x

Defining Corrugations

with rollDetect

IAOMCentral, Wheat State & Texoma District Conference

July 2015

Bill Ritchie

2 | © Bühler |

x

Being creative with new technology!

3 | © Bühler |

x

dddd | RT | 2011

Creative Ideas to help millers… Be more profitable!

New ways to

Monitor

Corrugated

Passages

Break release

Thinking outside the

box to obtain

consistent results!

4 | © Bühler |

x

Advancements in profile imaging.

Profile imaging provides

another way to determine

the corrugators

performance.

5 | © Bühler |

x

Defining Corrugations – establishing the performance limits of the roll profiles.

New Reconditioned Roll Same roll 9 months later

GM Roll Detect Service | 2014

6 | © Bühler |

x

How do we know when enough is enough…

GM Roll Detect Service | 2014

7 | © Bühler |

x

Roll performance increases with correct corrugations

3 key advantages with correct corrugations:

Smaller load on the subsequent grinding passes,

since a greater proportion goes directly to the

reduction passes

Fewer necessary steps in the reduction process

Significant energy savings in the whole grinding

process

8 | © Bühler |

x

Goals of roll Evaluation!

Customer Service | Stefan Kellenberger | 2014-08-16

Detection of the right timing for roll

re-fluting

Advantages:

• Objective measurements!

• Control extraction rate!

• Save energy!

• Determine actual wear on rolls!

:

Determine causes of roll wear!

Evaluate corrugation geometry –

• Focus on adding value to roll

performance!

9 | © Bühler |

x

Roll evaluation - Measure to help determine your performance!

Preparation

Measurement

Report

Customer Service r | 2014-08-16

10 | © Bühler |

x

Multi-

Point Cutting

Single Point

Verification of quality or condition.

Roll wear

11 | © Bühler |

x

Knowing when the worn roll is past its prime.

How do we stop this from happening to us?

12 | © Bühler |

x

A good example of 9% percent wear on a dull to dull installation.

Used Form 18 on a 1st break after 10 months

13 | © Bühler |

x

Sharp to sharp roll installation – high percentage wear.

What can we see from this corrugation

profile?

14 | © Bühler |

x

Dull to Dull installation of rolls showing 42% wear.

15 | © Bühler |

x

Sharp to Sharp wear on rolls – what are these rolls telling us?

16 | © Bühler |

x

Dull to Sharp configuration with 16% wear. What can we see happening here?

17 | © Bühler |

x

Both profiles are new rolls – both are Stevens 32 cuts/inch.

GM Roll Detect Service | 2014

18 | © Bühler |

x

Getchell cuts: defining when the radius becomes an oversized land.

19 | © Bühler |

x

New profiles

New Form 18

New Modified Dawson

20 | © Bühler |

x

This corrugated roll went pasts its limit.We can improve roll performance to minimize this…

Maybe we can totally stop this from happening all together in today’s

milling operations!

21 | © Bühler |

x

Things that are coming our way…Measuring the surface of smooth rolls.

22 | © Bühler |

x

Customer Service r | 2014-08-16

We know grinding action with corrugated rolls is a cutting action!

• Dull corrugated rolls use a compression action

for grinding and act like smooth rolls.

• Compression action takes more horsepower to

do the same work and is the type of action that

occurs with smooth rolls.

Optimized

Rolls

Maintain

milling

performance

23 | © Bühler |

x

Application of the information.

How can we apply the

information we collected from

our rolls?

Something new in the industry.

24 | © Bühler |

x

Tracking roll wear to determine savings!

Increasing

yield

and

saving

energy!

25 | © Bühler |

x

Optimizing the rolls: Establishing a “Best cost per ton”

26 | © Bühler |

x

Outlook: ecoReport

27 | © Bühler |

x

In the pursuit of quality - high achievers bring an approach to work that is methodical and demanding!

Pay rigorous attention to detail!

“Smart” Millers are the ones who know their success comes down to the smallest details. This helpsthem maintain a competitive edge and a quality finished product.

28 | © Bühler |

x

Defining Conclusions:

Our corrugations are telling us what is happening!

• Today we have available smart technologies to collect data from our roller mills to achieve a “Best Cost per Ton” on our mill performance.

• We can save money by using the data to our advantage by getting a competitive edge on mill performance!

• “Information is Power!” Plant managers, milling superintendents and head millers have the opportunity to make educated decisions on roll performance based on roll wear.

• Be inspired to be passionate about the details that produce quality!