Digital Re-print March | April 2013

Steaming ahead
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 2013 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

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Leave nothing to chance. With WinCos Care, the Service Management System of Bhler, you will put your maintenance work in order. The system, which is customized by Bhler to precisely fit the specific needs of your production system, takes charge of the entire planning and administration of all your maintenance jobs. This ensures efficient processes and maximum plant uptime.

Bhler AG, Grain Processing Customer Service, CH-9240 Uzwil, Switzerland, T +41 71 955 30 40, service.gp@buhlergroup.com, www.buhlergroup.com

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Maximum uptime: Prefabricated job cards are based on service hours or calendar intervals as well as individual job planning. Plug & Play: Efficient processes and customerspecifically programmed software for all plants. Always up to the minute: Automatic online updates and data backup. All in one system: Extensive documentation, among other things for certifications (e.g. International Food Standard).

Innovations for a better world.

FEATURE

STEAMING AHEAD
by Thomas Stuecken, chairman, Osprey Deepclean, UK
ygiene and food safety of raw materials and end products are vital in the grain and feed milling industry. Millers take great care to ensure processes meet all legislative and food safety requirements. At the same time, consumers expect food to be safe and are increasingly taking an interest in how their food is produced. Cutting corners in the area of food safety can have a serious impact on business. Grain and feed products in mills are at risk of being contaminated by foreign material, insects, microbes and vertebrate pests. In addition to high hygiene standards, effective sanitisa-

tion reduces the risk of fine organic dusts accumulating on ledges and crevices, which could result in damage from a fire or dust explosion. Food and site safety concerns, coupled with high costs for energy, water and wastewater treatment are motivating the requirement for hygiene systems that do not employ chemicals and that can save on large amounts of water. Just as steam power became the fuel that drove the Industrial Revolution dry steam technology is the latest development playing an increasingly important role in driving trends in 21st century industrial cleaning.

Innovative cleaning using minimal water

Compliance and stringent auditing requirements, combined with pressure of time constraints and cost concerns, means millers are looking for a hygiene system that can save money and work quickly, while being extremely effective. OspreyDeepclean and its sister manufacturer, OSPREYFRANK have developed an innovative dry steam technology system which uses less water than traditional cleaning-in-place (CIP) methods. The new technology meets the challenges of cleaning in environments such as dry food areas, where water systems cant be used or where there

10 | march - april 2013

Grain

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FEATURE is sensitive machinery, motors or anything electric and adversely affected by water. The technology, which is the first of its kind in the UK, uses a continuous flow heating coil system to heat water to such a high degree that it becomes extremely hot vapour. The emitted dry steam contains minimal moisture and efficient cleaning capability is produced from the steam pressure made on the surface area. As well as being applicable to a wide range of work settings, steam can be used to undertake innumerable cleaning tasks. The system can be used on feeding, mixing and blending vessels, machinery, conveyor belts, rollers, pipelines and also general floor areas, storage spaces and much more. As it is applied to the surface, dry steam leaves very little residue and can almost touch dry, especially when compared includes the fully auditable dry steam belt sanitation unit (BSU) which cleans conveyor belts to allergen level, saving up to 3 million litres of water per annum. The organisation has also developed a central steam system for food production and packaging areas. This is much like a central vacuum, which facilitates cleaning by simply plugging the steam hoses into central steam pipes without the need for handling cleaning machines. The sophisticated equipment can be used for the cleaning of heavy parts and for plastic parts cleaning. The machines start from a 3kW single phase unit and reach up to 144kW units available in electric, oil or gas heated coils.

Is all steam cleaning the same?

So steam is simply steam? Well actually, no. Steam can be produced in a range of different grades, each matching different industry applications. Picking the cleaning method best suited to your operation depends upon a number of options including the nature of the surface to be cleaned and the type of material or residue found on crushing or milling apparatus, conveyors and elevator pits and silos. To date, conventional CIP systems have tended to rely on traditional boiler systems which are only required to heat the water to a maximum of 75 degrees and rely on high water flow and minimal pressure, using a lot of water in the process. Most food related sites use hot water that comes off the boiler through hoses, using foamers, liquid chemicals and other sanitation agents. They can use between 200-1,000 litres of water per hour to blast a surface clean. They can also have the negative side effect of sending dangerous bacteria airborne, spreading them through the plant without killing them. This wet steam system does not use a vapour process.

Benefits of dry steam cleaning

Efficient cleaning capacity is produced from the steam pressure made on the surface to be cleaned and the solvent power of micro drops at a high temperature, with minimal moisture present. The continuous steam system provides constant steam quality which can be adjusted by volume and dryness. Water flow and heating power can be controlled and adapted by an electronic control system. The amount of water saved depends upon the flow rate of the water system and the pressure employed, but it can save up to 90 percent of water used. OspreyDeepcleans dry steam technology will typically use between 10-30 litres of water per hour, whereas a conventional system will use between 2001,000 litres per hour. Conventional cleaning leaves the risk of potentially dangerous residues contaminating food and raw materials. Then you also have the issue of getting into difficult spaces, such as tight crevices in storage areas or complex shaped equipment. Dry steam sanitises surfaces, penetrating cracks, crevices and other hard-to-reach areas where manual and traditional cleaning methods, which mainly rely on potentially hazardous chemicals, fail to achieve the required standards.
Grain

to any other cleaning method. No additional ingredients are required in the steam to improve cleaning power, as efficient cleaning capacity is produced from the steam pressure made on the surface to be cleaned and the solvent power of micro drops at a high temperature, with minimal moisture present. However, where specific tasks or locations demand it, ingredients can be added to improve the solidification of specific substances, for instance within liquid fat application devices which could congeal without the use of additional ingredients.

Dry steam machines for different applications

The technology Osprey Deepclean has developed is available in a range of dry steam machines for different applications, based on many years experience of creating bespoke steam solutions. This
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FEATURE

Electrical cabinet

Steam generators

This fully integrated system permits the whole cleaning process to become auditable using sophisticated PC software.

Training
Modern milling machinery is more efficient and faster than ever and is one of

the key investments a company makes. Given the significant sums of money for new machinery and the damage defective products can do, it pays to ensure staff are trained and confident to operating necessary equipment. Any new sanitation process will require

training with regards to correct usage. The new dry steam technology can be adjusted by volume and dryness to provide a constant steam quality, which can be easily managed and adapted by an electronic control system. Osprey Deepcleans technology is available in a range of dry steam machines for different applications. Training is required, so the various accessories can be used effectively to safely remove micro-organisms and bacteria. Due to the ease of use, industrial steam cleaners translate to labour savings as well. Running costs are reduced because the steam can reach the most inaccessible spots, avoiding repeated dismantling during maintenance and upkeep operations, which can halve time taken. This new boiler free technology is at the forefront of water saving science. Energy, water, and waste costs are kept to a minimum, reducing operating costs and overheads and therefore increasing turnover and profit. Thanks to its sanitising properties, environmental edge and extreme versatility for all settings and cleaning tasks, dry steam cleaning is most definitely here to stay. More inforMation:
Tel: +44 1242 513123 Email: info@ospreydc.com Website: www.ospreydc.com

12 | march - april 2013

Grain

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This digital Re-print is part of the March | April 2013 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.
March - April 2013

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In this issue:
Measures for increasing the energy efficiency of UFA feed mills in Switzerland Importance of trace minerals for nutrient stability in feed Managing mill maintenance - Maintenance
options and challenges

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Additives for flour standardisation

Part I: Enzymes

Fine grinding and BS3 Xylanase improve productivity in weaners

Super chilled grains

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