TAK High Capacity Separator
TAK Separator: High Capacity Grain Classification for Industry
The TAK High Capacity Separator developed by Tanış A.Ş. is an advanced technology solution that provides maximum efficiency and precise cleaning for your industrial scale grain classification needs. These innovative separators, produced in our production facilities based in Gaziantep with our experience in wheat, corn, and barley processing equipment, are optimized for large-scale mill operations.
TAK Separator is a high-capacity cleaning equipment that classifies grains according to size, weight, and shape characteristics and removes foreign materials. Its basic function is to precisely process large quantities of grain, providing homogeneous and clean product to the mill process.
High capacity technology is designed for mills operating on an industrial scale. TAK separators offer processing capacity up to 40 tons per hour, meeting the needs of large facilities. Thanks to its patented motion mechanism and wide screen surface, it demonstrates highly efficient classification performance.
Its strategic position in the mill cleaning line is generally after coarse cleaning, before fine cleaning and tempering stage. This position ensures the quality and homogeneity of grain going to subsequent stages of the mill process.
Its importance for large-scale operations stems from increasing efficiency and consistency. Being able to perform precise classification even when operating at high capacity is of critical importance for businesses wanting to increase production volume without compromising quality.
Industrial scale grain classification capability is the fundamental advantage of TAK Separator. Thanks to its wide screen surface and effective vibration pattern, it can process large quantities of grain quickly and efficiently.
The capacity advantage over traditional separators is evident. It offers 50-70% more capacity compared to standard separators. This means higher production volume with less equipment and reduces both investment and operating costs.
Efficient screening and classification technology is achieved through specially designed screen structure and patented vibration system. Grains and foreign materials of different sizes and shapes are precisely separated, maximizing cleaning effectiveness.
Maximum processing capacity with minimum space requirement increases facility efficiency. It requires 40% less floor space to provide the same capacity compared to traditional systems. This compact design provides great advantage especially for facilities with space constraints.
The balance between precise cleaning and high efficiency is TAK Separator’s most important technological achievement. While cleaning precision is usually compromised in high-capacity systems, TAK technology maintains cleaning precision while increasing capacity.
TAK (Tanış Advanced Kinetics) technology is a patented innovation of Tanış A.Ş. This technology is a combination of advanced motion dynamics, optimized screen surfaces, and precise control systems. Thanks to TAK technology, superior classification precision is achieved even when operating at high capacity.
Special design motion mechanism and dynamics ensure optimum distribution and movement of grain on the screen surface. The double eccentric drive system maximizes separation effectiveness by combining both circular and linear movements. This patented mechanism allows precise control of vibration amplitude and frequency.
Advanced screen technology and material properties offer long-lasting and efficient performance. High-quality stainless steel screens, specially designed hole geometries, and optimum screen tension form the foundation for precise classification.
Long-lasting components and durable structure provide reliable performance even under harsh working conditions. Vibration-resistant connecting elements, wear-resistant surfaces, and high-quality bearings extend equipment life while reducing maintenance needs.
Technical Specifications and Performance Parameters
TAK High Capacity Separator is offered in various technical specifications:
- Dimensions: 2200x1600x2100mm – 3000x2200x2500mm (according to model size)
- Capacity range: 35-240 tons/hour (depending on model and grain type)
- Weight: 1200-2500 kg (according to model size)
- Motor power: 3.0-7.5 kW (varies according to capacity)
- Screen layers: 2-4 (according to application need)
Motor power and energy consumption values are efficient thanks to the optimized drive system. Energy consumption per ton is 20-30% lower compared to traditional systems. This efficiency directly contributes to reducing operating costs.
Processing capacity depends on model size and grain type. The largest model, TAK-40, can process up to 40 tons of wheat per hour. This high capacity is ideal for large-scale mill operations.
Screen surface dimensions and classification precision provide superior cleaning performance. Total screen area varies between 8-16 m² according to model size. This wide surface provides sufficient contact time for effective classification even at high capacity.
Vibration mechanism and motion control are optimized with patented TAK technology. Frequency-controlled motor and precise balance adjustments allow adjustment of vibration characteristics according to different grain types.
Model Variations and Capacity Options
Model options are available for different capacity needs:
- TASC-152: For small-medium scale facilities with 15-35 tons/hour capacity
- TASC-154: For medium-scale operations with 35-60 tons/hour capacity
- TASC-158: For large facilities with 60-120 tons/hour capacity
- TASC-160: For industrial-scale facilities with 120-160 tons/hour capacity
- TASC-240: For industrial-scale facilities with 160-240 tons/hour capacity
Appropriate model selection criteria according to facility size are based on mill capacity, existing space constraints, and cleaning requirements. Tanış engineering team provides technical support in determining the most suitable model for your needs.
Configuration alternatives for special applications are offered. Different screen configurations, specially designed aspiration systems, or automatic control options can be adapted according to specific operation requirements.
Classification Performance and Cleaning Effectiveness
The precision of separating grains of different sizes and qualities is the fundamental performance indicator of TAK Separator. Using holes of different sizes from 0.8 mm to 10 mm in the screen system, grains are precisely classified according to their sizes.
Foreign material removal efficiency and quality control are at the highest level. Stones, soil, debris, broken grains, and other foreign materials are cleaned at 99% efficiency. This high cleaning effectiveness contributes to protecting mill equipment and increasing final product quality.
Precise size classification capability enables obtaining products of different qualities. Large, medium, and small-sized grains can be classified separately, which is ideal for production of different flour types. Especially in premium flour production, this precise classification provides great advantage.
Classification optimization and factors that increase efficiency are adjustable vibration parameters, screen slope, and air flow control. These parameters can be optimized for different grain types and moisture contents, thus achieving maximum efficiency.
Performance Evaluation and Test Results
Data obtained from laboratory and field tests confirm TAK Separator’s superior performance. In tests conducted under controlled conditions, 15-20% higher cleaning effectiveness was measured compared to traditional separators of the same capacity.
Capacity-efficiency relationship analysis reveals the most important advantage of TAK technology. While capacity increase usually causes efficiency decrease in traditional systems, TAK Separator maintains cleaning effectiveness even at high capacities.
Performance comparisons in different grain types show consistent results in various products. 99.5% cleaning effectiveness for wheat, 99.2% for corn, and 99.0% for barley were achieved. This consistency means reliable performance in a wide variety of grain processing applications.
Effect on Product Quality and Process Advantages
The positive effect of classification on flour quality stems from providing more homogeneous and clean grain input. Effective classification increases flour yield while reducing ash content. This means whiter and higher quality flour.
Its contribution to increasing mill process efficiency is evident. Clean and homogeneous grain enables mill equipment to operate at optimum performance, reduces wear, and minimizes downtime. This significantly increases total operational efficiency.
Ensuring product standardization and quality consistency is one of TAK Separator’s important advantages. Uniform classification of grain ensures consistency in final product quality. This is of critical importance especially for large-scale commercial operations.
The role of classification in production of different flour types becomes evident in the premium segment. Precise size and quality classification enables creating separate grain fractions for different flour types, increasing product diversity and profitability.
Installation and System Integration
Easy integration into existing mill lines is possible thanks to TAK Separator’s modular design. Standard inlet and outlet connections provide compatibility with existing systems with minimum modification. Even retrofit projects can be carried out quickly and smoothly.
Modular design and installation flexibility adapt to different facility configurations. Vertical or horizontal layout options can be optimized according to facility layout constraints. Inlet and outlet points can be positioned according to facility flow arrangement.
Optimum layout with minimum space requirement ensures efficient use of facility space. TAK Separator requires 40% less space compared to traditional systems. This compact design provides great advantage for both new facilities and modernization projects.
Installation process and required infrastructure features are planned in detail by our professional technical team. Basic requirements are a solid foundation, appropriate electrical connection, and aspiration system connection. A typical installation can be completed within 2-3 days.
Usage and Operating Features
Operator-friendly control system and interface provide easy use. Touchscreen control panel enables viewing and adjusting all operational parameters. Intuitive interface design enables effective use with minimum training.
Easily adjustable parameters and operating modes provide optimization according to different grain types and qualities. Parameters such as vibration frequency, screen slope, and air flow can be easily adjusted from the control panel.
Daily operating routine and monitoring requirements are minimal. Apart from simple visual checks and regular cleaning, TAK Separator operates almost completely automatically. Smart sensors and alarms detect potential problems at early stages.
Operating recommendations for optimum performance are provided in detailed user manual for each model. Basic recommendations include optimum feeding speed, regular screen control, and adjustment of vibration parameters according to grain type.
Maintenance and Service Ease
Low maintenance requirements and long service intervals reduce operating costs. High-quality components and wear-resistant materials minimize maintenance needs. Standard maintenance intervals are 2 times longer compared to traditional systems.
Easily accessible parts and service points shorten maintenance time. Quick access covers, modular design, and easily removable parts simplify service and cleaning operations. These features minimize downtime required for maintenance.
Screen replacement and cleaning procedures are simple and quick. Thanks to quick connection system, screens can be changed without using tools. Automatic cleaning ball system ensures screens stay clean even during operation.
Planned maintenance schedule and spare parts support are essential for uninterrupted operation. Tanış A.Ş. offers spare parts guarantee and fast service support for all models. This assurance ensures uninterrupted continuation of your mill operation.
Energy Efficiency and Sustainability
The balance between optimum power consumption and high efficiency is one of TAK Separator’s fundamental design goals. Efficient motor selection and optimized mechanical design minimize energy consumption per ton.
Energy-saving motor and motion technology reduce operating costs. IE3/IE4 efficiency class motors and frequency inverters optimize energy consumption. These technologies provide 20-30% energy savings per ton.
Low carbon footprint and environmentally friendly design contribute to your sustainability goals. Energy-efficient components, optimized process, and reduced maintenance needs minimize total environmental impact.
Contribution to sustainable production processes is not limited to energy savings alone. Long-lasting design, reduced spare parts needs, and optimized resource use support sustainable milling operations.
Economic Advantages and Investment Value
Positive effect on operating costs and savings potential are at the forefront of TAK Separator’s economic advantages. Low energy consumption, reduced maintenance needs, and higher capacity with less equipment significantly reduce operating costs.
Economic value of high capacity and production efficiency are evident for large-scale operations. Using less equipment for the same job reduces both initial investment cost and operating expenses. Additionally, higher process efficiency reduces waste rates and increases profitability.
Reduction in maintenance costs and operational advantages provide long-term economic benefit. Less downtime, reduced spare parts needs, and long-lasting components reduce total cost of ownership.
Investment payback period analysis typically shows a 2-3 year period. Increased efficiency, reduced operating costs, and improved product quality ensure rapid return on investment in TAK Separator.
Industrial Applications and Usage Areas
Large-scale flour factories and integrated facilities are the main usage areas of TAK Separator. Facilities processing hundreds of tons of grain daily benefit maximally from high capacity and efficiency advantages.
High-capacity grain processing centers benefit from the cleaning effectiveness and capacity advantages offered by TAK technology. Central cleaning facilities, grain storage centers, and grain processing terminals are ideal application areas.
Port and terminal operations require processing grain in high volumes. TAK Separator is an excellent solution for fast and effective cleaning and classification of large quantities of grain unloaded from ships.
Applications for different grain types vary. Besides basic grains like wheat, corn, and barley, TAK Separator offers an effective solution for special grains like rice, rye, and oats.
R&D and Technological Innovation
Tanış A.Ş.’s TAK technology development process continues continuously to meet changing needs in the sector. Our experience in the milling sector and customer feedback are the fundamental factors guiding our product development process.
Continuous improvement and innovation studies ensure continuous evolution of TAK technology. Innovations in vibration control, screen design, and material science areas continuously increase performance.
Developments made in line with customer feedback make the product suitable for practical needs. Every customer experience provides valuable contributions to the design of next-generation TAK Separators.
Research on future generation separator technologies is the focus point of Tanış R&D team. Smart sensors, remote monitoring, automatic adaptation, and higher efficiency are among the main themes of future innovations.
Frequently Asked Questions
What is TAK Separator’s energy consumption and savings potential?
Depending on model size, it uses motor power between 3.0-7.5 kW. Energy consumption per ton is 20-30% lower compared to traditional systems. This provides significant cost savings on an annual basis.
How long does screen replacement take and how frequently is it required?
Thanks to quick connection system, replacement of one screen layer takes approximately 15-20 minutes. Under normal operating conditions, it is recommended to check screens every 6-12 months and replace if necessary.
Can the same separator be used for different grain types?
Yes, TAK Separator can be used for different grain types. Screen configuration and operating parameters can be optimized for each grain type. Transition from wheat to corn or barley is possible with screen change and simple adjustments.
How long does integration into an existing mill line take?
A typical installation and integration can be completed within 2-3 days. This time may vary according to existing infrastructure and condition of connection points. Tanış engineering team provides professional installation service with minimum interruption time.
What are TAK Separator’s maintenance requirements?
Basic maintenance program for low-maintenance TAK Separator:
- Daily: Visual inspection and listening for abnormal sounds
- Weekly: Screen surface control and cleaning ball condition
- Monthly: Vibration mechanism and bearing control
- 6-Monthly: Comprehensive control and lubrication
- Annual: General overhaul and replacement of worn parts
For more information and TAK High Capacity Separator solutions suitable for your business, contact Tanış A.Ş. today. Our expert team is ready to offer solutions specific to your process needs.