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Defining Corrugations
with rollDetect
IAOMCentral, Wheat State & Texoma District Conference
July 2015
Bill Ritchie
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Being creative with new technology!
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dddd | RT | 2011
Creative Ideas to help millers… Be more profitable!
New ways to
Monitor
Corrugated
Passages
Break release
Thinking outside the
box to obtain
consistent results!
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Advancements in profile imaging.
Profile imaging provides
another way to determine
the corrugators
performance.
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Defining Corrugations – establishing the performance limits of the roll profiles.
New Reconditioned Roll Same roll 9 months later
GM Roll Detect Service | 2014
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How do we know when enough is enough…
GM Roll Detect Service | 2014
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Roll performance increases with correct corrugations
3 key advantages with correct corrugations:
Smaller load on the subsequent grinding passes,
since a greater proportion goes directly to the
reduction passes
Fewer necessary steps in the reduction process
Significant energy savings in the whole grinding
process
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Goals of roll Evaluation!
Customer Service | Stefan Kellenberger | 2014-08-16
Detection of the right timing for roll
re-fluting
Advantages:
• Objective measurements!
• Control extraction rate!
• Save energy!
• Determine actual wear on rolls!
:
Determine causes of roll wear!
Evaluate corrugation geometry –
• Focus on adding value to roll
performance!
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Roll evaluation - Measure to help determine your performance!
Preparation
Measurement
Report
Customer Service r | 2014-08-16
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Multi-
Point Cutting
Single Point
Verification of quality or condition.
Roll wear
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Knowing when the worn roll is past its prime.
How do we stop this from happening to us?
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A good example of 9% percent wear on a dull to dull installation.
Used Form 18 on a 1st break after 10 months
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Sharp to sharp roll installation – high percentage wear.
What can we see from this corrugation
profile?
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Dull to Dull installation of rolls showing 42% wear.
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Sharp to Sharp wear on rolls – what are these rolls telling us?
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Dull to Sharp configuration with 16% wear. What can we see happening here?
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Both profiles are new rolls – both are Stevens 32 cuts/inch.
GM Roll Detect Service | 2014
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Getchell cuts: defining when the radius becomes an oversized land.
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New profiles
New Form 18
New Modified Dawson
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This corrugated roll went pasts its limit.We can improve roll performance to minimize this…
Maybe we can totally stop this from happening all together in today’s
milling operations!
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Things that are coming our way…Measuring the surface of smooth rolls.
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Customer Service r | 2014-08-16
We know grinding action with corrugated rolls is a cutting action!
• Dull corrugated rolls use a compression action
for grinding and act like smooth rolls.
• Compression action takes more horsepower to
do the same work and is the type of action that
occurs with smooth rolls.
Optimized
Rolls
Maintain
milling
performance
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Application of the information.
How can we apply the
information we collected from
our rolls?
Something new in the industry.
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Tracking roll wear to determine savings!
Increasing
yield
and
saving
energy!
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Optimizing the rolls: Establishing a “Best cost per ton”
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Outlook: ecoReport
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In the pursuit of quality - high achievers bring an approach to work that is methodical and demanding!
Pay rigorous attention to detail!
“Smart” Millers are the ones who know their success comes down to the smallest details. This helpsthem maintain a competitive edge and a quality finished product.
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Defining Conclusions:
Our corrugations are telling us what is happening!
• Today we have available smart technologies to collect data from our roller mills to achieve a “Best Cost per Ton” on our mill performance.
• We can save money by using the data to our advantage by getting a competitive edge on mill performance!
• “Information is Power!” Plant managers, milling superintendents and head millers have the opportunity to make educated decisions on roll performance based on roll wear.
• Be inspired to be passionate about the details that produce quality!