Reception and storing raw materials:
The raw materials (wheat grain, rye) arrive to the enterprise both as by auto as by railway transport.
Before transporting on the elevator №1, 2 the grain is originally weighed on central automobile electronic-tenzometric scales "Ermak ВА 60-2-20" with tonnage 60 tons.
The grain arriving by railway transport is weighed on the railway scales with tonnage 150 tons. Sampling of grain from the transport is taken by a sampler of cellular type, Elevator №1 - allows to store 14 thousand tons of grain. Elevator №2 - allows to store 30 thousand tons of grain.
Technological process of preparation and grain processing:
In grain-cleaning section grain is exposed to careful clearing from every possible organic and mineral particles or particles of industrially-household character by special machine with set of sieves and air streams. The particles equal to the size of grain which are consist of metal or metal ores are separated on magnetic separators. Particles of a mineral origin: the stone, asphalt, earth lumps separate on stoning worm.
Practically the clear grain is plentifully presoaked and intensively mixes up in cars of a wet peeling where there is a partial branch of a seedcoat.
After binning the grain again goes on the second step of clearing where separate the covers of grain and casually remained other particles. After the secondary clearing grain again is being presoaked plentifully and goes in the bunker for the second binning for 2or 3 hours. After having passed through pneumoseparating cars, the clear grain moves to milling section. We will add thus, that the grain is presoaked during clearing by hot water with the temperature from 30 to 40 ° that it is not only raises the effect of branch of a seedcoat, but strengthens gluten of grains. During the hydrothermal processing humidity of grain increases in 3-5 %. Technological optimum humidity of the grain arriving on the mill should be 15-15,5 %.
Now there comes the most important stage in technology of processing of grain - its crushing and flour reception. Lengthy way passes grain while it will turn out to the flour. At first it is transported horizontally on the elevator and is strewed from the top to down for some times running a way in 500 m of length, in grain-cleaning section near 300 m and in milling section about 800 m. And altogether the grain will pass 1600 m to turn to a flour and bran.
In milling section the main equipment for getting flour is roller mill, in these machine the grain which falling between two rolls, pressed to each other and rotating so that grain, falling between them become crumbled not in a flour but in intermediate products, easier speaking in large, average and small grits. This dominant requirement in processing technique the flour.
And after roller mill the mix of a shredded product is grasped by an air stream from the car and raised on the top floor, where separating from air the product arrives on screening plant. The screening plant is arranged so that the product arriving on it will be devided into 3-5 fractions. Further from the screening plant the grits is arrived on winnowing machine, where passing through the sieves due to an air stream are separated from grits particles of seedcoat.
Clean white grits arrive on sizing rolls tools where it is split up, turning in small grits and dunst (smallest) further. These middlings, passing once again through winnowers, arrive on machine tools of middlings. Such middlings in a mill 8-11. Definitively to separate a floury part from a cover, a chop must pass these 11 middlings.
Except a flour, grits and brans on modern mills is provided system of selection of a germ of grain. This product represents a flat particle of times-merom of yellow of 2-2,5 mm, on biochemistry it is the most valuable product, but because of the maintenance in it of fat to 14 %, at hit in the ground kind in a flour, promotes it rancidity. As such germ represents valuable raw materials for making of medicaments, vitamins, fragrance range and as the food additive is used - in the confectionery industry. This product contain: protein 30 %, sugar 30 %, 21 name of microelements, variety of irreplaceable acids and vitamins, with domination of tocopherol (vitamin E).
So, the received flour a varietal stream repaired on rebolting sifter where separated casually particles of a cover of grain, and a ready clean flour by compressed air-in of the hoppers for storage of a flour or in pickings hoppers. With pickings hoppers the flour through bagger-weighers gets to a warehouse or is direct in the railway vehicle. The plant can laded of a flour - grits, bran as unpacked method and in package in weight a 50kg- wheat flour, manna groats.
On pre-packing №1 be carried out prepackaging best quality wheat flour in paper packages on 2kg, and as group packing in a thermopacking film on 10 packages.
On pre-packing №2 it is made 1 be carried out prepackaging best quality wheat flour in paper packages on 1, 5 and 10 kg, and as group packing manna groats in polyethylene bags on 1 kg. As well be carried out group packing in a thermopacking film of said production.
Preference of production of plant in comparison with production of competitors:
In 2006 to the enterprise 109 years from the date of creation will be executed. Preference of production of the plant high quality answering to the normative documents, and also the control of raw materials of production at each technological stage. The big share is played by improvement and introduction in technological processes of innovative technologies and the equipment.
For this period the plant once and again modernization, regenerate the technological and transport equipment was updated, the assortment yield extended.
All technical innovations are ride at release of high-quality production, product quality is confirmed by diplomas.
Reception of these awards was promoted, first of all, by laborious and daily work collective of the plant, beginning from acceptance of grain and finished goods issue to the consumer.
The big and responsible work on grade control of incoming grain and finished goods issue is carried out by workers PTL, using the modern equipment and methods o definition of quality.
Grade control is conducted at each step of technological process. At acceptance of grain sampling be carried out by hydraulic sampler of mark APPOLLO with definition of quality of grain on the modern equipment: Spektran-It, Infrotek 1241, hydrometers Vajl-55 with definition in laboratory of elevator quality indexes of the grain, defined by the specifications and technical documentation.
Under of grain storage on elevator be carried out the control on following factors: temperature conditions of grain mass, humidity, organoleptic test, grade of quality, contamination, quantity and quality gluten, natural weight, vitrescence, is carried out the control over primary purification of grain mass and forming milling blends in a percentage ratio between classes.
By relay preconceived milling blends of grain in productions departments of the plant grain on humidity, quantity and quality gluten, vitrescence and grade of quality is supervised. Under of preparation of grain for processing in screenrooms of production departments the laboratory control quality final purification of grain from impurity, process hydrothermal processing of grain (humidifying and sweating) and a grain direction in processing (in milling section).
Under of grain crushing in milling section and relay production on a warehouse it is supervised - quality of grain on following factors: humidity of grain, grade of quality; throughout change workers PTL supervise quality yield on humidity, organoleptic (colour, flavor, taste), fineness a grinding, metallomagnetic dirts, quantity and quality gluten, a flour whiteness, in mean-shift sample ash content and falling number. At canning, prepackaging and goods issue by unpacked method be carried out final good inspection by workers PTL as behind standard weight of pack units and goods issue with delivery of qualitative certificates on production.
On all production produced by the plant, there are < Sanitary conclusions >, < Protocols of efforts on safety index >. Production meets all requirements DSTU, specifications and GOST.
Description technological process making of the granulated bran.
In technological process making of the granulated bran are used process equipment firms < Prokop Invest a,s .> (Czech Republic).
Equipment in place on technical parametrs the best among domestic analogues with use on pellet-presses flat dies. Such presses good conditions of loading of end effectors are quieter in work, dies are cheaper in comparison with the cylindrical. Line is completed with two in parallel working pellet-press, two coolers and one vibration separator of pellet.
Alluvial wheaten bran enters operating rates by inject pneumatic transport on pipes capacity in 6 tons to hour. The giving scheme alluvial wheaten bran on a line granulation and issue of the granulated bran - universal, in capacities it is possible to store as alluvial, and the granulated bran. From operating rates alluvial bran by transport mechanisms goes to holding tank with separation of a metallomagnetic impurity in a stream. After rates by of screw feeder bran to move in steam mixers where wheaten bran is processed by steam, temperature 120-150 0С, and then arrives on pellet-press where bran is pressed by four pressing crush rollers into die holes and on the downside of die is cut off by knifes. After granule pressing are cooled to temperature 20 0С or on 5 0С above than an environment temperature on coolers.
The ready granulated bran is sifted on vibration separator where standard which comes back on repeated granulation. After separation the granulated bran rises on the top floor and goes to operating rates on storage. Issue by an embankment of the granulated bran is carried out both on a railway transportation and on motor transport.By the scheme it is provided sacking granulated and alluvial bran on bagging scales in bags in weight 30kg and issue to the consumer by band conveyors and loading machine. The granulated bran answers TUU 20047943-003-99.