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Flaking mill upgrade by Perry of Oakley Ltd
Perry of Oakley Ltd are the UK’s most experienced manufacturer of materials drying & handling equipment. Established in 1947, this year marks 70 years of successful installations of their British made machines. They export their machines globally and are well represented with a network of dealers & specialist engineers worldwide.
Perry of Oakley Ltd are best known for their grain handling and drying equipment, and are well established within the agricultural industry, however they have also provided solutions for many other industries including; coal, minerals, biomass (including wood chip, sawdust, shavings & pellets), sewerage & sludge, digestate, rubbish/refuse, grass & many others. The relatively recent launch of their Belt Drier now allows them to provide other industries with fast, efficient and cost effective drying solutions.
Perry of Oakley Ltd recently provided a complete flaking, drying & handling solution for a commercial feed plant that produces flaked maize for dairy cow feed. The installation was completed over several stages in order to not disrupt the ongoing production of the flakes.
Stage one of the upgrade involved increasing the input to the tempering bins in order to keep the planned and existing flaking lines fed with sufficient raw material. A new line between the day bin & the tempering bins was added. From the day bin a 10tph chain & flight store conveyor takes the corn through an aspiration unit, cleaning away any light impurities. An auger then feeds a 12.5m belt & bucket elevator, which in turn feeds a milling separating machine, another aspiration unit and then a de-stoner.
After the de-stoning process the kernels are taken via another belt & bucket elevator, through to a highly-sophisticated dampening system to take the moisture content from around 11% to 18%, ensuring the corn is ready for dampening. The dampening system comes with automatic moisture control & water dosage. It is a stainless-steel measuring channel with online temperature, moisture & hectolitre weight measurements.
A series of belt & bucket elevators and chain & flight conveyors then transports the dampened corn to tempering bins. The tempering process then takes between 8 & 10 hours.
Perry supplied and installed most of the equipment within the new pre-dampening line, including sourcing and installing the specialist machinery. They were able to adapt the existing machinery to suit the new system currently installed, helping to keep costs to the customer to a minimum.
Stage two of this installation was to install a third flaking line (LINE 3). The new flaking line takes the tempered kernels via a pre-existing belt & bucket elevator through a new bullet type magnet, which removes any metallic impurities ensuring the rolls within the flaking mill are not damaged. An existing conveyor then feeds a new store conveyor which feeds the new flaking line. The store conveyor is equipped with electro-pneumatic outlets, which allows surge bins to call for the kernels as and when they are needed. The surge bins then feed a steam chest, which slowly cooks the kernels as they pass down through the chest towards the flaking mill, the kernels are then fed through to the flaking mill by a pin feeder which controls the rate that the mill is fed with corn.
Perry’s range of store conveyors are capable of handling capacities of up to 1000tph and are all manufactured using highly durable galvanised steel. They come in widths from 7” right up to 1m wide. There is no metal to metal contact on any of the chain and flight conveyors, helping to increase the longevity of the conveyors. A range of chain speeds are offered to suit various different products, ensuring minimal damage to the product while being conveyed.
Once the corn has been flaked, the flakes are then discharged directly into a Perry Belt Drier/ Cooler, which takes the moisture content of the flakes from 23% down to 11% by drying and cooling the flakes, which gives the flakes a much longer storage life. The customer installed a 10tph belt drier, but currently only requires it to output approximately 8tph to keep on top of stock piles required for the herd.
The Perry belt drier has proven to be an effective tool for drying flaked maize as, unlike other driers, air is drawn down through the product bed, meaning there is minimal product lift. There are also no slats or chains to come into contact with the product, meaning there is minimal product damage during the drying and cooling process. The consistent air flow within the belt drier is aided by the fact that there are no louvres or perforations to become blocked, this also means that in this particular application the Perry belt drier requires less frequent cleaning than that of its competitors.
On discharging from the drier, the dry flakes are deposited into a new chain & flight conveyor that feeds directly into an existing belt conveyor, which in turn takes the dried flake in to stores.
Perry experienced engineers were able to supply and install the full flaking line, including the surge bin, steam chest and flaking mill along with adapting the existing machinery to ensure the whole process runs efficiently and smoothly.
With the new flaking line installed and working efficiently, the third stage of this installation involved shutting down LINE 2 in order to add a belt drier to dry and cool the flakes after the flaking process. Because the Perry Belt drier installed in LINE 3 had proven to be a lot more efficient and required a lot less maintenance than the existing drier in LINE 1 the customer opted to install another 10tph Perry Belt Drier.
The second Belt Drier discharges in the same manner as the first, including feeding the same belt conveyor that takes the dried flake to stores.By improving the pre-tempering line, adding a whole new line and improving the second line Perry have now increased their customers overall output to an average of 25tph. This has allowed the customer to meet their ever-increasing demand and allows for further growth. They also now have a stock pile of flaked maize, which reduces the pressure on all 3 lines, allowing them to work under their maximum output.
If you require a solution similar to the one described in this article, or another drying or handling solution please contact Perry of Oakley Ltd on +44 (0)1404 890300 or visit www.perryofoakley.co.uk