UK: OMAS START THE MOST ADVANCED MILL IN NORTHERN EUROPE

In December 2016 Omas was chosen to be the technological partner for the new mill belonging to E B Bradshaw & Sons. The engineering work started in 2017 and the plant was tested and started in early 2019.

The mill has been built alongside the plants completed in 1990 and 2005 and Omas was chosen thanks to the attention and precision of interpreting the clients’ three main needs

• food safety and the purity of the flour to safeguard consumer health;

• reduced energy consumption and minimum CO2 emissions;

• architectural designs with reduced impact in an area with restrictive regulations in terms of hygiene and environmental safety.

Let’s see in detail how Omas carried out the task.

The wheat cleaning line, as well as a vibrating separator, destoner and photo separator, have been equipped with a Giotto Sterilizer, the separator that provides optimum management of the degree of cleaning of the grain, thanks to the removal of the outer layers of lignin and cellulose. With this process developed by Omas, the surface of the caryopsis is scraped to remove the outer layers of the husk by varying amounts (from 0.2 to 2 %), purifying it by removing all inorganic impurities such as fertilisers, weed killers, insecticides, soil, sand and metals, as well as organic impurities such as bacteria, fungi, mould and mycotoxins.

Milling a cleaner grain means reducing the ash content in the flour, improve its colour, eliminate the presence of metals and, in general, obtain a healthier product. The removal of weed killers, fertilisers and chemical disinfectants is essential since recent studies have cited them as the origin of many food intolerances and allergies, previously blamed on flour and baked goods. Milling wheat that is free from organic impurities not only prevents contamination of the mill itself, but also the output is a microbiologically purified flour and bran, which can then be stored for longer periods.

Omas was also able to improve the mill energy savings, thanks to Leonardo Roller Mill.  The innovative Kers technology, patented by Omas, uses electrical regeneration of the kinetic energy created between the milling rolls, which means a reduction in the roller mill’s power use of 50%. Probes and frequency changers (VSD) are applied to the motors with higher power to make sure that only the energy required for each stage in the process is actually used. During the winter season, the mill can also recover the heat produced by the fans present in the plant, redirecting it throughout the building and therefore optimising energy use. This will in turn allow the plant to benefit from the tax breaks available with regard to CO2 emissions and to cut production costs. The mill will be remotely operated and thanks to independently controlled roller speeds, it will be possible to optimise milling yield according to the type of mix and flour.

In respect of the building layout, Omas provided the project following the building economy philosophy which consists in eliminating one whole floor. The roller mill motors are fitted directly to the rollers and therefore, there is no need for an expensive, noisy transmission floor. This means building weight and foundations reduction by 25 %. The roller mills will be raised above ground, making access easier for inspection and cleaning underneath the rollers, for an added guarantee of absolute hygiene. This will also benefit the power supply, which will come from above, avoiding the need for excavation or channels that are always a source of infestation. 

The building will be windowless, with air conditioning and recirculation system that prevents noise and dust emissions, guaranteeing besides energy savings also constant temperature inside the building, which in turn prevents the formation of condensation and mould. The work areas are compartmentalised using soundproof walls and materials, making it possible to operate the plant while remaining within the limits set by noise safety standards.

This project rewards the great innovation of Omas, that has always put the customer at the centre, offering the best and technologically advanced solutions.

For more detailed information, contact Pietro Barbalarga.