PETKUS Technologie GmbH
Innovations in Grain Preparation for Milling Roger Cook Senior Technical Specialist
Strong Seed. Healthy Grain. PETKUS.
PETKUS Technologie GmbH
PETKUS Technologie GmbH
Seed & Grain Technology
R&D Activity
Engineering & Installation
Customer
Flour & Feed Technology
PETKUS Technologie GmbH
PETKUS Technologie GmbH
PETKUS Technologie GmbH
Innovations in Grain Preparation for Milling Healthy flour and semolina can only be made from healthy grains Grain is subjected to attack from: - Insects - Bacteria - Atmospheric Conditions - Fungus - Materials Handling More focus is needed on: - Reducing Grain Loss - Delivering Safe Food
PETKUS Technologie GmbH
Why? United Nations FAO state that the annual spoilage of grain harvested worldwide is more than 20%...or 130 million tonnes of wheat alone! Major part of this loss is insect activity and mildew growth
What’s Needed? Effective preservation of stored grain Effective cleaning of grain for food safety
PETKUS Technologie GmbH
Preservation and Cleaning Together Insect activity is particularly prevalent in stored grain containing broken kernels and screenings Confused Flour Beetle Survival in 8% Moisture Wheat:
Cotton et al 1960 & Bhadriraju Subramanyam, KSU, IAOM SE Asia Conference 2013
PETKUS Technologie GmbH
Growing Demand in Asia – Volume & Quality • • • •
Improved economic status, willingness to pay for good & safe food More bread is being consumed, more protein consumed Growing demand for feed mills Western retailers, TESCO, Carrefour, etc have higher quality demands
PETKUS Technologie GmbH
New Innovations – Providing Solutions Silos Silos must be appropriate for their purpose, consider: - Long term/seasonal storage – Flat Bottom - Process silos/frequent loading or unloading – Hopper Bottom - Sealable for Fumigation (Australian Standard AS2628?) - Concrete or steel - Grade of galvanisation for steel silos - Combined silo and machine house/production buildings
PETKUS Technologie GmbH
PETKUS Silo Solutions - Medium size dryer and silo installation
PETKUS Technologie GmbH
PETKUS Silo Solutions - Storage for Flour and Feed Milling
PETKUS Technologie GmbH
PETKUS Profile & Smooth Wall Silo - Incorporating Machine House/Process Floors
PETKUS Technologie GmbH
PETKUS Profile & Smooth Wall Silo - Fast erection due to automatic laser welded panels and bolted supports
PETKUS Technologie GmbH Machine House Floors: Steel Underfloor
PETKUS Technologie GmbH Machine House Floors: Ready for Concrete
PETKUS Technologie GmbH Machine House Floors: Finished Floor – Strong, Sealed, Hygienic, Easy Clean
PETKUS Technologie GmbH Machine House Floors: Finished Floor – Strong, Sealed, Hygienic, Easy Clean
PETKUS Technologie GmbH
Optimising Materials Handling • •
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Grain handling produces 0.11-0.55% dust by weight Maize subjected to 2, 5 and 15 silo transfers had 0.9, 4 and 9% breakage respectively High capacity conveyors and elevators have high energy and maintenance costs and their own infestation issues
Design the site layout to: • Minimise handling • Minimise heights and distances • Allow safe and efficient truck movements and separation
PETKUS Technologie GmbH
Optimising Materials Handling
PETKUS Technologie GmbH
The Reality in Asia
PETKUS Technologie GmbH
Preventing Degradation Inside the Silo •
Dust Control at Intake – PETKUS Filter Wall
PETKUS Technologie GmbH
Preventing Degradation Inside the Silo •
PETKUS SM Cleaner
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Pre-Cleaning Galvanised 5, 7.5 & 10°° Angle 2 or 4 Screen Layers
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PETKUS Technologie GmbH
PETKUS SM Cleaner •
4 Screen Layers – Double the Capacity!
PETKUS Technologie GmbH
Preventing Degradation Inside the Silo •
PETKUS V Cleaner
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150 tph Wheat Pre-Cleaning Pre & Post Screening Aspiration 6 Screen Layers All Metal Construction
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PETKUS Technologie GmbH
PETKUS V Cleaner •
Sieve Cleaning and Material Flow Control System
Negative Pressure Chamber
PETKUS Technologie GmbH
PETKUS V Cleaner •
Sieve Cleaning and Material Flow Control System
PETKUS Technologie GmbH
Unique Advanced Manufacturing Technology No Weld Design
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Made in Germany
• The unique bolt design gives the special PETKUS appearance • Proven stability of the frame construction • Reduced maintenance work due to easier disassembly and access • Complete design of seed/grain plants with “no weld” technology • Clean PETKUS factory with no welding or grinding dust
PETKUS Technologie GmbH
Unique Advanced Manufacturing Technology No Weld Design Taper Locking Design Prevents Horizontal Movement
PETKUS Technologie GmbH
PETKUS Technologie GmbH
PETKUS Technologie GmbH PETKUS Unique Technology Design: “No Weld” PLC Controlled Gravity Table
PETKUS Technologie GmbH
Preventing Degradation Inside the Silo •
In Silo Conditions – Traditional Methods
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Effectiveness of Aeration Dependent on Ambient Conditions Fumigation has OH&S Risks & Requires Sealed Conditions Rotation can prevent grain heating, but uses energy, creates breakage and requires spare silo capacity
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Photos: GRDC Fact Sheet ‘Grain Storage’
PETKUS Technologie GmbH
Preventing Degradation Inside the Silo •
GRANIFIGOR™ Cooling Systems
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Reducing the Grain Temperature Forces Insects in to Diapause (hibernation) Cooling with Conditioned Air Prevents Mildew and the Mycotoxins that can follow Supported by PETKUS Worldwide
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PETKUS Technologie GmbH
GRANIFIGOR™ Cooling Systems Example: Grain at 14.5% Moisture o o
Grain Temp 24°°C – 64 Days Grain Temp 10°°C – 300 Days
Moisture Content
European Temperate Climate (Months)
Asian Tropical Climate (Months)
12 – 15
8 – 12
6–8
15 – 17
6 – 10
3–5
17 – 19
4–6
1–2
19 – 21
1–4
0.5 - 1
Primary Cooling in Europe to 10°°C Primary Cooling in Asia to 15°°C
PETKUS Technologie GmbH
GRANIFIGOR™ Cooling Systems Control Temperature – Control Insect Development
PETKUS Technologie GmbH
GRANIFIGOR™ Cooling Systems Operation:
PETKUS Technologie GmbH
One GRANIFIGOR™NMany Silos Cooling Each Silo Takes One Day, Stays Cool for 2 – 3 Months Even in Thailand!
PETKUS Technologie GmbH
One GRANIFIGOR™NMany Silos Cooling Each Silo Takes One Day, Stays Cool for 2 – 3 Months Even in Thailand!
PETKUS Technologie GmbH
Roeber OptoSelector OS900:
PETKUS Technologie GmbH
Key Points: •
Full Colour RGB Cameras
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Simultaneous Shape (Geometric) Recognition as Standard
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Sealed Optical Boxes
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Service Parts (Ejectors/Circuit Breakers, etc) in Separate Rear Cabinet
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LED Product Illumination and Active Backgrounds
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Focused Double Nozzle Ejectors
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TeachNSort Self-Learning Software
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Understand and Keep the Good – Reject the Rest
PETKUS Technologie GmbH Full Colour Cameras: •
4096 pixel full RGB Cameras •
‘Sees like the human eye’
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Real material images displayed
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Real material images used for sorting parameters and accept decision
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Intensive LED lighting ensures wide focus range (depth of field)
PETKUS Technologie GmbH Shape (Geometric) Recognition : •
Parameters •
Area
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Length
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Width
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Stretch
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Compactness
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Symmetry
PETKUS Technologie GmbH TeachNSort Software: •
Individual Grains are Displayed and Recognised
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Different Principle – Recognise the GOOD – Reject the UNKOWN
PETKUS Technologie GmbH Roeber OptoSelector OS900: •
Top Level Sorting Technology Combining Full Colour RGB and Shape
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Specialist Applications: •
DON Reduction
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Purple/White Wheat Separation for Snack Foods
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Extensive Seed Uses…wheat, maize, paddy, pulses, beans, etc
.....and much more to come
PETKUS Technologie GmbH Innovations in Grain Preparation for Milling: •
Site Planning
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Delivery Systems
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Preparing Grain for Storage
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Storage Methods
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Preservation Whilst in Storage
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New Cleaning Technology
Provide the ‘Asian Century’ Miller the Healthiest Raw Materials to Minimise Grain Spoilage and Maximise Profits
PETKUS Technologie GmbH PETKUS & MMW: •
German Innovation
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German Technology
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German Engineering
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Local Customer Service