Polygonal Bran Brush
Polygonal Bran Brush: Innovative Way to Boost Flour Yield in Milling
Increasing competitive conditions in the modern milling sector day by day necessitate innovative solutions that will maximize flour yield. The Polygonal Bran Brush developed by Tanış A.Ş. offers innovative technology that provides significant efficiency increases compared to traditional bran brushing systems. This system, which makes bran cleaning more effective thanks to its polygonal structure, has become indispensable equipment for modern mills.
Polygonal Bran Brush is a specially designed machine that performs the flour separation process from bran after grinding in the milling process. This system, which has a polygonal structure unlike traditional cylindrical designs, increases flour yield by providing more contact with the bran surface.
In the mill process, valuable flour particles are still found on the surface of bran obtained after grinding. Effective separation of these flour particles is a critical process that directly affects the mill’s overall yield. Polygonal Bran Brush performs this separation process with maximum efficiency, enabling 2-3% more flour to be obtained compared to traditional systems.
Its most important difference from traditional bran brushes is that it offers wider contact surface and intervention capability from different angles to bran thanks to its polygonal structure. This way, flour particles on bran are separated more effectively and mill efficiency increases significantly. Additionally, it reduces operating costs by optimizing energy consumption thanks to its special design.
The polygonal structure of Polygonal Bran Brush offers revolutionary technical advantages in bran cleaning process. Unlike traditional cylindrical brushes, the brushing surface has been expanded and contact capability from different angles has been provided thanks to the polygonal structure.
This innovative geometric design significantly increases brushing efficiency. Each surface of the polygonal structure contacts bran from a different angle, providing effective intervention to areas that cannot be reached in cylindrical systems. Thus, flour particles on bran are cleaned and separated more comprehensively.
Another advantage of polygonal design is that it provides homogeneous brushing. All bran particles contact equally with different surfaces of the brush, thus achieving uniform cleaning process. This homogeneity guarantees consistency of final product quality and continuity of yield increase.
Surfaces designed with special angles clean flour particles on bran with optimum force. This ensures that flour particles are separated without damage and quality is preserved. At the same time, this special design minimizes wear of brush surfaces, extending equipment life.
The polygonal structure of Polygonal Bran Brush has been optimized as a result of years of R&D studies. 8-sided polygonal structure is used in our standard models. Each side of this structure is positioned at 45-degree angles to maximize bran cleaning performance.
Side number and angle calculations have been determined as a result of comprehensive tests conducted on various wheat types and bran qualities. This geometric structure developed for optimum brushing performance both increases cleaning effectiveness and minimizes energy consumption.
In the technical design of polygonal structure, placement of brush elements has also been specially calculated. Brush positions on each surface are placed in a gradual order, ensuring effective cleaning of all bran particles. This detailed engineering approach forms the foundation of the machine’s superior performance.
Technical Specifications and Performance
Polygonal Bran Brush is offered with various model options to meet different capacity needs. Basic technical specifications are as follows:
| Model | Capacity (tons/day) | Dimensions (W×L×H) | Motor Power (kW) | Side Number | Weight (kg) |
|---|---|---|---|---|---|
| TMKF-4008 | 50 | 1.2×1.8×1.5 m | 5,5 | 8 | 850 |
| TMKF-4010 | 75 | 1.5×2.0×1.7 m | 7,5 | 8 | 1050 |
The following standard features are available in all our models:
- Stainless steel body structure (AISI 304 quality)
- Wear-resistant special alloy brush elements
- Adjustable brush pressure
- Frequency inverter system providing precise speed control
- Digital control panel
- Drive system optimized for low energy consumption
Brush elements are manufactured from specially developed nylon and steel mixture material, providing long-lasting and high-performance operation. This material combination offers the advantage of both effective bran cleaning and minimizing bran damage risk.
Model Variations and Capacity Options
As Tanış A.Ş., we have developed Polygonal Bran Brush models in various capacity classes to offer ideal solutions for mills of different scales. Factors to consider when selecting the model suitable for your business size and needs are:
- Mill daily production capacity
- Types of wheat processed and bran characteristics
- Existing system configuration
- Target yield increase
- Placement area constraints
In addition to our standard models, we also offer modified versions for your special production requirements. These include polygonal designs with different side numbers, special brush materials, and automation options.
Role in Increasing Flour Yield
The most important contribution of Polygonal Bran Brush to mill operations is increasing flour yield. The additional yield increase it provides compared to traditional cylindrical bran brushes directly affects mill profitability.
The system, which separates flour particles on bran more effectively thanks to its polygonal design, provides a 2-3% increase in total flour yield. This increase creates significant economic value on an annual basis for high-capacity mills.
Polygonal Bran Brush shows consistent performance when working with different wheat types and qualities. While providing yield increase up to 2.8% in hard wheats, this rate is around 2.2% in soft wheats. The yield increase achieved under all conditions optimizes mill operations profitability.
The system also preserves the quality of separated flour. The problem of flour quality decrease due to excessive brushing encountered in traditional systems is prevented thanks to the optimum pressure and contact characteristics of polygonal design. Thus, both yield increase and quality preservation are achieved together.
Efficiency Increase Statistics
The performance of Polygonal Bran Brush has been verified through comprehensive tests conducted at various customer facilities. The results obtained show that system investment provides return in a short period of 8-12 months on average.
According to our statistical data:
- Average flour yield increase: 2.5%
- Decrease in operating costs: 15%
- Energy savings: 20%
- Decrease in maintenance costs: 30%
- Equipment life: Average 10 years
Real data obtained from customer facilities confirm theoretical calculations and prove the economic advantages provided by Polygonal Bran Brush. For example, in a mill processing 250 tons of wheat daily, a 2.5% yield increase means approximately 1500 tons of additional flour production annually.
Installation and System Integration
Polygonal Bran Brush is designed to be easily integrated into existing mill lines. Thanks to its compact structure, it offers installation opportunity with minimum space requirement.
The installation process consists of the following stages:
- Preliminary survey and planning
- Infrastructure preparation and determination of mounting points
- Mechanical assembly operations
- Electrical and automation connections
- Commissioning and testing
- Operator training and usage instructions
Tanış expert team provides support at every stage of installation, guaranteeing smooth commissioning of the system. Average installation time can be completed within 2-3 days depending on facility condition.
For optimum efficiency, correct positioning of Polygonal Bran Brush in the mill flow chart is important. Ideal placement is as the final bran cleaning unit, after reduction rollers and before flour collection system. This positioning provides maximum flour separation performance.
Usage and Operation Features
Polygonal Bran Brush has ergonomic design providing ease of use and user-friendly control system. Operational parameters of the machine can be easily adjusted through the digital control panel.
Basic adjustable parameters are:
- Brush speed
- Brush pressure
- Bran feed rate
- Brushing time
These parameters are optimized according to the type of wheat processed and bran characteristics to achieve maximum yield. The system also has automatic safety functions that provide protection against overloading and abnormal operating conditions.
Usage recommendations for optimum performance:
- Do not keep brush pressure excessively high, this can cause bran damage and increased brush wear
- Adjust speed according to the product being processed, higher speeds can be preferred for hard wheat bran
- Follow regular cleaning and maintenance program
- Periodically check the condition of brush elements
Maintenance and Service Advantages
Polygonal Bran Brush stands out with its low maintenance requirements and easy serviceability features. Thanks to high-quality materials and robust structure, it provides long-term trouble-free operation.
Recommended maintenance schedule is as follows:
Daily Controls:
- Visual inspection
- Abnormal sound control
- Performance control
Weekly Maintenance:
- Brush elements control
- Drive system control
- Sealing control
Monthly Maintenance:
- Comprehensive cleaning
- Bearing control
- Electrical connections control
- Brush pressure adjustment control
Six-Monthly Maintenance:
- Brush elements replacement (if necessary)
- Drive system maintenance
- Comprehensive mechanical control
Brush elements are designed in modular structure, offering easy and fast replacement opportunity. This minimizes maintenance times and reduces production interruptions to minimum. As Tanış A.Ş., we guarantee continuous stock availability of all spare parts and shipment within 48 hours.
Economic Advantages and Investment Value
Polygonal Bran Brush investment amortizes itself in a short time with the efficiency increase and operating cost savings it provides. We can examine its economic advantages under the following headings:
Financial Value of Yield Increase: In a mill processing 200 tons of wheat daily, 2.5% yield increase provides approximately 1250 tons of additional flour production annually. This amount creates significant additional revenue on an annual basis depending on flour prices.
Operating Cost Savings: Polygonal design optimizes energy consumption, providing energy savings up to 20% compared to traditional systems. Additionally, it reduces operating costs with longer brush life and less maintenance requirement.
Total Cost of Ownership (TCO): The total cost of ownership of Polygonal Bran Brush over its 10-year service life is 25-30% lower than traditional systems, considering the advantages it provides. This calculation takes into account initial investment cost, energy consumption, maintenance costs, and production increase.
Investment payback period is between 8-12 months on average, although it depends on facility capacity and operating regimes. This period can be even shorter in high-capacity facilities.
Application Areas and Industrial Use
Polygonal Bran Brush can be used in facilities of various scales in the milling sector. Main application areas are:
Large-Scale Flour Mills: Ideal for modern flour mills with daily capacity of 300 tons and above. High-capacity PKF-3000 and PKF-4000 models meet the efficiency requirements of these facilities.
Medium and Small-Scale Mills: PKF-1000 and PKF-2000 models offer excellent solutions for mills with daily capacity of 100-300 tons. They are ideal for this segment with their compact dimensions and reasonable costs.
Facilities Processing Different Grain Types: Polygonal Bran Brush shows effective performance not only in wheat but also in processing other grain types such as corn, rye, and barley. Maximum yield is achieved thanks to optimized settings for each grain type.
Special Flour Production Lines: It is the ideal solution for facilities producing premium flour and special-purpose flour, increasing yield while preserving product quality. It meets high quality standards thanks to its precise control features.
R&D and Continuous Improvement
As Tanış A.Ş., we conduct comprehensive R&D studies to continuously develop our Polygonal Bran Brush technology. The first prototype was developed in 2010 and has been continuously improved since then based on customer feedback and technological developments.
In our development process, we work closely with leading companies in the milling sector, aiming to produce solutions to real problems encountered in the field. Thanks to this cooperation, we test theoretical engineering studies with practical applications and offer the most effective solutions.
Main improvements made based on customer feedback are:
- Increasing durability of brush material
- Making control system user-friendly
- Optimized operating parameters for different wheat types
- Increasing energy efficiency
- Design updates providing maintenance ease
Our work on next-generation bran brushing technologies includes fully automatic self-adjusting systems, remote monitoring and control features, and even more advanced polygonal geometries.
Customer Experiences and Success Stories
Polygonal Bran Brush, preferred by Turkey’s leading flour producers, makes a difference with the value it offers to its users. Here are a few customer experiences:
Anadolu Flour – Konya: “With Tanış Polygonal Bran Brush, we achieved a 2.7% increase in our yield. This increase created significant additional revenue on an annual basis while we did not compromise our product quality. Our investment amortized itself in 9 months.” – Mehmet Yılmaz, Production Manager
Bereket Milling – İzmir: “We use PKF-2000 model in our medium-scale facility. We achieved both energy savings and flour yield increase compared to our old system. Maintenance ease and longevity also provide important advantages.” – Ali Kaya, Facility Manager
Akdeniz Flour – Antalya: “We operate in the premium flour segment and product quality is very important for us. Polygonal Bran Brush became the ideal solution because it preserves flour quality while increasing yield. Technical support and service speed are also satisfactory.” – Ayşe Demir, General Manager
These success stories show the concrete benefits that Polygonal Bran Brush provides in mills of different scales and requirements. We aim for maximum customer satisfaction by offering solutions specific to each customer’s needs.
Frequently Asked Questions
Can Polygonal Bran Brush be integrated into my existing system?
Yes, Polygonal Bran Brush can be easily integrated into most existing mill systems thanks to its modular structure. Our Tanış engineering team ensures smooth installation by creating an integration plan specific to your facility.
What is the average life of brush elements?
Although it depends on operating conditions, the average life of brush elements is 6-8 months. This period can be extended with regular maintenance and correct use.
How much yield increase can I expect?
Depending on the type of wheat processed and the efficiency of your existing system, 2-3% yield increase is achieved. More precise information can be given as a result of analysis to be conducted at your facilities for exact values.
What is the investment payback period?
Although it depends on facility capacity and operating regime, average payback period is between 8-12 months. This period can be even shorter in high-capacity facilities.
Is special training required for use?
After installation, comprehensive training is given to operators by Tanış team. Basic level technical knowledge is sufficient for the system, which is quite easy to use.
Is it suitable for different grain types?
Yes, Polygonal Bran Brush shows effective performance in processing different grain types such as corn, rye, and barley in addition to wheat. Operating parameters can be optimized for each grain type.