In the modern milling industry, sustainable competitive advantage depends on your equipment operating at optimum performance. Detailed and regular performance controls maximize your mill system’s efficiency level while minimizing energy consumption and ensuring consistency in your product quality.
As Tanış A.Ş., with our over 60 years of sector experience and expert engineering staff, we analyze your mill system’s performance using scientific methods, identify potential improvement areas, and provide concrete solution recommendations. With regular performance controls, we prevent unexpected breakdowns, reduce your maintenance costs, and extend your mill’s lifespan.
Tanış A.Ş.’s performance control services offer a holistic approach covering all critical components of your mill:
Mechanical Performance Control: Efficiency and wear analysis of main equipment such as rolls, sifters, elevators, and conveying systems
Electrical and Automation Systems: Motor performance, automation programs, sensor and control systems analysis
Energy Efficiency Analysis: Energy consumption mapping and savings potential of the entire system
Product Quality and Yield Measurement: Evaluation of efficiency, extraction ratio, and quality parameters
Noise and Vibration Analysis: Equipment health assessment and early fault diagnosis
Raw Material Processing Performance: Effectiveness of tempering, cleaning, and preparation systems
Packaging Efficiency: Speed and precision control of filling and packaging systems
Our systematic and comprehensive performance control methodology is applied in 6 steps:
- Needs Analysis and Control Plan
- Determination of your operation’s specific needs
- Identification of priority control areas
- Creation of customized control plan
- Data Collection and Measurement
- On-site measurement with advanced technology test equipment
- Operational data collection and recording
- Documentation of operating parameters
- Comparison with Reference Values
- Comparison of obtained data with industry standards
- Benchmarking against manufacturer technical specifications
- Performance trend evaluation with previous measurements
- Detailed Report Preparation
- Comprehensive findings and analysis results
- Visual graphics and comparison tables
- Clear and applicable results
- Improvement Recommendations
- Solution recommendations for identified problems
- Prioritized action plan
- Cost-benefit analyses
- Follow-up and Continuous Improvement
- Post-improvement verification control
- Periodic follow-up and progress evaluation
- Continuous improvement consulting
Mechanical Performance Controls
We identify hidden performance losses through detailed analysis of your mill system’s mechanical components:
Roll and Cylinder Systems Analysis:
- Roll surface wear condition and profile measurement
- Roll gap and parallel operation control
- Pressure settings and load distribution analysis
- Fluting condition and corrugation analysis
Sifter Performance Measurement:
- Vibration amplitude and frequency
- Sifting efficiency and capacity control
- Sifter frame and tensioning condition
- Balance control
Transmission and Drive Systems:
- Belt-pulley system tension measurement
- Chain and gear wear control
- Coupling alignment precision
- Lubrication effectiveness and condition
Bearing and Support Systems:
- Bearing condition spectrum analysis
- Temperature and lubrication control
- Bearing clearance measurement
- Bearing wear control
Vibration analysis is one of the most effective methods for evaluating equipment health and enables early detection of failures:
Vibration Spectrum Analysis:
- FFT (Fast Fourier Transform) spectrum analysis
- Early detection of bearing, gear, belt problems
- Resonance and imbalance detection
- Structural weakness and looseness control
Noise Level Measurement:
- Frequency-based noise analysis
- Noise mapping
- Occupational health and safety evaluation
- Insulation effectiveness measurement
Shaft Misalignment and Imbalance:
- Shaft misalignment measurement with laser alignment
- Dynamic and static imbalance detection
- Balance control in rotating parts
- Structural stiffness evaluation
The effective operation of electrical and automation systems, which are the nervous system of modern mills, is critically important:
Motor Performance and Load Analysis:
- Motor load profile extraction
- Efficiency and power factor measurement
- Heating condition and insulation control
- Vibration and imbalance analysis
PLC and Control Systems:
- Program optimization control
- Process control loop analysis
- Communication and data transfer efficiency
- Alarm and safety system control
Sensors and Instrumentation:
- Precision and calibration control
- Response time and accuracy analysis
- Signal quality and stability measurement
- Connection and wiring condition
Automation Program:
- Recipe management optimization
- Process sequences and timing control
- User interface efficiency
- Data reporting and recording control
Energy costs constitute a significant portion of your operational expenses. We identify savings opportunities through comprehensive energy analysis:
Energy Consumption Mapping:
- Energy consumption profile of system components
- Peak load and fluctuation analysis
- Reactive power and harmonic analysis
- Energy consumption per ton calculation
Loss and Leak Points:
- Heat leak detection with thermal camera
- Compressed air leaks with ultrasonic control
- Motor and drive system efficiency analysis
- Insulation effectiveness evaluation
Energy Savings Potential:
- Comparative analysis of specific energy consumption (kWh/ton)
- Efficiency improvement potential calculation
- Energy savings potential per ton
- Energy cost reduction recommendations
We analyze in detail the product quality and productivity parameters that are the ultimate indicators of your production performance:
Product Quality Tests:
- Moisture, protein, gluten, ash content analysis
- Farinograph, alveograph, mixograph tests
- Color and particle size analysis
- Flour standardization level control
Efficiency and Productivity Analysis:
- Extraction ratio calculation and optimization
- Milling diagram efficiency
- Passage yields and product distribution
- Raw material-product conversion ratio calculation
Waste and Loss Analysis:
- Detection and measurement of in-process losses
- Dust leakage and filtration efficiency control
- Loss measurement in conveying systems
- Total loss ratio calculation
Our Performance Control Equipment
As Tanış A.Ş., we use the most advanced test equipment in the industry for mill performance controls:
Vibration Analysis Systems:
- CSI 2140 multi-channel spectrum analyzer
- Ivibration Bluetooth wireless vibration sensors
- ProCheck online vibration monitoring system
Thermal Imaging Systems:
- FLIR T640 high-resolution thermal camera
- Spot temperature meters and recording devices
Electrical Analysis Devices:
- Fluke 435-II power quality analyzer
- HIOKI PW3198 energy analyzer
- Motor current spectrum analyzers
Alignment Systems:
- Pruftechnik ROTALIGN ULTRA iS laser alignment system
- Pulley-belt alignment laser
Quality Control Laboratory:
- NIR (Near Infrared) analysis device
- Farinograph, extensograph, alveograph test systems
- Gluten analysis device
- Particle size measurement systems
Performance Control Report and Evaluation
At the end of each performance control, we present our findings in a comprehensive and understandable report:
Findings and Comparative Analyses:
- Measurement data and technical details
- Comparison with optimum values
- Trend analysis with previous controls
Visualized Data:
- Visualization of results with graphics and diagrams
- Thermal images and vibration spectra
- Heat maps and performance curves
Problem Prioritization:
- Identification of problems requiring urgent intervention
- Medium-term improvement requirements
- Potential problem areas to be monitored
Economic Evaluation:
- Potential cost of identified problems
- Return analysis of improvement investments
- Energy savings and efficiency increase potential
Basic Performance Control Package
- Basic control of mechanical systems
- Vibration analysis of critical equipment
- Basic energy consumption measurement
- Summary performance report and basic recommendations
- Affordable Price: Varies according to capacity and facility size
Based on control results, we provide clear and applicable recommendations for performance improvement:
Short-term Quick Gain Recommendations:
- Adjustments that can yield quick results with minimum investment
- Critical maintenance and repair needs
- Fine adjustments in operational parameters
Medium-term Improvement Projects:
- Partial equipment renewal recommendations
- Process optimization projects
- Efficiency-enhancing modifications
Long-term Investment Plans:
- Modernization and technological renewal recommendations
- Capacity-increasing investment plans
- Energy efficiency investments
Maintenance Strategy Recommendations:
- Creating proactive maintenance plan
- Special maintenance protocols for critical equipment
- Spare parts inventory optimization
Tanış A.Ş.’s performance control services provide concrete benefits for your mill:
Failure Prevention and Predictive Maintenance:
- Early detection of developing failures
- Up to 65% reduction in unplanned downtime
- 40% decrease in emergency repair costs
Energy Savings:
- 10-25% reduction in energy consumption per ton
- 15% annual energy cost savings potential
- Measurable reduction in greenhouse gas emissions
Production Efficiency:
- 2-5% increase in extraction ratio
- 8-12% improvement in capacity utilization rate
- 15-20% reduction in waste rates
Product Quality:
- More consistent and standardized product quality
- 30-40% reduction in customer complaints
- 25% decrease in product quality deviation
Equipment Life:
- 20-30% extension in machine life
- 25% reduction in spare parts costs
- 15-20% decrease in maintenance expenses
- We offer different performance control packages suitable for your operation’s needs and budget:
- Detailed analysis of all mechanical and electrical systems
- Comprehensive vibration and thermal imaging
- Detailed energy efficiency analysis
- Product quality and efficiency measurements
- Detailed reporting and action plan
- One month follow-up support
Premium Performance Optimization Package
- Most comprehensive performance control and analysis
- Long-term monitoring and data collection
- Online equipment condition monitoring setup
- Customized optimization recommendations
- Three months follow-up support and consulting
- Post-implementation verification control
Periodic Control Contract Advantages
- 2-4 periodic performance controls annually
- Discounted package pricing
- Priority intervention and technical support
- Performance trend analysis and comparative reporting
- Free phone and remote support
Frequently Asked Questions
Depending on facility size and control scope, a performance control generally takes 1-3 days. Planning should be made for 1 day for basic package, 2 days for comprehensive analysis, and 2-3 days for premium package.
Most measurements and analyses can be performed while production continues. Some special tests may require short-term (30-60 minutes) stops. We try to coincide these stops with your planned maintenance times.
Ideally, we recommend performance control every 3-4 months for large mills, and every 6 months for medium and small-scale mills. More frequent control will be beneficial in the first year for newly established facilities or systems with new equipment additions.
Before control, it will be useful to prepare recent production data, energy consumption records, and previous maintenance information. Additionally, informing us about problem areas you’ve identified and priority concerns will enable us to direct our controls more effectively.
Preliminary findings are usually shared at the end of control. Detailed performance report and improvement recommendations are delivered within 5-7 business days after control.
Yes, we offer performance control services for all grain processing facilities including flour mills, semolina mills, feed mills, bulgur plants, and rice mills. We can analyze equipment from all manufacturer brands.
Yes, our reports are prepared in accordance with international standards such as ISO 9001, ISO 17025, and ISO 13373 (vibration analysis). Our measurement equipment is regularly calibrated and certified.
Discover Your Mill’s True Performance
Tanış A.Ş.’s expert performance control team is with you to reveal your mill’s true potential. Take the first step for more efficient production, lower costs, and higher quality products.
Contact us immediately for a Free Preliminary Assessment. Let our experts visit your operation to determine your performance control needs and propose customized solutions.