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Digital Re-print - May | June 2011 Energy-efficient and cost-saving innovations for cereal processing Grain
Digital Re-print - May | June 2011 Energy-efficient and cost-saving innovations for cereal processing Grain
Digital Re-print - May | June 2011 Energy-efficient and cost-saving innovations for cereal processing Grain

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

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FEATURE

Energy-efficient and cost-saving

innovations for cereal

Energy-efficient and cost-saving innovations for cereal processing Vibronet ® - The Revolution for all tempering

processing

and cost-saving innovations for cereal processing Vibronet ® - The Revolution for all tempering processes R
and cost-saving innovations for cereal processing Vibronet ® - The Revolution for all tempering processes R
and cost-saving innovations for cereal processing Vibronet ® - The Revolution for all tempering processes R
and cost-saving innovations for cereal processing Vibronet ® - The Revolution for all tempering processes R
and cost-saving innovations for cereal processing Vibronet ® - The Revolution for all tempering processes R

Vibronet ® - The Revolution for all tempering processes

Vibronet ® - The Revolution for all tempering processes R esearch for tion and development and
Vibronet ® - The Revolution for all tempering processes R esearch for tion and development and

R

esearch

for

tion

and

development

and

pulse prepara-

processing

the optimum moisture content in the raw

material by as little as one percent results in

a less optimal product and higher manufac- turing cost. For example, optimising starch gelati-

nisation during heat processing is difficult without the accurate moisture content. Therefore, precise moisture management

is required to maximise operation profit-

ability, end product quality and thus eco- nomic 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 sys- tem accelerates water absorption and leads to a full cereal or pulse kernel damp- ening in two to 10 hours compared to the six to 48 hours required with conventional systems.

cereal

and

are

elementary building blocks ensuring

the success of the German company vibronet ® Gräf GmbH & Co KG.

With its patented vibration damping sys- tem, 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 proc- ess, which has not seen a lot of innovation during the past decades. Moisture control though is a critical ele- ment as water is money in fluid form. To manufacture perfect end products there is just one optimum moisture level. Varying

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.

22 | may - June 2011

Grain & feed millinG technoloGy

However, to eliminate the water surface tension with energy, a multiple of the accel- eration 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.

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 trans- port the dampening water faster in direction of the endosperm. After final studies, the Federal Institute of

FEATURE

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 homo- geneous 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 per- meability, transport and reaction conditions

in changed per- meability, transport and reaction conditions w w w . s y m a
in changed per- meability, transport and reaction conditions w w w . s y m a
w w w . s y m a g a . c o m "Over
w w w . s y m a g a . c o m
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Grain & feed millinG technoloGy

may - June 2011 | 23

FEATURE

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 pro- duced 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 temper- ing time, which is optimised for the grain variety or grain mixture used. Through vibration dampening, coarser

or grain mixture used. Through vibration dampening, coarser 24 | may - June 2011 bran is

24 | may - June 2011

bran is obtained during the first grinding proc- ess, which originates from the uniform distri- bution 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 pro- duction plant in grain processing has unused

potentials for cost savings and increasing profit, hygiene and flexibility. vibronet Gräf’s 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.

Continuing the revolution

The patented vibration dampening tech- nology has now been entirely redesigned for maximum profit and exceptional perform- ance. 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 cus- tomer’s 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 prepara- tion 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

More inforMation:

Sylvia-C. Gräf vibronet Gräf GmbH & Co. KG Neumühle 1 - 35633 Lahnau Germany

Tel: +49 6441 62031 Fax: +49 6441 62715 Email: info@vibronet.com Website: www.vibronet.com

Grain & feed millinG technoloGy

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LINKS This digital Re-print is part of the May | June 2011 edition of Grain

LINKS

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May 2011 • Choosing the right Hazard Monitoring System In this issue: • Conditioning •
May
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