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Digital Re-print -May | June 2013
Managing mill maintenance- Roller mill maintenance
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Managing mill
maintenanceRoller mill maintenanceby Alice Neal, associate editor, Grain and Feed Milling
Technology, United Kingdom
Akey concern for all millers is getting
maximum life and efficiency out
of equipment while maintaining a
high standard of product. Roller mills play
a key part in the milling process and have
a direct influence on subsequent process-es and eventually on the yield and quality
of the end product. Roller mills are a very
flexible piece of equipment as they can
perform a variety of tasks, be it crumbling
pellets, cracking, flaking grain or grinding.
They can also handle many different
products including corn, wheat, soybean,
pellets, and canola. However, despite the
diverse range of applications, the operation
and maintenance of roller mills general-
ly follows a standard procedure.
The manufacturing processThe main wear parts in roller mills are
the rolls. They are set up in pairs and one
machine can contain different numbers of
rolls depending on the application.
A high-quality roll represents real value
for a miller. A good roll will produce a
consistent product and help minimise costly
plant downtime and maintenance efforts.
Getting the maximum life and efficiency
out of a roller starts with the choice of metal.
A popular option is a two-component
chilled iron compound roll with a cast
iron inner core with a harder, chilled iron
outer layer. These rolls are typically made
by centrifugal casting. In this process, a
hard-metal alloy is fed into a die that spins
at high speed. Then the softer gray iron is
added. This technique produces rolls with
a high density and homogeneity which arecrucial for high wear and resistance. The
centrifugal process forces impurities up to
the surface of the roll during manufactur-
ing. Any impurities can be easily removed
before the roll is finished. These features
mean that centrifugal cast rolls last longer
than static cast rolls.
Another option is titanium, these rolls are
harder and more resistant to abrasions than
other materials. Titanium rolls are usually
made of cast iron with steel added as an
alloying element to increase strength and
wear resistance.
Flexibility in designMost manufacturers offer different rolls
of different hardnesses depending on the
application. The hardness is important: too
hard and the roll will lose its grip on the
product; too soft and the rolls will wear out
more easily.
Just as there are material choices to consider,
there are other areas of roller design which can
be altered depending on the application. All of
these will have an effect on wear and lifetime.
Longer rolls will last longer than a shorter
roll handling the same volume of material.
Similarly, rolls with a bigger diameter will
have a longer working life.
The flutes or corrugations will also affect
roll expectancy. Coarse flutes will last longerbut will produce a chunkier end product
whereas fine flutes, which produce a finer
end product, will need refurbishment sooner.
Effective operatingThe life expectancy of a roll depends
on several variables. First, the products
put through the machine will have an
impact on the wear. Large and hard
products such as canola or rapeseed will
pose more of a challenge to the roller
mill than smaller, softer materials such as
corn or wheat.
Cleanliness of the raw materials is also
a key consideration. Stones or tramp metal
can get stuck in the flutes, causing uneven
wear.
In addition, higher volumes of product
will make a roller mill work harder and rolls
will therefore wear out faster. No matter
how much product a roller mill has to
handle, it is important to ensure an even
flow of material through the machine as
inconsistent feeding will lead to one part of
the roll wearing at a disproportionate rate.
ImagecourtesyofUgurMakina
Gri&fd milliG tcholoG44 | may - June 2013
FEATURE
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Maintenance case study
Satisfying highest demands withTITAN rollsBhlers FERAN rolls have proven their
worth in the milling industry worldwide
over the last decades. They build the basis
of the milling roll portfolio.
Within the past years a need for evenlonger living rolls has been emerging. To
satisfy this need Bhlers casting experts
have conducted extensive research
efforts based on their long lasting expe-
rience. They came up with a further
developed mixing ratio between the
hard and the soft iron components
in the chilled iron alloy based on a
new metallurgical recipe.
Especially for corrugated rolls that are
subjected to particularly high stressing
TITAN rolls offer great value: they
considerably minimize the main-tenance costs and the undesired
downtime in the grinding process.
This is due to an increase of 30
percent and more in service life
compared to Bhlers standard FERAN
roll. It is obvious that this leads to a higher
availability of the milling plant since less
roll changes are required. Therefore main-
tenance costs are significantly reduced.
Apart from that the cost of working
capital decreases since less rolls need to
be stocked. Additionally and nowadays
more and more important in the milling
industry energy costs are reduced thanks
to the lasting sharpness of the corrugation.
Summing up, TITAN rolls stand for lowest
total cost of ownership for the miller.
The value that was added by TITAN rolls has
been proven in numerous milling companies
all over the world. We are very satisfied with
the TITAN rolls. Their service life is 60 percent
longer compared to local rolls, confirms a
Japanese flour milling company who stands
representatively for the large number of TITAN
roll users. Because of their high durability the
TITAN rolls are also very much appreciated by
the oilseed processing and ethanol industry.
MoreinforMation:
www.Bhlergroup.com
Installing a hopper between the conveyor or
elevator will stop surges in material entering
the roller mill.
Taking time over roller setup will pay
dividends in terms of roller life. The key
considerations are making sure the rolls
are parallel and level in relation to each
other.
Top rolls will wear quicker than bottom
rolls so switching top and bottom rolls will
ensure that the set wears evenly. This is
a good move, as it is more convenient to
replace a full set of rolls than pairs and will
result in less downtime.
Recorrugation/reflutingRolls can be refluted (or recorrugated)
when they are worn out. Manufacturers will
be able to provide the best advice but once
again there are roll-specific factors to take
into consideration.
Rolls with larger diameters can also be
refurbished a greater number of times than
a roll with a smaller diameter. Rolls with fine
flutes are ground smooth before refluting
while rolls with coarse corrugations can be
refluted using the exisiting flutes as a guide.
However, deeper corrugations will limit the
number of times a roll can be refurbished.
Other factors to considerBearings need regular greasing and this
task should be built into a maintenance
schedule. Drives, especially belt drives need
to be aligned, properly tensioned, and the
load limitations need to be adhered to.
ImagescourtseyofBhlerAG
Gri&fd milliG tcholoG may - June 2013 | 45
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