Omas was chosen to be the technological partner for the new project in Punjab province. After the engineering layout, the construction work started in 2022.
The project was born from the desire of an historic and renowned family, present in the sector since 1990, to create the lowest energy consumption milling plant in Pakistan with an eye over flour healthiness and quality. Omas was awarded the contract thanks to the attention and precision in interpreting the customer’s needs, which can be summarized in the following three points.
- High hygiene standards of the flour to safeguard consumer health;
- Energy Saving and reduction of electricity consumption;
- Flexibility of technology in milling recipes and production.
Let’s get to the heart of the project.
The wheat cleaning line, as well as a vibrating separator, destoner and color sorter, have been equipped with the latest Omas’ technology: the flour extraction booster.
Thanks to the DST – Dry Scrubbing technology, the flour booster provides an optimum management of the cleaning of Pakistani wheat variety, thanks to precise removal of the outer pericarp layers. With this process the surface of the caryopsis is scraped to remove the outer layers of the husk. The number of impurities removed can range from 0.1% up to 1,5% and include inorganic varieties such as fertilizers, insecticides, soil, sand, mud and left-over metals, usually measured in ashes contents, as well as organic impurities such as bacteria, fungi, mould and mycotoxins.
Milling a cleaner grain means to reduce ash content in flour and increase its extraction up to 1%, improve color quality, eliminate the presence of heavy microbial and fungi content and in general, obtain a healthier and top-quality product.
The removal of pesticides, herbicides 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. The grain free from organic impurities not only prevents contamination of the mill itself, but also the output is a microbiologically purified flour which has then a longer shelf life.
Concerning the energy efficiency of the plant, Omas was able to improve the mill energy savings, thanks to Leonardo Roller Mill. The absence of any power transmission belts combined with the innovative KERS technology, patented by Omas, allows electrical regeneration by kinetic energy created between the rollers, which means a net saving in the roller mill’s electric power between 20% to of 25% compare to any belt drive machinery. Inverters are applied to the motors with sufficient power to make sure that only the energy required for each stage in the process is actually used.
The direct application of torque motors on the roller mill, allows to vary independently cylinder’s speed ratio and controlling it, in order to optimize flour production from coarse to fine almost instantly; it is also possible to monitor and control level quality of gluten by avoiding unnecessary pressure, which is very unique feature. Finally, Leonardo allows shifting from one recipe to another in few easy quick steps without any risk to the production schedule.
In respect of building bayout, thanks to “build in motor” combined with our plug and mill Leonardo concept, we can literally eliminate one floor: the one dedicated to the installation of motors driving chairs. In this project the ground floor is entirely reserved to the packaging and storage of finished product, since there was no need install any motor. This means that the building height and foundations is reduced by 25 %; moreover, costs and time of construction are considerably reduced.
The high standards of hygiene required by the customer have been met thanks to the ease of cleaning and inspection of the roller mill, which is raised from the ground to allow a useful cleaning and maintenance.
Omas has completed the work by providing a remote monitoring service for web access (OTS) and multi-device management of the plant (optionally from phone, tablet or PC).
This tailor-made project rewards the great innovation of Omas, that has always put the customer in priority, offering the best and technologically advanced solutions.
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|Flexy Mill, Flour Extaction Booster, Energy Saving, Remote Monitoring and Assistance