World Grain - September 2020 - 38

the mill, with a 100-tph pre-cleaning section using the
MGSH 120 high capacity grain separator. In the 350-tpd
milling section, all the roller mills are Milleral/IMAS'
latest MML Multimilla model with diameters ranging
from 250 to 300 mm. The project also included jumboW\SHSDVVDJHSODQVLIWHUVDQGDQ063PRGHOSXUL¿HU
which has an aluminum body and steel base. The mill
KDVDIXOODXWRPDWLRQV\VWHP7KHÀRXUSDFNLQJVHFWLRQ
has a capacity of 40 tph and includes a mixer.
The mill has an automatic dampening machine and
DQ0)%$DXWRPDWLFÀRZEDODQFHU:KHDWLVVRXUFHG
IURPWKH8QLWHG6WDWHV8NUDLQHDQG.D]DNKVWDQ7KH
PLOOSURGXFHVÀRXUDQGEUDQ

Pioneer Foods
doubled the
capacity of its
wheat mill in
Durban with
the addition of
a second line
supplied by Alapala.

PIONEER DOUBLES FLOUR CAPACITY
Pioneer Foods, one of the largest South African producers and distributors of a broad range of branded
food and beverage products, recently doubled the capacity of its wheat mill in Durban with the addition of a
second line. The new equipment, supplied by Alapala,
EDVHGLQ&RUXP7XUNH\ZDVLQWHJUDWHGLQWRWKHPLOO¶V
existing automation and control systems. The equipPHQWLVH[SHFWHGWRLPSURYHRSHUDWLRQDOH൶FLHQF\DQG
ERRVWWKHTXDOLW\RIÀRXU
The company was established in 1997 and operates
mainly across South Africa but also exports to more
WKDQ FRXQWULHV 7KH JUDLQV EXVLQHVV LQFOXGHV ¿YH
ZKHDW PLOOV DQG WKUHH PDL]H PLOOV D SDVWD SODQW DQG
WZRULFHDQGGULHGYHJHWDEOHSDFNLQJIDFLOLWLHV
:LWKWKHDGGLWLRQRIWKHVHFRQGPLOOLQJOLQH3LRQHHU

LVDEOHWRSURGXFHKLJKTXDOLW\EDNLQJÀRXUIRULWVWZR
EDNHULHVLQ.ZD=XOX1DWDOSURYLQFHDQGVHUYHWKHUHJLRQDOPDUNHWPRUHH൵HFWLYHO\,WZDVGHVLJQHGWRSURGXFHDZLGHYDULHW\RIORZDVKSDVWU\DQGFDNHÀRXU
PXOWLSXUSRVHÀRXUDQGEDNHU\ÀRXUIRUEUHDG/RFDO
and imported wheat is used depending on seasonal
availability, cost and quality.
The plant design meets sanitation standards and food
safety regulations with food grade materials. Mill management is carried out through an advanced automation
system combined with Scada software that allows for
FHQWUDOL]HGPRQLWRULQJRIWKHHQWLUHPLOOLQJSURFHVVDQG
generating detailed reports on production data.
Automation software is combined with a yield conWUROPRGXOHZKLFKFROOHFWVDQGDQDO\]HVZHLJKLQJLQformation by DURA extraction scales from eight different places in the process.
Flour quality is controlled through near infrared techQRORJ\LQVWDQWDQDO\VLVWRWUDFNDQGGLDJQRVHDQ\GHviation in quality parameters such as ash and moisture.
$IWHULQWDNHZKHDWLVWDNHQLQWRGD\ELQVDQGJRHV
through the grain separator, dry stoner, scourer cleaning machines and magnetic separators. A color sorter
LV XVHG IRU D ¿QH UHPRYDO RI IRUHLJQ VHHGV GDPDJHG
NHUQHOVDQGPRUHWRHQVXUHDKLJKOHYHORIIRRGVDIHW\
A start-up silo is used at the start of production or durLQJWKHVKLIWLQJRISURGXFWLRQEHWZHHQÀRXUW\SHV7KH
purpose is to collect the residual material from the previous shift/production run to ensure hygiene and product
VWDQGDUGL]DWLRQ$LU 3OXV -HW )LOWHU .)6$ LV XVHG IRU
FOHDQLQJ RI WKH DPELHQW DLU LQ WKH PLOO 7KH ¿OWHUV DUH
equipped with explosion relief for operational safety.
The milling unit features Alapala's new generation machines, including the Similago II Roller Mill. It has PLCcontrolled product feeding and grinding control systems
for continuous and consistent grinding performance. The
UROOHU PLOO KDV DQ LQWHUQDOO\ DVSLUDWHG LQOHW EXQNHU ZLWK
polycarbonate inspection glass against condensation.
The feed rate is automatically controlled by using
D FDSDFLWDQFH VHQVRU DW WKH LQOHW EXQNHU ZKLFK VHQGV
a signal via PLC to regulate the speed of feed rolls.
Grinding rolls also have a sensitive grinding gap adjustment and are protected with a special mechanism
WKDWJLYHVÀH[LELOLW\WRWKHJULQGLQJUROOVDJDLQVWRYHUVL]HGREMHFWV7KHJULQGLQJJURXSDOVRLVHTXLSSHGZLWK
monitoring sensors.
Roll changes can be carried out within 20 minutes
and no special tools and lifting devices are required,
which reduces downtime. The graphical touchscreen
of the roller mills allows the setting of operational parameters, as well as monitoring feed roll speed, motor load, and power consumption. The central lubricaWLRQ V\VWHP LV RSWLRQDOO\ ¿WWHG LQ HDFK UROOHU PLOO IRU
easy maintenance.
September 2020 / World Grain / www.World-Grain.com

Photo courtesy of Alapala

FEATURE: FLOUR MILL CONSTRUCTION CONTINUES THROUGH PANDEMIC

http://www.World-Grain.com

World Grain - September 2020

Table of Contents for the Digital Edition of World Grain - September 2020