DIAMOND

FLOUR MILL

Prepared by Group 3:

Bakalian, Priscilla
Ejaz, Muhammad,
Martinez Diaz, Cesar A.
Noguera D., Carlos A.
Sanni, Tajudeen 0.
Siyananthan, Anantharasa

1

Contents
Monterrey (Mexico) ........................................................................................................................ 3
Wheat Classes: ................................................................................................................................ 4
US Wheat Associates (USW):..................................................................................................... 4
Estimated wheat price (yearly) .................................................................................................... 7
Raw wheat bins ............................................................................................................................... 7
The cleaning section ....................................................................................................................... 8
Screening grinding section ............................................................................................................ 10
Grinding section ............................................................................................................................ 12
Specific roller length of the break system: ................................................................................ 14
Specific roller length of the reduction system:.......................................................................... 15
Specific sifting Area:................................................................................................................. 16
Specific sifting area for the purifiers ......................................................................................... 18
Finished products .......................................................................................................................... 19
Power Calculation and Air requirement for the mill .................................................................... 21
Cleaning section ........................................................................................................................ 21
Screening section....................................................................................................................... 23
Grinding section ........................................................................................................................ 24
Air requirements for mill pneumatic and aspiration system ......................................................... 26
Finished Products ...................................................................................................................... 27
Laboratory ................................................................................................................................. 28
The Summary of the power consumption: .................................................................................... 29
Laboratory ..................................................................................................................................... 32
Operations ................................................................................................................................. 33
Product specification: ................................................................................................................ 36
HACCP ......................................................................................................................................... 37
I - Product description/Scope: ................................................................................................... 37
II - Prerequisites for HACCP: ................................................................................................... 37
III – HACCP Analysis: ............................................................................................................. 39

2

Monterrey (Mexico)

The location, Monterrey is chosen for our mill based on its altitude, industrial/metropolitan level.

Monterrey is the capital and largest city of the northeastern state of Nuevo Leon, Mexico.

The city is anchor to the third largest metropolitan are in Mexico and is ranked as the ninth

largest city in the nation. Monterrey serves as a commercial and industrial hub in the north of

the country and is the home of many significant international corporations.

As an important industrial and business center, the city is also home to an array of multinational

companies, like CEMEX, BMW Mexico, Mercedes Benz Mexico, Grupo Bimbo, Moctezuma

brewery and Heineken. Moreover, the city has a moderate climate with an average high of 28.4C

and average low of 16.3C

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 Country: Mexico

State: Nuevo Leon

Area of city: 969.70 Km2 (374.40 sq miles)*

Population: 1,130,960 (as of 2010)*

Altitude: 540m

GDP per capita: $46,634 US dollars.*

*Based on 2010 statistics

Wheat Classes:
Due to the location of our mill in Monterrey the best possible wheat in terms of quality

and logistics can be bought from the USA.

With respect to our customer demands and final product requirements, 3 different classes of

wheat will be required:

1. Hard red winter (HRW)

2. Hard red Spring (HRS)

3. Soft White (SWW)

US Wheat Associates (USW):

Our Suppliers for all three aforementioned wheat classes will be selected through US

wheat Associates. The main reason for selecting USW is based on their transparency and policy

on providing their customers with the best quality of wheat at a competitive price.

As a testament to that responsibility, USW provides critical information throughout the year

about US wheat crop and market conditions to wheat producers, buyers and users.

Source: www.uswheat.org/cropquality/doc

4

 2016 Production, Supply and demand

Crop year (million metric tons)

Wheat Variety 2012 2013 2014 2015 2016

Hard Red Winter 27.2 20.3 20.1 22.6 29.4

Hard Red Spring 13.7 13.4 15.1 15.4 13.4

Soft White 6.5 6.8 5.5 5.4 6.9

5

Summary of classes

2016 HRW HRS SWW

Test weight (lb/bu) 60.5 61.6 60.8

(kg/hl) 79.6 81.0 80.0

Grade 1 1 1

Dockage (%) 0.5 0.5 0.6

Moisture (%) 11.2 12.0 9.8

Protein (%) 11.5 14.1 10.1

Ash (%) 1.49 1.5 1.34

1000 kernel weight 31.7 30.9 36.3

Falling number (sec) 392 378 314

Flour semolina extraction (%) 76.6 66.8 75.0

Wet gluten (%) 24.8 33.6 23.6

Farinograph

Peak time (min) 4.0 8.1 2.4

Stability (min) 6.7 12.2 2.8

Absorption (%) 59.2 63.0 53.8

Alveograph (W) 211 394 85

Loaf volume (cm3) 821 986 N/A

Source: www.uswheat.org/cropquality/doc

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Estimated wheat price (yearly)

Wheat in tons/year
Mill capacity: 220t/day
Wheat requirement for the year: 220*365 80300t/yr

Assuming:
16 hours-hard wheat 70% 56210t/yr
8 hours-soft wheat 30% 24,090t/yr

Wheat price per ton* Wheat price per year

30% HRS 16,863t/yr 250$/ton $4,215,750
Hard wheat: 70% HRW 34,347t/yr 207$/ton $8,144,829
100% 56210t/yr
Soft wheat: 100% SWW 24,090t/yr 184$/ton $4,432,560
$16,793,139
*Prices estimated for 2016, are based on USW weekly wheat rates and are listed without taking
into considerations the logistics cost.

Our wheat procurement will be done four times in a year, to avoid long storage problems. Wheat

will be processed based on FIFO (first in first out) from our silos.

Raw wheat bins

The main purpose of the raw wheat bins is to serve a link between the grain storage and

the cleaning section. The total content of the raw wheat bins should be the same to that of the

daily capacity of the mill and handle different wheat varieties. In our case, the mill capacity is at

220tons/ 24hour and three wheat varieties are being handled therefore three raw wheat bins with

120ton/24hour each are selected, one raw wheat bin will be utilized for single grist. The raw

wheat bins are sufficient enough to provide wheat for the mill for 24 hours as we are mixing two

different varieties. And in the case of single wheat grist being grinded more often, two raw wheat

bins can be utilized.

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The cleaning section

“Generally, the hourly capacity of the first cleaning section is slightly higher than the one of the

mill. This is necessary to overcome time losses caused by changing the grist. As a rule, it should

be possible to process the daily capacity of the mill within 22 hours.” (Source: SMS Script)

Capacity of the mill: 220t/24h

Thus, the cleaning capacity of the mill: 220/22 = 10 t/h

The raw wheat supplied to the mill will require further cleaning; therefore a maximum of 1-3 %

impurities is expected. Our concept revolves around removing these impurities as well as

minimizing the filth content and total bacteria count. According to the market and the customer

specification our concept also focuses on having reliable processes in order to eradicate complex

issues of Don and vomitoxin. Our future product will be used for baby food as well, therefore all

these hygiene requirements are considered while designing the cleaning flow sheet.

The important concepts regarding the aforementioned issues are enlisted as below:

1. The use of fresh air, for aspiration is a must to avoid further contamination of sound

wheat kernel (mainly for combi-cleaner and scourer)

2. The light stream of the combi-cleaner, where maximum contamination is expected, is

sent to a sterilator where the infested kernels are broken down and then later aspirated.

The main task of optical sorter (Sortex) with an IR is to remove DON infested wheat

kernel. The Sortex is preceded by a scourer which ensures that the surface of the wheat

kernel going to the Sortex is not covered with a dried mud layer. In turn this arrangement

enhances the efficiency of the Sortex for better color detection. Moreover, it is important

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 to note that Sortex with climate control should be used, to ensure that outside temperature

and atmosphere does not affect the efficiency of this machine.

3. We have two first tempering bins each of 120 tons capacity. This will enable us to temper

a complete stream coming from the raw wheat bins to the cleaning section. We do not

need a third tempering bin because hard wheat and semi hard wheat will be mixed and

grinded together.

4. The second tempering bin of 120 tons capacity is installed only for hard wheat, and in

case of soft wheat grinding a bypass is provided to the third elevator/second cleaning.

5. In the second cleaning a scourer with fresh air aspiration is provided for the soft wheat.

This is to remove the soften bran particles from dampening and also to remove adhering

mud balls and dirt on the kernels.

6. The light peeler and water addition is basically installed for hygiene reasons for hard

wheat variety, where it is widely used to reduce bacteria count, toxic heavy metals,

microorganisms (over 1 log reduction possible) etc.

7. A bypass is provided between the scourer and light peeler, to change as needed.

8. All raw wheat and cleaning bins are provided with high and level sensors as well as

vibro-dischargers.

9

Screening grinding section

Important considerations in the screenings grinding

1. The option of manual filling through the hopper is also provided along with the

screenings from cleaning and intake, through an installed screw conveyor.

2. The scale is installed before the hopper, to have precise % of the impurities coming from

the cleaning section and the intake.

3. The screenings bin size is 25 m^3. This capacity is more than enough to store 1.5 days of

screenings in case the hammer mill breaks down. It has both high level and low level

sensors. High level to avoid overflow and the low level sensor signals to stop the hammer

mill in case the product level is below minimum.

4. The throughs of the sifter installed below the bins are directly going to the by-product

silo, to avoid wear and tear as well as clogging of hammer mill.

5. 8 hours night shift operation is preferred for running the hammer mill. This is because

only 4.6 tons per 24 hours is expected which can be covered in night shift. This in turn

will result in saving energy and labor cost.

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The capacity of the hammer mill and the storage bin is selected on the bases of the percentage of

screenings from the cleaning section, intake in 24 hours and the calculations are provided below:

Calculation for the Screenings Grinding section:

220 tons/24
Mill capacity:
hours

Capacity of cleaning: 220/22 = 10tons/hour

Assumed 1% of impurities from cleaning 100 kg/hour 0.1 tons/hour

section: for 24 hours 0.1*24
=2.4 tons/day
Capacity of pre-cleaning (assumed): 30 tons/hour
Amount of impurities (assumed): 1.50%

(30 * 1.5) / 100 0.4 tons/hour

for 24 hours 0.4 * 24
=2.25tons/day

Total screenings: 2.25+2.4 =4.65 tons/day

Specific weight of ungrounded screenings: 0.3

Volume of the screening bin: 25m3
Capacity of the screenings bins: 25*0.3=7.5tons

Night shift: 4.65/24 0.2tons/hour

=1.6 tons per 8
0.2*8hours
hours

Thus:
- Capacity of the hammer mill required (night shift operation): 2 tons/hour
- Capacity of the screenings bin: 7.5 tons

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Grinding section

Mill capacity for semi-hard wheat: 2200 [dt/24h]

Mill capacity for soft wheat: 1980 [dt/24h]

Important considerations:

1. A granulation of four is chosen since mainly semi-hard wheat is being grinded and

semolina has also to be marketed. Additionally the capacity of the mill is medium sized

mill; therefore granulation of 4 will be optimum.

2. Our market demands flours to be produced from semi hard and soft wheat, therefore a

compromise has to be made in the grinding section:

a. 5 break system and three times bran finishers are done because our consumers demand

products based on soft wheat. And a bypass is installed in the bran finisher in case of

semi hard wheat grinding. Moreover it is important to note that the capacity of the mill

will be reduced by 10% to 15% while grinding soft wheat.

b. The reduction system has also to be made of a compromise. That is in the case of semi-

hard grinding we will need a long reduction system. In our scenario, the mill has up to

C11 and 4 purifying passages (3 machines) are being used. If we are required by our

consumers to produce very low ash flour, a bypass for C1 and C2 detachers is available.

3. The option of C1/C2 as an 8 roller mill was available like B1/B2. But we opted for

individual 4 roller mills so that we can increase the starch damage and be more flexible.

Additionally, we selected a maximum specific roller length of 1 mm/dt/24h for passages

C1A and C2A, for increased starch damage.

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 4. To fulfill the requirements of consumers regarding quality germ (as finished product)

for the cosmetics industry, our flow sheet comprises of two times pressing. This is done

by having an option to bypass C1B (first pressing) to C4 (second pressing), and then to

the finished products silo. However, when we need a higher quantity of germs for feed

products, we can take germ out from C1B (one time pressing) and also from C4 (two

time pressing). This entitles us to be more flexible according to customer’s specification

in terms of germ extraction.

5. In case of future high ash flour requirements, the C10 passage can be replaced by fluted

rolls.

6. Our grinding sections consist of two filters, one is for pneumatic conveying and the

other one is for aspiration. The details regarding the power consumption of these filters

are present in the power calculation heading and in the flow sheet.

In order to calculate the specific roller length of the break system, reduction system and

the specific sifting surface of the sifter and the purifier some calculations were carried

out based on the theoretical values. And these calculations are represented in the

following tables.

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Specific roller length of the break system:

The following specific roller length of the break passage has been calculated on the bases of the

following theoretical guidelines

Mill capacity for semi-hard wheat: 2200 [dt/24h]

Mill capacity for soft wheat: 1980 [dt/24h]

Theoretical 5 breaks system Commercial roller length

Actual Roller
Specific roller Total roller
roller Pairs of length
Passage length Passage length
length rollers commercial
[mm/dt/24h] [mm]
[mm] [mm]
B1 1.2 2,640 2 1250 2500
B1/ B2
B2 1.2 2,640 2 1250 2500
B3 1.2 2,640 B3 2 1250 2500
B4c 0.4 880 B4c 1 1000 1000
B4f 0.4 880 B4f 1 1000 1000
B5c 0.4 880 B5c 1 1000 1000
B5f 0.4 880 B5f 1 1000 1000
Total: 5.2 11,440 Total: 11,500

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Specific roller length of the reduction system:

The following specific roller length of the reduction passage has been calculated on the bases of

the following theoretical guidelines

Theoretical reduction system Commercial roller length

Specific roller Total Roller Total
Pairs
Passage length length Passage length length
of rolls
[mm/dt/24h] [mm] [mm] [mm]
C1A 1 2,200 C1A 2 1250 2500
C2A 1 2,200 C2A 2 1250 2500
C1B 0.7 1,540 C1B 1 1250 1250
C2B 0.5 1,100 C2B 1 1250 1250
C3 0.8 1,760 C3 2 1000 2000
C4 0.5 1,100 C4 1 1250 1250
C5 0.6 1,320 C5 1 1250 1250
C6 0.5 1,100 C6 1 1000 1000
C7 0.4 880 C7 1 1000 1000
C8 0.4 880 C8 1 1000 1000
C9 0.3 660 C9 1 1000 1000
C10 0.3 660 C10 1 1000 1000
C11 0.4 880 C11 1 1000 1000
Total 7.4 16,280 Total 18000

Summary of mill roller length:

Breaks Reduction Total

Total length [mm] 11,500 18000 29,500
Specific roller length for semi-hard
[mm/dt/24h] 5.2 8.2 13.41
Specific roller length for soft [mm/dt/24h] 5.8 9.1 14.9
39.00% 61.00% 100%

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Specific sifting Area:
The specific sifting area had to be calculated based on theoretical values to obtain the

number of compartments needed and to determine the capacity and number of sifters

needed

Mill capacity for semi-hard wheat: 2200 dt/24 h

Mill capacity for soft wheat: 1980 dt/24h

Plantsifters theoretical sifting area

Specific sifting surface [m2/dt/24] Sifting Area [m2]
B1/B2 0.0065 14.3
B3 0.005 11
B4c / B4f 0.004 8.8
B5c / B5f 0.004 8.8

DIV I 0.004 8.8

DIV II 0.002 4.4
Df 0.002 4.4
DBr 0.001 2.2
C1A 0.004 8.8
C2A 0.004 8.8
C1B 0.002 4.4
C2B 0.001 2.2
C3 0.003 6.6
C4 0.002 4.4
C5 0.003 6.6
C6 0.002 4.4
C7 0.002 4.4
C8 0.001 2.2
C9 0.001 2.2
C10 0.001 2.2
C11 0.001 2.2
Total 0.056 122.1

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 Total Specific
Specific
Amount of Practical Real sifting
sifting area No. of sieves
Passage compartment compartment sifting area for
for hard per
required* required area soft
[m2/dt/24h] compartment
[m2] [m2/dt/24]
B1/B2 1.7 2 16.50 0.0075 22 0.008
B3 1.3 2 16.50 0.008 20 0.008
B4c/B4f 1.1 1 8.25 0.004 25 0.004
B5c/B5f 1.1 1 8.25 0.004 25 0.004
DIV I 1.1 1 8.25 0.004 25 0.004
DIV II 0.5 0.5 4.13 0.002 25 0.002
Df 0.5 0.5 4.13 0.002 12 0.002
DBr 0.3 0.5 4.13 0.002 12 0.002
C1A 1.1 1 8.25 0.004 25 0.004
C2A 1.1 1 8.25 0.004 25 0.004
C1B 0.5 1 8.25 0.004 22 0.004
C2B 0.3 0.5 4.13 0.002 12 0.002
C3 0.8 1 8.25 0.004 20 0.004
C4 0.5 1 8.25 0.004 20 0.004
C5 0.8 1 8.25 0.004 20 0.004
C6 0.5 0.5 4.13 0.002 25 0.002
C7 0.5 0.5 4.13 0.002 25 0.002
C8 0.3 0.5 4.13 0.002 12 0.002
C9 0.3 0.5 4.13 0.002 12 0.002
C10 0.3 0.5 4.13 0.002 12 0.002
C11 0.3 0.5 4.13 0.002 12 0.002
Total 14.8 18.0 148.50 0.068 0.075
*Obtained after selecting the type N sieves (MPAK 825 and MPAK 10/25) and dividing
the net sieve area of the whole sifter by the number of compartments, further details
below

Commercially available plantsifters and sieves - Buhler AG

Net sieve area in m2 Approx. weights in kg Volume
# of # of sieve
Type seapack
comp per comp. S. type N S. type B net gross by sea m3
MPAK-225 2 25 16.5 20.2 2085 2300 2500 13
MPAK-425 4 25 33 40.4 2490 4000 4200 19.8
MPAK-625 6 25 49.5 60.6 4585 5500 6100 32.4
MPAK-825 8 25 66 80.8 5870 6800 6800 41
MPAK-1025 10 25 82.5 101 6950 8200 8200 52.9

17

According to the above table, we have selected the following:

Net
Number of
Plant sifter sieving m2/compartment
compartments
area [m2]
1 x MPAK 825
66 8 8.25
NOVAPUR
1 x MPAK 1025
82.5 10 8.25
NOVAPUR
Total 148.5 18 8.25

Specific sifting area for the purifiers

The selection of the model and number of purifiers is established below:

Mill capacity for semi-hard wheat: 2200 [dt/24h] ; 220000 [kg/24h] / 24 [h] = 9250 [kg/h]

Product Capacity Capacity Required Real

Passage
expected [kg/h] [1/2 model 520] halves halves
P1 30% 2775 1500 1.85 2
P2 30% 2775 1400 1.98 2
P3 10% 925 1200 0.77 1
P4 10% 925 800 1.16 1
TOTAL 100% - - 5.76 6

Number of ½ machines: 6

Total number of machines: 3

Sieve width: 520 [mm]

18

Total sieving width: 3120 [mm]

Specific sieve width: total sieving width / capacity = 3120 [mm] / 2200 [dt/24h]

Thus, specific sieve width: 1.42 mm/dt/24h

Finished products

- Mill capacity: 220 t/24h = 9.2 t/h

- Flour extraction rate from wheat: maximum 80%

- Total flour produced per day: 9.2 t/h x 0.8 x 24 h = 176 tons

- Flour storage silo holding capacity: 6 bins of 75 tons = 450 tons

- Finished products silo holding capacity: 4 bins of 75 tons = 300 tons

- Important considerations:

1. A total of six-stream line, one for each product (flour 1, flour 2, pollard, semolina, bran

and germ) is proposed in our flow sheet. Each stream is placed on a weighing scale

(transflowmeter) to have an accurate weight measurement. And this scale is connected to

an online monitoring yield system (Wincos 2.0) to have a precise yield calculation. This

system will enable us to have traceability, as well as transparency throughout our process

lines.

2. Micro-feeders are available to add ascorbic acid and malt flour specifically to the stream

of flour 2.

3. In order to maintain the optimum extraction rate for flour 2, an ash loop has been

installed using an NIR in the spouting outlet of the paddle conveyor of flour 2. The

output of NIR (via control system) sends a signal to the frequency converter in the screw

conveyor of the pollard. Through this, the addition of pollard and in generic view the ash

content of flour 2 can be regulated to produce flour 3, automatically as well as accurately.

19

 4. To ensure the granulation range of our semolina, during the start up of the mill the

granulation of semolina will be checked and then the sieves of the purifiers will be

adjusted accordingly. Furthermore, customer feedback regarding semolina granulation

will be used to further enhance our product quality.

5. Flour 1 has two bins for 75 tons capacity each. The capacities of the silos are enough for

4 days.

6. Flour two has four bins for 75 tons capacity each. The capacities of the silos are enough

for 2.5 days. One of the bins for flour 2 can also be used as a startup bin for the grinding

section till the time the mill is stabilized. Secondly, there is an option of the same bin to

be used as a startup bin for the batch mixer; the first two or three batches can go to this

silo till it is stabilized.

7. For the production of flour 1, flour 2 and flour 3, a batch mixer is installed. The capacity

of the batch mixer is 500kg/batch and each batch can be processes in about 3 minutes.

8. In this system three additional micro-feeders are installed. These feeders can be used for

various purposes according to customer specifications.

9. The sterilators are installed in the pneumatic conveying lines to fulfill the hygiene

demand of our customers with regards to killing weevils and destroying the eggs.

10. The redresser is installed to ensure that our sifters are free from any damage/holes in the

sieves and the removal of any other foreign objects can be done through this machine.

11. The finished products silos have a holding capacity of 300 tons (for approximately 3

days). These silos can be used for flour 1, flour 2 or flour 3.

20

Power Calculation and Air requirement for the mill

General conditions:

- Main power supply: 3 x 460 V / 60 Hz (for motor data)

- Control voltage: 24 V DC

The following tables represent the cleaning section, screenings, grinding, mill, finished products,

and laboratory with general infrastructure. The summary of all the sections’ power consumption

is also mentioned.

Cleaning section

CLEANING SECTION: Air and Power Consumption

Air requirement
Machine Model Power Consumption
[m3/min]
[KW]
1 Raw wheat bins
2 Vibro discharger (3) MFVH-180 3.9
3 Transflowtron MSDG-60-R
4 Chain conveyor MNKA-50 1.3 5
5 Bucket elevator MGEL-250/150 2.5 10
6 Magnet MMUA-20
7 Aspiration channel MVSG-100 0.65 56
8 Intermediate Separator MANA-355
9 Airlock MPSN-25/23 0.75
10 Combicleaner MTKB-120/120 1.75 160
11 Impactor MJZD-G 30
12 Scourer MXHS 30/60 17 25
13 Aspiration channel MVSG-100 0.65 56
14 Sortex BSAB-3 VIVV 0.65 15
Automatic moisture
15 MYFE-30 10
controller
16 Bucket elevator MGEL-250/150 2.5 10
17 Turbolizer MOZL 30/150 4.6
18 Screw conveyor NFAS 300 1.3 10
19 Tempering bins 10
20 Vibro discharger (2) MFVH-180 2.6

21

 21 Flowbalancer MZAH-15
22 Screw conveyor NFAS 300 1.3 10
23 Screw conveyor NFAS 300 1.3 10
24 Bucket elevator MGEL-250/150 2.5 10
25 Dampener MOZG-1000
26 Screw conveyor NFAS 300 1.3 5
27 Tempering bins 5
28 Vibro discharger MFVH-180 1.3
29 Flow balancer MZAH-15
30 Aspiration channel MVSG-100 0.65 56
31 Screw conveyor NFAS 300 1.3 10
32 Bucket elevator MGEL-250/150 2.5 10
33 Magnet MMUA-20
34 Dampener 1st break MOZG-1000
35 Screw conveyor NFAS 300 1.3 5
36 Scourer MXHS 30/60 17 25
37 Light Peeler MXHM 40/65 60 25
38 Aspiration channel MVSG-100 0.65 56
39 Pre-break Bin 5
Transflowtron 1ST
40 MSDG-60
BK
41 Magnet MMUA-20
42 Filter MVRT 104/24 36.96*
43 Airlock MPSN-25/23 0.75
44 Filter MVRT 78/24 26.4*
45 Airlock MPSN-25/23 0.75
Total 226 599
* Calculations detailed in the filters selection section below

The total power consumption in the cleaning section is 226 KW

22

Screening section

SCREENINGS GRINDING: Air and Power Consumption

Power Air requirement
Machine Model Consumption [m3/min]
[KW]
Screw conveyor NFAS 300 0.65 5
Bucket elevator MGEL 250/150 1.75 10
Dump Scale MSBL-40 10
Screw conveyor MNSG-160 0.65
Mini Sifter MPAK-8 0.65
Hammer mill MJSA-0618 35 25
HP FAN 11 15
Total 49.7 65

The total power consumption in the screenings grinding section is 49.7KW

Filters selection:

Total air requirement is the sum of air volume for Cleaning and Screenings Grinding sections:

Total air volume = 599 + 65 = 664 m3/min.

Total air requirement = 730m^3/min (Adding a safety margin of 10%).

Thus, the air requirement of the Screenings Grinding section is being taken care of by the filters
in the Cleaning Section.
To reach a volume of 730 m3/min, we can use two (2) filters with detailed air requirement and
filter area for each filter presented in the table below:

Selection of filter size based on the area of filters and the volume required
Filters Volume [m3/min] Factor Area [m2]
1 x MVRT 104/24 415 4.6 89
1x MVRT 78/24 315 4.7 67
TOTAL 730 4.6 156

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Power Requirement of the filter fans:

Motor Fan 1:

Volume = 415 m3/min = 7 m3/s

Pressure = 3000 Pa = (3000 * 1.1) = 3300 Pa (with 10% safety margin)

P = (7 [m3/s] * 3300 [Pa]) / 0.75 = 30.8 KW (with Efficiency = 0,75)

Motor Power of Fan 1= 30.8 * 1.2 = 36.96 KW (with 20% safety margin)

Motor Fan 2:

Volume = 315 m3/min = 5.5 m3/s

Pressure = 3000 Pa = (3000 * 1.1) = 3300 Pa (with 10% safety margin)

P = (5.5 [m3/s] * 3300[Pa])/ (0.75) (with Efficiency = 0,75)

Motor Power of Fan 2 = 22 * 1.2 = 26.4 KW (with 20% safety margin)

Grinding section
MILL SECTION: Air and Power Consumption
Theoretical Commercial
Total
Power Power
machine Machine Model
Consumption consumption
s
[KW] [KW]
1 B1 MDDT 55 60
1 B2 MDDT 44 50
1 B3 MDDR 39.6 42
1 B4C MDDR 17.6 21
1 B4F MDDR 11 12.5
1 B5G MDDR 13.2 12.5
1 B5F MDDR 11 12.5
1 C1A MDDR 33 34
1 C2A MDDR 33 34
1 C1B MDDR 17.6 17
1 C2B MDDR 13.2 12.5
1 C3 MDDR 22 25
1 C4 MDDR 19.8 21
1 C5 MDDR 17.6 17
1 C6 MDDR 11 12.5
24

 1 C7 MDDR 8.8 8.6
1 C8 MDDR 8.8 8.6
1 C9 MDDR 8.8 8.6
1 C10 MDDR 6.6 6.4
1 C11 MDDR 6.6 6.4
1 Plansifter MPAK 825 11
1 Plansifter MPAK 1025 11
3 Purifier MQRG 1.38
5 Bran Finisher MKLA 45/100 27.5
MPAQ 10
1 Twin Rotostar sifter NOVA 2.2
1 Intensive Impact detacher C1A MJZF-51 18.5
1 Intensive Impact detacher C2A MJZF-51 17
1 Intensive Impact detacher C3 MJZF-51 12.5
1 Intensive Impact detacher C11 MJZF-51 12.5
Less intensive impact detacher
1 C2B MJZE-43 8.6
Less intensive impact detacher
1 C5 MJZE-43 6.4
Less intensive impact detacher
1 C6 MJZE-43 6.4
Less intensive impact detacher
1 C8 MJZE-43 6.4
Less intensive impact detacher
1 C9 MJZE-43 6.4
1 Drum detacher C1B MDL 300G 3.5
1 Drum detacher C4 MDL 300G 3.5
1 Drum detacher C7 MDL 300G 3.5
1 Drum detacher C10 MDL 300G 3.5
4 Pneumatic airlocks line 1-4 MPSN 25/23 x 5 2.6
1 Pneumatic filter airlock MPSN 25/23 0.65
1 Aspiration filter airlock MPSN 25/23 0.65
1 Blower Pneumatic GM-3S 2.2
1 Low pressure Fan motor 17
1 High pressure fan motor 52
Total 587.78

The total power consumption in the mill section is 588 KW

25

Air requirements for mill pneumatic and aspiration system

PNEUMATIC air requirement [m3/min/t/24hrs] [m3/min]

According to table: 8 roller mill at B1/B2 1.1
Required according to capacity (1.1 x 220 t/24h) 242
Plus 10% for aspiration of roller mills 266.2
Total with safety margin of 15% 306.13

ASPIRATION air requirement [m3/min/t/24h] [m3/min]

According to table: Purifiers MQRG 3 x 55* 165
According to table: Aspiration general equip. (scales,
screws, etc) 50
Total 270
Total with safety margin of 15% 310.5

Filter load for mill pneumatic [m2/m3/min] Area [m2]

1 x MVRT 104/24 89
Theoretical factor 3.4
Real factor 3.4

Filter load for mill aspiration [m2/m3/min] Area [m2]

1 x MVRT 78/24 67
Real factor 4.6

Motor for Aspiration Values Units

Volume 311 m3/min 12.44 KW (+) 20% safety
Pressure 3000 Pa 14.95KW*
Efficiency 75 %

Motor for Pneumatic Filter Values Units

Volume 307 m3/min 40.93 KW (+) 20% safety
Pressure 10000 Pa 49.12KW**
Efficiency 75 %
*17KW for 60hz
** 52KW for 60hz

26

Finished Products

Air and Power Consumption (Finish Product section)

Total Power Air

No. of
Machine Model consumption requirement
machines
[KW] [m3/min]
2 Micro feeder MSDF-20 1.3 0
5 Screw conveyor MNSH-125 6.5 25
2 Screw conveyor MNSH-80 2.6 10
1 Paddle table screw conveyor NFAS 200 1.75 7
1 NIR measurer MYRG 0 5
4 Transflowtron MWBO 140/160 0 16
2 Transflowtron MSDA 100/125 0 8
6 Filter MVRW 4/12 0 24
3 Blower GM-4S 25.8 0
3 Blower GM-25S 75 0
4 Airlock MPSH 22/22 2.6 0
4 Sterilator MJZH-100 34.4 0
1 Germ storage bin General 0 5
1 Elevator MGEL 250/150 2.5 10
12 Bin top Filter MVRW 12/24 0 36
14 Vibro discharger MFVH-125 9.1 0
6 Screw conveyor MNSG-250 7.8 5
1 Batch mixer DFML-1000 21 15
3 Micro dosing feeder MZMO-32-R 1.95 0
1 Rotary feeder MSDG 26/25 1.3 0
1 Turbosifter MKZF 40/90E 5.5 10
2 Airlock MPSH 28/30 2.6 0
1 Sterilator MJZH-165 17 0
2 Bran storage bin 35MT 0 20
2 Vibro discharger MFVH-125 2.6 0
1 Airlock MPSN 25/23 1.3 0
1 Low pressure fan motor ABB 12.5 0
Total 235.1 196.00

Aspiration for all machines (including 10% safety margin): 215.6 m3/min

Filter for Aspiration [m2/m3/min] Area [m2]

1 x MVRT 52/24 44.7
Real factor 4.8

27

 Aspiration fan motor Value Unit Calculation
Volume 215.6 m3/min 8.6
Pressure 3000 Pa (+) 20% safety
Efficiency 75 % 10.32

Laboratory
Power Consumption (Laboratory)
Power
No. of
Machine Type/model consumption
machines
[KW]
1 Analytical Scale Mettler Toledo 0.65
1 Precision Scale Mettler Toledo 0.65
1 RO water distilling system Thermo Fisher 0.65
1 Oven for Ash Binder 1.75
1 Oven for Moisture Content Binder 1.3
1 Extensograph Brabender 1.3
1 Farinograph Brabender 1.3
1 Alveograph Chopin 1.3
1 SD Matic Chopin 0.65
Perten DA
NIR analyzer
1 7200 0.65
1 Falling Number Perten 1000 0.9
1 Glutomatic+Gluten Index Centrifuge+Glutork Perten 2200 1.3
1 Lab Mill Perten 3100 1.3
1 Oven for baking test MIWE 4.6
1 Kneader for baking test Perten 1.3
1 Lab Mill Buhler 1.3
1 Lab Sifter Buhler 0.65
General services (ilumination, connections,
1 computers, etc) 2.5
Total 24.05

28

The Summary of the power consumption:

Power for the each section in the mill is shown in detail in the aforementioned tables from these
values the total power calculation of the plant is calculated approximately and compared with
other mills’ power consumption

Summary of Power Consumption in the plant

kwh/t of Total Power
Total Power kwh/t of
wheat with % of Consumption
Sections consumption Diversity wheat with
100% Total base on
[kw] Diversity
Diversity Diversity
Cleaning 226 19.73 0.75 18.7 170 14.8
Screening 50 4.34 0.25 1.4 12 1.1
Grinding 588 51.30 0.85 55.1 500 43.6
Finished
235 25.54 0.6 15.3 141 12.3
Product
Laborator
25 2.16 0.25 0.7 6 0.5
y
Utilities* 77 6.71 0.75 6.5 58 5.0
Total 1200 104.76 887 77.4
DIVERSITY: 100% & DIVERSITY: various values &
UTILIZATION: 0.8 UTILIZATION: 0.8

♦ Utilities*: 7% of (Cleaning, Screen Grinding, Grinding and Finished Product)

Power consumption in utilities = 0.07 * (226 + 50 + 588 + 235) = 76.93 KW

♦ The specific energy of consumption of the mill is calculated for the individual sections and

for the total consumption base on 100% diversity and by adjusting the various diversity

according to sections included in the listing 80% utilization applies in both cases. The

adjustment of the diversity is justified as follows:

I. Cleaning Section: Idle elevators and conveyors when receiver bins are full, change of

wheat grist, bypass of scourer etc.

II. Screen Grinding: This is based on 12hrs operation, hence, most of the machines will

only work for 12hrs or less

29

 III. Grinding: This is based on down during maintenance, roll change, grist change, and

stoppages due to problems in the mill, like cleaning choke, filter blockage etc.

IV. Finished Product: Filter fans on the product bins is considered because not all will

work at the same time and maintenance work can create down time e.g. fixing of belt

conveyor

V. Laboratory: Test are not being carried out throughout the 24hrs of operation, hence

equipment are not running for long ours throughout the day.

VI. Utilities: These include, Air-conditioning systems, light, elevators, infrastructures,

blower, compressor, dryer etc. Only the blower, Air-conditioning systems, dryer and

compressor are working mostly all the time. Lightings are out in administrative

blocks during the night and some other infrastructures.

♦ The total power consumption in the plant: 1200KW with 100% Diversity

Total power consumption in the plant: 960KW with 80% utilization

Total capacity of the plant: 220t/24hrs(9.2t/hr.)

Power consumption per ton of wheat = 960 [KW] / 9.2 t/hr = 104.34 kwh/t

This value is based on (100% Diversity and 80% Utilization)

♦ The total power consumption in the plant: 887KW with various % of diversity

Total power consumption in the plant: 709.6KW with 80% utilization

Total capacity of the plant: 220t/24hrs(9.2t/hr.)

Power consumption per ton of wheat = 709.6 [KW] / 9.2 [t/h] = 77.13 kwh/t

This value is based on (Different adjustments of diversity for each section according to time

of operation of machines as explained above and 80% Utilization)

30

 Energy"kwh/day"
UDliDes*
Laboratory Cleaning
7%
1% 19%
Finished Product
18% Screening
1%

Grinding
54%
Cleaning Screening Grinding Finished Product Laboratory UDliDes*

Fig: Energy Utilization in the various plant sections per day

According to a report on the manufacturing industry prepared by the U.S. Census Bureau in

2005, energy use in the United States was approximately 4 to 7 kilowatt hours (Kwh) per cwt of

flour produced. (80-140kwh/t).

http://www.world-grain.com/Departments/Milling-Operations/2008/9/Electrical-energy-savings-

in-flour-milling.aspx.

♦ Diamond Plant Utilizes: 77.13KWh/ton of specific energy consumption.

Assuming a safety margin of 10% power reserve, the total projected specific energy

consumption would be: 84.81KWh/ton.

♦ Diamond flourmill utilizes 84.81kwh/ton of energy per day compared to a maximum of

140kwh/ton as prepared by U.S census bureau in 2005.

♦ As such, our mill is in a lower range of power consumption.

♦ The possible reason for these differences are as follows:

31

 o The project focus does not include pre-cleaning, intake and packing.

o The level of automation in the running of the machines is for sure an important

consideration.

Although our power consumptions are in lower values expert electricians should evaluate our

calculations in a detailed manner.

Our mill will include 8% of reserve for spare power in the case of future mill

extension or unexpected circumstances. Therefore, total power can be considered to

be 958 Kw.

♦ Potential sources to reduce the energy consumption in Diamond flour mills includes:

I. Using energy efficient motors.

II. Using equipment to full load rather than partial load capacity

III. The use of automated control to aid energy conservation.

IV. Turning equipment off when not needed.

V. Avoid compressed air leakage and leaks in sight glasses, rotary valves, connections to

reduce energy demands.

VI. Cleaning and adjusting equipment, keeping them clean reduces energy demands (e.g.

avoiding dust on motors).

VII. Using energy saving bulbs for lightings and turn off when it is not needed).

32

Laboratory:

Operations:

The mill has 4 laboratory employees: 1 senior technician and 3 laboratory operators. Each

operator comes for one of the milling shifts (6:00-14:00 / 14:00-22:00 / 22:00-6:00), and the

senior technician comes from 8:00 to 5:00. The senior technician is responsible for wheat

blending and additives formulations. At the end of each shift, the responsible miller prepares a

sample for each finished product (flours 1, 2, 3, Biscuit Flour) for lab testing.

Main tests to be completed on the wheat from each truck at intake:

- Moisture content (%) – NIR Method (1’)

- Ash content (%) – NIR Method (1’)

- Protein content (%) –NIR Method (1’)

Total operating time per sample: 1 minute

Main tests to be completed on the wheat from the whole batch (representative sample from

all the trucks), tested as flour after milling with Buhler lab mill:

- RIDA Mycotoxin Analysis (10’)

- Test Weight (5’)

- Moisture content (%) – Oven and NIR Method (10’)

- Ash content (%) – Oven NIR Method (10’)

- Protein content (%) – NIR Method (1’)

- Falling Number (5’)

- Wet gluten content (40’)

- Baking test (40’)

Total operating time per sample: 2 hours

33

Main tests to be completed on all flour samples after each milling shift and finished

product samples:

- Moisture content (%) – Oven and NIR Method(10’)

- Ash content (%) – Oven and NIR Method (10’)

- Protein content (%) – NIR Method (1’)

- Chopin Alveograph (40’)

- Chopin SD Matic (10’)

- Falling Number (5’)

- Wet gluten content (40’)

Total operating time per sample: 2 hours

Tests to be completed on Flours 1, 2:

- Brabender Farinograph (50’)

- Gluten Index (40’)

Total operating time per sample: 1.5 hours

Tests to be completed on flours for baby food applications:

- RIDA Mycotoxin Analysis (10’)

Total operating time per sample: 10 minutes

Tests to be completed at every change of grist or for further analysis:

- Brabender Extensograph (50’)

- Baking Test (40’)

Total operating time per sample: 1.5 hours

34

Furthermore, the miller, as well as, the packing operator sends samples to the lab, every 2 hours,

to be controlled tested with NIR. Pollard germ and other by-products will be tested only for ash,

moisture and protein and in case of special customer demand.

In case of non-conformity, the flour would be analyzed to determine if it is acceptable or not, and

the actions to be taken place (in accordance to the HACCP and quality system).

Microbiological testing will be outsourced to certified laboratories (for the batch representative

wheat sample and the finished products), since private lab results are not certifiable, and we

would have to outsource it anyway. Thus, we cannot have an active release procedure since we

need to wait for outsourced test results and must be always ready for corrective actions and

product recall. Reference samples are stored for the period of the shelf life – 6 months.

Budget:

List of Lab Equipments Price $

Mettler Toledo Analytical Scale 4,000
Mettler Toledo Precision Scale 7,500
Thermo Fisher RO water distilling system 4,000
Oven for Ash 4,000
Oven for Moisture Content 3,000
Brabender Extensograph 50,000
Brabender Farinograph 55,000
Chopin Alveograph 50,000
Chopin SD Matic 22,000
Perten DA 7200 NIR Analyzer 50,000
Perten Falling Number 1000 25,000
Perten Glutomatic 2200 + Gluten Index Centrifuge 2015 + Glutork 2020. 30,000
Perten Lab Mill 3100 7,500
Oven for baking test 20,000
Kneader for baking test 5,000
RIDA mycotoxin analyzer 2,000
Buhler Lab Mill 45,000
Buhler Lab Sifter 6,000
Test tubes, decicator, crucibles, graduated cylinders, beakers … 10,000
TOTAL $400,000

35

Allocated Budget for yearly operational costs:

Description Expense (yearly)

Allocated budget for operations (maintenance, spare-parts, 24,000$
calibration, reagents, … )
Outsourced laboratory testing 16,000$
Salary for Senior Laboratory Technician 24,000$
Salary for 3 Laboratory Operators 36,000$
TOTAL 100,000$

Product specification:

36

HACCP
I - Product description/Scope:

In Diamond Flour Mills, three different types of flour are being produced and biscuit flour will

be a future product. The ash content of all the flours varies from <0.44% to 0.60%. Moreover,

Germ with a fat content >9% has also to be marketed in our concept. All the flours that are being

produced are not intended to be consumed raw, mainly they are baked to different bread,

biscuits, and baby food products. The shelf life of all flour will be 6 month. The water activity of

the flour is considered to be very low (lower than 0.65) which also has to be considered for the

storage purposes and for the purpose of HACCP.

HACCP is required as an integral part of our processes due to various important reasons. Firstly,

our customer demands a high requirement in terms of minimizing Don/Vomitoxin in our

products. This is because the flour is needed to be used for baby food. Secondly, we need proper

traceability of our products. And thirdly, HACCP is needed to fulfill the growing hygienic and

safety requirements of the overall consumer market. Thus integrating HACCP in our process is

an absolute must.

II - Prerequisites for HACCP:

To implement HACCP, it is a must to fulfill its prerequisites. These prerequisites include good

manufacturing practices (GMPs), personnel hygiene, safe working conditions, effective

maintenance schedules, pest control program and employees having food education and food

safety trainings. Other prerequisite that have to be followed in the operating procedure are

enlisted below:

37

 1. Water treatment using sand filters, chlorination with carbon filter, softener and UV light.

This is to decrease microorganism count, and reduce the risk of chemical contamination.

2. The raw materials to be used on our mill like additives are to be bought from credible and

audited suppliers.

3. The pre-cleaning of wheat is the beginning of HACCP where the raw wheat is tested and

at the same time the impurities are removed. This in turn improves the hygienic

conditions of our raw wheat storage.

4. Apart from microbiological testing, allergens and heavy metals tests will also be

outsourced to certified labs, as scheduled routine checks. Monthly samples from our

water supply will be sent as well, to monitor the effectiveness of our water treatment.

5. Proper traceability is ensured during and after operations by the company’s quality

management system and records management system with batch numbers, referencing

documents and archiving software (eg. SAP). As already mentioned in the “Laboratory”

part, reference samples are stored for the period of the shelf life – 6 months.

38