach to product development is very much bottom-up

through discussions with the end-user upwards, rather than

sales-driven. -And it is this industry driven approach to product

development that has led the engineering team to develop 2

distinctive multi-function hazard monitoring systems, each

of them well researched and tested and using the same high

quality components, but different in the variety of sensor

options and the scope of the applications they can cover.

For more information:4B Braime Elevator Components

Hunslet Road

Leeds

LS10 1JZ

United Kingdom

Tel: +44 113 246 1800

Web: www.go4b.co.uk


The T500 Elite Hotbus System

This is 4B’s top of the range system, able to monitor entire plants where the

bucket elevators and conveyors being monitored are spread out across large

distances.

A multi-function hazard monitor, it can monitor belt speed/alignment, bearing

temperature, pulley alignment and plug condition. It has been designed as a

serial communication system, to monitor up to 256 sensors, with a scan time

of only 4 seconds! With automatic machine shutdown capability and PLC /

PC compatibility, this advanced microprocessor based system offers low cost

installation, versatility and easy system expansion.

Logging and trending software is also available for historic data analysis and

preventative and predictive machine maintenance.

It is ATEX, CSA and IECEx certified.

The Watchdog Elite System

A well proven multi-functional hazard monitor for bucket elevators and conveyors,

the Watchdog Elite has recently been relaunched with continuous bearing

temperature monitoring.

The Watchdog Elite allows complete monitoring of multiple hazards in a bucket

elevator or conveyor, including belt and pulley alignment (top and bottom), bearing

temperature, belt speed and blocked chute conditions.

The Watchdog Elite system uses a range of compatible sensors to monitor

different hazards, such as the belt misalignment sensors “Touchswitch”, BAP2”

and WDA3”, the WDB bearing temperature sensors and the “Binswitch” capacitive

sensor.

An LCD screen displays elevator status messages (available in four different

languages) and a super-bright LED screen displays belt speed. RS485

communication is also available for connection to plant computers / PLCs.

Calibration and parameter adjustment are all menu-driven and kept simple.

The system is ATEX, CSA and IECEx certified.

T500 Elite

ü (continuous)

max. 256 sensors*

ü (continuous)

max. 256 sensors*

ü max. 256 sensors*

ü

RS485 API

ü

ü

ü

Multiple elevators & conveyors;

remote monitoring across site

ATEX CSA

IECEx

Watchdog Elite4B has an extensive range of CSA / ATEX / IECEx approved

sensors that work with these control units, including bearing

temperature sensors, speed sensors, misalignment switches,

level indicators and choke switches. The range is constantly

evolving to offer customers the best technical standard.

4B’s technical team can recommend the ideal combination

of sensors and monitoring systems to suit their customers’

requirements and budget. They can also offer a scalable

solution starting with carefully chosen equipment and systems

that can be expanded at a later date to encompass other

machines in the plant.

4B also offers a commissioning service as well as a competent

after-sales technical service to help customers overcome any

technical problems with their monitoring equipment.

ü (continuous)

max. 6 sensors*

ü (continuous)

max. 1 sensors*

ü max. 4 sensors*(Touchswitch)

ü

RS485 API

ü

ü

ü

Several elevators & conveyors

ATEX CSA

IECEx

Bearing temperature

Belt speed

Belt Alignment

Plugged condition

Communication interfaces

Test function

Alarm & shutdown

Logging & trending

Applications

Certifications


IDMA 2013 TOUR PACKAGES

5***** Contracted Hotels 03 - 07 April 2013 / 4 Nights accomodation04 - 08 April 2013 / 4 Nights accomodation

IDMA 5th International Flour, Semolina, Rice, Corn, Bulghur, Feed Milling Machinery & Pulse, Pasta, Biscuit Technologies Exhibition

IDMA 5th International Flour, Semolina, Rice, Corn, Bulghur, Feed Milling Machinery & Pulse, Pasta, Biscuit Technologies

Exhibition which takes place 4-7th April 2013 organised by Parantez Group

IDMA – is an event aimed to enable the directors and managers of companies to exhibit their products, directly communicate with

their customers, find new sales markets and partners for conclusions of agreements.

There has been a significant increase in the number of expected delegates and exhibitors 2013 compared to compared to 2011.

Now more than 10,000 thousand local and international visitors are expected from 120 countries. The exhibition allows it to be the

major negotiating point for international and Turkish milling and grain processing companies. This exhibition is helping to attract

and gather such manufacturers to share their experiences in the industrial and scientific field.

The Exhibition also offers a good experience and a chance for students who are studying in this field to declare themselves or to

find a good job.

If you are interested in visiting IDMA, please see our special visitor tour packages below and email [email protected].

WOWISTANBUL HOTEL

TITANICPORT HOTEL

COURTYARDMARRIOT HOTEL

Package Includes:4 Nights accomodation & breakfastAirport - Hotel TransferHotel - Fair Area TransferFair Entrance CardFair BrochureBosphorus Boat Tour (Evening)Half Day Historical Peninsula Tour

4**** Contracted Hotels 03 - 07 April 2013 / 4 Nights accomodation04 - 08 April 2013 / 4 Nights accomodation

WOWISTANBUL HOTEL

TITANICPORT HOTEL

Package Includes:4 Nights accomodation & breakfastAirport - Hotel TransferHotel - Fair Area TransferFair Entrance CardFair BrochureBosphorus Boat Tour (Evening)Half Day Historical Peninsula Tour

Price Per Person in a Double Room 512 €Price Per Person in a Single Room 949 €

Price Per Person in a Double Room 512 €Price Per Person in a Single Room 827 €

Since January 01, 2013, price of tour packages will increase by 10%

2013

EV

ENT

LIS

T January 201329th-31st January

International Production &

Processing Expo (IPPE),

Atlanta, GA, USA

February 201323rd-26th February

GEAPS 2013, Louisville,

Kentucky, USA

March 201311th-15th March

Purchasing & Ingredient

Suppliers Conference,

Texas, USA

13th-15th March

VIV Asia,

Bangkok, Thailand

26th-28th March

AGRA Middle East,

Dubai

April 20134th-7th April

IDMA 2013,

Istanbul, Turkey

8th-12th April

The 4th Global Feed and

Food Congress (GFFC),

Sun City, South Africa

29th April-3rd May

117th Annual IAOM, International

Association of Operative Millers,

Ontario, Canada

May 201322nd-24th May

VIV Russia,

Moscow, Russia

29th-31st May

CIMAE 2013,

Beijing, China

30th May – 2nd June

Surabaya Agri Expo,

Surabaya, Indonesia

June 201310th June

International Grains Council,

London, UK

12th-13th June

Cereals 2013,

Lincolnshire, UK

27th-28th June

The Nottingham Feed Conference,

Nottingham, UK

July 201313th-16th July

IFT Food Expo 2013,

Chicago, USA

August 20137th-9th August

Livestock Philippines 2013,

Manila, Philippines

25th-28th August

ICC Conference 2013,

Perth, Australia

September 201310th-12th September

Liquid Feed Symposium,

St Louis, MO, USA

24th-26th September

Livestock Asia 2013,

Kuala Lumpur, Malaysia

October 20136th-9th October

International Baking Industry

Exposition, IBIE 2013,

Las Vegas, USA

November 201310th-16th November

Agritechnica,

Hannover, Germany

December 20138th-10th December

NGFA Country Elevator

Conference & Tradeshow,

St Louis, Missouri, USA

Please visit www.globalmilling.com/global-milling-events/ for more information on these events


June 201310th June

International Grains Council,

London, UK

12th-13th June

Cereals 2013,

Lincolnshire, UK

27th-28th June

The Nottingham Feed Conference,

Nottingham, UK

July 201313th-16th July

IFT Food Expo 2013,

Chicago, USA

August 20137th-9th August

Livestock Philippines 2013,

Manila, Philippines

25th-28th August

ICC Conference 2013,

Perth, Australia

September 201310th-12th September

Liquid Feed Symposium,

St Louis, MO, USA

24th-26th September

Livestock Asia 2013,

Kuala Lumpur, Malaysia

October 20136th-9th October

International Baking Industry

Exposition, IBIE 2013,

Las Vegas, USA

November 201310th-16th November

Agritechnica,

Hannover, Germany

December 20138th-10th December

NGFA Country Elevator

Conference & Tradeshow,

St Louis, Missouri, USA

back cover

Global Milling DirectoryGlobal Milling Directory a new online directory

Global Milling has become a brand new reference source for the Grain, Feed, Flour, Cereals, Rice, and Pasta

industries. Covering all aspects from equipment to raw materials and including all suppliers and manufacturers

working within the industry.

Bringing you the latest up-to-date relevant news, upcoming industry events, Universities and worldwide company contact information – Everything you need in

one place!

Keep up-to-date with Global Milling!

www.globalmilling.com

global milling advances november 2012 -

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