![Page 1: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/1.jpg)
1 | © Bühler |
Key factors to drive efficiency in a flour mill
IAOM-MEA
Rabih Al Halabi
![Page 2: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/2.jpg)
2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
Agenda.
1
2
3
High flour yield
Cost in operation
Making the best out of wheat
![Page 3: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/3.jpg)
3 | © Bühler |
Agenda.
1
2
3
High Flour Yield
Cost in Operation
Making the best of the Wheat
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 4: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/4.jpg)
4 | © Bühler |
Quality starts with the raw material.
Wheat is a natural product with quality
fluctuations
Wheat contains impurities
Wheat comes in different varieties
How can we get the best out of wheat?
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 5: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/5.jpg)
5 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
Accurate cleaning of wheat.SORTEX A Optical Sorter.
Higher sorting efficiency
Increased capacity up to 32 t/h
Consistent sorting performance
Higher sorting yield
Integration in plant automation and conformity with
ATEX and UL-CSA
![Page 6: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/6.jpg)
6 | © Bühler |
Setting new brenchmark in optical sorting.SORTEX A Optical Sorter.
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 7: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/7.jpg)
7 | © Bühler |
Dark sort defects.
deseased grain
foreign seeds
spot coloured defects
foreign grains (e.g. oats)
immature grain
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 8: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/8.jpg)
8 | © Bühler |
Light sort defects.
accept reject
unthreshed
grain
straw
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 9: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/9.jpg)
9 | © Bühler |
Flow sheet with colour sorter SORTEX with pre-tempering bin.
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 10: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/10.jpg)
10 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
SORTEX Business Case Investment Costs.Return on Investment.
Conventional
Mechanical Sorting
Innovative Optical
Sorting
Benefits Opitcal
Sorting
Wheat before
cleaning (t/y)80,000 t 80,000 t
Screenings 2.5% 1.7%Accurate
classification 0.8%
Wheat after cleaning 78,000 t 78,640 t 640 t more wheat
Savings of wheat
per year with optical
sorting
640 t x $ 185 t
= $ 118,400
Optical Sorting vs. Conventional Mechanical Sorting
based on European Wheat, Cleaning Cap. 12 t/h
![Page 11: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/11.jpg)
11 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
SORTEX Optical Sorter.
![Page 12: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/12.jpg)
12 | © Bühler |
Agenda.
1
2
3
High Flour Yield
Cost in Operation
Making the best of the Wheat
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 13: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/13.jpg)
13 | © Bühler |
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 1st and 2nd break
Specific grading system
Balanced roll length of C- Passages
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 14: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/14.jpg)
14 | © Bühler |
Flour quality in Premium Flour Flow.
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 15: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/15.jpg)
15 | © Bühler |
Solution: 8-Rollermill for 2Bk passage.
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
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 16: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/16.jpg)
16 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
Bühler plant impression.
![Page 17: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/17.jpg)
17 | © Bühler |
Agenda.
1
2
3
High Flour Yield
Cost in Operation
Making the best of the Wheat
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 18: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/18.jpg)
18 | © Bühler |
Raw material 75 - 82 %
Cost structure of a flour mill. Example of a European flour mill.
Capital cost: 4 - 8 %
Amortization ~4 %
Interest ~4 %
Profit ? - ? %
Production: 5 - 9 %
Energy 3 - 4 %
Staff 2 - 4 %
Maintenance ~1 %
Distribution: 3 - 6 %
Packing ~1 %
Transportation ~2 %
Staff ~2 %
Marketing ~1 %
75 - 82 %
5 - 9 % ? - ? %3 - 6 % 4 - 8 %
high flour yield
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 19: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/19.jpg)
19 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
Cost in operation.Energy Saving.
Optimum energy efficiency.
Reduction of running costs
Environmentally friendly production
Sustainable production
Profound advise
Excellent implementation
![Page 20: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/20.jpg)
20 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
Cost in operation.Energy Management.
Energy cost is constantly increasing
![Page 21: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/21.jpg)
21 | © Bühler |
Energy consumption measuring
PLC
Plant operating
Profibus-DP
Ethernet
WinCoS. Energy Management.Monitoring of energy consumption.
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 22: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/22.jpg)
22 | © Bühler |
Load controlled Drive Systems.Energy savings on high pressure fans.
Avoiding starter peak
Setting to optimal fan characteristic
High pressure fan with frequency converter
Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
![Page 23: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/23.jpg)
23 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
Bühler plant impression.
![Page 24: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/24.jpg)
24 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
Training and Education.Bühler Services.
Training Center Bühler
Uzwil / Switzerland
Swiss Milling School Bakery Innovation
Center
Bühler International
Courses in:
-Mechanical Maintenance
-Electrical Maintenance
-Milling Technology I & II
-Expert Milling
-Milling for Executives
Degree programm:
-Milling Technologist SMS
Broad education in milling
science, technology and
operation
Courses in:
-Baking Technology
-From Wheat to Bread
Training Center in:
-Bühler Switzerland
-Bühler South Africa
-Bühler China
-Bühler India
-Bühler USA
![Page 25: Key factors to drive efficiency in a flour mill · 2016-10-21 · 2 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011 Agenda. 1 2 3 High](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ec838bd1ad37b522a7eaf69/html5/thumbnails/25.jpg)
25 | © Bühler | Key factors to drive efficiency in a flour mill | Rabih Al Halabi | 04.10.2011
www.buhlergroup.com