Research and development for cereal and pulse preparation and processing are elementary building blocks ensuring the success of the German company vibronet® Gräf GmbH & Co KG.

1. Digital Re-print - May | June 2011
Energy-efficient and cost-saving innovations for cereal processing
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2. FEATURE FEATURE
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.
Vibration energy opens up and cleans all Grain Research in Detmold, Germany, has
Research capillaries, tube cells and openings which are come to the following conclusions:
There are various explanations as to why otherwise closed by dust, so that the water >>… Based on theoretical findings and
vibration dampening reduces tempering time: can penetrate easily. practical investigations, vibration treatment
Vibration energy changes the molecular As the tube and the longitudinal cells of can be regarded as a process
structure of water. It eliminates the surface the kernel are filled with air, they work like a with the help of which homo-
tension of the water. A water film surrounds membrane pump, through which the water geneous and accelerated water
Energy-efficient and cost-saving the entire kernel and penetrates evenly
through the entire hull into the endosperm.
For the first time tempering water can
is pumped in during vibration.
Vibration energy activates the minerals
situated in the grain hull so that they trans-
absorption and penetration in
cereal grain can be achieved.
The vibration effect can be compared with
innovations for cereal processing enter also through the crease of the cereal
kernel. The cereal crease roughly covers 1/6
of the entire kernel surface.
port the dampening water faster in direction
of the endosperm.
After final studies, the Federal Institute of
an intensive agitating effect in the initial phase
of hydration, which results in changed per-
meability, transport and reaction conditions
Vibronet - The Revolution for all tempering processes
®
R
esearch and development the optimum moisture content in the raw The development
for cereal and pulse prepara- material by as little as one percent results in It all started with the question: How
tion and processing are a less optimal product and higher manufac- can water penetrate quicker into a kernel
elementary building blocks ensuring turing cost. so that the long temper time and the large
the success of the German company For example, optimising starch gelati- amount of space such as temper bins, can
vibronet® Gräf GmbH & Co KG. nisation during heat processing is difficult be reduced?
without the accurate moisture content. Speeding up the process of conditioning
With its patented vibration damping sys- Therefore, precise moisture management grain is especially important in countries with
tem, vibronet® has been a pioneer in the field is required to maximise operation profit- very dry grain, where a high percentage of
of research for dramatically reduced temper ability, end product quality and thus eco- water has to be added prior to the grinding
times and simpler production processes nomic return. process.
since 1990. Thinking out of the box and looking into This search brought up the idea of
the production removing the surface tension of tempering
“How can water penetrate process is what
made MSc
water.
Water could then surround the entire
symaga_quarter page_IAFD2011 13/5/11 10:09 Page 1
Engineer and kernel as a water film and penetrate equally
quicker into a kernel so that Master Miller into the cereal through the hull and not www.symaga.com
Dieter Otto only through the germ, as with conventional
the long temper time and the Graef invent dampening systems. When observing a drop
the vibronet® of water on a glass plate, the water particle
large amount of space such as vibration forms a round ball due to surface tension. It
dampener in is generally known that the surface tension of
temper bins, can be reduced?” 1986 in his
own flour mill
water can be eliminated with, for example,
dishwashing detergent. However, for the
"Over 20 years of experience in the design, construction
and supply of storage solutions, worldwide"
in Germany. purposes of producing food and feed this
Water management in cereal and grain It was the first system to revolutionise method cannot be used. ALL TYPES OF SILOS INSTALLATIONS TO COVER THE MARKET NEEDS
conditioning has long been a neglected proc- how fluids can be added faster and more During first experiments, a mixture of
Silos for seeds, cereals, malts, oil seeds (soya, sunflower, rape, ...), pellets, meals, rices, and in
ess, which has not seen a lot of innovation economic to cereals and pulses. The sys- grain and water which were stirred lightly by
general, products for agriculture, agrifood industry, biofuels, and biomass (wood pellets, ...)
during the past decades. tem accelerates water absorption and hand, were dropped on a baffle plate from
Moisture control though is a critical ele- leads to a full cereal or pulse kernel damp- a height of about 30 meters. The results
Ctra. De Arenas, km 2,300, 13210 Villarta de San Juan. Cludad Real - Espana
ment as water is money in fluid form. To ening in two to 10 hours compared to the proved that water penetrates faster if the www.symaga.com antonio.benitez@symaga.com
manufacture perfect end products there is six to 48 hours required with conventional surface tension is eliminated through the Phone: +34 91 726 43 04/ +34 926 64 04 75 Fax: +34 91 361 15 94/ +34 926 64 02 94
just one optimum moisture level. Varying systems. application of a high accelerating force.
22 | may - June 2011 Grain &feed millinG technoloGy Grain &feed millinG technoloGy may - June 2011 | 23

3. FEATURE
News May - June 2011 NEWS
The Hydro-Probe II Moisture Sensor
Cal-BMS-KSL to be renamedMeasures MoistureTechnologies
Cultura & Reduces Cost
F
ive Agri-Food software strengthen geographic reach Victam International 2011 saw the our commitment to product
businesses within and e x pe r t ise of fe red t o launch of Cultura Technologies. innovation creating long-term
t h e Vo l a r i s G r o u p companies in the agriculture The newly named company brings value for customers, employees,
adopt global brand to and food industry. together five leading Agri-Food and our owners,” stated Jim Baker,
software organisations: Cal president of Cultura Technologies.
Software, BMS Computer Cultura is all about connecting
Solutions and Kinross people and processes across the
Merger of ESM (UK) Ltd and Software (KSL) of the United broader Agri-Food
Kingdom, AGRIS Inc and supply chain, helping
Satake Europe Ltd ExtendAg of the United States. to nurture Agri-Food
Bringing together these advancement through
companies and their strengths technology. Cultura’s
S
atake Corporation is pleased We are pleased to announce further solidifies all that name has its roots in the Latin
to announce the merger of this merger to all our Cultura is. The organisation microwave moisture--sensor means
The Hydro-Probe II digital word “agricultura” which provides
its vision systems business customers in Europe, Africa believes in strong cost effective agriculture – and “cultivate” – which
accurate and customer moisture control in feed meals and
trading as ESM (UK) Ltd and its and the Middle East as it will relationships and thatand pulses: foster growth or development.
pellets, grain, cereal the is to
cereal milling engineering business facilitate greater efficiencies • Monitor people moisture levels in real time
strength of itsand adjustand We are Cultura Technologies. We
trading as Satake Europe Ltd into within our business and as such • Reduce energy make bring drying process
their expertise can costs during theAgri-Food solutions to life.
a single company. will allow us to reflect such the • Reduce waste and improve quality
difference in delivering
benefits when dealing with technology solutions that More inforMation:
• Suitable for bins, silos, conveyors and chutes
The name of ESM (UK) Ltd is now your requirements. enable Agri-Food businesses Meaghan Wilkinson,
redundant and the newly combined Should you have any to • Not affected by dust or colour
efficiently produce, Cultura Technologies,
causing a quicker and better penetration bran is obtained during the first grinding proc- Continuing the revolution businesses will trade under the questions or require further process and deliver quality 5800 Explorer Drive, 5th
of the water into the cereal. The influence ess, which originates from the uniform distri- The patented vibration dampening tech- name of Satake Europe Ltd. clarification, please contact food and bio-products. Floor, Mississauga, ON,
of vibration tempering on the moisture bution of water on the surface of the grain. nology has now been entirely redesigned for Satake Europe Ltd is a division a m e m b e r o f t h e S at a ke “With this rebrand to L4W 5K9, Canada
content in flour reaches values after around Especially when milling Durum wheat, maximum profit and exceptional perform- of Satake USA Inc, a wholly management team or refer Cultura Technologies,
enquiries@hydronix.com Tel: +1 647 8012945
six hours which are equal to those achieved higher yields in middling and semolina are ance. The reduced built-in height fits even in owned subsidiary of the Satake to the website www.satake- we aim to strengthen Email: meaghan.wilkin-
after standard preparation of approximately achieved, as the water enters the wheat the smallest spaces. Corporation, Japan. europe.com www.hydronix.comson@culturatech.com
collaboration between
24 hours. Easily milled wheat with softer kernel over its entire surface and not – as Available capacities range from one to our global businesses and Website: www.culturatech.com
structure can be milled after only one hour with conventional dampening systems – 40tph. Optimised vibration energy utilisation
of tempering after vibration dampening. mostly through the germ. allows adding up to 12 percent dampening Grain &feed millinG technoloGy may - June 2011 | 7
There was no change seen in mineral In summary, it can be said that every pro- liquid in one single pass. A new redesigned GFMT quarter page vertical 105 x 147 plus 3mm bleed.indd 1 21/04/2010 09:56:21
content and colour …<< duction plant in grain processing has unused precision water distribution system permits
Statements from various millers around potentials for cost savings and increasing to add even the smallest amount of liquids.
the world confirm these findings. profit, hygiene and flexibility. vibronet Gräf’s The process can be adapted to the cus-
Not only are lighter coloured flours pro- patented cereal damping system creates tomer’s demand: water, water soluble liquid,
duced but the vibration dampening increases such a savings potential. Compared to chlorine, or dressing agent. The vertical
total flour yield by 0.5 – 1.0 percent. This conventional damping systems: Clean-Design dampener drastically reduces
is due to the fact that vibronet® brings the - vibronet® reduces temper time to a temper time to two to 10 hours making use
dampening water also into the crease of minimum: The vibration dampener of 0.2kW/tph only.
each kernel which represents 1/6 of the drastically reduces temper time by The minimum temper time guarantees
entire grain surface. Prerequisite is a temper- more than half of the time needed by lowest total bacteria count and maximum
ing time, which is optimised for the grain conventional systems. production process flexibility.
variety or grain mixture used. - vibronet® reduces energy cost: A The system offers energy-efficient prepara-
Through vibration dampening, coarser vibration dampener uses half the energy tion of an extensive choice of raw materials:
only of an intensive dampener, that is ≤ Wheat, durum, rye, oats, barley, spelt,
0.2kW/tonne/hour. sorghum, corn, lentils, peas, beans, soybeans,
- vibronet® reduces operating cost: A seeds and seed care, cocoa beans, coffee
vibration dampener cuts service and beans, malt
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 More inforMation:
reduced temper time, a vibration Sylvia-C. Gräf
dampener reduces silo bin space as vibronet Gräf GmbH & Co. KG
well as the associated transport and Neumühle 1 - 35633 Lahnau
conveying elements. Germany
- vibronet® guarantees hygienic end Tel: +49 6441 62031
products: The self-cleaning vertical Fax: +49 6441 62715
construction of the vibration dampener Email: info@vibronet.com
and the minimal temper times Website: www.vibronet.com
guarantee a drastic reduction of total
bacteria count in the cereal and thus in
the end product.
24 | may - June 2011 Grain &feed millinG technoloGy Grain &feed millinG technoloGy may - June 2011 | 5

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