Digital Re-print - July | August 2009

Feature: Promotional Feature

Feature title: Delivering World Cass Roll Chill Technology and Service

Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom.
All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies,
the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of
information published.
©Copyright 2009 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form
or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

www.gfmt.co.uk NEXT PAGE

Promotional | Feature
DELIVERING WORLD CLASS
ROLL CHILL TECHNOLOGY
AND SERVICE
TIMELY REFURBISHMENT
Even new materials need regular refur-
bishment. From both a safety and perform-
ance reliability point of view, it is essential
that mill maintenance is carried out to a
pre-determined schedule. However, when
delivery dates need to be met and staffing
levels are stretched, this can prove difficult.
At such times, a resource such as the Satake
UK Site Services Team can help.
QUALITY AND
SAFETY
The quality of the
grinding and fluting
processes, whether
being carried out on
a new roll or during
refurbishment, deter-
mines the performance of the roll and, thus,
the quality of the end product. An integral part
of each refurbishment is the careful inspection
of each roll or ‘roll pack’ module before any
work can begin. This exercise is followed by
the compilation of a complete inspection
report, detailing the findings, recommenda-
tions for action required and associated costs.
Re-fluting, using tungsten carbide fluting
bits, restores the profile to the exact speci-
fication required for the client’s application.
24 | July-august 2009
In Satake UK’s experience, one in ten
rolls sent for refluting displays defects, which
would have a fundamental effect on mill
performance and safety – such as a damaged
spindle, less than the recommended chill
diameter, or chill quality, which could affect
roll performance.
STATE OF THE
ART ROLL
GRINDING
TECHNOLOGY
All of these
would be identified
and reported on,
supported by relevant data compiled using
a combination of engineering skills and high-
tech instrumentation.
From its flour milling ‘Centre of Excellence’
in Bredbury, near Manchester, Satake UK
offers a standard roll refurbishment turna-
round of 3 weeks and an emergency service
of 72 hours.
Many of the defects can be rectified, and
Satake UK offers the full range of remedial
operations, including re-gudgeoning, reduc-
ing the need for such defective rolls to be
scrapped.
Once the completed report has been
e-mailed or faxed to the customer and work
instructions agreed, rolls are ground until a
smooth, parallel surface is obtained.
Re-fluting, using tungsten carbide fluting
bits, restores the profile to the exact specifi-
cation required for the client’s application. A
profile shadowgraph is used to examine the
pitching, depth, angle and land of the flutes,
as well as for checking thread forms and flut-
ing tools within the Bredbury facility.
The optimum number and profile of
the flutes, relevant to the application of the
roll, have been developed over many years
and are specified to high levels of accuracy.
Satake UK offers a standard range of more
than 100 different flute/corrugation profiles,
with other bespoke arrangements available.
GRINDING
AND FLUTING
Smooth rolls
are ground with
either a taper or
camber to a toler-
ance of 4 microns
over a diameter of
250mm. The frosted finish, necessary to
ensure immediate grip when the rolls go into
grind, is achieved by blasting highly abrasive
particles at the surface using automated
shotblast equipment.
Grain &feed millinG technoloGy
Before des-
patch, each roll
undergoes test-
ing which, in the
case of roll packs,
includes a running
period on a roll
bearing test bed.
This ensures the
shortest possible
interval between
delivery, installa-
tion and regaining
full production in
the mill.
Custom-built
machinery laid out
in a cellular style
and standing on 4
metre deep foun-
dations to elimi-
nate transfer of
vibrations, provide
the capability of
produce 1,500 new and 4,000 refurbished Extending flute/corrugation life and NEW ROLLS MANUFACTURED
rolls per year for customers in Europe, the enabling chills to be refurbished up to 15
FOR ALL MAJOR ROLLERMILL
Middle East and Africa. times, modern metallurgical developments
TYPES TO CUSTOMER
have extensively widened the miller’s range
of options. REQUIREMENTS
DELIVERED
Whatever the material – and chilled
ON SPECIALLY
DESIGNED
cast iron rolls remain the traditional choice Standard rolls – chilled iron, cen-
for break and reduction work – the outer trifugally cast and dynamically balanced
PALLETS surface of fluted/corrugated rolls needs to for greater precision, providing a consis-
To ensure that be resistant to abrasive wear in order to
tent uniform hardness.
refurbished rolls retain the required profile.
arrive back at a cli- The surface must be hard but not brittle C12 rolls – high chrome alloy, giving
ent’s mill in the same precision-ground to avoid chipping, and it is important that the an average life twice that of a standard
condition as when they left the fluting sec- cast iron roll, resulting in reduced mill
tion, Satake UK has devised a special pallet downtime for roll changing.
design.
Mitak rolls – specially annealed
On completion, the rolls are coated with
chromium steel, giving an average life
rust –preventative food safe oil, covered
three times greater than a standard cast
in rust –preventative paper and sealed in
iron chill on highly abrasive applications.
a protective plastic sleeve before being
mounted on the pallet, accompanied by Self Matting rolls – with a mate-
documentation detailing destination, flute rial compostion formulated to maintain
specifications and a unique roll number. a heavier frosted finish for special reduc-
This ensures complete traceability for each tion applications.
individual roll and enables a statistical history
Water cooling Water-cooled roll
to be maintained which can prove invaluable roll chill can be machined with conventional options are available for all of the above
when monitoring mill throughput. tools avoiding unnecessary cost when re- types
fluting. Smooth rolls require an outer surface
INNOVATIVE that can be ‘frosted’ creating a matt or non- Fluted to your individual specifications.
USE OF glazed surface which will effectively grip the Spindles are machined or ground as
MODERN product and be resistant to abrasive wear. required. The available roll size is up
MATERIALS to 450mm diameter and extends to
As the largest ContaCt: 1500mm in length.
roll chill supplier Satake Corporation UK Division
in the UK, Satake P.O. Box 53 Bredbury, Stockport, ContaCt:
offers new and refurbished rolls for all makes Cheshire SK6 2FG Paul Airey
of rollermill. With a portfolio of four different Tel: +44 (0) 161 -406 3800 Tel: +44 (0) 161 406 3864
types of roll Satake has an in depth knowledge Fax: +44 (0) 161-406 3801 e.mail: pja@satake.co.uk
of a range of those featuring new materials e.mail: sales@satake.co.uk
available from leading manufacturers. www.satake.co.uk
Grain &feed millinG technoloGy PREVIOUS PAGE NEXT PAGE Promotional | Feature
This digital Re-print is part of the July | August 2009 edition of Grain & Feed Milling Technology magazine.
Content from the magazine is available to view free-of-charge, both as a full online magazine on our
website, and as an archive of individual features on the docstoc website.
LINKS
Please click here to view our other publications on www.docstoc.com.

August 2009 • See the full issue

• Growing
concerns over
mycotoxins • Visit the GFMT website
In this issue:
• Vacuum plays an
• Enzymes in important role in

• Contact the GFMT Team

breadmaking: delivering
Economic relevance,
markets, and future
micro-ingredients
perspectives to livestock
• Are you ready
for new crop?
• Preserving
feed materials • FOCUS:Europe
after harvest
a multifaceted
approach to
mycotoxins
• Flour
a delivery system
for vitamins and
minerals receives WHO
• Subscribe to GFMT
endorsement

A subscription magazine for the global flour & feed milling industries - first published in 1891

GFMT0904.indd 1 29/07/2009 15:48

To purchase a paper copy of the magazine, or to subscribe to the paper edition please contact
our Circulation and Subscriptions Manager on the link adove.

ADVERTISERS LINKS INFORMATION FOR ADVERTISERS - CLICK HERE

www.gfmt.co.uk PREVIOUS PAGE