It would be wonderful if maintenance were easy. If machines only broke down during scheduled maintenance shutdowns parts could be sourced quickly, maintenance would be simple. But of course, life is never so straightforward and things go wrong at the most inconvenient times.

1. Digital Re-print -
September | October 2012
Managing mill maintenance
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2. FEATURE
Managing mill
maintenance
by Alice Neal, associate editor, Grain and
Feed Milling Technology, United Kingdom
I
t would be wonderful if maintenance were production costs escalating, the importance its assets, it is necessary to have an effective
easy. If machines only broke down during of a well thought out and structured mainte- planned maintenance strategy in place. This
scheduled maintenance shutdowns parts nance schedule is vital. will ensure that plant failures diminish; it is
could be sourced quickly, maintenance far better to discover a potential problem
would be simple. But of course, life is never Prevention rather than cure before it results in an unplanned stoppage,”
so straightforward and things go wrong As the old saying goes, prevention is bet- says Nigel Bennett, Company Secretary and
at the most inconvenient times. ter than cure but what is preventative main- Employment Affairs Manager, nabim.
tenance and how can it be of use in the mill? Checks need to be part of every day
Aside from the cost of shutting down a Preventative maintenance is the simple,
processing line, poor maintenance can have day-to-checks and monitoring which help
multiple impacts. Failing to check equipment keep a mill running smoothly. The main aim American Feed Industry
regularly can lead to a reduction in product of a preventative maintenance schedule is to Association, USA and
quality. Inconsistent products can lead to reduce major repair bills by addressing minor international
increased costs and do little to ensure cus- problems as they occur. A preventative main- The American Feed Industry
tomer confidence. tenance programme needn’t cost the earth Association (AFIA) has instituted the
If defective products leave the mill, they and will save money in the long run. Feed Mill of the Year programme, as
can endanger human and animal health. In a “In order for a flour mill to benefit well as creating several voluntary, third-
worst-case scenario, lack of maintenance can consistently from the maximum utilisation of party certification programs, including:
cause the deaths of both staff and end users. Safe Feed/Safe Food and its international
This responsibility towards consumers counterpart and more recently, the Pet
is echoed by the American Feed Industry GEAPS/KSU Program, Food Manufacturing Facility and the
Association (AFIA). “We believe that feed distance learning Pet Food Ingredient Facility certification
mill maintenance is of the utmost impor- The Grain Elevator and Processing programs.
tance. Properly maintaining feed mills and Society (GEAPS) works with partner- The organisation believes it is
other feed facilities is the industry’s demon- ship with Kansas State University to responsible for the industry producing
stration of its commitment to its consum- offer a multitude of distance learning safe feed, feed ingredients, pet food
ers,” says Leslie Malone, communications courses. Covering topics such as the and pet food ingredients in order to
manager, AFIA. course run periodically throughout the produce safe, healthy animals. Designing
In addition to product quality and health year however, larger groups can request the certification programs to meet and
and safety concerns, cost is a compelling rea- on-demand course. The Grain Elevator exceed the highest standards of food
son to adhere to good maintenance. With Equipment Maintenance course aims and feed safety, demonstrates AFIA’s
to familiarise participants with the commitment to its members and to the
proper and safe function, monitoring, industry.
Wolfson Centre for Bulk adjustments, maintenance and repair of
Solids Handling Technology, www.afia.org
equipment used in everyday grain facili-
UK ties operations.
Based at the University of
www.geaps.com
Greenwich, the Wolfson Centre has IAOM, USA
been running short training courses for The Association of Operative Millers
more than 25-years. All courses are (IAOM) runs a range of educational
designed to suit the needs of engineers nabim, distance learning programmes in the USA throughout
across different industries involved in The National Association of British the year. The popular Mill Maintenance
the handling of bulk solid materials or and Irish Millers (nabim) offers modern I course is an opportunity for mainte-
the flow of powders. Previous qualifi- mill training via correspondence cours- nance staff to gain the training, contacts
cations are not required – only a basic es. Divided into seven parts, several of and confidence to keep their mills run-
technical education and/or industry the modules contain a maintenance ele- ning at maximum capacity. The agenda
experience. For more information on ment, which relates specifically to the includes bearings, gates and valves, belts
the forthcoming Particulate Handling theme of the module. Wheat and the and chains, process auditing, power
Technology at the Wolfson Centre, Screenroom, Power and Automation transmissions, electric motors, safety,
read our interview with Prof Mike and Flour Milling Management all sifters, preventative maintenance and
Bradley on page 42 involve maintenance. electrical troubleshooting.
www2.gre.ac.uk www.nabim.org.uk www.iaom.info
28 | September - october 2012 Grain &feed millinG technoloGy

3. FEATURE
working life. It is often machine operators, training – not just for their own safety but to Other factors to consider
who have the greatest hands on contact with ensure a quality end product. Although all mill staff have a responsibility
equipment, who detect faults first. Their Different positions will require different to look out for maintenance issues, ultimately
concerns should be listened to and acted training. Those in management roles in feed it is the responsibility of the mill maintenance
upon. mills will require specific feed technology manager to oversee the correct running of
Timing is key to effective maintenance: training covering the whole production proc- the mill.
repair or replace troublesome parts as soon ess. Pre-milling, managers may be involved in Apart from milling machinery, buildings
as problems occur. Similarly, scheduled main- the selection and purchasing of appropriate and grounds need to be well maintained.
tenance needs to be completed on time and ingredients. Once on site, the manger will be Again, it is simple things such as keeping
worn or dangerous parts should be seen to responsible for manufacturing, storage and premises waste and litter free, making sure
as a matter of urgency. handling of feeds. A solid understanding of the good repair of the structure of the
Pay attention to equipment guidelines the maintenance issues at each stage of the building is in sound and internal fixtures and
which should give an overview of required process will help the mill run smoothly. fittings are in good repair.
maintenance. To ensure a consistently high-quality Proper lighting, heating and ventilation
Larger failures will happen occasionally product, training needs to be an ongoing helps with staff safety, manufacturing and
but a good preventative maintenance pro- process. New equipment and machinery will storage.
gramme will help minimise the damage. obviously require new training but employers Cleaning also plays an important role in
should not underestimate the usefulness of any milling operation. A clean and ordered
Training refresher training mill can help ensure product quality, staff
Effective maintenance is not just about In addition to workplace based train- safety and increased equipment life.
machinery; staff training also plays a crucial ing, many of the major milling associations Milling machinery is slicker, faster and
role in ensuring the smooth running of a and societies run recognised maintenance than ever but it remains the key investment
mill. Time must be taken to ensure staff courses. These courses can either be a company makes. Given the significant
are trained and confident operating neces- attended face-to-face or studied for by sums of money for new machinery and the
sary equipment. Personal responsible for distance learning. See side panel/box for damage defective products can do, it pays to
feed formulation must also receive adequate more information. maintain mills.
Grain &feed millinG technoloGy September - october 2012 | 29

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