THE MACHINES OF THE MILL: THE DEBRANNER
The article describes the machines that make up the mill, in particular the debranner.
In recent years, the debranning pre-milling process has become increasingly popular among milling operators. It improves the milling performance of cereals. The process can be considered as one of the major and substantial innovations of the milling process.
The debranner is a turning point in improving the health aspect of cereals. It is placed at the beginning of the traditional milling process to eliminate the cortical part, keeping the grain intact.
Most of the bran is removed by a progressive and controlled surface abrasive action. This allows to increase the extraction performance compared to the standards, to improve the cleaning of the semolina and to increase the production capacity.
The characteristics of the debranner
- Decortications chamber;
- Abrasive stones;
- Vertical rotating shaft;
- Perforated shells;
- Impulsion fan.
The grain, wet and conditioned, enters the machine from the top. It is distributed uniformly and automatically, in the decortications chamber.
Inside, special conveyors arrange to place the grain in relation to the abrasive stones to uniformly decorticate it.
The bran is expelled through the perforated shells surrounding the rotor (vertical rotating shaft). It comes out thanks to the aspiration transport to which the machine is connected and to the impulsion fan provided by the machine.
The degree of decortication depends on the amount of cereal in the machine and also on the time the cereal is kept. These are determined by an electronic software that control the exit valve.
The preventive removal of the tegumental layers by abrasion and friction actions conducted on the grain makes it possible to greatly simplify the grinding diagram by reducing machines and grinding passages.
The advantages of the debranner
In general, husking may improve the hygiene and health characteristics of durum wheat by increasing the safety of the use of finished products. In addition, a useful tool for nutritional and health purposes, to enrich the raw material with bioactive compounds such as fibers and antioxidants.
The debranning process is able to:
- Increase the milling yield;
- Reduce α-amylase activity in flour (germinated grains);
- Obtain by-products with bioactive components;
- Obtain safer flour from the hygienic-sanitary point of view (less presence of phytopharmaceutical residues, heavy metals and mycotoxins);
- Improve the quality of flours (less stains, moulds, bacteria, mycotoxins and ash).
It has been studied the debranning treatment applied to wheat caryopsis with a level of contamination higher than the legal limits and different debranning times have been tested.
The results showed the effectiveness of this treatment in reducing the level of DON (deoxynivalenol, a mycotoxin) in the shelled grain and a progressive concentration of mycotoxin in the husking waste.
The first debranner of Molitecnica Sud
As far as the company reality of Molitecnica Sud is concerned, the first debranner built in our factory dates back to 2012. Today we are able to design and build not only high quality shelling machines entirely produced in Italy, but also complete grinding plants suitable for every need. To learn more about milling plants click here.
MOLITECNICA SUD CERTIFIED MADE IN ITALY 100%
Molitecnica Sud certified 100% Made in Italy by the Institute for the Protection of Italian Producers.
The registration n° IT01.IT/2129.118.V certifies that Molitecnica Sud is a certified trademark with the requirements of the system IT01 – 100% Original Italian Quality. It is valid in the field of equipment and machinery for mills, feed mills, pasta factories and bakeries.
Click here, to view the certification.
Made in Italy 100% Certificate
Here are the words that are a source of pride for every Italian producer. Made in Italy is an ancient prestige. It is based on creativity, quality and inventiveness.
Made in Italy, from fashion to footwear, from furnishings to inventions and scientific discoveries, has always distinguished us in the world.
The Institute for the Protection of Italian Producers
The Institute for the Protection of Italian Producers ITPI is the certifying body of the product entirely made in Italy.
Italiananity of the brand awarded contributes to the immediate recognition of our products, which boast and elevates them in terms of quality as well as general image. The brand “Made in Italy 100%” can only be awarded to products made entirely in Italy, such as our machines and our plants. Click here, to learn more about the Institute.
How the certification takes place
The Institute for the Protection of Italian Producers has created a certification system through which producers like Molitecnica Sud distinguish their creations from those of dubious Italian origin. Giving certainty to the final consumer about origin and quality.
Recent sociological studies have shown that the consumer’s determination to purchase depends on a guarantee. No product can therefore have a distribution perspective without representing and being the bearer of a guarantee.
The products of Molitecnica Sud, certified Made in Italy, fulfil all the following requirements:
1) Entirely designed and manufactured in Italy:
- Made with exclusive drawings and design of the company;
- Entirely built in Italy;
- Made with Italian semifinished products;
- Traceability of the processes.
2) Built with natural and high quality materials:
- Individual or compound natural materials;
- High quality materials and first choice for the intended use;
- Traceability of the origin of raw materials.
3) Built on typical traditional workings:
- Specific processes of the company;
- Use of traditional typical techniques.
4) Realized in the respect of job, hygiene and safety:
- Realized in full respect of the job;
- Health and safety at the workplace and of the manufactured products used.
The other certifications of Molitecnica Sud
THE MACHINES OF THE MILL: THE PLANSICHTER
The article describes the machines that make up the mill, in particular the plansichter.
We have described the cleaning process (you can read about the cleaning here) and grinding the grain (you can read about the cylindrical grinding here and about the stone grinding here). Contrary to what one might think, flour does not come directly from the milling processes, but is obtained thanks to the screening and selection processes, which are carried out in the plansichter.
The history of the plansichter
The history of grinding began in the Egyptian era, with the first attempts to sift the products of grinding. So we can trace back to this time the birth of flour as well as the beginning of the history of plansichter.
The evolution of the plansichter continues in the Roman era, when they began to use rotating hexagonal sifter.
In the Middle Ages it was then switched to centrifugal sifter, consisting of an external rotating drum, a metallic net and a counter-rotating, to push the flour thanks to the centrifugal force.
In 1880 when the flat sifter was invented and in 1905 it was equipped with a free oscillation system. The new machine conceived is patented and called “plansichter”.
The characteristics of the plansichter
- Loading handles in flexible fabric for the loading of flour to be screened;
- Stacks, housed inside the channels contained in the steel case;
- Channels containing “parcels” of detachments consisting of overlapping sieves and frames;
- Insulated doors of the channels, to prevent condensation and limit noise;
- Suspension rods made of fibreglass, are connected to the case on one side, and to the ceiling on the other. They hold the machine suspended and are flanked by metal cables that hold the case in case of accidental breakage;
- Unloading handles made of flexible fabric that send the waste of the stacks to subsequent processing or to the flour silos.
The plansichter receives the milled products from the mills and selects the various fractions of these flour, through the stacks and the different veils:
- Rollermills receive the coarsest fractions for the subsequent grinding steps;
- Purifier receive the semolina and the semolina, of intermediate grain size;
- Bran finisher receive the cortical fractions, corresponding to the outer layers of the grain, for subsequent processing;
- Storage silos receive flour.
In order to carry out these tasks, the detachment is mounted on a frame that has the function of separating the two adjacent detachments and collecting the product passed through the top detachment. Ejectors send the unloaded fraction to subsequent processing, pushing the flours towards the chassis drains. The movement of the ejectors, and their particular shape, equipped with brushes or rungs, allows to keep clean the veils, which would otherwise lose effectiveness remaining clogged.
The first plansichter of Molitecnica Sud
As for the company reality of Molitecnica Sud, the first plansichter built in our factory dates back to 1989. Today we are able to design and build not only high quality plansichter entirely produced in Italy, but also complete plants and suitable for every need. To find out more about the mills click here.
THE MACHINES OF THE MILL: THE ROLLERMILL
The article describes the machines that make up the mill, in particular the rollermill.
We have already talked about cylindrical grinding (you can read about cylindrical grinding here). This process allows you to break the grain of wheat, sift the product and regrind it to obtain the flour. The machine used for the breakage and the regrind is called a rollermill.
The history of the rollermill
In ancient times, alternative grinding systems to stone grinding (you can read about stone grinding here), such as the rollermill, were developed.
The first news of an iron machine that could grind wheat goes back to the time of the Emperor Charles V of Spain. In 1500 he ordered the construction of grinding rollers equipped machines.
But only after 150 years machines with two grinding rollers, similar to the current rolling mills, were born. These machineries were able to crush grain.
The efficiency and the qualitative performance of the milling on several passages was realized. This gave a great boost to the milling evolution reaching its current characteristics around 1870.
It can be seen that these machines have maintained some characteristics unchanged for about 150 years:
- The rolling mills are topped by a transparent bell through which the grinding product is loaded. It allows an immediate visual inspection of the product to be processed;
- The grinding product is sent to the pair of grinding rollers using feeding rollers. They ensure a regular dosing of the product;
- Each rollermill contains 2 pairs of rollers;
- The rollers are carved for the first grinding passages and smooth in the regrinding passages;
- The rollers that make up each pair are counter–rotating, and they move with differentiated speed. This is because for a correct grinding it is necessary, not only to crush, but also to break and stretch the grain of wheat;
- The rollers are enclosed in a metal frame that prevents the entry of unwanted elements;
- Distance between grinding rollers is adjusted by a lever system;
- The collection hopper collects the freshly ground product.
Modern rolling mills offer essential improvements compared to those of the past:
- Level sensors electronically adjust the speed of feeding rollers, depending on the amount of product in the bell;
- Increased hygiene level thanks to the elimination of wood and glass elements and geared transmissions in oil bath. Also due to the introduction of scrapers that keep the surface of the rollers clean;
The first Molitecnica Sud rollermill
Regarding Molitecnica Sud business reality, the first rollermill built in our establishment dates back to 2005. Today we are able to design and build not only high quality rollermills, entirely produced in Italy, but also complete grinding plants, suitable for every need. To find out more about our mill plants click here.