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| wheat flour mill factory layout |
The stability of product quality is the common pursuit of flour producers, operators and consumers.
"Not for the best, but for stability" of the production and management philosophy, by everyone to accept. But the flour in the production process, due to the diversity of devices, the material instability, arbitrary operation, climate variability and other uncertain factors exist together, which brings great difficulties to the stability of product quality. How to ensure the relative stability of the product quality is the problem that the flour milling workers have been pursuing and exploring.
Summing up the experience of successful enterprises and famous brands, combined with years of in-depth practical research results, from the flour production process to explore ways to stabilize product quality.
1. grain quality is stable
1.1 wheat flour stable source of market competition, to a certain extent, is the capital and talent competition, embodied in the advanced, stability and innovation of material control and production technology. The small and medium-sized factory due to funding and capacity constraints, the uncertain factors and constraints in the grain purchasing. The main procurement of them are farmers and some small dealers, effects of purchasing instability, wheat quality without selectivity, supplier's uncertainty and many other factors, to maintain the stability of the grain supply is difficult. The special period, even there is a disconnect for grain supply, and restrict the production of the phenomenon. How to solve the problem of wheat source stability can be considered from the following aspects:
- maximize the funds to solve the problem of storage and.
Take different ways to establish a stable purchasing network.
Cooperate with local government or growers to establish order farming or cooperative cropping mechanism.
The establishment of regional professional associations or enterprises to form a community of interests, integration of resources, complementary advantages, mutual benefit.
1.2 reasonable blending
Wheat collocation is different from wheat blending. The wheat collocation is to match the wheat with different indexes according to the specified proportion, while the mixed collocation contains both the content of the collocation and the meaning of the mixture. At present, due to China's wheat planting way is to farmers' planting, variety and quality of different raw material, in order to stabilize the production process and product quality, combined with their own actual, on the grain compounded reasonable is very important. Generally speaking, with mixed grain is divided into five steps:
receive mixed and conditional factories
The factory in good condition to talke more ways to unloading wheat and one way to loading wheat into the bin ,completed the first hybrid.
Material bin
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| moisture bin |
The function of material bin is not only to meet the storage requirements, but also to meet the requirements of mixing. Less than six of material bins, can meet a uniform; more than eight material bins, can meet the two uniform; more than twelve material bin, can meet the three uniform; There are more material bins, The more in mixing times, the higher in uniformity of mixing.
Matching wheat bin homogeneous
After the homogeneity of the same kind of wheat, the wheat enter into the matching wheat bin and complete the distribution of wheat with the specified proportion.
Wheat cleaning bin homogeneous
According to the actual situation of storage,bin type, suitable in the set (a) bin homogenization device, unless a long time, about silo 10% should not be used independently. Flour produced from wheat at the bottom of the warehouse should not be used as a normal product.
The real condition is that the majority of small and medium-sized factory does not have the above conditions.Especially the material bin only with storage function,no uniform function. Some small plants even without material bin. The most simple and effective is manual overturned and mixing wheat to put in storage bin.
To ensure the mixing effect, the precleaning process must be strengthened. Due to the difference of harvesting, drying, storage and transportation of wheat, the types and amounts of raw grains have changed , especially the wheat straw and dust, and the impurities of wheat bran have obviously increased, so the precleaning process and configurtion can not meeting this work. In order to ensure the accuracy and consistency of compounding effect and effectively increase the storage capacity, the screening and suction effect of the precleaning process must be strengthened. It was proved that: Plane rotary sieve removal of wheat straw impurities is higher than the vibtating cleaner efficiency, but in the selection type and screening holes type should pay attention.
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| wheat flour cleaning section |
1.3 The cleaning effect is stable "Good cleaning has completed half of milling", in order to obtain a stable cleaning effect, we must do the following:
Stable wheat flow. In the workshop without the flow scale , it is unreliable to control the flow simply by using the wheat mixer or value. A simple and effective method is to add a flow control cabinet in front of the begaining of the equipment.
Selection of cleaning equipment is correct, the parameters are suitable and the process is reasonable. For aging, outdated, inefficient, high-energy equipment and the key components have failed, must be promptly replaced; for adaptability, flexibility, poor controllability of the process, we must promptly upgrade.
Strengthen the routine maintenance and management of equipment to keep the equipment running stably and efficiently.
Develop a realistic and quantifiable clean-up process and strictly supervise the implementation.
It is worth noting that the phenomenon of "re-purifying powder milling and light cleaning" is quite common. Some factories do not even have a special person to manage the cleaning process. Multi-export wheat barn is not more than export, with the clogging of the device, equipment feeding or parallel equipment, uneven material, screen surface or to the stone surface sieve plugging, sieve tube (plate) rupture, playing plate or bag hole wear, suction Tube blockage, throttle misalignment, corroded water, water flow control failure, warehouse floor material mildew and other phenomena have occurred, the key is not found in the first time, resulting in cleaning effect is not stable. It must be remembered that cleaning equipment and processes is not a panacea, and operation and maintenance can not be ignored.
1.4 Stable effect
at present, most plants give more concerned about the products into the water and the average moisture mill net wheat, but pay low attention to the significance and process control. Such as: different wheat quality, different original moisture, different environmental temperature and humidity control; how to control the water uniformity and suitable water distribution ratio of wheat into the mill.
In order to ensure the stability of quenching and tempering effect, we should pay attention to the following aspects:
l Ensure the stability of wheat flow and the uniformity of original moisture.
l The water quality is good, the water pressure is stable, the flow control is accurate and reliable.
l According to the grain quality, water content, environmental temperature and humidity, tempering requirements, timely and accurate control of the tempering time and frequency. General: one time moisture tempering, to meet the changes of physicochemical properties of wheat grain; two times with water tempering, meet the materials moisture in uniform. The time depends on the specific conditions.
l Strictly control the amount of spray water and storage time, and maintain the appropriate water partition ratio between cortex and endosperm.
2. Milling process stable
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| wheat flour milling section |
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| roller mill for wheat |
2.1 The milling effect of milling machine is effected by materials properties, flow rate, feeding effect, mill running parameters and effect of grinding parameters and the machining quality of roller surface, the grinding roller assembly quality and cleaning effect, operation index and other factors. To stabilize milling effect, the following points should be done well:
Ensure the quality, flow and uniformity of incoming materials. Special grinding system supplies, must achieve the true meaning of "homogeneous merger"
Mill operating parameters reasonable and accurate, safe and reliable work.
· Roller surface parameters suitable, accurate processing, well-equipped. Roller surface parameters are not static, should be based on material properties, flow, grinding requirements, such as the appropriate temperature and humidity adjustment.
· Fine operation, strictly according to the requirements and indicators control milling machine, rather than according to personal experience and habits. Skinning system to achieve the goal of stripping, stripping rate in strict control of each and take the powder rate at the same time, control the total stripping rate, take the powder rate and the integrity of the bran. The heart-grinding system to achieve the goal to take the powder, in ensuring the branded starburst is not excessive at the same time, the goal of extracting the corresponding quality and size of the flour. Practice has proved that: a selective grinding to take the powder and non-selective grinding powder, the resulting flour quality is different.
In the grinding process, there are often the following errors:
· Front Road Light Rear Road, especially the front road mill, the majority of operations are too tight, always think that the front road is not tight, the total output rate will be reduced. Practice has proved that: 1B stripping rate of more than 30%, 1-2B stripping rate of more than 70%, 1-2P incoming less, quality changes, smaller particle size. The company is located in:
· Center of gravity light leather mill heart is the main part of the mill to take the place, but the heart of the incoming quality and quantity depends on the purpose of leather mill operation. When the total mill powder take-over rate of more than 15%, the flour quality and the yield of the former good powder will be significantly affected.
· Grinding light weighting Without good screening there is no good milling, grinding and screening relationship as the relationship between the human mouth and appetite, complement each other.
The key to stabilizing the mill is to achieve the goal of each mill. The target must be determined with the raw grain, equipment, technology, product requirements and other adaptations, and timely adjustments should be based on the actual situation appropriate amendments.
2.2 the screening effect is stable in incoming and screen motion state in certain circumstances, sieve length, sieve width, mesh quality, stretched quality and arranged screen surface cleaning effect will affect the sifting effect. In the actual production process, the focus of stabilizing sieve effect is:
Establish an accurate and perfect maintenance system and strictly implement it. Mainly includes: sieve running state detection system; screen mesh, cleaning block, push block procurement, inspection and replacement system; screen and the quality of its inspection and supervision system and so on.
Establish timely adjustment rules for screen and screen path. The small amplitude of short time, grain moisture, climate change, adaptation can be achieved by mill control. When the milling machine is difficult to control or affect the overall index, it is necessary to adjust the sieve in a timely and appropriate manner.
First sieve or first grade, flour sieve is "dilute dense" or "Dense dilute", there is no clear conclusion , need to make a concrete analysis according to the specific circumstances,.
2.3 Powder cleaning effect stable.
Powder cleaning process is a barometer of the milling process. As long as the intention to observe, fine operation, can be found accurately and timely change of grain quality and water and change the grinding and screening effect. In recent years, more and more attention has been paid to the cleaning process. The more the number of powder cleaning machines is, the more clear the range of cleaning powder is, the more and more clean powder lanes are, and the repeated cleaning powder can be used in the conditional factories. This has played a positive role in improving the quality of products, especially in improving the yield of low ash flour. However, many factories have found that the use effect of the powder cleaner is not ideal, and the following points should be done to stabilize the powder taking effect:
l feeding control
According to the working principle of the purifier, the material must be balanced in quality, uniform in size and suitable in flow rate. To do these, firstly is the stability of grain quality and water, secondly is the mill machine must mill the target,thirdly is the plansifter must sieve the target.
l Working condition
The working condition of the purifier mainly includes: sieve body amplitude, throw angle, screen angle, screen surface quality, tension, cleaning, horizontal level, suction configuration and adjustment, etc. It is not difficult to find out the difference by observing and testing the working state of each purifier. Causes: there are equipment quality problems, but also installation, commissioning, use, maintenance issues, should be specific analysis of the specific circumstances. Although these differences are not easy to find or fail to pay enough attention to, but the effect of cleaning flour and the effect of the whole milling process is obvious.
l fine control
The key is the coordination among the material feeding, screen mesh, air suction and movement. Observing the purifier working condition of flour plants is not difficult to find: feeding material quality and size difference; feeding uneven material take unilateral screen surface material; the movement is not smooth; clogging; various riddlings the quality and quantity of the suction chamber (Road); powder; damper failure; observation the window can not see the air leakage and so on, can be seen everywhere.
3. Flour composition is stable
In the process of milling, the quality and quantity of flour extracted by different systems are different, even in the same system, there are differences in flour with different particle size range. Make good use of the uniformity and difference of the quality and granularity of the flour, and reasonably constitute the products that meet the needs of the users.
3.1 flour flow stability
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| flow chart for wheat flour mill |
The flour flow stability is the premise, raw grain, equipment and operation stability. The key to obtain flour is to grasp the quality and quantity of flour flow accurately, and we should pay attention to the following points for accurate realization:
Try to avoid different material mixed during grinding and screening. Flour mill requires homogeneous combination of same quality raw materials, high square sieve feed also requires homogeneous combination. Otherwise, fine flour and less fine flour mixing can not achieve the goal of flour extraction.
In the formal main flour extracted parts, extract different kind quality and different size flour saperately. To realize the target of flour extract well. Like this, it will reduces re-rolling, increase the output rate, reduce power consuming, change the milling section condition, and also can create the condition for flour’s content and match
Accurately grasp the quantity, quality, particle size range and change rule of each powder flow.
3.2 Flour update improvement stability
at present, flour brightener has quit the stage of history, people rely on flour improver may be relatively increased. However, green, nutrition, safety and convenience are the mainstream of flour production and consumption. The use of flour improver must be based on the premise of ensuring the quality of raw powder, comply with the provisions of the state, reasonable and stable addition. Specific attention should be paid attention to the following points:
The quality of the improver and the operation of the adding machine should be safe, stable and reliable.
Quantity and quality stability of flour flow;
Add position, mix properly, mix evenly;
Adding amount checking method is correct, checking result is accurate.
The "change" of flour production is absolute, and "stability" is relative. Only by grasping the law of change can we find a steady way. But in all the "change" factors, human are the first. In order to eliminate human error, we must strengthen the education of employees, improve the overall quality of staff occupation technology, strengthen the brand and quality awareness, to overcome the "genius enterprise culture", establish and improve the system of quantitative operation and management process, stable product quality to solve the problem fundamentally, it is feasible and is the only effective.
Contact details Ms. Jane Liu for flour milling machines. M: +86 132 2344 2174 (whatsapp/viber/imo/wechat)
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