Dual-Layer Pneumatic Roller Mill

Roller Options and Capacities

*Capacity values may vary depending on the type of grain processed and grinding fineness.

Power Consumption

Efficiency Comparison

Our dual-layer pneumatic roller mill system, compared to two separate single roller systems of the same capacity:

• Takes up 30% less space
• Consumes 15% less energy
• Offers 20% lower maintenance costs
• Provides 25% faster installation opportunity

Application Areas and Usage Scenarios

Medium and Large Scale Flour Mills

In flour mills with daily capacity of 100 tons and above, the dual-layer pneumatic roller mill system is ideal with both space savings and high capacity advantages. It increases grinding capacity by efficiently using vertical space, especially in multi-story mill facilities.

High Capacity in Limited Space Conditions

It offers an excellent option for businesses in city centers or facilities with limited space that want to meet capacity increase needs with a compact solution. It provides capacity increase without changing existing infrastructure.

Modernization and Capacity Increase Projects

In modernization or capacity increase projects of existing mill facilities, it becomes possible to increase production capacity without building new buildings or expanding existing buildings with the dual-layer roller system.

Wide Application Area for Various Grain Types

Our dual-layer pneumatic roller mill system shows superior performance in processing various grain types:

• Wheat: Adjustable grinding parameters for different hardness wheat types
• Corn: Ideal solution for gradual breaking of hard corn kernels
• Barley: Superior control capability in barley processing requiring precise grinding

Considering Turkey’s 4.8% share in barley production and 3% share in wheat production, our dual-layer pneumatic roller mill system developed in accordance with domestic production conditions is an optimized solution for the Turkish milling sector.

Flour Quality and Processing Advantages

Effect of Dual-Layer System on Flour Quality

The dual-layer pneumatic roller mill system significantly improves final product quality by offering the advantages of the gradual grinding principle:

• Optimal breaking of grain is achieved on the first floor
• Desired fineness is obtained with precise grinding on the second floor
• Homogeneous particle size distribution
• Lower starch damage
• Improved gluten quality

Adjustability for Different Flour Types

Thanks to independently adjustable parameters for each floor of the dual-layer system, you can produce various flour types with a single machine:

• Bread flour
• Pasta and pastry flours
• Special purpose flours
• Premium quality flours

You can create a production line offering variety by determining the most suitable roller surface profile and pneumatic pressure values for each flour type.

Homogeneous Grinding and Particle Size Control

The gradual grinding provided by the dual-layer system ensures precise control of product particle size:

• Narrowed particle size distribution
• Less over-crushed particles
• Production suitable for desired granulation

Extraction Rates and Optimization Opportunities

Our dual-layer pneumatic roller mill system helps you optimize flour extraction rates:

• 2-5% increased extraction rate
• Reduced flour loss to bran
• Optimized ash content
• Consistent and repeatable production parameters

Assembly, Installation and Operation

Modular Design and Easy Installation

Our dual-layer pneumatic roller mill system is designed with a modular approach to accelerate assembly and installation processes:

• Pre-assembled components
• Standardized connection points
• Easy alignment mechanisms
• Quick commissioning

Integration with Existing Systems

In modernization projects, we offer special solutions for integrating the dual-layer roller unit to your existing mill systems:

• Adapter connection parts
• Custom-made transport equipment
• Control units compatible with existing automation systems
• Gradual transition plans

Commissioning and Start-up Process

Services provided by our expert team for commissioning the dual-layer pneumatic roller mill system:

1. Hardware installation and physical integration
2. Configuration of control systems
3. Initial test runs and parameter adjustments
4. Full load operation tests with gradual capacity increase

Operator Training and User Manual

We provide comprehensive training programs and document support for the most efficient use of your system:

• Practical operator training
• Comprehensive user manuals
• Video-based training materials
• Online technical support portal

Maintenance and Service Requirements

Regular Maintenance Program and Control Points

Recommended maintenance program for long-lasting and efficient operation of the dual-layer pneumatic roller mill system:

• Daily control points
• Weekly maintenance procedures
• Monthly detailed maintenance operations
• 6-monthly comprehensive control and service

Easily Accessible Maintenance Areas

Specially designed access points to facilitate and accelerate maintenance operations:

• Wide service doors
• Ergonomic working platforms
• Quickly removable protective covers
• Integrated lighting for maintenance operations

Spare Parts and Consumables Information

As Tanış A.Ş., we provide comprehensive spare parts support for your dual-layer pneumatic roller mill system:

• Stock list of critical spare parts
• Long-lasting consumables
• Fast supply chain for original parts
• Roller surface renewal services

Remote Support and Service Facilities

Thanks to our technological infrastructure, we offer advanced remote support services for your dual-layer pneumatic roller mill system:

• Online fault diagnosis
• Remote parameter optimization
• Remote software updates
• 24/7 technical support line

Economic Advantages and Investment Analysis

Initial Investment and Operating Cost Analysis

The dual-layer pneumatic roller mill system offers significant economic advantages compared to two separate single roller units:

• 20% lower initial investment cost
• 15% reduced operating expenses
• Less spare parts inventory need
• Reduced maintenance personnel requirement

Economic Value of Space Savings

Efficient use of facility space in the modern milling sector directly creates economic value:

• Smaller building construction cost
• Reduced land requirement
• Optimized infrastructure use
• Available space for expansion

Energy Efficiency and Operating Costs Comparison

The energy efficiency-focused design of our dual-layer pneumatic roller mill system significantly reduces your operating costs:

• Dual-layer operation with single drive system
• Optimized motor selections
• Efficient mechanical transmission systems
• Reduced heat losses

Payback Period and Return on Investment Calculations

According to analysis conducted for an average mill operation:

• 18-24 months payback period
• Over 35% return on investment in 5-year use
• 15% annual savings in operating costs
• 20% reduction in maintenance costs

Why Should Tanış Dual-Layer Pneumatic Roller Mill Be Preferred?

Patented Technology and Innovative Solutions

As Tanış A.Ş., patented technologies we developed for our dual-layer pneumatic roller mill system:

• Synchronized dual-stage grinding system
• Smart pneumatic pressure control mechanism
• Optimum roller gap adjustment mechanism
• Quick roller change system

Tanış A.Ş.’s Product Development Philosophy

With our experience of over 60 years in the milling sector, we adopt the following principles in our product development processes:

• Customer needs-focused solutions
• Sustainable and energy-efficient designs
• Reliability and durability-focused engineering
• Continuous improvement and innovation

Competitive Advantages and Differentiating Features

Features that distinguish the Tanış Dual-Layer Pneumatic Roller Mill system from its competitors:

• Completely domestic technology designed and manufactured in Turkey
• Design optimized according to the needs of the Turkish milling sector
• Global brand assurance exporting to 40+ countries
• Industry 4.0 compatible digital control infrastructure

Tanış A.Ş. Assurance and Experience

As Tanış A.Ş., values we offer to our customers with our deep-rooted experience in the milling machinery sector:

• 24/7 technical service support
• 10-year spare parts guarantee
• Free periodic maintenance controls
• Free update recommendations for technological innovations

Frequently Asked Questions

Technical Questions

Does the dual-layer pneumatic roller mill system require special infrastructure for installation?

The infrastructure found in standard mill facilities is sufficient for the installation of our dual-layer pneumatic roller mill system. A floor that can carry the total weight of the system, standard electrical connections, and compressed air supply are basic requirements. If integration is to be made into an existing facility, minor modifications may be required for transport system connections. Before installation, our technical team will evaluate your facility’s infrastructure and inform you about necessary preparations.

What is the capacity difference between dual-layer pneumatic roller mill and single rollers?

Our dual-layer pneumatic roller mill system offers performance equivalent to the total capacity of two single rollers with the same roller length. For example, a 1000 mm long dual-layer roller system can perform the work of two 1000 mm long single rollers with a single machine footprint. What’s important in this comparison is the space savings achieved without compromising capacity. Additionally, energy efficiency increases thanks to the use of a single control unit and fewer auxiliary equipment.

What kind of adjustment process is required when switching between different grain types?

When switching between different grain types, roller settings for both floors, pneumatic pressure values, and feeding speed need to be changed. Thanks to our modern control panel, these transitions can be made quickly using pre-recorded recipes. A typical wheat to corn transition process takes approximately 30-45 minutes including cleaning. Using appropriate roller surface patterns for each grain type is recommended; if roller change is required, this time may extend.

How long does it take to change roller cylinders and does this process require special equipment?

Changing roller cylinders in our dual-layer pneumatic roller mill system takes an average of 2-3 hours. Thanks to the special quick access mechanisms in our design, this time is very close to the change time in single rollers. Standard lifting equipment (crane or hoist) and basic mechanical tools are sufficient for the process. The roller change kit provided with the system includes special apparatus and detailed instructions. A trained maintenance personnel can easily perform this operation.

Maintenance and Spare Parts Questions

What are the regular maintenance requirements and how often should they be performed?

The recommended maintenance program for our dual-layer pneumatic roller mill system is as follows:

• Daily controls: Control of oil levels, temperature values, pressure indicators, and general performance parameters
• Weekly maintenance: Belt tension control, sealing element control, feeding system cleaning
• Monthly maintenance: Bearing temperature control, pneumatic system filter cleaning, general tightness controls
• 6-monthly maintenance: Oil change, bearing control, comprehensive mechanical inspection, calibration and adjustment controls

Compliance with the maintenance program ensures the system’s long life and optimum performance operation.

What is the spare parts supply time and which are the critical parts that should be kept in stock?

As Tanış A.Ş., we keep standard spare parts in stock continuously and can usually ship your orders within 48 hours. For custom-made parts, there is a maximum 2-week supply time.

Critical spare parts we recommend keeping in your facilities:

• Pneumatic pressure regulators
• Sealing elements set
• Sensor spares
• Belt set
• Roller surface cleaning equipment

These basic spares will help you keep production interruption to a minimum in possible emergency situations.

How often should roller surfaces be renewed?

Roller surface renewal time varies depending on the type of grain processed, daily working hours, and grinding fineness. On average, in intensive use (20+ hours per day) 8-12 months, in normal use (8-16 hours per day) 12-18 months, control and renewal of roller surfaces if necessary is recommended. Roller surface renewal service is provided by our expert team and roller cylinders need to be sent to Tanış A.Ş. workshops for this process.

Does the pneumatic control system need calibration?

Yes, annual calibration is recommended for optimum performance of the pneumatic control system. This process is necessary to ensure that pressure sensors, valve systems, and pressure regulators are working correctly. Calibration service is provided free of charge within the scope of your service agreement. The process usually takes 2-3 hours and affects production minimally.

Capacity and Efficiency Questions

What is the effect of the dual-layer pneumatic roller mill system on efficiency rates?

Our dual-layer pneumatic roller mill system positively affects efficiency rates thanks to the gradual grinding principle. Compared to traditional single roller systems, flour with lower ash content can be obtained at the same extraction rate. In wheat grinding, while the system typically operates at 78-82% extraction rate, it can reduce the amount of flour passing to bran by 1.5-2%. This provides significant economic gain on an annual basis.

Can the roller systems on two floors be used simultaneously for different grain types?

While technically possible, processing the same grain type is recommended for efficiency and product quality. However, in special cases, various product types can be obtained by using different grinding finenesses or different roller surface patterns on two floors. For such special applications, we recommend consulting with our technical team. The system can be adapted to such flexible uses when necessary modifications are made.

Compatibility and Integration Questions

Is the dual-layer pneumatic roller mill system compatible with other brand mill equipment?

Yes, our dual-layer pneumatic roller mill system is designed to work compatibly with most brand mill equipment using standard industrial connection points and interfaces. Adapter parts and special connection elements that may be needed during integration are included in the installation package. Connection to your existing automation systems can also be provided via standard communication protocols (Modbus, Profibus, Ethernet/IP).

How long does the integration process to an existing mill line take?

The integration process to a medium-scale mill line takes an average of 5-7 days including planning and preparation stages. Approximately 2-3 days of this time is allocated to active assembly and connection operations, and 1-2 days to commissioning and test work. With good planning, it is possible to limit production interruption to 48 hours in this process. Our expert assembly team prepares an installation plan to provide maximum efficiency with minimum interruption.

Conclusion and Contact Information

Our Dual-Layer Pneumatic Roller Mill system is an innovative solution designed to meet the space and efficiency demands of modern mill operations. With its compact design, superior performance, and economic advantages, it will take your mill operations to the next level.

As Tanış A.Ş., you can contact us to get more detailed information about this system we developed with our experience of over 60 years and continuous R&D studies, to get quotes for solutions suitable for your special needs, or to visit our demo facilities.