Delivering world class roll chill technology and service


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Even new materials need regular refurbishment. From both a safety and performance reliability point of view, it is essential that mill maintenance is carried out to a pre-determined schedule. However, when delivery dates need to be met and staffing levels are stretched, this can prove difficult. At such times, a resource such as the Satake Europe Site Services Team can help.

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Delivering world class roll chill technology and service

  1. 1. Digital Re-print - November | December 2012 Delivering world class roll chill technology and serviceGrain & 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 ofinformation published.©Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any formor by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872
  2. 2. FEATUREDelivering world class roll chilltechnology and service by Neil Reedy, Service Engineering Manager, Satake Europe Ltd, United KingdomE ven new materials need regular Re-fluting, using tungsten carbide fluting microns over a diameter of 250 mm. The refurbishment. From both a safety bits, restores the profile to the exact speci- frosted finish, necessary to ensure immediate and performance reliability point of fication required for the client’s application. grip when the rolls go into grind, is achievedview, it is essential that mill maintenance is In Satake Europe’s experience, one in ten by blasting highly abrasive particles at the sur-carried out to a pre-determined schedule. rolls sent for refluting displays defects, which face using automated shotblast equipment.However, when delivery dates need to would have a fundamental effect on mill Before despatch, each roll undergoesbe met and staffing levels are stretched, performance and safety – such as a damaged testing which, in the case of roll packs,this can prove difficult. At such times, spindle, less than the recommended chill includes an optional running period ona resource such as the Satake Europe diameter, or chill quality, which could affect a roll bearing test bed. This ensuresSite Services Team can help. roll performance. the shortest possible interval between delivery, installation and regaining full State of the art roll grinding production in the mill.Quality and safety technology Custom-built machinery laid out in a The quality of the grinding and fluting processes, All of these would be identified and cellular style and standing on four metrewhether being carried out on a new roll or during reported on, supported by relevant data deep foundations to eliminate transfer ofrefurbishment, determines the performance of the compiled using a combination of engineering vibrations, provide the capability of produceroll and, thus, the quality of the end product. An skills and high-tech instrumentation. 1,500 new and 4,000 refurbished rolls perintegral part of each refurbishment is the careful From its flour milling ‘Centre of Excellence’ year for customers in Europe, the Middleinspection of each roll or ‘roll pack’ module before in Bredbury, near Manchester, Satake Europe East and Africa.any work can begin. This exercise is followed by offers a standard roll refurbishment turna-the compilation of a complete inspection report, round of three weeks and an emergency Delivered on specially designeddetailing the findings, recommendations for action service of 72 hours. palletsrequired and associated costs. Many of the defects can be rectified, and To ensure that refurbished rolls arrive back Satake Europe offers the full range of reme- at a client’s mill in the same precision-ground dial operations, including re-gudgeoning, condition as when they left the fluting section, reducing the need for such defective rolls to Satake Europe has devised a special pallet be scrapped. design. Once the completed report has been On completion, the rolls are coated with emailed or faxed to the customer and work rust –preventative food safe oil, covered in instructions agreed, rolls are ground until a rust –preventative paper and sealed in a pro- smooth, parallel surface is obtained. tective plastic sleeve before being mounted Re-fluting, using tungsten carbide fluting on the pallet, accompanied by documenta- bits, restores the profile to the exact specifi- tion detailing destination, flute specifications cation required for the client’s application. A and a unique roll number. This ensures com- profile shadowgraph is used to examine the plete traceability for each individual roll and pitching, depth, angle and land of the flutes, enables a statistical history to be maintained as well as for checking thread forms and flut- which can prove invaluable when monitoring ing tools within the Bredbury facility. mill throughput. The optimum number and profile of the flutes, relevant to the application of the Innovative use of modern roll, have been developed over many years materials and are specified to high levels of accuracy. As the largest roll chill supplier in the UK, Satake Europe offers a standard range of Satake Europe offers new and refurbished more than 100 different flutes profiles, with rolls for all makes of rollermill. With a port- other bespoke arrangements available. folio of four different types of roll Satake Europe has an in depth knowledge of a range Grinding and fluting of those featuring new materials available Smooth rolls are ground with either from leading manufacturers. a taper or camber to a tolerance of four Extending flute/corrugation life and ena-26 | november - december 2012 Grain &feed millinG technoloGy
  3. 3. FEATUREbling chills to be refurbished up to 15 times, fluting. Smooth rolls require an outer surface by experienced engineers for all aspectsmodern metallurgical developments have that can be ‘frosted’ creating a matt or non- of millwork, roll changes, airlocks to sifterextensively widened the miller’s range of glazed surface which will effectively grip the maintenance and frame recovering services,options. product and be resistant to abrasive wear. we are here to help. Whatever the material – and chilled cast iron With many mills running 24 hours sevenrolls remain the traditional choice for break and Site services days a week, it has become even morereduction work – the outer surface of fluted/ To compliment our projects and machine important that mill equipment is kept wellcorrugated rolls needs to be resistant to abrasive sale capability, Satake Europe also offers maintained. Mills however do not employwear in order to retain the required profile. a full range of maintenance and spares more maintenance staff than is necessary for The surface must be hard but not brittle services. Our aim is to become the number the day-to-day running of the mill so duringto avoid chipping, and it is important that one choice for process and mechanical sup- the down periods, additional staff is oftenthe roll chill can machined with conventional port in the milling industry. Building on our required to assist with the extra maintenancetools avoiding unnecessary cost when re- long history we can offer tailored support and process work on the plant.Grain &feed millinG technoloGy november - december 2012 | 27
  4. 4. FEATURE able to carry out this Sieving solutions New rolls manufactured for work and in addition We have sieve a re-covering department all major rollermill types to to this, we can assist that can meet the demands of the industry customer requirements in the development of and ensure the covers for process work are planned, preventative available when required; our pneumatically maintenance programs stretched screens have a controlled tension Standard rolls - chilled iron, centrifugally cast and dynamically to ensure greater that allows for consistency across the entire balanced for greater precision, providing a consistent uniform plant performance and sieve surface. With the use of our own hardness. efficiency, giving cus- adhesives, these also secure all of the threads C12 rolls – high chrome alloy, giving an average life twice that tomers less downtime, unlike stapled sieves, and the sanitary bond of a standard cast iron roll, resulting in reduced mill downtime resulting in improved helps eliminate the threat of insect infesta- for roll changing. efficiency and produc- tion in this area. tion. The sieve cloth stretching equipment and ‘Self mating’ rolls – with a material composition formulated Milling engineers new binding techniques have improved he to maintain a heavier frosted finish for special reduction also require staff avail- quality of the sieves and when done in con- applications. able at short notice to junction with sifter maintenance have helped Water cooling - Water-cooled roll options are available for assist with emergencies dramatically improved the efficiency of the all of the above types. with all types of equip- sifting operation and could increase through- ment; Satake Europe put by one percent. Whilst maintaining good Fluted to your individual specifications. has a team of mechani- chill roll condition can increase initial yield Spindles are machined or ground as required. The available cal engineers familiar and reduce the rework of product giving a roll size is up to 450 mm diameter and extends to 1500 mm with many types of saving in time, power consumption and cost in length. milling equipment who per tonne of final product. can respond to these requests. With the use of It is common practice to have inde- preventive maintenance programmes and More inforMation: pendent contractors in flourmills working service agreements, it is possible to create Satake Europe Limited along side or independent to the mill a schedule well in advance of the shutdown Tel: +44 161 406 3800 maintenance team, to tackle such tasks detailing the tasks required and ensure the Fax: +44 161406 3801 Email: as roll changes and sifter maintenance. necessary resources are in place to complete Website: Here at Satake Europe our professional all the planned tasks on time and help con- mechanical and process teams are avail- trol mill running costs. Die and roll re-working machines ATEX LEvEL swiTch The capacitive proximity switches in the DOL 40R series are now available with ATEX approval for use in areas with constant danger of dust explosion. • Designed for detection on grain, feed and granules • Zone 20 approved - for use inside bins and hoppers • With integrated amplifier and change-over relay • • Reliable and resistant Easy to mount Phone: +45 75 14 22 55 O&J Højtryk A/S Fax: +45 82 28 91 41 Ørnevej 1, DK-6705 mail: Esbjerg Ø dol-sensors Tel. +45 72 17 55 55 CVR.: 73 66 86 11 28 | november - december 2012 Grain &feed millinG technoloGyAD_o&j.indd 1 21/11/2012 15:48
  5. 5. Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full LINKS This digital Re-print is part of the November | December 2012 edition of Grain & Feed 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 November - December 2012 • See the full issue • The art of a modern miller working with wheat, cereals, grains and … • Visit the GFMT website plastics and metal • • Contact the GFMT Team The changing face of pallets In this issue: • Delivering world class roll chill technology • EXTRUSION: and service • Subscribe to GFMT an ever growing aspect of the Indian food processing • Managing mill industries maintenance • 2012/13 company profiles A subscription magazine for the global flour & feed milling industries - first published in 1891 To purchase a paper copy of the magazine, or to subscribe to the paper edi- tion please contact our Circulation and Subscriptions Manager on the link adove. INFORMATION FOR ADVERTISERS - CLICK HERE Article reprints All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these have been used as point of sale materials, promotional materials for shows and exhibitions etc). If you are interested in getting this article re-printed please contact the GFMT team for more informa- tion on - Tel: +44 1242 267707 - Email: or visit