Digital Re-print - May | June 2011

Energy-efficient and cost-saving innovations for cereal processing

Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

www.gfmt.co.uk

NEXT PAGE

FEATURE

FEATURE

However, to eliminate the water surface tension with energy, a multiple of the acceleration of gravity (g) is needed. Therefore, experiments continued and trials were made with a standard concrete vibrator as used in the construction industry. After inserting this vibrator several times into a grain-water mixture, there was no more free water on the surface after 30 minutes. A concrete vibrator runs with about 10,000rpm, which means that the energy input corresponds to a multiple of the gravity g. Finally the right solution was found. The first vibration dampener was developed and tested in daily operation in a 120 tonnes per day flour mill. With this patented dampening process temper time could be reduced to two to 10 hours only.

Research
There are various explanations as to why vibration dampening reduces tempering time: Vibration energy changes the molecular structure of water. It eliminates the surface tension of the water. A water film surrounds the entire kernel and penetrates evenly through the entire hull into the endosperm. For the first time tempering water can enter also through the crease of the cereal kernel. The cereal crease roughly covers 1/6 of the entire kernel surface.

Energy-efficient and cost-saving innovations for cereal processing

Vibronet - The Revolution for all tempering processes

Vibration energy opens up and cleans all capillaries, tube cells and openings which are otherwise closed by dust, so that the water can penetrate easily. As the tube and the longitudinal cells of the kernel are filled with air, they work like a membrane pump, through which the water is pumped in during vibration. Vibration energy activates the minerals situated in the grain hull so that they transport the dampening water faster in direction of the endosperm. After final studies, the Federal Institute of

Grain Research in Detmold, Germany, has come to the following conclusions: >> Based on theoretical findings and practical investigations, vibration treatment can be regarded as a process with the help of which homogeneous and accelerated water absorption and penetration in cereal grain can be achieved. The vibration effect can be compared with an intensive agitating effect in the initial phase of hydration, which results in changed permeability, transport and reaction conditions

esearch and development for cereal and pulse preparation and processing are elementary building blocks ensuring the success of the German company vibronet Grf GmbH & Co KG. With its patented vibration damping system, vibronet has been a pioneer in the field of research for dramatically reduced temper times and simpler production processes since 1990.

How can water penetrate quicker into a kernel so that the long temper time and the large amount of space such as temper bins, can be reduced?
Water management in cereal and grain conditioning has long been a neglected process, which has not seen a lot of innovation during the past decades. Moisture control though is a critical element as water is money in fluid form. To manufacture perfect end products there is just one optimum moisture level. Varying
22 | may - June 2011

the optimum moisture content in the raw material by as little as one percent results in a less optimal product and higher manufacturing cost. For example, optimising starch gelatinisation during heat processing is difficult without the accurate moisture content. Therefore, precise moisture management is required to maximise operation profitability, end product quality and thus economic return. Thinking out of the box and looking into the production process is what made MSc Engineer and Master Miller Dieter Otto Graef invent the vibronet vibration dampener in 1986 in his own flour mill in Germany. It was the first system to revolutionise how fluids can be added faster and more economic to cereals and pulses. The system accelerates water absorption and leads to a full cereal or pulse kernel dampening in two to 10 hours compared to the six to 48 hours required with conventional systems.

The development
It all started with the question: How can water penetrate quicker into a kernel so that the long temper time and the large amount of space such as temper bins, can be reduced? Speeding up the process of conditioning grain is especially important in countries with very dry grain, where a high percentage of water has to be added prior to the grinding process. This search brought up the idea of removing the surface tension of tempering water. Water could then surround the entire kernel as a water film and penetrate equally into the cereal through the hull and not only through the germ, as with conventional dampening systems. When observing a drop of water on a glass plate, the water particle forms a round ball due to surface tension. It is generally known that the surface tension of water can be eliminated with, for example, dishwashing detergent. However, for the purposes of producing food and feed this method cannot be used. During first experiments, a mixture of grain and water which were stirred lightly by hand, were dropped on a baffle plate from a height of about 30 meters. The results proved that water penetrates faster if the surface tension is eliminated through the application of a high accelerating force.
Grain

symaga_quarter page_IAFD2011

13/5/11

10:09

Page 1

www.symaga.com

"Over 20 years of experience in the design, construction and supply of storage solutions, worldwide"

ALL TYPES OF SILOS INSTALLATIONS TO COVER THE MARKET NEEDS

Silos for seeds, cereals, malts, oil seeds (soya, sunflower, rape, ...), pellets, meals, rices, and in general, products for agriculture, agrifood industry, biofuels, and biomass (wood pellets, ...) Ctra. De Arenas, km 2,300, 13210 Villarta de San Juan. Cludad Real - Espana www.symaga.com antonio.benitez@symaga.com Phone: +34 91 726 43 04/ +34 926 64 04 75 Fax: +34 91 361 15 94/ +34 926 64 02 94

&feed millinG technoloGy

Grain

&feed millinG technoloGy

may - June 2011 | 23

FEATURE

News

May - June 2011

NEWS

Cal-BMS-KSL to be renamedMeasures MoistureTechnologies Cultura & Reduces Cost

ive Agri-Food software businesses within t h e Vo l a r i s G r o u p adopt global brand to

The Hydro-Probe II Moisture Sensor

strengthen geographic reach and e x pe r t ise of fe red t o companies in the agriculture and food industry.

Merger of ESM (UK) Ltd and Satake Europe Ltd

S
causing a quicker and better penetration of the water into the cereal. The influence of vibration tempering on the moisture content in flour reaches values after around six hours which are equal to those achieved after standard preparation of approximately 24 hours. Easily milled wheat with softer structure can be milled after only one hour of tempering after vibration dampening. There was no change seen in mineral content and colour << Statements from various millers around the world confirm these findings. Not only are lighter coloured flours produced but the vibration dampening increases total flour yield by 0.5 1.0 percent. This is due to the fact that vibronet brings the dampening water also into the crease of each kernel which represents 1/6 of the entire grain surface. Prerequisite is a tempering time, which is optimised for the grain variety or grain mixture used. Through vibration dampening, coarser bran is obtained during the first grinding process, which originates from the uniform distribution of water on the surface of the grain. Especially when milling Durum wheat, higher yields in middling and semolina are achieved, as the water enters the wheat kernel over its entire surface and not as with conventional dampening systems mostly through the germ. In summary, it can be said that every production plant in grain processing has unused potentials for cost savings and increasing profit, hygiene and flexibility. vibronet Grfs patented cereal damping system creates such a savings potential. Compared to conventional damping systems: - vibronet reduces temper time to a minimum: The vibration dampener drastically reduces temper time by more than half of the time needed by conventional systems. - vibronet reduces energy cost: A vibration dampener uses half the energy only of an intensive dampener, that is 0.2kW/tonne/hour. - vibronet reduces operating cost: A vibration dampener cuts service and maintenance cost by 80 percent and has due to few mechanic parts minimum wear and tear. - vibronet reduces silo space and machine park: Due to the drastically reduced temper time, a vibration dampener reduces silo bin space as well as the associated transport and conveying elements. - vibronet guarantees hygienic end products: The self-cleaning vertical construction of the vibration dampener and the minimal temper times guarantee a drastic reduction of total bacteria count in the cereal and thus in the end product.

atake Corporation is pleased to announce the merger of its vision systems business trading as ESM (UK) Ltd and its cereal milling engineering business trading as Satake Europe Ltd into a single company. The name of ESM (UK) Ltd is now redundant and the newly combined businesses will trade under the name of Satake Europe Ltd. Satake Europe Ltd is a division of Satake USA Inc, a wholly owned subsidiary of the Satake Corporation, Japan.

Continuing the revolution

The patented vibration dampening technology has now been entirely redesigned for maximum profit and exceptional performance. The reduced built-in height fits even in the smallest spaces. Available capacities range from one to 40tph. Optimised vibration energy utilisation allows adding up to 12 percent dampening liquid in one single pass. A new redesigned precision water distribution system permits to add even the smallest amount of liquids. The process can be adapted to the customers demand: water, water soluble liquid, chlorine, or dressing agent. The vertical Clean-Design dampener drastically reduces temper time to two to 10 hours making use of 0.2kW/tph only. The minimum temper time guarantees lowest total bacteria count and maximum production process flexibility. The system offers energy-efficient preparation of an extensive choice of raw materials: Wheat, durum, rye, oats, barley, spelt, sorghum, corn, lentils, peas, beans, soybeans, seeds and seed care, cocoa beans, coffee beans, malt

Victam International 2011 saw the our commitment to product launch of Cultura Technologies. innovation creating long-term The newly named company brings value for customers, employees, together five leading Agri-Food and our owners, stated Jim Baker, software organisations: Cal president of Cultura Technologies. Software, BMS Computer Cultura is all about connecting Solutions and Kinross people and processes across the Software (KSL) of the United broader Agri-Food Kingdom, AGRIS Inc and supply chain, helping ExtendAg of the United States. to nurture Agri-Food Bringing together these advancement through companies and their strengths technology. Culturas further solidifies all that name has its roots in the Latin We are pleased to announce The Hydro-Probe II digital word agricultura which provides Cultura is. The organisation microwave moisture--sensor means this merger to all our accurate and customer moisture control in feed meals and believes in strong cost effective agriculture and cultivate which customers in Europe, Africa pellets, grain, cereal the relationships and thatand pulses: foster growth or development. and the Middle East as it will is to strength of itsand adjustand We are Cultura Technologies. We facilitate greater efficiencies Monitor people moisture levels in real time their expertise can costs during theAgri-Food solutions to life. within our business and as such Reduce energy make bring drying process the Reduce waste and improve quality difference in delivering will allow us to reflect such technology solutions that More inforMation: benefits when dealing with Suitable for bins, silos, conveyors and chutes enable Agri-Food businesses Meaghan Wilkinson, your requirements. to Not affected by dust or colour efficiently produce, Cultura Technologies, Should you have any process and deliver quality 5800 Explorer Drive, 5th questions or require further food and bio-products. clarification, please contact Floor, Mississauga, ON, With this rebrand to L4W 5K9, Canada a m e m b e r o f t h e S at a ke Cultura Technologies, management team or refer enquiries@hydronix.com Tel: +1 647 8012945 we aim to strengthen to the website www.satakeEmail: meaghan.wilkinwww.hydronix.comson@culturatech.com collaboration between europe.com Website: www.culturatech.com our global businesses and
may - June 2011 | 7
GFMT quarter page vertical 105 x 147 plus 3mm bleed.indd 1 21/04/2010 09:56:21

Grain

&feed millinG technoloGy

More

inforMation:

Sylvia-C. Grf vibronet Grf GmbH & Co. KG Neumhle 1 - 35633 Lahnau Germany
Tel: +49 6441 62031 Fax: +49 6441 62715 Email: info@vibronet.com Website: www.vibronet.com

24 | may - June 2011

Grain

&feed millinG technoloGy

Grain

&feed millinG technoloGy

may - June 2011 | 5

This digital Re-print is part of the May | June 2011 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on www.docstoc.com.

LINKS

May

2011

See the full issue

In this issue:
Synthesis of animal feed formulation techniques:

Choosing the right Hazard Monitoring System

Visit the GFMT website Contact the GFMT Team Subscribe to GFMT

Conditioning as part of the pelleting process

Linear and Non-Linear model

Pelleting:
The link between practice and engineering

Pellet production to save energy, improve feed efficiency and safety

A subscription magazine for the global flour & feed milling industries - first published in 1891

To purchase a paper copy of the magazine, or to subscribe to the paper edition please contact our Circulation and Subscriptions Manager on the link adove.

INFORMATION FOR ADVERTISERS - CLICK HERE

Article reprints
All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these have been used as point of sale materials, promotional materials for shows and exhibitions etc). If you are interested in getting this article re-printed please contact the GFMT team for more information on - Tel: +44 1242 267707 - Email: jamest@gfmt.co.uk or visit www.gfmt.co.uk/reprints

www.gfmt.co.uk

PREVIOUS PAGE