managing mill maintenance - roller mill maintenance

7/28/2019 Managing mill maintenance - Roller mill maintenance

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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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managing mill maintenance - roller mill maintenance

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