Automatic Conditioning Machine
Automatic Conditioning Machine: Precise Moisture Control in Milling
The first step to quality flour production in the milling industry begins with proper conditioning. With Tanış A.Ş.’s advanced Automatic Conditioning Machine, maximize your flour quality and yield by moistening your grains homogeneously at ideal moisture levels. Experience the advantage of continuous and precise moistening without the need for manual intervention thanks to fully automatic conditioning technology.
The Automatic Conditioning Machine is an advanced technology equipment that automates the grain conditioning process, one of the most critical stages of milling operations. Conditioning is the process of bringing grains such as wheat, corn, and barley to a specific moisture level before the grinding process. This process facilitates the separation of bran and endosperm parts of grain, enabling higher yield and quality flour production.
The Tanış Automatic Conditioning Machine ensures that each grain variety reaches its ideal moisture level through sensors that continuously measure grain moisture content and a precise dosing system. Its fully automatic structure eliminates human-factor errors and provides consistent moistening performance.
This machine, which has strategic importance in the cleaning and conditioning stage of mills, directly affects the efficiency of flour production process. Grains conditioned at the correct moisture level facilitate bran and endosperm separation, increase grinding efficiency, and enhance flour quality.
Traditional manual conditioning systems produce variable results based on operator experience and require constant human intervention. The Tanış Automatic Conditioning Machine eliminates human-factor errors, offers 24/7 continuous operation capability, and provides moisture control with ±0.2% precision.
Our Automatic Conditioning Machine works with advanced moisture sensors and microprocessor-controlled dosing system. The system continuously compares the grain’s current moisture level with the target moisture value, calculates and applies exactly the required amount of water. This precise control ensures homogeneous distribution of moisture level throughout the entire grain mass.
Our Automatic Conditioning Machine is equipped with industrial-grade high-precision moisture sensors. These sensors measure grain moisture level in real-time, enabling the system to add the correct amount of water. Our sensors can be calibrated for different grain types and provide consistent results under various operating conditions.
The system continuously measures and records grain input moisture level, added water amount, and output moisture value. This data can be easily monitored from the control panel and reported when necessary. Our moisture sensors compensate for ambient temperature changes, providing accurate measurements under all conditions.
Technical Specifications and Performance Parameters
The Tanış Automatic Conditioning Machine has the following technical specifications:
- Capacity: 5-50 tons/hour (varies by model)
- Water Dosing Precision: ±0.3%
- Moisture Measurement Range: 0-30%
- Target Moisture Control Range: 10-20%
- Power Consumption: 3-7 kW (varies by model)
- Operating Voltage: 380V, 50Hz, 3 Phase
- Water Pressure Requirement: 2-4 bar
- Automation System: PLC-based touch control panel
- Connection Features: SCADA compatible, remote access support
- Dimensions (LxWxH): 2500x1200x2200 mm (for main model)
Thanks to its compact design, it occupies minimum space and can be easily adapted to existing facilities.
Model Variations and Capacity Options
As Tanış A.Ş., we offer various models to meet different capacity needs:
- ATM-5: 5-10 tons/hour capacity, for small and medium-scale mills
- TMOT-B-25: 1-25 tons/hour capacity, for medium-scale facilities
- TMOT-M-60: 10-50 tons/hour capacity, for large-scale facilities
- ATM-50: 35-50 tons/hour capacity, for industrial-scale integrated facilities
Moisture Control and Conditioning Performance
Precise Moisture Control and Reaching Target Moisture Value
Our Automatic Conditioning Machine can reach the targeted moisture value with ±0.2% deviation. This precision provides great advantages especially in cases where specific moisture ranges are critical for quality flour production.
The specially designed mixing system ensures homogeneous distribution of water within the grain mass. This homogeneity increases the effectiveness of the conditioning process and enhances final product quality.
Conditioning Process and Optimization
The optimum conditioning time of grain depends on its type, hardness, and target moisture level. The system calculates the optimum conditioning time according to these parameters and provides recommendations to the operator. Different grain types require different moisture values for optimum grinding:
- Hard wheat: 16.5-17.5% moisture
- Soft wheat: 15.5-16.5% moisture
- Durum wheat: 17.0-18.0% moisture
- Corn: 16.0-18.0% moisture
- Barley: 14.0-15.0% moisture
Our Automatic Conditioning Machine contains these values in pre-programmed form and can be easily selected by the operator.
Effect on Yield and Flour Quality
Properly conditioned wheat facilitates bran and endosperm separation during grinding process. This separation means higher flour yield. A 2-3% increase in flour yield can be observed with our Automatic Conditioning Machine.
Correct moisture level preserves and develops wheat’s protein structure. This enhances the baking quality of final flour. Homogeneous moistening ensures protein quality is consistent throughout the entire flour batch.
Ideal moisture level enables easier separation of wheat bran from endosperm. This means cleaner separation process and less bran-contaminated flour. Homogeneously conditioned wheat provides more consistent grinding in roll systems.
Automation and Control System
Our Automatic Conditioning Machine is controlled by industrial standard PLC systems. A 10-inch color touch screen enables easy monitoring and adjustment of all system parameters.
All system parameters can be monitored and controlled remotely via internet connection. This feature provides great convenience especially for multi-facility management.
The system records and reports all process parameters (input moisture, added water amount, output moisture, processing time, etc.). This data can be used for quality control and process optimization. Our Automatic Conditioning Machine is fully compatible with industrial SCADA systems.
Installation and System Integration
Thanks to its compact design and modular structure, it can be easily integrated into existing mill lines. Installation time is usually completed within 3-5 days including preparations.
The system requires clean water connection (2-4 bar pressure) and three-phase electrical connection. All connection points are strategically positioned for easy access.
After installation, detailed commissioning and calibration process is performed by our expert technical team. During this process, comprehensive training is provided to operators and the system is optimized according to facility’s specific needs.
Ease of Use and Operation
The intuitive touch screen interface can be easily used even by operators with limited technical knowledge. All functions are logically grouped and easily accessible.
The system contains pre-defined programs for different grain types and operating conditions. The operator can operate the system by simply selecting grain type and target moisture value.
Daily operations consist of routine controls and simple cleaning procedures. Since the system operates largely autonomously, daily operating routine is minimal.
The system is equipped with comprehensive alarm and warning systems to detect potential problems in advance. Conditions such as water pressure drop, sensor failure, motor overload are immediately reported.
Maintenance and Service Requirements
Our Automatic Conditioning Machine is designed to require minimum maintenance. Routine controls and maintenance can be performed at 3-month intervals.
The system reminds when critical components need to be checked. A detailed maintenance schedule is provided in the user manual and can be monitored from the user interface.
Water filters need to be cleaned or replaced regularly. Valve systems should be checked annually and cleaned if necessary. Moisture sensor accuracy should be checked at 6-month intervals and calibrated if necessary.
Energy and Water Efficiency
The precise dosing system uses only the required amount of water, preventing water waste. The system uses optimum amount of water per ton of processed grain.
Thanks to energy-efficient motors and smart power management, the system operates with minimum electricity consumption. Standby mode provides energy savings when not in use.
Optimum water and energy use reduces the mill’s ecological footprint. As Tanış A.Ş., we consider supporting sustainable production processes as one of our fundamental principles.
Optionally offered water recovery system filters part of used water for reuse. This system provides valuable advantage especially in regions with limited water resources.
Economic Advantages and Investment Value
Compared to manual conditioning systems, reduction of labor needs up to 80% provides significant operational savings. Fully automatic structure offers 24-hour continuous operation capability.
A 2-3% increase in flour yield means significant economic gain on annual basis. High-quality flour production positively affects product sales price.
Low energy consumption, minimum water use, and long service intervals reduce operating costs. Durable structure and quality components provide reliable performance for many years.
For an average mill, the payback period for Automatic Conditioning Machine investment is between 12-18 months. This period may vary according to operating capacity, current conditioning method, and regional factors.
Industrial Applications and Usage Areas
Our high-capacity ATM-30 and ATM-50 models are ideal for large flour mills with daily capacity of 500 tons and above. In these facilities, fully automatic conditioning system maximizes production efficiency.
Our ATM-5 and ATM-15 models offer excellent solutions for small and medium-scale mills with daily capacity of 50-300 tons. In this segment, labor savings and quality improvement are especially valuable.
The system can be adapted to specific conditioning needs of different grain types. Special configurations are available for facilities processing corn and barley in addition to wheat.
For facilities producing special-purpose flour (pasta flour, pizza flour, baklava flour, etc.), precise moisture control is critically important. Our Automatic Conditioning Machine guarantees standard quality special flour production by providing this precision.
R&D and Technological Innovations
We continuously follow the latest innovations in conditioning technology and develop original solutions with our own R&D team. Innovations in sensor technologies and automation systems are continuously integrated into our products.
Adopting the “Kaizen” philosophy, we continuously improve our products. Each new model is designed to be more efficient, more user-friendly, and more durable than the previous one.
We carefully evaluate feedback from our customers and place it at the center of our product development process. Practical experiences from the field are as valuable as theoretical engineering knowledge.
We are working on technologies such as artificial intelligence-supported automation, cloud-based remote monitoring, and IoT integration. Our next-generation conditioning systems are being developed in accordance with Industry 4.0 vision.
Frequently Asked Questions
How is the Automatic Conditioning Machine integrated into my existing mill line?
Thanks to its modular structure, the system can be easily integrated into both newly installed and existing mill lines. Our technical team prepares the most suitable integration plan according to your facility’s specific requirements and performs the installation.
What adjustments are required when switching between different grain varieties?
The system has pre-programmed settings for different grain types. The operator can easily switch by selecting the relevant grain type from the touch screen. Sensor calibration and dosing parameters are automatically adjusted.
What are the maintenance requirements of the system?
Basic maintenance requirements are regular cleaning of water filters, 6-month control of sensor calibration, and annual maintenance of valve systems. These routine maintenances guarantee continuous and precise operation of the system.
How does the system behave in case of power outage?
The system performs safe shutdown in case of power outage and can automatically continue operating from the last settings after the outage. Critical control functions can be maintained during power outage with optional UPS support.
How much water savings can be achieved?
Compared to manual systems, the Automatic Conditioning Machine provides 25-35% water savings. With optional water recovery system, this rate can reach 40-50%.
Our Services
As Tanış A.Ş., we provide full support from Automatic Conditioning Machine purchase to installation and subsequent maintenance processes:
- Free needs analysis and system design
- Professional installation and commissioning
- Operator training and technical documentation
- 24/7 technical support line
- Regular maintenance and service packages
- Spare parts guarantee
Meet the Tanış Automatic Conditioning Machine to modernize your milling processes and increase your flour quality and yield. Our expert team is just a phone call away to provide customized solutions for your needs.