Thor Pneumatic Roller Mill

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

All models have the following standard technical features:

• Grinding precision: Adjustable in the range of 5-2000 microns
• Pneumatic pressure range: 0.5-8 bar
• Maximum operating speed: 600 rpm
• Bidirectional operation capability
• Digital control panel
• Industry 4.0 compatible communication interface
• Fully automatic lubrication system

Energy Efficiency and Operational Advantages

Thor Pneumatic Roller Mill sets a new standard for the sector in terms of energy efficiency:

• Optimized Motor Power: Specially selected high-efficiency motors for each model minimize energy consumption.
• Smart Starting System: Thanks to gradual starting technology, high energy consumption at startup is prevented.
• Load-Based Energy Optimization: Automatically adjusts energy consumption based on real-time load measurement during grinding.
• Efficient Mechanical Transmission: High-quality bearings and transmission elements minimize friction losses.

Operational advantages provided:

• Fast Installation: Easy integration and fast installation in facilities thanks to modular design.
• Minimum Downtime: Easy access to parts requiring maintenance shortens service times.
• Low Operating Cost: Long-lasting components and efficient operating principle reduce operating costs.
• Easy Use: Intuitive control interface enables operators to use the system effectively with minimum training.

Durability and Long Life

Thor Pneumatic Roller Mill is designed to operate trouble-free for many years under harsh industrial conditions:

• High-Quality Materials: Wear-resistant special alloy steel roller cylinders.
• Robust Body Construction: Heavy-duty steel body that dampens vibrations.
• Advanced Surface Treatments: Special hardening processes applied to roller cylinders provide long-term precise grinding performance.
• Protective Elements: Effective sealing systems preventing dust and moisture from reaching sensitive components.
• Proactive Maintenance Monitoring: Integrated sensor systems that detect potential problems early.

Thor Pneumatic Roller Mill stands out as a technology shaping the future of the milling sector with these superior features and advantages. This system, developed with Tanış A.Ş.’s over 60 years of sector experience and engineering knowledge, is a perfect response to the increasing quality and efficiency demands of modern flour mills.

Technical Specifications and Performance

Thor Pneumatic Roller Mill has detailed technical specifications designed to meet the high performance and precision requirements demanded by modern mill operations. This section provides comprehensive information about the system’s technical structure and performance values.

Detailed Technical Specifications

General Features:

Mechanical Features:

• Roller Cylinders: Made from high-carbon, special alloy steel, heat-treated to 62-64 HRC hardness
• Surface Pattern: Different surface pattern options for fine, medium, and coarse grinding
• Bearing System: Heavy-duty, high load capacity bearings
• Drive System: Direct coupling or belt-pulley transmission options
• Cooling System: Internal cooling channels in roller cylinders (optional)

Pneumatic System Features:

• Operating Pressure: 0.5-8 bar
• Pressure Precision: ±0.1 bar
• Pressure Sensor: Digital, high precision
• Air Consumption: Approximately 0.3-0.5 m³/hour
• Pneumatic Control Units: SMC or FESTO components
• Pistons: Double-acting, long-life cylinders
• Filter-Regulator Unit: Integrated moisture and particle filters

Electronics and Control System:

• Control Panel: 7″ color touchscreen
• Processor: Industrial PLC system
• Communication Protocols: Modbus RTU/TCP, Ethernet IP, Profinet
• Data Recording Capacity: Last 90 days operation parameters
• Remote Access: Technical support and updates via VPN
• Alarm System: Audio and visual warning system, SMS/email notification (optional)

Roller Length and Diameter Options

Thor Pneumatic Roller Mill is offered with various size options according to different capacity needs:

For special orders, different length and diameter combinations can also be produced for specific capacity requirements.

Motor Power and Energy Consumption

Thor Pneumatic Roller Mill systems are equipped with high-efficiency electric motors. Motor powers and energy consumption values by models:

*Energy consumption values are hourly averages at full load. Actual consumption may vary depending on the type of grain ground and grinding fineness.

An additional 3-5% energy saving can be achieved with IE4 Super Premium Efficiency class motors offered as an option.

Grinding Capacity (tons/24 hours)

The grinding capacity of Thor Pneumatic Roller Mill varies depending on grain type and desired grinding fineness:

These values are capacities obtained under optimum operating conditions. Factors such as grain quality, moisture content, and cleanliness level can affect capacity values.

Precise Adjustment Features

One of the most important features of Thor Pneumatic Roller Mill is the precise adjustment capabilities it offers:

• Roller Gap Adjustment: Adjustable with 0.01 mm precision
• Pneumatic Pressure Control: Precise pressure control system adjustable in 0.1 bar steps
• Digital Position Sensors: High-precision sensors continuously monitoring roller position
• Automatic Calibration: Automatic zero point calibration at system startup
• Recipe Management System: Ability to save and recall 100 different grinding recipes
• Speed Control: Adjustable speed between 300-600 rpm with optional frequency inverter

Thanks to these precise adjustment features, ideal grinding parameters can be easily set for different grain types and qualities, thus always achieving optimum performance and product quality.

Quality Flour Production with Thor Pneumatic Roller Mill

Effect on Flour Quality

Thor Pneumatic Roller Mill enables high-quality flour production by optimizing many factors that play a decisive role in flour quality:

• Homogeneous Particle Size: Thanks to the equal pressure distribution provided by the pneumatic system, homogeneous particle size is achieved throughout the roller length.
• Minimum Starch Damage: Precisely adjustable pneumatic pressure optimizes starch damage, improving baking quality.
• Improved Protein Structure: Controlled grinding process preserves the protein structure in wheat, improving the bread-making properties of flour.
• Consistent Quality: Thanks to the digital control system and recipe management, standard flour quality is achieved without variation from shift to shift.
• Reduced Heat Generation: Optimized grinding parameters and cooling option minimize heat generated during processing, ensuring preservation of flour’s natural properties.

Suitability for Different Grain Types

Thor Pneumatic Roller Mill provides ideal grinding conditions for various grain types thanks to its wide pressure adjustment range and changeable roller surface patterns:

• Wheat: Optimized grinding parameters for hard, semi-hard, and soft wheat types.
• Corn: Ideal pressure control system for breaking hard corn kernels and degermination (embryo separation) processes.
• Barley: Precisely adjustable roller gap for malt production.
• Rye: Suitable grinding conditions for rye with special rheological properties.
• Other Grains: Adaptable parameters for processing other grains such as rice, oats, and sorghum.

Extraction Rate and Yield Values

Thor Pneumatic Roller Mill provides significant improvements in extraction rates and yield values thanks to optimized grinding parameters:

*Yield increase is the improvement rate achieved compared to traditional roller systems.

These improvements provide significant economic gains on an annual basis, especially in large-capacity mill operations.

Micron Precision and Homogeneous Grinding

Thor Pneumatic Roller Mill offers full control capability at the micron precision required for different grinding stages:

• B1-B2 Breaking Stages: 500-2000 microns
• B3-B4 Breaking Stages: 200-500 microns
• C1-C3 Grinding Stages: 100-200 microns
• Final Grinding Stages: 5-100 microns

The system increases the efficiency of subsequent sifting and separation processes by providing homogeneous grinding at the determined micron level. Standardization in particle size distribution increases the consistency of flour’s rheological properties, improving final product quality.

Industrial Applications and Usage Areas

Thor Pneumatic Roller Mill is designed to show high performance in different segments and applications of the milling sector. Its ability to be used for different purposes in facilities of various scales makes this system an indispensable equipment in the sector.

Large-Scale Flour Mills

Large-scale flour mills with daily capacity of 200 tons and above benefit maximum from the advanced technology features offered by Thor Pneumatic Roller Mill:

• High Capacity Requirements: T-1250 and T-1500 models offer ideal solutions for continuous and high-volume production.
• Integration with Central Control Systems: Industry 4.0 compatible communication interface provides seamless integration with the facility’s central automation system.
• Quality Standardization: Quality standardization, which is important in large-scale facilities, is maintained from shift to shift thanks to the recipe management system.
• Energy Efficiency: In high-volume production, energy costs are critically important. The energy optimization features of Thor Pneumatic Roller Mill help keep operating costs under control.
• Multiple Line Installations: In facilities with multiple production lines, all line parameters can be centrally monitored and managed.

Medium-Scale Mills

Medium-scale mills with daily capacity of 50-200 tons benefit from the flexibility and efficiency features of Thor Pneumatic Roller Mill:

• Adaptable Capacity: T-800 and T-1000 models offer ideal capacity and cost balance for medium-scale mills.
• Fast Product Change: It responds to product diversity demands frequently encountered in medium-scale facilities with easily adjustable parameters and recipe management system.
• Easy Modernization: In modernization projects of existing facilities, the modular structure of Thor Pneumatic Roller Mill provides easy integration.
• Optimum Operating Cost: Operating costs, which are critically important for medium-scale businesses, are optimized thanks to the efficient operating principle.
• Future-Oriented Investment: For facilities with capacity increase plans, it offers a flexible solution that can adapt to future needs.

Special Purpose Grinding Facilities

Thor Pneumatic Roller Mill shows excellent performance in special purpose grinding applications as well as standard flour production:

• Organic Flour Production: Precise temperature control and optimum grinding parameters preserve the natural structure of organic flours.
• Gluten-Free Products: Provides ideal grinding conditions for precise processing of gluten-free grains such as corn and rice.
• Special Purpose Flours: Offers precise control capability to achieve specific particle size distribution required in production of special flours such as pasta, pizza, and baklava.
• R&D Facilities: In new product development processes, allows different grinding experiments with changeable parameters.
• Educational Institutions: It is ideal educational equipment for practical application of grinding principles in institutions providing milling education.

Role in Integrated Mill Systems

Thor Pneumatic Roller Mill is a critical component of modern integrated mill systems:

• Coordination with Cleaning Systems: Can automatically adjust grinding parameters according to the quality of product coming from grain cleaning systems.
• Integration with Tempering Processes: Works compatible with tempering processes by optimizing grinding pressure according to grain moisture content.
• Communication with Sifting Systems: Increases system efficiency by adjusting grinding parameters based on feedback from sifting systems.
• Quality Control Before Packaging: Guarantees standard quality in packaging processes by ensuring consistency in final product quality.
• Connection to Central SCADA Systems: Provides seamless integration with central control systems that coordinate all processes in the facility.

Installation, Maintenance and Service

Easy Installation Features

Thor Pneumatic Roller Mill has features designed for fast and trouble-free installation:

• Single-Piece System: The main unit is shipped as a single piece, requiring minimum assembly on site.
• Standard Connection Points: Input-output connections compliant with international standards provide easy integration with existing systems.
• Infrastructure Compatible with Ready Installation: Design suitable for ready installation for electrical, pneumatic, and data connections.
• Self-Level Foot System: Adjustable feet that tolerate floor irregularities.
• Comprehensive Installation Manual: Detailed documentation containing step-by-step installation instructions.
• Quick Commissioning: Quick commissioning process thanks to pre-calibrated equipment.

Tanış A.Ş.’s expert installation team professionally performs the integration of Thor Pneumatic Roller Mill into your facilities. A typical installation process is completed within 1-3 days depending on size.

Maintenance Requirements and Periodic Controls

Although Thor Pneumatic Roller Mill is designed with minimum maintenance requirements, the following periodic maintenance operations are recommended for optimum performance:

Daily Controls:

• Control of roller pressure values
• Control of general operating sound
• Control of roller gap indicator
• Control of pneumatic system pressure indicator

Weekly Controls:

• Control of belt tension
• Control of pneumatic hoses and connections
• Control of lubrication points
• Body and motor cleaning

Monthly Controls:

• Control of bearing temperatures
• Pneumatic filter cleaning
• Control of electrical connections
• Control of sensor calibrations

6-Monthly Maintenance:

• Detailed inspection of roller surfaces
• Complete system test and calibration
• Oil change
• Control of sealing elements

These controls are regularly performed by expert technicians within the scope of maintenance contracts offered by Tanış A.Ş.

Spare Parts and Service Services

We offer comprehensive spare parts and service support for Thor Pneumatic Roller Mill:

• 24-Hour Spare Parts Supply Guarantee: 24-hour shipping guarantee for critical spare parts.
• 10-Year Spare Parts Availability Guarantee: Availability of all spare parts for the system for a minimum of 10 years.
• Original Parts Guarantee: All spare parts are original Tanış A.Ş. products manufactured to the same quality standards.
• Fast Service Intervention: Service intervention within 24 hours throughout Turkey, technician support within 72 hours for overseas locations.
• Remote Diagnosis and Support: Remote diagnosis and troubleshooting service via VPN connection.
• Service Documentation: Detailed report and recommendations after each service operation.

Operator Training and Support

We provide comprehensive training and support programs for the most efficient use of Thor Pneumatic Roller Mill:

• Comprehensive Operator Training: Comprehensive operator training for facility personnel after system installation.
• Training Materials: Detailed user manuals, quick reference cards, and video training materials.
• Periodic Advanced Training: Periodic training programs for new personnel or for knowledge refreshing.
• Technical Support Line: 24/7 accessible technical support line.
• Online Training Platform: Keeping knowledge and skills current with continuously updated online training platform.
• On-Site Support: On-site technical support service for complex situations.

These comprehensive installation, maintenance, and support services guarantee that Thor Pneumatic Roller Mill always operates at maximum performance in your facilities. Tanış A.Ş.’s 60 years of sector experience and widespread service network ensure the uninterrupted continuation of your mill operations.

Data Showing Contribution to Efficiency

The contributions of Thor Pneumatic Roller Mill to mill operations have been measured through various performance indicators:

Production Efficiency Improvements:

*Values obtained from actual customer data compared to traditional mechanical rollers.

Improvements in Quality Parameters:

• Particle Size Distribution: 30% more consistent distribution
• Starch Damage Control: 25% more precise control
• Ash Content Variation: 65% reduction in shift-to-shift deviation
• Protein Quality: 15% improvement in gluten index
• Color Values: Higher and more consistent L* value

Return on Investment (ROI) Analysis

Comprehensive ROI analyses have been conducted to evaluate the economic return of investment in Thor Pneumatic Roller Mill system.

Why Should Thor Pneumatic Roller Mill Be Preferred?

Competitive Advantages

Fundamental advantages that distinguish Thor Pneumatic Roller Mill from its competitors:

• Full Industry 4.0 Compatibility: New standard in mill automation with advanced digital integration features.
• Roller Surface Monitoring Technology: Smart sensor system that continuously monitors roller surface condition and provides advance notice of maintenance needs.
• AI-Supported Grinding Optimization: Artificial intelligence algorithms that analyze grain quality and suggest optimal parameters (in Premium models).
• Integrated Energy Monitoring: Smart system offering real-time energy consumption monitoring and optimization recommendations.

Long-Term Benefit Analysis

Long-term benefits of investing in Thor Pneumatic Roller Mill:

• Technological Infrastructure Assurance: Minimum 10 years of technological support and update guarantee.
• Adaptation Capability: Flexible structure adapting to changing market conditions and product diversity.
• Sustainability: Environmentally friendly technology providing energy efficiency and resource optimization.
• Operating Cost Advantage: Low operating cost throughout product life cycle.
• High Second-Hand Value: High second-hand value of Tanış equipment in the market provides advantage in future renovation projects.

Tanış A.Ş. Assurance and Expertise

When you choose Thor Pneumatic Roller Mill, you also benefit from Tanış A.Ş.’s 60 years of sectoral experience and expertise:

• Global References: Proven performance with 500+ active installations in 40+ countries.
• R&D Investments: Company policy allocating more than 5% of annual turnover to R&D for continuous innovation.
• Production Quality: ISO 9001, ISO 14001, and OHSAS 18001 certified production facilities.
• Strong Service Network: Widespread service and support network worldwide.
• Training and Knowledge Transfer: Continuous training and knowledge sharing on milling technologies.
• Customer-Focused Approach: Flexible approach developing special solutions for each customer’s specific needs.

Frequently Asked Questions

Technical Questions

What are the fundamental advantages of Thor Pneumatic Roller Mill system compared to traditional mechanical or hydraulic rollers?

Thor Pneumatic Roller Mill provides much more precise pressure control compared to traditional systems. The pneumatic system is adjustable with 0.1 bar precision and can respond to sudden load changes within milliseconds. While spring fatigue is seen in mechanical systems and temperature-dependent performance changes in hydraulic systems, the pneumatic system is free from these disadvantages. Additionally, pneumatic technology offers a cleaner, easier to maintain, and more energy-efficient solution.

Can the same roller unit be used for different grain types?

Yes, thanks to Thor Pneumatic Roller Mill’s wide adjustment range and changeable roller surface patterns, the same unit can be used for different grain types. The system can store optimized recipes for different grains such as wheat, corn, barley, and rye in its memory. During grain changes, the operator can simply select the relevant recipe to automatically adjust parameters such as roller gap, pressure, and speed. For some special applications, roller surfaces may need to be changed, which can be quickly performed by Tanış A.Ş. service team.

What quality of compressed air is required for the pneumatic system?

Thor Pneumatic Roller Mill shows optimum performance with compressed air at 6-8 bar pressure, class [1:4:1] according to ISO 8573-1:2010 standard (in terms of solid particle, water, and oil content). The filter-regulator unit provided as standard with the system filters possible contaminants in facility air, ensuring protection of pneumatic components. Average air consumption is around 0.3-0.5 m³/hour depending on model and operating conditions.

How does the digital control system behave during power outages?

Thor Pneumatic Roller Mill’s digital control system has protection features against power outages. In case of power loss, the system automatically applies a safe shutdown procedure and saves all critical parameters to permanent memory. When power returns, the last used settings are remembered, but for safety reasons, the system does not start automatically. After operator approval, normal operation is resumed with a gradual startup procedure. With the optionally offered UPS system, the control unit can continue to operate unaffected by short-term outages.

How often should roller cylinders be changed or renewed?

The life of roller cylinders depends on factors such as the type and quality of grain processed, daily working hours, and roller surface pattern. On average, high-quality Thor Pneumatic Roller Mill cylinders can be used for 3-5 years under standard operating conditions. The system can provide advance notice of renewal time thanks to sensors monitoring roller surface wear. Roller surface renewal is performed by Tanış A.Ş.’s expert teams, preserving the original surface pattern and hardness. This process is generally 40-50% of the original cylinder cost.

Maintenance and Operation Questions

What is the recommended maintenance frequency for Thor Pneumatic Roller Mill?

While the system requires less maintenance compared to traditional rollers, certain periodic controls are recommended for optimum performance. We recommend daily simple visual controls, weekly general condition controls, monthly sensor and calibration controls, and 6-monthly comprehensive maintenance program. Within the scope of maintenance contracts offered by Tanış A.Ş., these controls are performed regularly and detailed maintenance reports are provided. Regular maintenance extends the system’s life while minimizing unexpected failure risk.

How long does operator training take and what does it cover?

Standard operator training takes 2 days after completion of system installation and covers the following topics: system introduction and operating principles, control panel use, recipe management, daily controls and maintenance procedures, basic troubleshooting, safety measures. More comprehensive technical training for maintenance personnel may take an additional 2-3 days. Training is conducted with practical applications on actual equipment at your facility and detailed training materials are provided to all personnel. Repeat training can be organized in case of personnel changes.

What are the critical parts that should be kept in spare parts stock?

For uninterrupted operation of your business, we recommend keeping the following critical spare parts in stock: pneumatic pressure regulators, sensor sets, control card, sealing elements set, belt-pulley set. As Tanış A.Ş., while we offer fast supply guarantee for all spare parts, keeping critical parts at the facility minimizes possible downtime. Comprehensive spare parts list and recommendations are provided by our technical team during system installation.

Warranty and Service Questions

What is the warranty period for Thor Pneumatic Roller Mill?

Thor Pneumatic Roller Mill is offered with 2 years parts and labor warranty as standard. This warranty covers all problems arising from manufacturing defects. With the optionally offered extended warranty package, this period can be extended up to 5 years. Warranty coverage includes all functional problems that may occur under normal usage conditions. Special warranty conditions apply for wear parts and these details are clearly stated in the warranty contract.

How quickly is service support provided and what is the cost?

As Tanış A.Ş., we commit to providing technical service support within 24 hours within Turkey’s borders and within 72 hours at overseas locations. For emergency situations, our remote technical support service via VPN connection can be activated immediately. Service costs are free for failures covered under warranty. Standard service rates apply for out-of-warranty service support. Special discounted service rates are offered for customers with regular maintenance contracts. Within the scope of service contracts, advantages such as planned maintenance visits, preventive maintenance services, and priority intervention rights are provided.

How are software updates performed and are these updates paid?

Thor Pneumatic Roller Mill’s control software has a continuously developed and improved structure. Software updates containing security updates and minor functional improvements are provided free of charge during the warranty period. These updates can be performed by Tanış A.Ş. service technicians during routine maintenance visits or via remote connection. A nominal fee may be requested for updates containing new features and major functional improvements. All systems are backed up before software updates and comprehensive tests are performed after updates, ensuring no interruption in your production processes.

What measures have been taken against possible failures in the system?

Thor Pneumatic Roller Mill is designed with various measures to minimize failure risk and limit the impact of possible failures. The system has comprehensive self-diagnostic capability and can detect and report potential problems before they become critical. Redundant design is applied for critical components; for example, the pneumatic control system has backup valves that activate when the primary system fails. Emergency procedures are designed to safely shut down the system and preserve product quality. Additionally, a comprehensive failure log system accelerates troubleshooting processes. All these measures increase system reliability while minimizing possible downtime.