Innovations in Grain Preparation for Milling

PETKUS Technologie GmbH Innovations in Grain Preparation for Milling Roger Cook Senior Technical Specialist Strong Seed. Healthy Grain. PETKUS. PE...
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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 • •



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



Simultaneous Shape (Geometric) Recognition as Standard



Sealed Optical Boxes



Service Parts (Ejectors/Circuit Breakers, etc) in Separate Rear Cabinet



LED Product Illumination and Active Backgrounds



Focused Double Nozzle Ejectors



TeachNSort Self-Learning Software



Understand and Keep the Good – Reject the Rest

PETKUS Technologie GmbH Full Colour Cameras: •

4096 pixel full RGB Cameras •

‘Sees like the human eye’



Real material images displayed



Real material images used for sorting parameters and accept decision



Intensive LED lighting ensures wide focus range (depth of field)

PETKUS Technologie GmbH Shape (Geometric) Recognition : •

Parameters •

Area



Length



Width



Stretch



Compactness



Symmetry

PETKUS Technologie GmbH TeachNSort Software: •

Individual Grains are Displayed and Recognised



Different Principle – Recognise the GOOD – Reject the UNKOWN

PETKUS Technologie GmbH Roeber OptoSelector OS900: •

Top Level Sorting Technology Combining Full Colour RGB and Shape



Specialist Applications: •

DON Reduction



Purple/White Wheat Separation for Snack Foods



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



Delivery Systems



Preparing Grain for Storage



Storage Methods



Preservation Whilst in Storage



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



German Technology



German Engineering



Local Customer Service