Sunflower Dehulling

Sunflower
Dehulling
Bühler AG
2014
Oilseeds World Production 2013/2014.
Focus: Sunflower and Rapeseed
Canada
Russia
RS
World No
2
Prod. mio.t :
18
Growth 2012: +29%
Growth 2011: +23%
EU-27
World No
Prod. :
Growth 2012:
Growth 2011:
SF
RS
3
1
8.53
20.8
+21.8% +8.2%
+2.7% +8.9%
Ukraine
USA
SB
China
SB
World No
2
Prod. mio.t :
88.0
Growth 2012: +7.3%
Growth 2011: +32.3%
RS
SB
World No
4
5
Prod. mio.t :
7.0
11.8
Growth 2012:
+2.9% +2.6%
Growth 2011: +7.6% +7.2%
World Wide
Production
Soybeans:
Rapeseed:
Sunflower:
Total oilseeds*:
mio t
284,94
69,97
42,43
502,27
Source: USDA
2 | © Bühler | Schlayer| 2014
SB RS
World No
4
3
Prod. mio.t :
12.2
14.2
Growth 2012:
-6.9% +1.3%
Growth 2011: -15.8% +5.9%
India
Brazil
World No
3
4
Prod. mio.t : 54.5
2.7
Growth 2012: +10.5% -13.0%
Growth 2011: +35.9% -22%
SF
World No
1
Prod. mio.t :
11.5
Growth 2012: +27.7%
Growth 2011: +9.5%
World No
1
Prod. mio.t :
88.66
Growth 2012: +7.3%
Growth 2011: +5.2%
Argentina SB SF
SF
World No
2
Prod. mio.t :
10
Growth 2012: +25.6%
Growth 2011: +4.1%
*Includes: Soybeans, Rapeseed, Cottonseed,
Sunflower, Peanut, Palm kernel, Copra
2012
+ 6,2 %
+ 11,0 %
+ 16,5 %
+ 5,8 %
2011
+ 19,3 %
+ 13,6 %
+ 5,3 %
+ 13,8 %
Sunflowerseed Production
Market Outlook
Growth of sunflowerseed production in Europe and Eastern Europe
Demand for high valuable products like animal feed and vegetable oil
due to growth of world population and increase of living conditions
Especially important:
o High yields of oil (low oil residues and low oil losses)
o High content of protein in meal
o Digestibility of meal due to less fiber content
3 | © Bühler |
Sunflower Preparation Processes
Sunflower Seed
Dehulling
o beating by impactors
OR
o crushing by corrugated roller mills
Dehulling
Hulls + Kernels (fine)
Separation
Hull Control
Kernels + Hulls
Kernels (fine)
Hull Control
o sifting of hulls and kernels
Flaking
Flaked Seed
4 | © Bühler |
Separation
o separation of hulls & kernels
by oscillating sieves
o aspiration of hulls by air
Hulls
Flaking
o flaking of kernels to open oil cells
Dehulling
Key Preparation Technology
Corrugated Roller Mill
Capacities
Sunflower up to 260 - 320 t/24h
Vertical Impact Dehuller
Capacities
Sunflower up to 150 - 180 t/24h
Horizontal Impact Dehuller
Capacities
Sunflower up to 150 - 180 t/24h
* All capacities and performances values are depending on raw material specifications & conditions.
5 | © Bühler |
Dehulling
Corrugated Roller Mill
For high capacity multi-seed crushing
- Suitable for multi-seed processes
- High capacity
- Limited dehulling efficiency
The roller miller assures flexible processing of multiseeds.
6 | © Bühler |
Dehulling
Working Principles of Corrugated Roller Mill
1
2
level controlled feeding device
Differential4
Speed
3
5
feeder allows consistent distribution over
entire roll width
sharp to6sharp
7
permanent magnet removes ferrous particles
in feed
individual roll gap adjustment
1. Inlet bin with product level sensor
2. Pneumatic metering slide gate
scraper knives cleans rolls from seed residues
3. Roll feeder with variable speed
4. Permanent Magnet
5. Product guide plate and roll end sealing
6. Cracking rolls with pneumatic driven roll gap
7. Scraper knife
7 | © Bühler | OLCB | Cracking Mill OLCB | 2012
Dehulling
Vertical Impact Dehuller
For efficient multi-seed impact dehulling.
- Suitable for multi-seed dehulling
- Smooth dehulling for low fines content
- Quiet, clean and safe operation
The versatile dehuller adapts to your requirements.
8 | © Bühler |
Dehulling
Working Principle of Horizontal Impact Dehuller.
Feeder screw for even feed
Level indicator (top/bottom) avoids choking
5
Permanent Magnet
Grooved rotor for controlled, fines avoiding
product impact
Dehulling degree adjustment through adjustable
impact cone (spacers)
1.
2.
3.
4.
5.
9 | © Bühler |
Product feed
Rotor
Impact cone
Outlet
Dehulling tuner
Dehulling
Especially Suited for Multi-Seed Oil Mills.
Main advantages:
Applicable for dehulling of various oilseeds
incl. sunflower, cotton seed, and soybeans
High process safety due to screw feeder,
magnet and level probes
1. Rotor
2. Wear plates
3. Impact paddles
Continuously adjustable screw and rotor speed
allow perfectly controlled process
Alternative impact cone surface characteristic
(smooth, fluted) for optimized dehulling
Efficient especially with higher moisture
content
10 | © Bühler |
Impact cone characteristics
Smooth: Sunflower
Fluted: Soy, cotton seed
Dehulling
Horizontal Impact Dehuller
For state-of-the-art sunflower dehulling.
- Smooth dehulling for low fines
- Long machine lifetime
- Easy maintenance of key parts
Applied in the sunflower seed processing industry exclusively.
11 | © Bühler |
Dehulling
Working Principle of Horizontal Impact Dehuller.
1
Feeder roll with integrated frequency converter
5
Magnet
3
Wear resistant and adjustable impact chest
2
Only applicable for sunflower seeds
5
4
1.
2.
3.
4.
5.
12 | © Bühler |
Product feed
Rotor
Impact chest
Outlet
Dehulling tuner
Dehulling
Simple Way of Dehulling.
Main advantages:
Simple and fast adjustment of impact chest
and thus excellent dehulling quality
Permanent magnets
Impact chest adjustment
Impact rotor
Impact chest
No aspiration required
Simple and easy accessible and
exchangeable wear parts
Efficient especially with lower moisture
content
13 | © Bühler |
Dehulling
System Comparison.
Corrugated
Roller Mill
Vertical
Dehuller
Horizontal
Dehuller
Dehulling Efficiency
+
++
++
Sunflower Suitability
+
++
++
Other oilseeds
++
+
N/A
End Product Quality
+
++
++
Integrated Safety Features
+
++
+
Aspiration
Yes
Yes
No
Throughput (t/h)
++
+
+
Efficiency (kWh/t)
++
0
+
Space requirement
0
++
+
++
+
++
Serviceability
* ++ … very good;
14 | © Bühler |
+ … good; 0 … acceptable; N/A … not applicable
Dehulling
Technical Datas - Overview.
Corrugated
Roller Mill
Vertical Dehuller
Horizontal
Dehuller
Dimensions (mm)
Length
Width
Height
2.920
1.900
1.130
2.110
550
1.820
2.923
2.003
1.925
Rotor / Roll diameter (mm)
Rotor / Roll length (mm)
300
1.600
600
-
800
2.150
Aspiration needed (m3/min)
20
15
0
Motor power (kW)
Feeder drive
Main drive
0,75
18,5
0.37 (FC optional)
15-22 (FC optional)
0.33
18
Weight (kg, net)
3.690
825
2’640
2
8
16
260 – 320
500 - 800
230 – 260
150 - 180
120 - 150
120 - 150
150 - 180
-
Impact Dehuller
Beaters / Throw paddles / Rolls
Throughput (t/24h)
Sunflower
Soybean
Cotton seed (max. 4% lint)
15 | © Bühler |
Separation
Hull Separator
Efficient sifter for hull separation.
-
Optimal separation of oilseed kernels from hulls
High throughput capacities
Easy operation and maintenance
Designed especially for oilseed separation
Applied in the oilseed processing industry for the dehulling of sunflower seeds and soya.
16 | © Bühler |
Separation
Key Preparation Technology
Hull Separator SMA 203-3 OL
1
1. Proven main hull aspiration system
Easy adjustable, powerful suction nozzles
2
2. Proven post hull aspiration system
Multi-tunable aspiration channel
Large control window for optimal setting
17 | © Bühler |
Separation
Working Principle and Technical Data
Cleaning
backflow of undehulled seed
coarse hulls
Impact Dehuller
fine hulls
fine seed to flaker
dehulled seed to 2nd stage or to flaker
18 | © Bühler |
hulls to sifter
Separation
Working Principle and Technical Data
backflow of undehulled seed
Impact Dehuller
fine seed to flaker
hulls to hull control
dehulled seed to 2nd stage or to flaker
19 | © Bühler |
Sunflower Preparation Processes
Objective
• reduction of fiber content in meal by hull removal
• increase of final protein content
• highest oil yield
Different Dehulling Processes
2- stage Dehulling
Hull Removal from 26% to 10%
1- stage Dehulling
Hull Removal from 26% to 14 – 12 %
Differentiation through the rest of hull content and amount of kernel loss by
efficient hull controls
* additional 2,5-3 % botanical oil content in hulls
20 | © Bühler |
Sunflower Preparation Processes
2- stage Dehulling with Total Hull Control
10% rest hull
1,0-1,2% oil loss with hulls*
1
3
2
5
4
2
Separation
* additional 2,5-3 % botanical oil content in hulls
21 | © Bühler |
Hull Control
6
1.
2.
3.
4.
5.
6.
Dehuller
Separator
Filter/Cyclone
Hull Sifter
Hull Drum Sieve
Hull Separator
Sunflower Preparation Process.
1- stage Dehulling with Total Hull Control
12% rest hull
0,9-1,1% oil loss with hulls*
dehulling results
low kernel/ oil losses
3
high investment
1
5
2
4
Separation
* additional 2,5-3 % botanical oil content in hulls
22 | © Bühler |
Hull Control
6
1.
2.
3.
4.
5.
6.
Dehuller
Separator
Filter/Cyclone
Hull Sifter
Hull Drum Sieve
Hull Separator
Sunflower Preparation Process.
1-stage Dehulling with Partial Hull Control
14% rest hull
1,0-1,2% oil loss with hulls*
3
1
2
4
Separation
* additional 2,5-3 % botanical oil content in hulls
23 | © Bühler |
Hull Control
1.
2.
3.
4.
Dehuller
Separator
Filter/Cyclone
Hull Sifter
Sunflower Preparation Process
Yields
SUNFLOWER INPUT SPECIFICATION
Moisture content
Oil content
Crude fiber content
Protein content
Hull content
Impurities
8,00 %
43,00 % NS
17,50 % NS
18,00 % NS
26,00 % NS
< 1,00 % NS
YIELDS AFTER DEHULLING
1 stage
1 stage
DEHULLING
2 stage
partial
total
Rest hull content in dehulled fraction
10 %
14 %
12 %
26 %
Capacity prior to dehulling
Capacity prior to expeller pressing
no dehulling
100 t/24h
80 t/24h
100 t/24h
84 t/24h
100 t/24h
82 t/24h
100 t/24h
100 t/24h
18 t/24h
0,21 %
37 t/24h
44,5 %
19 %
1,0 %
34 t/24h
7 t/24h
14 t/24h
0,16 %
41 t/24h
41 %
23 %
1,0 %
33 t/24h
8 t/24h
16 t/24h
0,17 %
39 t/24h
42,5 %
22 %
1,0 %
33 t/24h
8 t/24h
0.0 t/24h
0.0 %
56.2 t/24h
31.4 %
29.3 %
1,0 %
30 t/24h
11 t/24h
YIELD
Total hulls removed
Additional oil loss*
Extraction meal
Protein content
Crude fiber content
Oil content
Expeller crude oil
Extraction crude oil
* based on seed input; all figures determined with Bühler Oil Balance calculation
24 | © Bühler |
Sunflower Preparation Process.
Performance Figures
SUNFLOWER INPUT SPECIFICATION
Moisture content
Oil content
Crude fiber content
Protein content
Hull content
Impurities
8,00 %
43,00 % NS
17,50 % NS
18,00 % NS
26,00 % NS
< 1,00 % NS
Dehulling Stages
2-stages
1-stage - partial
1-stage - total
Rest Hull Content
10 %
14 %
12 %
Protein Content
44,5 %
41%
42,5 %
Loss of Oil
1,2 – 1,0 %
1,2 – 1,0 %
0,9 – 1,1 %
0,2 - 0,3 %
0,15 – 0,2 %
0,17 – 0,2 %
based on Hulls
Loss of Oil
based on seed input
25 | © Bühler |
Flaking is Key in Achieving Low Rest Oil in Meal.
State of the art features
Flake thickness adjustment during operations
Easy access for regular maintenance
Correct roll type and surface
Optimal Sunflower throughput
(at 0.4mm flake thickness, cold, 8% H2O)
capacities of approx. 400 t/24h
26 | © Bühler |
www.buhlergroup.com
27 | © Bühler |
Bühler’s High Performance Flaking Mill OLFB.
Bühler’s state-of-the-art flaking mill.
-
High performance flaking mill
Flake thickness adjustment during operations
Compact and efficient
Easy maintenance, safe operation