SIZE REDUCTION

PROCEDURE SIZE REDUCTION

 Cutting: reduce material size using a sharp tool on one

side. The results is to get uniform cut and minimal
damage.
 Crushing: Grinding: reduce material size by emphasizing
the blunt object to the materials so its broken to all
direction with irregular shape. The level of damage to
the materials is high.
 Shearing: reduce material size with a tool that has sharp
edge on one side and blunt side in other side. This
procedure is a combination of cutting and crushing.
HAMMER MILL
 Is the machine to grind materials into smaller parts.
Some industries that use a hammer mill :
 Ethanol industries (corn grinder)
 A farm machine, which mills grain into coarse flour to
be fed to livestock
 Fluff pulp industries
 Fruit juice industries
 Shredding paper
 Shredding yard and garden waste for composting
 Crushing large rocks
 Hammer mill is basically a drum or cylinder with
vertical or horizontal knives or hammers that
mounted in drums or cylinders. The hammers
are free to swing on the ends of the cross, or
fixed to the central rotor. The rotor is spun at a
high speed inside the drum while material is fed
into a feed hopper. The materials will be milled
or cut by hammer and materials that were
smaller than the filter under the drum will come
out of the machine.
SIZE REDUCTION TOOLS

 Hammer mill :
 The parts hammer mill: hopper, hammer, walls, and
filter.
 Mechanism :
• The milled material is inserted into the mill through
a hopper
• Materials that enter mill will hit by rotating hammer.
Materials will have impact from hammer and wall so
it will destroyed. The smaller materials than
filter/sieve holes will going out and the larger will
continue to impact the hammer and wall.
• Materials will be exposed to a hammer randomly,
either head or handle of a hammer so that fractions
of material size is not uniform.
 Hammer mills work on the principle that most
materials will crush, shatter, or pulverize upon
impact using a simple four step operation:
 Material is fed into the mill’s chamber typically
by gravity.
 The material is struck by ganged hammers
(generally rectangular pieces of hardened steel)
which are attached to a shaft which rotates at a
high speed inside the chamber.
 The material is crushed or shattered by the
repeated hammer impacts, collisions with the
walls of the grinding chamber as well as particle
on particle impacts.
 Perforated metal screens, or bar grates covering
the discharge opening of the mill retain coarse
materials for further grinding while allowing
properly sized materials to pass as finished
product.
 Hard, heavy materials such as glass, stone or
metals exit the mill via gravity. Pneumatic
suction us used to assist in the discharge of
lighter materials such as wood, paper or
other low bulk density products
 Advantages of hammer mill :
▪ Easy to install and to operate
▪ Not broken when operating empty
▪ Not over increase the material temperature
▪ Maintenance costs are relatively cheaper
▪ Low power
 Disadvantages of hammer mill :
▪ Investment costs are relatively high
▪ The results are not uniform
 The hammermill can be used as a primary,
secondary, or tertiary crusher.
 Small grain hammermills can be operated on
household current. Large automobile shredders
can use one or more 2000 horsepower (1.5
MW) diesel engines to power the hammermill.
 The Screenless hammer mill uses air flow to
separate small particles from larger ones. It is
designed to be more reliable, and is also
claimed to be much cheaper and more energy
efficient than regular hammermills.
BURR MILL
A burr mill or burr grinder is a device to grind
hard, small food products between two revolving
abrasive surfaces separated by a distance
usually set by the user.
 When the distance is larger, the resulting
ground material is coarser. When the two
surfaces are set closer together, the resulting
ground material is finer and smaller. Usually the
device includes a revolving screw that pushes
the food through. It may be powered electrically
or manually.
 Devices with rapidly rotating blades which chop
repeatedly (see food processor) are often
described as grinders, but are not burr grinders.
Burr mills do not heat the ground product by
friction as much as blade grinders, and produce
particles of a uniform size determined by the
separation between the grinding surfaces.
 Food burr mills are usually manufactured for a
single purpose: coffee beans, dried
peppercorns, coarse salt, spices, or poppy
seeds, for example. Coffee mills are usually
powered by electric motors; domestic pepper,
salt, and spice mills, used to sprinkle a little
seasoning on food, are usually operated
manually, sometimes by a battery-powered
motor.
 Burr mill :
 The part of burr mill: hopper, cylinder, wall plate
 Mechanism : the material get into hopper which
then enter into the gap between the cylinder and
the wall plate . Materials will be milled and screw
over into unloading.
• Advantages of burr mill :
▪ The results are more uniform
▪ Investment costs are cheaper
  Disadvantages of Burr Mill::
▪ Thermal effects on materials
▪ If empty operation, the cylinder will wear out/broken
▪ Required skilled operator to adjust the distance between
cylinder and wall
▪ Require relatively high energy
▪ Standard of smoothness and uniformity
▪ Smoothness and uniformity are measured by the
modulus of smoothness and uniformity index
 Sieve Retained Percentage of Multiple
number Material (g) Retained Percentage of
Material Retained Material
and Sieve number
7 20 20 140
6 30 30 180
5 15 15 75
4 10 10 40
3 10 10 30
2 10 10 20
1 5 5 5
Pan 0 0 0
Total 100 100 490
 Smoothness modulus (MK): 490/100: 4.9
 If all the material retained in pan, so MK = 0 means
a very smooth
 If all the material retained on sieve No. 7, so MK = 7
means very rough.
 MK = 4.9 means rough

 Uniformity index (IK):

 Sieve 5-7: roughly categorized
 Sieve 3-4: rather rough categorized
 Sieve 1, 2, and pans : smooth categorized
 From the table above showed that IK results are:
65: 20: 15 or 6.5: 2.0: 1.5
RICE MILLING

 History:
 The first rice mill in England about 140 years ago
 Modern rice milling machine 35 years later in
Japan
 Modern rice milling 40 years later
 Primary Technical Criteria:
 Produce maximum head rice yield
 Rice husker uniformly so rice color according to desired

 Secondary Technical Criteria:

 Maximum milling capacity
 Minimal energy consumption
 Lower consumable parts
 Productivity of operator maximum
THE POTENTIAL OF MILLED GRAIN (YIELD)

Potential milled grain is determined by:

 Characteristic of varieties :
 Percent husk: 17-24% of the grains
 Grain shape (ratio of length and width). Slender grain
is easily broken than round grain.
 Hardness degree: Hardness of rice is varieties
characteristic. Rice that has a hard layer tends to
produce the high quality and yield.
 Calcification: can be a characteristic of the variety or
because of the environment. Calcification effect on
yield and quality.
 Grain Quality :
 Moisture content: The optimum moisture content of grain
for milling is 14%
 Percent of empty grains: standard <3%
 Cracked grains: Late harvest or too mature grains cause
cracking. This will result in a lower yield of milled rice and
head rice.
 Green grains: immature green grain and when it milled
tends to be small, green, calcify and will give broken or
destroyed rice .
 Yellow grains and damage grains: yellow grains occur
because it can not be dried. Damaged grain generally
occur because fungus attack. Often produce rice with
black spots.
MAIN MACHINES

 Mechanical Cleaning Machine:

 to remove impurities: pieces of rice straw, dust,
stone, metal, glass, insect .
 Paddy Cleaner . Tool consists of a filter/sieve and
an aspirator. Material moves down across the
screen because filter is installed sloping. The
larger impurities are filtered out in the first filter,
while the smaller than grain will be filtered in the
filter after the grain. The lighter impurities than
grain will be separated with aspirator.
 Distoner. Separates grains from stone, clay,
glass, or heavier objects. Distoner is gravity
separator. Heavy objects (dirt) flow to the top of
the slope, while the grain tends to bottom.
Objects that have higher density than grain will
separate with different flow directions.
 Precleaning
▪ Precleaning machine is responsible for cleanup of dust
that can be cause problems at mill
▪ In small mills used Distoner (gravity separator)
▪ At the big mill or all types miller made ​in Japan coupled
with aspirator and precleaning machine that separates
empty grain and green grain.
Doble Action Rough Rice Cleaning Machine
Type of Engelberg
PADDY HULLER/HUSKER

 Grain enter into gap between the two rubber roll that rotate
with different speeds and inopposite directions.
 Friction and pressure of the two rubber roll will release
brown rice (PK) from the husk, and will be mixed after going
through the roller gap.
 Furthermore, a mixture of brown rice and husk enter into
aspirator. In aspirator, a mixture of brown rice and husk will
pass through a thin layer and fall into column with flow and
arranged air .
 Furthermore, husk blown out and separate with brown rice.
 The factors that determine Efficiency of the
Brown Rice Milling :
 Grain moisture content, generally too wet causing
no peeling grain
 The uniformity of incoming grain into rubber roll
husker.
 Ratio of Two rubber roll speed : lower the
difference rotational speed between the two roll
causes low efficiency of milling.
 Pressure between two rubber roll. Higher pressure
make more grain peeling, but will cause a broken
rice and roll wear faster.
 The uniformity of incoming grain to aspirator.