Even new materials need regular refurbishment. From both a safety and performance reliability point of view, it is essential that mill maintenance is carried out to a pre-determined schedule. However, when delivery dates need to be met and staffing levels are stretched, this can prove difficult. At such times, a resource such as the Satake Europe Site Services Team can help.

1. Digital Re-print -
November | December 2012
Delivering world class roll chill
technology and service
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2. FEATURE
Delivering world class roll chill
technology and service
by Neil Reedy, Service Engineering Manager, Satake Europe Ltd, United Kingdom
E
ven new materials need regular Re-fluting, using tungsten carbide fluting microns over a diameter of 250 mm. The
refurbishment. From both a safety bits, restores the profile to the exact speci- frosted finish, necessary to ensure immediate
and performance reliability point of fication required for the client’s application. grip when the rolls go into grind, is achieved
view, it is essential that mill maintenance is In Satake Europe’s experience, one in ten by blasting highly abrasive particles at the sur-
carried out to a pre-determined schedule. rolls sent for refluting displays defects, which face using automated shotblast equipment.
However, when delivery dates need to would have a fundamental effect on mill Before despatch, each roll undergoes
be met and staffing levels are stretched, performance and safety – such as a damaged testing which, in the case of roll packs,
this can prove difficult. At such times, spindle, less than the recommended chill includes an optional running period on
a resource such as the Satake Europe diameter, or chill quality, which could affect a roll bearing test bed. This ensures
Site Services Team can help. roll performance. the shortest possible interval between
delivery, installation and regaining full
State of the art roll grinding production in the mill.
Quality and safety technology Custom-built machinery laid out in a
The quality of the grinding and fluting processes, All of these would be identified and cellular style and standing on four metre
whether being carried out on a new roll or during reported on, supported by relevant data deep foundations to eliminate transfer of
refurbishment, determines the performance of the compiled using a combination of engineering vibrations, provide the capability of produce
roll and, thus, the quality of the end product. An skills and high-tech instrumentation. 1,500 new and 4,000 refurbished rolls per
integral part of each refurbishment is the careful From its flour milling ‘Centre of Excellence’ year for customers in Europe, the Middle
inspection of each roll or ‘roll pack’ module before in Bredbury, near Manchester, Satake Europe East and Africa.
any work can begin. This exercise is followed by offers a standard roll refurbishment turna-
the compilation of a complete inspection report, round of three weeks and an emergency Delivered on specially designed
detailing the findings, recommendations for action service of 72 hours. pallets
required and associated costs. Many of the defects can be rectified, and To ensure that refurbished rolls arrive back
Satake Europe offers the full range of reme- at a client’s mill in the same precision-ground
dial operations, including re-gudgeoning, condition as when they left the fluting section,
reducing the need for such defective rolls to Satake Europe has devised a special pallet
be scrapped. design.
Once the completed report has been On completion, the rolls are coated with
emailed or faxed to the customer and work rust –preventative food safe oil, covered in
instructions agreed, rolls are ground until a rust –preventative paper and sealed in a pro-
smooth, parallel surface is obtained. tective plastic sleeve before being mounted
Re-fluting, using tungsten carbide fluting on the pallet, accompanied by documenta-
bits, restores the profile to the exact specifi- tion detailing destination, flute specifications
cation required for the client’s application. A and a unique roll number. This ensures com-
profile shadowgraph is used to examine the plete traceability for each individual roll and
pitching, depth, angle and land of the flutes, enables a statistical history to be maintained
as well as for checking thread forms and flut- which can prove invaluable when monitoring
ing tools within the Bredbury facility. mill throughput.
The optimum number and profile of
the flutes, relevant to the application of the Innovative use of modern
roll, have been developed over many years materials
and are specified to high levels of accuracy. As the largest roll chill supplier in the UK,
Satake Europe offers a standard range of Satake Europe offers new and refurbished
more than 100 different flutes profiles, with rolls for all makes of rollermill. With a port-
other bespoke arrangements available. folio of four different types of roll Satake
Europe has an in depth knowledge of a range
Grinding and fluting of those featuring new materials available
Smooth rolls are ground with either from leading manufacturers.
a taper or camber to a tolerance of four Extending flute/corrugation life and ena-
26 | november - december 2012 Grain &feed millinG technoloGy

3. FEATURE
bling chills to be refurbished up to 15 times, fluting. Smooth rolls require an outer surface by experienced engineers for all aspects
modern metallurgical developments have that can be ‘frosted’ creating a matt or non- of millwork, roll changes, airlocks to sifter
extensively widened the miller’s range of glazed surface which will effectively grip the maintenance and frame recovering services,
options. product and be resistant to abrasive wear. we are here to help.
Whatever the material – and chilled cast iron With many mills running 24 hours seven
rolls remain the traditional choice for break and Site services days a week, it has become even more
reduction work – the outer surface of fluted/ To compliment our projects and machine important that mill equipment is kept well
corrugated rolls needs to be resistant to abrasive sale capability, Satake Europe also offers maintained. Mills however do not employ
wear in order to retain the required profile. a full range of maintenance and spares more maintenance staff than is necessary for
The surface must be hard but not brittle services. Our aim is to become the number the day-to-day running of the mill so during
to avoid chipping, and it is important that one choice for process and mechanical sup- the down periods, additional staff is often
the roll chill can machined with conventional port in the milling industry. Building on our required to assist with the extra maintenance
tools avoiding unnecessary cost when re- long history we can offer tailored support and process work on the plant.
Grain &feed millinG technoloGy november - december 2012 | 27

4. FEATURE
able to carry out this Sieving solutions
New rolls manufactured for work and in addition We have sieve a re-covering department
all major rollermill types to to this, we can assist that can meet the demands of the industry
customer requirements in the development of and ensure the covers for process work are
planned, preventative available when required; our pneumatically
maintenance programs stretched screens have a controlled tension
Standard rolls - chilled iron, centrifugally cast and dynamically to ensure greater that allows for consistency across the entire
balanced for greater precision, providing a consistent uniform plant performance and sieve surface. With the use of our own
hardness. efficiency, giving cus- adhesives, these also secure all of the threads
C12 rolls – high chrome alloy, giving an average life twice that tomers less downtime, unlike stapled sieves, and the sanitary bond
of a standard cast iron roll, resulting in reduced mill downtime resulting in improved helps eliminate the threat of insect infesta-
for roll changing. efficiency and produc- tion in this area.
tion. The sieve cloth stretching equipment and
‘Self mating’ rolls – with a material composition formulated Milling engineers new binding techniques have improved he
to maintain a heavier frosted finish for special reduction also require staff avail- quality of the sieves and when done in con-
applications. able at short notice to junction with sifter maintenance have helped
Water cooling - Water-cooled roll options are available for assist with emergencies dramatically improved the efficiency of the
all of the above types. with all types of equip- sifting operation and could increase through-
ment; Satake Europe put by one percent. Whilst maintaining good
Fluted to your individual specifications. has a team of mechani- chill roll condition can increase initial yield
Spindles are machined or ground as required. The available cal engineers familiar and reduce the rework of product giving a
roll size is up to 450 mm diameter and extends to 1500 mm with many types of saving in time, power consumption and cost
in length. milling equipment who per tonne of final product.
can respond to these
requests.
With the use of
It is common practice to have inde- preventive maintenance programmes and More inforMation:
pendent contractors in flourmills working service agreements, it is possible to create Satake Europe Limited
along side or independent to the mill a schedule well in advance of the shutdown Tel: +44 161 406 3800
maintenance team, to tackle such tasks detailing the tasks required and ensure the Fax: +44 161406 3801
Email: sales@satake-europe.com
as roll changes and sifter maintenance. necessary resources are in place to complete
Website: www.satake-europe.com
Here at Satake Europe our professional all the planned tasks on time and help con-
mechanical and process teams are avail- trol mill running costs.
Die and roll re-working machines ATEX LEvEL swiTch
The capacitive proximity switches in the DOL 40R series are now
available with ATEX approval for use in areas with constant danger
of dust explosion.
• Designed for detection on grain, feed and granules
• Zone 20 approved - for use inside bins and hoppers
• With integrated amplifier and change-over relay
www.oj-hojtryk.dk •
•
Reliable and resistant
Easy to mount
Phone: +45 75 14 22 55 O&J Højtryk A/S
Fax: +45 82 28 91 41 Ørnevej 1, DK-6705
mail: info@oj-hojtryk.dk Esbjerg Ø
dol-sensors Tel. +45 72 17 55 55 www.dol-sensors.com
CVR.: 73 66 86 11
28 | november - december 2012 Grain &feed millinG technoloGy
AD_o&j.indd 1 21/11/2012 15:48

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