Innovative process design to challange market demands

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1 Innovative process design to challange market demands

2 Global Trends. The world needs every year mio. tones of additional grain Globalization, Energy consumption will go up and up Fluctuation of commodity prices is increasing Water shortage The world population will get older People will care much more about health and wellbeing 2 Bühler IAOM SEA 2015 Dominique Kull

3 Grain Industry Trends. Changing eating habits, that means: more convenient food Demand for healthy and safe food Luxury and live style products Trends in the supply chain New supply sources quality variation contaminated and effected with disease Operational challenges Energy prices availability of (qualified) labor 3 Bühler IAOM SEA 2015 Dominique Kull

4 New cleaning concepts in a flour mill.

5 New cleaning concepts in a flour mill. Requirements for a state of the art grain cleaning. Constant and high quality of the finish products. Efficient reduction of harmful substances. Fulfillment of legal requirements. Optimization of the production costs. Cleaning efficiency with sharp sorting Optimizing milling yield 5 Bühler IAOM SEA 2015 Dominique Kull

6 Modern Wheat Cleaning Concepts. First cleaning with High-performance Grain Classifier VEGA and Optical Sorter SORTEX. Elevator MGEL Scale MSDL Elevator MGEL Liquid Flow Controller MOZF Dampener Turbolizer MOZL Separation of light, coarse and fine impurities. High-Level Indicator High-Performance Grain Aspirator MTVA Magnet MMUA Intermediate Separator MANB High-Performance Grain Classifier MTVA Screw Conveyor NFAS High-Level Indicator Separation of soybeans, corn, etc. Fan MHTP Fan MHTP Separation of stones. Raw Wheat Bins Elevator MGEL Destoner MTSC Destoner MTSC Tempering Bins Optical sorting of the entire stream of grain. Low-Level Indicator Outlet Hopper MFAK Flow Balancer MZAH S Depot Optical Sorter SORTEX MSOB Separation of discoloured kernels and impurities. Screw Conveyor NFAS Autom. Moisture Controller MYFC 6 Bühler IAOM SEA 2015 Dominique Kull

7 New cleaning concepts in a flour mill. Accurate classification of grain. Removal of impurities and light product. Raw grain Coarse impurities Maize Soya beans Sunflower kernels Large grain Option: grain classification Medium grain small grain Light product Dust Spelt Shriveled kernels Fine impurities Sand Weed seeds 7 Bühler IAOM SEA 2015 Dominique Kull

8 Precise optical sorting. Dark defects - Impurities Input Foreign grain + seeds Ergot Discoloured grains Light defects - Impurities Ligth Braid Spelt, Straw Various defects - Impurities One module Two/Three Module Four/Five Module Semi-transparent Stones, Glas, Plastics, Accepte Reject Mycotoxin damaged Diseased kernels 8 Bühler IAOM SEA 2015 Dominique Kull

9 Sort example and analysis Up to 1 % less Wheat loss of good wheat going to screenings 9 Bühler IAOM SEA 2015 Dominique Kull

10 Reduction in Total Microbial Activity Through Buhler s Modern Cleaning Systems Shown results are considered as indications only. Success in reduction depends on incoming contamination as well as distribution throughout the kernels Raw Wheat 25 After 1st Cleaning After Tempering 20 After 2nd Cleaning 5 Flour 10 Bühler IAOM SEA 2015 Dominique Kull

11 Reduction in Vomitoxin (DON) Raw wheat < 4ppm (DON) 4 Shown results are considered as indications only. Success in reduction depends on incoming contamination as well as distribution throughout the kernels ppm Raw Wheat After 1st Cleaning After 2nd Cleaning Flour 11 Bühler IAOM SEA 2015 Dominique Kull

12 Wheat Cleaning with Vega and Sortex. Customer benefits. Once calibrated no adjustment needed (lights out) Less aspiration consumption, resulting in smaller filter and less energy Expulsion of foreign seeds and reduction of Vomitoxin (DON) Further increase efficiency YIELD (minimal wheat loss) Safer and cleaner finished product CONSISTENCY Controlling & Adjustment of Food Safety Regulations FLEXIBILITY Ease of use for operators with remote monitoring and diagnostics via modem SIMPLICITY 12 Bühler IAOM SEA 2015 Dominique Kull

13 New milling concepts.

14 Premium Flour Flow. Benefits Higher extraction on low ash flour Adjustment of starch damage to achieve target water absorption Maximum total flour yield Solution 3-step break system on 1 st and 2 nd break Specific grading system Balanced roll length of C- Passages 14 Bühler IAOM SEA 2015 Dominique Kull

15 8-Rollermills in Asian Flowsheets: Extend 1 passage into 2 grinding steps More semolina Lower ash content Higher yield of top quality flour Lower wheat quality requires better milling systems 15 Bühler IAOM SEA 2015 Dominique Kull

16 Solution: 8-Rollermill for 2Bk passage. 1B 2B T 2B B The proposed 3-step break system for retrieval of semolina 1st quality allows: - Lower break release on 1Bk usage mainly for coarse semolina production - Compensation with higher break release on 2Bk with higher semolina extraction Result: The semolina quality on 1Bk as well as 2Bk will be improved resulting in overall improved milling performance 16 Bühler IAOM SEA 2015 Dominique Kull

17 2Bk semolina production (CWRS / DNS) with double Rollermill with single Rollermill Features: Higher semolina percentage for purifification internediate Semolina has lower ash < Bühler IAOM SEA 2015 Dominique Kull

18 IPO - Intelligente Prozess Optimisation.

19 Intelligent Automation Solutions. Market demand. Millers like: to monitor the process to control the process to automate the process Process control Therefore we offer: Reliable process data in real-time The possibility to regulate the process parameters Control Data elaboration Sensing 19 Bühler IAOM SEA 2015 Dominique Kull

20 Intelligent process optimization with sensor technology. Product Overview. NIR Multi Online Analyzer MYRG Protein, Moisture, Ash PSM Online MYTA Particle Size measurement Optical Measurement Online MYHB Color and Specks 20 Bühler IAOM SEA 2015 Dominique Kull

21 Intelligent process optimization with sensor technology. PSM Online MYTA. Solution: Online determination of particle size distribution in the range of microns. 21 Bühler IAOM SEA 2015 Dominique Kull

22 Antares Plus. Automatic Process Optimization. Roll gap adjustment 22 Bühler IAOM SEA 2015 Dominique Kull

23 Intelligent process optimization with sensor technology. Customer benefits of process optimization. Production and availability Process stabilization Reduction of down times Quality of final products Improved product consistency Higher product quality Productivity and economic efficiency Maximum use of capacity, increased utility Optimization of cost drivers Cost Profit Earnings 23 Bühler IAOM SEA 2015 Dominique Kull

24 One step ahead. 24 Bühler IAOM SEA 2015 Dominique Kull

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